Marine Technology: Connectivity Under and Around Water

Connectors and cables are integral to many harsh environment applications, but marine technology requires considerations unique to underwater conditions.

Nearly three-quarters of our planet is covered by water, and while the marine environment has always been vital for our survival, it has also become valuable to scientific, commercial, and military activities. According to From Sea to Shining Sea – Connectors Support Marine Applications, a white paper from Bulgin, nearly 90% of global trade occurs via ocean travel. Our oceans and waterways are a significant source of our food. They are key sites for energy exploration through oil & gas and hydropower operations, as well as a source of vital minerals like copper and zinc. Using, understanding, and protecting these waters requires sophisticated marine technology.

Subsea Cables

ROVs (remotely operated vehicles) are used to monitor, maintain, and support many different missions, in large and small bodies of water, for defense and commercial applications. They are used to gather data, including images, for a variety of purposes, such as inspecting an oil rig, conducting scientific studies of fish and other marine life, and even searching for sunken ships. Reliable subsea cables are required to supply power and data communications.

Xtreme-Net cables from Winchester Interconnect are built to deliver high-speed Ethernet data transmission in the most demanding subsea conditions. Used for ROV tethering, for subsea monitoring for oceanographic research, or to establish underwater communication networks for oil & gas and marine industries, these cables ensure reliable performance at depths up to 10,000 PSI. Customizable configurations and armored versions are available

Subsea cables are used for static and dynamic applications, dynamic meaning they move around. They must be flexible and lightweight. On fixed install applications, where they are hooked up and left on the bottom of the lake or ocean for extended periods, they must be able to perform in the harsh underwater environment.

Winchester Interconnect’s San Marcos, California, facility specializes in high-performance cables for subsea and other harsh environments. Back in the mid-90s, the company, known then as Falmat Cable, began offering standard cable in any length (no minimum) in addition to its custom cables. “Our Xtreme brand is ruggedized for subsea use. As you know in subsea applications there’s a lot of handling by personnel on ships and vessels and potential for abrasion from coral, rocks, marine life, and objects that can damage the cable. Our cables are rugged from outside in and from inside out,” said Shawn Amirehsani, Eastern Sales Manager at Winchester. More and more applications require Ethernet or fiber optics, which are available in the Xtreme line.

Winchester’s Xtreme-Light fiber optic cable is designed for use in the harshest subsea environments. They offer superior durability and survivability in deep-sea applications. Tested to withstand hydrostatic pressures up to 15,000 PSI and depths of up to 10,000 meters for underwater communications, ROV tethering, and subsea monitoring. They provide reliable, high-speed data transfer for offshore operations, subsea research, and deep-sea exploration.

In addition to using higher grade materials that ensure their integrity over a long period of time, Winchester uses a proprietary compound as a water blocking material. “Water blocking really helps to ruggedize the cable and protect it in case of any damage or cuts. If the cable is cut underwater and water gets in, it will do a lot of damage to the termination and the entire system will ultimately fail,” said Amirehsani. “The material that we use is very flexible and pliable. It is used to fill in any voids, gaps, or spaces inside the cable. This protects the core, the conductors, and the other elements like optical fibers from getting damaged.”

Materion’s copper-beryllium Alloy 165 is used to make repeater housings for subsea cables.

Repeaters are used to protect the sensitive optical amplification systems of subsea cables and are designed to withstand pressures at 8,000-meter depths. To protect them, the material used must resist corrosion and be strong enough to withstand the pressure on the ocean floor, without impairing the connectivity of the cables.

“Our copper beryllium undersea repeater housings demonstrate exceptional durability, often remaining operational for several decades. Recently, we retrieved housings that had been submerged for 40-50 years, and remarkably, their interior surfaces were still pristine. These housings were extracted because the electronics inside needed to be replaced, not because of any degradation of the housings themselves,” said Sharon Mazzaro, global marketing director at Materion Corporation.

Marine Connectors

Bulgin’s 400 Series Buccaneer power connectors are lightweight, rugged, and highly reliable for underwater applications.

Bulgin’s Standard Series Buccaneer connectors are rugged and reliable sealed RJ45 connectors that provide high performance Cat5e Ethernet connections in harsh environments. These sealed industrial Ethernet solutions help provide high speed data connections and protect the integrity of data transmissions. They are IP67, IP68 and IP69K rated for use above water.

Connectivity solutions in ship deck systems, marinas, boating equipment, and other above water marine applications are at constant risk from high corrosion and water ingress. Underwater operation requires components with even higher levels of ruggedness and reliability to counter the effects of pressure, extreme temperatures, and saltwater. More companies are  going to greater depths and for longer periods. This has increased demand for submersible connectors with longer life cycles and simplified product maintenance. Sealed and robust components are mandatory protection for power, signal, and data connections in these conditions that put connectivity at risk.

The Amphenol Sine AT Series SR02 connectors from Chief Enterprises are ideal for marine applications because their extended strain relief wire cavities protect each individual wire seal, eliminating stress on the rear seal while maintaining an IP68/69K rated (mated) performance regardless of wire bundle direction or improper installation. The additional shroud is ideal for adding heat-shrink, should the customer feel more confident with it.

Connecting systems in marine applications can be time-consuming and prone to errors. Marine technology often involves making connections with complex wiring in tight spaces and where additional strain relief is needed, especially with the added IP68/69K waterproof ratings. They act as a visual “cheat sheet”—green connects to green, grey to grey—eliminating guesswork and reducing assembly time. This intuitive approach not only speeds up installation but also minimizes the risk of cross-connection errors.

To learn more about the companies mentioned in this article, visit the Preferred Supplier pages for Winchester Interconnect, Materion Corporation, Bulgin, and Chief Enterprises.

Like this article? Check out our other Ethernet and Fiber Optics articles, our Transportation Market Page, and our 2024 and 2025 Article Archives. 

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