ROV New Hire Course

ST UD ENT GUI DE

Gulf of Mexico Region

WWW.OCEANEERING.COM
Morgan City Training Center
5004 Railroad Avenue
Morgan City, Louisiana 70380
 ROV New Hire Course: Student Guide, Gulf of Mexico Region, Revision 1
Copyright © 2014 by Oceaneering International, Inc. (OII). All rights reserved.

The Oceaneering International, Inc., ROV New Hire Course: Student Guide, Gulf
of Mexico Region is intended for training purposes only. The guide is designed to
give new OII ROV technicians a general understanding of the major components
of OII’s ROV systems, including the power and signal flow of those systems.
This document and all of the information disclosed herein is the sole property of
Oceaneering International, Inc., and is furnished on the condition and understanding
that it shall not be reproduced in any manner nor shall the information conveyed herein be
used or disclosed to others for any purpose unless specifically authorized in writing by OII.

Darian Breux
A 1/5/15 Second Release All All
Training Manager
Scott Beggs
A 1/5/15 All All
Technical Manager
Michael Daigle
A 1/5/15 All All
Operations Manager
Content Format
Rev Date Reviewed By Approved Remarks
Pages Affected

ii ROV NEW HIRE COURSE - Gulf of Mexico Region

Table of Contents
About This Guide............................................................................................................................xi
Icons...................................................................................................................................................xi
Sections at a Glance........................................................................................................................xii
List of Abbreviations.....................................................................................................................xv
Course Schedule.............................................................................................................................xvi
Section 1 ROV Fundamentals...............................................................1-1
Introduction....................................................................................................................................1-3
Objectives........................................................................................................................................1-3
What are ROVs?.............................................................................................................................1-4
ROV Working Platforms...............................................................................................................1-4
ROV Classes....................................................................................................................................1-4
Inspection Vehicles................................................................................................................1-5
Work-Class Vehicles...............................................................................................................1-5
ROV Comparison Table................................................................................................................1-7
ROV System Components............................................................................................................1-8
Control Van.............................................................................................................................1-8
Work Van.............................................................................................................................. 1-10
Launch and Recovery System (LARS)............................................................................. 1-11
Subsea Deployment System (Cage).................................................................................. 1-13
ROV Vehicle System .......................................................................................................... 1-16
Offshore Management System.................................................................................................. 1-22
Section Review............................................................................................................................. 1-23
Knowledge Check....................................................................................................................... 1-23
Section 2 Hazardous Energy Control.................................................. 2-1
Introduction....................................................................................................................................2-3
Objectives........................................................................................................................................2-3
What is Hazardous Energy?.........................................................................................................2-4
What Can Be Done to Control Hazardous Energy?........................................................2-4
Hazardous Energy Sources in the ROV Workplace.........................................................2-5
Why Use Lockout/Tagout?..................................................................................................2-6

iii
 When to Use Lockout/Tagout.............................................................................................2-6
Lockout/Tagout Terminology.............................................................................................2-6
Lockout Devices ....................................................................................................................2-7
Tagout Devices.......................................................................................................................2-8
Oceaneering’s Lockout/Tagout Procedure................................................................................2-8
Step 1 - Preparation for Shutdown......................................................................................2-8
Step 2 - Shutdown and Deactivation...................................................................................2-8
Step 3 - Isolation of Energy to the Equipment................................................................2-8
Step 4 - Attachment of a Lockout Device and Tag..........................................................2-8
Step 5 - Attachment of a Tagout Device...........................................................................2-9
Step 6 - Release of Stored Energy.......................................................................................2-9
Step 7 - Verification of Isolation.........................................................................................2-9
Step 8 - Release from Lockout.............................................................................................2-9
Lockout/Tagout Log.......................................................................................................... 2-10
Brady Lockout/Tagout Posted Procedures............................................................................ 2-10
Additional Information.............................................................................................................. 2-10
Temporary Removal of Lockout/Tagout....................................................................... 2-10
Outside Personnel............................................................................................................... 2-10
Group Lockout or Tagout................................................................................................. 2-10
For Shift or Personnel Changes ....................................................................................... 2-11
Section Review............................................................................................................................. 2-12
Knowledge Check....................................................................................................................... 2-12
Section 3 Power Distribution............................................................... 3-1
Introduction....................................................................................................................................3-3
Objectives........................................................................................................................................3-3
System Power..................................................................................................................................3-4
Power Distribution Unit................................................................................................................3-4
Power Distribution Unit Components...............................................................................3-4
PDU Power Flow ....................................................................................................................... 3-10
Transformers................................................................................................................................ 3-12
House Power Transformer ............................................................................................... 3-13

iv ROV NEW HIRE COURSE - Gulf of Mexico Region

 Vehicle/TMS Electrics Step-Up Transformers.............................................................. 3-13
Vehicle/TMS HPU Step-Up Transformers.................................................................... 3-13
Step-Down Transformers.................................................................................................. 3-14
High Voltage Safety.................................................................................................................... 3-14
Electric Hazards.................................................................................................................. 3-14
Transmission Paths..................................................................................................................... 3-16
Vehicle and Cage Power Flow........................................................................................... 3-19
Motor Power Electrical Flow ........................................................................................... 3-19
Monitoring The System.............................................................................................................. 3-22
Section Review............................................................................................................................. 3-31
Knowledge Check....................................................................................................................... 3-31
Section 4 Communications.................................................................. 4-1
Introduction....................................................................................................................................4-3
Objectives........................................................................................................................................4-3
Telemetry.........................................................................................................................................4-4
Serial Communication...................................................................................................................4-5
Data Protocol.................................................................................................................................4-5
Short Whip......................................................................................................................................4-6
Fiber Optics....................................................................................................................................4-8
Fiber Composition.................................................................................................................4-8
Fiber Optic Wavelengths.......................................................................................................4-9
Fiber Optics System............................................................................................................ 4-10
Fiber Optic Safety............................................................................................................... 4-12
Fiber Optic Termination.................................................................................................... 4-12
Section Review............................................................................................................................. 4-14
Knowledge Check....................................................................................................................... 4-14
Student Activity........................................................................................................................... 4-14
Section 5 Oceaneering Power and Control.......................................... 5-1
Introduction....................................................................................................................................5-3
Objectives........................................................................................................................................5-3
OPAC Arrangement......................................................................................................................5-4

v
 PCB Configuration........................................................................................................................5-5
Power Supply PCB A1...........................................................................................................5-5
Control PCB ..........................................................................................................................5-6
I/O Backplane PCB...............................................................................................................5-8
OPAC Power Supplies........................................................................................................ 5-12
Non-OPAC Stack PCBs..................................................................................................... 5-13
Temperature and Distance Monitoring................................................................................... 5-13
A12 Thermocouple Transmitter Module........................................................................ 5-13
Altimeter............................................................................................................................... 5-13
Section Review............................................................................................................................. 5-14
Knowledge Check....................................................................................................................... 5-14
Section 6 Control Telemetry and Graphics......................................... 6-1
Introduction....................................................................................................................................6-3
Objectives........................................................................................................................................6-3
CTAG...............................................................................................................................................6-4
CTAG Monitoring.........................................................................................................................6-4
Power Supply PCB.................................................................................................................6-4
Control PCB...........................................................................................................................6-5
CTAG Main Display......................................................................................................................6-6
Soft Keys ........................................................................................................................................6-7
Tether/Cage Depth and Heading ..............................................................................................6-7
Subsea Telemetry............................................................................................................................6-8
Console Telemetry.........................................................................................................................6-8
Vehicle and Cage Serial Devices..................................................................................................6-8
CTAG Troubleshooting............................................................................................................. 6-10
CTAG for Windows (CFW)...................................................................................................... 6-10
Section Review............................................................................................................................. 6-12
Knowledge Check....................................................................................................................... 6-12
Section 7 Hydraulic Principles and Safety.......................................... 7-1
Introduction....................................................................................................................................7-3
Objectives........................................................................................................................................7-3

vi ROV NEW HIRE COURSE - Gulf of Mexico Region

 Basic Hydraulics.............................................................................................................................7-4
Viscosity...................................................................................................................................7-4
Flow and Pressure Comparison...........................................................................................7-4
Pressure....................................................................................................................................7-4
High-Pressure Hydraulic System.................................................................................................7-5
Reading Hydraulics Diagrams......................................................................................................7-5
Hydraulic Safety........................................................................................................................... 7-11
Improper Operation........................................................................................................... 7-11
Improper Components...................................................................................................... 7-11
Unauthorized Modifications.............................................................................................. 7-12
Improper Selection of Fluid Conductors........................................................................ 7-12
Fittings.................................................................................................................................. 7-12
If a Leak is Discovered.............................................................................................................. 7-13
Section Review............................................................................................................................. 7-14
Knowledge Check....................................................................................................................... 7-14
Section 8 Subsea Hydraulics............................................................... 8-1
Introduction....................................................................................................................................8-3
Objectives........................................................................................................................................8-3
Hydraulic Power Unit (HPU).......................................................................................................8-4
Hydraulic Pump..............................................................................................................................8-4
Hydraulic Reservoir.......................................................................................................................8-6
Valve Packs......................................................................................................................................8-6
Miscellaneous Valves, Gauges, and Filters.........................................................................8-8
ROV Thrusters...............................................................................................................................8-8
Pan and Tilt.....................................................................................................................................8-9
Tether Management System (TMS).............................................................................................8-9
Drive Chains........................................................................................................................ 8-10
Cage Clamps........................................................................................................................ 8-10
Section Review............................................................................................................................. 8-11
Knowledge Check....................................................................................................................... 8-11
Section 9 Manipulators........................................................................ 9-1

vii
 Introduction....................................................................................................................................9-3
Objectives........................................................................................................................................9-3
Manipulator Types.........................................................................................................................9-4
Conan.......................................................................................................................................9-4
Rigmaster.................................................................................................................................9-4
Titan 4......................................................................................................................................9-4
Atlas..........................................................................................................................................9-5
Manipulator Control Methods.....................................................................................................9-5
Rate-Controlled Manipulators..............................................................................................9-5
Spatially Controlled Manipulators.......................................................................................9-6
Best Practices..................................................................................................................................9-6
Maintenance Checks......................................................................................................................9-7
Pre-Dive Check.......................................................................................................................9-7
Daily Checks...........................................................................................................................9-7
Weekly Checks........................................................................................................................9-7
Monthly Checks......................................................................................................................9-7
Manipulator Arm Considerations................................................................................................9-8
Limitations...............................................................................................................................9-8
Hazards....................................................................................................................................9-8
Section Review................................................................................................................................9-9
Knowledge Check..........................................................................................................................9-9
Section 10 Subsea Tooling.................................................................. 10-1
Introduction................................................................................................................................. 10-3
Objectives..................................................................................................................................... 10-3
Normal Load Out....................................................................................................................... 10-4
Hydraulically Actuated Soft Line Cutter.......................................................................... 10-4
Hydraulically Actuated Wire Rope (Hard Line) Cutter................................................. 10-5
Hydraulic Rotary Grinder.................................................................................................. 10-6
3” Dredge/Jet Pump (Trash Pump)................................................................................. 10-7
Sealing Ring (AX/VX) Gasket Replacement Tool........................................................ 10-9
Additional Tooling.................................................................................................................... 10-10

viii ROV NEW HIRE COURSE - Gulf of Mexico Region

 Hotstab............................................................................................................................... 10-10
Marsten Bentley Pump..................................................................................................... 10-12
Rotary Torque Tools......................................................................................................... 10-12
Hydraulic Wellhead Cleaning Tool................................................................................. 10-13
pH Meter............................................................................................................................ 10-14
Section Review........................................................................................................................... 10-15
Knowledge Check..................................................................................................................... 10-15
Section 11 Surface Hydraulics............................................................. 11-1
Introduction................................................................................................................................. 11-3
Objectives..................................................................................................................................... 11-3
Launch and Recovery System (LARS)..................................................................................... 11-4
Hydraulic Power Unit (HPU)............................................................................................ 11-4
Main Lift Winch ................................................................................................................. 11-4
A-Frame................................................................................................................................ 11-5
ROV Overboarding Devices............................................................................................. 11-5
Moon Pools.......................................................................................................................... 11-5
Rail Cursor System.............................................................................................................. 11-6
Auxiliary Power Unit (APU)...................................................................................................... 11-6
Communication Systems............................................................................................................ 11-7
Safety Awareness......................................................................................................................... 11-7
Operational Considerations....................................................................................................... 11-8
Section Review............................................................................................................................. 11-9
Knowledge Check....................................................................................................................... 11-9
Section 12 Umbilicals.......................................................................... 12-1
Introduction................................................................................................................................. 12-3
Objectives..................................................................................................................................... 12-3
Key Terms.................................................................................................................................... 12-4
Umbilical Design......................................................................................................................... 12-6
Models................................................................................................................................... 12-7
Construction........................................................................................................................ 12-8
Cost....................................................................................................................................... 12-9

ix
 Re-Armor..................................................................................................................................... 12-9
Operational Factors.................................................................................................................. 12-10
Umbilical Inspection................................................................................................................. 12-10
Principals and Frequency of Inspections...................................................................... 12-10
Inspection Methods.......................................................................................................... 12-11
Knifing........................................................................................................................................ 12-12
Reterminations........................................................................................................................... 12-12
Umbilical Maintenance............................................................................................................. 12-13
Lubrication......................................................................................................................... 12-13
Application Methods........................................................................................................ 12-14
Core Luber......................................................................................................................... 12-15
Umbilical Termination............................................................................................................. 12-16
Pre-Job Meeting................................................................................................................. 12-16
Umbilical Retermination.................................................................................................. 12-17
Post-Job Meeting............................................................................................................... 12-20
Section Review........................................................................................................................... 12-21
Knowledge Check..................................................................................................................... 12-21
Appendices...............................................................................................1
Safety Considerations....................................................................................................................... 3
Safety Symbols Used in These Appendices.................................................................................. 3
Internal Safety Symbols.................................................................................................................... 3
Appendix A High Voltage Test Box....................................................A-1
Appendix B Light Source and Meter...................................................B-1
Appendix C Megohmmeter.................................................................C-1
Appendix D Optical Time Domain Reflectometer............................ D-1
Appendix E Serial Communications...................................................E-1

x ROV NEW HIRE COURSE - Gulf of Mexico Region

About This Guide
This guide is divided into sections by topic. Each section is represented by a designated
color. These color designations will also be present on the Gulf of Mexico ROV Learning
Management System (LMS).
Blue sections represent general topics.

Orange sections represent safety topics.

Green sections represent electrical topics.

Gray sections represent hydraulic topics.

Each section has key terms, learning objectives, and content designed to help students retain
the information they are learning. The instructors may modify the time spent on each section
depending on the needs of the students. Knowledge checks are to be completed as a review
after each section.
While taking this course, keep in mind that there are several different configurations for ROV
systems. This course focuses on baseline information that is universal for all ROV Systems.
Information that is specific to one type of ROV will be identified. Always remember that this
student guide is for training purposes only.
Supplemental resources include an electronic copy of this guide, course assessments, and
additional learning topics on the Gulf of Mexico ROV LMS.

Icons
Icon Description Icon Description

Knowledge Checks are questions to test

Warning - Personal Injury
what the student has learned.

Course/Module Review is a summary

Tech Tips are technical aspects that the
of what was discussed throughout the
user will find resourceful.
section.

Questions Student Activity

Caution – Damage to equipment Valuable Information

xi
 Sections at a Glance
ROV Fundamentals Power Distribution
This section introduces the types of remotely operated This section describes the ROV’s main components and
vehicles and the major components of the ROV. flow of power and outlines high voltage safety factors.
• Describe Oceaneering working-class ROV’s • Identify system input power and source(s)
• Describe ROV main components and their • Identify the power distribution
physical layout components and describe how they
• Discuss and describe system main interconnect and operate together to
components to include the following: the include circuit breakers, contactors and
control van, work van, launch and recovery transformers
system (LARS), sub-sea deployment • Discuss high voltage safety to include
system, and vehicle electrical hazards and electrical shock
• Discuss the purpose and size of the • Define OHMS Law
different conductors in the tether and • Understand and identify power
umbilical transmission paths
• Discuss precautions taken during • Describe power flow and control
mounting, storage, and maintenance to
prevent damage to cameras and lights • Explain the purpose of the ground fault
circuits on the system and what they are
• Explain the relevance of PBOF connectors monitoring
and the use of pressure compensation
systems • Explain why technicians continuously
monitor motor current, system volts, and
• Discuss the system components that are oil levels while operating the system
monitored with pressure gauges
• Explain where technicians monitor motor
Hazardous Energy Control current, system volts, and oil levels while
This section explains how to recognize hazardous operating the system
energy sources in the ROV workplace and lockout/ • Explain how to isolate a system for
tagout procedures. repairs such as slip ring change out, tether,
umbilical, reterms, motor and pump
• Explain hazardous energy change outs
• Recognize hazardous energy sources in the • Explain how a GFI circuit works and why
ROV workplace it is important
• Define lockout/tagout terminology and • Explain telemetry
describe equipment
• Demonstrate the correct steps to affix Communications
or remove lockout or tagout devices to This section discusses the communication between the
hazardous energy sources on the ROV surface controls to and from the vehicle and cage.
system
• Identify and discuss major components in
• Identify Brady lockout/tagout posted the fiber optic system
procedures and use them to complete the
• Explain the concepts of multiplexing
lockout/tagout process
• Discuss various data protocols
• Discuss the basic process to terminate a
fiber optic cable
xii ROV NEW HIRE COURSE - Gulf of Mexico Region
Oceaneering Power and Control Hydraulic Principles and Safety
This section introduces the control system (OPAC) This section introduces students to basic hydraulic
used by Oceaneering ROVs. principles, theory, and symbology.
• Identify the purpose for each OPAC • Identify basic hydraulic symbols
printer circuit board • Understand principles of hydraulic flow
• Identify the purpose for each GESPAC • Define viscosity
printer circuit board
• List ROV high pressure hydraulic
• Recall where to find information pertaining components
to the power supply for each component
• Understand Pascal’s Law
• Discuss the importance of powering
equipment down before plugging/ Subsea Hydraulics
unplugging the cable This section covers subsea hydraulics and the
• Identify major components on a typical components utilized.
ROV electronics/sensory layout
• Identify the pumps currently being used by
• Discuss the purpose of the major Oceaneering
components on a typical ROV electronics/
sensory layout • Describe how pumps work
• Describe how pumps are controlled
Control Telemetry and Graphics • Discuss how to maintain and store the
This section discusses the software package that allows pumps
the pilot to monitor, troubleshoot, tune up, and set up • Describe thrusters used and how they are
behavior for the system. controlled
• Discuss layout and function of various • Describe rate functions to include P&T
CTAG pages tether circuit
• Discuss how power adjustment is beneficial
for the joystick gain feature in CTAG Manipulators
• Locate the diagnostics page for setting This section covers manipulators used by the ROV.
joystick gain • Identify the different types of manipulators
• Recall the importance of closely on the system
monitoring alarms • Explain the importance of proper
• Show where water and ground fault alarm manipulator maintenance
information is displayed in CTAG • Explain the two different control methods
• Discuss the actions to be taken if a water for the manipulators
alarm is triggered • Discuss the advantages and disadvantages
• Discuss the actions to be taken if a ground of each control method
fault alarm is triggered • Identify best practices for proper ROV
manipulator use
• Explain the importance of effective
communication while conducting ROV
manipulator operations

xiii
 Subsea Tooling Umbilicals
This section discusses the commonly used tooling that This section discusses the function of the umbilicals
helps the ROV crew to perform work assignments and the importance of maintaining them.
successfully. • Discuss umbilical corrosion and methods
• Identify subsea tooling that is required for to reduce corrosion to the umbilical
a normal load out • Discuss the importance of performing an
• Recall where to find the pressure and flow umbilical inspection and lubrication
rates for each tool • Discuss the costs associated with umbilical
• Recall where to find information about the replacement
tooling checks • Explain how and why a re-termination is
completed
Surface Hydraulics
This section covers surface hydraulics and the Appendices
components utilized. This section contains supplementary information for
• Discuss the principles of the launch and use during the course.
recovery of the ROV System • How to use a high voltage test box
• Explain how environmental conditions (sea • How to operate a light source and meter
state, wind, and current) affect the ROV as
it is launched and recovered • Identify what a megohmmeter can measure
and how
• Explain actions that can be taken to
mitigate the adverse conditions • Understand how an optical time domain
reflectometer fiber optic testing device
• Describe the operation and safety concerns works
for the ROV system winch
• Recall the basic concepts of serial
• Describe the proper communication communication
procedures during ROV operation
• Explain the responsibilities of each crew
member during a launch/recovery
• Describe the unique differences and safety
concerns with fixed A-frame, docking
head, cursor, guide wire, and rail LARS
operations
• Describe auxiliary power unit (APU)

xiv ROV NEW HIRE COURSE - Gulf of Mexico Region

List of Abbreviations
Abbreviation Description Abbreviation Description

AC Alternating Current LOTO Lock Out / Tag Out

ADC Analogue to Digital Converter MPEG Motion Picture Expert Group

AHPU Auxiliary Hydraulic Power Unit MSW Meters of Seawater

Amp Ampere NTSC National Television Standards Committee

APU Auxiliary Power Unit OMS Offshore Management System

AVI Audio Video Interlaced OPAC Oceaneering Power and Control

CCW Counter-Clockwise OSHA Occupational Safety & Health Administration

CPR Cardiopulmonary Resuscitation PAL Phase Alternating Line

CTAG Control Telemetry and Graphics Software PBOF Pressure Balance Oil Filled

CW Clockwise PCB Printed Circuit Board

DC Direct Current PDU Power Distribution Unit

DGC Digital Gyro Compass PPE Personal Protective Equipment

DOS Disk Operating System PRV Pressure Reducing Valve

DTS Deepwater Technical Solutions PSI Pounds Per Square Inch

ELEX Electrics RJB Rotating Junction Box

EMF Electromagnetic Field RFI Radio Frequency Interference

EMI Electromagnetic Interface ROV Remotely Operated Vehicle

GIPS Galvanized Improved Plow Steel RPM Revolutions per minute

GFI Ground Fault Interuption SC Spatially Correspondent

GFM Ground Fault Monitoring SIT Silicon Intensifier Target

GPM Gallons per minute STBD Starboard

hp Horse Power TMS Tether Management System

HPU Hydraulic Power Unit UPS Uninterruptible Power Supply

Hz Hertz UHMW Ultra High Molecular Weight

JSEA Job Safety and Environment Analysis v Volt

Kv Kilovolt VAC Voltage Alternating Current

LAN Local Area Network VCR Video Cassette Recorder

LARS Launch and Recovery System VDC Voltage Direct Current

LCD Liquid Crystal Display VGA Video Graphics Array

LED Light Emitting Diode VPP Volts Peak to Peak

xv
 Course Schedule
The course will consist of classroom training for safety and technical topics, hands-on training
for piloting, and hands-on practical application training onboard the International Rig Museum.
The course schedule is subject to change but will include the following:

ROV NEW HIRE COURSE SCHEDULE

OCEANEERING ORIENTATION
Oceaneering New Hire Orientation
ROV Training Center Classrooms

PEC Basic Safety Awareness

SAFETY TRAINING Rigging
ROV Training Center Classrooms & Offsite CPR/AED, First Aid, Bloodborne Pathogens
Water Survival, Swing Rope
ROV Fundamentals
Hazardous Energy Control
Power Distribution
Communications
Oceaneering Power and Control (OPAC)
TECHNICAL TRAINING Control Telemetry and Graphics (CTAG)
ROV Training Center Classrooms Hydraulic Princples and Safety
Subsea Hydraulics
Manipulators
Subsea Tooling
Surface Hydraulics
Umbilicals

HANDS-ON TRAINING
Practical Application Training (PAT)
International Rig Museum

HANDS-ON TRAINING
PIloting
ROV Piloting Simulator Room

xvi ROV NEW HIRE COURSE - Gulf of Mexico Region

 Section 1
ROV Fundamentals

Morgan City Training Center

1-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

1-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
This course is designed to provide the participants with detailed knowledge of remotely
operated vehicles (ROV), ROV components, and ROV current practices. Whether the student is
just entering the field or making a transition into the ROV field from another career, this section
will provide the student with knowledge about the history of the ROV, types of ROVs, major
components of ROVs, as well as challenges faced by Oceaneering’s ROV professionals.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Describe Oceaneering’s working class ROV’s
• Describe ROV main components and their physical layout
• Discuss and describe system main components to include the control van, work van,
launch and recovery system (LARS), sub-sea deployment system, and vehicle
• Discuss the purpose and size of the different conductors in the tether and umbilical
• Discuss precautions taken during mounting, storage, and maintenance to prevent damage
to cameras and lights
• Explain the relevance of PBOF connectors and the use of pressure compensation
systems
• Discuss the system components that are monitored with pressure gauges

SECTION 1: ROV FUNDAMENTALS 1-3

 What are ROVs?
ROV (remotely operated vehicle) is the generally accepted title given to tethered underwater
robots in the oil and gas industry. ROVs are unmanned, they have exceptional maneuverability,
and they are remotely operated by a person aboard a vessel. In the past, ROVs were essentially
cameras with propellers, but after years of technical development, they became high tech tools
for the oil and gas industry, scientists and the military.

ROV Working Platforms

The ROV is used in various setups and applications. The recovery of oil and gas from the
bottom of the sea would be virtually impossible without ROVs. Some of the work platforms
where you will find ROVs include the following:
• Dive support vessels
• ROV support vessels
• Jack up rigs
• Mobile offshore drilling units
• Production platforms and crane

ROV Classes
There are three primary types of ROVs used by Oceaneering: inspection class, working class,
and heavy working class. This course will focus on the two working-class vehicles, but is
important to briefly discuss the other types.

1-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Inspection Vehicles
Inspection vehicles are small with limited or no capacity by which to carry tooling. They are
mainly used for general visual inspection (GVI) and close visual inspection (CVI) work. There
are two types of inspection vehicles: the Spectrum and the Sea Maxx.

Spectrum
The Spectrum is a fully electrically powered ROV. It provides
high quality video for inspection work and is capable of
operating light tools.

Sea Maxx
The Sea Maxx ROV is designed to operate in tandem as Spectrum
a satellite to a larger work class ROV. It is mounted to
the underside of the work class TMS, which provides AC
power and controls. The SAT-ROV is powered by four
thrusters. It is also equipped with a wide angle HDTV
camera module and two variable intensity 40 watt LED
lights.

Work-Class Vehicles
Working class vehicles get their classification because of
Sea Maxx
their ability to be equipped with manipulators and various
subsea tooling. They are much more powerful than inspection-class vehicles and can be utilized
in a broader range of work scopes. Vehicles in this class can range from 50 HP to 220 HP.

Magnum
The Magnum was originally designed and manufactured by Oceaneering in the mid 1990s. It is
still a viable design for normal drill support and barge operations, but its work scope is limited
due to its horsepower, tether length, data transmission, and propulsion system.

Magnum Dimensions
Length 5.5 ft.
Width 3.75 ft.
Depth 2,438 MSW
Propulsion 2 X forward / aft, 2 X lateral, 2 X vertical
Payload 450 lbs.
Umbilical 3,505 M
Tether 183 M
Hydraulic 100 HP Magnum
Manipulator 7-function rate or spatially correspondent

SECTION 1: ROV FUNDAMENTALS 1-5

 Magnum Plus
The Magnum Plus was designed to stay within the previous generation Magnum’s physical
dimensions but with added capabilities. The enhancements to the hydraulic system have
increased its ability to operate a wider range of tools. In addition, the enhanced fiber optic
system allows for a larger array of survey sensors to be utilized.

Magnum Plus Dimensions

Length 7.75 ft.
Width 4.6 ft.
Depth 3,050 MSW, 4,000 MSW optional
Propulsion 4 X vectored, 2 X vertical
Payload 600 lbs.
Umbilical 3,505 M
Tether 548 M standard (cage), 1219 M optional (cage), 396 M (top-hat)
Hydraulic 2 X 85 P
Manipulator 7-function rate or spatially correspondent Magnum Plus

Millennium
The Millennium was manufactured in response to the continuing need for the ROV to carry
larger capacity payloads, lift heavier objects, and perform more complex work tasks. The
Millennium’s primary advantage is its ability to carry large tooling packages that are attached to
the underside of the frame without impeding the ROV’s ability to maneuver.

Millennium Dimensions
Length 5.5 ft.
Width 5 ft.
Depth 2,438 MSW
Propulsion 2 X forward / aft, 2 X lateral, 4 X vertical
Payload 550 lbs.
Umbilical 3,810 M
Tether 146 M
Hydraulic 150 HP
Millennium
Manipulator 7-function rate or spatially correspondent

Millennium Plus
The Millennium Plus was designed based on its predecessor, the Millennium. The system’s
attributes include an enhanced hydraulic system, vectored thruster configuration, and a
redesigned foam block to maximize front end lift, which allows improved performance of the
four vertical thrusters. The enhanced video system allows up to eight cameras to be fitted, and
the fiber optic multiplexer allows easier integration of survey sensors.

1-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Millennium Plus Dimensions
Length 11.5 ft.
Width 5.5 ft.
Depth 3,048 MSW
Propulsion 4 X vectored, 4 X vertical
Payload 900 lbs.
Umbilical 3,048 M
Tether 305 M
Hydraulic 2 x 110 HP (220 Total)
Manipulator 7-function rate or spatially correspondent
Millennium Plus
Heavy Work-Class Vehicles
Heavy working class ROVs are basically the same as working-class ROVs but are larger in size
and have a heavier payload. These ROVs are mostly used for advanced construction work
depending how working class and heavy working class are defined. A good example of a true
heavy working-class ROV based on payload is Oceaneering’s Maxximum vehicle, which has a
power output of 300 HP.

Maxximum
The Maxximum ROV was designed to perform the most complex
and heaviest lift tasks required in the subsea arena. The location
of the thrusters on the Maxximum allows maximum efficiency
for pushing, pulling, or lifting objects. The vast number of tooling
valves on this ROV ensures tooling built in the future can be
interfaced easily. Due to its size, weight, and power requirements,
the Maxximum can only be installed on limited vessels.
Maxximum

ROV Comparison Table

Magnum Magnum Plus Millennium Millennium Plus
Length 5.5 ft. 7.7 ft. 5.5 ft. 11.5 ft.
Width 3.75 ft. 4.6 ft. 5 ft. 5.5 ft.
Depth Rating 2,438 MSW 3,050 MSW 2,438 MSW 3,048 MSW
Propulsion 2 X FWD/AFT 4 X Vectored 2 X FWD/AFT 4 X Vectored
2 X Lateral 2 X Lateral 4 X Vertical
2 X Vertical 2 X Vertical 4 X Vertical
Umbilical 3,505 Meters 3,505 Meters 3,810 Meters 3,048 Meters
Tether 183 Meters 548 Standard (cage) 1,219 146 Meters 305 Meters
Optional (cage)
396 Top Hat
Hydraulic 100 HP 2 X 85 (170 total) HP 150 HP 2 X 110 (220 total) HP
Manipulators 7 Function Rate or 7 Function Rate or 7 Function Rate or 7 Function Rate or
Spatially Correspondent Spatially Correspondent Spatially Correspondent Spatially Correspondent

SECTION 1: ROV FUNDAMENTALS 1-7

 ROV System Components
It is Oceaneering’s goal to standardize the fleet as much as possible, but it is important to
remember the configuration of some systems may vary slightly depending on the application
and the type of vessel. No matter the configuration, all ROV systems will be comprised of five
major components:
• Control van
• Work van
• Launch and recovery system
• Subsea deployment system (cage)
• Vehicle

Control Van
The control van is the operational control
center during ROV subsea operations. The
entire operator interface with the cage and
the vehicle takes place in the control van. The
control van is equipped with a climate
control system, GFI-rated 110 VAC
electrical outlets, fire alarms, and fire
extinguishers. The control van also serves as
the system office.
The control van is comprised of two major
subsystems, which are vital for the operation
and control of the ROV system. The two Control Van
systems are the control console and the PDU
(power distribution unit).

Control Console
The control console is the interface point of the operator with the cage, vehicle, navigation, and
video recording/control equipment. The console consists of three distinct sections: the pilot
console/pilot chair, center console, and navigator console.
Pilot console/pilot chair. The functions of the pilot console and pilot chair can be broken
down into the following categories:
• Telemetry provides functional control, data and video transmission
• Power controls provide AC power on/off for each major sub-system
• Ground fault system provides ground fault monitoring and power shutdown
• Visual displays provide graphic overlays and imagery from the system cameras

1-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

The pilot chair is an ergonomically designed chair that groups the vehicle and TMS functional
controls into a convenient and comfortable arrangement. The chair is also equipped with a
touch screen display. Its overall function is the same as the pilot console.
Center console. The center console is often customized but generally contains the following:
• CTAG for Windows diagnostic display
• Three system computers
• Additional display monitors for navigation
• Sonar computer and display

Navigator console. The navigator console can be customized to the operation, but usually
contains the following:
• Video switching unit
• Video recording equipment
• Additional video monitors

Controle Console

SECTION 1: ROV FUNDAMENTALS 1-9

 Power Distribution Unit (PDU)
The second sub-system of the control van is the power distribution unit (PDU). The
PDU provides power to all of the various circuits. System power from the platform
(480 VAC 3 Phase) is routed directly to the control van PDU. The PDU is the interface point
for all control, data, and video signals to and from the winch, cage, and vehicle. Deck cables
provide the path for the power and the signals between the control van and the winch.

PDU Exterior PDU Interior

Work Van
The work van is air conditioned, heated, lighted, and fitted with fire alarms and fire
extinguishers. The work van contains a workbench and portable tool chest. It is equipped with
all of the necessary hand tools and power tools required to conduct system maintenance. In
addition, standard electronic maintenance and test equipment is included in the maintenance
van. Some examples of the maintenance and test equipment are voltmeters, a megohmmeter, an
optical laser light source, and an optical power meter.
The work van is outfitted with a minimum of ten 110 VAC duplex outlets and two 220 VAC
duplex outlets with a capability of 20 amp service. All of the outlets are U.S. standard
receptacles.

Work Van Exterior Work Van Interior

1-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

Launch and Recovery System (LARS)
The launch and recovery system, also known as LARS, consists of four separate components:
• A-frame launch skid
• Hydraulic power unit (HPU)
• Winch
• Umbilical cable

Launch and Recovery System (LARS)

A-Frame Launch Skid

The A-frame launch skid provides the means to position
the cage and the vehicle at a safe distance over the side of
a vessel for deployment and retrieval. The A-frame uses
hydraulic cylinders to provide the mechanical means to
swing outboard and inboard. A-frame launch skids are
also equipped with a docking head that holds the ROV
in position during the launch and recovery evolution.
Hydraulic power is provided by the hydraulic power unit
(HPU).

A-Frame Launch Skid

SECTION 1: ROV FUNDAMENTALS 1-11

 Hydraulic Power Unit (HPU)
The hydraulic power unit provides all of the hydraulic power
for the main lift winch and A-frame launch skid. This hydraulic
power unit is powered by a 75 HP (480 VAC, 3 Phase, 60 Hz)
electric motor, which is normally connected directly to the
vessel’s power supply. This motor drives a 35 GPM (132.5 LPM)
hydraulic pump, providing adequate power for the handling
system.
Hydraulic Power Unit (HPU)

Main Lift Winch

The main lift winch is manufactured by the DYNACON
corporation and is used to raise and lower the vehicle and provide
a place to store and manage the umbilical. It houses the 12,000 –
16,000 feet of umbilical. The winch is normally fitted with a level
wind mechanism to ensure even spooling of the umbilical cable
onto the winch drum.

Main Lift Winch

Main Lift Umbilical Cable

The main lift umbilical cable is a high strength, armored, opto-electromechanical cable. The
main lift umbilical transmits power and telemetry data between the surface and the cage and
provides the means to launch and recover the cage and the vehicle.

Umbilical Cable

Cursor system. Cursor systems are not a sub-component of the launch and recovery system
but can be used in conjunction with the LARS.
A cursor may take many forms, but all cursors do the same thing: they stabilize and guide the
vehicle by controlling the unwanted horizontal movement of
the ROV during the launch and recovery process.
Some of the reasons a cursor system may be used include the
following:
• Heavy weather operations
• Underwater obstructions such as pontoons
• Deployment through a narrow opening such as a
moon pool

Cursor System

1-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

Subsea Deployment System (Cage)
The subsea deployment cage performs a number of essential tasks:
• Protects the vehicle during launch and recovery operations
• Delivers the vehicle to the job depth
• Acts as a depressor
• Minimizes the effect of currents
• Provides additional stowage for tooling and other equipment

The deployment system is comprised of three subsystems:

• Cage frame
• Tether management system
• Pressure compensation system

Deployment Cage
The cage frame protects the tether management assembly and the vehicle from damage during
launch and recovery. There are two variants of the cage frame. The first type is the side-entry
(most common), which offers greater protection to the ROV. The second type is known as a
top-hat. As the name states, the top hat sits on the ROV like a hat. The top hat is used when the
water entry point is more restricted.

Top-Hat Cage Side-Entry Cage (garage type)

SECTION 1: ROV FUNDAMENTALS 1-13

 Tether Management System (TMS)
The term “tether management” refers to the ability of the TMS to “pay out” or recover tether
as commanded by the pilot as well as the tether drive mechanism’s ability to cleanly and evenly
spool tether on and off the tether storage drum.
The drum holds 600 - 3,000 feet of tether
that connects the cage to the vehicle.
Like umbilicals, tethers also have copper
conductors and fiber optic cables running
their lengths.
The purpose of the conductors is to
transmit power from the cage to the
vehicle. Twelve-gauge conductors are used
for electric and vehicle motor tethers.
The tether transfers data and video signal
through fiber optic cables.
Tether Management System (TMS)
Pressure-tolerant cans
While the pressure compensation system is used for a large portion of the system, some
components are not able to be immersed in fluid. These components must be housed in
pressure-tolerant devices.
Pressure-tolerant cans, also referred to as pressure-resistant or one-atmosphere cans, provide an
interior environment that is equivalent to the surface pressure.
Standard pressure-tolerant cans on the cage TMS include the following:

• Telemetry can • Camera housing

• Vehicle gyro • ROS lights
• Pressure transducer can • Fiber optic can

Pressure Compensation
Nearly all submersible systems in operation today use oil-filled housings when the components
inside will not be damaged by oil submergence. The purpose is to keep water out of the
housings, which have walls too thin to withstand any appreciable external pressure. The
benefits of using thin-walled housings are lower material costs and higher payloads. The
drawback of oil-filled housings is that the behavior of air must now be considered. For this
reason, all the major components of each compensation system are interconnected. This
allows for fluid transfer and equal pressurization throughout the system. Fluid transfer is
possible by using a special connector called a pressure-balanced oil-filled connector
(PBOF). PBOFs allow oil to pass between eguipment that contains a bulkhead
penatration and fill the body of the connector preventing water
from entering the connection.
PBOF Connector
1-14 ROV NEW HIRE COURSE - Gulf of Mexico Region
All pressure compensators used on the ROVs are simply types of accumulators. They are oil-
filled, variable-volume, spring-biased devices used to maintain an above-ambient pressure inside
a housing. They also provide a volume of oil to make up for small amounts of leakage and
compensate for small amounts of trapped air. Also, they act as an expansion chamber allowing
for changes in oil volume caused by temperature.
Compensators. The pressure compensation system will utilize one or more types of
compensators, with the Firestone being the most common.

OIE Compensator
Firestone Compensator Bellofram Compensator

The Magnum Plus vehicles have six independent compensators that maintain positive pressure
within the vehicle’s oil-compensated housings. The names shown in parentheses indicate the
label name on the gauge that is attached to each compensator:
1. Termination can/transformer can (ELECT)
2. Valve pack compensator (VP)
3. Thruster shaft seals (SS) compensator
4. Port motor (PMTR) compensator
5. Starboard motor (SMTR) compensator/overflow comp on newer systems

1 2 3 4 5

SECTION 1: ROV FUNDAMENTALS 1-15

 The compensator pressure is normally kept at a positive pressure between five and seven psi
(.3~.5 Bar) above ambient:
• Any leaks will result in oil coming out rather than water going in; a small external leak is
infinitely less damaging to the system than seawater ingress would be.
• It is usually a simpler process to find and repair an external leak than to repair damage
caused by the ingress of seawater into a compensated system.
Each compensator is connected to an individual pressure
gauge that allows for monitoring of any pressure changes due
to oil loss, valve leakage, thermal expansion, air bubbles, etc.
technicians will use the vehicle cameras to view the gauges.

Pressure Gauges

ROV Vehicle System

The vehicle is a compact, open-framed, dual manipulator work vehicle utilizing a number of
tool and video camera arrangements to provide subsea observation, inspection, intervention,
and work capabilities. The typical vehicle consists of the following components:
• Vehicle frame
• Vehicle flotation
• Vehicle manipulators
• Vehicle thrusters
• Vehicle electrical system

Vehicle Frame
The Magnum Plus Vehicle is constructed using a free-flooding frame to provide support
and mounting areas for all the components of the vehicle. The frame consists of structural
members, brackets, mounting plates, skids, and bumpers. Structural members and some
mounting brackets are extruded 6061-T6 aluminum shapes welded to form an open frame.
Ultra high molecular weight (UHMW) polyethylene skids and bumpers are fastened to the sides
and stern of the main frame and protect the vehicle from abrasion.
Aluminum plating is bolted to the underside of the frame to protect vehicle components from
protruding objects and to support the lead ballast.
The Magnum Plus Vehicle depicted on the next page is intended to be used with a cage-type
TMS, which uses a rear-mounted tether strain relief.

1-16 ROV NEW HIRE COURSE - Gulf of Mexico Region

Magnum Plus vehicle with foam block removed (stbd/aft view).

Magnum plus vehicle with foam block removed (port/aft view).

SECTION 1: ROV FUNDAMENTALS 1-17

 Vehicle Flotation Device
The foam block is made from syntactic foam, which is a material made up of hollow
glass micro-spheres (also called micro balloons), bound into an epoxy resin matrix.
Syntactic foam can provide compact, easily shaped blocks of high-density flotation
that also have extreme crush resistance, making it an ideal material for use on an ROV
system.
As the vehicle’s operational needs and capabilities have changed, Magnum Plus vehicles have
utilized three major styles of syntactic foam blocks:
The single-tunnel design contains a single telemetry tunnel through
the forward section of the foam block. This foam block is the smallest
of the three and was used on only a few of the early Magnum Plus
vehicles.
The dual-tunnel design contains two
Single-Tunnel Foam Block molded-in tunnels. The aft tunnel will
normally contain the telemetry housing while
the forward tunnel will normally contain a removable plug made of
syntactic foam.
The dual-tunnel, high-capacity design is similar to the dual tunnel Dual -Tunnel Foam Block
design but with increased buoyancy and no forward “horse shoe”
shaped cut out.
In the dual-tunnel design foam blocks, one tunnel will contain the
telemetry can, while the second tunnel will contain a syntactic foam
plug made of the same density foam as the foam block itself. Both the
telemetry can and the syntactic foam plug tunnels are protected on both
sides of the foam block by removable aluminum covers held in place by
Dual-Tunnel High-Capacity
stainless steel screws. The vehicle is also provided with ballast weights
Foam Block used to trim the vehicle and to produce slightly negative buoyancy.
After extended periods at greater depths, syntactic foam will absorb
seawater, requiring decreased ballast weight. Ballast weight must also be altered with the addition
or subtraction of tooling.

Vehicle Manipulators
Manipulators are what qualify the ROV as a working-class vehicle. The vehicle is equipped with
two manipulators, each with of a wide range of motion and substantial work capabilities.
Two types of manipulators are used:
1. Rate-controlled manipulators move at a set speed.
2. Spatially correspondent manipulators are operator controlled. The operator controls
the movements of the SC Master Arm and in turn, the manipulator mimics the master
arm’s movement.

1-18 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Rate Controller Atlas Manipulator SC Master Computer Titan 4 Manipulator

Vehicle Thrusters
Thrusters are used on both the cage and vehicle to achieve thrust and control. The thrusters are
used to move the vehicle around in its three different axes. A thruster consists of a hydraulic
motor driving a shroud-enclosed, three-blade propeller. Thrusters are arranged in either an axial
or vectored configuration.
In the axial thruster configuration, two thrusters are located at the aft of the ROV that provide
forward and reverse thrust. Two thrusters located on the center line provide lateral thrust. The
flaw in this design is that during lateral movement some of the thrust strikes equipment on the
ROV, making it less efficient. Also, this configuration causes the vehicle’s rotation point to be in
the rear of the vehicle as seen in the figure below.

Vectored Thrust - Water Flow Axial Thrust - Water Flow

The newer design using the vectored thrusters reduces the loss of thrust by positioning all
four thrusters on the corners of the ROV. With this design, all four thrusters work together in
moving the vehicle forward/aft and laterally. This design also repositions the vehicle’s center of
rotation to the center of the vehicle, which allows better maneuverability of the ROV.

SECTION 1: ROV FUNDAMENTALS 1-19

 Vehicle Electrical System
While most of the “work” performed by the ROV is conducted by the system is hydraulic
equipment, the electrical system provides required power conditioning and interconnects the
various electric components:
• Vehicle lights
• Vehicle cameras
• Telemetry and fiber optic cans
• Termination can
• Transformer can
• Vehicle sensors

Vehicle lights. Two variants of lights are used on Oceaneering vehicles:

quartz halogens and light emitting diodes (LED).
The quartz halogen lights are the older of the two. They were good sturdy
lights, but they did not have the intensity needed for the newer cameras. They
also posed maintenance problems. The design of these lights allowed for
troubleshooting and repair by technicians, but if re-assembly procedures were Quartz Halogen Light
not performed correctly, water intrusion caused faults in the system.
Oceaneering needed a high-quality, dependable multi-purpose light that could
be used in all conditions. They found this in the LED light produced from
Deep Sea System Incorporated (DSSI). These lights are bright and have a long
service life because of the LED technology. These lights also reduce down
time due to light repair because they are not repaired by the technicians. These
lights are just unhooked and replaced as a whole unit, and the faulty light is
sent in for repair.
LED Light

Vehicle cameras. The vehicle can be equipped with several

different camera systems. Standard camera packages may vary
due to changing manufacturers or manufacturers improving
their technology. Some common types used include the fol-
lowing:
• Color camera
• Low light monochrome mini CCD wide-angle
• Monochrome mini CCD wide-angle
• Color CCD with integrated pan/tilt (dome camera)
• HD (high definition)
Vehicle Cameras
• SIT (silicon intensified target)

1-20 ROV NEW HIRE COURSE - Gulf of Mexico Region

Some precautions that should be taken during mounting, storage, and maintenance of cameras
and lights to prevent damage to cameras and lights are listed below:
• Always perform a fresh water rinse and install the lens cap after each dive
• If not in use, the cameras should be stored in the container provided in a controlled
environment
Telemetry and fiber optic cans. The telemetry can, in conjunction with the fiber optic can,
constitutes the vehicle’s telemetry system. The telemetry can provides a dry, one-atmosphere
environment for the vehicle’s OPAC (Oceaneering Power and Control) electronics, power
supplies, and interconnecting wiring. The telemetry can’s penetrator end cap provides the
various bulkhead connectors needed to connect the internal electronics to the many external
devices found on a vehicle.
The fiber optic can provides a dry, one-atmosphere environment for the vehicle’s fiber optic
multiplexer (FO mux), MD88 (mini-drive 88) system, power supplies, and interconnecting
wiring. The FO mux can’s penetrator end cap provides the various bulkhead connectors needed
to connect the internal electronics to the many external devices found on a Magnum Plus
vehicle.
Termination can. The termination can is where the umbilical or tether’s electrical and fiber
optic connections are mated to the cage or vehicle systems.
Transformer can. The transformer can houses a step down transformer that receives the
1300 VAC from the step up transformer located under the power distribution unit (PDU) and
reduces it to a suitable voltage to be used by the vehicle’s electrical system.
Vehicle sensors. The term sensors is used universally throughout this course to represent all
additional monitoring devices. Examples of sensors include the following:
• Sonar
• Altimeter
• Temperature sensors
• Pressure sensors
• Gyroscopic compass
Sonar Head Altimeter

Pressure Transducer Paro Scientific Gyro Compass Honeywell Compass

SECTION 1: ROV FUNDAMENTALS 1-21

 Offshore Manegement System (OMS)
The Offshore Management System (OMS) software application provides offshore
ROV crews with the tools necessary to administer their systems (i.e., carry out planned
maintenance, order parts, report daily operations activities, etc.).

The best description of OMS is that the application is a facilitator for the flow of
information between an ROV system working offshore and its onshore operational base.
ROV system daily reports, STOP/Observation cards, umbilical status reports, tether length
logs, planned maintenance tasks, inventory requests, equipment move orders (EMOs), etc.,
are all examples of information generated by an ROV system, and that information must
to be sent onshore on a regular basis. Conversely, technical bulletins, inventory updates,
return EMOs, operational updates, etc., are examples of the information that the onshore
operations base needs to send out to the ROV system. OMS deals with the flow of
information in both directions.

1-22 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Section Review
ROV (remotely operated vehicle) is the generally accepted title given to tethered underwater
robots in the oil and gas industry. ROVs are unmanned, they have exceptional maneuverability,
and they are remotely operated by a person aboard a vessel.
The typical ROV system, when assembled in a working environment, consists of the following
main components:
• Control van
• Work van
• Launch and recovery system (LARS)
• Subsea deployment system (cage)
• Vehicle

Knowledge Check

It is important to remember that the configuration of some systems may vary slightly depending
on the application and the type of vessel on which it is installed. ROVs are used in various
setups and situations, but the work scope usually determines the exact configuration of the
ROV as well as the components that will be utilized.
1. Name the two working class ROVs used by Oceaneering.

2. How many main components are there, and what are they?

3. What are the sub-components of the LARS?

4. How many vertical thrusters are on the Millennium?

SECTION 1: ROV FUNDAMENTALS 1-23

1-24 ROV NEW HIRE COURSE - Gulf of Mexico Region
Section 2
Power Distribution

Morgan City Training Center

2-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
All of the ROV major components and sub-systems interconnect and operate together. As
discussed previously in Section One, the ROV system consists of five major components:
1. Control van
2. Work van
3. Launch and recovery system
4. Cage
5. Vehicle
Each of the five components and their subsystems use the installation’s power as needed,
whether transforming it or converting it to a direct current (DC) voltage.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Identify system input power and source(s)
• Identify the power distribution components and describe how they interconnect and
operate together
• Discuss high voltage safety to include:
- Electrical hazards
- Electrical shock
• Define OHMS law
• Identify and explain power transmission paths
• Describe power flow and control
• Explain the purpose of the ground fault circuits on the system and what they are
monitoring
• Explain why technicians continuously monitor motor current, system volts, and oil levels
while operating the system
• Explain where motor current, system volts, and oil levels are monitored while operating
the system
• Explain how to isolate the system for repairs such as slip ring change out, tether,
umbilical, reterms, motor, and pump change outs

SECTION 2: Power Distribution 2-3

 System Power Vessel / RIG
System power is power that originates from the rig or vessel 3 Phase 480 VAC
on which the ROV system is installed. In general, the
electrical supply is provided to the system by the work
platform that the ROV system is installed on. Power Conditioning
Mini-MG
In other cases, power may be supplied by an on-deck diesel
generator or a combination of work platform power and a House Transformer
PDU
small electric motor generator (mini-MG).
Console

Power Distribution Unit Boost Transformer

The power distribution unit (PDU), which is located in the LARS /Winch
control van, is the heart of power distribution on the ROV
system. TMS (CAGE)

The PDU, along with the pilot console power tray, Vehicle
provides for all of the vehicle and cage electrical power
switching. System Power Flow Model

The PDU is the location of circuit breakers 1-6, the contactors,

and the overload relays, as well as voltage, current, and phase
monitory functions for the 3-phase 480 VAC input power.
The system is broken down into discrete circuits that are
controlled by several independent circuit breakers. Circuit breakers
are manually operated switches that serve as high voltage on/off
switches and as safety devices that will automatically disconnect
the input line power to each circuit in the event of a sudden
PDU (exterior view) current overload.
Breakers also serve as the primary means of isolating the supply to each circuit for maintenance
or troubleshooting purposes. When the circuit is to be locked out/tagged out (LOTO), the
breaker is turned off and a locking device is attached to its control lever.

Power Distribution Unit Components

PDU Circuit Breakers
The PDU contains the following circuit breakers:
BK1 - When enabled, a 480 VAC single-phase power is provided to the house power
transformer. This steps down the 480 VAC input voltage to the 120 VAC unswitched power that
is used by the console to control switching functions in the PDU. This is extremely important
because the console power contactor cannot be energized without the enabling of this breaker.
If the console power contactor is not energized, none of the additional five contactors will be
energized.
2-4 ROV NEW HIRE COURSE - Gulf of Mexico Region
BK2 - When enabled, a 480 VAC single-phase power is provided to the cage (CAGE ELEX)
contactor K4. The cage electrics contactor cannot be energized until the console power is
enabled and the contactor is energized.
BK3 - When enabled, a 480 VAC single-phase power is provided to the vehicle (VEH ELEX)
contactor K3. The vehicle electrics contactor cannot be energized until the console power is
enabled and the contactor is energized.
BK4 - When enabled, a 480 VAC 3-phase power is provided to the cage (CAGE HPU)
contactor K5. The cage HPU contactor cannot be energized until the console power and cage
electrics power are enabled and the console power contactor and cage electrics contactors are
energized.
BK5 - When enabled, a 480 VAC 3-phase power is provided to the vehicle (PORT HPU)
contactor K6. The vehicle port contactor cannot be energized until the console power
and vehicle electrics power are enabled and the console power contactor and cage electrics
contactors are energized.
BK6 - When enabled, 480 VAC 3-phase power is provided to the vehicle (STBD HPU)
contactor K7. The vehicle starboard, contactor cannot be energized until the console power and
vehicle electrics power are enabled and the console power contactor and cage electrics
contactors are energized.

PDU (interior view)

SECTION 2: Power Distribution 2-5

 PDU Contactors (Motor Starters)
Contactors are remotely operated, fast-acting, high-powered switches. This allows each contactor
to be controlled by an associated power on/off switch located on the pilot console’s power tray.
It also allows each circuit to be interlocked or remotely disabled by other devices, such as the
ground fault monitoring/interruption (GFM/GFI) system.
Although they are often just referred to as contactors, the assembly actually consists of a
contactor and a thermal overload relay coupled together. Such configurations are commonly
referred to as motor starters.
The PDU contains the following contactors (motor starters):

• K2 (CONSOLE) • K5 (CAGE HPU)

• K3 (VEH ELEX) • K6 (PORT HPU)
• K4 (CAGE ELEX) • K7 (STBD HPU)
The overload relay, shown below the horizontal dashed line, is used to protect the device(s) and/
or wiring from damage due to excess current.
The overload trip point is a manually
adjustable value that is determined by
the load being protected.
An overload relay trips off because
the current flowing through the
device is higher than the user-adjusted
overload trip point for some specific
period of time. The higher the
current, the faster the trip will be.
Once the relay has become overloaded
and tripped, the voltage on the line
needs to be dissipated. This is
accomplished by the contactor
PDU Contractors varistor.
Varistors are non-linear, voltage-dependent resistors whose
value of resistance decreases with an increasing voltage. At low
currents and voltages, varistors have a high resistance, but at
higher voltages and currents, the resistance drops dramatically.
A varistor is connected across each of the contactors coil
connections and is used primarily to suppress the back EMF
generated from the switching of the contactor coil itself. This
back EMF can damage the more sensitive components in the
PDU, such as voltage/current monitoring devices and GFM
systems.
Contactor Varistor
2-6 ROV NEW HIRE COURSE - Gulf of Mexico Region
Console Control
The control console power tray contains the power control switches and AC current meters as well as
the GFI/GFM controls and/or displays.
In each console version, the power control switches are located on the pilot console’s power
tray, and each switch operates in the same manner. The only difference is the sub-system being
controlled and how the switches or contactors are interlocked.
The various console power On/Off switches are all identical, and each is composed of two
momentary switches in a single housing: the upper (START) button is a momentary, normally
open (NO) push-button switch, and the lower (STOP) button is a momentary, normally closed
(NC) push-button switch. The terms NO (normally open) and NC (normally closed) refer to
the state of a switch, relay, or contactor’s electrical contacts when the device is in an unpowered
state. Electrical contacts can only be in one of two possible conditions: open, meaning no
electrical connection from one terminal to the other, or closed, meaning the terminals are
electrically connected.

Control Console Power Tray

Console Power Tray Switches

• CONSOLE POWER ON/OFF. Controls console power supply.
• CAGE ELEX. Controls the electrical power to the TMS (cage) electrics (step-up)
transformer.
• VEH ELEX. Controls the electrical power to the vehicle electrics (step-up) transformer.
• CAGE HPU. Controls the electrical power to the TMS (cage) boost (step-up)
transformer.
• PORT HPU. Controls the electrical power to the vehicle port HPU boost (step-up)
transformer.
• STBD HPU. Controls the electrical power to the vehicle starboard HPU boost (step-up)
transformer.

SECTION 2: Power Distribution 2-7

 Energizing the Contactors
Console PDU Console PDU
1 2

120VAC 120VAC
Coil Coil

120VAC Neutral 120VAC Neutral

C C C
C C C C C C
C C C

Console PDU Console PDU

3 4

120VAC 120VAC
Coil Coil

120VAC Neutral 120VAC Neutral

C C C
C C C C C C
C C C

Energizing the Contactors

Interlocks
Interlocking is a method used to control under what conditions a contactor can be turned on or is
automatically shut down. This is typically a safety function.
Interlocks are separate electrical or electro-mechanical or purely mechanical devices that are
connected to the contactor or its control circuit and will act to prevent/remove the control
voltage from the contactor’s coil circuit.
The advantage of using interlocks is contactors can be interlocked by as many (or as few)
interlocks as its safe function requires.

2-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Before the HPU contactor can be enabled, it must first meet four separate conditions:
• Vehicle electrics contactor must be energized
• Three-phase input AC voltage must meet specifications
• No current overload (i.e., thermal overload contacts are closed)
• No ground fault present
In the example below, the vehicle electrics switch has been depressed and the 120 VAC is passed
through the (NO) switch to the upper side of the coil. This voltage, in conjunction with the
120 VAC neutral, energizes the coil and closes the circuit allowing the three phases of voltage to
flow.
The last phase shown in blue is used as the interlocking voltage (in this case) to the port HPU
motor. If this voltage were not present on the contactor, the port HPU could not be energized.

Interlocking

Console PDU

120VAC
Coil

Cage
Elex 120VAC Neutral

C CC
CC C

Console PDU

120VAC
Coil

Cage
HPU

C CC
CC C

Interlocking

SECTION 2: Power Distribution 2-9

2-10
Key:
Orange Color = 480V 3 Phase Work Platform
Blue Color = 480V Single Phase 480 VAC 3 Phase
Green Color = 120 V Interlocking Voltage
Red Color = 120V Activation Signal
Light Blue Color = 1300V Single Phase
PDU Power Flow

Electronics
Black Color = 2300V (Magnum) or 3000V
(Millenium) 3 Phase Power
to HPU’s BK 1 BK 2 BK 3 BK 4 BK 5 BK 6

ROV NEW HIRE COURSE - Gulf of Mexico Region

House
XFMR

Console K3 K4
contactor K2 as represented by the green line below.

ON K2
Power OFF
Cage ON
Electrics
OFF
Vehicle Boost XFMR Boost XFMR
ON K5 K6 K7
Electrics OFF
Cage ON
Motor OFF

Port / FWD ON
Motor Coffin Boost XFMR Boost XFMR Boost XFMR
OFF
Assembly
STBD / AFT ON
Motor OFF
Winch
position, power is supplied to the house transformer. The 120 VAC “neutral” is applied to
With breakers BK 1 - BK 6 receiving 480 VAC power from the rig and all breakers in the on
 Key:
Orange Color = 480V 3 Phase Work Platform
Blue Color = 480V Single Phase 480 VAC 3 Phase
Green Color = 120 V Interlocking Voltage
Red Color = 120V Activation Signal
Light Blue Color = 1300V Single Phase
console power functions.

Electronics
Black Color = 2300V (Magnum) or 3000V
(Millenium) 3 Phase Power
to HPU’s BK 1 BK 2 BK 3 BK 4 BK 5 BK 6
is displayed with a green line below.

House
XFMR

Console ON K2 K3 K4
Power OFF
Cage ON
Electrics
OFF
Vehicle Boost XFMR Boost XFMR
ON K5 K6 K7
Electrics OFF
Cage ON
Motor OFF

Port / FWD ON
Motor Coffin Boost XFMR Boost XFMR Boost XFMR
OFF
Assembly
STBD / AFT ON
Motor OFF
Winch
When enabled by the console power on/off power switch on the console power tray, K2
supplies “switched” 120 VAC to the pilot console power tray, where it is used to control the

SECTION 2: Power Distribution

With console power applied and the 120 VAC interlock control voltage being applied to K3 and
K4, system power up can continue by pressing corresponding switches. The interlocking voltage

2-11
 Transformers
Transformers are necessary devices in any power distribution system as they provide important
functions within the ROV system:
• Transformers allow electrical isolation from the source power; isolating each circuit
allows the GFI modules to monitor each individual circuit for ground faults. Without
individual circuit electrical isolation, a GFI monitor would shut down the entire system if
a ground fault occurred in any part of it.
• Transformers transform the source 480 VAC input power into the voltage levels required
by the various parts of the system.
• Transformers permit larger horsepower motors and/or longer umbilical to be used
by increasing the voltage and reducing the current carried by the lift umbilical. The
reduction in current allows for smaller conductors to be used in the umbilical and tether.
The transformer is based on two principles: first, an electric current can produce a magnetic
field (electromagnetism). Second, a changing magnetic field within a coil of wire induces a
voltage across the ends of the coil (electromagnetic induction). Voltage induced is proportional
to the number of windings on either the primary or secondary side.
ROV systems use step-up transformers to
transmit electricity at high voltage to reduce
the voltage drop due to resistance. Another
advantage of transformers is when voltage
is increased by a transformer, the current is
reduced proportionally. This allows smaller
conductors to be used in the umbilical and
tether, which will allow more umbilical and
tether to be stored on the drum.
Transformer
ROV systems use step-down transformers
to reduce the high voltage to a more usable voltage, which is accomplished by reducing the
number of coils on the secondary side of the transformer. Reducing the voltage also increases
the current available.
ROV systems utilize four different types of transformers:
• House power transformers
• Vehicle/TMS electrics step-up transformers
• Vehicle/TMS HPU step-up transformers
• Step-down transformers

2-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

House Power Transformer
A single-phase transformer wired for a 480 VAC input and two secondary single-phase 120 VAC
windings connected in parallel are located in the control van under the PDU. The house
transformer is supplied with single-phase 480 VAC and is used to supply the console and PDU
with single-phase 120 VAC service/control power. The house power transformer is the source
of the un-switched 120 VAC used in the console power switches.

Vehicle/TMS Electrics Step-Up Transformers

These transformers are identical single-phase transformers with a 480 VAC primary winding and
a multi-tap 1,200 / 1,250 / 1,300 / 1,350 / 1,400 VAC secondary. The transformers are located
in the cabinet under the PDU.
The vehicle transformer is supplied with 480 VAC directly from the PDU K3 contactor. The
transformers supply the vehicle’s step-down transformer primary with ~1,300 VAC.
The cage transformer is supplied with 480 VAC directly from the PDU K4 contactor. The
transformers supply the cage step-down transformer primary with ~1,300 VAC.

Step-Up Transformer

Vehicle/TMS HPU Step-Up Transformers

The TMS HPU step-up transformer (also known as boost transformer), the vehicle PORT HPU
boost transformer, and the vehicle STBD HPU boost transformer are each identical 3-phase
step-up transformers with multi-tap primary and multitap 2,300 – 3,000 VAC secondary
windings.
Each transformer is rated at 100,000 V, and all three transformers
are mounted within the boost transformer housing (transformer
coffin) that is typically deck mounted near the umbilical winch.

Boost Transformer

SECTION 2: Power Distribution 2-13

 Step-Down Transformers
Having been efficiently transferred to the cage and vehicle, the electrics power is required to
supply electrical and electronic circuits. These do not require high voltages, so the high voltage
needs to be reduced. This is achieved with step-down transformers, which, in a typical ROV
system, would step the input voltage of 1,300 Vac down to two 120 Vac and 17 Vac. The 17 Vac
is converted to solenoid 24 Vdc by a power supply unit.
The cage and vehicle step-down transformers have
multiple output windings with different voltages. This is
important when it comes to isolating the different
circuits that use these voltages, particularly when it
comes to ground faults.

Step-Down Transformer

High Voltage Safety

High voltage areas of the ROV system need to be isolated using lock out/tag out procedures.
You must verify that no high voltage is present when working on any of the areas of the system
that contain high voltage equipment.
Some of the high voltage electrical hazards on the ROV include the following:
• Any junction box
• Umbilical
• Tether management system (TMS)
• Cage
• Vehicle
• Power distribution unit (PDU)

Electric Hazards
Electricity has become such a familiar part of the work environment that it is often not treated
with the respect it deserves. Three types of hazards are associated with electricity: arc flash, arc
blast, and electric shock. While arc flash and arch blast are worth mentioning, understanding
electric shock hazards is vital.

2-14 ROV NEW HIRE COURSE - Gulf of Mexico Region

Electric shock is normally associated with contact with high voltage. Electrical dangers include
a variety of hazards, including psychological damage, physical burns, neurological damage, and
ventricular fibrillation resulting in death.
Most electric shock injuries are from current, not voltage. Current flow can be determined using
Ohms Law.

Ohms Law: I = E/R

Where: I = Current, E= Voltage, and R = Resistance

Other dangers of electricity cause interference with nervous control, especially over the heart
and lungs. The blood flow through the heart is caused by the contractions of the heart muscles,
which are controlled by electrical impulses. An outside electric current as little as 75 mA can
upset the rhythmic, coordinated beating of the heart by disturbing the nerve impulses. When
this happens, the heart is said to be in fibrillation, and the pumping action stops. Death will
occur quickly if the normal heartbeat is not restored. Remarkable as it may seem, what is needed
to defibrillate the heart is a shock of even greater intensity.
Current Range and Effect on a 150 lb (68 Kg) Man

Current Physiological Phenomenon Feeling or Lethal Incidence

1mA None Imperceptible
1mA Perception threshold
1-3 mA (Effects of a 110 VAC household Mild sensation
circuit begin here)
3-10 mA Painful sensation
10 mA (110 V shock standing Paralysis threshold of arms Cannot release hand grip; if no grip, victim may be thrown
in water) clear (may progress to higher current and be fatal)
30 mA (480 V shock standing Respiratory paralysis (frequency Stoppage of breathing
in water) fatal)
75 mA Fibrillation threshold 0.5% Heart action discoordinated (probably fatal)
250 mA Fibrillation threshold 99.5%
(>5 seconds exposure)
4 Amp Heart paralysis threshold (no fibril- Heart stops for duration of current passage. For short
lation) shocks, may restart on interruption of current (usually not
fatal from heart dysfunction).
5 Amp Tissue bleeding Not fatal unless vital organs are burned

SECTION 2: Power Distribution 2-15

 Transmission Paths
Once power is routed to its destination via the PDU and the associated transformers, it must
travel to the ROV. Next, the power will follow a path through several major components, several
of which serve the same function but have different names.
ªª Deck leads
ªª Winch stationary junction box
ªª Winch slip ring assembly
ªª Winch rotating junction box
ªª TMS/cage umbilical termination (matrix) can
ªª Cage slip ring assembly
ªª TMS rotating junction box
ªª Vehicle termination can

Deck Leads
Deck leads route the electrical power conductors from the PDU to the winch stationary
termination J-box and/or the boost transformer termination box.

Winch Stationary Junction Box

The winch stationary J-box serves as the termination point for the electrical power conduit from
the boost transformer termination J-box, which is then routed to the winch slip rings. It is also
a termination point for the deck lead from the vehicle and cage electrics step-up transformers.
The winch stationary J-box will also contain either the Megacon voltage adaptor modules or the
DTEC sense resistors for the TMS HPU, vehicle port, and starboard HPUs (depending on the
GFI system in use).

Winch Stationary J-box

2-16 ROV NEW HIRE COURSE - Gulf of Mexico Region

Winch Slip Ring Assembly
Slip rings serve a basic function of
coupling signals through a rotating
assembly. The slip ring assembly consists
of a number of metal rings mounted on
an insulated shaft. Individual brushes are
in contact with each of the rings,
continually transferring electrical power
between the brushes and the rings as the
housing is rotated.
Winch Slip Ring Assembly (exterior view)

Winch Slip Ring Assembly (interior view)

Winch Rotating Junction Box

The winch rotating J-box, directly mounted
to the winch’s drum flange, is the
termination point for connections to the
armored lift umbilical. This is where the
umbilical is connected to the slip rings.

Winch Rotating J-box

SECTION 2: Power Distribution 2-17

 TMS/Cage Umbilical Termination (Matrix) Can
The lift umbilical armor is mechanically terminated at the cage in a bullet, while the opto-electro
core is routed through the cage upper framework to the cage umbilical termination can where
the core is terminated.

Mechanical Armor Term (bullet)

Cage Umbilical Termination Can

Connections intended for the vehicle are routed to the TMS slip ring assembly for connection to
the tether. Electrical connections intended for the cage are routed directly to the cage telemetry
can, cage HPU, and cage transformer can.

Cage Slip Ring Assembly

The cage slip rings are similar in design and function to the winch slip rings except for having
fewer electrical paths. The cage slip rings are also oil-filled, but the winch slip rings are not.
Electrical conductors intended for the vehicle are routed from the cage umbilical termination
can to the cage slip ring
assembly mounted in the
tether drum. After passing
through the cage slip rings,
electrical connectors are
terminated in the TMS
tether termination J-box
where connections are Cage Slip Ring Assembly
made to the tether.

TMS Rotating Junction Box

The TMS tether termination can (rotating
J-box) is an oil-filled housing mounted
on the TMS tether drum flange. It is also
called the pancake.

TMS Rotating Junction Box (pancake)

2-18 ROV NEW HIRE COURSE - Gulf of Mexico Region

Vehicle Termination Can
On most vehicles, the vehicle termination can is located on the aft port side. The tether termination
can is the point where the tether’s electrical connections are mated to the vehicle’s systems. Oil-
compensated cables are routed from the tether termination can to the transformer can and the
two HPU motors.

Vehicle Termination Can

Vehicle and Cage Power Flow

The two contactors for cage and vehicle electrics power are controlled from two start/stop
switches by the pilot. When the start button for an individual electronics circuit is pressed, the
corresponding contactor is energized in the control van. This allows the voltage to flow through
the contacts and down to either the TMS or vehicle transformer cans located on the TMS and
vehicle. The flow path for each power circuit is almost identical with the exception of the TMS
circuit, whose flow stops at the system’s TMS transformer can. Connected at the bottom of
both the cage electronics power contactor and the vehicle electronics power contactor are two
conductors, which ultimately make their way to the appropriate transformer.

Motor Power Electrical Flow

The three contactors for cage, vehicle port, and vehicle starboard motors are controlled from
start/stop switches by the pilot. When the start button for an individual motor is pressed, the
corresponding motor contactor is energized, which allows the motor voltage to flow through
the contactors and down to the motor via a thermal overload relay and into a step-up
transformer which are located in an oil filled box next to the winch called the Coffin. This
transformer boosts the voltage to as much as 2,300 VAC for Magnums and 3,000 VAC for
Millenniums in order to compensate for volt drop in the umbilical and tether. The flow path for
each motor is almost identical with the exception of the cage motor because flow stops
at the system’s cage and does not continue down to the vehicle. The thermal overload relay
provides over-current protection and will automatically de-energize the contactor in the event of
excessive current draw. The high voltage output from the transformer is then routed to the
motors on the cage and vehicle.

SECTION 2: Power Distribution 2-19

 Vehicle and Cage Power Flow

2-20 ROV NEW HIRE COURSE - Gulf of Mexico Region

Motor Power

Motor Power Electrical Flow

SECTION 2: Power Distribution 2-21

 Monitoring The System
For most work platforms, providing clean, highly regulated electrical power to an onboard ROV
is not a high priority. Consequently, it is important to constantly monitor the system’s power to
prevent injury to personnel and damage to equipment. Systems and components that should be
monitored diligently include motor current, system voltage, oil levels, and runtime on subsea
motors.
Proper monitoring is accomplished by utilizing the devices in the PDU. The monitoring
equipment includes the following:
• Voltmeter multiplier
• Voltage sensor
• 3-phase voltage monitor
• Current sensors (transformers)
• Ground fault monitoring (GFI/GFM)
• Motor run-time hour meters
The monitoring sensors will display on either analog meters located on the console or digitally in
the CTAG program.

Voltmeter Multiplier
The voltmeter multiplier is a meter shunt (resistor) that is used
to decrease the 480 VAC supply voltage to a level that can
be directly applied to the AC Voltage and frequency meters
mounted in the PDU or console.

Voltage Sensor
The voltage sensor (sometimes referred to as a potential
Voltmeter Multiplier
transformer) is a monitoring device used to convert a 0-480
VAC input voltage to a proportional 0-5 VDC voltage. This
voltage is then applied to the console’s OPAC stack.
The OPAC stack, in turn, converts this analog voltage to a
digital value that is passed on to CTAG for display on the
pilot’s graphics display.
The PDU employs three separate sensor modules to
monitor the incoming 480 VAC supply. Each sensor module
monitors a single phase-to-phase voltage.
Voltage Sensor

2-22 ROV NEW HIRE COURSE - Gulf of Mexico Region

Three-Phase Voltage Monitor
Three-phase voltage monitors are used to continuously monitor the
three-phase 480 VAC supply lines for abnormal voltage conditions.
The PDU employs three separate voltage monitors for the cage
HPU, port HPU, and starboard HPU circuits. The following three-
phase supply voltage fault conditions will trip the monitor:
• Phase loss
• Phase reversal
Three-Phase Voltage Meter
• Low-input voltage
All three three-phase voltage monitors are wired to the same 480 VAC source. If the source
voltage is bad, then all three 3-phase voltage monitors will trip off line at the same time.
When an AC supply with the correct voltage and phase rotation is applied to the three-phase
voltage monitor, the internal relay energizes. The normally open (NO) contact is wired in series
with the contactor coil. If the three-phase voltage monitor detects a fault condition in the
supply voltage, the contact will open and remove the 120 VAC neutral from the coil, thereby
disabling the contactor until the fault that tripped the three-phase voltage monitor is corrected
or removed.

Current Sensors
Current sensors are devices used to step-down a large primary current to a smaller, easy-to-manage
secondary current that is proportional to the primary current.
The PDU employs two different types of current transformers; both types are similar in the
manner in which they function, but differ in the output that each one provides.
• The larger 100:5 current transformer outputs an AC current proportional to the primary
current, providing an analog output to meters on the pilot console.
• The smaller current sensors output a 0-5 VDC voltage that is proportional to the primary
current, providing an output directly to the CTAG display.

Current Sensors

SECTION 2: Power Distribution 2-23

 Current Meters
Current monitoring is displayed on meters located
on the upper section of the power tray on the
control console and the CTAG display. The 100:5
current transformers are used to drive the cage
motor, port motor, and starboard motor current
meters mounted on the pilot console power tray Current Meters (Console)
panel.
The 0-5 VDC output current sensors are used
to convert the HPU motor currents to a voltage
range (0-5 VDC) that the console OPAC stack
can accept and to convert to a digital format and
pass to CTAG in order to display the HPU motor
currents on the pilot’s graphics display.

480 VAC Meter Current Meters (CTAG)

The 480 VAC input supply voltage is monitored by an analog panel meter mounted on the PDU
front panel. On older systems, the meter is mounted on the pilot console on a panel above the
pilot console power tray.

480 VAC Meter

Ground Faults
A ground fault, simply defined, is a fault or condition that establishes an electrical connection
between a previously isolated electrical circuit and chassis ground. As the Magnum Plus system
uses 2,300 VAC electrical power for its HPU motors and 1,300 VAC for vehicle and cage
electronic systems, a ground fault can present a potentially lethal situation for anyone working
on the system.

2-24 ROV NEW HIRE COURSE - Gulf of Mexico Region

Ground fault monitoring and interrupt systems are used on the ROV systems for two reasons:
1. To protect personnel from injury due to electrical shock from faulty equipment.
2. To protect the equipment itself from damage.
A ground fault occurs when electricity “leaks” out of a system usually due to insulation break
down caused by mechanical damage or water intrusion. Ground fault detection systems used in
ROV systems will monitor for this electrical leakage and will de-energize certain circuitry when
necessary. This is achieved by applying a small DC voltage between chassis ground and the
circuit being monitored. When no ground fault exists, there is no path for current to flow in the
circuit as illustrated below.

Sense Line

Vdc

T1 T2

Primary Secondary Primary Secondary

No Ground Fault

Ground faults can only be detected through circuits that are physically connected. Ground fault monitors
will not monitor across a transformer.

When a fault is present, the sense voltage is shunted to ground and completes the circuit as
displayed below.
Sense Line

Vdc

T1 T2

Ground Fault
Primary Secondary Primary Secondary

Ground Fault
SECTION 2: Power Distribution 2-25
 The terms ground fault monitoring (GFM) and ground fault interrupting (GFI) have been
used interchangeably to mean the same thing. To some extent this is correct; GFM is normally only a
monitoring system, while GFI will have monitoring and an interuption capibility to stop energy flow.

The ground fault interruption (GFI) system constantly monitors the vehicle’s high voltage
circuits for the presence of a ground fault. If a fault develops and reaches 1 Mega-Ohms, the
GFI system will shut down the faulty circuit by de-energizing the contactor and giving the
operator a warning that there has been a fault detected in the circuit.
There are two different GFI systems used on ROV systems: Megacon GFI system and DTEC
GFI system. The Megacon GFI is replacing the older DTEC GFI in all newly built systems, but
the DTEC GFI can still be found in use on many systems.

Examples of Circuits Monitored on the Surface

Incoming system power 480 VAC 3-phase
Cage electrics power 480 – 1,300 VAC single-phase
Vehicle electrics power 480 – 1,300 VAC single-phase
Cage motor power 2,300 – 3,000 VAC 3-phase
Vehicle port motor power 2,300 – 3,000 VAC 3-phase
Vehicle starboard motor power 2,300 – 3,000 VAC 3-phase

Ground Fault Monitoring/Interrupting (DTEC)

The DTEC GFI PCB requires external sense resistors for all
of its monitored circuits. The DTEC systems sense resisters
are located in the PDU for the 480 VAC supply input voltage.
These resistors are mounted directly to the secondary terminals
of the cage ELEX and vehicle ELEX step-up transformers
and are located in the winch stationary j-box for the HPU
boost transformers. DTEC Monitoring

Ground Fault Monitoring/Interrupting

(Megacon)
Megacon GFI requires an external voltage adapter only
if the voltage to be monitored is higher than 500 volts.
Megacon voltage adapter modules for the cage ELEX and
vehicle ELEX step-up transformers are located in the PDU,
while the adapter modules for the HPU boost transformer Megacon Monitoring
are located in the winch stationary junction box. Potential
causes of ground faults include the following:
• Water intrusion • Corrosion
• Insulation breakdown • Improper installation/incorrect wiring
• Condensation

2-26 ROV NEW HIRE COURSE - Gulf of Mexico Region

 These circuits are monitored on the surface but are not restricted to surface units. For example, the vehicle
motor ground fault monitoring obviously extends all the way down to the vehicle.

Ground Fault Meters

The DTEC monitoring system displays on a single meter on the pilot console. For the meter
to display an analog output, the selector switch below the meter has to be positioned on the
correct circuit for display. If the 1 Mega-Ohms are reached, the system will shut down and a red
indicator located beside the meter will illuminate.

DTEC Meter

The Megacon meters function like the DTEC meters except that there is a meter for every
circuit monitored.

Megacon Meters
SECTION 2: Power Distribution 2-27
 480 GF Monitoring Circuit

Cage Elx. GF Monitoring Circuit

Veh. Elx. GF Monitoring Circuit

Cage Motor GF Monitoring Circuit

Source 480 VAC
3Φ
Port Motor GF Monitoring Circuit LOTO Point
480 GF
Starb. Motor GF Monitoring Circuit

480 VAC 1Φ 480 VAC 1Φ 480 VAC 1Φ 480 VAC 3Φ 480 VAC 3Φ 480 VAC 3Φ
BK1 BK2 BK3 BK4 BK5 BK6
Console Power Cage Elx. Veh. Elx. Cage Motor Port/Aft Motor Starb/Fwd Motor
LOTO Point LOTO Point LOTO Point LOTO Point LOTO Point LOTO Point
Contactor & Thermal Contactor & Thermal Contactor & Thermal Contactor & Thermal Contactor & Thermal Contactor & Thermal
Overload Relay Overload Relay Overload Relay Overload Relay Overload Relay Overload Relay
GF Monitor Circuit GF Monitor Circuit GF Monitor Circuit GF Monitor Circuit GF Monitor Circuit GF Monitor Circuit

Primary 480 VAC 1Φ Primary 480 VAC 1Φ Primary 480 VAC 1Φ

480 GF 480 GF 480 GF
Console Power Xfmr Cage Elx. Xfmr Veh. Elx. Xfmr
Secondary Secondary Secondary
220/110VAC 1300VAC 1Φ 1300VAC 1Φ
1Φ Cage Elx. GF Veh. Elx. GF

220 VAC 1Φ
Breaker Panel
LOTO Point Primary 480 VAC 3Φ Primary 480 VAC 3Φ Primary 480 VAC 3Φ
Lights/AC/ 480 GF 480 GF 480 GF
Electrical Outlets Cage Motor Port/Aft Stbd/Fwd
Coffin Xfmr Secondary Coffin Xfmr Secondary Coffin Xfmr Secondary
3000/2300VAC 1Φ Cage 3000/2300VAC 1Φ Port 3000/2300VAC 1Φ Strb.
Motor GF Motor GF Motor GF

Cage Motor Port Motor Starb. Motor

GF GF GF Winch Winch
Monitoring
Circuit
Monitoring
Circuit
Monitoring
Circuit Slip Rings Rotating
Junction Box

Winch Stationary Junction Box

To
Page 2 Umbilical

2-28 ROV NEW HIRE COURSE - Gulf of Mexico Region

480 GF Monitoring Circuit

Cage Elx. GF Monitoring Circuit From

Page 1
Veh. Elx. GF Monitoring Circuit

Cage Motor GF Monitoring Circuit

Port Motor GF Monitoring Circuit

Starb. Motor GF Monitoring Circuit

Tether

Primary 1300 VAC

Cage Elx. GF
Cage Xfmr
Vehicle Elx. Cage Elx.
Secondary 2x110VAC
1300 VAC 1Φ 1300 VAC 1Φ
& 17 VAC

Cage
Vehicle Port
Motor
2300 VAC 3Φ
Matrix Can

Vehicle Starb. Cage Motor Cage Motor

Motor Power 3000/2300 VAC 3Φ
2300 VAC 3Φ 2300 VAC 3Φ Cage Motor GF

Cage
Cage Rotating
Junction Box
Slip Rings

To
Page 3 Tether

SECTION 2: Power Distribution 2-29

 480 GF Monitoring Circuit

Cage Elx. GF Monitoring Circuit From

Page 2
Veh. Elx. GF Monitoring Circuit

Cage Motor GF Monitoring Circuit

Port Motor GF Monitoring Circuit

Starb. Motor GF Monitoring Circuit Tether

Vehicle Port
Motor
2300 VAC 3Φ

Vehicle
Termination
Can

Vehicle Starb.
Motor Vehicle Elx.
2300 VAC 3Φ 1300 VAC 1Φ

Vehicle Port/Fwd.
Motor
3000/2300 VAC 3Φ
Veh. Port. Motor GF

Primary 1300 VAC

Veh. Elx. GF
Secondary 2x110 VAC
& 17 VAC

Vehicle Starb/Aft
Motor
3000/2300 VAC 3Φ
Veh. Port Motor GF

2-30 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section Review
This section discusses how the major components of the ROV system and their
subsystems work together and how the components use system power. System power is
sent to the PDU via connection points called breakers 1 – 6, which control the system’s
power. BK1 – BK6 also control six circuits inside the PDU, which are console power, cage
electric power, vehicle electric power, cage motor power, vehicle motor power, and vehicle
starboard power. The 120 VAC is referred to as unswitched voltage until it is allowed to
pass through the console contactor where it becomes switched voltage.
Console power must be on before cage and vehicle power can be energized. Furthermore,
cage and vehicle power must be energized before their respective motors can be energized.
Lastly, thermal overload protection devices are attached to the contactors and are set to trip
the control voltage out when a specific current value is reached.

Knowledge Check
1. What are the voltages on the primary and secondary sides of the PDU cage and
vehicle transformer on the Magnum Plus?

2. What is the interlocking sequence for starting the vehicle port motor?

3. What is the purpose of the ground fault system?

4. What are the six surface systems monitored for ground faults?

SECTION 2: Power Distribution 2-31

2-32 ROV NEW HIRE COURSE - Gulf of Mexico Region
Section 3
Communications

Morgan City Training Center

3-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
The Oceaneering ROV fleet uses various configurations of hardware for passing data between
surface and subsea. While hardware may vary, the underlying principles are the same: data is
multiplexed into a serial data stream and transmitted optically between surface and subsea.
This section focuses on one such configuration, but the principles apply equally to the other
types currently in use. The ROV system telemetry consists of four individual computers: pilot
computer, auxiliary computer, vehicle, and cage computers. Communication to the cage and
vehicle is accomplished through the pilot computer. The vehicle and cage computers are both
linked to the surface via separate serial data links. These serial links are used to transfer data
from the surface controls to the cage and vehicle. They also allow the transfer of sensory and
diagnostic data from the cage and vehicle to the pilot computer for display in CTAG graphics.
The control/feedback data is combined with video signals by a pair of fiber optic multiplexers.
These multiplexers are linked via optical fiber.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Explain telemetry
• Identify major components in the fiber optic portions of the system
• Explain the concepts of multiplexing
• Discuss various data protocols
• Identify fiber optic connectors and retermination kits
• Discuss the basic process to terminate a fiber optic cable
• Explain a short whip
• Describe the benefits of using a short whip

SECTION 3: Communications 3-3

 Telemetry
Telemetry can be defined as the communication/signal data link between processors. It is
the data/signal path sending and receiving operational information used to control various
functions within the scope of the system’s capabilities. It is a stream of electrical and light signal
impulses between two or more information processors.
Telemetry also allows the transfer of data from the subsea systems to the surface so the
condition of these systems can be monitored. Typically, this data represents conditions such as
oil level, oil pressure, water intrusion, ground fault level, voltage and current levels. A computer
software program called Control Telemetry and Graphics (CTAG) controls this serial link, which
utilizes both electrical and fiber optic resources in the data link.
There are two general configurations associated with telemetry that specify the nature of the
data/control transfer:
1. Full duplex: This is commonly shortened to “duplex.” This communication method has
two dedicated channels. Each channel has a transmit (TX) and a receive (RX).
2. Half duplex: This communication method has only one channel. The channel is shared
by both transmitters, but only one can use it at any one time.
Telemetry is transmitted either using electrical signals or by the use of fiber optics, which use
light signals. In an ROV system, both electrical and optical signals are used depending on the
length of the link.

Standard Distance Configuration

RS232 50 ft. Duplex
RS485 4,000 ft. Half Duplex
RS422 4,000 ft. Duplex
Optical 30,000 ft. Duplex

Telemetry General Configurations

3-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Serial Communication
The name serial comes from the fact that a serial port “serializes” data by taking a byte of data
and transmitting the eight bits in the byte one at a time. The advantage of serial communication
is that it only requires one wire to transmit the eight bits. In serial communication, the whole
data unit, say a byte, is transmitted one bit at a time. With serial transmission, only one wire is
used for data transfer. Its logic level changes according to the bit being transmitted (either 0 or
1) and needs some form of synchronization. Serial transmissions are based on a logic level of
either high or low. Typically, serial is used to transmit ASCII data. Communication is completed
by using three transmission lines: ground, transmit, and receive.

Data Protocol
RS-232
RS-232 is limited to point-to-point connections between PC serial ports and devices. RS-232
hardware can be used for serial communication up to distances of 50 feet, while longer distances
are capable of using line drivers and specialized cables. RS-232 can use numerous connector
sizes, of which only three pins are normally used for transmit, receive, and ground.
The RS-232 standard defines the voltage levels that correspond to logical one and logical zero
levels for the data transmission and the control signal lines. An RS-232 circuit is referenced to a
common ground.
Valid signals include the following ranges:
• +3 to +15 volts (logic 0)
• -3 to -15 volts (logic 1)
The range between -3 to +3 volts is not a valid RS-232 level.
+15V Space

LSB MSB

Start 1 1 0 1 0 0 1 0 Stop

+3V
LSB MSB
Least Most
Significant Start b0 b1 b2 b3 b4 b5 b6 b7 Stop Significant
Bit Bit

-3V

IDLE IDLE

Time
-15V MARK
Diagram of RS232 signalling as seen when probed by an Oscilloscope for an uppercase ASCII “K” character (0x4b)
with 1 start bit, 8 data bits, 1 stop bit

SECTION 3: Communications 3-5

 RS-422
RS-422 uses a differential electrical signal as opposed to unbalanced signals referenced to
ground with the RS-232. Differential transmission, which uses two lines each for transmit and
receive signals (a total of four lines), results in greater noise immunity and longer distances
compared to the RS-232. With a differential signal, there would be two wires; when one, for
example, goes from 0V to 5V, the other goes from 5V to 0V (or other voltage levels are also
popular). There is not really a need for a third 0V (ground) wire.

RS-485
The noise immunity and multi-drop capability make RS-485 the serial connection of choice
in industrial applications requiring many distributed devices networked to a PC. RS-485 is a
superset of RS-422; thus, all RS-422 devices may be controlled by RS-485.
Even though the data is transmitted over a two-wire twisted pair bus, all EIA-485 transceivers
interpret the voltage levels of the differential signals with respect to a third common voltage.
Without this common reference, a set of transceivers may interpret the differential signals
incorrectly. In a typical setup, this third voltage is implied in the power supply common/ground
connection. However, fundamentally speaking, there is nothing requiring this common voltage
to be the same as the power supply. In fact, certain MS/TP wiring requires full isolation between
the various EIA-485 devices and must run the third wire for the common connection.

Short Whip

The telemetry short whip is nothing more than a section of Fiber optic cable or shielded, twisted
wire pair (STWP) cable. The STWP cable with a male DB-25 connector soldered on one end
and a 5 pin phoenix connector soldered to the other end. The short whip is meant to be
connected between the Fastcomm channel, one DB connector, and the cage or vehicle’s
Telemetry Module on the OPAC Control PCB. The Fiper optic cable will have an SD connector
on each enad and can be connected between any two connecton points in the fiber optic system
path.
To correctly define the “short whip” would be to say it is more of a bypass system used to
isolate specific components or areas of interest that could possibly cause telemetry string
failures. The short whip can be used to isolate major sections of telemetry flow throughout the
system. This allows the technician to narrow down possible causes to three main sections, which
are the surface, cage, and vehicle. The whip is easily connected between two processors to
quickly provide results that can be used to identify bad sections within the telemetry string.

3-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Signal Deck Lead
Basic Telemetry Flow
SJB
Thrusters
Lights Cage Telemetry
RS232 F.O.
Fastcom Unit
Analogue #2
Console
Digital Stack Pilot
FORJ
PC
RS232
Manipulators
Pan/Tilt Fastcom F.O.
Clamps #1 RS232 Unit
Vehicle Telemetry

RJB

Winch

Control Van

Umbilical

Vehicle
Stack
FORJ
Telemetry Can Matrix
Can

F.O.
Tether Cage F.O.
Termination Drum Can
Can Can Stack Unit

SECTION 3: Communications
Vehicle Cage Telemetry Can

3-7
 Fiber Optics
Fiber Optics have been incorporated into almost every Oceaneering ROV umbilical in the
work class sector. Most new ROVs use fiber optics for telemetry signals in the signal deck leads.
Understanding what fiber optics are and how they are incorporated into ROV systems is very
important from a training perspective. A technician must be able to identify the fiber, construct
terminations, and test fiber optic lines to effectively maintain the telemetry link for the system.
Fiber optics, in the simplest of terms, is a manufactured glass cable used for carrying information
in the form of a light signal. A basic fiber optic communications layout has three major
components:
• The transmitting device is the light signal generator.
• The fiber optic cable is in itself a passive piece of equipment.
• The receiving module is the destination point for the source information. Light signals
received at the module are distributed to respective sources or are converted back to an
electrical signal.

Console Module Remote Module

Single Mode Fiber

The fiber optic cable is in itself a passive piece of equipment, meaning it does not generate
any active transmissions until acted upon by the transmitter module. The cable is simply
the connection medium between the transmitter and receiver. The receiving module is the
destination point for the source information. Light signals received at the module are distributed
to respective sources or are converted back to an electrical signal (as in the case of the ROV
equipment). Fibers transmit at a certain frequency, which is the speed of the modulation, or in
other words, the number of pulses per second that are emitted from the light source. A pulse a
second is equal to 1 Hz. For fiber transmissions, however, the practical measurement is Mega Hz
or millions of pulses per second.

Fiber Composition
In some cases, several fiber cables will be housed in PVC tubing that is encased by a
protective buffer layer and finally an outer plastic or PVC jacket. The six to twelve fibers
inside of the ROV umbilicals have similar protection plus a steel armor.

3-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Single mode fibers transmit only one wavelength of light at a time. They are used for long
distance transmissions because of the signal quality, efficiency, and speed. The glass core of a
single mode fiber can be almost a quarter the size of a multimode fiber.

Single Mode Fiber

Fiber Optic Wavelengths

The single mode 1310 and 1550 nanometers’ (nm)(billionths of a meter) wavelengths are both
in infrared range of the spectrum and were selected for a particular reason. The light people
are most familiar with is, of course, the light they can see. Human eyes are sensitive to light
that has a wavelength in the range of about 400 nm to 700 nm from the blue/violet to the red.
Fiber optics use light in the infrared region, which has wavelengths longer than visible light,
typically from 600 to 1,600 nm. The infrared frequency range has much less attenuation than the
visible spectrum. The attenuation of glass optical fiber is caused by two factors, absorption and
scattering.

Optimal Characteristics
Absorption occurs in several specific wavelengths called water bands due to the absorption by
minute amounts of water vapor in the glass.
Scattering is caused by light bouncing off atoms or molecules in the glass. It is a function of
wavelength, with longer wavelengths having much lower scattering. Some people may wonder
why the sky is blue. The reason is because the light from the sun is more strongly scattered in
the blue.
Attenuation is the loss of optical power as the light signal travels further from the emitting
transmitter. The value is measured in decibels (dB). The higher the dB reading means the fiber
has a greater attenuation or signal loss from the measured start and stop points. Attenuation can
be classified into two categories: either intrinsic or extrinsic.
Intrinsic attenuation means something is wrong with the fiber itself, such as an impurity in the
glass, causing the light to be scattered or dispersed.
Extrinsic attenuation can be caused in two ways: macrobending and microbending.

SECTION 3: Communications 3-9

 Macrobending is an extreme bend in a fiber optic line that causes the
bent portion to be strained, which will affect the refractive properties
of light in that area leading to optical signal loss. To prevent loss, all
fibers have a maximum bend radius associated with them. As a rule
of thumb, the bend radius for bare single mode fiber should be no
more than 1 ½ inches or 10 times the cable’s outside diameter (OD)
for non-armored cable and 15 times the OD for armored cable. Macrobending

Microbending is a small-scale distortion, typically where pressure

has been applied to the cable, such as a Ty-wrap being too
tight. There are several causes: temperature extremes or
something pressing against or set on top the fiber cable.
The problem will be centered around a small area and can
Microbending
sometimes be seen by the unaided eye.
Dispersion will refer to the “spreading out” of light as it travels down the fiber core. As the pulses
become more distorted, the receiver may not be able to interpret the original signal. This type
of problem is related to wide-ranging wavelengths traveling at different speeds. This type of
problem is most associated with multimode fiber.
Bandwidth is the amount of information a fiber can carry efficiently to be easily distinguishable
by the receiver module. Bandwidth is measured in MHz.
Acceptance cone is a maximum allowable angle of light entrance into the fiber core to maintain
signal quality. Single mode fiber has a very small acceptance cone, so any deviation in a
connection could cause some signal loss.
Acceptable fiber loss below is a table of general figures for anticipated loss of signal in multi- or
single-mode fiber lines. For connectors there should be less than a 0.5 dB loss.

Connection Single Mode Loss (dB)

Loss per Km 0.5
Connector 0.5
Mechanical 0.2 - 0.3
Fusion Splice 0.1

Fiber Optics System

Oceaneering uses fiber in most of its umbilicals as the medium for telemetry, video, and
sonar communications between the subsea equipment and the surface. There are six to twelve
fibers inside of the umbilical with five being used at anytime. Most Oceaneering fibers are
either 2.4 or 3.0 mm in size.

Fiber optic equipment multiplexes and converts the down link data electrical signals to light
signals. These light signals are then transmitted down the fiber optical cable. The fiber optic

3-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

equipment will also receive multiplexed uplink data light signals from the cage or vehicle via a
fiber optic cable and convert and de-multiplex that data into individual signals. This fiber optic
system is called the Focal 903 video/data multiplexer. The Focal unit is powered by 120 VAC.
Two fibers link the Focal unit to the cage or vehicle. One fiber is for the up link / down link
path from the surface to the cage or vehicle. The second fiber is connected to the secondary
port and will be used if the primary fiber is damaged or causing degrading of the system.
In the standard configuration, the down link is telemetry and sonar data and is transmitted at
1550 nm. The up link is telemetry/sonar data and video signals and is transmitted at 1310 nm.
The focal 903 is normally mounted on the rear of the console group.

Multiplexer

Focal 903

Multiplexing
Multiplexing (also known as muxing) is a method by which
multiple analog message signals or digital data streams
are combined into one signal over a shared medium. The
multiplexed signal is transmitted over a communication channel
that may be a physical transmission medium. The multiplexing
divides the capacity of the high-level communication channel
into several low-level logical channels, one for each message
signal or data stream to be transferred. A reverse process,
known as demultiplexing or demuxing, can extract the original
channels on the receiver side.
Multiplexer

SECTION 3: Communications 3-11

 Fiber Optic Safety
The most important safety issue in reference to fiber optics is the proper handling and disposal
of pieces of glass fiber created by cutting, re-terminating, or accidently breaking the fibers.
Safety glasses with side shields are always necessary when working with fiber optics. Leather
gloves are also recommended. Fiber optic splinters are similar to glass splinters and should be
treated with the same care. These small pieces of glass can easily cut or become lodged in the
skin. Contact wears must not handle their lenses until they have thoroughly washed their hands.
Food and beverages must be kept out of the work area. If fiber particles are ingested, they can
cause internal hemorrhaging. All precautions must be taken to minimize the transfer of fiber
particles onto clothing. Fiber particles attached to clothing can be transferred to food and drinks
and later ingested; the particles can be ingested by other means as well.
Technicians should not touch their eyes while working with fiber optic systems until their hands
have been thoroughly cleaned.
Technicians should never look directly into the end of fiber cables until they are positive there is
no light source at the other end. Fiber optic power meters should be used to ensure the fiber is
“dark.”

When using an optical tracer or continuity checker, look at the fiber from an angle at least six inches away
from your eye to determine if the visible light is present.

Fiber scraps should be disposed of carefully and properly. A special “sharps” container is
preferred, but, at a minimum, a disposable paper cup can be used to collect all fiber scraps. Care
should be taken to keep scraps off the floor and clothing.

Fiber Optic Termination

Before terminating a fiber, supplies should be readily available and a safe, clean area to work
in should be prepared. The following procedures are primarily related to termination of an ST
Hotmelt connector.
1. Safety glasses with side shields are required during fiber optic termination.
2. Insert the hotmelt connector, ferrule end first, into the universal hotmelt connector
holder.
3. Place the connector holder into an available heater port in the oven. (Note: The classic
blue hotmelt connectors should be in the oven for no less than 60 seconds. The ultra
high temperature or red hotmelt connectors should be in the oven for at least 90
seconds.)
4. Slide the white strain relief down the fiber, small end first.
5. Lay the cable onto a strip template and mark the location of where to cut
(approximately one inch from the end).

3-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

6. Score the jacket with the jacket stripper and remove jacket by hand.
7. Fold back the protective wires and cut as close to the jacket as possible.
8. Using the buffer and acrylate slot of the fiber stripper, remove the buffer in small
pieces until 1/8 of an inch is protruding from the end of the jacket.
9. Clean the fiber with an alcohol pad to remove any debris.
10. Remove the universal connector holder from the oven by grasping the cool touch
handle. Take care not to touch the metal part of the handle as it will be hot!
11. Feed the fiber into the back of the connector until the jacket is secure in the connector.
12. Push the jacketed fiber into the cable retention slot until creating a slight bow in the
cable to keep the cable seated in the connector.
13. Place the holder in one of the cooling ports provided on either side of the oven, letting
it sit for five minutes.
14. Remove the connector from the holder, taking care not to break the fiber protruding
from the end of the connector.
15. Place the fiber scribe parallel to the end of the connector perpendicular to the fiber on
the bead of the adhesive.
16. Gently slide the blade of the scribe against the fiber once. (Note: The fiber should not
break.)
17. Grip the fiber with the thumb and forefinger and pull it in the direction of the
connector. If the fiber does not easily pull off, repeat the scribing process.
18. Dispose of the piece of scrap fiber in the designated fiber debris can.
19. Perform an initial air polish by holding the black five-micron polishing film over the
connector and make a circular motion gently on the tip of the adhesive bead.
20. Clean the polishing pad with alcohol and a lent-free cloth.
21. Place a small amount of water on the polishing pad and set a piece of black five-
micron paper on the pad, shiny side down. The water will help the polishing film stick
to the pad.
22. Place a couple of drops of water in the center of the paper and begin to make figure-
eight motions for about 30 seconds. Inspect the tip for residual epoxy and continue
with the five-micron if necessary.
23. Set up for the one-micron polishing with the water (green paper shiny side down).
Polish for about 30 seconds.
24. Inspect the fiber using the fiber microscope.
25. If the fiber looks good, clean the connector tip with the lint free wipes and denatured
alcohol and cap off. If not, repeat polishing steps until fiber is acceptable.
26. After all the fibers are completed, test the fibers for dB loss and record findings.
27. If the connectors show a high loss, try polishing the one-micron paper again before
more drastic measures are taken.

SECTION 3: Communications 3-13

 Section Review
This section discusses the communication between the surface controls and the vehicle and
cage. The Oceaneering ROV fleet uses various configurations of hardware for passing data
between surface and subsea. While hardware may vary, the underlying principles are the
same: data is multiplexed into a serial data stream and transmitted optically between surface
and subsea. The communication to the cage and vehicle is accomplished through the pilot
computer. The vehicle and cage computers are both linked to the surface via separate serial
data links. These serial links are used to transfer data from the surface controls to the cage
and vehicle. They also allow the transfer of sensory and diagnostic data from the cage and
vehicle to the pilot computer for display in CTAG graphics. The control/feedback data is
combined with video signals by a pair of fiber optic multiplexers.

Knowledge Check

1. What method is used by RS-232 for communication to allow a simple connection

of three lines?

2. What type of transmitting device is used in the fiber optic system?

3. ___________ is a small-scale distortion, typically where pressure has been applied

to the cable.

4. What type of connectors are used to connect to the Focal 903?

Student Activity

1. In groups, conduct a fiber optic termination utilizing the ST Hotmelt Connector.

3-14 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section 4
Oceaneering Power and Control

Morgan City Training Center

4-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
Oceaneering Power and Control (OPAC) is a hardware system that will continue to grow to
meet high tech demands presented in the future. The system is designed around a central core or
“stack” of circuit boards that provide digital, analog and serial I/O (input/output), along with
AC and DC power distribution. The OPAC system is a highly flexible and adaptable system that
is easily configured for use in any system by adding or deleting I/O backplanes and/or modules
as required. Completely different input and output configurations can be accomplished by only
minor firmware changes to the Rabbitcore processor module.
The OPAC system is designed to provide control and sensor data between a source and
a remote device. OPAC improves the telemetry and control systems by providing greater
diagnostic feedback, improved structural design, and increased functionality. These
improvements translate into faster fault finding, as well as efficient component replacement.
The same basic stack is used in the pilot console, cage, and vehicle, each one only differing in
the combination of I/O modules used. Wherever possible, socketed ICs (integrated circuits)
have been used to enable quicker component replacement during fault finding.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Identify the purpose for each OPAC printed circuit board
• Recall where to find information pertaining to the power supply for each component
• Discuss the importance of powering equipment down before plugging/unplugging the
cable
• Identify major components on a typical ROV electronics/sensory layout
• Discuss the purpose of the major components on a typical ROV electronics/sensory
layout
• Explain the reason for the position of water alarm sensors

SECTION 4: Oceaneering Power and Control 4-3

 OPAC Arrangement
The primary function of each OPAC stack is to collect or output digital and analog signals. The
OPAC stacks will consist of a control printed circuit board (PCB), power supply PCB, and may
contain as many as three I/O backplane PCBs. Each of the three OPAC stacks deals only with
the gathering and/or outputting of analog and digital signals in its respective section of the
ROV system and is configured for the location in which it is installed. The three OPAC stacks
are located in the pilot console, cage, and vehicle.

OPAC Stack

Each stack is customized due to its physical location and operational purpose, but the basic
architecture is consistent. Each OPAC stack will consist of the following:
• Control PCB - top level (any stack)
• I/O backplane - level two
• I/O backplane - level three
• I/O backplane - level four (vehicle stack only)
• Power supply PCB - level 0ne(any stack)

Both supervisors and technicians must ensure that when OPAC stacks are disassembled and then
reassembled, they contain the correct modules in the correct position on the I/O backplane with the correct
I/O backplane in the correct layer (A2/A3/A4 J1, J2, J3, and the GFD jumpers correctly set).
Additionally, all addressing must be correctly set for the stack node location (A5 J3).

Although the onboard modules installed on the I/O backplanes will differ according to the
physical location of the stack, the arrangement of major PCBs within the stack will remain the
same. It is important to realize since the vehicle and surface/Cage OPAC stacks have a different
number of PCBs in their layers, the actual PCB that carries a specific module name (A2, A3, A4,
or A5) can be different between the system nodes.

4-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

The bottom layer of the stack is titled A1 no matter which stack is being discussed. As the
boards are stacked on top of each other, they count upwards. In the case of the vehicle stack,
the power supply PCB would be A1; next, the first I/O backplane would become A2, then A3,
and A4, ending at the top of the stack with the control PCB being A5. Because the boards stack
onto each other through various headers and pins, there is always the chance that a board may
be misaligned.

PCB Configuration
To improve reliability, the control system
is assembled as a stack using PC104 style
connectors for inter-PCB connection. All
connections to external components are via
plugs along either side of the I/O PCBs. A
complete “stack” can be changed quickly in the
event of catastrophic failure ( i.e., a flooded can)
IO Backplane
to minimize downtime.

Power Supply PCB A1

The A1 OPAC power supply PCB is always the bottom PCB in any OPAC stack. The PCB
is multifunctional, providing several different functions within the OPAC stack and the ROV
telemetry system:
• It provides multiple isolated voltages generated from the sensor +24 VDC input supply
on J1.
• It monitors and feeds voltage levels and current draw back to CTAG.
• It provides switched sensor +24 VDC, switched sensor +12 VDC, unswitched sensor
+12 VDC, and unswitched +5 VDC outputs.
• It provides switched and unswitched solenoid +24 VDC outputs.
• It provides switched proportional +24 VDC outputs.

Power Supply

SECTION 4: Oceaneering Power and Control 4-5

 The power supply PCB controls most of the power flow in the OPAC system and provides
diagnostic feedback of current/voltage for the circuits it provides power to. The incoming
+24 VDC sensor supply (indicated by LED1) is stepped down to produce sensor +/-12 VDC.
The presence of these supplies are indicated by LED3 and LED4. The PCB then steps down
sensor +12 V to produce sensor +5 VDC, which is indicated by LED2.
DC-DC converter PSU2 transforms sensor +24 VDC into +/-12 VDC, which is used for
powering the output stage of the analog out module. This isolated supply prevents a flooded
valve pack or cable from affecting the other devices connected to the sensor ground plane
(cameras, sonar, etc.). The presence of these supplies is indicated by LED5 and LED6.
PSU3 and PSU4 are identical +/-15 VDC DC-DC converters that are powered from sensor
+24 VDC. Their outputs are linked in series to produce the +60 VDC that the ground fault
module applies between chassis ground and each circuit being monitored. PSU5 produces an
isolated +5 VDC supply that powers the electronics on the ground fault module itself. The
presence of GFD +60 VDC and +5 VDC is indicated by LED7 and LED8 respectively.
DC-DC converter PSU6 converts sensor +24 VDC into +/-12 VDC, which is referenced to
processor ground. This is used for powering the system’s diagnostic circuitry.
R21 through R26 are ground fault sense resistors, which are used by the ground fault module to
monitor the sensor +24 VDC, solenoid +24 VDC, and proportional +24 VDC supplies. The PS
PCB has nine onboard relays for controlling power to various valve packs and sensors. LEDs 10
through 18 provide positive indication that the relays are energized. In addition, the board can
control the relays on up to four separate light control PCBs and also four relays on the 110 V
monitoring PCB. All relay drive commands are received, which energizes the GFD test relay
RL10. This relay, in turn, energizes the self-test relays on the ground fault module.

Control PCB
The control PCB sits at the very top of the OPAC stack and, as its name suggests, is the main
controller of the OPAC system and forms the central communications hub for all of the I/O
modules and peripheral serial devices. Its primary function is to provide an interface between
the Rabbit microprocessor and the rest of the system. It has a number of features and is the
attachment point for two plug-in daughter modules, which consist of the Rabbit microprocessor
and the TTL/RS232. It can also host a single I/O module.

Control PCB

4-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

The control PCB operates from a +24 VDC supply (referred to as processor power), whose
presence is indicated by LED1. A bridge rectifier provides protection against reverse polarity.
Processor +24 VDC is used for powering relays both within the stack and on peripheral boards
such as the light controller PCB. It is stepped down to +5 VDC and +3.3 VDC respectively.
The +3.3 VDC supply powers the Rabbit processor. LEDs indicate the presence of each supply.
A MAX1271 A-D converter measures each power supply on the control PCB and passes the
values to the Rabbit processor via the serial peripheral interface (SPI) communications bus. It
also measures the voltage drop across low value resistor R1, which provides a measure of the
current being drawn from the incoming supply, the values of the temperature, and the humidity
sensor.
The Rabbit processor has four serial ports that are converted to RS-232 by the multichannel
transceiver chip and made available at J7. This allows the Rabbit processor to multiplex data
from external serial devices with the CTAG telemetry stream. Each of these serial ports is
optically isolated from the Rabbit.
The telemetry daughter card converts the TTL data link from the Rabbit processor into a
standard format for communication with the outside world. It comes in two versions: RS-232
for short haul transmission, such as the link between the cage OPAC and the fiber optic modem,
or the pilot tray and pilot PC; RS-422 is for longer distance transmission between vehicle and
cage via the tether.

Rabbit Microprocessor
The “brain” of the OPAC stack is the RCM3200
Rabbitcore Microprocessor Module. This small board is
a daughter assembly of the A5 OPAC control PCB and
hosts a Rabbit 3000 processor executing firmware that
resides within non-volatile memory. Rabbit Processor
The RabbitCore module communicates serially with CTAG via the telemetry daughter board,
which converts its TTL-level signals to either RS-232 or RS-422 standard.
Identical firmware is loaded in each RabbitCore (console, cage and vehicle) and, depending
on the setting of jumpers A0 through A7, on the control PCB, the Rabbit processor executes
the appropriate code for its location. Updating the firmware in the RabbitCore module can be
accomplished by one of three methods:
• A special cable connected between a PC and the RabbitCore module.
• A software utility used to install the firmware.
• Direct from the pilot PC via CTAG.
LED4 on the control PCB will blink whenever a valid data packet is received by the Rabbit
processor. A valid data packet is one that has been error checked for validity. LED5 blinks
whenever a valid data packet has been transmitted by the Rabbit processor.

SECTION 4: Oceaneering Power and Control 4-7

 TTL/RS232 Telemetry PCB
The TTL/RS232 converts the TTL signals to RS-232 standard.
An isolated +5 VDC supply powers the RS-232 line driver. This provides further protection for
the Rabbit processor. LED3 indicates the presence of processor +5 VDC, and LED4 indicates
the presence of the isolated +5 VDC supply. LED1 and LED2 indicate the presence of Tx and
Rx data.
LED4 & LED5 on the control PCB work in conjunction with the Tx and Rx LEDs on the
RS-232 telemetry PCB to provide an aid for troubleshooting telemetry problems. LED5 blinks
whenever a valid data packet has been transmitted by the Rabbit processor. LED4 blinks
whenever a valid data packet is received by the Rabbit processor. A valid data packet is one that
has been error-checked for validity. Therefore, if the RS-232 telemetry PCB’s Rx LED is
blinking, but LED4 on the control PCB is not, the Rabbit processor is receiving invalid data.

TTL/RS232 Telemetry PCB

I/O Backplane PCB

The OPAC I/O backplane PCB acts as a motherboard for up to three OPAC I/O modules.
Control signals and power are provided to the module through the OPAC I/O backplane. Each
OPAC I/O backplane PCB is identical and can host up to three OPAC I/O modules.
The type and position of each module installed on the OPAC I/O backplane PCB is, however,
pre-defined by the OPAC stack operating firmware and cannot be changed. Their position in the
stack is identified by the jumper settings on J1, J2 and J3. There are four additional jumpers that
must be installed on the A3 OPAC I/O backplanes that host the ground fault module (A3-M3).

The OPAC stack configuration is pre-defined, and if an I/O backplane PCB is changed out, care must
be taken to ensure the replacement I/O backplane PCB has the same modules and jumper setting as the
original.

4-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

 I/O with Jumpers

The following I/O modules are available to be mounted:

Analog input 14 input channels
Analog output 12 output channels
Digital input 24 input channels
Solenoid driver 20 output channels
Water alarm - 10 channel WA 10 input analog water alarm channels
6 input digital alarm channels
Camera/sensor power 8 channel power control channel focus/zoom
4 channel video switching commands
4 channel general purpose digital out
Ground fault 8 ground fault monitoring channels

Analog Input Module

The OPAC analog input module has twelve identical 12-bit
analog to digital channels and two additional 16-bit channels.
The capture range of all 14 channels is 0 to +5 VDC.
Summary of features:
• Channels 1 thru 12 are 0 to +5 VDC input at 12-bit
resolution.
• Channels 13 and 14 are 0 to +5 VDC input at 16-bit
resolution.
The OPAC analog input module does not have any jumper
settings. The analog input module receives command from all
three locations and may consist of hydraulic pressure,
joystick functions, lights, altimeter, etc. Analog In

SECTION 4: Oceaneering Power and Control 4-9

 Analog Output Module
The vehicle OPAC stack contains two analog output modules, and
they are both located on the A4 OPAC I/O backplane. The OPAC
analog output module has 12 identical outputs that produce a signal
between -10 VDC and +10 VDC with 10-bit resolution.
The outputs are derived from an isolated +/-12 VDC supply (DAC
PWR) provided by the A1 OPAC power supply PCB, which adds a
layer of protection for the OPAC stack.
The analog output module issues command to the cage and vehicle
components and may consist of the proportional packs, thrusters,
Analog Out lights, etc.

Digital Input Module

The OPAC digital input module has 24 identical active-low
channels. Each input is held high by a pull-up resistor tied to sensor
+5 V and is turned ON by pulling the input to sensor ground.
The digital input module only receives command from the pilot
console through CTAG and consists of the camera, by-pass switch,
foot pedals, and rate manipulators.

Solenoid Driver
Digital In
The OPAC solenoid driver module has 20 identical
low-side driver outputs that are used for driving coils on solenoid valves. The
output is normally held high (+24 VDC) until a command is received from
the pilot, at which point the output is pulled to ground. The solenoid driver is
responsible for controlling valves in the rate packs on the cage and vehicle.

Solenoid Driver

Water Alarm Module

The water alarm module has 10 inputs for connection to water alarm
probes, plus six general purpose digital inputs. The general purpose
inputs are used in the ROV vehicle for monitoring latch switches on
compensators and the telemetry can’s vent plug switch.
All circuitry on the board is powered from an isolated +5 VDC supply
that is derived from sensor +5 VDC. This provides isolation from the rest
of the system as the water alarms are effectively tied to chassis ground
when activated by contact with seawater. A control on the water alarm
module page of CTAG enables this output, which then simultaneously Water Alarm Module
pulls each of the ten water alarm inputs low, thereby simulating actual water alarms.

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Camera/Sensor Module
The OPAC camera/sensor power module provides eight switched
+24 VDC power outputs for external devices such as cameras, sonar,
altimeter, etc. The vehicle OPAC stack contains a single OPAC camera/
sensor module that is located on the A3 OPAC I/O backplane.
Summary of features:
• Six channel focus/zoom control; tri-state control (0 VDC, Hi Z,
+12 VDC).
• Eight channel low-side driver that consists of
- Three channels: video switcher control Camera/Sensor Module

- One channel: still camera trigger

- Four channel: relay drivers for survey interface PCB

MD 88 Board
There are two MD 88’s in the vehicle fiber optic can. They receive
the RS-232 signal from the control PCB via the survey interface
board. MD 88 number one is used to control functions from term
board A6. MD 88 number two is used to control the functions of
MD 88 Board
term board A8
Ground Fault Module
The OPAC ground fault module simultaneously monitors eight
individual circuits with a remote test facility on all channels. In
normal operation, the flow of current in this circuit will be zero,
but when the circuit has a leakage path to chassis, a finite current
will flow. The isolated +60 VDC applied to each circuit is generated
on the power supply PCB and routed to the ground fault module
through the I/O backplane interconnects.

Ground Fault Module

The ground fault module is the only PCB that uses a 20-pin connector A; all other modules use a 16-pin
connector A. The extra pins on the ground fault module connect the module with the isolated GFD +60
Vdc, GFD +5 VDC and GFD Gnd supplied by the A1 OPAC power supply PCB through the
OPAC stack internal Con4 connector.

SECTION 4: Oceaneering Power and Control 4-11

 OPAC Power Supplies
The OPAC system creates several isolated power supply planes in order to reduce the risk
of one piece of equipment bringing the whole system down. The main processor operates
from its own completely isolated power supply that, coupled with opto-isolation of the SPI
communications bus, provides an effective barrier against telemetry failure.
It is important the technician realizes an isolated power plane means each power plane is
electrically separated from all other power planes. For example, if a technician attempts to
measure the +24 VDC sensor power, he must have the meter ground probe connected to the
+24 VDC sensor ground and not the solenoid, proportional, processor, etc., ground.
Regulated power is not a requirement for certain 24 VDC devices (e.g., solenoid valves) in an
ROV system, and the PS111 power supply has been designed with this in mind. The power
supply produces unregulated +24 VDC to the rate packs from a 17 VAC input by using a bridge
rectifier and capacitor combination.
In addition to the power supply PCB, the OPAC stack has additional “stand alone” power
assemblies:
• PS1: +24 VDC supply, known as solenoid power, is used to provide switching power to
the hydraulic rate valves. PS1 uses a bridge rectifier to convert 17 VAC to 24 VDC via the
PS111.
• PS2: +24 VDC supply, known as proportional power, is used to provide control power
to the PWM PCB in the proportional control unit (PCU).
• PS3 & PS4: +24 VDC supplies, together known as sensor power, are mounted to and
part of the Vicor VIPAC1 power supply module. The +24 VDC sensor power is the
most widely used of the three primary telemetry can power supplies.

Vehicle Power Flow

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Non-OPAC Stack PCBs
The OPAC system has additional PCBs that are utilized but not located in the OPAC stack.
These PCBs provide miscellaneous functions within the OPAC system and are housed in the
telemetry can. They are as follows:
• OPAC survey interface PCB, a multi-function PCB, supplies switched and unswitched
DC voltage outputs and provides wiring interconnections between the OPAC stack and
subcomponents. This is accomplished by the MD 88.
• OPAC 110 VAC monitoring PCB supplies switched and unswitched 110 VAC outputs,
voltage, current, and ground fault monitoring for the 110 VAC.
• Lamp control PCB (PPC1 to PPC4) provides variable control of a 110 VAC lamp
circuit. Each PCB can also provide current and ground fault sensing of the circuit it
supplies.
• Gyro/compass data switcher PCB provides a means of switching the heading sensor
input between a primary heading source (typically a survey-spec Gyro) and a secondary
heading source (typically a Honeywell HMR-3,000).

Temperature and Distance Monitoring

When a technician is flying an ROV, system temperature and distance to the seabed can be
monitored from two instruments specifically designed to relay information to the pilot via
CTAG. The hydraulic oil temperature is monitored using the A12 thermocouple transmitter
module, and the distance above the seabed is detected utilizing the altimeter.

A12 Thermocouple Transmitter Module

A thermocouple is a device composed of two dissimilar metal wires that are welded together at
a point. This dissimilar metal junction will generate a very small voltage that is proportional to
the temperature the junction is exposed to.
The A12 transmitter module operates by converting the thermocouple’s junction voltage into a
4-20 mA current loop. The voltage drop across the load resistor R1 is then used as the input to
the OPAC A4-M1 analog-in module.

Altimeter
Oceaneering uses two varients of altimeters on its ROV’s. The first, an older model, is a 33- to
2-foot range, and the second is a 300- to 2-foot range model that is set at manufacturing to
read from 100 to 2 feet. When the vehicle is within the tolerance range, the hight above
seabed values are reported to the pilot via CTAG on the console.
The altimeter operates on 24 VDC taken from the vehicle’s telemetry can and is connected by a
4-pin RMG-4FS connector whip potted to a 5-pin MSAJ.

SECTION 4: Oceaneering Power and Control 4-13

 Section Review
OPAC is a power and control hardware system that will continue to grow to meet high tech
demands presented in the future. The system is designed around a central core or “stack”
of circuit boards that provide digital, analog, and serial I/O (input/output) along with AC
and DC power distribution. OPAC is a highly flexible and adaptable system that is easily
configured for use in any system by adding or deleting I/O backplanes and/or modules as
required.

Knowledge Check

1. The PCB found at the top of the OPAC stack would be a __________ , and its
purpose is to __________.

2. The __________ power supply provides the power supply PCB with the required
24Vdc it needs for its power.

3. What is the recommended location for finding information pertaining to the power
supply of each component?

4. What jumpers allow the connection of the ground fault card to the systems moni-
tored?

5. Which board takes in data from the oil level, altimeter, temperature, and depth
transducer sensors?

4-14 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section 5
Control Telemetry and Graphics

Morgan City Training Center

5-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
The ROV system has a software package that allows the pilot to monitor, troubleshoot, tune
up, and set up behavior for the system. This package is control telemetry and graphics (CTAG),
and when used in conjunction with OPAC, it is a very useful monitoring tool. CTAG should
be consulted immediately when problems arise. The more the technicians understand CTAG,
the easier it is to utilize when diagnosing a problem. Most technicians will find the program
remarkably flexible because it can provide the crew with a great deal of information and a
number of choices.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Discuss how power adjustment is beneficial for the joystick gain feature in CTAG
• Locate the diagnostics page for setting joystick gain
• Recall the importance of closely monitoring alarms
• Show where water and ground fault alarm information is displayed in CTAG
• Discuss the actions to be taken if a water alarm is triggered
• Discuss the actions to be taken if a ground fault alarm is triggered

SECTION 5: Control Telemetry and Graphics 5-3

 CTAG
CTAG is an indispensable diagnostic tool used in conjunction with OPAC. CTAG software is
the basis for all functions associated with the cage and vehicle. Loaded onto the pilot and
auxiliary computers, it is used to enable, monitor, manipulate and disable various functions
throughout the sub-sea systems.

CTAG Main Display

CTAG Monitoring
CTAG monitoring conveniently allows for the following checks:
• Remote voltage monitoring of power supplies
• Remote monitoring of power supply currents
• Circuit isolation via double pole relays (GFI isolation, etc.)
• Telemetry can humidity and temperature monitoring
• Remote ground fault module testing
• Remote water alarm module and digital input module testing
• Real analog output monitoring (thruster, lamp, etc.)

Power Supply PCB

The power supply PCB page is available for the console, cage, and vehicle stacks. This page
monitors the various power supply voltages and amps while the right hand side monitors relays
attached to the power board that can be used to switch on various circuits or control power
distribution to other areas of the system. This page will allow inspection of all the sensor
voltages and the total sensor current used. The power supply PCB page can be used to monitor
and diagnose problems.

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Console Stack
This page allows the voltages supplying the analog input modules and the digital input modules
to be checked on the console stack. It also gives a real figure of the current used, which can
serve as a benchmark. In addition, this page can indicate whether the alarm buzzer, cage HPU
shutdown, or vehicle HPU shutdown signals have been sent, but this page does NOT indicate
if the relays have been activated.

Cage Stack
The power supply PCB page displays all the sensor voltages and the total sensor current
used for the cage stack. The solenoid and proportional supply voltages and currents are also
monitored, as is the telemetry 110 VAC supply current. The telemetry 110 VAC supply voltage
is not presently implemented and will show a low and flickering value. The 110 VAC lights
supply is monitored as well as the current of any lamps used (usually two). All of this should be
benchmarked so any potential problems can be spotted.

Vehicle Stack
The power supply PCB page provides information on the voltages and currents for the vehicle.
The 110 VAC supply monitoring is not implemented. The top nine relays are on the power
supply PCB itself. The first three distribute solenoid power to the port rate pack, starboard rate
pack, and auxiliary rate pack/mini RCU, respectively. The fourth is a spare for solenoid power
distribution.
The next four relays distribute sensor power. The first two supply 24 VDC to the survey
interface PCB and the camera/sensor module, respectively. The remaining two distribute 12
VDC, one to the compass and the other is a spare. Following these are the signals to switch on
the lights. These relays are actually located on the lamp control PCBs.
In the event of a solenoid ground fault on a vehicle, in order to isolate where the ground fault
is coming from, the relay’s switching power to the port, starboard, and AUX could be isolated
in turn. When the ground fault disappears, whatever was isolated is causing the problem. On
the bottom right is a ground fault test relay, which is located on the power supply PCB. This, in
turn, energizes the relays on the ground fault module.

Control PCB
This page is available for the console, cage, and vehicle stacks. The parameters monitored here
are processor 24 VDC, 5 VDC, 3.3 VDC, and telemetry 5 VDC. Humidity and temperature are
also monitored. Humidity and temperature will be system dependent, so the best way to use this
information is to benchmark it and note when it changes. With benchmark information, any
unusually high humidity indicates possible moisture in the can. An unusually high temperature
may mean the cooling fans are off or the power supply heat sinks are not installed properly.
Processor current is very useful for checking the operation of relays. The relays on the power
supply PCB, light controllers, and 110 V monitoring board are all powered from processor
24 VDC.
SECTION 5: Control Telemetry and Graphics 5-5
 CTAG Main Display
The main CTAG screen can be broken up into different
sections for explanation of purpose. The first section 1 2 3
concerns the six “cells” on the main page, each displaying
various information to the pilot. Pilots should click on these
cells to display the secondary images behind the primary cells 4 5 6
or to clear the information all together.

Cell 1 CTAG Main Display in Sections

Cell 1’s primary screen is a line graph depicting the cage’s depth (a grey
line) and location (a yellow line) relative to the cage. The yellow line also
indicates the amount of tether out. The secondary page shows the oil level
on the electrics compensation system.
Cell 1
Cell 2
Cell 2 is a compass with several built in functions. Most noticeable is the
large arrow that rotates around the compass depicting the vehicle’s current
heading. An artificial horizon bar is located in the center showing the
altitude of the vehicle in reference to level flight. A violet line extending
from the arrow outward to the edges of the compass records a two-
minute history of the vehicle’s heading. There is no secondary screen. Cell 2

Cell 3
Cell 3 is used to monitor the hydraulic oil pressure, level, and
temperature in the vehicle’s main reservoir. A sensor affixed to
the Firestone compensator measures the oil level. If it is at least
75 percent full, the bar graph is green. If the level drops below 75
percent, the bar graph turns yellow and an alarm will sound. If the oil
level drops below 25 percent, the bar graph will turn red and a new Cell 3
alarm will sound. If the level drops below 15 percent, the HPU will automatically shutdown.
The background page shows information about the vehicle’s oil temperature inside the
Firestone bladder and the electronics’ temperature inside the telemetry can.

Cell 4
Cell 4 contains a scrollable list of ground fault indicators. Monitored
circuits for both cage (left bar graph) and vehicle (right bar graph) are
telemetry/110, lights, sensor, prop, and rate power supplies. If the resistance
is above 500,000, the bar will be blue. If the resistance drops below 500,000,
the bar will turn red. The second background page displays information on
the cage’s hydraulic oil level and pressure. The third background page shows
the cage’s main and electrics temperature. Cell 4

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Cell 5
Cell 5 illustrates the depth of the cage and vehicle. Once in range, the ocean floor
can be seen as a brown line. A blue line shows the depth of the vehicle, and a
violet line shows the depth of the cage. A scale of the depth is seen to the right
of the cell and is updated automatically. This is recorded as a two-minute history.
Cell 5

Cell 6
A graphic of the vehicle is used to illustrate operator inputs from the
vehicle’s lights and thruster controls on the console . Lights are shown as
yellow triangles around the vehicle that grow as the brightness is turned up.
The second background page shows information on the motor current. The
third background page shows information on the motor voltage. Cell 6

Soft Keys
The CTAG display has eight soft keys across the top. The four that are most commonly utilized
are discussed below:
• Alarms - When an alarm is activated, the button flashes red with white lettering. When
the alarm’s button is clicked, a bank of indicators is seen. The block associated with the
alarm will flash when activated.
• GFX - This allows the pilot to switch on and off the graphic’s shown in the six cells
located in the center of the screen.
• DIAG - This allows the pilot to access the diagnostics pages.
• SW Arms - When selected, this changes which manipulator is functioned by the pilot’s
manipulator controller. This is a function for systems that have two rate arms.

Tether/Cage Depth and Heading

In the first graphic, the uppermost number that is in green
represents the amount of tether that has been paid out from the
cage in “units.” The next number down in yellow is the cage’s
depth. The number at the bottom of the stack in yellow indicates
the cage’s current heading.
In the second graphic, the first number indicates the vehicle’s Cage Depth
depth. The second number is the altimeter reading from sea floor
if the altimeter is energized. The altimeter has a range of 33 to 2
feet or 100 to 2 feet (depending on the model) and will show
three asterisks if it is out of range on the high side. The bottom
number in the stack is a total depth on the spot, which is
calculated by adding the vehicle’s depth to the altimeter reading.

Vehicle Depth
SECTION 5: Control Telemetry and Graphics 5-7
 Subsea Telemetry
This page can be accessed from the main diagnostics page top left, or, if in either the cage
or vehicle stack pages, by selecting the telemetry module. The left-hand side of the page
pertains to the pilot–vehicle link and the right hand side of the page to the pilot–cage link. The
first parameter is the total number of packets transmitted by the pilot computer. In normal
operation, the packet count should be changing at a rate of about 20 - 40 times per second.

Console Telemetry
This page can be accessed by selecting the console stack then the telemetry module. It displays
exactly the same kind of information as the subsea telemetry pages, except it is for the pilot–
console link.

Vehicle and Cage Serial Devices

This page is accessed for either the cage or vehicle stacks by selecting serial devices above the
control PCB layer. The page lists the four serial ports that can be used to connect to external
devices. Usually only one is used on the cage for a digital compass (gyro). On the vehicle, all
four are used to connect to the gyro, the paroscientific depth sensor, and both the MD 88s.

Port 1 Gyro
This page is specifically for the gyro and displays the communication link parameters and the
details of the measurements being made. The Rx total should be incrementing and the Rx valid/
sec can be between five and twenty depending on the system. The Tx total will steadily clock
up until the gyro is turned on and communications are established. Then this Tx total number
will increment very slowly. If these values are benchmarked for the system when it is working
correctly, the information can be used to assist when diagnosing problems should they arise.

Port 2 Paroscientific
This page is for the main depth transducer and displays the communication link parameters as
well as the pressure and temperature readings. The Rx total should be incrementing, and the Rx
valid/sec should be between four and six. Tx total should be incrementing and have a similar
value to Rx total.

Port 3 and Port 4

These two pages are for the MD 88s, which are microcontrollers used to switch on relays
situated on four separate boards. These relays are used to switch on/off cameras and survey
equipment. The serial communications data is monitored. Tx total should be incrementing, and
Tx per second should be five. Rx per second should also be five. There are seventeen functions
shown on the right of each of these pages. These indicate which functions CTAG has asked to
be switched on or off.

5-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Water Alarm Module
These pages are available on the cage and vehicle stacks. This page monitors ten channels
for water ingress, and an additional six digital input channels are used for “contact closure”
operations such as vent plug, tool turns, latch, and tether count.
Should a problem arise with either the water alarms or the digital inputs, a test can be performed
on each to check the integrity of the water alarm module. The two test switches appear at the
bottom of the page. These tests feed inputs into either the water alarm circuitry or the digital
input circuitry and should result in all the water alarms and digital inputs shown on the page
being activated.

Testing Water Alarms

Water alarms should be tested whenever possible. Water intrusion, especially in the telemetry
can or transformer can, may cause even greater damage if not detected quickly. Any time a can
is opened, the water alarm should be tested prior to resealing and/or re-filling the can.

These tests do NOT test the circuit continuity out to the water alarms sensors themselves or to the digital
input switches.

Camera Sensor Module

These pages are available on the cage and vehicle stacks. They have a more accurate
representation (two decimal points) of sensor 24 VDC, +12 VDC, -12 VDC, and the sensor
current. The increased resolution of the current value may be valuable in checking whether low
current sensor equipment has actually been switched on.
On the vehicle, only the altimeter is powered directly from this module. The gyro itself is also
powered from the sensor 24 V PS, so when the gyro is switched on, both the TSS itself and the
TSS relay coil currents are measured.

Ground Fault Module

These pages are available on the cage and vehicle stacks. The page monitors eight channels for
ground fault level. The measured ground fault level is displayed in Ohms, and if the level is
500,000 Ohms or less, an alarm is activated. A test is provided for the ground fault module
itself.

This test does not check the continuity out to the various circuits being measured. For instance, this test
will “work” if the jumpers connecting the sense lines to sensor, solenoid, and proportional are not in place
and if the wiring to the light controllers and 110 V monitoring board are disconnected. This test only
checks the ground fault module itself and not any of the associated circuitry.

SECTION 5: Control Telemetry and Graphics 5-9

 CTAG Troubleshooting
The following CTAG pages can be used as a quick reference for troubleshooting:
• Power supply PCB page (console, cage, and ROV)
• Control PCB page (console, cage, and ROV)
• Subsea telemetry (cage and ROV)
• Console link (console only)
• Vehicle and cage serial devices (paro, heading, and MD 88s)
• Analogue input modules (console, cage, and ROV)
• Analogue output modules (cage and ROV)
• Digital input modules (console only)
• Camera sensor module page (cage and ROV)
• Touch screen link (console only)
• Alarm bar

CTAG for Windows (CFW)

Since around 1993, Oceaneering’s ROV systems have been controlled by CTAG. This software
was designed to work with the Microsoft DOS operating system. The DOS operating system
has proved to be a very stable platform, but it cannot support more complex applications with
high quality graphics. The CFW application has been developed to provide an up-to-date user
interface with high resolution graphics. As its name suggests, the application works with a
Windows operating system.
In order to retain the stability that users have become accustomed to with DOS, the pilot PC
will remain unchanged; it will still run the DOS version of CTAG. The PC running CFW will
become an add-on, similar to the current aux PC. The primary advantage of CFW over CTAG
is better graphical user interfaces (GUI).
Even though CFW provides the same data as CTAG for DOS, it provides the pilot a more user-
friendly screen to view information. It also has additional features that give the pilot telemetry
status, for instance, and provides a diagram. CFW also provides a graph function where you can
map any CTAG function to a realtime graphical output.

5-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

 CTAG for Windows Main Display

CTAG for Windows Subpage Displaying Telemetry Connections

SECTION 5: Control Telemetry and Graphics 5-11

 Section Review
CTAG software is the basis for all functions associated with the cage and vehicle. CTAG
allows the pilot to monitor, troubleshoot, tune, and set up behavior for the system.
Technicians should immediately refer to CTAG when problems arise. The software is
loaded onto the pilot and auxiliary computers, which allows the pilot to enable, manipulate,
and disable various functions throughout the subsea systems.

Knowledge Check
1. In normal operation, how many times per second should telemetry be counted in
CTAG?

2. Where in CTAG is ground fault alarm information displayed?

3. Where is Cage depth and heading information displayed?

4. True of false CTAG for Windows is a stand alone Program.

5-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section 6
Hydraulic Principles and Safety

Morgan City Training Center

6-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
Section 7 covers the basic principles of hydraulic functionality and safety factors involved in
working with hydraulics. A technician must have a basic understanding of viscosity, comparison
between flow and pressure, and Pascal’s Law. The technician must be able to read hydraulic
schematic diagrams, which are route maps of hydraulic systems that indicate the placement
of all the components and the way they are connected with each other within the circuit using
hydraulic symbols. This will allow checks to be carried out at specific system points to determine
whether signals, power, and fluid supplies are present.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Define and explain Pascal’s Law
• List ROV high pressure hydraulic components
• Define viscosity
• Explain principles of hydraulic flow
• Identify basic hydraulic symbols
• State the three main hazards of hydraulic systems
• Discuss the lowest PSI at which oil will penetrate the skin
• Explain the consequence of oil injected into the skin
• Explain the proper method of finding a leak

SECTION 6: Hydraulic Principles and Safety 6-3

 Basic Hydraulics
Hydraulics is the use of fluid (usually oil) to transmit energy. This energy, when directed upon
an area with a force sufficient enough to overcome any opposing resistance, produces work.
The generation of heat by working energy is system inefficiency. The following is necessary for
system efficiency:
• Appropriate viscosity
• Properly sized tubing and minimal bends

Viscosity
Viscosity, or how thick the oil is, will affect pressure. Oil that is thin or hot has less resistance to
flow than oil that is thick or cold. This is especially evident on a cold winter day when higher
than normal pressures are seen. When the system gets too hot, lower than normal pressures are
seen.

Flow and Pressure Comparison

Flow equals the actuator motion (movement-speed). Flow in the hydraulic system is created by
the pump. Pressure equals the actuator force. There is a one-sided relationship between flow and
pressure: Pressure can exist without flow, but flow cannot exist without pressure.

Pressure
Simply stated, pressure is the product of resistance to flow. Pascal’s
Law states that pressure applied on a confined fluid is transmitted,
undiminished in all directions, and acts with equal force on equal areas
and at right angles.
A pressure gauge on an OPEN outlet of a pump equals 0 PSI and 0 Pascal’s Law Triangle
resistance. As components are added, resistance to flow is increased and pressure is increased
up to the level it takes to overcome the added resistance. The gauge placed at the pump outlet
will read pressure needed to move the load and pressure needed to overcome the resistance of
fittings, tubing, and components.
Pressure differential is the difference in pressure between any two points in a system. Flow
is proportional to the pressure differential. For flow to happen, there must be a pressure
differential in the system. Where there is no pressure differential, there will be no flow. Pressure
differential is as follows:
• High differential = High flow
• Low differential = Low flow

6-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

The high pressure hydraulic system provides flow and pressure to the thrusters, manipulators,
and tooling. The low-pressure hydraulic compensation system provides minimal pressure (seven
to ten PSI) for non-rated components in order to protect against the depths of the ocean.

High-Pressure Hydraulic System

The major components of the high-pressure hydraulic system are comprised of the following:
• Main reservoir
• One 8 station proportional control manifold (Magnum) Two 4 station manifolds (Millennium)
• Eleven station solenoid rate pack
• High-pressure filtration system 12 micron absolute (nominal 3 micron)
• Oil/water separator (Cardev)
• Fixed displacement bent axis thruster motors
• Pressure-relief valve
• Pressure-reducing, flow-control, and counter-balance valves
• Variable-displacement, pressure-compensated, axial-piston pump

Reading Hydraulics Diagrams

Hydraulic symbols are used by technicians to read hydraulic schematics. A hydraulic schematic
diagram is a line comprising of hydraulic symbols. It is a route map of a hydraulic system
indicating the placement of all the components and the way they are connected with each other
within the circuit. The ROV crew should be able to easily identify these symbols, which will help
in simplifying the task of visualizing hydraulic circuits.

Hydraulic Diagram

SECTION 6: Hydraulic Principles and Safety 6-5

 Hydraulic Symbols and Circuits

Basic Symbols
Symbol Function

Work line - flow line

Dashed line - pilot, drain

Long chain thin - enclosure of two or more functions contained in one unit

Circle - energy conversion units (pump, compressor, motor)

Circle - measuring instruments

Semi-circle - rotary actuator

Squares - control components

Diamond – condition apparatus (filter, separator, lubricator, heat exchanger)

Spring

Fixed-orifice or flow-control valve

Oil pressure gauge

Check valve - can use a ball and seat or spring behind the ball

6-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Hydraulic Symbols and Circuits
Pumps and Motors
Symbol Function

Pump, fixed displacement

Pump, variable displacement

Pump, variable displacement over center (reverse direction)

Motor, one direction

Motor, bidirectional

Air compressor

Conditioning of the Hydraulic Oil

Symbol Function

Filter

Filter with water trap

Heater

Cooler

Water cooled cooler

SECTION 6: Hydraulic Principles and Safety 6-7

 Hydraulic Symbols and Circuits
Valves
Symbol Function

Pressure-relief valve

Pressure-reduction valve

4-way, 3-positions; float center (open to tank)

4-way, 3-positions; closed center

4-way, 3-positions; tandem center

Control valve: tandem

Control valve: closed center

Control valve: open center

Other Symbols
Symbol Function

Tank reservoir: oil center tank under surface of oil in tank

Tank reservoir: compensator as used in Oceaneering drawing

6-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Reading Lines

A pilot line A drain line returns

operates a valve or leakage oil to the The pressure line
other control reservoir is a working line

Pump inlet line is a

working line

Return lines are working lines

Reading Symbols for Pumps and Motors

The energy triangle points out,

showing the pump as a source The triangle points in. The motor
receives energy

Two triangles indicate

that the pump can Pump Motor
operate in reverse

Two triangles denote

the motor is reversible

Reversible Pump
Reversible Motor

SECTION 6: Hydraulic Principles and Safety 6-9

 Understanding Valves

Three envelopes mean Port connections are

that the valve has drawn to center or
three positions neutral

position

Arrows show flow

paths and direction of
flowposition

Horizontal bars
indicate infinite
positioning ability

Each block represents

a finite spool position

6-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

Hydraulic Safety
Understanding the dangers associated with hydraulics can help to prevent personal injury,
equipment damage, or any adverse impact to the environment. Hydraulics is a powerful form
of energy that, when properly controlled, produces useful work. The force required to do the
work can range from just a few pounds to tens of thousands of pounds and more. This force
develops from pressure being applied to an area and is directly proportional: the greater the
pressure or the area that the pressure is applied to, the more force that will be applied.
The speed of the work is determined by the amount of flow being provided by the actuator.
This speed can range from very slow to extremely fast. Failure to properly control this flow can
also have disastrous results. There are three hazards common to all hydraulic systems:
• The unexpected movement of an actuator
• A sudden, unexpected release of pressurized oil from the system
• The intentional release of pressurized oil from the system
Each of these hazards has several possible root causes. In order to avoid the consequences of
these hazards, it is important all technicians understand the root causes and aggressively strive to
eliminate them.

Improper Operation
Improper operation can lead to failures. Not being familiar with the proper operation of a piece
of equipment can lead to unexpected movement, which, in turn, can cause injury or property
damage. Just because a technician thinks he can operate a machine, does not mean he can!

If you have not been trained to operate a piece of machinery, including emergency procedures, do not
operate it!

Improper Components
A valve or other components like an actuator, filter, etc., that have been improperly selected can
cause either unexpected movement or a sudden, unexpected release of oil from the system. This
can become a problem when the operating characteristics of the valve or other components are
unknown.

NEVER use a valve or component without knowing what its pressure and flow rating is!
REMEMBER, the highest pressure in the system can be substantially higher than the setting of the
pump or relief valve. REMEMBER, the flow out of the cap end of a cylinder can be substantially
higher than the pump capacity.

SECTION 6: Hydraulic Principles and Safety 6-11

 Unauthorized Modifications
Modifications made to a hydraulic system may achieve the desired results, but if the effect of
the modification on the system as a whole was not thoroughly analyzed beforehand, it can also
result in component and plumbing failures. These failures can cause the following:
• Unexpected movement
• Unexpected release of oil from the system
• Projectiles in the form of failed fittings, valves, or other hardware
Temporary or permanent modifications require engineering approval, typically through
the management of change process. Otherwise, none of the items above will be formally
addressed, setting the stage for an incident. Additionally, unauthorized modifications are seldom
documented. This will not only cause confusion when troubleshooting a problem, but could
also compromise safety.

Improper Selection of Fluid Conductors

Correct installation of the hose is crucial from a safety standpoint. Improper plumbing practices
are a large contributor to accidents associated with hydraulic equipment. All hose, tubing, and
pipes have a safe working pressure rating. The maximum safe working pressure is a function of
the burst pressure and is set at a safety design factor of 3:1 for static applications and 4:1 for
dynamic applications. When establishing a safe working pressure, temperature may also have to
be considered.
• It is important to note that the safe working pressure of this tubing decreases as the
temperature rises.
• Hoses, tubing, or pipe should not be installed without first determining its safety.
• A hose, tubing, or pipe should NEVER be installed without first determining its
maximum pressure.

Fittings
The most common cause of fitting failure is due to over tightening in an attempt to stop leaking.
If a fitting has been properly installed and there is a leak, there is a problem with the fitting.
Fittings should be finger tight and then tightened one flat (1/6 of a turn) past finger tight,
unless a specified torque is annotated. The types of torque are as follows:
• Wet torque - any bolt that is lubricated or coated with an anti-seize compound
• Dry torque - any bolt that is not lubricated or coated with an anti-seize compound

Do not over tighten a fitting in an attempt to stop a leak. Over tightening a fitting might stop the leak;
however, over tightening may also damage the valve bodies and destroy fittings.

6-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

If a Leak is Discovered
The fittings involved must be removed, cleaned, and inspected. If any damage is seen, the
fittings must be replaced. If there is no damage, the fitting should be reinstalled using the
proper procedure and tested. All personnel must be well clear of the testing area when pressure
is applied. Following the proper procedure is the only way to ensure a leak-free connection.
Examples of fitting tightening include the following:
• Tapered pipe thread fittings (NPT) require a “turns from finger tight” value
• Straight thread, or ORB fittings, have a wet torque specification
• Swagelok fittings use a “turns from finger tight” value
• Thirty-seven degree flared (JIC) fittings (both tube and hose) use a “flats from finger
tight”
• Four-bolt flange fittings have a dry torque specification and require the use of grade five
fasteners

Locating Leaks
Technicians must NEVER use their hands to locate the source of a hydraulic leak! If the source
of a leak must be located, technicians should use a piece of paper or cardboard. An injection-
type injury usually does not look serious, so prompt treatment is generally not sought. Any
injection of oil into the skin is a medical emergency requiring the immediate evacuation of the
injured person to a medical facility equipped to handle emergency trauma. The treatment for
this type of injury calls for the surgical removal of all traces of the oil. Even if treatment has
been promptly given, there is an amputation rate between 16 and 48 percent. If treatment has
not been given within 10 hours of the accident, the amputation rate is near 100 percent.
A pinhole leak in a hydraulic hose that is under pressure can release toxic fluid at a speed of
600+ feet per second or approximately 410 miles per hour. Oil from a pinhole leak at pressures
as low as 100 PSI can penetrate the skin and cause problems. Oil coming from the same pinhole
at 3,000 PSI can amputate fingers even through gloves. Penetration has been recorded at
distances up to four inches between fluid source and skin.

SECTION 6: Hydraulic Principles and Safety 6-13

 Section Review
The hydraulic system uses fluid to transmit energy. Understanding the way a hydraulic
system works is every technician’s responsibility. Schematics are the drawings that the
technician uses to see how a system is built. Additionally, a schematic is used to locate
a component in the system. The technician must be able to read hydraulic and circuit
diagrams of the system that he has to maintain and troubleshoot. This will allow checks
to be carried out at specific system points to determine whether signals, power, and fluid
supplies are present. Safety is the first concern for any technician, and if he/she knows
the capabilities of the hydraulic system, more precautions will be taken to enhance a safe
working environment.

Knowledge Check

1. What is used to limit the maximum pressure in a ROV system?

2. Can pressure be measured without flow?

3. What is the lowest PSI in which oil will penetrate the skin?

4. What valve is represented here?

5. Should technicians use their hands to check for hydraulic leaks?

6-14 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section 7
Subsea Hydraulics

Morgan City Training Center

7-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
The major components of subsea hydraulics are the cage hydraulic system and the vehicle
hydraulic system. Since subsea hydraulics refers to submersible components, precautions must
be taken to keep the submersible components protected from water damage. The subsea
hydraulic system is used to power and control the tether management system (TMS), the cage
thrusters, the camera pan and tilt, and the unit and the vehicle hold-down clamps. Spare valves
are available to operate additional functions as required.
The hydraulic system is comprised of the following:
• Hydraulic power unit (HPU)
• Reservoir
• Valve packs
• Miscellaneous valves, gauges, and filters
• TMS
• Manipulators
• Thrusters

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Identify major components on a typical ROV hydraulic layout
• Identify the pumps currently being used
• Explain how the pumps work
• Discuss how the pumps are controlled
• Describe how to maintain and store the pumps
• Identify thrusters and how they are controlled
• Rate functions IE P&T tether circuit

SECTION 7: Subsea Hydraulics 7-3

 Hydraulic Power Unit (HPU)
The cage hydraulic system consists of one electro-hydraulic
power unit that is used to provide hydraulic power for
the cage. The components of this power unit are the
motor, coupling, and pump. The electric motor is an oil-
filled, 3-phase, 60 Hz motor turning at about 1760 RPM.
Depending on the type of motor, the operating voltage
will typically be 2,300 VAC on Magnum and 3,000 VAC on
Millennium with a horsepower rating of 85Hp for Magnum Hydraulic Power Unit
and 110 HP for Millennium. A straight jaw-type coupler is
used to couple the motor to the hydraulic pump. The vehicle hydraulic system consists of two
electro-hydraulic power units, identical to the cage hydraulic power unit that is used, and they
produce 85 HP each.

Hydraulic Pump
The hydraulic pumps used on the ROV system are the A10 series
swash plate design. The pumps are variable displacement, pressure
compensated, axial piston pumps capable of generating flow rates
of 26 GPM (gallons per minute). The pump generates these flow
rates at full displacement and imparts to the fluid the necessary
pressure forces up to 4570 PSI. Maximum pressure is determined
by the setting of the DR control portion of the DFR control
block. There are components that have a safe operating level of Eaton Pump
only 3000 PSI, so the maximum setting is 3000 PSI.
The two hydraulic pumps utilized by Oceaneering on the ROV system are the Rexroth V10
series and the Eaton 420 series. While there are construction differences between these two
pumps, they function in the same manner. The Rexroth V10 series is still being used, but it is
being phased out by the Eaton 420 series.
The vehicle hydraulic pumps are plumbed in parallel. Considering that they are plumbed in
parallel, setting both pumps at the same pressure will cause problems if they are not exactly
the same. The pump set to a lower pressure will start stroking and de-stroking at a very high
rate/frequency and will soon self destruct; consequently, the pumps are set at 50-100 PSI apart.
The pump set to the higher pressure is the lead pump, and the pump at the lower pressure is the
lag or standby pump.
There are two check valves that isolate each pump. The check valves also allow for the operation
of just one pump and provide isolation to the pumps when using the AHPU (auxiliary hydraulic
power unit). Since one pump is typically working harder than the other, they need to be swapped
from lead to lag and lag to lead as part of a scheduled maintenance.

7-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Hydraulic Bypass
The Eaton 420 series has a DFR block containing
two adjustable spool valves identified respectively as
DR and FR. This block is bolted onto the side of
the pump port plate.
When the swash plate has moved far enough so the
pistons are no longer stroking in or out, the pump is
considered to be de-stroked. Even though the pump DFR Control
is considered to be a de-stroked system, pressure will be
maintained, and the pump will supply a small amount of oil to
make up for any internal leakage. When a demand is sensed, the
pump will again come on stroke, supplying flow as required at
whatever pressure is required to overcome the resistance to flow
up to the setting of the DR control.
The FR section allows the pump the produce a pressure lower
than the DR setting. For example, if the FR is set at 500 psi
and the DR at 3,000psi, the pump can be adjusted at any
DR (cutaway) pressure between 500 and 3,000 PSI.
In Oceaneering’s application, the pump will be de-stroked at either
the DR or FR setting and not at a pressure in between. This is done
by controlling pressure seen at the X port of the DFR control. This
X port is positioned on the spring chamber for the FR spool. With
no pressure on the X port, the FR spool will open when pump
pressure is high enough to overcome the force of the spring
(500PSI). As pressure is applied to the X port, it will assist the
spring and apply a greater force for the pump pressure to overcome
without physically changing the setting of the FR control. Oil is FR (cutaway)
supplied to the X port from a connection to high pressure plumbing external to the pump.
Since pressure from the pump itself is being applied to the X port, the FR will want to be
500PSI over that pressure. Therefore, pressure will continue to increase until it reaches
3,000PSI, overcoming the force of the spring for the DR spool.
Before the oil gets to the X port, it first flows through an orifice. The
purpose of the orifice is to provide a minimum flow to create the
required pressure needed to operate the circuit. Once past the orifice,
the oil enters a tee. One side of the tee is connected to the X port,
with the other side connected to a valve, making up what is called the
sense line. The valve is used to block the flow back to the reservoir.
When the valve is functioned, pressure at the X port is vented to the
reservoir, reducing system pressure down to the setting of the FR
control.
FR Orifice Fitting

SECTION 7: Subsea Hydraulics 7-5

 The only difference between the cage and vehicle bypass circuit is that the vehicle has two
hydraulic pumps and the cage has one. The vehicle pumps share the same sense line fixed orifice
to supply a pressure differential for the FR control. Because of this, the bypass function cannot
be selected individually. Therefore, if only one pump is running, that pump will need to be put
in bypass before the second pump is brought up. Then both pumps are brought out of bypass
together. The bypass (FR) setting of both pumps can be set to the same pressure without
damaging either pump.

Hydraulic Reservoir
Firestone air mounts of varying capacities are
used as reservoirs. There is a spring inside of
each air mount that will maintain a positive
pressure on the oil inside. Depending on the
system, air mounts will be used with sizes
ranging from two to thirteen gallons. These air
mounts pressurize the oil, forcing it into the
pump inlets and maintaining above ambient
pressure in the hydraulic system. This pressure
is monitored by the HP gauge that can be
viewed with a camera or pressure transducer Hydraulic Reservoir
that relays information to CTAG.

Valve Packs
The basic function of a valve is to direct oil flow. Valves can be controlled mechanically or
electronically. A valve pack is simply a group of valves mounted in a common “package” or
housing.
There are two types of valve manifold packs used on newer ROVs:
• Solenoid-controlled, rate valve packs
• Solenoid-controlled, proportional valve packs
The valve packs are primarily used to control the thrusters, manipulators, camera pan and tilt
unit, tooling, bypass circuit, and other hydraulic functions. All valve packs are oil-filled and
compensated for the depth pressure.

Rate Valve Packs

The rate valve packs are primarily used to control any hydraulic functions other than the control
of the thrusters, such as the manipulators and some subsea tooling. The valve packs are rated
for a flow of 4 GPM, and the flow rate is adjustable for each valve. The rate valve packs use
a conventional DC solenoid. When a conventional solenoid is energized, the armature travels
its full stroke, which generates a constant force through the stroke. Since the force is constant,
there is no variability.

7-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

 The valve packs have eleven valves in the housing. This
valve pack also includes two pressure-reducing valves,
referred to as PRV1 and PRV2. The pressure-reducing
valves enable the technician to preset the pressure on
deck before deploying the system. The first pressure-
reducing valve (PRV1) can reduce the pressure to three
of the valves (1, 2, and 4; outlined in red below). The
second pressure-reducing valve (PRV2) can set the
other eight valves. PRV 1 will be read on gauges PLP-1
or SLP-1, while PRV2 will be read on gauges PLP-2 or
Rate Directional Control Valve
SLP-2. These gauges can be seen using the ROVs
onboard pan and tilt camera.

3 5 7 9 11
PRV2

PRV1

1 2 4 6 8 10

Rate Pack

Proportional Valve Pack

The solenoid-controlled proportional valve pack
is an oil-filled, pressure-compensated, housing/
manifold. The ROV systems use a force-controlled
solenoid to control the thrusters, cage tether circuit,
and some subsea tooling. Proportional valves are
less susceptible to particles in hydraulic fluid than
previously used valves; they are also less costly and
easier to repair.
The proportional valve pack is designed to have
Porportional Valve Pack
the solenoid acting on a relief valve, which applies

SECTION 7: Subsea Hydraulics 7-7

 back pressure on the drain port of a pressure-reducing valve. When the solenoid is energized,
the amperage of the signal produces force on the relief valve. Hydraulic pressure will increase
behind the relief valve to overcome the force of the solenoid. This pressure is applied to the
drain port of the reducing valve. This pressure at the drain port will assist the spring, requiring
a higher pressure exiting the reducing valve to close it. By varying the amplitude of the signal
being sent to the solenoid, the amount of pressure can be controlled exiting the proportional
valve.

Miscellaneous Valves, Gauges, and Filters

System Relief Valve
The hydraulic pump can produce the necessary pressure forces up to 4,570 PSI but should
always be adjusted to accommodate a safe operating pressure of 3,000 PSI. To prevent the over
pressurization of the system in the event of a failure in the pump’s DR control, a Sun RPEC-
LWN-FAL pilot-operated relief valve has been plumbed in the system. The valve is adjusted
using a hex head wrench by turning clockwise to increase the pressure setting.
The valve is set at 1,000 PSI when shipped new, so testing and adjustment of the valve will
always be necessary before it can be utilized on the ROV system. The DR control setting of
the pump must be increased until the valve opens, but it should never exceed 3,500 PSI. After
the setting is reduced, if the valve still has not opened, it should be replaced. This relief valve
should be set at 200 PSI above maximum system pressure.

ROV System Filters

Filtration of the hydraulic system is vital for extending the life of the system and hydraulic
components. The filter assembly is rated at 3,000 PSI and 30 GPM. The element filters to three
microns, is eight inches long, and 3,000 PSID (pounds per square inch differential) collapse
rated. The high pressure (HP) collapse rating is used due to the lack of a filter bypass circuit.
The non-bypass option protects servo and proportional by not allowing any unconditioned fluid
to reach the valves. The three-micron filtration requirement exceeds all manufacturer’s filtration
recommendations. In addition to the HP filter, there is another filter on the system. The Cardev
filter filters water from the system’s mains.
If system performance is reduced, the filter should be changed. If there is a pressure differential greater
than 60 PSI across the filter, the filter should be replaced.

ROV Thrusters
Sub Atlantic is now the producer of ROV thrusters, which are responsible
for movement of the vehicle. Each thruster consists of a hydraulic motor,
shaft adapter housing, cort nozzle, and a prop. Two are installed on the
cage, and when combined with a heading sensor on the cage, they assist in
maintaining a constant heading. The vehicle is propelled on all three axis,
ROV Thruster
whether vectored or axial, by six to eight Sub Atlantic thrusters.
7-8 ROV NEW HIRE COURSE - Gulf of Mexico Region
Pan and Tilt
The pan and tilt unit has cameras and lights attached and
is supplied hydraulic fluid from the rate pack to control
camera movement. The camera provides 355 degrees of
pan travel and 120 degrees of tilt. Pan travel is limited by
stop pins due to light and camera whips.

Tether Management System (TMS)

Pan and Tilt Unit
The mechanical assembly that handles the tether spooling
and unspooling functions is comprised of the following sub-assemblies:
• The storage drum holds the tether.
• The drum drive assembly consists of a hydraulic
drive motor, drive sprockets, chain tensioners,
and an anodized aluminum mounting plate.
• The level wind assembly consists of a sprocket, a
diamond screw, and a guide roller box.
• The tether sheave assembly consists of a sheave,
four tension wheels, and seven guide wheels.
• The sheave drive motor provides a small amount
of torque when a tether-in command is given to
Tether Management System (TMS)
maintain tension on the tether.

Tether In / Out Function

When the tether-in command is given,
the tether drum motor starts to spin in
the pay-in direction. At the same time,
the sheave motor maintains a small
amount of back pressure to ensure a
snug wrap on the drum.
When the tether-out command is given,
the tether drum motor maintains a
small amount of back pressure while
the sheave motor pulls the teather off
the drum. TMS Parts

The tether circuit is being accomplished by using proportional valves. This is being done to lessen or
eliminate the “snapping” of the fiber tethers that occurs from operating the tether circuit with a rate valve.

SECTION 7: Subsea Hydraulics 7-9

 Drive Chains
The tether drum is turned by a stainless steel chain driven by a hydraulic motor. One of the
most important aspects of the drive chain is to ensure proper tension on installation. The
second most important aspect to check for is chain stretch. Oceaneering chain has a maximum
of three percent wear. Improper chain tension can damage the chain and the sprocket.

Drive Chain Drive Train Parts

Cage Clamps
The vehicle is held in the cage by two clamp assemblies that are comprised of four hydraulic
cylinders used to extend or retract a clamping pad. The clamps, if properly adjusted, will
hold the vehicle in place during all normal launch and recovery operations. In addition to the
cage clamps, a vehicle safety latch was added to the lower starboard cage framework to help
prevent the vehicle from
unintentionally exiting the
cage. The pilot hydraulically
retracts the safety latch
before exiting the cage.
When the vehicle returns to
the cage, the spring-loaded
latch will depress from the
vehicle’s weight and will
automatically extend back up.

Cage Clamps

Lower Clamp

7-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section Review
This section discusses subsea hydraulics and the major components that are utilized. The
major components of subsea hydraulics are the cage hydraulic system and the vehicle
hydraulic system. Both the vehicle and cage hydraulic systems must adhere to a pressure
compensation system, which keeps the components from collapsing under the water
pressure. Lastly, this section covers the components that are used to convey a fluid from one
point to another.

Knowledge Check
1. What are the major components on a typical ROV hydraulic layout?

2. What is the maximum setting of the FR control?

3. PRV1 of the rate pack controls the pressure for what valves?

4. The system relief valve should be set at what amount of PSI above maximum sys-
tem pressure?

SECTION 7: Subsea Hydraulics 7-11

7-12 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Section 8
Hazardous Energy Control

Morgan City Training Center

8-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

8-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
An energy source, including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or
other sources in machines and equipment, that can be hazardous to workers is called hazardous
energy.
During the servicing and maintenance of machines and equipment, the unexpected startup or
release of stored energy could cause injury to employees.

Objectives
Upon completion of this section, technicians will be able to complete the following objectives:
• Explain hazardous energy
• Recognize hazardous energy sources in the ROV workplace
• Define lockout/tagout terminology and describe equipment
• Demonstrate the correct steps to affix or remove lockout or tagout devices to hazardous
energy sources on the ROV system
• Identify Brady lockout/tagout posted procedures and use them to complete the lockout/
tagout process

SECTION 8: Hazardous Energy Control 8-3

 What is Hazardous Energy?
An energy source, including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or
other sources in machines and equipment, that can be hazardous to workers is called hazardous
energy.
Workers servicing or maintaining machines or equipment may be seriously injured or killed
if hazardous energy is not properly controlled. Injuries resulting from the failure to control
hazardous energy during maintenance activities can be serious or fatal! Injuries may include
electrocution, burns, crushing, cutting, lacerating, amputating, or fracturing body parts.
Scenarios like the following are all possible if hazardous energy is not controlled in the
workplace:
• A steam valve is automatically turned on, burning workers who are repairing a
downstream connection in the piping.
• A jammed conveyor system suddenly releases, crushing a worker who is trying to clear
the jam.
• Internal wiring on a piece of factory equipment electrically shorts, shocking an employee
who is repairing the equipment.
Craft workers, electricians, machine operators, and laborers are among the 3 million workers
who service equipment routinely and face the greatest risk of injury. Workers injured on the job
from exposure to hazardous energy lose an average of 24 workdays for recuperation.

What Can Be Done to Control Hazardous Energy?

OSHA standard 1910.147 - The Control of Hazardous Energy (Lockout/Tagout), outlines
measures for controlling different types of hazardous energy for general industry. OSHA
requires employers to maintain an energy control program made up of energy control
procedures, employee training, and periodic inspections. This program is known as lockout/
tagout. Oceaneering has adopted this OSHA standard for our lockout/tagout procedures.
All employees who work in an area where energy-control procedure(s) are utilized need to be
instructed in the purpose and use of the energy control procedure(s) and about the importance
of never attempting to restart or reenergize machines or equipment that are locked or tagged
out.
All employees who are authorized to lockout machines or equipment and perform service and
maintenance operations need to be trained to recognize applicable hazardous energy sources in
the workplace, the type and magnitude of energy found in the workplace, and the means and
methods of isolating and/or controlling the energy.

8-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Hazardous Energy Sources in the ROV Workplace
It is vital that an ROV technician recognize the areas of the ROV system that contain hazardous
energy sources. Hazardous energy is located in numerous places in the ROV system.

APU (Auxiliary Power Unit)

While the ROV is on deck, the APU provides power to comp up the
vehicle and test tools on deck. The APU can also be used as an oil
and water separator.

HPU (Hydraulic Power Unit)

The HPU provides all of the hydraulic power for the main lift winch
and A-frame launch skid. It is powered by a 75 HP (480 VAC, 3
Phase, 60Hz) electric motor, which is normally connected directly to
the vessel’s power supply.
APU

PDU (Power Distribution Unit)

The PDU, located in the control van, provides power to all of the
various circuits. System power from the platform (480 VAC 3 phase)
is routed directly to the control van PDU.

Vehicle
Any of the types of ROVs are a source of hazardous energy. The
most commonly used work-class vehicles can range from 50 HP to
200 HP. A heavy work-class vehicle has a power output of 300 HP.
HPU

PDU Vehicle

SECTION 8: Hazardous Energy Control 8-5

 Vehicle Cage
The vehicle cage protects the tether management assembly and
the vehicle from damage during launch and recovery. The entire
cage is a potential hazardous energy source.

Work Van
The work van is located on the deck and is equipped with all of
the necessary hand tools and power tools required to conduct
system maintenance. Vehicle Cage

Host Power
No matter what type of vessel, the host power is a potential source of hazardous energy.

Work Van Host Power

Why Use Lockout/Tagout?

Proper lockout/tagout (LOTO) practices and procedures safeguard workers from the release
of hazardous energy. LOTO protects maintenance personnel from power being reapplied by
mistake. Failure to control hazardous energy accounts for nearly 10 percent of the serious
accidents in many industries.

When to Use Lockout/Tagout

Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying,
and maintaining or servicing equipment require lockout/tagout. Lockout/tagout any energy
isolating-devices whenever replacing or making major repairs to equipment, when renovation or
modification of equipment is performed, OR when new equipment or machines are installed.

Lockout/Tagout Terminology
Before learning the steps to lockout/tagout equipment, it is necessary to understand the
terminology. You should be familiar with the following terms:

8-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

Authorized Employee
An authorized employee locks or tags out equipment in order to perform servicing or
maintenance. Authorized employees are trained to use Lockout/tagout (LOTO). Authorized
individuals may be Oceaneering or contract personnel.

Affected Employee
Affected employees are required to work in approved areas while equipment is being serviced
or maintenance is being performed. Also, an affected employee’s job may require him or her to
operate or use equipment that is being serviced under lockout or tagout conditions.

Energized
Something that is connected to an energy source OR contains residual or stored energy.

Energy Isolating Device

A mechanical device that physically prevents the transmission or release of energy, including but
not limited to the following: a manually operated electrical circuit breaker; a disconnect switch;
a manually operated switch by which the conductors of a circuit can be disconnected from all
ungrounded supply conductors, and, in addition, no pole can be operated independently; a line
valve; a block; and any similar device used to block or isolate energy. Push buttons, selector
switches and other control circuit-type devices are not energy-isolating devices.

Energy Source
Any energy source is any source of electrical, mechanical, hydraulic, pneumatic, chemical,
thermal, or other energy.

Lockout
Placing a lockout device on equipment that isolates energy to ensure the equipment will not
function until the lock is removed.

Lockout Device
A lockout device uses positive means such as a single-keyed lock, to hold an energy isolating
device in the safe or off position, preventing the energizing of equipment.

Tagout
Placing a tagout device on equipment that isolates energy, indicating that the equipment may not
be operated until the tagout device is removed.

Lockout Devices
A lockout device is a device that uses positive means such as a lock, either key or combination
type, to hold an energy isolating device in the safe position and prevent the energizing of a
SECTION 8: Hazardous Energy Control 8-7
 machine or equipment. Blank flanges and bolted slip blinds are included as lockout devices.
Lockout devices must be substantial enough to prevent removal without excessive force or
unusual techniques such as bolt cutters.

Tagout Devices
A tagout device is a prominent warning device that can be securely attached to an energy-
isolating mechanism to alert employees that equipment is not to be operated until the tag is
removed. Tagout devices must be:

• Substantial enough to prevent • At least equivalent to a nylon cable tie

inadvertent or accidental removal
• Non-reusable attachment means • Always considered as a supplement to the lock
• Attachable by hand, self-lockable

Oceaneering’s Lockout/Tagout Procedure

Step 1 - Preparation for Shutdown
The authorized employee will survey the area and review the procedure. Affected employees
must be notified that equipment is to be locked out.

Step 2 - Shutdown and Deactivation

The machine or equipment will be shut down using the established procedures for that machine
or equipment.

Step 3 - Isolation of Energy to the Equipment

All energy-isolating devices (circuit breakers, power cords, air lines, hydraulics, etc.) that control
the flow of energy to the equipment must be identified and configured so that they isolate the
machine or equipment from the source of energy.
If there is any stored hazardous energy within the equipment, use the proper procedure to
prevent that stored energy from releasing inadvertently.

Step 4 - Attachment of a Lockout Device and Tag

A lockout device and a tag will be affixed to isolate each source of potential energy.
When using a lockout device and tag, the device is to be affixed in a manner that will hold the
energy-isolating device in a safe or off position.
A “Danger - Do Not Operate” tag (or a danger tag with similar wording) must be attached to
each lockout device.
The tag contains the name of the person who applied the lock, the date, and the reason why the
lockout device was attached.
8-8 ROV NEW HIRE COURSE - Gulf of Mexico Region
Step 5 - Attachment of a Tagout Device
When a machine or piece of equipment is incapable of accepting a locking device, a tagout
device will be affixed in such a manner as will clearly indicate that the operation or movement
of energy isolating devices from the “safe” or “off ” position is prohibited.
Where a tag cannot be affixed directly to the energy isolating device, the tag must be located as
close as safely possible to the device, in a position that will be immediately obvious to anyone
attempting to operate the device.

Step 6 - Release of Stored Energy

After the lockout device and tag have been attached, all potentially hazardous stored energy
should be released. This may include the discharge of capacitors, the bleeding of hydraulic or
gas pressure, and the securing of weights against physical stops so that no potential energy
remains downstream of the point of isolation.

Step 7 - Verification of Isolation

Verify that equipment is de-energized (check with voltage meter, attempt to energize
equipment).
The control of hazardous energy is not complete until authorized personnel verify isolation.
Verification should be done, at a minimum, at the beginning of the workday and following
breaks when activity has not been monitored.

Step 8 - Release from Lockout

A lockout device may only be removed by a person who attached it. Before lockout devices are
removed and energy restored to the machine or equipment, the actions listed below are to be
taken by an authorized employee:
• The work area must be inspected to ensure that tools and parts have been removed,
guards restored, and the equipment components are operationally intact.
• The work area must be inspected to ensure that all personnel are safely positioned.
• All affected employees must be notified that the lockout device will be removed.
• Verify all controls are in the safe or off position to prevent unexpected start up upon re-
energizing.
• Re-energize equipment and test all functions.
In situations that require that the equipment be energized for testing, the above actions should
be taken prior to the removal of locking devices and energizing. Following the testing, the
machine or equipment will be de-energized and energy control measures reapplied. If a lockout
device must be removed, the employee who attached the lockout device is to be located and
requested to remove the locking device. If the employee is unavailable, then only another
authorized employee may remove a locking device, provided a local written procedure for

SECTION 8: Hazardous Energy Control 8-9

 lockout device removal is followed. Attempt to contact the employee to inform him/her that
the lockout device has been removed. Ensure that the employee has knowledge of the removal
before he/she resumes work at the facility. Unauthorized or improper removal of a lockout
device is grounds for serious disciplinary action.

Lockout/Tagout Log
The last thing the authorized employee must always do is record all lockout/tagout activities
in a log.

Brady Lockout/Tagout Posted Procedures

The Brady procedures are equipment specific lockout/tagout procedures that identify isolation
points, lockout points, and verification points for the user for a specific component of the ROV
system.
A Brady Lockout/Tagout posted procedure will be located visibly on all systems that contain
hazardous energy sources.
These information sheets provide specific instructions for the lockout application process, how
many lockout points the system contains, and the exact location and method to lockout/tagout
the energy sources.

Additional Information
Temporary Removal of Lockout/Tagout
Lockout/tagout devices can be removed temporarily when testing or positioning equipment.
• Clear tools and materials
• Clear employees from equipment area
• Remove lockout/tagout devices
• Energize and test or position the equipment
• De-energize systems and reapply energy control measures to continue servicing

Outside Personnel
Contractors and other outside personnel must inform the on-site employer of lockout/tagout
procedures. They must follow Oceaneering’s lockout/tagout procedures unless their own are
more stringent.

Group Lockout or Tagout

Primary responsibility is vested in an authorized employee for a set number of employees
working under the protection of a group lockout or tagout device.
8-10 ROV NEW HIRE COURSE - Gulf of Mexico Region
Each primary authorized employee shall affix a personal lockout or tagout device to the group
lockout device.
Each employee will remove his or her own lock or tag when his or her part of the operation is
completed.

For Shift or Personnel Changes

Continuity of lockout/tagout protection must be ensured by following specific procedures for
shift and personnel changes, including the orderly hand-off of lockout and tagout devices.

SECTION 8: Hazardous Energy Control 8-11

 Section Review
This section discussed the following:
• Hazardous energy and where it can be found in the ROV workplace
• Lockout/Tagout terminology and equipment
• The lockout/tagout steps
• How to read and use Brady lockout/tagout posted procedures

Knowledge Check
1. Why do we lockout/tagout?

2. Give examples of hazardous energy sources on the ROV system.

3. When would only a tagout be used?

4. List the eight lockout/tagout steps in order.

8-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section 9
Manipulators

Morgan City Training Center

9-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
The manipulators are what qualify the ROV as a work-class vehicle. The vehicle is equipped
with two manipulators, each capable of a wide range of motion, and each possess substantial
work capabilities. Two control methods are used: rate-controlled and spatially correspondent.
This section covers the purpose, capabilities, and limitations of the manipulators used by
Oceaneering.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Identify the different types of manipulators on the system
• Explain the importance of proper manipulator maintenance
• Explain the two different control methods for the manipulators
• Discuss the advantages and disadvantages of each control method
• Identify best practices for proper ROV manipulator use
• Explain the importance of effective communication while conducting ROV manipulator
operations

SECTION 9: Manipulators 9-3

 Manipulator Types
Manipulators are selected based on the type of work the ROV will perform. Job tasks can
range from heavy lifting of hardware to more intricate tasks such as valve operation or cable
installation work. Technicians should ensure the appropriate arm is outfitted to the vehicle based
on the assigned task.
Oceaneering uses four types of manipulator arms:

Conan
• Category: heavy work
• Material: anodized aluminum and stainless steel
• Control: rate
• Reach: 6 ft.
• Lift capacity: 350 lbs.
• Depth: 3,000 MSW Conan Manipulator Arm

Initially, the Conan was known as the “work-horse” of the Gulf, but due to structural integrity issues, it
is currently being phased out by the Atlas and Atlas Hybrid.

Rigmaster
• Category: heavy work
• Material: anodized aluminum, stainless steel, titanium
• Control: rate
• Reach: 4.5 ft.
• Lift capacity: 595 lbs.
• Depth: 6,500 MSW
Rigmaster Manipulator Arm
Titan 4
• Category: heavy work
• Material: primarily titanium
• Control: position
• Reach: 6.3 ft.
• Lift capacity: 268 lbs.
• Depth: 4,000 MSW

Titan 4 Manipulator Arm

9-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Atlas
• Category: heavy work
• Material: anodized aluminum and stainless steel
• Control: position or rate
• Reach: 5.5 ft.
• Lift capacity: 551 lbs.
• Depth: 6,500 MSW
Atlas Manipulator Arm

The Atlas also has a hybrid version that can be converted to a spatially controlled manipulator.

Manipulator Control Methods

Rate-controlled and spatially correspondent manipulators are utilized on ROVs. Both the
rate-controlled and spatially correspondent manipulators are operated by a joystick that sends a
signal to the ROV, which, in turn, feeds hydraulic fluid to the arm. Neither type of manipulator
provides feedback from the arm to the controller if it has reached its movement limit or
movement has been interrupted by a stationary object. This can lead to damage on both the arm
and the ROV.

Rate-Controlled Manipulators
The rate-controlled manipulators (also known as a bear claw) move at a fixed speed that is set by
the individual flow controls for each valve. All seven manipulator functions can be operated:
• Shoulder pitch, up/down
• Elbow pitch, up/down
• Wrist pitch, up/down
• Wrist yaw, left/right
• Wrist rotate, CW/CCW
• Swing, left/right
• Jaw, open/close

Bear Claw (front view) Bear Claw (back view)

SECTION 9: Manipulators 9-5

 Spatially Controlled Manipulators
The spatially correspondent arm operates on
a synchronous, instantaneous response system
from the joystick to the arm resulting in a
more fluid, simultaneous movement. It is also
equipped with an auto-function feature. This
gives the operator the capability to program the
manipulator to “remember” certain movements
and functions. When utilized, this expedites
manipulator deployment and stowage. Care
should be taken when utilizing the auto-function
to ensure the manipulator arm is not damaged Spatially Controlled Manipulator
by hitting the ROV or other structures.

Best Practices
Before the ROV is deployed, it must be outfitted and ready to complete the assigned task.
Depending on the depth of the job, resurfacing can consume valuable time. Certain questions
need to be asked by the crew, especially the ROV supervisor:
• What tools are needed for the task?
• At what angle will the tool be best deployed?
• Is it necessary to band the tool to the manipulator arm?
• What happens if the tool is dropped or broken during use?
Depending on the depth of the structure and the details of the task, both appropriate tool
and jaw configuration is vital to the success of the job. Beacuse diving and resurfacing are long
processes. The complexity of a job is based on many variables:
• The number of tasks involved
• Weather conditions and/or poor visibility
• Various subsea structures
• Divers in the water during ROV operations
• Multiple ROV operations

9-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

Maintenance Checks
Before launching the ROV, a thorough pre-dive check must be carried out to verify the ROV’s
various systems are fully functional and ready for use.

Pre-Dive Check
The pre-dive check will be executed by at least two people. The pilot will operate the controls of
the ROV. The technician observing equipment functionality must check for the following:
• All hoses, fasteners, and fittings are properly connected and secure.
• Air has been purged from the hydraulic system if any hoses or components have been
disconnected for either maintenance or repair.
• Personnel and/or objects are clear of the manipulator’s range of motion.

In addition to the pre-dive check, routine maintenance procedures and scheduling should be conducted in
accordance to the Offshore Management System (OMS).

Daily Checks
Required daily checks are as follows:
• Check for loose or missing fasteners.
• Check hoses for evidence of kinking or abrasion.
• Check hose fittings for leaks.
• Check actuator rods for damage, and check actuators for signs of hydraulic leaks.
• Thoroughly wash the exterior of the manipulator arm with fresh water.
• Remove any entrapped debris.

Weekly Checks
Required weekly checks include the daily checks as well as the following:
• Check anodes and replace when 1/3 or fewer remain.
• Push on the arm and check for excessive free play, which may indicate worn bearings or
pins.
• Torque all external fasteners to specified values.
• Check jaw actuation bearings and T-bar plate for damage.

Monthly Checks
Required monthly checks include the daily and weekly checks as well as the following:
• Ensure all hydraulic fittings are tight.
• Remove external fasteners individually and torque to specified values.

SECTION 9: Manipulators 9-7

 Manipulator Arm Considerations
The manner in which a manipulator arm is used when carrying out a task could potentially lead
to damage. Proper positioning of the manipulator arm will allow the operator to carry out a task
safely and efficiently.

Limitations
The manipulator arm has a range of motion that is limited based on the joint and the plane.
Manipulator arm limitations that must be considered include the following:
• Lift capacity at full extension
• Maximum lift capacity
• Gripping force
• Wrist torque

Hazards
The manipulator arm faces several hazards when in use. Some are as follows:
• Poor operator technique
• Damage caused by the ROV itself
• Improper manipulator arm movement
• Subsea currents
• Surface currents on the ROV cage and umbilical
• Suspended loads
• Stored energy

9-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section Review
This section discusses the two manipulators that come equipped on the vehicle. Each
manipulator is capable of a wide range of motion and possess substantial work capabilities.
The manipulators are controlled by valves in the rate and proportional packs. Two types of
manipulators are used: rate-controlled and spatially correspondent. The rate-controlled
types move at a fixed speed that is adjusted by the individual flow controls for each valve.
The spatially correspondent types are servo controlled and move in direct proportion to
the command level being given. It is important to properly use, check, and maintain the
manipulators, which helps keep the system in good operating condition.

Knowledge Check
1. Identify four manipulator models that are currently in use at Oceaneering.

2. What are two types of control methods for the manipulator?

3. Which control method allows the manipulator arm to move at a fixed speed that is
adjusted by the flow controls for each valve?

4. What are the advantages of using a spatially correspondent manipulator arm?

5. Where can a crew member find the routine maintenance procedure and scheduling?

SECTION 9: Manipulators 9-9

9-10 ROV NEW HIRE COURSE - Gulf of Mexico Region
Section 10
Subsea Tooling

Morgan City Training Center

10-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
All normal load outs of the ROV system have standard subsea tooling. (ROV technicians will
use this tooling to successfully perform tasks associated with the job assignment.) Whenever
there is a question about any of these tools, whether related to the pressure and flow rate or the
tooling check schedule, the technician should always verify the information in the Deepwater
Technical Solutions (DTS) tooling manual and associated paperwork in the control van.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Identify subsea tooling that is required for a normal load out
• Recall where to find the pressure and flow rates for each tool
• Recall where to find information about the tooling checks

SECTION 10: Subsea Tooling 10-3

 Normal Load Out
The ROV system uses a standard range of tools for a normal load out. Some of the most
common tools include the following:
• Hydraulically actuated soft line cutter
• Hydraulically actuated wire rope (hard line) cutter
• Hydraulic rotary grinder
• 3” dredge/jet pump: (trash pump)
• Sealing ring (AX/VX) gasket replacement tool

Hydraulically Actuated Soft Line Cutter

The soft line cutter is a small hydraulically actuated, manipulator-deployed tool designed to cut
up to a one-inch diameter fiber rope, hydraulic hose, and 1/4” or smaller wire rope. It consists
of a hardened tool steel blade and side plates, a hydraulic cylinder, and a T-handle. The blade is
attached to the cylinder ram and slides in the blade housing, producing a shearing cut on the
rope. When the cylinder is extended, the blade acts like a guillotine, severing the rope between
the blade and the side plates. The cylinder is then retracted to allow for the next cut. The cutter
receives hydraulic fluid from the rate packs.

Soft Line Cutter

The tool usually has a manipulator handle attached to it.

The soft line cutter needs to be secure yet maneuverable
in order to gain access to tight areas. Depending on the
job, the tool should either be setup in a cutter entry
facing out or in the down position. If the cutter is the
only tool needed on the arm, technicians should “band”
the jaw closed to prevent an accidental drop or the shock
of the cable popping, knocking the tool out of the jaw.
There is a good chance a hydraulic hose will be damaged
if the tool is dropped.
Soft Line Cutter With Manipulator

Always setup properly to alleviate stress on the manipulator arm.

10-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Applications
The “soft line cutter” is a commonly used cutter in the field because of its capability to cut
most soft rope up to 1 inch in diameter, which covers most of the rope cutting tasks found in
an offshore subsea environment. Listed below are some of the regulations technicians should
follow when using the soft line cutter:
• Do not hold on to the cable being cut with the other arm in order to steady the vehicle.
This is dangerous to the arm.
• Do not use the tool as a hammer or battering ram.
• Do not use the cutter to hold onto something rather than cut.
• Do not hold the tool while making a practice cut on deck.
• Always ensure the tool is oil filled and has a new blade.
• The cutter should be tested on deck and put on a momentary switch circuit.
• Painting the end of the tool black with white or yellow stripes near the cutter entrance
may improve visibility in low light or murky situations.
• Hoses should be routed and secured in the least intrusive way, and technicians should
limit the length of hose attached to a tool. There is no need to have 25 feet of hose on a
tool that never leaves the arm’s length.
• When approaching a cable for a cut, technicians should visualize what will happen when
the wire is cut, thinking about how the ROV may be affected in respect to follow-up
actions after making the cut.

Always check the tool on deck with a piece of cable similar to the one to be cut subsea to ensure proper
operation and proper energy availability.

Hydraulically Actuated Wire Rope (Hard Line) Cutter

The “hard line” cutter is a medium to heavy
duty guillotine-type of cutter that is capable of
cutting wire rope up to 1 ½ inches in diameter.
The hard line cutter consists of a hardened tool
steel blade, blade housing, a hydraulic cylinder,
and a T-handle. The blade is attached to the
cylinder ram and slides into the blade housing,
producing a shearing cut on the hard line. When Hard Line Cutter
the cylinder is extended, the blade acts like a guillotine, severing the rope between the blade and
the side plates. The cylinder is then retracted to allow for the next cut.

SECTION 10: Subsea Tooling 10-5

 Applications
The hard line cutter is probably the most commonly used cutter in the offshore environment
because of its capability to cut either rope or wire rope up to 1 ½ inches in diameter. Listed
below are some of the regulations technicians should follow when using the hard line cutter:
• Do not hold on to the cable being cut in order to steady the vehicle.
• Do not use the tool as a hammer or battering ram.
• Do not use the cutter to hold on to an object that is not being cut.
• Never hold the tool while making a practice cut on deck.
• Always assure the tool is oil filled and has a new blade.
• Technicians should ensure replacement parts for the cutter are the proper grade and
length as listed by the manufacturer.
• Technicians should confirm that no stored energy is in the cutter before replacing parts.
• Two people must be on the job when attaching the tool to the arm. The tool is too heavy
and too difficult to position and secure with only one person.

Always check the tool on deck with a piece of cable similar to the one to be cut subsea to ensure proper
operation and proper energy availability.

Hydraulic Rotary Grinder

The Stanley GR29 heavy duty hydraulic grinder is used
for a variety of cutting operations including bolts, pipes,
and wire. The disk grinder is suitable for cutting wire
rope or cables in places the hard line cutter cannot access;
the disk grinder is also suitable for removing bolts and
fasteners. The maximum diameter of the disc is nine
inches; however, the unit is flexible and will accept smaller
diameter discs when access is limited.
Rotary Grinder
Operations
Some precautions for tool operation are listed below:
• Technicians must always grip the tools with both hands during startup.
• Technicians must also maintain full balance before starting the grinder rotation.
• The grinder must always be started with the wheel away from the work surface.
• The hydraulic flow must be started at one gpm, and flow must be slowly increased to
a level that produces desired efficiency while still allowing the technician to maintain
balance and operation.

10-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

Maintenance
The most important maintenance practice is to keep the hydraulic fluid clean at all times because
contaminated fluid causes rapid wear and/or failure of the internal parts.

3” Dredge/Jet Pump (Trash Pump)

The dredge pump, or trash pump, is an ROV mounted tool that
allows the ROV operator to add or remove items such as sand or
debris from a subsea work site. Depending on the work scope,
the trash pump can either be used as a jetter (blower) or a suction
(removal) tool. It can move large quantities of liquids at low
pressure and can handle 25 percent by volume concentrations of
solids up to three inches in size. Trash Pump

Application
The trash pump can be mounted on the ROV in several different ways. The two most common
ways are to center the pump on top of the front light (crash) bar or on the side of the ROV.
In any orientation, the operation of the pump is the same (either as a jetter or a suction tool),
depending on the placement of the hoses and the number of hoses used.
For jetting purposes, the trash pump is extremely effective in clearing debris, mud, or silt
from a subsea structure. When used as a suction tool, the debris, mud, or silt is sucked up and
discharged to the rear of the vehicle. Suction is the preferred method for making trenches or
clearing bulk mud from around or off a structure.
The trash pump can be used in a variety of roles, but some of the most common uses include
the following:
• Clearing mud and silt from a structure
• Dredging around or in preparation of a structure
• Acting as a subsea vacuum cleaner for an array of tasks
Good piloting skills will undoubtedly increase the effectiveness of the pumps. More importantly,
how the tool is applied to the task will have a greater impact on the effectiveness of the pumps.
Two important considerations must be made in reference to the pumps:
• Should the tool be used as a jetting or suction device? Usually, it is better to use the tool as a
suction device to transport the mud cloud or debris out of the back of the ROV instead
of stirring a cloud up in front of the pilot’s camera while jetting.
• Where should the manipulator-attached hose be placed? The hose is usually attached to a
fabricated T-handle for easy controllability of the manipulator. If the hose is to remain in
the jaw, it is best to secure the jaw closed with Ty-wraps or even band clamps. If the hose
will be temporary, it should be attached to the sub’s framework with Ty-wraps so the
manipulator can grab the protruding T-handle.

SECTION 10: Subsea Tooling 10-7

 During operations, the nozzle of the hose (or working end) should be kept at a slight angle in
relation to the work site. A horizontal or vertical position can cause restrictions in the hose and
increase the difficulty of the spatial orientation. The hose should be routed from the trash pump
to the end of the manipulator with as few bends as possible to ensure good flow or intake, and
the hose should be periodically secured as well.
A holster can be designed and attached to the front of the ROV to allow the end of the hose to
have a resting place when not in use. This allows the manipulator to be free for other functions
and keeps the hose from dangling below the vehicle while in flight. If the hose comes free
during operations, a few methods can be used to recover it with the manipulator:
• The technician should attempt to land the hose on top of an object. He or she should
extend the manipulator with the jaw open to its lowest position and slowly vertical down
with the ROV until the manipulator is within range of the handle; then grab the handle.
Slow, deliberate motions will keep the ROV or the manipulator from slamming into the
fixed object the hose has been landed on.
• The technician should position the manipulator down closest to the hose straight out
and increase altitude. Next, the technician should vertical down until the hose floats up in
front of the ROV slightly higher than the extended manipulator. He or she should turn
the manipulator counter-clockwise or clockwise depending on the manipulator being
used, driving the hose toward the manipulator allowing it to come to rest on top of the
manipulator. The other manipulator should be used to grab the T-handle. It is important
to maintain an awareness of the proximity to the sea floor as well as the direction in
which the manipulator was turned.

Design
The three-inch working capacity of the pump makes it useful in almost every application
requiring a jetting/suction-type tool. At the heart of the system is an impeller that drives the
direction of water and trash flow inside the pump. The impeller is driven by a hydraulic motor
that can be connected to a tooling stack, a Marsten Bentley (MB) pump, or other plumbing
configuration that will allow the required 138 bar (2,000 PSI) and 26-34 LPM (seven to nine
GPM) flow rate.
A three-inch brass lever-locking connector is supplied with the pump, which attaches the
working end hose to the pump while a standard threaded-type barb connector is supplied to
attach the discharge hose to the offset port on the tool. The tool should be engaged on deck
prior to a dive to ensure it is in good working condition.

10-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Sealing Ring (AX/VX) Gasket Replacement Tool
The AX/VX ring tool is a specially built, task-
oriented tool used to remove or replace and install
18 ¾ inch metal ring gaskets. This tool is designed
to grip the inner bore of the gasket allowing it to be
carried and maneuvered into place without damaging
the outer sealing surfaces. The design of the tool
makes it impossible to damage the outer sealing
surfaces of the ring, and it holds the ring internally
with its curved rubber-sealed shoes. This tool is used
whenever a riser, subsea tree, or other connection
point requires a sealed joint or the sealed connection
is broken and the gasket needs to be retrieved to the
surface. It can be used during completions work to AX/VX Ring Tool
cap or uncap subsea structures or to connect subsea
trees to risers when a sealing gasket is required.
The tool is hydraulically actuated by the use of a single cylinder, but it also uses tension springs
to apply pressure against the inner walls of the metal gasket to hold it in the tool during
handling and transportation to the work area.
Two of the primary reasons for the development of the gasket ring tool include the following:
• The sealing ring is usually left behind on top of the wellhead housing when a BOP or
tree is released subsea.
• A new sealing ring is required when a BOP or tree is to be installed on a wellhead.

Application
The AX/VX ring tool is connected to the rate pack on the ROV and is held by the manipulator.
Its job is simple, as well as its operation. The pilot uses the hydraulic circuit the ring is plumbed
into to retract and expand the “shoes” or plate seating surface. When the tool is in the closed
position, the diameter is small enough for the tool to fit into the diameter of the gasket ring.
Once the tool is fully inside the ring, the operator actuates the hydraulic circuit to expand or
open the tool so the pressure exerted on the inside of the ring by the tool’s “shoes” is sufficient
to hold the ring onto the tool for transportation. There are two high tension springs on the tool
that help to keep the tool extended or that take over for the hydraulic circuit in the event of a
pressure loss in order to prevent the ring from detaching during transportation from the cage to
the work site.
Two springs are used to ensure the gasket will not drop out of the tool should there be a
problem with the ROV hydraulics; however, because there is no manual override if the problem
cannot be resolved, the ROV will have to be recovered back to the surface with the ring.

SECTION 10: Subsea Tooling 10-9

 AX Gasket Tool Test Procedure
The tooling, while on deck, should be tested before making the dive to establish exactly what
circuit opens and closes the tool. Technicians should also check the tool extends, grabs, and
retraces inside the gasket of the AX gasket tool.
Anytime a problem arises, the following steps may fix the situation:
• Complete a fresh water rinse after the dive.
• Flush each component with fresh, hot water.
• Lubricate all moving parts.

Additional Tooling
These tools are also commonly used, but may not be part of the normal load:
• Hotstab
• Marsten Bently pump
• Torque tool
• Wellhead cleaning tool
• pH meter

Hotstab
The hotstab is important to subsea
well completions because it is
commonly used to transfer hydraulic
energy or fluid from an ROV to a
connection block associated with
the subsea installation or subsea
completion. This is important
because products in a subsea
environment are at a greater risk
of corroding. The transfer of
fluid helps to prevent corrosion. Hotstabs
The hotstab has several passages
for different fluid circuits and has a complementary fit to the corresponding conduits in the
connection block. The hotstab system is comprised of male and female mating halves. Typical
applications are actuator operations, pressure testing, chemical injections, and planned and
emergency release. The male stab is deployed by the ROV. The male stab is fitted with seals and
is loosely secured to the female. The female receptacle is mounted to the subsea system. The
receptacle is self-sealing and watertight when unoccupied.

10-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

Typical Application
In many cases a hotstab will be positioned on the subsea equipment as part of a dummy plug or
some type of engaging or releasing system. It is optimal if the stab has a lanyard. Without the
lanyard, there is the chance the stab may be dropped to the sea floor and sink below the mud
line. The photographs below show a close up view of an intervention panel with a “stab” and
a “park” female receptacle. In this situation, the technician would remove a dummy plug from
the “stab” location and place it in the “park” receptacle then insert the proper hotstab into the
“stab” receptacle and initiate the work required. Once the work is complete, the hotstab would
be removed and the dummy plug reinserted into the “stab” receptacle. The dummy plug stab
protects the receptacle while it is not in use.
The hotstab is usually connected to the pump and holstered on the vehicle while not in use. It is
not recommended to have the hotstab in the manipulator jaw prior to the dive because the
hotstab can be damaged this way.

Intervention Panel (left) Intervention Panel (right)

Checks and Maintenance

The team members should discuss any questions, formulate a plan for implementation
of the work, and test all tools before interfacing the tools to the ROV for the job prior to
commencement of work. This will ensure the work is done successfully.
When installing the hotstab on the hydraulic circuit to be used, it is important to have a cross
pilot check valve in place to prevent the loss of fluid from the reservoir and to minimize
water contamination to the fluid system used. Choose the right rating for the hose and fittings.
Pressure can range greatly, so always confirm the components that are used in the circuit. Lastly,
the fluid is under large amounts of pressure when exiting the ports, so any testing needs to be
done with special safety precautions.

SECTION 10: Subsea Tooling 10-11

 Marsten Bentley Pump
The Marsten Bentley (MB) pump is a proprietary ROV-
integrated isolated hydraulic supply system. The MB
pump can be set up to provide a variety of functions;
it can be used as a standalone pump or in conjunction
with other components, allowing it to provide hydraulic
power to an assortment of tooling. Many times the
MB pump is used on torque tools because it has three
different pressure settings available. Marsten Bentley Pump

The MB pump is a VOAC F11-10 hydraulic motor that drives a VOAC F11-5 motor, effectively
turning it into a pump. The two motors are coupled with a Lovejoy coupler and are bi-
directional. The addition of a three-stage tooling stack allows three circuits to be actuated with
spare valves on the ROV rate pack. These three valves are adjustable up to 5,000 PSI, and, with
an intensifier in circuit one valve in the stack, are capable of achieving an output of 689.5 bar
(10,000 PSI). The addition of the tooling stack supplies the system with three pilot-operated
directional-control, pressure-reducing, flow-control valves, as well as dual pilot-operated check
valves. The third stack does not contain the pilot-operated check valves due to the intensifier
having its own check valves that will open at 3 PSI.
The MB pump can receive a maximum input of 22.7 LPM (6 GPM) at 200 bar (2,900 PSI),
which will supply an output of 13.2 LPM (3.5 GPM) at 331 bar (4,800 PSI). One stack is
capable of achieving an output pressure of 689.5 bar (10,000 PSI) with the Iverson intensifier
in circuit. The pump without the tooling stack can also be configured to suck in sea water and
pump it out through a hotstab.

Application
Operational requirements and client needs affect how the MB pump will interface with the ROV.
Different types of fluid will be supplied by the client for use in the MB pump. The fluid will
have its own reservoir installed somewhere on the vehicle and will be the point of both supply
and return to the F11-5 pump. The reservoir can be installed in multiple locations on the ROV.
The MB pump is powered by the ROV’s hydraulic supply. The directional control of the
hydraulic circuit is controlled by hydraulic solenoid-controlled proportional valves located on the
ROV.

Rotary Torque Tools

Many times, when installing subsea equipment or performing well
completions, a torque higher than what can be provided by the ROV
manipulator is required. Currently, there are six classes of torque tools
utilized by Oceaneering with an option for a seventh by installing a
gear adapter on a class 4 torque tool.
Rotary Torque Tool

10-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

The torque tool allows an ROV to perform many different tasks, including the following:
• Manually operate gate, ball, or needle valves
• Override remotely operated gate, ball, and needle valves
• Install flying lead junction plates (FLJP)
• Connect multiple quick connects (MQC)
• Complete lockout operations on upper and lower surface controlled sub-surface safety
valve (SCSSV) circuits
• Provide a docking function to stabilize the ROV during critical manipulator operations

Application
Docking of the torque tool is accomplished by guiding the nose of the tool into the receptacle’s
conical entrance. This leads to a circular bore of a slightly larger internal diameter than the
outside diameter of the tool. Once in the bore, a socket installed on the square drive will then
engage the head of the valve stem or the lead screw of a MQC or FLJP. Once engaged, the
latches can be actuated, locking the torque tool in place. Even though locked in place, the
hydraulic circuit for the tool has been designed so that should hydraulics be lost, the latches will
retract allowing the tool to be retrieved.

For the socket to be properly engaged, the motor might need to be cycled on and off.

Hydraulic Wellhead Cleaning Tool

The hydraulic wellhead cleaning tool is used to thoroughly clean the
wellhead sealing surface and hub where the ring gasket is seated.
This tool is designed to interface with an 18-3/4 inch wellhead and
fits directly over the top of it. The tool self-centers on the exposed
wellhead. When the rotary brushes are energized, the tool cleans
the gasket ring groove on the face of the wellhead. A hydraulic
motor situated on top of the tool provides the rotary motion. Two Wellhead Cleaning Tool
hydraulic functions from the ROVs rate-control units are required to
operate the tool in a bidirectional rotation:
• The brush carrier assembly is made up of the carrier plate and four brush segments
bolted to it from underneath. The entire assembly is then attached to the centralizing
assembly’s motor bearing component.
• The centralizing ring assembly consists of the centralizing ring weldment, four-ring
spacers (attached to the inner sides), the hydraulic motor on top of a handle, and two
torque reaction pins. Torque reaction pins are to be held by the jaw of the manipulator
arm to help stabilize the tool once operations begin.
The tool must be tethered to the ROV in order to prevent loss or damage. The line used to tether the tool
must be shorter than the hoses and installed in a way that will not allow entanglement with the hoses.
SECTION 10: Subsea Tooling 10-13
 pH Meter
The subsea pH meter is a self-contained, self-powered tool that reads the pH in water depths
to 10,000 fsw. This tool can be used by a wide range of ROVs. The pH reading is displayed on
an Intelligent Display that can toggle between awake mode or sleep mode by flashing the ROV
lights. The Intelligent Display also allows the control of the pH measurement update time,
automatic sleep mode, and other features.
While detailed instructions for use and setup will be provided by DTS, some factors must me
kept in mind.
• The meter will be shipped with a protective “boot” over the tip of the probe, which must
be removed prior to but no more than five minutes before launch.
• The probe should never be inserted in mud.
• When attaching the probe to the cage, attach in a position to minimize exposure to light.
If the cage or vehicle lights are shined on the rear of the probe, the light will activate the
tool and cause premature battery depletion.

pH Meter

10-14 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section Review
All normal load outs of the ROV system have standard subsea tooling. This tooling, in
addition to other commonly used tooling, allows the crew to successfully perform work
assignments. Whenever there is a question about any of these tools (e.g., questions about
the pressure and flow rate or the tooling check schedule), the technician should always
verify the information in the Deepwater Technical Solutions tooling manual in the control
van.

Knowledge Check

1. Which tool is used for cutting wire rope?

2. Which tool is used for cleaning and removing drill cuttings from drilling templates?

3. Which tool is used for a variety of cutting operations such as bolts, pipes, and wire?

4. Which tool is a device used to move fluid from one device to another?

5. Which tool is constructed from the brush carrier assembly and the centralizing ring
assembly?

SECTION 10: Subsea Tooling 10-15

10-16 ROV NEW HIRE COURSE - Gulf of Mexico Region
Section 11
Surface Hydraulics

Morgan City Training Center

11-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
Every ROV system must have a means of moving the ROV from the deck into the water and
then back to the deck. The system will also need some type of over boarding device. The
method chosen to launch and recover is based on several safety considerations, operational
functionality, and job or task duration. In addition to completely understanding the launch and
recovery system process, the crew must ensure the temperature is controlled in the hydraulic
system on the surface so the equipment does not overheat on deck. This section covers the key
principles that are applicable during the launch and recovery of the system as well as the actions
the crew must take to ensure the surface hydraulics are working properly.

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Discuss the principles of the launch and recovery of the ROV system
• Explain how environmental conditions (sea state, wind, and current) affect the ROV as it
is launched and recovered
• Explain actions that can be taken to mitigate adverse conditions
• Describe operation and safety concerns for the ROV system winch
• Describe proper communication procedures during ROV operation
• Explain the responsibilities of each crew member during a launch/recovery
• Describe the unique differences and safety concerns with fixed A-frame, docking head,
cursor, guide wire, and rail launch and recovery system (LARS) operations
• Describe the auxiliary power unit (APU)

SECTION 11: Surface Hydraulics 11-3

 Launch and Recovery System (LARS)
Since every ROV must have a means of being inserted into
the water and retrieved, most of the launch and recovery
tasks will be accomplished using one of the following
methods:
• Over the side of the vessel
• Through a moon pool in the vessel
• On a rail or guide-wire cursor transition package
Regardless of the method used, a winching device is ROV with Skid
required in conjunction with either an A-frame suspension
platform or some other type of pulley configuration augmented with a controlled launch/
recovering subsystem.
Safe launches and recoveries are as critical to the success of the job as the actual subsea task.
Personnel safety and equipment care are paramount during these critical path evolutions. Proper
application of the technology and consideration of the possibilities and limitations each type
of launching application provides will lead to the optimal means of controlling the surface
operation.

Hydraulic Power Unit (HPU)

The hydraulic power unit provides all of the hydraulic
power for the main lift winch and A-frame launch skid.
This hydraulic power unit is powered by a 75 HP (480 VAC,
3-Phase, 60 Hz) electric motor, which is normally connected
directly to the vessel’s power.

Main Lift Winch HPU Side View

The main lift winch is used to raise and lower the vehicle as well
as provide a place to store and manage the umbilical. It includes
the winch motor and slip ring. A hydraulic winch motor is
installed in the winch, which is suitably sized to cater to the size
of the winch drum, the weight of the deployed ROV and TMS,
the weight of the umbilical, and any dynamic amplification
factors to be applied to the design. The winch motor is powered
by the hydraulic power unit (HPU). An appropriate slip ring
with sufficient passes to match the conductors required in the
umbilical must be specified and installed in the winch drum. Winch Front View

11-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Level Wind Mechanism
The winch will normally be fitted with a level wind
mechanism to ensure even spooling of the umbilical cable
onto the winch drum.
• Level winds can be directly driven or chain or gear
driven.
• Depending on the design, the winch will move
umbilical guides by lead screw, diamond screw,
cylinder, or mechanical level. Level Wind

A-Frame
The mechanism used to lift and “overboard” the ROV is
an A-frame (or crane) suitably rated to accommodate the
maximum weight to be deployed. This rating must include
the weight of the umbilical in air or water and the applied
dynamic amplification.
A-frame

Sheave
The crane or A-frame will have a sheave wheel fitted that is of greater
diameter than the minimum bend radius of the ROV umbilical.

ROV Overboarding Devices

Each system has its own combination of equipment and layout for Sheave
launching the system, but all systems need a means of overboarding the ROV. Overboarding
may be in the form of a simple sheave mounted over an opening in the deck (commonly known
as a moon pool), or it may be a cursor system. A cursor may take many forms, but all cursors all
do the same thing. They stabilize and guide the vehicle by controlling the unwanted horizontal
movement of the ROV during the launch and recovery process.

Moon Pools
The ROV system can be deployed through a hole in the deck or
hull of the vessel. Such openings are referred to as moon pools.
Moon pool operations are beneficial because the design provides
for a covered, safer work environment for the crew and storage
of the ROV. Moon pools tend to be associated with ship and
barge operations, but they are not limited to just that application.
Special safety precautions need to be addressed when using a Tophat with Vehicle
moon pool door because the open hatch leaves a direct potential
to fall to the sea unless barricades are constructed and used as required. Often, moon pools will
be pneumatically driven, requiring additional maintenance support.
SECTION 11: Surface Hydraulics 11-5
 Rail Cursor System
Oceaneering utilizes the rail cursor system as a method of
deployment and recovery of the ROV. This method is best
suited to drill ships, dive support vessels, and vessels that
launch through a moon pool because no horizontal movement
is desirable. Typical rail lengths are 70 – 80 feet in length. The
rails are attached to the vessel at several points between the
ROV deck and the vessel A-frame or through a moon pool
with a fixed A-frame assembly overhang. Both of these systems
provide excellent heavy weather launch performance and
decrease the potential for personnel injuries during launch and Rail Cursor
recovery to nearly zero. This method is highly desirable for a
long-term project aboard a ship or other unstable launching platforms.

Guidewire Cursor System

The guidewire cursor system typically consists of a pair of
two-inch paralleling wire ropes that are attached to a
stationary A-frame at the launch point on deck down to a
submerged pontoon or other solid structure on the vessel.
Specially designed breakaway joints allow for zero damage to
the structure and crew in the event that a wire becomes
overloaded. Turnbuckles on the A-frame are used to provide
adequate tension to the lines. This cursor system provides a
level of increased usability in rougher seas that would
normally prevent the launch of a non-guided wire system,
leading to more uptime for the rig. Guidewire Cursor

Cursors do not eliminate the restrictions of weather and current; they just raise the limits.

Auxiliary Power Unit (APU)

While the ROV is on deck, the APU allows for the
following tasks to be performed:
• Comp up the vehicle
• Test tools on deck
• Utilize as an oil and water separator

APU

11-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

Prior to start up, the following tasks must be conducted:
• The flow control valve should be fully closed by turning the control knob in a clockwise
direction.
• The pump pressure control should be set at a minimum by turning the control knob fully
counterclockwise.

Communication Systems
The ROV system is equipped with the David Clark communications system.
This system allows conversations between all of the crewmembers and is critical
during launch, recovery, and other deck operations. It is also an invaluable tool
for pre-dive operations and maintenance activities.
Headset
There are two primary types of headsets to be utilized offshore:
• The behind-the-head Model H3340 is the most common headset used by the winch
operator and the deck handler.
• Inside the control van, the crewmembers will typically use the “lightweight headsets.”

Safety Awareness
Launching and recovering a vehicle can be incredibly dangerous for various reasons, including
but not limited to the following:
• The type of LARS utilized for operation
• Weather conditions (i.e., sea state, current sea direction, wave height, etc.)
• Crew experience
A job safety environmental analysis (JSEA) should be reviewed and a safety brief given prior to
any LARS operation that involves the potential for an injury or equipment damage. Constant
communication must be maintained by all personnel involved in the operation; this includes the
supervisors, operators in the control van, the winch operator, and the deck hands.

The ROV supervisor has the final say as to whether or not the weather conditions are acceptable to carry
out a launch.

SECTION 11: Surface Hydraulics 11-7

 Operational Considerations
In addition to identifying and mitigating safety hazards, operational considerations must be
made prior to any launch or recovery:
• Is the sea state within allowable limits for the operation to progress?
• Is there a reasonable expectation the weather/sea state will allow a normal recovery upon
completion of the job?
• Are communications established between the ROV control and the vessel bridge, the
wheelhouse, and/or the control room?
• Will the vessel be required to secure any thrusters during launch and recovery operations?
• What is the speed and direction of the prevailing current?
• What will be the affect of the prevailing current?
• Is the equipment fully functional?

11-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section Review
Each vessel or rig must have a way of moving the ROV from the deck into the water
and then back to the deck. The method chosen to launch and recover is based on several
safety considerations, operational functionality, and job or task duration. The crew must
be familiar with the various launching methods and the equipment used to launch and
recover the ROV as well as the hazards associated with each type of operation. In addition
to completely understanding the launch and recovery system process, the crew must ensure
the temperature is controlled in the hydraulic system on the surface so the equipment does
not overheat on deck.

Knowledge Check
1. What are three of the main components of a LARS?

2. What overboarding device is most commonly prefered in rough weather conditions?

3. Who has the final authority to execute an ROV launch?

4. Who has the authority to stop an ROV launch?

SECTION 11: Surface Hydraulics 11-9

11-10 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Section 12
Umbilicals

Morgan City Training Center

12-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

12-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
The umbilical is one of the most critical and expensive parts of Oceaneering’s ROV systems.
Proper maintenance of the umbilical is necessary to help preserve the life of the umbilical, and
termination of the umbilical is only necessary for these four reasons:
1. Installation of a new umbilical
2. Failure in the main lift umbilical
3. Routine maintenance of the umbilical
4. Preventative maintenance of the umbilical

Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Discuss umbilical corrosion and methods implemented to reduce corrosion of the
umbilical
• Discuss the importance of performing an umbilical inspection and lubrication
• Discuss the costs associated with umbilical replacement
• Explain how and why a retermination is completed

SECTION 12: Umbilicals 12-3

 Key Terms
Variable/Acronym Definition
AI Aluminum
AWG American wire gauge
Cu Copper
E-Kink A test performed on individual wire strands to test tensile strength
GALFAN Galvanized fantastic
GIPS Galvanized improved plow steel
HDPE High density polyethylene
Hockling A condition in which the umbilical is forced into a tight looping turn, creating a buckling effect
Knifing A condition on the drum in which the top layer is improperly seated in the grooves produced by the
underlying layer
LARS Launch and recovery system
SCPE Semi-conductive polyethylene
Strand separation A condition in which the armor strands begin to pull away from the umbilical core

Umbilical’s Role in the System

The umbilical serves two important functions: the winches lift cable for the subsea package
(cage/vehicle), and the umbilical provides the medium for the subsea electrical requirements that
consist of operating power, data communications, and video signals. This makes the umbilical
the lifeline of the system.
The flow of the umbilical:
1. The surface termination point is inside the rotating junction box.

Rotating Junction Box

12-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

2. The umbilical spools onto the winch drum, typically in lengths of 10,000-16,000 ft.

Umbilical in Winch Drum

3. Then, the umbilical is fed through the level wind system.

Level wind System

4. Next, the umbilical goes down to the top of the cage and through the cage bullet to
finally terminate inside the cage matrix can, which may be square or round.

Cage Bullet Cage Matrix Can

SECTION 12: Umbilicals 12-5

 Umbilical Design
The umbilical is literally a machine in its own right. The umbilical is designed with precision
engineering, advanced construction methods, and high reliability. The contra-helix armor in
itself is a complexly calculated torque, angle, and strength formula to give the umbilical optimal
dexterity, functional control, superior protection, and enhanced support. The umbilical has
two layers of “water ingression preventing” Hytrel jacketing surrounding the conductors and
fibers on the inner layer and outer layer. The outside of the umbilical is made of two layers of
GALFAN armor, which adds five percent aluminum in the galvanized coating to help prevent
corrosion even more as the layer of galvanized coating wears down. The GIPS armor provides
the lifting strength to the umbilical and acts as a mechanical protective barrier to the internal
components. The GIPS layers are wound in opposing directions to give the umbilical a better
resistance from the tendency to rotate excessively, which can cause the umbilical armor strands
to separate from their normal seating arrangement. Hockling will result if too many stressed
turns are put into the umbilical. If turns continue, umbilical parting is likely.
There are six main elements to the 4549 umbilical:
• GIPS (galvanized improved plow steel) armor housing (two layers)
• Insulating Hytrel belt made of a polypropylene material to protect the umbilical
conductors from water ingression
• Single phase cage/vehicle electrics power (Element A)
• Spare conductors can be used for CP/Inst./422 signals (Element B)
• Motor electrical power conductors (Element C)
• Fibers (Element D)

Umbilical Design

12-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

Models
The two primary manufacturers of Oceaneering ROV umbilicals are Rochester and Nexans.
The major difference between the two umbilicals is the incorporation of a steel tube housing
twelve fibers in the Nexans compared to the six fibers spaced throughout the umbilical structure
in the Rochester. Other differences are worth noting as well:

Rochester
This model is made up of the following elements:
• (9) 10 AWG power conductors - motor power requirements for cage and vehicle
• (4) 12 AWG - cage and vehicle electronics single-phase power
• (4) 20 AWG spare conductors - used for instrumentation, CP, 422 or power
• (6) Single mode fibers - used for video and data communications links

Rochester Umbilical

Important specifications on the 4549 umbilicals are also noteworthy:

• Overall diameter - 1.34 inches
• Weight in seawater - 1.67 pounds per foot
• Breaking strength - 92,000 pounds
• Bending radius - 24 inches
• Voltage rating - (12 AWG) 1,200 volts (20 AWG) 800 volts (10 AWG) 2300 volts
• Optical attenuation rate - 1310 nm (.45dB / 3280 ft.) 1550nm (.35dB/3280 ft.)

SECTION 12: Umbilicals 12-7

 Nexans
The latest umbilical to be incorporated into Oceaneering’s
work class system is the Nexans. Oceaneering uses two
different types of the Nexans, one on the Magnum
ROV and the other on the Millennium ROV. Although
there is not much difference in the conductor numbers
and layout, the Millennium umbilical is rated for higher
electrical and working loads.
Nexans, a company headquartered in Norway, developed
and improved upon existing ROV umbilical technology
and produced an umbilical with a very unique feature. Nexans Umbilical
Twelve loose optical fibers were encased in a laser welded
metal tube inside the structure of the umbilical and proved to provide greater reliably and
protection over a longer life cycle. The tube is referred to as “Fibers In a Metal Tube” (FIMT)
design and will require some special procedures during reterminations, which will be covered in
future sections of this guide.
The Magnum Nexans model number is 10061674. This umbilical has an overall diameter of
about 1.34 inches of minimum bend, a diameter of 47 inches, and a safe workload rating up to
29,225 pounds. It is made up of the following elements:
• (9) 8 AWG motor power conductors
• (5) 14 AWG cage vehicle electrics conductors, plus a spare
• (1) 22 AWG quad cable
• (1) steel tube containing 12 fibers

Construction
Construction of the umbilical is a combination of engineering and machining. The conductors,
fibers, and fillers are all determined for location marks within the umbilical and then applied to
a “spinner” that will mechanically interlace all of the wires together in one run. This is a small
picture of such an event.
Once the conductors, fibers, and fillers are laced, the
protective sheathes, insulating tapes, or protective wraps
will be applied by special machinery. The critical step is now
encasing all of the wires inside an armor housing. The armor
is applied by a piece of machinery similar in concept to the
electrical wiring spinner. The engineering used to determine
the exact angles the armor needs to lay is part of a torque
balancing. This allows maximum efficiency between the two
layers of armor, which are contra-helically wound, meaning
one layer will go in one direction and the other in the opposite. Umbilical Being Spooled

12-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

The umbilical ends are bound to prevent the armor from springing out of place. The umbilical
is then spooled onto a drum of appropriate size to prevent exceeding the maximum bend
radius. One of the most important points to remember about the construction of the umbilical
is that twisting (such as spinning the cage) can be harmful if done in excess. The opposing
windings will work against each other as the umbilical is twisted and will eventually cause a
failure of some type.

Cost
The umbilical is the most expensive part of an ROV system. The prices can reach nearly a
quarter of a million dollars in some cases, which is a huge investment on behalf of Oceaneering
and a great responsibility on the part of the system’s crew. There is absolutely no reason not to
give the umbilical the needed attention it deserves (and demands). Frequent inspections, proper
maintenance, and sufficient reporting are what protect the umbilical from an unjustifiable
failure.
Keeping an accurate account of umbilical length and consulting with the operation’s manager
prior to cutbacks is a good habit and may lead to better and less costly decisions. If the armor is
old and failing, chances are the conductors are still good, so sending an old drum of umbilical
to be re-armored is cheaper than scraping the remaining cable.

Re-Armor
Re-armoring an umbilical tends to be less expensive and generally prolongs the useful life of the
umbilicals. Good candidates for re-armor include the following:
• Umbilicals that have been exposed to environmental elements for long periods with little
to no maintenance.
• Umbilicals that have excessive or repeated strand failure or show badly worn galvanized
coatings.
• Umbilicals that have been maintained properly but have been in service for several years
and have experienced multiple cutbacks.

Re-armoring of the Umbilical

SECTION 12: Umbilicals 12-9

 Operational Factors
Many issues need to be addressed in order to effectively operate the umbilical. The responsibility
as a crew member to proactively maintain the umbilical is the most important job. Neglecting
the umbilical will certainly lead to problems that could otherwise be avoided if the crew
members maintain the umbilical properly.
When launching and recovering, it is important to understand and properly operate the LARS
equipment. During operations in bad weather, it is very important to prevent the umbilical from
being shock loaded or, in other words, relaxing and then tightening up dramatically. This is
something experienced during high seas launch and recovery and boat jobs where the A-frame is
on a moving platform and the cage does not react as quickly as the moving platform does.
All of Oceaneering’s umbilicals have several elements in common:
• All umbilicals are protected by GIPS (galvanized improved plow steel) contra-helical
wound rods.
• All umbilicals have electrical conductors for motor power, vehicle/cage electrics power,
and ground (drain) lines.
• All umbilicals have fiber optics in different numbers and protective construction.

Umbilical Inspection
One of the most important goals of an ROV crew is to extend the life of the umbilical as long
as possible while still operating under serviceable conditions. Inspection is the first defense
against deterioration and/or umbilical failure. The inspection process involves examining the
condition of the armor and the manner in which the umbilical lays on the winch.

Principals and Frequency of Inspections

Umbilical inspections are preventive maintenance tasks that will ensure the continued
serviceable operation of an umbilical. For umbilical inspections to be effective, the technician
must do regular inspections, and he or she must be knowledgeable about the optimum
umbilical condition. Therefore, the crew has to make umbilical inspections a routine part of
daily operations in an effort to prevent potential problems, especially problems that might
become major issues. The crew should visually inspect the umbilical’s condition, especially in
the area around the bullet and routing into the term can, as part of pre-dive, post-dive, or daily
maintenance.
No matter how well a crew cares for its umbilical, however, major problems with the umbilical’s
integrity will eventually develop. The following illustrations are common umbilical problems that
may occur.

12-10 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Umbilical Conditions
Properly lubricated umbilical. The umbilical looks wet, but it also
has the “rusty” look that is characteristic of some lubrications.

Condition known as “strand separation.” This condition is a

typical result of either vertical excessive stress or rotational strain
placed on the umbilical. The armor begins to pull away from the
umbilical core in varying degrees of severity.

Exaggerated hockling condition that resulted in over ten broken

strands. A broken strand is obvious in most cases and can be
repaired if the proper kit and trained crew members are available.

Inspection Methods
There are two types of inspection methods that can be used in reference to the umbilical: visual
and trending.

Visual
This is the process of looking at close range for particular anomalies in the umbilical’s armor
or connection points. This process includes all terminations, entry points, initial fiber readings,
and the general condition, to include lubrication of the umbilical armor as best as can be seen.
Obvious abnormalities seen during visuals include knifing, broken strands, bulges, lubrication
needs, and drum lay. Using gloved hands, technicians should feel for anomalies in the cables
around the bullet area. It is also effective for a technician to extend his reach when inspecting an
umbilical that has a layer of lubricant on it.

SECTION 12: Umbilicals 12-11

 Trending
Trending is a process that involves the use of measurement methods and techniques to see
what the eyes do not recognize. By making reference marks on the umbilical or re-inspecting
fiber readings, technicians are employing a trending inspection method. As an example, if a
technician makes a reference mark around the umbilical using a straight edge (near the bullet
entry for best results), he or she will see a distortion in the line if the umbilical is elongating or
twisting unnaturally after several dives. Abnormalities that are more noticeable with trending
are inconsistent umbilical tension during recovery, fiber optic signal loss, insulation/conductor
deterioration, lubrication history, armor failures, and time in service. Because umbilical problems
are not always obvious, inspections must be carried out carefully and systematically

Knifing
Knifing is readily noticeable on the drum because the uniformed smooth lay of the cable is
upset. Technicians may hear a “squeaky” or grinding noise and sometimes a pop when the cable
finally falls off the underlying layer into the next groove. Knifing was long associated with the
condition known as strand separation, but, in fact, knifing refers to the lay of the umbilical on
the drum or, better said, the improper laying of the umbilical on the drum. There are several
reasons why an umbilical may be knifing on the drum. In every case it is important that the
problem is fixed before the condition becomes irreparable. Knifing will be most prevalent at
the crossovers where the cable is laid to the drum sidewall and begins its journey to the other
side. One of the biggest causes of knifing is the lack of constant equal tension on the umbilical
throughout the haul in. These differences are small, but they compound as more wraps are
placed on the drum. A loose wrap on the first layer will transcend to the outer most layer in an
increasingly noticeable pattern. Another factor is the performance of the level wind and the
synchronous operation between the level wind and the winch drum.

Reterminations
Umbilicals will likely go through several reterminations within their
life cycle; however, depending on the severity of a failure or the
length of time an umbilical has been in service, it may be more
beneficial to replace or re-armor rather than reterminate.
Umbilicals are a combination of machinery and electrical
components, both of which will potentially fail as usage times Separating Umbilical
increase. With this in mind, it is important that accurate records and
proper maintenance be a part of the umbilical’s life history in
order to determine if it is time for an umbilical retermination.
The picture on the top right shows a dry rusty armor separating
umbilical. The picture on the bottom right shows a lubricated
umbilical with a broken strand. Both umbilicals could rate a
retermination, but the dry “rusty” umbilical, depending on the Lubricated Umbilical With Broken Strand

12-12 ROV NEW HIRE COURSE - Gulf of Mexico Region

extent of its condition, may be a candidate for a replacement due to the large area affected by
corrosion. The broken strand can be repaired (and should be) rather than cutback.

Umbilical Maintenance
Generally, umbilical maintenance is neglected in favor of vehicle or cage maintenance;
however, since the umbilical is the most expensive component on the ROV system, it should be
maintained properly by the crew.
Examples of umbilical maintenance are as follows:
• Lubrication
• Fresh water rinsing
• Alternating drum park positions
• Slip and cut

Lubrication
Lubrication is probably the single most important preventative maintenance action that can be
implemented on the umbilical. The reason is simple: proper lubrication (corrosion prevention)
and reasonable operational use will allow the maximum life cycle of the umbilical to be realized.
Lubrication is a “tool” to help reduce the effects of corrosion on the armor layers. The
chemicals or compounds used for Oceaneering’s lubricators have specific qualities that take this
corrosion prevention process to high levels. These compounds actually work to dissipate water
and create protective seals while at the same time embedding between strands to help reduce the
armor chaffing that occurs over long periods of time.

A “maintenance” issue in the past was using a wire brush to clean the umbilical because it appeared to
be rusty or may have had some surface rust on it. DO NOT do this! A wire brush will tear down the
protective zinc coating and actually speed up the corrosion process.
Wiping down the umbilical while the winch is running or the umbilical is under tension IS NOT
recommended or within safety guidelines. Do not fabricate or attach any make-shift devices to
the winch or umbilical (even with good intentions) unless authorized by a technical manager or
operations manager.

Types of Lubrication
Lubrication products continually evolve just like other technical products. Cost has never really
been a factor due to the comparative cost of premature umbilical failure replacement. Methods
of application such as injection, brushing, or spraying all relate to the ideal application for the
specific product used.
PreLube 19 & 15 - Discontinued because it would leave a hardened coating similar to a varnish
that would flake and provide no protection.

SECTION 12: Umbilicals 12-13

 SnoKote - Discontinued because it would actually trap moisture in the cable.
Tuff Kote - Discontinued because the grease would seal in moisture and promote corrosion
although it gave a nice sheen to the outside of the cable.
OceanLube - A heavy inhibitor that would also trap moisture.
OLL X1 - A thin lubricant that worked well but was ultimately determined to have too little
inhibitor ingredients in the mixture.
OLL X4 - Another version of OLL that has four times the amount of inhibitor, thus making it
a little heavier in viscosity but still usable in a bug sprayer.
OLL - Made of approximately 95 percent carrier (non-inhibiting) and five percent active
inhibiting agent. Reusing the product does absolutely no good because only the carrier (non-
protective) is being applied at that point.
Lubricating the umbilical is a must and should become part of the
crew’s routine maintenance; however, there are cases where looks
can be deceiving. If the appearance of salt is seen on the umbilical,
that may be galvanic corrosion, meaning the protective layer of
the umbilical has been compromised, and it is only a matter of
time before rust takes over. In some cases, salt may be found on
the umbilical, but if it is a fine white powder, the umbilical is on an
unrecoverable path to replacement. Ferrous rust is red in color while
galvanized rust is white and powdery. Cable Segment

Application Methods
Lubrication can be applied in several ways. The application method is simply determined by the
lubricant type and manufacturer’s suggestions. Technicians make adaptations to the methods to
fit their capabilities offshore, but the primary goal, no matter what method is used, is complete
coverage in sufficient amounts. The primary application methods are as follows:
• Injection - This process uses compressed air to transfer the lubricant into a metal
housing that has two rubber sleeves around the umbilical to keep the lubricant inside of
the metal housing. The pressure behind the lubricant transfer allows for a penetration
throughout the section of umbilical passing through the housing. A set of small chains
secures the housing to an object.
• Brushing - Paint rollers, paint brushes, or even mops are used to spread the lubricant
over the umbilical. Since there is no force entry of the lubricant, there may be no
guarantee of sufficient penetration, and coverage may not be as complete as intended.
• Spraying - This method requires the least equipment and can be performed by the
winch operator. The spray lubricant can be placed in a bug sprayer and sprayed onto the
umbilical as it is recovered.

12-14 ROV NEW HIRE COURSE - Gulf of Mexico Region

 • Fresh water rinse - Although this is not considered a lubricant, it is a vital part of
reducing saltwater corrosion on the umbilical. There are several methods to apply the
rinse, but the best method is through a fixed station, either on the winch or cursor,
that will allow freshwater to make contact with practically all of the surface area on the
section of umbilical passing by or through the rinse.
Oceaneering follows the manufacturer’s suggestions for lubrication frequency. It is important to
keep the umbilical “wet looking” and use on-site judgment for additional lubrication in addition
to company policies regarding lubrication. Umbilicals that have some rust will tend to use more
lubricant than a non-rusted umbilical because rust acts like a sponge and will continue to accept
lubricant until the rust particle is saturated. It cannot be stressed enough just how important it
is to keep the umbilical properly lubricated regardless of the cost of lubricant. The system will
have a longer lifespan if the umbilicals are properly maintained.

Core Luber
This process uses compressed air to transfer lubricant into a metal housing that has two rubber
sleeves inside a housing that encases the umbilical. The pressure allows for a penetration
throughout the section of the umbilical passing through the housing.

Luber Housing

Complete Core Lubrication System

SECTION 12: Umbilicals 12-15

 Umbilical Termination
An umbilical termination is required for one of four reasons:
1. Installation of new umbilical
2. Failure in the main lift umbilical
3. Routine maintenance
4. Preventative maintenance
In the case of a failure, it is critical to know where the fault is in the cable. The umbilical must
be cut, the bad section removed, and a test must be done to verify the fault has been removed.
If the retermination is completed for routine or preventative maintenance, the hose clamps
should be placed just past the amount of umbilical that must be removed.

Pre-Job Meeting
Prior to starting work, it is extremely important that all work team members sit down, read the
umbilical termination procedure, discuss any questions, and formulate a plan for implementing
the work at hand. Items of discussion and action should include the following:
• Safety equipment availability and use
• Safety procedures and concerns
• Reason necessitating work
• Goals (short and long)
• Task assignments
• Time required for performing work
• Verify all spares and consumables are on hand
Always consult with the client prior to commencing major work; cover at least the following:
• Reason requiring procedure to be performed
• Personnel required for task
• Time required to complete task (always add some time to allow for unforeseen problems)
• Pertinent entries required for system log books and completion of any equipment failure
reports (EFR)
• Reporting to operations manager
• Review Material Safety Data Sheets (MSDS) on lead-based products

12-16 ROV NEW HIRE COURSE - Gulf of Mexico Region

Umbilical Retermination

Umbilical Retermination Steps

1. Perform lockout and tagout (LOTO) procedure on breakers to ensure no power is available at the cage and vehicle.
2. Prior to cutting the umbilical away from the bullet end, place hose clamps on the umbilical starting approximately 50 feet
away from the cutting area. Start at the winch end and place the clamps every three feet going toward the cage end while
working loose strands back into position and ensure the strands are seating properly. Place a clamp on each side of the
cutting mark no more than four inches away from the mark.
3. Be sure to use a face shield and cutting wheel that is in good condition.
4. Verify power to the umbilical is locked out; then cut the umbilical from the bullet between the two hose clamps placed no
more than four inches away on each side of the cut mark. Most systems will use a grinder with a cut-off wheel or maybe
even a hacksaw. Be aware of springing armored strands during the cut and realize the cut armor will be sharp. After the
cut is complete, cap the bullet side of the umbilical with some Duct tape to prevent cut strand end exposure. Do not cap
the winch side.

5. Perform an E-Kink test on the winch-end armored strands. If the strands pass, proceed to step 6; if not, contact the
operations manager to discuss options of cutting back more umbilical.
6. Drain the termination can on the cage. Then disconnect the umbilical from the termination can connection points.
Unscrew the gland nut and pull the disconnected umbilical from the term can. Once the umbilical is pulled free from the
term can, remove the grommet and nut. Disconnect and remove the bullet from the cage while feeding the disconnected
umbilical through the hole on the top of the cage until the entire assembly is cleared from the cage.
7. Remove all epoxy from the bullet using tools available. Then clean it up in preparation of the new resin compound.
8. Determine how far back the umbilical needs to be cut depending on the situation and make a mark on the umbilical at
that point. Place hose clamps in the same manner as was done for the umbilical cut off from the bullet.
9. Once the umbilical has been cut back, use the total length measurement from the old termination and make a mark for
that distance on the new section of umbilical where the armor will be scored and removed.
10. Slide the bullet onto the umbilical bringing the bottom of the bullet ten to fifteen inches past the point just marked on the
umbilical. Replace the clamps as the bullet passes.
11. Position the bullet on the deck or other hard surface allowing for minimal amounts of tension on the umbilical. Place a
hose clamp directly in front of the umbilical entry point on the bullet (top half). Place two more hose clamps three to four
inches (seven to ten cm) on each side of the score mark.
12. Use a grinder to score the outer armored strands between the two hose clamps just placed. Once the outer strands are
scored, begin removing the hose clamps starting at the bitter (cage) end until all clamps on the bitter end are removed.
BE VERY careful of sharp armor ends or any springing tendency they may have as clamps are removed.
13. Bend back the scored strands and work back and forth. They should weaken and break. Be careful at this point; these
strands are very sharp.
14. Score the inner armored strands using the grinder once all the outer layer strands are removed. Be extremely careful not
to “nick” or damage the waterproof Hytrel jacket or you WILL be starting all over.

SECTION 12: Umbilicals 12-17

 Umbilical Retermination Steps
15. Bend and remove these strands to expose the inner jacket. On a Rochester umbilical, remove the marker tape that is
between the Hytrel jacket and the armored strands and record this data in the system logbook. On a Nexan’s umbilical,
the data is ink jetted onto the poly jacket. Log the data on the outside of the poly jacket in the system logbook. Once you
have the information, clean the waterproof jacket with WD-40 or paint thinner.
16. Move the umbilical and bullet into a suitable working environment. Note: If possible, a temperature of about 75˚F should
be maintained and moisture or air contaminants avoided.
17. Adjust clamps so the position of the umbilical allows the severed strands to stick out from the bottom of the bullet about
eight to ten inches. Once the strands are extending past the bullet bottom, move a clamp flush with the bullet top (entry)
and remove any that are below the bullet. Broom out the strands but do not exceed a 60 degree angle on the strands.
Remember, we are no longer incorporating “fish hooks.”
18. Clean all of the armored strands to a shiny state using emery cloth. The goal is to rough up the surface of the strand,
allowing the resin to grip the zinc coating. Use a degreaser to clean and remove debris. The integrity of the socket termi-
nation is absolutely dependent on the cleanliness of the strands.
19. Move the bullet only to leave about three to four inches of armor sticking out from the bullet bottom. Slide the hose clamp
nearest the top of the bullet flush with the top of the bullet. Take time to inspect the armor in this area of the umbilical to
ensure all of the strands are lying correctly. If not, they need to be repositioned for proper torque balance and load bear-
ing of the umbilical.
20. Leaving about three to four inches of wire strand sticking out gives you the opportunity to use a couple of Ty-wraps to
go around the stands and tighten them up just a little to make the strands sit a little closer to the core. Ideally, you want
about a ¼ inch gap between the side of the bullet wall and the wire strands so the strands are completely encased in
the resin and not situated on the very edge of resin coverage. Using Ty-wraps and positioning bolts, you can obtain the
desired effects of getting the strands off of the bullet walls and positioning the umbilical for the curing process.
21. Put putty around the bottom to prevent the resin you pour from seeping out once it is in place.
22. Level the bullet as much as possible.
23. Thoroughly mix the resin before adding the catalyst until it is of uniform consistency. Be sure to scrape the sides and
bottom during the mix.
24. Pour the now activated resin into the bullet. Make sure the poured liquid is flush with the surface of the bullet and the
umbilical is centered.
25. Use a strand of armor or something similar to poke into the compound to help release trapped air. This can show how
much resin to pour, but remember we will have about three to four inches of armor strands sticking out with ty-wraps pull-
ing the strands just a little off the bullet wall.
26. Use a pointed device to write the date of the pouring in the resin for future reference as the resin begins to harden.
27. Remove all the hose clamps and Ty-wraps from the umbilical when the resin is completely cured.
28. Now we must flush cut the armor strands. Use some type of properly sized piping to protect the Hytel jacket. You will cut
off the three or four inch pieces of armor to make the strands as flush as possible with the resin.
29. Install the bullet and umbilical assembly on the cage. Route the inner jacket around the edge of the cage frame while
paying special attention to chaffing, sharp edges, and turn radius. Use the routing method that is the most efficient and
safe. The idea will be to also leave yourself enough umbilical to complete the electrical termination.

12-18 ROV NEW HIRE COURSE - Gulf of Mexico Region

 Umbilical Retermination Steps
30. Mark the inner jacket where it will enter the termination can once the routing is determined. You can use the length you
took from the old section of umbilical or determine the best solution depending on your situation. Practically all system
lengths will vary a little depending on several factors.
31. Inspect the grommet, gland nut, and matrix can threads for damage; replace parts if necessary.
32. Spray the inner jacket with silicon spray to help the grommet slide onto the inner jacket.
33. Slide the gland nut on first and then the rubber grommet at least a few feet up the umbilical inner jacket.
34. Determine the amount of exposed conductors required to make the electrical and fiber optic terminations.
35. Remove the pre-determined amount of the inner Hytrel waterproof jacket to expose the conductors.
36. Use a heat gun to loosen the glue that bonds the copper tape to the conductors and peel it off.
37. Move outer layer conductors away from the core.
38. Repeat step 37 on the inner core and move conductors away from center.
39. To help loosen the glue that surrounds the conductors, soaking the entire exposed conductor section of the umbilical in a
solvent has proven effective. To do this, you should use a two foot PVC, aluminum, or plastic pipe with a cap on one end
and strap it to a vertical member on the cage. Insert the end of the umbilical with the glue-covered wires into the tube.
40. Fill the tube with WD-40 or paint thinner and allow the umbilical to soak for 15-20 minutes.
41. Remove the umbilical from the soak tube and clean off remaining glue with a rag soaked in WD-40 or paint thinner.
42. Remove all water-blocking rubber inserts and use a rag to clean all the conductors and the fiber tube. Be very careful
with the fiber tube.
43. Insert conductors/fibers into the termination box. Hand tighten gland seal nut.
44. Route the wire conductors and fibers in a clean, neat manner; remember to put a service loop in your wires and fibers.
45. Conduct a continuity and isolation test of all conductors prior to energizing the system. Record the values in the logbook
for future reference and test the fiber conductors using the OTDR once all fibers are terminated.
46. Secure the matrix can end-bell (round) or top plate (square) so no shorts or pinched wires exist.
47. Remove LOTO for system testing.
48. Energize the system and perform a complete pre-dive noting any discrepancies. Troubleshoot and correct if discrepan-
cies exist. Remember to LOTO the system if wiring changes in the matrix (term) can need to be made. Remove LOTO
and repeat pre-dive. Continue this step until no discrepancies are noted.
49. With the system in LOTO state, secure the matrix can cover then tighten the gland seal nut being careful not to over
tighten. The gland seal extruding out of the center hole in nut indicates over tightening. Compensate (oil-fill) the can
ONLY after all system functions are working properly.
50. Repeat steps 48 and 49.
51. Secure the inner jacket run of the umbilical throughout its route back to the bullet using large Ty-wraps. Be sure to place
a protective cover, such as a split hose, over the sections of umbilical that lay over exposed edges.
52. Complete an updated Umbilical Status Report with E-Kink data and send into the office any time a retermination is
completed.

SECTION 12: Umbilicals 12-19

 Post-Job Meeting
After completion of work, it is important all team members sit down to discuss the job
performed, fill out any logs or required paperwork, and agree on any procedural changes.
Check off items listed below as completed or deemed not applicable:
• Discussion of changes to operation that may aid in preventing future failures
• Completion of all paper work including:
1. EFRs/ EMOs
2. Requisition of replacement supplies and any parts damaged/broken
3. Log book entries
4. Update system specification sheet
5. Submit procedural change suggestions that may improve performed procedure
6. Reporting, if required, to operations manager
7. Review material safety data sheets (MSDS) or manufacturer’s catalogue data on lead-
based products and any other chemicals used in this process
8. Safety items

12-20 ROV NEW HIRE COURSE - Gulf of Mexico Region

Section Review
This section discusses the umbilical. The umbilical’s role in the ROV system is vital. It has
six main elements and provides two functions. The umbilical is the most expensive single
part of the ROV system, so regular maintenance is important. Making sure the umbilical is
lubricated properly is the most important preventative maintenance requirement.

Knowledge Check

1. What are some methods that are used to reduce umbilical corrosion?

2. What indicates a correctly lubricated umbilical?

3. What are the benefits of lubricating the umbilical?

4. What are the occasions that a retermination is carried out?

5. Why is it important to inspect the umbilical?

SECTION 12: Umbilicals 12-21

12-22 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Appendices

Morgan City Training Center

1 ROV NEW HIRE COURSE - Gulf of Mexico Region

2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Safety Considerations
When using these appendices, please bear in mind the following safety considerations:
• Do not install substitute parts or perform any unauthorized modifications to any equip-
ment.
• Adhere to all cautions and warnings associated with equipment.
• Steps in these appendices should be used as a guide, not as a substitute for technical
manuals or instructions provided with equipment.

Safety Symbols Used in These Appendices

The following symbols are used in this appendices and other lessons to alert the student of the
potential for injury or damage to equipment:
• The danger symbol (shown at right) calls to attention the potential of injury to
the equipment operator or others standing nearby if the equipment is used im-
properly or the accompanying procedure is not followed as stated.
• The caution symbol (shown at right) calls attention to a procedure or practice,
which, if not performed correctly, could result in damage/destruction of part or
all of the product as well as to nearby property.

Internal Safety Symbols

The following international safety symbols are used in this appendices:
• The equipment caution symbol (shown at right) requires the equipment opera-
tor to refer to the equipment manual in order to protect against personal injury or
damage to the equipment.
• The electric shock symbol (shown at right) warns the equipment user of the risk
of injury from electrical shock if the equipment is used improperly or if precau-
tions are not heeded.
• Do not proceed into an area labeled with any safety symbol until the indicated
conditions are fully understood and met.

High voltage (up to 4,000V) is present on all FORCE connectors. Circuits should always be OFF
before inserting or removing the test unit from the circuit.

APPENDICES 3
4 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Appendix A
High Voltage Test Box

Morgan City Training Center

A-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

A-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
In this Oceaneering training course, we will help you understand how to correctly use the high
voltage test box. We assume you have no working knowledge of how the device works, and we
will provide clear, understandable explanations for each function that is used.
Louisiana Electric Rig Service, Inc. began manufacturing Oceaneering’s high voltage test box in
early 2000. The objective was a safe method for measuring the voltage and current for the cage
and vehicle electric motors. This testing had previously been done in a very primitive manner
with terminal strips with Plexiglas covers and HV probes attached to a meter. The terminal
strips were on a block of plastic, or worse, on a block of wood that got wet, which was not a
safe method for testing even at 1,300 VAC. The increase in motor voltage from 1,300 VAC to
2,400 VAC necessitated a new testing method.
The test box has now been updated to the Tinitron, Inc., high voltage test unit, and both of the
units listed above are commonly used to test and measure high voltages and currents found in
ROV deck and umbilical cables.
The Tinitron high voltage test unit provides a safe means of measuring the high voltage and
currents found in ROV deck and umbilical cables. Voltage is measured from the secondary side
potential transformer that reduces the 4,000 VAC on the cable down to 400 VAC, which can be
measured at the test jacks with a standard digital multimeter.
In addition to the jacks, three lights provide an indication of high voltage being present in
the box. Current is measured by placing a clamp-on ammeter around any of the three loops
provided on the top of the box. The box is self-contained and requires no additional power;
simply attach the cables (via the connectors provided) to the matching transformer and ROV
cables and begin making measurements. The voltage measured is 1/10th of the actual voltage,
so simply multiply the indicated figure by 10.

Objectives
At the end of this section, technicians will be able to complete the following objectives:
• Recall the main function of the high voltage test box
• Identify how to safely operate a test box and correctly use test cables
• Define what high voltage is and be able to list the hazards involved
• Describe how to test each electrical phase for volts and amperes
• Explain why two people are required to safely conduct testing
• Recall how to calculate the correct voltages using the step down ratio

APPENDIX A: High Voltage Test Box A-3

 Safety Considerations
• Ensure the ground in the cable is bonded to earth ground.
• Never operate the test unit with one cable end open.
• Inspect the HV test unit before use for any cuts or damage to the
insulation system, including the input and output cables and current loops.
• DO NOT USE the test unit if any part of the insulation system is
compromised.

Operating Procedure
1. With power OFF, disconnect the FORCE connectors where you want to make a mea-
surement.
2. Connect the FORCE connectors from the high voltage test unit to each end of the con-
nectors separated in step 1.
3. Connect grounding lug to earth ground.
4. Ensure all three lamps are lit, indicating high voltage is present.
5. You can measure the line-to-line voltages by placing a meter across A, B, and C test jacks.
The voltage measured is 1/10 of the actual voltage. To get the actual voltage, simply mul-
tiply the meter reading by 10.
6. To measure the current in each line, place a clamp-type ammeter or amprobe around one
of the loops located on the top of the box. The loops are protected by a double layer of
insulation and are safe to 6,000 VAC.
7. When all measurements are finished, power down the circuit, disconnect the test unit,
and re-connect the umbilical connectors. Power can now be restored to the circuit.
The input and output cables are provided with four-conductor metal-shell aluminium FORCE
connectors. The four lines are L1, L2, L3 and neutral. The four lines are routed into a three
phase Wye connected potential transformer, through the three current loops on the top of the
box, and then to the output connector.
The potential transformer provides a precise step down by a 10:1 ratio, so the voltage displayed
on the digital multimeter is 1/10 of the voltage on the line. The primary lines are protected with
high voltage 1/2 amp fuses.
The secondary side of the transformer has two taps, a low-voltage tap to drive the lamps and
a higher voltage tap that goes through the fuses to the measurement jacks. The low voltage
taps are directed to three AC to DC power supplies that provide a regulated +12V to the LED
indicator lamp.

A-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Maintenance
The high voltage test unit requires no calibration and very little maintenance. It is advisable
to keep the unit clean and free of dirt and grime, which may cause unwanted arcing. Inspect
the test unit on a regular basis for insulation nicks and cuts and replace any worn cables or
insulation.

Troubleshooting
Male input MSSM connector
1: L1
2: L2
3: Neutral
4: L3

Female output MSSM connector

1: L1 Out
2: Neutral
3: L2 Out
4: L3 Out

Symptom Possible Problem Corrective Action

HV present, but lamp(s) does/do not light HV is less than 2,000V Check for >200 V at test jacks
HV is not present Verify high voltage is available
Primary fuse Replace fuse

F1, F2, F3 blown

+12 VDC power supply is dead Replace power supply
LED lamp is burnt out Replace LED lamp
HV present, lamp lit, but no HV on test jacks Meter jack fuse F4, F5, F6 blown Check and replace fuse if necessary

APPENDIX A: High Voltage Test Box A-5

A-6 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Appendix B
Light Source and Meter

Morgan City Training Center

B-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

B-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
In this Oceaneering training course, we will help you to understand how to correctly use the
FOTEC “Smart Test” Kit. We assume that you have no working knowledge of how the kit
works, and we will provide clear, understandable explanations for each function that is used.
The FOTEC “Smart Test” kit is used on many ROV systems for fiber optic testing. The most
common use is in checking fiber losses after a re-termination. The fibers with the lowest losses
are normally hooked up in the telemetry system. Readings for the remaining fibers are recorded
in the system logbook for future reference.
This module is intended as a basic reference. Please consult the manufacturer’s literature for
more detailed information.
The basic kit consists of a laser source and power meter. The test kit used for this module is an
“FT330.” The source is an “FS380,” and the meter is an “FM310.” Sources are available for the
different wavelengths used by the fiber optics on a particular ROV system.
The accessories include an AC adapter/battery charger, short fiber cables and connectors, and
an RS-232 cable for use in conjunction with the “FOtest” and “FOdoc” programs.

Section Objectives
At the end of this section, technicians will be able to complete the following objectives:
• Recall the main function of the light source and meter
• Identify how to safely operate a meter and interpret readings
• Explain decibel ratios of output power to input power
• Know what losses (attenuation) and gains (amplification) happen while testing
• Discuss the difference between relative power and absolute power
• Recall how to calculate fiber losses through varying wavelengths

APPENDIX B: Light Source and Meter B-3

 Definitions
It is important to understand some basic terminology used in dealing with fiber optic testing and
power measurements. The most important concept is the decibel. The decibel (dB) represents the
ratio of output power to input power. The decibel does NOT represent a specific power level. It
is a logarithmic expression used to calculate “gain” or “loss” of an amplifier or other device.
dB=10 log P out/Pin
The origin of the “logarithm” is beyond the scope of this guide; however, it is important to
understand a few basic concepts. A gain or loss of 10 dB will increase or decrease the input by
a factor of ten. A -3 dB loss attenuation is a loss of half the input. A +3 dB gain (amplification)
means the output is double the input. When decibel amounts are added, the power levels are
multiplied. In the example below, there are two amplifiers and two attenuators. The input is 1
watt, and the final output is 50.

Power Flow
By adding the decibel numbers, we find the total gain is +17 dB. An easy way to determine the
total amplification or attenuation is to combine the stages in groups of 10 dB and 3 dB changes.
Adding the first three stages yields a +20 dB gain.
This is equal to an output 100 times the input or 100 watts. Remember, the dB’s are added
(10 + 10), but the power levels are multiplied (10 x 10). We can now subtract the final stage. Its
attenuation is -3 dB, which means that the output of the final stage will be half its input, or 50
watts.

Relative Power
In many applications, we need a logarithmic expression of the actual power level rather than
a ratio. A standard reference is the dBm. dBm stands for “decibels per milliwatt.” The dBm
is a relative amount of power, referenced to one milliwatt. This is useful in measuring receiver
sensitivity. A value of zero dBm is equal to 1 mw minus dBm.
(-dBm) represents a power level below one milliwatt, while plus dBm (+dBm) represents a
power level greater that one milliwatt. “Decibels per microwatt,” or dBu is sometimes used.
Since 1 uw = 1/1000 mw, 0 dBu = -30 dBm.

B-4 ROV NEW HIRE COURSE - Gulf of Mexico Region

Absolute Power
Power is measured in milliwatts or microwatts, with 1 mw = 1000 uw. The following table is
used to compare these units:
• +20 dBm = 100 mw
• +10 dBm = 10 mw
• +6 dBm = 4 mw
• +3 dBm = 2 mw
• 0 dBm = 1 mw (1000 uw) = +30 dBu
• -3 dBm = 0.5 mw (500 uw) = +27 dBu
• -10 dBm = 0.1 mw (100 uw) = +20 dBu
• -20 dBm = 0.01 mw (10 uw) = +10 dBu
• -30 dBm = 0.001 mw (1 uw) = 0 dBu

Wavelength
Fiber optic equipment operates at a wavelength above the visual spectrum; 850, 1310, and 1550
nanometers (nm) are popular wavelengths.
While 850 nm may be as visible as a red light, 1300 and 1550 nm are not visible; however, severe
eye damage from these wavelengths is possible. Please follow the appropriate safety precautions
at all times.
Prizm is a single-mode system, operating at 1310 nm.
Focal is multimode. The wavelengths are 1310 nm “uplink” and 1550 nm “downlink.”
Math Associates is also multimode and operates at 850 and 1310 nm.

APPENDIX B: Light Source and Meter B-5

 The fiber optic systems utilized on Oceaneering’s ROV systems use different wavelengths. If
testing a multimode system, testing must be conducted at both wavelengths. A multiple
wavelength source will also be used.
The following graphic shows the rated fiber losses at the various wavelengths:

Wavelength Chart

Dual Light Source

General Inspection
Verify the unit is in working order by completing the
following steps:
1. Turn the light source on and allow it to warm up for
five minutes.
2. Remove the plastic cap from the light source out- put
port and connect the appropriate patchcord (mul-
timode for 850 and 1300nm, single mode for 1310,
1490, and 1550 nm).
Note: By convention, jacketed fiber is color-
coded: yellow for single mode; orange, gray, or
another color for multimode.
3. Connect the free end of the patchcord to the power
meter and set the meter to the appropriate wave-
length. FIS Meters

B-6 ROV NEW HIRE COURSE - Gulf of Mexico Region

 4. Verify Light Source power levels read approximately:
LED sources
17 dBm (20.0 uW) @ 850 nm (multimode)
17 dBm (20.0 uW) @ 1300 nm (multimode)
LASER sources
0.0 dBm (1 mW) @ 1310 nm (single mode)
0.0 dBm (1 mW) @ 1550 nm (single mode)
0.0 dBm (1 mW) @ 1490 nm (single mode)

Button Controls
ON/OFF: Turns unit on or off. Disables power save function when held down for more than
five seconds or until LED flickers.
CW/MOD: Modulation select switch. Press to choose continuous wave or 2-kHz pulse train.
When the modulated wave is selected, the LED annunciator for currently selected source
flashes. The modulation function is for use with a fiber identifier.
SELECT SOURCE: Source select buttons. Toggles between two light sources.
Note: Only one source may be activated at a time. LED annunciator indicates the
currently active source.

Troubleshooting Guide
Symptom Possible Cause Corrective Action
Unit is completely inoperative, no keypad 1. Battery is dead 1. Replace battery
LED’s illuminate, or unit does not respond
2. Electronic control circuitry requires reset 2. Disconnect and reconnect after
to button commands
15 minutes
3. Unit malfunctioning
3. Return unit for service
Indicator LED is on, unit responds 1. Faulty patchcord or connector 1. Replace patchcord
to button commands, no power output
2. Light source emitter is faulty 2. Retuwn unit for service
measured at patchcord end
Measured power output is significantly 1. Dirty connectors 1. Inspect and clean connectors
lower than unit’s specification
2. Excessive attenuation in patchcord 2. Examine and, if necessary,
replace patchford
3. LASER emitter has fallen out of calibra-
tion 3. Return unit for service

APPENDIX B: Light Source and Meter B-7

 Power Meter
General Inspection
Verify your unit is in working order by completing the following steps:
1. Turn on the power meter and allow it to warm up for one minute.
2. Verify the display is on. The display should read between -50 dBm and -70 dBm with the
cap on (-45 dBm for CATV).
3. Remove the cap and verify the power meter responds to variations in input optical power
by alternately covering and uncovering the optical port with your hand. If the power
meter is functioning properly, the power meter reading on the display will change as the
level of light admitted to the optical port changes.
4. Verify the display change to dB when the dB/dBm button is depressed. Verify the display
changed back to dBm after hitting the dB/dBm key again.
5. Verify the display reading goes to 9 dB when the “ZERO SET” button is pressed.

Button Controls
ON/OFF: Turns unit on or off. Disables power save function when held down for more than
five seconds or until display flickers.
DB/DBM: Unit select switch. Toggles between loss unit (dB) measurements and raw power
unit (dBm) measurement. Used in conjunction with Zero Set Function.
λ: Wavelength select. Toggles among 850 nm, 1310 nm, 1490 nm, and 1550 nm for incoming
light source.
Zero set: Used only when measuring loss. Adjust display to
red 00.0 dB after reference reading is obtained with patchcord
connected along. Enables user to read loss measurement (in dB)
of fiber under test directly from display. Eliminates need for
subtraction. Each wavelength may be set with a unique 00.0 dB
reference point, and each reference reading is held in memory until
reset.

Fluke Meters

B-8 ROV NEW HIRE COURSE - Gulf of Mexico Region

Troubleshooting Guide

Symptom Possible Cause Corrective Action

LCD display is blank; unit will not turn on 1. Battery is dead 1. Replace battery

2. Electronic control circuitry requires 2. Disconnect and reconnect after 15

reset minutes

3. Unit malfunctioning 3. Return unit for service

LCD display reads significantly below 1. Photo detector lens dirty 1. Remove adapter and clean lens
expected power level
2. Patchcord connector ends dirty or 2. Clean connectors, replace patchcord
patchcord faulty if necessary

3. Check input light source

LCD display is on; unit does not respond Electronic control circuitry requires reset Disconnect battery and reconnect after 15
to button commands minutes

Taking Power and Loss Measurement

To take loss measurements in a patchcord (connectorized on both ends) the following items are
needed:
• 1 light source
• 1 power meter
• 1 reference patchcord (cord #1)
• 1 test patchcord (cord #2)
• 1 mating sleeve
Note: Before beginning the test, allow the unit a five-minute warm up and ensure all connector
ferrules are clean. Fiber optic connectors account for the most significant source of loss (or
attenuation) in fiber optic links. The loss incurred by a system due to length of the fiber used is
usually negligible for short distances.
To accurately measure connector losses, the “connectorized” end of the fiber under test must be
isolated from the light source. This is necessary to more closely simulate the loss characteristics
of the connector when joined to another connector - as it would actually appear on a fiber optic
link. For this reason, the use of a reference cord is necessary.

APPENDIX B: Light Source and Meter B-9

 Pre-test Setup
Step 1: Determine the power level of the light exiting the reference patchcord.
Step 2: Determining the loss of a patchcord may be done in two different ways. One way is to
record the power (reference) level and perform subtractions. The second (and simpler) method
is to use the “Zero Set” feature present on all FIS OV Series power meters. Both methods are
described here.

Test Setup
Step 1: Obtain a reference power level prior to measuring loss in the fiber-optic patchcord.
Depressing the ZERO SET button here eliminates the need for subtraction. Optical mandrel
shown in the diagram is for the purpose of stripping out cladding modes from multimode fiber.
Note: The mandrel must be secured in place for testing. The mandrel is not required for a single
mode fiber.
The setup and first step for both the zero set method and for the subtraction method are
identical. You must first connect one end of the reference patchcord to the light source and
the other end to the power meter. Wrap this patchcord three to four times around the mandrel
(or loosely around a highlighter pen) to disperse any light that may be entering the patchcord
through the cladding (cladding modes). It is very important to make sure all connections are
physically secure and cannot move while taking measurements. Movement of the patchcords or
test equipment involved will cause fluctuating or “stray” readings. Securing the patchcords to a
flat surface with masking tape is recommended. Once connections are physically secure, ensure
both the light source and power meter are set for the same wavelength. You are now ready to
read the reference power level. It is at this point the two methods differ. If using the subtraction
method, record the dBm reading. If using the zero set method, proceed to the next step.
Step 2: At this point, depress the ZERO SET button. Notice this will have two different effects
on the display. The display will simultaneously be set to read 00.0, and the units will change from
dBm (power measurement units) to dB (loss measurement units).
Disconnect the connector from the power meter and insert this Test Setup for Steps 2-4.
After obtaining a reference using patchcord #1, this setup allows you to measure the loss of
patchcord #2. The use of the ZERO SET button in the previous step enables you to read the
loss measurement directly from the meter display in units of dB.
Remove reference Patchcord #1 from the power meter and connect it to the mating sleeve.
Insert one end of patchcord #2 (the cord to be tested) into the open side of the mating sleeve
and the other end of this patchcord into the power meter. At this point, you may directly read
from the meter. The loss (in dB) that would be incurred from inserting patchcord #2 into a fiber
optic system.
Step 3: If using the subtraction method, you will not have depressed the ZERO SET button. After
having connected patchcord #2, read the second power level reading from the meter display (Example:
-17.5 dBm). Subtract the first reading from the second (Example: -17.5 - [-17.1 dBm] = -0.4 dB). The
B-10 ROV NEW HIRE COURSE - Gulf of Mexico Region
difference between the two readings is the typical loss (in decibels, not dBm) that will be incurred
by insertion of patchcord #2 into a fiber optic system. This loss figure represents the loss of one
connector and one mating sleeve as well as the loss incurred from the length of fiber itself.
Step 4: It is recommended to take a second reading by switching the connector locations of the
patchcord under test (patchcord #2) at the mating sleeve and power meter. Again, subtract the
results from the reference reading and record this result. By averaging these two figures, any
potential error caused by a difference between the two connectorized ends of the fiber under
test (fut) will be minimized.
Note: Up to three unique zero references (one for each wavelength) may be stored in the power
meter’s memory. Zero references will stay in memory until reset by pressing the ZERO SET key.
Zero references are not lost from memory when unit enters sleep mode or when unit is turned
off.

Continuous Wave/Modulation Function

The light source continuous wave/modulation function enables the user to distinguish
individual fiber conductors from one another by sending a pulse of varying intensity through
the fiber already installed in a network. Depressing the CW/MOD key generates a two kilohertz
square-wave pulse that may be detected through the use of a fiber identifier (sold separately).
A fiber identifier clamps on the outside of a fiber under test and detects the presence of light
through the jacket.
Note: The handheld power meter is designed to measure primarily continuous wave (cw)
light sources. A modulated light source may produce erratic power meter readings under most
circumstances.

Minimizing Error in Test Procedures

Accurately measuring power and loss in fiber optic systems is generally more difficult than in
comparable electrical networks. Fiber optic systems are highly susceptible to fluctuating readings
induced by movement, temperature variation, and loosely mated or dirty/damaged connectors.
Physically securing patchcords to a work surface with adhesive tape prior to taking readings is
a common and highly recommended practice. Additionally, it is common practice to frequently
clean connector ends with lint-free tissue prior to making connections. Please note fiber optic
connectors will exhibit wear over time through repeated mating and un-mating.

APPENDIX B: Light Source and Meter B-11

 Temperature Stability
The operating temperature for FIS hand held-test equipment is between +14˚F to +122˚F
(-10˚C to +50˚C). Although there is little difference in the detection characteristics of the power
meter with variations in temperature (particularly above freezing (32˚F [0˚C]), light source
output power will vary slightly with changes in temperature. This variability is most prominent at
temperatures below freezing. For optimum results, all readings (reference, raw power, and loss)
should be obtained at a constant surrounding (or ambient) temperature after the five-minute
warm up time.

SimpliFiber Pro

BW Fluke
1. On/off key.
2. Softkeys - provide functions related to the current display. The functions are displayed
above the keys.
3. Selects the meter’s measurement mode. To enter setup mode, hold down MODE button
for four seconds.
4. LCD display.
5. Input port with interchangeable connector adapter.
6. USB port for uploading test records to a PC.
7. Selects auto wavelength mode; the AUTO LED lights; press λ to change the wavelength;
the wavelength LEDs indicate the wavelength.
8. Switches between continuous wave and 2 kHz modulated output signals; the CW/2 kHz
LED lights if the output is continuous; it blinks if the output is modulated; use these
modes if using the source with a meter other than a SimpliFiber Pro meter; also enables
or disables auto power-off.
9. Selects FindFiber mode; the ID LED lights if the source is in FindFiber mode.
10. The LOW BATTERY LED blinks continuously if the battery is low; the LED blinks oc-
casionally if auto power-off is disabled.
11. Output port with SC adapter.
B-12 ROV NEW HIRE COURSE - Gulf of Mexico Region
Battery Installation, Life, and Status

Back Cover

Note: Fluke Networks recommends alkaline batteries.

Device Battery Life Low Battery Indicator

Meter >50 hours (blinks continuously)

Multimode source 40 hours LOW BATTERY LED blinks continuously

Single mode sources 30 hours

FindFiber source >80 hours LED blinks continuously

APPENDIX B: Light Source and Meter B-13

 Meter Display Features

Front Display

1. Indicates that pressing F1 or F2 scrolls through choices in the current mode.

2. Indicates that pressing F1 saves the power or loss measurement.
3. Label for the record number. VIEW RECORD indicates the meter is displaying saved
measurements.
4. Label for the reference level in loss mode; dBm is the measurement unit for the reference
level.
5. Indicators for CheckActive™ mode; CheckActive™ indicates the meter is testing for
fiber activity.
6. Numeric display with units for loss (dB) and power measurements (mW, μW, dBm).
7. Numeric display for the wavelength.
8. Indicates the meter is testing for a FindFiber source; ID is the label for the source’s iden-
tification number, which appears on the numeric display (6).
9. The meter is measuring power.
10. The meter is measuring power loss.
11. Low battery indicator.
12. The meter detects a 2 kHz modulated optical signal.
13. The meter is connected to a PC through the USB port.
14. The meter detects a wavelength identifier in the optical signal.

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 15. The operation succeeded (OK) or failed .
16. Indicators for maximum (Max) and minimum (Min) power measurements.
17. Indicates that pressing F3 deletes the current record; DELETE ALL? indicates that
pressing F3 deletes all records.
18. Indicates that pressing F3 saves the power measurement as the reference value.
19. Indicates that pressing F2 changes the wavelength being measured.

Setting User Preferences

For the meter:
1. To enter setup mode, hold down MODE for four seconds.
2. To scroll through the setup items, press MODE. To change settings, press F1 .
3. To exit setup mode, press MODE until the meter is in the desired test mode.

Meter Setup Item Choices

Enable or disable Min/Max mode for power measurements.

Select a unit for power measurements.

Turn the backlight off or on.

Select a time period for the meter to turn off automatically if no keys are pressed. The
meter will not turn off if it is connected to a source that is in AUTO or ID mode. Dashes
( - - ) indicate auto power-off is disabled.

For the Source

If auto power-off is enabled, the source turns off after 30 minutes if no keys are pressed.
To disable or enable auto power-off, hold down MODE for four seconds.
1. If auto power-off is enabled, all LEDs turn on for three seconds.
2. If auto power-off is disabled, all LEDs blink for three seconds and the LOW BATTERY
LED blinks occasionally.

Auto Wavelength Mode

In auto wavelength mode, the source’s signal includes an identifier that tells the meter which
wavelength to measure. The source can be set to one wavelength or to automatically switch
between wavelengths. When the source is automatically switching, the meter can automatically
measure loss or power at each wavelength in one test. By saving the measurements, the meter
saves all wavelengths measured in one record.
APPENDIX B: Light Source and Meter B-15
 To set the source to auto wavelength mode:
1. If the AUTO LED is not on, press AUTO.
2. Press λ to manually switch wavelengths (one wavelength LED is on) or to set the meter
to automatically switch between wavelengths (wavelength LEDs blink alternately). If the
meter detects the auto wavelength signal, AUTO appears on the display, and the meter
automatically measures at the correct wavelength.

Cleaning Connectors and Adapters

Always clean and inspect fiber connectors before making connections. Use fiber optic solvent
and optical-grade wipes or swabs to clean connectors.

Cleaning Bulkhead Connectors (sources and patch panels)

1. Touch the tip of a fiber optic solvent pen or swab soaked in solvent to a lint-free dry
wipe or fiber cleaning card.
2. Touch a new, dry swab to the solvent spot on the wipe or card.
3. Push the swab into the connector, twist it around three to five times against the end-face;
then remove and dispose of the swab.
4. Dry the connector with a dry swab by twisting it around in the connector three to five
times.
5. Inspect connectors with a fiber microscope.

Cleaning the Meter’s Connector

1. Remove the connector adapter to expose the photodiode lens.
2. Use the method described in steps 1 and 2 in the section above to dampen a swab with
solvent.
3. Twist the damp swab around the lens three to five times; then twist a dry swab around
the lens three to five times.

Cleaning Fiber Adapters

Periodically clean fiber adapters with a swab and fiber optic solvent. Dry with a dry swab before
use.

Cleaning Connector Ends

1. Touch the tip of a fiber optic solvent pen or swab soaked in solvent to a lint-free dry
wipe or fiber cleaning card.
2. Wipe the connector end-face across the solvent spot, then back and forth once across
the dry area of the wipe or card.
Note: Some connector styles, such as VF-45, may require a different cleaning method. Always

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cover unused connectors with protective caps. Clean caps periodically with a swab or wipe and
fiber optic solvent.

Changing the Connector Adapter

You can change the meter’s connector adapter to connect to SC, ST, and LC fiber connectors.
Additional adapter styles may be available.

Cover all connectors with dust caps when not in use.

Store extra connector adapters in the canisters provided.
Do not touch the photodiode lens.

Do not over tighten the adapter or use tools to tighten the adapter.
To install a connector adapter, refer to the picture below and complete the following steps:
1. Locate the slot in the meter’s connector and the key on the adapter ring.
2. Holding the adapter so it does not turn in the nut, align the adapter’s key with the meter
connector’s slot and slide the adapter onto the connector.
3. Screw the nut onto the meter connector.

Changing Connector Adapter

APPENDIX B: Light Source and Meter B-17

 Detecting Active Fibers
The meter’s CheckActive™ mode lets you quickly determine if a fiber is connected to active
equipment. This mode helps you locate active links and avoid exposure to hazardous radiation.
To use CheckActive™ mode:
1. Press MODE until CheckActive™ appears.
2. Connect the meter to a fiber. The meter indicates fiber activity as shown in the figure
below.
Note: Ambient light can activate the CheckActive™ tone. To avoid this, keep a patch cord
connected to the meter if the meter is in CheckActive™ mode.

Detecting Active Fibers

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Locating Fibers
FindFiber™ mode helps you quickly identify link connections at patch panels. To use
FindFiber™ mode:
1. Connect the meter and a SimpliFiber™ source or one or more FindFiber™ sources to
the links as shown in the figure below.
2. Turn on the meter and the source or FindFiber™ sources.
3. On the meter, press MODE until FindFiber™ appears.
4. The meter indicates connectivity as shown in the table below:

Locating Fibers

Source Connected ID Number on the Meter

SimpliFiber Pro multimode source

SimpliFiber Pro single mode source 1310/1550 nm

SimpliFiber Pro single mode source 1490/1625 nm

FindFiber source Number indicated by the source’s LED

No continuity or incompatible source connected

APPENDIX B: Light Source and Meter B-19

 Measuring Optical Power
The power measurement shows the optical power level produced by a source such as an optical
network interface card or optical test equipment.
1. Clean the connectors on the link to be tested. Use fiber optic solvent and optical-grade
wipes or swabs to clean connectors.
2. On the meter, press MODE until POWER appears.
3. Make the connections like in the pictures below.

Measuring Optical Power

4. If the source’s AUTO LED is not on, press AUTO.

5. If you want the source to automatically switch wavelengths, press λ until the wavelength
LEDs blink alternately, or you may press λ to switch wavelengths as needed.
6. To save the measurement, press F1 SAVE.

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Optical Meter Display

Measuring Optical Power

1. The wavelength being measured.

2. Indicates the meter is in auto wavelength mode.
3. The power measurement.
4. Pressing F3 SET REF saves the measured power level as the reference and switches the
meter to loss measurement mode.
5. Pressing F1 SAVE saves the measurement. If the source was automatically switching
wavelengths, the meter saves measurements for all wavelengths in one record.

Using the Min/Max Function

The Min/Max function shows the minimum and maximum power levels measured for each
wavelength.
To enable the Min/Max function:
1. On the meter, hold down MODE for four seconds to enter setup mode.
2. Press F1 so appears.
3. Press MODE until POWER appears; then press M again to see the Min/Max measure-
ments. The meter shows the minimum (Min) and maximum (Max) power levels mea-
sured since you entered the power measurement mode at the selected wavelength.
4. To switch between minimum and maximum values, press F1 .
Notes: The meter records new minimum and maximum values each time the wavelength
APPENDIX B: Light Source and Meter B-21
 changes. You cannot save power measurements or set the reference if Min or Max
appear on the display.

Min/Max Function

Measuring Loss
The loss measurement shows how much optical power is lost in a link’s fiber and connectors.

About 1 Jumper Connections

The reference and test connections shown in this section produce 1 Jumper results. 1 Jumper
results include the loss of the fiber plus the loss of the connections at both ends of the link.
This is the most commonly used method for testing installed fiber links.
1 Jumper connections require connector adapters that match the connectors in the link under
test.

Testing the Test Reference Cords

Why You Must Do This Test
To get accurate measurements of loss, you must use high quality test reference cords that are in
good condition and comply with ISO/IEC 14763-3. Measurements of optical power loss are
very much affected by the condition of the end faces on the fiber connectors. Dirty end faces
and end faces with damage are the most common causes of problems in fiber links.

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When You Must Do This Test
Test your test reference cords at these times:
• At the start of each day
• When you move your equipment to a different area
• When you change your equipment to test links that have a different type of connector
After you do the test given, use the procedure given with the procedures for certifying cabling to
monitor the condition of the cords.

Equipment You Must Have

SimpliFiber Pro Fiber Cleaning Supplies Microscope Test Reference Cord Single Mode Adapter

SimpliFiber™ Pro optical power meter: Use the connector adapter that connects to the cords
you will test.
Fiber cleaning supplies.
A microscope for inspecting fiber connectors (the FT500 FiberInspector Mini Video
Microscope is shown).
A test reference cord that you are sure is good. One connector is SC. The other connector is the
same as on the cords you will test.
Single mode adapter for the connectors on the cords you will test.
A fiber microscope, which you must have to do this procedure. You cannot be sure your
cords are good unless you can examine the end faces on the connectors. An end face that is
dirty or has damage can give a good loss measurement but can cause problems later.

Clean and Inspect the Connectors

1. Test reference cords must have end faces that are clean and have no damage. Always use
correct procedures to clean end faces.
2. After cleaning an end face, use a fiber microscope to examine the end face. The pictures
on the next page show examples of what can be see with a fiber microscope.

APPENDIX B: Light Source and Meter B-23

 A clean end face that has no damage. This is the only condition acceptable for
a test reference cord.

Clean End Face

Dirt that is not on the core does not change the loss measurement, but the dirt
can move when the fiber is connected.

Dirt ot in the Core

Dirt is on the core. Also, there are scratches that were caused by incorrect
procedures for cleaning.

Dirt in the Core

The cladding has damage. This does not change the loss measurement but can
cause damage to other end faces.

Damaged Cladding

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Set the Reference
1. Set the reference.
2. Make sure the reference value is good:
• For 50/125 μm fiber, the reference value must be better than -24.50 dBm (for
example, -23.50 dBm is a better value).
• For 62.5/125 μm fiber, the reference value must be better than -20.00 dBm (for
example, -19.50 dBm is a better value).
• For 9/125 μm fiber, 1310/1550 nm, the reference value must be better than -8.00
dBm (for example, -7.50 dBm is a better value).
• For 9/125 μm fiber, 1490/1625 nm, the reference value must be better than -4.00
dBm (for example, -3.50 dBm is a better value).
3. If the value is not good, do the reference procedure again with a different test reference
cord.

Test the Cord in Both Directions

1. Disconnect the test reference cord from the meter.

Disconnect the Cord

2. Connect the cord you want tested.

Connect the Cord

APPENDIX B: Light Source and Meter B-25

 3. On the meter, press MODE until LOSS appears.
4. If the source’s AUTO LED is not on, press AUTO.
5. If you want the source to automatically switch wavelengths, press λ until the wavelength
LEDs blink alternately, or you may press λ to switch wavelengths as needed.
Note: If you are not using a SimpliFiber Pro source, set the source to the desired wavelength
and to continuous wave output. On the meter, press F2 λ to select the wavelength generated by
the source.
6. Compare the loss measurement to these limits:
• Multimode test reference cord: 0.10 dB or less
• Single mode test reference cord: 0.20 dB or less
If the connectors show no contamination or damage, but the loss is higher than these limits, the
cord does not comply with ISO/IEC 14763-3. Do not use the cord as a test reference cord.
7. Connect the cord in the opposite direction, then repeat step 6.

Connect the Cord

About Referencing
The reference serves as the baseline power level for loss measurements. Regular referencing
helps account for minor variations in source power and connection integrity. Also, since the
reference is the baseline for measurements, the losses of the test reference cords and adapters
used for referencing are excluded from test results.
For the most accurate test results, you should set the reference at these times:
• At the beginning of each day
• Anytime you reconnect a test reference cord to the source
• Anytime you see a negative loss measurement

Setting the Referencing

You may set the reference from power or loss mode. Fluke Networks recommends using power
mode because the meter shows the actual power level produced by the source. In loss mode, the
meter shows the difference between the power level and the previous reference level.

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To set the reference:
1. Clean the connectors on the meter, source, and a test reference cord. Use fiber optic sol-
vent and optical-grade wipes or swabs to clean connectors.
2. Turn on the meter and source and let them warm up for five minutes. Allow additional
time if the equipment has been stored above or below ambient temperature.
3. Make the connections shown in the picture below.

Test Reference Cord

4. If the source’s AUTO LED is not on, press AUTO.

If you want to set the reference for both wavelengths, press λ until the wavelength LEDs
blink alternately.
Note: If you are not using a SimpliFiber™ Pro source, set the source to the desired wave-
length and continuous wave output.
5. On the meter, press MODE until POWER appears.
Note: You cannot set the reference if Min or Max appears on the display. Setting the reference
from power mode allows you see the source’s power level before saving it as the reference level.
You may also set the reference from loss mode.
6. Press F3 SET REF. The meter switches to loss mode, the display shows 0.00 dB, OK ap-
pears briefly, and the new reference value appears.
If the reference value is less than -60 dBm or if the source is in ID or 2 kHz mode, the meter
briefly shows and . Check the connections and the source’s mode or try setting
the reference again using another test reference cord.
If you disconnect the source’s output after setting the reference, you must set the reference
again to ensure valid measurements.

APPENDIX B: Light Source and Meter B-27

 Measuring Loss
1. Set the reference as described on the previous page.
2. Clean the connectors on the link to be tested and on a second test reference cord. Use
fiber optic solvent and optical-grade wipes or swabs to clean connectors.
Disconnect the test reference cord from the meter; then make the connections shown in the
picture below.

Measuring Loss

Do not disconnect the test reference cord from the source’s output. If you do, you must
set the reference again to ensure valid measurements.
3. On the meter, press MODE until LOSS appears.
4. If the source’s AUTO LED is not on, press AUTO.
5. If you want the source to automatically switch wavelengths, press λ until the wavelength
LEDs blink alternately, or you may press λ to switch wavelengths as needed.
Note: If you are not using a SimpliFiber™ Pro source, set the source to the desired
wavelength and to continuous wave output. On the meter, press F2 λ to select the wavelength
generated by the source.
6. To save the measurement, press F1 SAVE. The meter briefly shows the record number
and OK.

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 If the source was automatically switching wavelengths, the meter saves measurements for all
wavelengths in one record.

1. The wavelength being measured.

2. Indicates the meter is in auto wave-
length mode.
3. The loss measurement. If the loss
measurement is blinking, the loss is
negative and less than -1.0 dB.
4. The reference value.
5. Pressing F3 SET REF saves the
measured power level as the reference.
6. Pressing F1 SAVE saves the
measurement. If the source was
automatically switching wavelengths,
the meter saves measurements for all
wavelengths in one record.
Measuring Loss

If Loss is Negative
A negative loss measurement means the reference power level is less than the measured power
level. This can be caused by the following:
• The fiber ends were dirty during referencing.
• The connections to the source were disturbed after referencing.
• There was a kink in a test reference cord during referencing.
• The connectors were not properly aligned during referencing.
• The meter and source were not set to the same wavelengths during referencing or testing.
• The testers were much colder during referencing than during testing.
• You did not allow enough time for the source to warm up before setting the reference.
• You measured loss on a fiber that is shorter than the test reference cord used to set the
reference.
If loss is negative, set the reference again and retest the link.

Memory Functions
The meter stores up to 1000 loss or power records. If memory is full, the meter shows
when you try to save a measurement.

APPENDIX B: Light Source and Meter B-29

 Viewing and Deleting Records
To view records, press MODE until
VIEW RECORD appears.
1. The wavelength and the
measurement. If the record
contains measurements for
multiple wavelengths, the
display alternates between the
measurements.
2. The record number.
3. To delete the record you are
viewing, press F3 DELETE
twice.
If you delete a record below the
highest record number, the meter Viewing and Deleating Records
does not reuse the empty memory
location. Deleted records show for the measurement.
To delete all records, hold down F3 DELETE until DELETE ALL? appears; then press F3
again.
4. Press F1 or F2 to stroll through records.

Uploading Records to a PC
1. Install the latest version of LinkWare software on your PC.
2. Turn on the meter.
3. Connect the meter to the PC with the USB cable provided,
as shown in the picture to the right.
4. Start LinkWare software on the PC.
5. Click Import on the LinkWare tool bar; then select Sim-
pliFiber™ Pro.
6. Enter project information; then click OK.
7. Import all records from the meter or select records to im-
port. Computer

Note: The meter’s record numbers are in the Cable ID column in LinkWare.
8. To delete all records in the tester, select Utilities > SimpliFiber™ Pro > Delete All Tests
in Memory.

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Maintenance

WARNING!
To avoid possible fire, electric shock, personal injury, or damage to the tester:
• Do not open the case. No user-serviceable parts are inside.
• Replacing electrical parts yourself will void the tester’s warranty and might compromise
its safety features.
• Use only specified replacement parts for user-replaceable items.
• Use only Fluke Networks authorized service centers.

Cleaning
Clean the display with glass cleaner and a soft, lint-free cloth. Clean the case with a soft cloth
dampened with water or water and mild soap.
To avoid damaging the display or the case, do not use solvents or abrasive cleansers.

Checking the Meter’s Software Version and Calibration Date

Turn the meter on while holding down the F2 and F3 keys.
Use F1 to toggle between the following:
• : Software version
• : Factory calibration date. The day and month (DDMM) is on the top line, and the
year (YYYY) is on the bottom line.
To exit this mode, turn the meter off.

Loss Test Methods

The number of fiber connections represented in loss test results depends on the reference and
test connections. This section describes the three common methods: 1 Jumper, 2 Jumper, and 3
Jumper.

1 Jumper Method
Results from the 1 Jumper method account for the loss of two connections plus the fiber in the
link. This method is suitable for testing premises fiber, where patch cords are typically used at
both ends of the link and connector loss is a significant portion of the total loss.
1 Jumper reference connections cancel out the effects of the test reference cords, as shown on
the next page.
Loss results for the 1 Jumper method, therefore, represent both connections plus the fiber
in the link. ANSI/TIA/EIA-526- 14A and 526-7 specify the 1 Jumper method for testing

APPENDIX B: Light Source and Meter B-31

 multimode and single mode premises fiber where connector loss is a significant portion of the
total loss.

Loss Test Method

2 Jumper Method
Results from the 2 Jumper method account for the loss of one connection plus the fiber in the
link. This method is suitable for links where the fiber’s loss is a significant portion of the total
loss, such as when the link is long or a patch cord is used at only one end.
2 Jumper reference connections cancel out the effects of one connection and two test reference
cords, as shown in the picture below.
The test connections add one connection, plus the fiber in the link, to each path. Loss results
for the 2 Jumper method, therefore, represent only one connection plus the fiber in the link.
Because the results omit one connection, ANSI/TIA/EIA-526- 14A and 526-7 do not
recommend the 2 Jumper method for testing premises fiber where patch cords are typically used
at both ends of a link and connector loss is a significant portion of total loss.

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2 Jumper

APPENDIX B: Light Source and Meter B-33

B-34 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Appendix C
Megohmmeter

Morgan City Training Center

C-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

C-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
Insulation testers are used to check for proper electrical isolation on wiring and other devices.
These pieces of test equipment are also known as “megohmmeters” or simply “meggers.”
The most common applications of this tool include testing deck leads, wiring, and electrical
motors. This module will cover the basic uses for the megger, what to do, and, equally
important, what not to do in order to avoid injury and equipment damage.

Section Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Recall how megohmmeters work
• Identify what a megohmmeter can measure and how it works
• Recall the most common applications of use
• Describe when to use the guard terminal and why
• Understand how to use the meter safely in high voltage conditions
• Identify the various functions and abilities of the meter by using the animated simulation

Simpson Model 405 Amprobe AMB 5KV

Simpson Model 501 Fluke 1550b

APPENDIX C: Megohmmeter C-3

 Theory of Operation
This instrument can be used to measure the insulation of the equipment. It will apply the
requested voltage to the object being tested, measure the circulating current, and calculate the
relevant insulation resistance.
When measuring, the instrument simultaneously detects and displays the resistance, making it
possible to calculate its variation through time.
Insulation depends on the dimension and physical properties of the material involved. From
an electrical point of view, insulation appears as resistance, of course, of a very high value. The
higher the resistance, the better the insulation is. If the resistance diminishes as the voltage is
increased, the insulator is not of good quality.
Each kind of material has its maximum permissible voltage, depending on its thickness. When
this value is exceeded, the insulation may be perforated (discharged).
Testing should be stopped if the insulation resistance decreases drastically.

Types of Megohmmeters Used on Oceaneering

Systems
Many types of meggers are in use on Oceaneering’s systems. The Simpson Model 405 is still
being used on many systems.
Other models may be found on some systems. The Simpson, megger, and Fluke have various
models available, including the 1550b, which we will be using as an example in this module.

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Fluke 1550b Features
The Fluke 1550B MegohmMeter (hereafter “the meter”) is a high voltage insulation tester for
testing general circuits, including switchgear, motors, and cables.

Fluke 1550b Features

The meter has the following features:
• Large liquid crystal display (LCD) with text display
• Five pre-set test voltage: 250 V, 500 V, 1000 V, 2500 V, and 5000 V
• Programmable test voltage: 250 V to 5000 V (50/100 V steps)
• Resistance measurement:0 Ω to 1 Ω
• Polarization index (PI) measurement
• Dielectric absorption ratio (DAR) measurement
• Ramp mode that linearly increases (100 V/s) the applied test voltage
• Test timer and storage for test results with user settable ID tag
• Breakdown voltage indication
• Infrared (IR) port for downloading test data
• PC software supplied

APPENDIX C: Megohmmeter C-5

 Symbols
Symbols on the meter and in the course are explained below:

Symbol What It Means

Conforms to European Union standards

TUV guide

This product complies with UL3111-1, CAN/CAS C22.2

No. 1010.1 for test and measurement equipment

Risk of danger - See the Fluke 1550b manual for information

Hazardous

Equipment is protected by double or reinforced insulation

Do not use in distribution systems with voltages higher than 660 V

Interference may be present. Displayed value might be outside of specified accuracy.

Ramp mode indicator

Electrical breakdown

Volts AC

Earth ground

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Using the Guard Terminal
For most tests, only two test leads are used connecting the positive (+) and negative (-) terminals
on the meter to the circuit under test. The guard (G) terminal is left unconnected.
When measuring very high resistances, you can obtain accurate readings by making a three-
wire measurement using the guard terminal. The guard terminal is at the same potential as the
negative (-) terminal and can be used to prevent surface leakage or other unwanted leakage
currents from degrading the accuracy of the insulation resistance measurement.
The top picture shows how to measure the resistance from one of the conductors to the outer
shield. In this case, there is a leakage current along the surface of the inner insulation near the
end of the cable. This leakage adds to the current the negative terminal detects and will cause
the meter to read a lower resistance than it should.
The second picture shows how to prevent surface current leakage by connecting a lead from the
guard.

APPENDIX C: Megohmmeter C-7

 Taking Measurements
Connecting to the Circuit Under Test

To avoid possible electric shock or personal injury, remove all power from the circuit under test and
discharge circuit capacitance before testing a circuit with the meter. Connect the test leads to the meter
inputs before connecting to the circuit under test. Before and after testing, confirm the meter does not
indicate the presence of a hazardous voltage at the terminal(s). If the meter beeps continuously and a
hazardous voltage is shown on the display, disconnect test leads and remove power from the circuit under
test.

To connect the circuit under test:

1. Rotate the safety shutter to expose the terminal connections.
2. Insert the test leads in the terminals shown in the diagram and connect the test leads to
the circuit under test.

Megger Body

Options to Consider Before Making an Insulation Test

In addition to performing a basic insulation test, the meter includes a series of features and
functions that allow you to more precisely tailor the test to your requirements. These include
defining a test voltage, selecting a ramp test, setting a time limit (duration) for the test,
measuring the polarization index (PI), measuring the dielectric absorption ratio (DAR), and
measuring capacitance. Each of these features is described in the following paragraphs. These
features can be used in combination and should be set, cleared, or accounted for (as appropriate)
before initiating an insulation test.

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Selecting a Pre-Set Test Voltage
To select a pre-set test voltage:
1. With the meter turned on, press the function button to select test voltage.
2. Press the UP or DOWN button to scroll through the pre-set test voltage options (250 V,
0 V, and 5,000 V).
The selected test voltage appears in the upper right area of the display.

Test Volatage

Programming a Test Voltage

To set a test voltage in between the pre-set test voltages, proceed as follows:
1. With the meter turned on, press the function button to select test voltage.
2. Press the UP or DOWN button to scroll through the pre-set test voltage options (250 V;
500 V; 1,000 V; 2,500 V, and 5,000 V). Select the voltage closest to the level required.
3. Press the enter button. TV=xxxxV appears flashing in the lower-left area of the display.
4. Press the UP and DOWN buttons to increment and decrement the voltage. When the
correct voltage level shows, do not press the enter button. Doing so will return the test
knowledge to the next lowest last pre-set voltage selection. Instead, press the function
button to go to the next function.

The actual test voltage can be up to 10% higher than the selected voltage.

Selecting a Ramp or Steady-State Test

The ramp-test function is an automated test that checks insulation for a breakdown. During a
ramp test, the output voltage starts at 0 V and increases linearly (100 V/s) until it reaches the

APPENDIX C: Megohmmeter C-9

 specified test voltage or until a sudden drop in measured resistance is detected. Then, the ramp
stops, the test voltage drops to zero, and the voltage at the breakdown point is stored in memory
on the meter. All other test results are declared invalid if the test does not reach the specified
test voltage. If the test successfully meets compliance without breakdown, the only valid test
results are test voltage and insulation resistance.

To enable or disable the ramp function, proceed as follows:

1. With the meter turned on, press the function button to select RAMP test.
2. Press UP or DOWN to toggle the ramp on or off.
If the ramp is on, the ramp icon will blink in the upper left-hand corner of the display.

Setting a Timed Test

You can control the length of an insulation test by setting a timer. The time (test duration) can
be set in one-minute increments up to 99 minutes. During a timed test, the time limit appears on
the right bottom of the display, and the elapsed time is shown in the middle of the display. At
the end of the elapsed time, the insulation test has been completed, and the test is terminated.
To enable or disable the ramp function, proceed as follows:
1. With the meter turned on, press the function button to select the time limit.
2. Repeatedly press the UP button to increment and set the test time (in one-minute inter-
vals).

Polarization Index (PI)

As part of the insulation test, the meter measures and stores polarization index (PI) when
appropriate. Since, by definition, a polarization index test requires 10 minutes to complete, it is
measured and stored as invalid data for all insulation tests under 10 minutes. When an insulation
test is 10 minutes or more, the polarization test is completed and stored. The results are available
for display during a test by pressing the R button or by storing the test results and scanning the
RESULTS fields. The field is identified by:

R x 10 min
PI = ————————
R x 1 min

Dielectric Absorption Ratio

As part of the insulation test, the meter measures and stores dielectric absorption ration (DAR)
when appropriate. Since, by definition, a DAR test requires one minute to complete,
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it is measured and stored as invalid data for all insulation tests under one minute. The field is
identified by:

R x 1 min
DAR = ——————
R x 30 min

Measuring insulation resistance requires the application of potentially dangerous voltages to the circuit.
This may include exposed bonded metal work. To avoid possible electric shock or personal injury:

• Remove all power from the circuit under test and discharge circuit capacitance before
testing a circuit with the meter.
• Before proceeding, ensure the installation is wired correctly and no personnel are
endangered by any tests.
• First, connect the test leads to the meter inputs before you make the connection to the
circuit under test.

Performing an Insulation Test

To perform an insulation test, use the following procedure:
1. With the meter turned on, set the available measurement options to meet your test re-
quirements. These include
• test voltage – set range: 250 V to 5,000 V (50 V / 100 V increments)
• ramp test – toggle On or Off
• time limit – no minimum limit; max limit of 99 minutes

To avoid possible electric shock or personal injury before and after testing, confirm that the meter does not
indicate the presence of a hazardous voltage at the terminals.

2. Connect the probes to the circuit you want to test.

3. Press the T button for approximately one second in order to start the insulation test.
The meter beeps three times as the test begins, and the W icon flashes on display,
indicating potentially hazardous voltages may be present on the test terminals.
Once the circuit has been stabilized, the digital display indicates the measured insulation
resistance. The bar graph displays this value continuously (in real time) as a trend.

APPENDIX C: Megohmmeter C-11

 Any of the following conditions immediately terminates an insulation test:
• User stop (pressing the T button)
• Timer limit reached
• Interference on the test circuit
• Breakdown occurs with ramp test enabled
• Battery depleted
Should breakdown occur with the ramp test enabled, press the E button before going to
step 4.
Following the termination of an insulation test, the meter beeps when a potentially
hazardous voltage remains on the test terminals due to charged-circuit capacitance or
from the presence of an external voltage.
4. When the test is terminated, STORE RESULT displays. If appropriate, store the test re-
sults as described in the next procedure. The meter contains enough memory to store the
results of up to 99 insulation tests for future reference. Otherwise, terminate the STORE
RESULT prompt by pressing the D button.

Storing the Results of an Insulation Test

To store the results of an insulation test, use the following procedure:
1. Press UP to save the measurement results. The meter will assign and display a sequential
tag number (00 to 99) to identify the measurement.
2. If the tag number is acceptable, press the ENTER button to store the data. If a differ-
ent tagging convention is required, proceed as follows to provide a custom four-character
tag.
a. Notice that an * is blinking on the display. This is the first of the four characters
available for tagging the test results. Repeatedly press the scroll button to cycle
through the character positions.
b. At each character position, use the UP and DOWN buttons to assign a character (0-9,
A-Z).
c. Press the ENTER button to store the results.
The meter can store 99 sets of test data, including the following options:
• Tags
• Rap on or off
• Insulation resistance
• Timer reading at termination of test (timer)
• Test voltage selected (TV)

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 • Actual test voltage (V)
• Capacitance (C)
• Polarization index (PI)
• Dielectric absorption ratio (DAR)
• Test current (I)
• Reason for ending the test
• Limit-off or timer setting (1 to 99 minutes) (T. Limit)
To view stored test data:
3. With the meter turned on, press the FUNCTION button to select the RESULTS func-
tion.
4. Press ENTER to access the test results storage locations. The ID tag location appears on
the bottom right of the display.
5. Press UP or DOWN to step through the stored locations.
6. Stop at the location you want to view.
7. Press SCROLL to view the stored test data for a specific test. Test data appears on the
alphanumeric text display and on the LCD.
8. Press ENTER to return the meter to test voltage mode.

APPENDIX C: Megohmmeter C-13

C-14 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Appendix D
Optical Time Domain Reflectometer

Morgan City Training Center

D-1 ROV NEW HIRE COURSE - Gulf of Mexico Region

D-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
In this Oceaneering training course, we will help you to understand how an optical time
domain reflectometer (OTDR) fiber optic testing device works. The OTDR is a device that
locates, identifies, and measures reflective and loss events in multimode and single mode fibers.
Typical maximum test ranges are 35 km maximum at 1300 nm for multimode fiber and 130 km
maximum at 1550 nm for single mode fiber. Oceaneering is currently utilizing two different
OTDRs, the Anritsu MT9083 Series and the Fluke Network OptiFiber Pro.

Section Objectives
• By the end of this section, technicians will be able to complete the following objectives:
• Recall the main function of the optical time domain reflectometer (OTDR)
• Identify the five external ports used for communication on the OTDR
• Locate and select the appropriate front panel controls
• Identify the proper sequence for the fiber testing procedure
• Utilize the proper formula to determine breaks in the umbilical

Basic Layout of the ODTR

Fluke Network OptiFiber Pro

1. LCD display with touch screen.
2. Single mode OTDR port with interchangeable SC
adapter and protective cap. The LED in front of
the port turns on when the port emits an optical
signal.
3. Multimode OTDR port with interchangeable SC
adapter and protective cap. The LED in front of
the port turns on when the port emits an optical
signal.
4. Visual fault locator port and protective cap. The
LED in front of the port turns on when the port
emits an optical signal. BW OTDR
5. Button that controls the VFL.
6. Micro-AB USB port: This USB port lets you connect the tester to a PC so you can up-
load test results and install software updates in the tester.
7. Type A USB port: This USB host port lets you save test results on a USB flash drive or
connect a video probe to the tester.
8. Headset jack.
APPENDIX D: Optical Time Domain Reflectometer D-3
 9. To start a test, you can also tap TEST on the display.
10. Power key.
11. Press “HOME” to go to the home screen.
12. Connector for the ac adapter. The LED is red when the battery charges and green when
the battery is fully charged. The LED is yellow if the battery will not charge.
13. RJ45 connector for functions available in future software releases.
14. Decal with laser safety information.

Anritsu MT9083
1. Eight hour battery life plus quick recharge.
2. Optical power meter options with up to +30 dBm measurement range.
3. Visible laser source for easy fiber identification and bend/break location.
4. Up to four wavelengths from a single port for any application.
5. Dual USB ports for easy data trans-
fer and connecting inspection micro-
scope.
6. IP options for verifying QoS of
10/100/1,000 MB links.
7. Numeric keypad with dedicated keys
for easy operation.
8. Dedicated function keys for selecting
parameters.
9. Rotary dial for precision cursor
movement.
10. Arrow keys for quick zooming and
navigation through menus.
11. START key for simple one-button Anritsu
testing.
12. Six-and-a-half-inch color TFT-LCD display with simple menus.

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Cleaning Fiber Endfaces
When a fiber optic link does not operate
correctly, the cause is frequently a dirty endface
in a connector. Always clean and inspect the
endfaces in fiber connectors before you make
connections. Fluke Networks recommends that
you use a mechanical device, such as the Fluke
Networks IBC OneClick cleaner, to clean
connectors. If you do not have such a device,
or if the device does not clean the connector
sufficiently, use another optical-grade solvent
and supplies to clean connectors.

Fiber

Do not look directly into optical connectors. Some optical equipment emits invisible radiation that can
cause permanent damage your eyes.

Fiber Testing Procedures

Launch and tail cords allow the tester to measure the loss and reflectance of the first and last
connectors in the cabling and to also include them in the measurement of overall loss. To
measure the properties of a connector, the tester must measure the backscatter before and after
the connector. A poor OTDR connection increases the dead zone at the connector. The dead
zone can hide faults that are near the OTDR connector.
A poor connection also decreases
the strength of the signal from the
OTDR. The weaker signal causes
more noise on the trace, which can
cause the OTDR to miss events. It
also decreases the dynamic range.
When the test is completed, the quality
gauge shows in the details for the
OTDR Port event on the EventMap
screens. The tester includes the gauge
with the test results you save.

Fluke Parts

APPENDIX D: Optical Time Domain Reflectometer D-5

 Basic steps for conducting a test on the Fluke Network OpticFiber Pro
are as follows:
1. On the HOME screen, tap the TEST SETUP panel.
2. On the TEST SETUP screen, tap the panels to change settings for the test and save
when completed.
3. On the CHANGE TEST screen, you will have the option to set up a new OTDR test,
tap NEW TEST; then tap Auto OTDR, Manual OTDR, or DataCenter OTDR.
4. On the CHANGE TEST screen, make sure the button next to the test is selected; then
tap USE SELECTED.
5. Ensure that the source wavelength and range, resolution, and pulse width are all set ac-
cordingly.
6. Clean and inspect the connectors on the launch and tail cords and the fiber to be tested.
7. Connect the tester and press TEST.

Basic steps for utilizing the Anritsu MT9083 Series in standard mode are
as follows:
1. Press F3 and change wavelength.
2. Press F4 and user can see three different selections here: range, density, and pulse width.
(According to umbilical length, range should be selected. In this case, range is of 5 km
for 3 km of fiber. Select density to high and pulse width to maximum.)
3. Press F5 and select display from origin.
4. Press F1 and select average time to 30 seconds.
5. Press F3 and choose loss mode to 2-Pt loss. Press F6 now two times and user will be on
first page of settings.
6. Press F1 (Manual Mode ON) and wait for 30 seconds for OTDR to shoot pulse.
7. To get loss in complete system, scroll navigator to left hand side of screen and click.
8. To calculate loss on a particular connector, place navigation lines on both sides of con-
nector.

OTDR Results
The tester shows measurements with “>” or “<” when the actual value is possibly more or less
than the value shown. For example, this can occur for hidden events or for measurements that
are out of the range of the tester. When a test is completed, the type of screen the tester shows
first (EventMap, TABLE, or TRACE) is the type you looked at last.

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An example of an event map of results for the Fluke Network
FiberOpti Pro may look like the following:
1. The ID for the results. If Auto Save is off, “Result not
saved” shows.
2. The end of the fiber.
3. The length of the fiber segment between two events.
4. A reflective event:
Reflective event, which is usually a connector.
Measurements for the event are all within the test limits.
One or more measurements for the event exceeds the limit.
5. Launch and tail cords and their connectors show in gray.
The map shows these if Launch Compensation is on OTDR Results
and the cords are connected.
The arrow icon shows when there are more events that do not show on the screen.
6. When more than one button shows at the bottom of the screen, the tester highlights one
in yellow to recommend which one to tap.
7. The fiber type and test limit the tester used for the test and the ID the tester will use for
the next results that you save.
8. When a test is completed, the window shows information for the event that has the
worst measurement. The information windows show the worst results of the wave-
lengths used for the test.
The measurement exceeds the limit.
The measurement is within the limit.
9. Overall loss – The loss of the cabling. This does not include the OTDR connection and
the loss of the last event. If Launch Compensation is on, the overall loss includes the
launch and tail connectors, but not the launch and tail fibers.
(If you did the test at two wavelengths, the tester shows the highest loss of the two
wavelengths. N/A shows for the overall loss if the tester cannot measure the loss. This
can occur when events are too close together or when there is a large reflective event
near the end of the fiber.)
10. Fiber length – The length of the fiber. The units show in meters (m) or feet (ft). If
Launch Compensation is on, the length does not include the length of the launch and tail
cords.
11. PASS/FAIL – The overall result for the fiber.
PASS – All measurements are within the test limits.
FAIL – One or more measurements exceed the limit.

APPENDIX D: Optical Time Domain Reflectometer D-7

 Trace Lists
An example of an ODTR trace for the Fluke Network FiberOpti Pro may look like the
following:
1. The decibel scale shows the level of backscatter
that is approximately set at 0 dB.
2. To measure loss and distance, tap the yellow circle
so that MARK shows, drag the cursor to the start
of the measurement, tap MARK, then drag the
cursor to the end of the measurement.
3. When the cursor is on an event, this area shows
the event type. The text is green if the event
passed, red if the event failed, or black if there is
no limit for measurements.
4. Tap to see help for this screen.
5. Tap to see the settings for the test.
6. Tap to move the cursor to another event.
Trace List
7. The wavelength the tester used for the test. If
the tester used more than one wavelength, tap onscreen arrow or to see the other wave-
length.
8. When more than one button shows at the bottom of the screen, the tester highlights one
in yellow to recommend which one to tap.
9. The distance scale shows the distance along the fiber.
10. Markers for the end of the launch cord and the beginning of the tail cord are orange,
dashed lines.
11. PASS – All measurements were within the limits. FAIL – One or more measurement
exceeded its limit.

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An example of an ODTR trace for the Anritsu MT9083 Series may look like the following:

Trace List

OTDRs store a fiber’s trace in a trace file, which contains the trace data, OTDR parameters,
user-supplied text (such as notes and comments), and trace events. A trace file via a trace list
contains trace files grouped together according to criteria determined by the user. For example, a
trace list may be created for all the traces taken on a cable’s fiber at a certain wavelength, in one
direction, and at initial installation.
Each data point within a cable event represents the relative frequency of the occurrence of that
data point in the selected traces’ events. Only selected trace events with an absolute loss greater
than or equal to the loss threshold are considered. Visually, this representation appears as a
vertical bar above the waveform base. A data point at base value indicates that no selected trace
events above the threshold occur at that data point.
The event frequency waveform is a waveform that indicates the selected trace’s event
distribution and frequency through the use of vertical bars called cable events. Each cable event
also doubles as a template event so the smart template can be applied directly to the traces that
were used to generate it.

APPENDIX D: Optical Time Domain Reflectometer D-9

 OTDR Measurment Explanations

Measurement Explanation

Dead zone The distance from the beginning of an event to the point at which backscatter is defected
and subsequent events can be accurately detected and measured. Expressed in meters.

Distance Distance from the beginning of the fiber to the event. Expressed in meters, feet, or miles.

Distance delta The loss between the event and the preceding event. Expressed in kilometers.

Distance tolerance The repeatability of the distance measurement at each event. Expressed in kilometers.

Link loss The total loss from the beginning of the fiber to the event. Expressed in dB.

Loss delta The total loss from the beginning of the fiber to the event. Expressed in dB.

Loss tolerance The repeatability of the splice loss at the event. Expressed in dB.

Reflectance Ratio of reflected optical power to the incident optical power for reflective events.
Expressed in dB.
Slope The attenuation of the fiber between an event and the preceding event.
Expressed in dB/km.
Splice loss The optical power loss due to the event. Expressed in dB.

Test Results
The user can view the results for a specific project or a summary of the results in all projects. If
the results are considered to have failed, they must be tested again. The ODTR can display a
summary of all of the results, but both ODTRs that are currently being used have the capability
of exporting data onto a laptop or flash drive.

Do not remove the USB flash drive while the LED on the drive flashes. Doing so can corrupt the data
on the drive. You can lose a USB flash drive, cause damage to it, or accidentally erase the contents of the
drive. It is recommended that users save no more than one day of test results on a flash drive.

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An example of the ODTR test results for the Fluke Network FiberOpti Pro may look like the
following:

Test Results

1. The name of the active project.

2. The number of results that passed.
The number of results that failed.
3. The cable IDs that have FAIL results and must be tested again.
4. The cable IDs that have PASS results.
5. Tap VIEW ALL to see a summary of the results in all the projects in the tester.
6. Tap UPLOAD to copy results to a flash drive.
7. Tap MANAGE to delete or rename results.
8. The icons show the types of test results that the result contains.
9. Used to label trace by either date or ID number.

APPENDIX D: Optical Time Domain Reflectometer D-11

D-12 ROV NEW HIRE COURSE - Gulf of Mexico Region
 Appendix E
Serial Communications

Morgan City Training Center

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E-2 ROV NEW HIRE COURSE - Gulf of Mexico Region
Introduction
The name “serial” comes from the fact that a serial port “serializes” data. That is, it takes a
byte of data and transmits the eight bits in the byte one at a time. The advantage over other
protocols, for example “parallel,” is that a serial port needs only one wire to transmit the eight
bits (while a parallel port needs eight wires). The disadvantage is it takes eight times longer to
transmit the data than it would if there were eight wires. Serial ports lower cable costs and make
cables smaller.

Section Objectives
By the end of this section, technicians will be able to complete the following objectives:
• Recall the basic concepts of serial communication
• Classify the main differences between RS-232, RS-422, and RS-485
• Identify which protocol is applicable to a given task
• Indicate the concepts behind software and hardware “handshaking”
• Express an understanding of baud rate, data bits, stop bits, and parity

Binary, Bits, Bytes

Introduction
If you have used a computer for more than five minutes, you will have heard the words bits
and bytes. Both RAM and hard disk capacities are measured in bytes, as are file sizes when you
examine them in a file viewer.
You might see an advertisement that says, “This computer has a 32-bit Pentium processor with
512 megabytes of RAM and 200 gigabytes of hard disk space.” In this sub-topic, we will discuss
bits and bytes so you have a complete understanding of these terms.

Decimal Numbers
The easiest way to understand bits is to compare them to something you know: digits. A digit
is a single place that can hold numerical values between 0 and 9. Digits are normally combined
together in groups to create larger numbers. For example, 6,357 has four digits. It is understood
that in the number 6,357, the 7 is filling the 1’s place, the 5 is filling the 10’s place, the 3 is filling
the 100’s place and the 6 is filling the 1,000’s place. More specifically:
(6 x 1000) + (3 x 100) + (5 x 10) + (7 x 1) = 6000 + 300 + 50 + 7 = 6357

APPENDIX E: Serial Communications E-3

 Another way to express the number 6,357 would be to use powers of 10. Assuming we are
going to represent the concept of “raised to the power of ” with the ^ symbol (so “10 squared”
is written as “10^2”), another way to express 6,357 is like this:
(6 x 10^3) + (3 x 10^2) + (5 x 10^1) + (7 x 10^0) = 6000 + 300 + 50 + 7 = 6,357
What you can see from this expression is each digit is a placeholder
for the next higher power of 10, starting in the first digit with 10
raised to the power of zero. That should all feel pretty comfortable
since we work with decimal digits every day. The great thing about
number systems is there is nothing that forces you to have 10
different values in a digit. Our base-10 number system likely grew
up because we have 10 fingers, but if we happened to evolve to
have eight fingers instead, we would probably have a base-8 number
system. You can have base-anything number systems. In fact,
there are lots of good reasons to use different bases in different
situations.
Computers happen to operate using the base-2 number system, also
known as the binary number system (just like the base-10 number
system is known as the decimal number system).
Binary Number System

The Base-2 System and the 8-bit Byte

The reason computers use the base-2 system is because this protocol makes it a lot easier
to implement computers with current electronic technology. You could wire up and build
computers that operate in base-10, but they would be fiendishly expensive right now. On the
other hand, base-2 computers are relatively cheap.
So computers use binary numbers and, therefore, use binary digits in place of decimal digits.
The word bit is a shortening of the phrase “binary digit.” Whereas decimal digits have 10
possible values ranging from 0 to 9, bits have only two possible values: 0 and 1. Therefore, a
binary number is composed of only 0s and 1s, like this: 1011. How do you figure out what the
value of the binary number 1011 is? You do it in the same way we did it above for 6,357, but
you use a base of 2 instead of a base of 10. So:
(1 x 2^3) + (0 x 2^2) + (1 x 2^1) + (1 x 2^0) = 8 + 0 + 2 + 1 = 11
You can see in binary numbers, each bit holds the value of increasing powers of 2. That makes
counting in binary pretty easy. Starting at zero and going through 20, counting in decimal and
binary looks like the figure on the right.
When you look at the sequence, 0 and 1 are the same for decimal and binary number systems.
At the number 2, you see carrying first take place in the binary system. If a bit is 1, and you add
1 to it, the bit becomes 0 and the next bit becomes 1. In the transition from 15 to 16, this effect
rolls over through 4 bits, turning 1111 into 10000.

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Bits are rarely seen alone in computers. They are almost always bundled together into 8-bit
collections, and these collections are called bytes. Why are there 8 bits in a byte? A similar
question is “Why does 12 equal a dozen”? The 8-bit byte is something that technical pioneers
settled on through trial and error over the past 50 years.
With 8 bits in a byte, you can represent 256 values ranging from 0 to 255, as shown below:
0 = 00000000
1 = 00000001
2 = 00000010
...
254 = 11111110
255 = 11111111

What is Serial?
As stated in the introduction to this appendix, the name “serial” comes from the fact a serial
port “serializes” data. Most computers include two RS-232 based serial ports, and it is also a
common communication protocol used by many devices for instrumentation; furthermore,
serial communication can be used for data acquisition in conjunction with a remote sampling
device as shown on the next page.
The concept of serial communication is simple. The serial port sends and receives bytes of
information one bit at a time. Although this is slower than parallel communication, which allows
the transmission of an entire byte at once, it is simpler and can be used over longer distances.
For example, the IEEE 488 specifications for parallel communication state the cabling between
equipment can be no more than 20 meters total, with no more than two meters between any
two devices; serial, however, can extend as much as 1,200 meters.

APPENDIX E: Serial Communications E-5

 In serial communication, the whole data unit – say a byte – is transmitted one bit at a time.
With serial transmission, only one wire is used for data transfer. Its logic level changes
according to the bit being transmitted (either 0 or 1) and needs some form of synchronization.
(Synchronization will be explained in the following paragraphs.)

+15V Space

LSB MSB
Start 1 1 0 1 0 0 1 0 Stop

+3V
LSB MSB
Least Most
Significant Start b0 b1 b2 b3 b4 b5 b6 b7 Stop Significant
Bit Bit

-3V

IDLE IDLE

Time
-15V MARK
Diagram of RS232 signalling as seen when probed by an Oscilloscope for an uppercase ASCII “K” character (0x4b)
with 1 start bit, 8 data bits, 1 stop bit

RS232
Typically, serial is used to transmit ASCII (American Standard Code for Information
Technology) data. Communication is completed using three transmission lines:
1. Ground
2. Transmit
3. Receive
Since serial communication is asynchronous, the port is able to transmit data on one line while
receiving data on another. Other lines are available for handshaking but are not required. The
important serial characteristics are baud rate, data bits, stop bits, and parity. For two ports to
communicate, these parameters must match.

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What is RS-232?
RS-232 (ANSI/EIA-232 Standard)
is the serial connection found on
IBM-compatible PCs. It is used for
many purposes, such as connecting a
mouse, printer, or modem, as well as
industrial instrumentation. Because
of improvements in line drivers and
cables, applications often increase the
performance of RS-232 beyond the
distance and speed listed in the standard.
RS-232 is limited to point-to-point
connections between PC serial ports
and devices. RS-232 hardware can be
used for serial communication up to
distances of 50 to 1,200 ft, depending
on the environment. Standard 9-pin RS-232 Connector
The diagram at above right shows a standard 9 pin RS-232 connector, of which only three pins
are normally used as a minimum (transmit, receive, and ground).

Connection Types
If you wanted to do a general RS-232 connection,
you could take a bunch of long wires and solder
them directly to the electronic circuits of the
equipment you are using, but this tends to make a
big mess and often those solder connections tend
to break and other problems can develop.
To deal with these issues and to make it easier
to setup or take down equipment, some
standard connectors have been developed
that are commonly found on most equipment
using the RS-232 standards, often called D-sub.
These connectors come in two forms: male and
female connectors. The D-sub is a common
type of electrical connector used particularly in
computers.
Calling them “subminiature” was appropriate
when they were first introduced, but today they
are among the largest common connectors used
with computers. The part-numbering system uses DB Connectors

APPENDIX E: Serial Communications E-7

 a D as the prefix for the whole series, followed by a letter denoting the shell size:
• A = 15 pin
• B = 25 pin
• C = 37 pin
• D = 50 pin
• E = 9 pin
Following the actual number of pins is the gender (P = plug, S = socket).

EIA/TIA 574: “DB-9”

The female “DB-9” connector, properly known as DE9F, is
typically used as the “plug” that goes into a typical PC. If you
see one of these on the back of your computer, it is likely not
to be used for serial communication, but rather for things like
early VGA or CGA monitors (not SVGA) or for some special
control/joystick equipment.
The male “DB-9” connector, properly known as DE9M, is the
connector you are more likely to see for serial communications
on a “generic” PC. Often you will see two of them side by side
(for COM1 and COM2). Special equipment that you might
communicate with would have either connector or even one of
the DB-25 connectors listed below.

DB-9 Pin - Signal Functions

One thing to keep in mind when discussing these pins and their Dual Connectors
meanings is that they are closely tied together with modems and modem protocols.
Whenever interconnecting any serial ports, it will be well to note that whatever the case, it
should always follow that only one <output> should be tied to one or more <inputs> generally
speaking. Further, it should be noted that signal names at the COMx end will generally be the
opposite of the <in>-<out> -sense- at the modem end of things, even though carrying the
same mnemonic names.
Often you do not have a modem attached in the loop, but you still treat the equipment as if it
were a modem on a theoretical level. At least such that you minimally have an <output> going
to every <input> in some manner, with no two <outputs> in conflict or without any “floating”
<inputs> tied to no <output> at all.

RS-232C: DB-25
The female DB-25 connector, also known as DB25F, is what you normally find on an IBM-
compatible PC used as the parallel (printer) port. It is also on the computer end of a modem
cable in older PCs that have 25-pin serial port connectors. This connector type is also used
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frequently for equipment that conforms to RS-232 serial data
communication as well, so do not always assume if you see
one of these connectors that it is always parallel. When the
original RS-232 specification was written, this was the kind of
connector that was intended, but because many of the pins
were seldom, if ever, used, IBM PC compatible serial ports
were later switched to the DB-9 DE9S connectors carrying all
the required signals as on the DB connectors in the original
IBM-PC. (Yes, this is comparatively recent equipment for this
standard).
The male DB-25 connector, also known as DB25M, is usually
used on one end of a PC printer cable for parallel data
DB-25 Connector
communication which is beyond the scope of this series of
articles. The DB25P is also used on the modem end of an external modem cable. You should
be aware this connector is also used for serial communications on many different types of
equipment, using many different types of communications protocols.

DCD (Date Carrier Detect)

This is a signal to indicate from the communications equipment (DCE) that the phone line is
still “connected” and receiving a carrier signal from the modem at the other end. Presumably
well-written software or serial equipment could detect from this logic state when the telephone
has been “hung up” on the other end. Null-modems often tie DCD to DTR at each end since
there is no carrier signal involved.

RX (Receive Data)
Input to receive the data.

TX (Transmit Data)
The reverse of RX. This is where the terminal equipment (DTE) is transmitting serial data,
using the same format and protocol the receiver is expecting. More on the exact protocol
further below. Like RX, think along the lines of “terminal transmit” when designing equipment
that will be using this pin.

DTR (Data Terminal Ready)

DTR is basically a signal from the DTE that says, “Hello, I’m ready if you are.” This is a general
indicator to the DCE that the terminal is ready to start sending and receiving data. If there is
some initialization that needs to happen in the communications equipment, this is a way for
the terminal equipment to “boot” the receiving equipment. In a null modem setup, this signal
is often connected to DCD, so the device signals itself that an (imaginary) carrier has been
detected, indicating the transmission line is up.

APPENDIX E: Serial Communications E-9

 GND (Signal Ground)
This is an interesting pin to look at. What it does is try to make a common “ground” reference
between the equipment that is being connected to compare the voltages for the other signals.
Normally, this is a good thing because sometimes different pieces of equipment have different
power supplies and are some distance away. The not-so-pleasant thing about this wire is it
usually is a physical piece of copper that can conduct electricity that is not normally supposed to
go down the wire like a short-circuit or a bolt of lightning (it happens far more often than you
would normally think for this sort of equipment). Unexpected electrical currents can damage
both the DCE as well as the DTE.
Things like fiber converters and ground isolators can prevent damage from happening, yet
damage from short circuits is always a concern. Over short distances, however, this is generally
not a problem.

DSR (Data Set Ready)

DSR is the counterpart to DTR with the communications equipment (or computer peripheral
on the serial line). When the DTR is sent as a signal, the communications equipment should
change this signal to -15 V to indicate it is ready to communicate as well. If the DCE goes
through a “boot” sequence when the DTR gets signaled, it should not signal DSR until it is
complete. But many connectors “hard wire” this pin to be directly connected to the DTR pin at
each end to reduce the number of wires needed in the cable. This can be useful for connecting
devices using existing telephone wires, but it prevents applications from using the DTR and
DSR for handshaking.

RTS (Request To Send)

Setting the RTS signal (logic “1” or -12 V) indicates to the DTE that the DCE wants to send it
data. Resetting the RTS signal (logic “0” or +12 V) indicates to the DTE that the DCE has no
more data to send.

CTS (Clear To Send)

CTS is the response signal from the DCE regarding if the terminal equipment should be
transmitting any data. When this signal is -15 V, the terminal is “permitted” to transmit data.
Like the DTR/DSR pins, this one can be directly connected to the RTS pin to reduce the
number of wires needed, but this eliminates the possibility of hardware flow control. Some
software ignores this pin and the RTS pin, so other flow control systems are also used, which
will be explained when we get to actual software.

RI (Ring Indicator)
Thinking back to a telephone modem, RI is a signal that indicates the telephone is “ringing.”
Generally, even on a real telephone modem, this is only occasionally set to -15 V for the signal.
Basically, when you would normally hear a “ring” on your telephone, this pin would be signaled.
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On null modems, often this wire is not even connected to anything. If you are connected to
a real modem, this does have some strong uses, although there are other ways to have the
terminal equipment (like a PC connected to an external modem) be informed; there are ways to
communicate this information through the data pins as well, which will be covered lightly in the
software section.

What is RS-422?
RS-422 (EIA RS-422-A Standard) is the serial connection used on Apple Macintosh computers.
RS-422 uses a differential electrical signal, as opposed to unbalanced signals referenced to
ground with the RS-232. Differential transmission, which uses two lines each for transmit and
receive signals, results in greater noise immunity and longer distances as compared to the RS-
232.
What is meant by “differential” is that a typical single-ended signal could be used with two
wires, where one has a voltage of either 0 V or 5 V and the other wire is 0 V (ground). With a
differential signal, there would be two wires, when one, for example, goes from 0 V to 5 V, the
other goes from 5 V to 0 V (or other voltage levels are also popular). There is not really a need
for a third 0 V (ground) wire.
However, such a third wire is often included because it is used as a shield for the first two wires,
sometimes improving noise immunity. If a shielded cable is used, the ground would connect to
the shield. Also, the third wire can bring the transmit and receive circuits to the same ground
level. This can also help to improve noise immunity.

RS-422
Standard EIA RS-422
Physical media Twisted pair
Network topology Point to point, multi-dropped
Maximum devices 10 (1 driver and 10 receivers)
Mode of operation 1,200 meters
Maximum baud rate Differential
Voltage levels 10 Mbps - 100 Kbps
Mark (1) -6 V to +6 V (maximum voltage)
Space (0) Negative voltages
Available signals TX+, Tx-, Rx+, Rx- (full duplex)
Connector types Not specified; commonly screw terminals

APPENDIX E: Serial Communications E-11

 What is RS-485?
RS-485 (EIA-485 standard) is an improvement over RS-422 because it increases the number of
devices from 10 to 32 and defines the electrical characteristics necessary to ensure adequate
signal voltages under maximum load. With this enhanced multidrop capability, you can create
networks of devices connected to a single RS-485 serial port.

RS-485

The noise immunity and multidrop capability make RS-485 the serial connection of choice in
industrial applications requiring many distributed devices networked to a PC or other controller
for data collection, HMI, or other operations.
RS-485 is a superset of RS-422; thus, all RS-422 devices may be controlled by RS-485. RS-485
hardware may be used for serial communication for up to 4,000 feet of cable.
Even though the data is transmitted over a two-wire twisted pair bus, all EIA-485 transceivers
interpret the voltage levels of the differential signals with respect to a third common voltage.
Without this common reference, a set of transceivers may interpret the differential signals
incorrectly. In a typical setup, this third voltage is implied in the power supply common/ground
connection. However, fundamentally speaking, there is nothing requiring this common voltage
to be the same as the power supply. In fact, certain MS/TP wiring requires full isolation between
the various EIA-485 devices and has to run the third wire for
the common connection.
EIA-485 signals are used in a wide range of computer and
automation systems. In a computer system, SCSI-2 and SCSI-
3 may use this specification to implement the physical layer
for data transmission between a controller and a disk drive.
EIA-485 is used for low-speed data communications in a
commercial aircraft cabin’s vehicle bus. It requires minimal Arline Seats

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wiring and can share the wiring among several seats, reducing weight. EIA-485 is used as the
physical layer underlying many standard and proprietary automation protocols used to
implement industrial control systems, including the most common versions of Modbus and
Profibus.
These are used in programmable logic controllers and on
factory floors. Since it is differential, it resists electromagnetic
interference from motors and welding equipment. In theatre
and performance venues, EIA-485 networks are used to
control lighting and other systems using the DMX512
protocol. Theater
EIA-485 is also used in building automation as the simple
bus wiring, and long cable length is ideal for joining remote
devices. It may be used to control video surveillance systems
or to interconnect security control panels and devices such
as access control card readers. Although many applications
use EIA-485 signal levels, the speed, format, and protocol
of the data transmission is not specified by EIA-485.
Interoperation, even of similar devices from different
manufacturers, is not assured by compliance with the signal Alarm
levels alone.

Serial Communication - Type Summary

RS-232 RS-422 RS-485
Differential No Yes Yes
Max number of devices 1 1 32

Max number of receivers 1 10 32

Modes of operation half duplex half duplex half duplex

full duplex
Network topology point-to-point multidrop multipoint
Max distance (acc standard) 15 M 1200 M 1200 M
Max speed at 12 M 20 kbs 10 Mbs 35 Mbs
Max speed at 1200 M (1 kbs) 100 kbs 100 kbs
Receiver input sensitivity +/- 3V +/- 200 mV +/- 200 mV
Receiver input range +/- 15 V +/- 10 V -7 to 12 V
Max driver output voltage +/- 25 V +/- 6 V -7 to 12 V

APPENDIX E: Serial Communications E-13

 What is Handshaking?
The method used by RS-232 for communication allows for a simple connection of three lines:
Tx, Rx, and ground. However, for the data to be transmitted, both sides have to be clocking
the data at the same baud rate. Even though this method is sufficient for most applications, it
is limited in being able to respond to problems, such as the receiver getting overloaded. This is
where serial handshaking can help.
In this section, we will discuss two of the most popular forms of handshaking with RS-232:
software handshaking and hardware handshaking.

Software Handshaking
The first form of handshaking we will discuss is software handshaking. This style uses actual
data bytes as control characters, similar to the way GPIB uses command strings. The lines
necessary are still the simple three line set of Tx, Rx, and ground since the control characters
are sent over the transmission line like regular data. The function SetXMode allows the user to
enable or disable the use of two control characters, XON and XOFF. These characters are sent
by the receiver of the data to pause the transmitter during communication.
As an example, assume the transmitter begins to transmit data at a high baud rate. During the
transmission, the receiver finds the input buffer is becoming full due to the CPU being busy
with other duties. To temporarily pause the transmission, the receiver sends XOFF, typically
decimal 19 or hex 13, until the input buffer has been emptied. Once the receiver is ready for
more data, it sends XON, typically decimal 17 or hex 11, to resume communication.
The software application will send XOFF when its input buffer becomes half full. In addition,
in case the XOFF transmission was corrupted, the application will also transmit XOFF when
the buffer has reached 75 percent and 90 percent capacity. Obviously, the transmitter must also
be following this protocol for it to succeed.
The biggest drawback to this method is also the most important fact to keep in mind: decimal
17 and 19 are now off limits for data values. In ASCII transmissions, this typically does not
matter since these values are non-character values; however, if the data is being transmitted via
binary, it is very likely these values could be transmitted as data and the transmission would fail.

Hardware Handshaking
The second method of handshaking is to use actual hardware lines. Like the Tx and Rx lines,
the RTS/CTS and DTR/DSR lines work together with one being the output and the other the
input. The first set of lines are RTS (request to send) and CTS (clear to send).
When a receiver is ready for data, it will assert the RTS line indicating it is ready to receive data.

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This is then read by the sender at the CTS input, indicating it is clear to send the data. The next
set of lines are DTR (data terminal ready) and DSR (data set ready).
These lines are used mainly for modem communication. They allow the serial port and the
modem to communicate their status. For example, when the modem is ready for data to be sent
from the PC, it will assert the DTR line indicating that a connection has been made across the
phone line. This is read in through the DSR line, and the PC can begin to send data.
The general rule of thumb is that the DTR/DSR lines are used to indicate the system is ready
for communication, while the RTS/CTS lines are used for individual packets of data.

APPENDIX E: Serial Communications E-15

E-16 ROV NEW HIRE COURSE - Gulf of Mexico Region