ASSEMBLY PROCEDURE
Fixation of armouring wire
Document No : NeNo-AP-77
Version
01
02
Date
09.09.05
16.09.05
Prepared by
JWA
JWA
Checked by
AHa
AHa
Released by
IJV
IJV
CONFIDENTIAL.
All rights reserved. Passing on or copying of this document, use and communication of its content is not
permitted without prior written authorization from Nexans Norway AS.
CONTENTS
1
INTRODUCTION .............................................................................................................................................. 3
2
REFERANCES ................................................................................................................................................... 3
3
DEFINITIONS .................................................................................................................................................... 3
4
GENERAL........................................................................................................................................................... 3
5
SAFETY............................................................................................................................................................... 3
6
ACTIVITIES....................................................................................................................................................... 4
6.1
6.2
6.3
TOOLS .............................................................................................................................................................. 4
MATERIALS.................................................................................................................................................... 4
PROCEDURE ................................................................................................................................................... 4
Side 2 av 8
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1
INTRODUCTION
This procedure describes the fixation of armouring wires, to be applied on cables where
one or more wires in the outer armouring layer have been severed. The objective of the
fixation is to prevent uncoiling of the loose wire ends. The fixation does not contribute to
the cable axial strength. The procedure cannot be applied on single armoured cables. The
fixation technique results in a minimal increase of the cable outer diameter, in the order of
0,7 mm. The technique forms a continuous transition between the original outer diameter
and the repair.
2
REFERANCES
None
3
DEFINITIONS
None
4
GENERAL
Severing of armour wires may occur as a result of localized corrosion, overload or
mechanical damage. The wire ends have a tendency to uncoil and cause severe problems
during operation of the cable. The problems may in some cases be solved by removing the
affected cable section altogether, or removing the severed wire along its entire length. If
these solutions are not viable, the wire ends must be fixated, preferably with a minimal
impact on the cable outer diameter.
5
SAFETY
This procedure assumes that the cable under repair is neutral. Do not apply this
procedure on a cable under tension. If there is a risk that the cable might come under
sudden tension during the course of the work, ensure no loop is formed. Such a loop is a
serious hazard to all personnel involved.
Solvents must not be inhaled over prolonged time. All spilling of solvents should be
removed without delay, and preferably be avoided.
Wear protective glasses when using grinding machine /”Dremel” and when handling steel
wire ends.
Side 3 av 8
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6
ACTIVITIES
6.1 TOOLS
•
•
•
•
•
•
•
•
•
•
Working table with vice
Protective glasses
Felt pen
Hammer
Plate scissors
Plastic hammer
File
”Dremel” with cutting wheel and grinding wheel
Misc. pliers
Large side cutter
6.2 MATERIALS
•
•
•
•
•
•
•
•
White spirit
Isopropanol
Parafin
Hose clamps (10 off ) for cable OD
Galvanized steel band , 10mm x 0,7 mm, ca 50 cm
Zinc spray
Cable grease
Red/yellow textile tape
6.3 PROCEDURE
a) Remove uncoiled armouring wire and clamp cable in a vice. (Protect cable with rags,
do not overtighten vice.)
b) Remove grease on cable with kerosene and attach hose clamps approximately 200
mm on each side of the wire end.
c) Using ”Dremel” with grinding wheel, form a ramp (approx. 45 degrees) on wire end.
Also remove sharp edges on wire end.
Severed wire with ramp
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d) Using felt pen mark a section on the wire, 15 mm from its end. Width of section shall
equal width of galvanized steel band.
e) Grind down the marked section approximately half the wire diameter.
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f)
Approximately 30 mm to the right of the wire end carefully insert a screw driver
under three armouring wires. Insertion shall be tangential.
g) Form an “omega” (Ω) of the steel band, using three short pieces of armouring wire
in a wise. Length of steel band: approximately 150 mm.
h) Insert steel band under the three armouring wires.
i)
Insert screw driver under three armouring wires at opposite side.
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j)
Insert steel band, so that steel band is positioned under six armouring wires.
k) Push steel band (”clamp”) axially over wire end and into grove machined in wire.
l)
Remove both excess ends of the protruding clamp, as close as possible to the third
armouring wire. Use “Dremel” with cutting wheel. Do not damage neighbouring
armouring wires.
m) Using screwdriver pry an opening between armouring wire no 3 and 4, and push in
end of clamp carefully with a second screwdriver. Repeat for other side of clamp.
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n) Distribute armouring wires along circumference. Use plastic hammer.
o)
p)
q)
r)
Rinse area with kerosene and isopropanole.
Spray with zinc spray
Mark section with two red/yellow textile tapes (for future inspection)
When zinc spray is dry apply cable protective grease over section.
Side 8 av 8
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ASSEMBLY PROCEDURE
Cutting Armouring
in ROV Cables
Document No.: NeNo-AP-147-01 (Cutting ROV armouring).doc
Version
01
Date
07.04.08
Prepared by
BJS
Checked by
KOG
Released by
IJV
CONFIDENTIAL.
All rights reserved. Passing on or copying of this document, use and communication of its content is not
permitted without prior written authorization from Nexans Norway AS.
INNHOLDSFORTEGNELSE
1
INTRODUKSJON .......................................................................................3
2
TOOLS ........................................................................................................3
3
HEALTH, SECURITY AND THE ENVIRONMENT ........................................3
4
CUTTING OF ARMOURING.......................................................................4
4.1
4.2
4.3
First armouring layer........................................................................................................... 4
Second armouring layer ...................................................................................................... 5
Roud off the wire ends......................................................................................................... 6
5
DOCUMENT HISTORY ...............................................................................6
Page 2 of 6
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1
INTRODUKSJON
This procedure describes cutting of steel armouring in ROV cables, by using a small disc
grinder. Because of the high grade steel wires is a ROV cable, a disc grinder is the best
tool to use. The disc grinder can easily create too much heat, therefore a slow working
intensity is required.
2 TOOLS
Tools used to cut armouring are:
• 4 pcs. hose clamps*
• A small disc grinder w/ stainless steel cutting blade (1mm thick)
o (blade example: Norton A60V-BF41, 125mmx1.0mmx22mm)
• Face guard
• Ear protection
• Working gloves
*) 4 pcs. hose clamps for cables with 2 armouring layer. For additional layers, add one hose clamp for each
layer.
3
HEALTH, SECURITY AND THE ENVIRONMENT
Using a disc grinder requires a face guard to protect the face and eyes. Working gloves
and ear protection.
Figur 1. Safety tools when using disc grinder.
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4
CUTTING OF ARMOURING
4.1 First armouring layer
1. Fasten 2 pcs. of hose clamps, one clamp on each side of the wanted cut (clamp no. 2
and 3 on the picture). Distance between the clamps shall be about 1.5 cm (max 2 cm).
Fasten one more hose clamp some short distance from the cutting area, at the cable
length of the cut. Location of the clamp depends on the application. Make sure to make
maximum torch on the clamps.
Figur 2. Fasten three hose clamp. The right side of the hose clamps is the part to remove.
2. Use the small disc grinder to carve into the steel wires. The cut shall not carve more
than half the thickness of the wires, and make the cut in several steps. Make the first cut
only 1/3 of the thickness, and 1/6 of the outer circumference of the cable. Check your cut
visually, and make a new cut into half the wire thickness.
Continue through the whole circumference, 1/6 at the time. Let the cable cool down
during the cutting, to avoid overheating of cable. Do not work to intensive on the carving.
Figur 3. a) A small disc grinder to carve into the wires. b) Carve ½ the wire thickness.
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3. Remove one of the hose clamp (clamp no. 3). Bend one steel wire at a time, until it
breaks. Move the wire in small movements back and forth, and let the wire break by it self.
For thin or medium sized steel wire, apply work on two wires at a time is possible. For
larger wires (larger than 3 mm thickness) apply work on one wire at a time only.
Figur 4. Move one (or two) wires back and forth until the wire break.
4.2 Second armouring layer
4. Fasten the hose clamp (clamp no. 3) back at its original place, and fasten a new hose
clamp 1.5 cm apart from the other clamp (clamp no. 4). Use the disc grinder the same
way as above, remember to let the cable cool down during the carving. Make the cut not
deeper than half the thickness of the wires. Do not work to intensive at this part.
Figur 5. Hose clamp and cutting of second layer of armouring.
5. Remove the hose clamp no. 4. Bend one steel wire at a time, until it breaks. Use the
same method as above. Move the wire in small movements to provide a clean cut. For
steel wires larger than 3 mm, only apply work on one wire at a time.
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Figur 6. End result.
4.3 Roud off the wire ends
At the end you need to protect or clean the wire end, depending on what you are going to
use the cable for.
If you terminate the wires in some termination cones, or other applications as the wire
ends are moved some distance from the cable core. Make a clean cut on every wire with
the disc grinder.
Other usages of the cable, you may only need to file the wire ends to remove the sharp
bits. Keep the hose clamps, and protect the wire ends with protective wrapping.
5
DOCUMENT HISTORY
Revisjon
01
New document
Page 6 of 6
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permitted without prior written authorization from Nexans Norway AS.
ASSEMBLY PROCEDURE
Fixation of armouring wire
Document No : NeNo-AP-77
Version
01
02
Date
09.09.05
16.09.05
Prepared by
JWA
JWA
Checked by
AHa
AHa
Released by
IJV
IJV
CONFIDENTIAL.
All rights reserved. Passing on or copying of this document, use and communication of its content is not
permitted without prior written authorization from Nexans Norway AS.
CONTENTS
1
INTRODUCTION .............................................................................................................................................. 3
2
REFERANCES ................................................................................................................................................... 3
3
DEFINITIONS .................................................................................................................................................... 3
4
GENERAL........................................................................................................................................................... 3
5
SAFETY............................................................................................................................................................... 3
6
ACTIVITIES....................................................................................................................................................... 4
6.1
6.2
6.3
TOOLS .............................................................................................................................................................. 4
MATERIALS.................................................................................................................................................... 4
PROCEDURE ................................................................................................................................................... 4
Side 2 av 8
CONFIDENTIAL.
All rights reserved. Passing on or copying of this document, use and communication of its content is not
permitted without prior written authorization from Nexans Norway AS.
1
INTRODUCTION
This procedure describes the fixation of armouring wires, to be applied on cables where
one or more wires in the outer armouring layer have been severed. The objective of the
fixation is to prevent uncoiling of the loose wire ends. The fixation does not contribute to
the cable axial strength. The procedure cannot be applied on single armoured cables. The
fixation technique results in a minimal increase of the cable outer diameter, in the order of
0,7 mm. The technique forms a continuous transition between the original outer diameter
and the repair.
2
REFERANCES
None
3
DEFINITIONS
None
4
GENERAL
Severing of armour wires may occur as a result of localized corrosion, overload or
mechanical damage. The wire ends have a tendency to uncoil and cause severe problems
during operation of the cable. The problems may in some cases be solved by removing the
affected cable section altogether, or removing the severed wire along its entire length. If
these solutions are not viable, the wire ends must be fixated, preferably with a minimal
impact on the cable outer diameter.
5
SAFETY
This procedure assumes that the cable under repair is neutral. Do not apply this
procedure on a cable under tension. If there is a risk that the cable might come under
sudden tension during the course of the work, ensure no loop is formed. Such a loop is a
serious hazard to all personnel involved.
Solvents must not be inhaled over prolonged time. All spilling of solvents should be
removed without delay, and preferably be avoided.
Wear protective glasses when using grinding machine /”Dremel” and when handling steel
wire ends.
Side 3 av 8
CONFIDENTIAL.
All rights reserved. Passing on or copying of this document, use and communication of its content is not
permitted without prior written authorization from Nexans Norway AS.
6
ACTIVITIES
6.1 TOOLS
•
•
•
•
•
•
•
•
•
•
Working table with vice
Protective glasses
Felt pen
Hammer
Plate scissors
Plastic hammer
File
”Dremel” with cutting wheel and grinding wheel
Misc. pliers
Large side cutter
6.2 MATERIALS
•
•
•
•
•
•
•
•
White spirit
Isopropanol
Parafin
Hose clamps (10 off ) for cable OD
Galvanized steel band , 10mm x 0,7 mm, ca 50 cm
Zinc spray
Cable grease
Red/yellow textile tape
6.3 PROCEDURE
a) Remove uncoiled armouring wire and clamp cable in a vice. (Protect cable with rags,
do not overtighten vice.)
b) Remove grease on cable with kerosene and attach hose clamps approximately 200
mm on each side of the wire end.
c) Using ”Dremel” with grinding wheel, form a ramp (approx. 45 degrees) on wire end.
Also remove sharp edges on wire end.
Severed wire with ramp
Side 4 av 8
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permitted without prior written authorization from Nexans Norway AS.
d) Using felt pen mark a section on the wire, 15 mm from its end. Width of section shall
equal width of galvanized steel band.
e) Grind down the marked section approximately half the wire diameter.
Side 5 av 8
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permitted without prior written authorization from Nexans Norway AS.
f)
Approximately 30 mm to the right of the wire end carefully insert a screw driver
under three armouring wires. Insertion shall be tangential.
g) Form an “omega” (Ω) of the steel band, using three short pieces of armouring wire
in a wise. Length of steel band: approximately 150 mm.
h) Insert steel band under the three armouring wires.
i)
Insert screw driver under three armouring wires at opposite side.
Side 6 av 8
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permitted without prior written authorization from Nexans Norway AS.
j)
Insert steel band, so that steel band is positioned under six armouring wires.
k) Push steel band (”clamp”) axially over wire end and into grove machined in wire.
l)
Remove both excess ends of the protruding clamp, as close as possible to the third
armouring wire. Use “Dremel” with cutting wheel. Do not damage neighbouring
armouring wires.
m) Using screwdriver pry an opening between armouring wire no 3 and 4, and push in
end of clamp carefully with a second screwdriver. Repeat for other side of clamp.
Side 7 av 8
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permitted without prior written authorization from Nexans Norway AS.
n) Distribute armouring wires along circumference. Use plastic hammer.
o)
p)
q)
r)
Rinse area with kerosene and isopropanole.
Spray with zinc spray
Mark section with two red/yellow textile tapes (for future inspection)
When zinc spray is dry apply cable protective grease over section.
Side 8 av 8
CONFIDENTIAL.
All rights reserved. Passing on or copying of this document, use and communication of its content is not
permitted without prior written authorization from Nexans Norway AS.