DESIGN METHODOLOGY FOR UNDERSEA UMBILICAL CABLES

bY

R.H.Knapp, Professor and T.T.Le, Research Assistant

Department of Mechanical Engineering

M.J. Cruickshank, Technical Director

Marine Mineral Technology Center

University of Hawaii at Manoa

Honolulu, Hawaii 96822

ABSTRACT Nomenclature
Umbilical cables are widely used in the ocean industry for = layer area
exploration and recovery of petroleum and mineral resources. = core area
Development of these cables requires careful design to satisfy = coefficients of radial displacement function
simultaneously power, communication and strength functions. The = matrix of penalty parameters
present paper suggests a design methodology to facilitate the = helical wire coverage
mechanical design of umbilical cables. A design nomograph and simple = wire diameter
formulas suitable for hand-calculation are presented as preliminary = elastic tensile modulus
design aids. Computer software to assist in finalizing the design is = core compressive modulus
described. = factor of safety
= core shear modulus
= core effective polar moment of inertia
INTRODUCTION = cable cross-sectional stiffness matrix
= stiffness
Todays umilical cables are as diverse in design as their many = length
applications in the ocean including power cables, control cables, tow = cable bending moment
cables, remotely-operated vehicle (ROV) cables, subsea wellhead cables = number of wires
and mining cables. Umbilical cables may consist of numerous = number of harmonic terms
dissimilar components to conduct electrical power, optical control = matrix dependent on contact angles, pi
signals, and fluid power. Also, armoring wires are needed to protect = local displacement vector
these conductor components. This paper is concerned with the = global displacement vector
mechanical design of a composite umbilical cable under the = radius in polar coordinates
simultaneous actions of tensile, twisting, bending, pressure, and = boundary constraint matrix
thermal loads. A design nomograph and simple formulas are presented = wire radius
for preliminary design. Finally, computer models for more refined = pitch radius
analysis are described. A numerical example is presented to illustrate = global load vector
and verify the accuracy of the design method. = core outer radius
= yield strength
= penalty function matrix
Mechanical Failure Modes = cable tension
= radial displacement
CQmposite cables are subject to electrical, optical and = circumferential displacement
mechanical failure modes. This paper is concerned with the mechanical
failure modes described below. Tensile failure occurs if the tension = helical wire lay angle: t) right-hand lay; (-) left-hand lay
applied to the cable produces yielding or fracture of any of its = angle to contact point {Figure 3)
= cable strain
components. Excessive rotation of a free-end cable can produce = 0 : rigid core assumption
excessive cable elongation and unequal load sharing among the helical = 1 : incompressible core assumption
armor layers as load transfers from layers that are loosening to those = circumferential angle in polar coordinates
layers that are tightening. Excessive torque of a fixed-end cable can = total potential energy
lead to cable hockling (unstable looping) if the applied tension is = axial stress
insufficient to maintain a straight cable. Bending failure frequently = cable torque
occurs near supports, terminations and where the cable bend radius is = cable rotation
small enough to produce significant bending stresses. Fatigue failure = cable curvature angle
occurs due to the cyclical application of any load, but is most Subscripts:
frequently the result of repeated bending, especially near terminations
or supports. Temperature changes can produce damaging internal a = antisymmetric 1 = layer number
stresses, especially for plastic materials and delicate optical fibers. d = dependent layer L = total number of layers
e = condensed ring element m = macro-element
k = Fourier series harmonic s = symmetric

19$1.COO1991 EEE
-&7803-M02-8/91/OOm-13
 DESIGN PROCESS

The process of designing an umbilical cable is illustrated by the

flowchart in Figure 1 and further detailed in Tables 1 to 7.

Operational Parameters START

To begin the design process, each operational parameter

identified in Table 1 must be defined or estimated. All core
Specify Operational Parameters
components including the size and quantity of conductors (electrical,
(see Table 1)
optical and fluid) are selected to meet the needed transmission
requirements. The desired geometry of the cable suspension, the cable
weight and current velocity profiles are to be estimated. To facilitate
cable storage, deployment and retrieval from a support vessel, physical I
characteristics of the cable such as weight, overall diameter, axial
stiffness, torsional stiffness, and bending stiffness must be carefully
considered. The stiffnesses need to be matched to the cable handling
system. Helical strength members having small lay angles provide
greater strength and axial rigidity but reduced torsional and bending
flexibility. The opposite is true for large helical lay angles. The design
method must permit tradeoff studies to satisfy strength and
deformation criteria and handling requirements.

Umbilical cables must be designed for repeated deployment and

retrieval. Suitable materials must be selected to minimize corrosion,
fatigue and surface abrasion.

Table 1. Operational Parameters

Cable Transmission:
Conductors
insulation Layers
Fluid Conduits

Cable Suspension:
Cable End Coordinates
Cable End Excursions
Cable Weight/Length
Current Velocity Profile

Cable Handling:
Cable Weight/Length
Overall Diameter
Axial, Torsional and Bending Stiffnesses

Cable Strength:
End Conditions (fixed or free to rotate)
Loads (tension, twist, bend diameter, bend cycles, pressure, Prototype Testing
temperature) (see Table 7)
Factors of Safety

FINISH
Figure 1. Mechanical Design Flowchart
Table 2. Preliminary Design

Specify Conductors:
Electrical
Optical
Fluid

Armor Area
Helical Wire Coverage
Torque and Stress Balance
Linear Cable Equilibrium Equations
Helical Wire Axial Stress
Cable Hockling

1320
 Table 3. Cable Cross-Section Armor Area. The strength members serve to carry the applied
cable loads and to provide mechanical protection to the electrical,
optical and fluid conductors located within the cable core. For the
Geometrical Layout:
latter purpose, such strength members are referred to as armor. To
Size & Number of Conductors (electrical, optical, fluid)
provide bending flexibility, the armor wires are nearly always helically
Insulation Layers (sheaths, jackets)
Filler Wires served around the cable core.
Armor Wires
The nomograph presented in Figure 2 permits rapid estimates
Select Materials: of the armor area in any layer. This nomograph is based on a linear
Elastic Modulus formulation subject to the assumptions:
Yield and Ultimate Strengths
Poissons Ratio (1) the ends of the cable are fixed against rotation;
(2) the core is radially rigid and its axial rigidity is neglected;
Nonlinear Stress-Strain Curve
(3) each layer of armor carries an equal fraction of the applied tension;
Hardness (4) wire bending and torsional stresses are neglected.
Thermal Coefficient of Expansion
Specific Gravity
To use the nomograph, follow the steps outlined in Table 8.

If a standard circular wire diameter, d,, is to be used for layer

l, the number of wires, nl, in a layer is computed by the formula,

Table 4. Cable Properties

Wire Coverage
Cable Outer Diameter
Cable Weight/Length
Structural Stiffnesses (axial, torsional, bending) Helical Wire Coverage. The wire coverage is a measure of how
completely the number of wires, nI, fills a layer. For a compact cable
cross-section, it is desirable to choose a coverage above 90%, but less
than 100%. Wire coverage in this range helps to maintain a stable
construction during handling. Nowak[ 151 presented a formula for
coverage based on an elliptical approximation to the shape of a helical
Table 5. Cable Suspension Analysis
wire cut transverse to the cable axis. This coverage formula is
sufficiently accurate for cables of practical interest. After some
Maximum Axial Tension, rearrangement, Nowaks coverage formula becomes,
Maximum Rotation
Maximum Bending Moment Cl[%] = -XI00
n14
(2)
Minimum Bend Radius 21rR,coscul
Hockling (unstable looping)

where RI is the pitch radius measured from the cable axis to the wire
axis.
Table 6. Computer-Aided Design
Torque and Stress Balance. The helically-served components
Cable Strain that render the cable flexible also induce a torque as each helical wire
Cable Diameter Reduction layer tries to unwind with the application of tension. The net torque
Cable Torque or Rotation produced causes a free-end cable to rotate with some layers tightening
Component Stresses and Strains and some loosening. This means that some layers will be stressed at
Minimum Bend Diameter higher levels than others, thereby lowering the cable breaking strength.
Radial Pressure Distribution Furthermore, long cables that are restrained from rotating can develop
sufficient torque to produce hockling (unstable loop formation) if the
cable tension is relaxed. To minimize the cable torque and potential
hockling, contrahelical layers of armor (alternating left- and right-
hand lay directions) can be employed in the cable design.
Table 7. Prototype Testing
For structural efficiency, it is important that each armor layer
Conductor Performance: carries a fraction of the total tension proportional to its yield strength.
Electrical, Optical, Fluid This condition is termed stress balance.

Mechanical Performance: Knapp[7] has demonstrated that the torque and stress balance
Deformation, Strength, Fatigue conditions are approximately met if the following equation is satisfied:

Preliminary Design
In this section, a design nomograph and simple linear cable
models, suitable for hand-calculation, are suggested as preliminary
design tools. They are used to estimate the size and quantity of
strength members needed and the overall response of the cable to
applied tension, twist and bending actions. This initial definition 0.f
the cable cross-section is subsequently subject to refinement using
computer-aided design tools.
sinad = - (3)
where ad = lay angle of dependent layer, d (usually the outermost
layer).
Linear Cable Equilibrium Equations. The preliminary selection
of armor can be improved by use of equilibrium equations [6][11] that
relate the applied tension, T, torque, 9,and bending moment, M, to the
cable axial strain, ec, twist, Aq5/Lc and bend curvature, A$/LC.

1321
 A B C

--loo0
--goo
--800
-- 700
-
I
3
--600

--500
2
2z -400

--300
> +
U
Y
- - l --250
t;
-- --200
5 -- -- 175
U
- 150
5 -
K
0 __ U --125

2 - - 3 L --loo
Y
m --75

m
9
-
U
-- 50 Y
U

- -'2

-- 25

Figure 2. Nomograph for Estimating Area of Armor Layer

Table 8. Use of Nomograph where the stiffness terms are

(1) Specify the factor of safety, FS, on yielding for the cable
kT, = c
"L [ qAIEI(l-.!-tan2al)cos5al]
RC
+ ACEc
tension, T. 1.1 2 RI
(2) Select the armor material and compute the ratio, E/S, for
each layer. "L
kT, = qAIElRlsinalcos2aI (6)
(3) Draw a line intersecting the FS, E/S, values and the A-axis 1=1
for each armor layer.

(4) Guess at a helical lay angle, a, for each armor layer. "L
k,, = e Rc
qAIEIRl(1 ---tan2al)sinalcos2al (7)
(5) Draw a straight line from the intersection on the A-axis (step 1=1 2 4
3) to the lay angle axis labeled A (right-side of chart) for each
armor layer. Select the maximum value which intersects the B-
axis.

(6) Draw a straight line from the maximum value on the B-axis
(step 5) to the lay angle axis labeled B. Repeat this for every
layer and mark the intersections on the C-axis.

(7) Draw a straight line from each intersection on the C-axis to

the Number of Armor Layers line, nL. labeled C. Where these
lines cross the Armor Area line determines the dimensionless
value, AE/T, for each layer. Knowing E and T, the armor area,
A, can be computed. "L
= nlEIIl + EcIc (with wire slip) (10)
1=1

where
If wires within a layer are of identical size and symmetrically
disposed around the cable axis, the linear equilibrium equations are 6 = 0 : radially rigid core
(11)
given by = 1 : incompressible core

and other terms in the above equations are defined in the

Nomenclature. Note in equation (4) that the bending equation is
decoupled from the axial-torsional equations. This is a consequence of
the previously stated symmetry assumption that is justified if a
sufficiently large number of wires occupy a layer. Also, equations (6)

1322
and (7) reveal that the stiffness matrix is not symmetrical if 0=!;viz.,
kT+ # k,c. This is a result of treating the core as an ideally
incompressible material where the core diameter change depends only
on the axial strain and not on core twist. The bending stiffnesses given
by equations (9) and (10) represent the two ideal cases of beam bending
(no wire axial slip) and individual wire bending (with wire axial slip).
Since real cables experience some slip dependent on the bend
curvature, the actual value of kM$ will lie somewhere between these
two values as has been experimentally verified by Durelli, et al. [4].
For an improved analysis of bending behavior, Lanteigne[ 1 I] has
proposed a wire slip criterion that can be used to select either equation
(9) or (IO) for each wire layer in the cable. He also presents stiffness
terms in equation (4) that couple the tension, twisting and bending
actions when symmetry cannot be assumed. For preliminary design,
however, equation (4) should be satisfactory.
Helical Wire Axial Stress. In general, the helical wire will
experience axial, bending and torsional shearing stresses. For
preliminary design estimates, only the axial stress component will be
considered here. A simple expression for the wire axial stress has been
derived in terms of the cable axial strain, the bending-induced wire
axial strain, cable twist and radial deformations of a rigid @=O) or
incompressible (+=I) core:
where, preceding f, the (+) and (-) signs refer to the outside and inside
of the bend, respectively, and
f = 0 (wire slip) (13)
= I (no wire slip)
Cable Hockling. A cable that is not designed for torque-
balance may develop a sufficiently large torque relative to the applied
cable tension, that relaxation of the tension (momentary slack cable)
can result in hockling (unstable looping) as the cable tries to relieve the
torsional strain energy. If a loop were to develop, reapplication of the
full tension could damage cable components as the hockle curvature is
increased.
Several investigators have proposed models to predict the
tension, T, needed to maintain a straight cable configuration for an
induced torque, +. Greenhill's formula [ 5 ] , which was also derived by
Liu[ 131 using Timoshenko's buckling formula for a slender rod,
represents the tension at the onset of hockling,
T = -5 2
4EI
By assuming that the loop diameter must be a magnitude to minimize
the torque, Ross[21] obtained,
which is twice as large as was obtained by Greenhill and Liu.
Liu presented the empirical formula,
T =
332
- (experimental)
SEI
which is halfway between the values given by equations, (14) and ( 1 9 ,
and therefore might be used for preliminary design. Recently,
Coyne[3] p.roposed a more rigorous model that depends on cable length.
His result is also bounded by equations (14) and (15).
The flexural rigidity, EI, appearing in these equations can be
estimated by the stiffness factor,?,k in equations (9) and (10).
1323
Cable Cross-Section
Based on the preliminary analysis performed in the previous
section, or following a computer-aided analysis (described below), the
cable cross-section is defined (or redefined).
The electrical, optical and fluid conductor components are
specified and geometrically arranged within the cable core. Filler
wires may be provided to occupy interstitial voids between adjacent
core components. The core may be provided with a protective outer
sheath around which layers of helical armor wires are served (for
example, see Figure 4). Also, an optional outer jacket may be provided
to protect the outer armor layer from abrasion during handling.
In addition, all material properties listed in Table 3 must be
specified. For nonlinear materials, a stress-strain curve is needed for
the computer analysis. For components such as the core sheath, a
compressive stress-strain curve is preferable. Polymeric or elastomeric
cylindrical layers may be indented by adjacent circular wire layers.
Such wire indentation can greatly affect the cable strain and the
induced cable torque. To account for this effect, the computer
software described below requires the hardness of the indented layer
to be specified.
Cable Properties
Following the flow chart in Figure 1, the cable properties listed
in Table 4 should be checked. Wire coverage can be approximated by
equation (2). It is important to ascertain that the cable outer diameter
is geometrically compatible with all handling equipment such as the
overboard sheave. Cable weight may be limited by the load ratings of
the deck handling equipment, and it needs to be specified for a cable
suspension analysis. Also needed for the cable suspension analysis are
the axial (AE), torsional (JG) and bending (EI) stiffnesses. In terms of
the approximate linear equation (4), AE = kTr, JG = k,, and El = kM+.
Cable Suspension Analysis
The analysis of a cable suspension is needed to determine the
maximum values of cable tension, rotation and bending moment that
the cable must be designed to withstand. Since the cable structural
properties must be known for the cable suspension analysis and the
maximum loads acting on the cable must be known to determine the
structural properties needed to prevent any component failures, the
design iteration described in the flow chart of Figure 1 is suggested.
Modeling of cable suspensions has been undertaken by
numerous investigators. It is beyond the scope of this paper to discuss
numerical solutions. The reader is referred to the pertinent literature
including Walton & Polacheck[221 who developed a finite difference
solution for nonlinear transient motion of cables, and Obrien[l6] and
Peyrot[ IS] who developed special cable elements based on the equations
of an elastic catenary when bending stiffness is negligible. Leonard[l2]
and McNamara[l4] describe the use of finite element analysis including
bending stiffness, and Riggs and Leraand[20] proposed an improved
cable element for static analysis that includes an algorithm for adaptive
discretizations of the cable when fluid drag forces are present.
Oliveira, et al. [I71 describe simple analytical methods involving the
cable catenary that can be used to find the maximum tension and
bending moment of flexible pipes subject to uniform fluid drag. This
latter method may be suitable for preliminary design estimates.
Computer-Aided Design
The SAC (Stress Analysis of Cables) computer program has
been developed as a design tool for the cable industry [9][10]. After
establishing a preliminary design as previously described, this software
can be used to rapidly perform parametric studies of geometrical and
material quantities to achieve an optimal design.
 Fundamentally, the SAC model consists of adjacent or
overlapping concentric circular layers of any thickness. A layer can be
a thick-wall cylinder or filled with equally spaced circular or keystone
wires. The wires can be solid or fibrous sections. The geometry of the
model is defined by layer inner and outer diameters, wire sizes and lay
lengths. Structural properties of all layers are computed by the
program; however, the user can override this feature and manually
input structural properties. For example, this would be useful to model
more accurately a copper strand. For helically-served layers, the
program assists in selecting the correct number of wires to "fill" a layer
e=o
for the desired coverage. Moreover, since the coverage formula used
is geometrically exact, it will give the correct coverage for wire layers
having large lay angles.

Loads can act alone or in combination with other loads

including axial tension, twist, bending, clamping, and internal pressure.
Hydrostatic pressure and temperature change can be specified
independently for each layer. For bending analyses, the program E
computes the minimum bend diameter for layer yielding as well as the
bend diameter that produces circumferential wire contact at the inside
of the bend where wires are "pinched." Figure 3. Macro-Element for Typical Cable Component

The highly nonlinear layer equations are solved so as to satisfy

all equilibrium conditions and deformation compatibilities in the axial, where
radial and circumferential directions. Nonlinearities include nonlinear
stress-strain curves, large deformations such as rotation and plastic Ig(r) = b, + bzr + b3rz
indentation of circular wires into adjacent (inner or outer) cylindrical
layers. For wire indentation, any initial radial indentation and the V&r) = b, + bsr + b6r2
Durometer hardness of the indented cylindrical layer must be specified. ua(r) = b7 + b8r + b9rz
Va(r) = blo + b l l r + bl,r2
The SAC model computes layer and cable weights based on the
specific gravities of wires, wire jackets, sheaths, jackets and void
fillers. Program data files may be converted among the English, and the upper limit, N, is chosen to satisfy convergence of the series.
Metric, and SI measurement systems. Plots showing the exact scaled The subscripts 's' and 'a' represent the symmetric and antisymmetric
geometry of the cable cross-section and analysis results are generated terms relative to the $=0 axis in Figure 3.
by the program.
Using equations (17) and (18) and following the stiffness
formulation for a ring element [2][24], element stiffness matrices
representing symmetric and antisymmetric terms can be found for
Finite Element Model every harmonic term from k = 0 to N.

Limitations of the present SAC program include the Next, the nodes of all ring elements are condensed [23] to leave
assumptions of geometrical and load symmetry about the cable axis and only two nodal points, A and B, on the inner and outer surfaces of the
material isotropy. If dissimilar components are arranged within a cable component as shown in Figure 3. This leads to the stiffness matrix,
core as illustrated in Figure 4, the radial deformation of the core will [k], of the condensed ring element,
not be uniform about the cable axis. Also, fiber-reinforced layers used
for hydraulic tubes and protective jackets may possess sufficient
anisotropy to influence cable deformations. A new finite element
model has been developed that accounts for material anisotropy and
unsymmetrical radial deformations. The example presented in the
following section illustrates the accuracy of this element. A brief
discussion of this model is given below; however, a detailed derivation
will be presented in a forthcoming publication.
This is an 8(N+1 square matrix with all harmonic terms decoupled In
Briefly, each component in the cable core is modeled as a equation (20),
macro-element having nodal degrees-of-freedom at all points of the
inner and outer surfaces that contact adjacent components; for )
example, points C, D and E in Figure 3.

Ring Element. Due to the unsymmetrical deformations These matrices correspond to the nodal displacement vectors,
expected for a typical ring element, radial and circumferential
displacement shape functions, u(r,8) and v(r,$), respectively, are
expressed in polar coordinates according to the following Fourier series
[2] with quadratic variations in the radial direction:

Macro-Element. The condensed ring element that represents the

N component in Figure 3 can now be treated as a linear elastic structure
v(r,8) = [ v,(r)sink8 - va(r) cosk8 ] (18) in static equilibrium with the applied forces applied at its contact
k=O points C, D and E. The unit displacement theorem [19] is used to
obtain the stiffness matrix, [k],, of this component with respect to the
U and v displacements at all contact points.

1324
 A column vector of [k],, corresponding to a unit displacement
(U or v) at any contact point, is generated by determining the attendant
reaction forces for the degrees-of-freedom at all contact points. A
typical contact point, C, making an angle, Bc, with the axis line, 5 = 0
as shown in Figure 3, illustrates the procedure. If a unit displacement,
u=l, is imposed at point C, equations (17) and (18) become,
u(r,5) = 1
(5 = &; r = rB )
= 0 (5 = BD, BE; r = r, )
v(r,O) = 0 (5 = Bc. BD, BE; r =rg 1
where rB = outer radius of the component. Substituting comparable
equations for all contact points leads to the displacement constraint
equation,
where [p] consists of constant terms related to the j3 angles above; (9)
is the unknown displacement vector,
where (q),,Lk) are expressed by equation (22). (rp) is a column vector
whose elements equal 0 or 1.
A penalty function will be defined as
such that (t) = (0) when equation (24) is satisfied. The total potential
enygy, II, of the structure can be augmented by the quantity,
(t) [c](t)/2, without changing its value as (t) approaches (0). [c] is a
diagonal matrix of constant penalty parameters, ci. According to the
principle of minimum potential energy, equilibrium is achieved for the
stationary condition, aIT/aq, = 0, which leads to the result,
[ WI, + I = [PI~[cI{~,}
[ P I ~ M [ P]I41
where [k], is given by equation (20).
Following the penalty method [2][24], the parameters, ci, are
incrementally determined such that (9) found by equation (27) satisfies
equation (26); viz., (t)=(O). Having determined (q), the reaction forces
at any of the contact points can be found by the equations,
( i = l at r=rA; i = 3 at r = r B )
N
F,(r,B) =
k=0
[ [hj]!k)(q}!k)sink5 - [hj]r){q}?)coskB ]
( i = 2 at r=rA; i = 4 at r = r B )
and j=1,4 for both equations. [kij],,.(k) and (q), Jk) are defined by
equations (21) and (22), respectively. These ieaction forces are
evaluated at all contact points. This solution represents one column of
the stiffness matrix, [k],, corresponding to the direction of the
imposed unit-displacement. This process is repeated for all contact
points. In this manner, the entire stiffness matrix for the macro-
element of the component shown in Figure 3, [k],, is generated.
Assembly Procedure. Finally, the stiffness matrices for all
macro-elements are transformed to a global coordinate system and
assembled into the system equation for the entire cable cross-section
[I19
[KHQ)= {RI
where [K] is the stiffness matrix for all cable components; (Q) is the
unknown global displacement vector of all component contact points;
and (R) is the global load vector consisting of concentrated loads
applied at the contact points.
Prototype Testing
(23) The final verification of the cable design is to subject the as-
built cable to simultaneous conductor and mechanical performance
tests. These tests are needed to confirm that all conductors perform
satisfactorily while all pertinent proof loads are applied to the cable.
Measured mechanical data may include cable strain, torque or rotation,
flexural rigidity, cable diametrical reduction and cable breaking
strength.
Analytical models that accurately predict the fatigue strength
of a cable have not yet been developed, although a modest attempt has
been made to describe the cyclical tension fatigue mechanism [SI. The
most important failure mode is flexural fatigue where radially
compressed layers experience relative motion during cable bending.
This motion may cause surface fatigue cracks (fretting) to develop at
interlayer contact points. Cables which are to be operated over
shipboard winches and sheaves should be subjected to rigorous cyclical
bending tests.
DESIGN EXAMPLE
The remotely-operated vehicle (ROV) electro-optical umbilical
cable depicted in Figure 4 will be subjected to the design process
described in Figure 1. Three electrical conductors (layer 2) and three
jacketed optical fibers (layer 3 ) are contained within a core jacket
(layer 5). Filler wires (layers 1 and 4) serve to stiffen the core package.
Two round wire layers provide the external armor (layers 6 and 7). All
core components are served with a common lay length and the two
armor layers are contrahelically laid to reduce the induced torque.
Preliminary Design
The electrical, optical and filler wires are placed in the most
(27) compact form possible and contained within a high-density
polyethylene sheath having a 11.15 mm outer diameter. This cable is
to be subjected to a 68 kN tensile load and a factor of safety on yield
of at least 2.5 is desired. The armor wires are super extra-improved
galvanized plow steel with an elastic modulus, E = 1 . 9 3 ~ 1 0MPa,
~ and
yield strength, S, = 1.97~10' Mpa.
Armor Area. The nomograph in Figure 2 is used to determine
the armor wire area needed for each layer. See Table 8 for a
description of the procedure. For FS = 2, E/S = 100, and an initial
guess of an 18 degree lay angle for each layer, d=
225 or E, = 0.44% is
obtained. For two armor layers, nL = 2, the nomograph yields AE/T
= 130. Substituting the value for E and T given above, the armor area
(28) for each layer, A = 46 mm2.
Next we choose two standard round wire diameters of 1.93 mm
and 1.27 mm for layers 6 and 7, respectively. Using equation (l), we
obtain 15 wires for layer 6 and 36 wires for layer 7.
Wire Coverage. Coverage for both layers should be
approximately 95%. From Figure 4, the pitch radii are found as R, =
6.54 mm and R, = 8.14 mm. Equation (2) requires that the number of
wires in layer 6 be increased to 19 wires.
Torque and Stress Balance. For this preliminary design, the
torque contribution of the core components is neglected. Selecting the
outer layer 7 to be the dependent layer and the lay angle of layer 6 set
to 18 degrees (right-hand lay), equation (3) yields -17.6 degrees for
layer 7. This result is rounded to -18 degrees (left-hand lay).
(29)
1325
 CBBLE CROSS-SECTION
ROU U m b i l i c a l C a b l e
Layer nnez- D i a muter D i n
Cnnl C nnl
~

.e .694E-91
.887E-E1 .246E+EE
.12iE+9C .246E+99
.183E+BC .246E+90
.246E+BC .l l S E + B l
.115E+91 .591E+91
.501E+01 .755E+91

P n e s s ENTER t o C o n t i n u e . . B n r l y s i r by t k c S B C C o m p u t e r P p o g r a n

Figure 4. Design Example

70 70

60 60 A Mean Data
SAC

-5
z
50

40
50

40
1 SAC/FEM

E
(3

[I1 30 30
$
E3
\\
20
Test D a t a
20 U .

\\\ ...
\\\
10 SAC 10 A m
U\
T,
0 0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 17.1 17.2 17.3 17.4 17.5 17.6 17.7
(%) Axial Strain [mm/mm] C a b l e Diameter [mm]

Figure 5. Axial Strain of ROV Umbilical Cable Figure 6. Diametrical Reduction of ROV Umbilical Cable

13%
 Linear Analysis. Using the preliminary design values obtained
above, a linear analysis is used to estimate the cable strain and torque.
The effective axial rigidity of the core, considering only the copper
conductors and polyethylene sheath, ACE, = 2 . 6 ~ 1 0 'N. Also, the core
is approximated as an incompressible material (9 = 1). Equation (4),
reduced for a straight cable with fixed ends (Ad=O) becomes,
from which E, = 0.40% (approximately the same value obtained using
the nomograph) and S = -2.28 N-m. This is an acceptably small
torque.
HelicalWire Axial Stress. The wire axial stresses computed with
equation (12) yield a stress of approximately 670 MPa for both layers
6 and 7. For a yield strength of 1,970 MPa, this gives an acceptable
factor of safety of 2.9.
Computer-Aided Design
The SAC program was used to finalize this ROV umbilical
cable design. The SAC analysis considered all core and armor wire
components illustrated in Figure 4. The nonlinear stress-strain curve
for the polyethylene core sheath and indentation of the wire layer 6
into the sheath layer 5 were considered in the analysis.
Following its manufacture, this cable was subjected to a tension
test where both the cable diameter and axial strain were measured.
Based on the as-built geometry and a measured compressive stress-
strain curve for the polyethylene sheath, the SAC analysis was
performed. Comparisons of this analysis with the experimental data
are presented in Figures 5 and 6. Also shown in Figure 6 is the SAC
analysis enhanced with the finite element model of the radial core
deformations described above. These analysis results are in excellent
agreement with the experimental results. The SAC/FEM analysis was
able to more accurately predict the change of cable diameter as shown
in Figure 6.
CONCLUSIONS
This paper presents a design methodology for undersea
umbilical cables. Simple analysis procedures to obtain preliminary
design estimates have been described. Cable design software and a new
finite element have been introduced as a cable design tool. An example
of an as-built ROV umbilical cable demonstrates the design process
and verifies the accuracy of the computer software.
ACKNOWLEDGEMENTS
This work was supported in part by a grant from the U.S.
Bureau of Mines, Marine Mineral Technology Center. The test results
of the ROV umbilical cable were obtained by the first author at
Sumitomo Electric Industries, Ltd. in Osaka, Japan. The authors are
grateful to Dr. S. Takeuchi, Mr. Y. Murata, and Mr. T. Mitsui of
Sumitomo for their generous support of the cable tests.
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