Fibre Optics CT is an independent cable-testing lab

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TESTING - Test lab for optical, electrical cables and signalling cables

In our in-house tensile testing facility we carry out static or dynamic tensile tests on cables at

ambient and extreme temperatures, and determine and evaluate the resulting changes in

mechanical, optical and electrical properties.

Over 45 years experience with cables and standards enables us to run these tests in a

practical way, under realistic environmental and operating conditions and in accordance

with the relevant IEC (international) and DIN EN (European) standards.

We constantly seek to improve existing methods for testing and sample conditioning, and

to innovate new procedures aimed at achieving reproducible tests and state-of-the-art

cable quality assessment.

Consulting & Testing GmbH

CONSULTING

Technical Terms of Delivery and Contract

We supply expert advice to clients on technical issues related to terms of delivery and

contract, including special requirements for signal or optical outdoor cables. This is done

in compliance with current international framework/generic specifications. If clients so

require, we also draw up the documents on their behalf.

It is our aim to define

• the properties of optical and electrical cables

• the construction of cable duct installations (incl. calibration and seal-monitoring)

• conformity to environmental requirements for cable installations

• cable laying procedure, etc.

in such a way that cables can go through the processes of design, manufacture, laying in

ducts and installation without any negative property changes throughout a service life of 20-

35 years.

CONSULTING

Training sessions

The issues covered in training sessions include basic information on optical cables,

installation and measuring technology

Seminars held: 140 (since 1995) Number of participants: 1127

Participants: from Germany, Switzerland, Austria and the Czech Republic

Groups from Telekom, railways, telecom networks, energy suppliers, telecom

construction companies, waterways and motorway authorities

• Construction supervision of optical cable installation, measuring technology

• Cable basics and measuring technology (beginners)

• Approval of optical cable installations and fault detection (advanced)

• Acceptance tests for optical cables, incl. IEC test "Tensile performance and

bending under tension" and fibre elongation

Themes:

FIRM HISTORY

Fibre Optics CT Consulting & Testing GmbH

was founded in 2002, with the hiving-off of the following services areas from Wolf

Kabeltechnik GmbH (founded 1982):

• Type approval testing of optical and electrical cables

• Monitoring of the quality of optical fibre cables

• Training courses (seminars)

• Preparation of assessment reports

• Consulting

• Development (optical fibre sensors and sealing technology)

COOPERATION with other testing facilities

Subcontractors or laboratories hired for testing purposes

Institute for Materials

Testing, Stuttgart Univ.

• Material fault

analysis

Metals

Klaus Kimmich

Messtechnik-Service

Hohentwielstr 14

70199 Stuttgart

• Measurement of fibre

excess length and fibre

elongation

• Measuring technology

seminars

Institut for plastics

technology (IKT)

Stuttgart University

• Material fault

analysis

Plastics

GE Sensing & Inspection

Technologies GmbH

Branch Office Stuttgart

• 3D computer

tomography

• 2D X-ray analysis

accredited not accredited accredited accredited

RANGE OF CABLE TESTS

Qualification tests carried out on

electrical or optical cables

Tensile performance

Laying properties

Environmental tests

Mechanical tests

Tests on optical fibres

3D computer tomography

2D X-ray analysis

Measurement of fibre elongation

Example:

3D computer tomography

D1: Fibre compression

D2: Air bubbles

Assessing cable faults

Our managing director, has had 45 years experience in the field of test techniques and

planning (at SEL-Kabelwerk, then in his own firm, Wolf Kabeltechnik) and over 20 years of

realistic testing in his own lab or in other facilities with his own equipment. This know-how

enables us to carry out tests and assessments independently of manufacturers, e.g. on

behalf of telecom network operators and cable manufacturers

• Thermogravimetric analysis (TGA)

• Infrared spectroscopy (IR)

• Light microscopy (LM)

• Laying properties

• Ageing tests

Type approval tests for plug connections

Ferrule end-face geometry

Thermic ageing and temperature cycling, frost and dew test

Ageing caused by condensation and humidity/ Condensation cycling/

Temperature cycling after condensation

Drying-out test/ Water resistance

Vibration

Bending/ Cable torsion/ Tensile performance of coupling mechanism

Transmission under tension

Durability (mating cycles)

Impact/ Tightness under tension/ Pressure

NEED FOR a neutral, independent cable testing lab

Experience has repeatedly shown that in many cases, despite

• Manufacturers' certification in acc. with ISO 9001

• Type approval acceptance tests or inspections with other certificates

of approval

the mechanical and/ or optical properties of cables can be affected by installation

and operational conditions to such an extent that proper function is hazarded or may

become seriously impaired within service lifetime.

NEED FOR a neutral, independent cable testing lab

shorter

service

Price Quality

higher

costs for

corrections

Reasons for quality loss:

Competition between price and quality

has led to constant cut-backs in:

Materials

(to compensate for increases

in material and staff costs)

Quality assurance measures

Training schemes for employees

Consequence:

Shortened service life and higher costs for

corrections, repairs etc.

Fault statistics of the ITU (International Telecommunication

Union) 1994

Structural damage in duct cables Reference magnitude

cable - km

Structural damage

With damage to cables (breakage)

1.338 faults/ 100 cable-km * yr 2003 39 faults

0.445 faults/ 100 cable-km * yr 2003 --- 8 faults

Cables without faults (no

breakage)

0,583 faults/ 100 cable-km * yr 2003 17 faults ---

Telecom network operators

Participants in research 9 5

Construction fault statistics (Source: Research by Fibre Optics CT GmbH

Consulting & Testing Stuttgart – Testing lab)

1.22 faults/ 100 km & year

(WAN communication network)

0.93 faults/ 100 km & year

(LAN connection network)

Distribution according to fault area

31% joint faults

28% sheath faults

19% fibre faults

16% structural damage with cable

faults

5% connection faults

1% plug faults

FAULT STATISTICS - What happens in practice is the best argument

for quality assurance

"Trust is good, control is better!"

Unfortunately, this well-known saying has repeatedly proved true since 2005, when we first

introduced the cable installation test into our seminar programme No. 203 as "Construction

supervision of optical-cable installation and measuring technology" During the seminar, the

cable-laying test is carried out on cable samples belonging to participants, to check compliance

with the requirements in the manufacturer‘s data sheet.

Experience shows that…

the actual tensile performance values do not correspond to those as specified and

guaranteed for standard-installation conditions in the manufacturer‘s data sheet

technical cable data sheets are often incomplete, which may result in a shortening of the

cable‘s service life.

The following information, relevant to the operative area of the cable, is usually missing:

max. fibre elongation under tension < 0,33%

max loss under tension, bending/ torsion/ temperature change/ crush < 0,1 dB

(at wavelengths 1550 nm, 1625 nm)

Example:

Cable production fault:

inadmissible cable length change

Apart from faults in the joint box installation, the

main cause of leakage in the joint area is length

change in cables, which occurs with ageing.

Fault statistics of Fibre Optics CT test lab 60% faults "inadmissible cable length change"

20% other faults

20% no faults

Photo:

This cable sheath has shrunk

considerably with age:

Actual value: 12,5% = 125 mm

Guideline value: 3% = 30 mm

Practical consequences:

The sheath becomes detached

from the joint box, thus

creating space for water

penetration

This may have far-reaching consequences

for traffic.

Water penetration leads to

- disintegration of the induction protection

- changes in capacitance

- corrosion and breakage of copper conductors

Consequence:

Disruption or breakdown of the signalling

system

Water penetration as a result of cable faults can

endanger personal safety!

Example:

Water penetration in armoured, induction-protected signalling installations

Water penetration as a result of cable faults can

cause high costs!

Example: Water penetration in optical fibre

telecommunication equipment

Optical fibre communication channels are in operation day and

night for the transmission of large amounts of data.

Particularly when optical fibres are rented singly to clients, the expectation is that availability

will be practically 100%. Unnoticed water leakage into the optical fibre facility leads to

sudden network failure. Depending on the provider and extent of the failure, numerous users

are affected by the breakdown in communication.

Network breakdown results in costs for switching over, repairs (underground works, cable

replacement) and the consequences for service failure, as there may also be compensation

to pay for damages.

EXAMPLE: Type approval and batch type tests Tests may be carried out in the presence of the client

Temperature cycling in acc.

with IEC 60794-1-2 Verf. F1

Tensile performance in acc.

with IEC 60794-1-2 Verf. E1

and cable laying properties

under tension in acc. with

IEC 60794-1-2 Verf. E18

Optical and mechanical property changes during

temperature cycling, on lengths up to 2000 m

Optical, electrical and mechanical property changes under

static/ dynamic tension, on lengths up to 200 m

Measurement of optical fibre (over)length,

measurement of stress after ageing

Measurement of optical fibre elongation

in acc. with IEC 60794-1-2/ method E1B

Measurement of mechanical and transmission

properties before, during and after testing

EXAMPLE: Type approval and batch type tests Tests may be carried out in the presence of the client

Tensile stress on lengths of ~ 7 to 10 m

at lowest or highest admissible temperatures

Static and dynamic test over a fixed S-shaped deflecting device, over rollers and over

S-shaped roller deflecting devices

Tightness check on the inner and outer sheath

under tension and with reversed bending stress

(Shaping behaviour of cables at 7.5 x D)

Measurement of the mechanical properties of the cable sheath,

design type and inner construction elements of signalling or

mine cables under installation conditions

REFERENCES Cable testing/ Assessments

Telekom: Deutsche Telekom Telekom Austria

Cable manufacturers: Pirelli Cables NKT Cables Corning Cables

NOKIA Brugg Kromberg & Schubert

Gebauer & Griller Essex Leonische Drahtwerke

Bayka Kabelwerke LG Cable ABB

Huber + Suhner

Network operators: Memorex Telex Gasline/ Ruhrgas (EON)

Thales Rail

Signalling Solutions

Others: Gisma Steckverbinder Gabler Maschinenbau

DEVELOPMENT and PLANNING

Gas- and pressurised water sealing systems and accessories (EU patents)

Optical fibre measurement devices [FO5] Pat. pending for the detection of depth levels, temperatures, dangerous substances or water

mixtures in collecting tanks

Type ADE/V Cables, cable ducts,

house connections etc.

Source:

Wolf Kabeltechnik GmbH

Type UA/V Power cables with requirement

conductor short circuit at 90°C,

waste water pipe seal

Source:

Type UA/V (S) For special applications

Sealing area from

Ø 250 mm to > 1000 mm

Source:

Gas and pressurised-water sealing systems and accessories (EU patents)

or SAS-T sandwich sealing

system [WO22]

The SAS-T sealing system

(foam seal) replaces

ineffective rodent protection

Info FO 01/3

DEVELOPMENT and PLANNING Sealing control system for cable trays/ cable ducts/ cable sheaths

Area of application:

Monitors pressure and tightness for

sheaths up to 65 mm Ø.

For use at place of manufacture, during

transport, in storage and during installation

(E = single use only)

Art. No. 55 PLS-E

For monitoring the seal of (un)installed cables

Area of application :

Monitors pressure and tightness of

assembled cables with steel-tape

armouring (induction protection)

in cable installations.

(E = single use only)

Art. No. 55 PSKA-E

For monitoring the pressure and tightness of

installed and assembled cables in cable ducts

Pressure and tightness control of

stell-tape armoured cables

(induction protection) in cable

systems.

(W = can be reused several

times)

Art. No. 55 PSKA-W

Pressure control of installed

cables in cable systems

Art. No. 55 PKKA-W

Pressure control of occupied

or unoccupied cable ducts

Tightness control of cable ducts

with an inner Ø of 150, 125, 115,

100, 80, 60, 50, 45, 40, 35 mm

Tightness control and

dehumidification system for

assembled cables with

increased RIso or C values

(E = single use)

Art. No. 55 EPV-E

Pressure control and/or dehumidification

system for assembled cables

PLANNED: Special developments (up to serial production)

Remote monitoring system in single mode

optical fibre technology

For conservation of value (e.g. monitoring the transport

of raw materials to prevent water loss, etc)

Safety in close proximity to dangerous substances

(e.g. monitoring fuel storage depots)

Sensor switches for doors, mineshafts

Temperature differences (e.g. long-distance heating)

and lots more...

CONTACT

Zazenhäuser Str. 52

70437 Stuttgart

Germany

Tel. ++49 (0) 711 87 08 572

Mail: service@fibreopticsct.de

www.fibreopticsct.de

Fibre Optics CT is an independent cable-testing lab

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