Steven S. Thumbeck

October 5-8, 2003NIKHEF, Amsterdam

VLV ν T Workshop"Technical Aspects of a Very Large Volume

Neutrino Telescope in the Mediterranean Sea"

Subsea Electric and Optic Connections Allowing for Flexible System Architecture

April 18, 2023

Subsea SystemsSubsea Systems

• Large scale structures (Infrastructure)• Test beds or prototype systems

demonstrate the feasibility• The “real” test is when the scientist is out

at sea on the installation vessel and the deployment is commenced.

• Many factors to consider• Total system cost versus functionality and

reliability. • Subsea connections and their impact on

system cost, functionality and reliability.

April 18, 2023

Subsea ConnectorsSubsea Connectors

• WHO SHOULD USE SUBSEA CONNECTORS?

• Not everyone • Only when the value of the component

exceeds its cost should it be considered.

April 18, 2023

Subsea ConnectorsSubsea Connectors

• Expenditures associated with the servicing and or installation of the equipment.

• What type of vessel is required to perform the service?

• How many days will an operation take? Will weather affect the installation or service?

• Will adding a subsea connector help reduce these associated costs of ship time and maintenance?

April 18, 2023

Subsea ConnectorsSubsea Connectors

• Typical installation would have a cable coming from shore to a remote location on the seafloor

• At the cable end would be a termination assembly where the fiber communications and electrical power would be broken out.

• This structure is normally referred to as the termination or junction box.

• From the termination is the distribution point to various subsea components containing instruments and communication equipment.

April 18, 2023

Subsea ConnectorsSubsea Connectors

• This staged deployment method will minimize risks and safety concerns during operations in the event of severe weather conditions.

April 18, 2023

Subsea ConnectorsSubsea Connectors

April 18, 2023

ReliabilityReliability

• Newly introduced products, such as wet-mate connectors will always have reliability concerns.

• Wet-mate electrical connectors have over a decade of field history. More than 28,000 are estimated to be installed subsea.

• With this volume and field history fewer questions arise as to their reliability.

• By contrast, underwater mateable fiber connectors are relatively new to the market with roughly 3,000 units deployed world wide.

• The subsea electrical connectors utilize standard electrical sockets and electrical pins and are packaged for subsea use.

• Similarly, the optical circuits utilize standard epoxy polished optical ferrules and split sleeve technology.

• Mechanical materials such as Titanium, Stainless Steel and Natural rubber elastomeric compounds, have a longstanding history of performance for subsea applications

April 18, 2023

Wetmate Electrical and Optical Wetmate Electrical and Optical Connector ComponentsConnector Components

• Electrical Connectors• Conductor and contact band arrangement

• Optical Connectors• Ferrule and split sleeve arrangement

High reliability components repackaged for subsea applications.

Wetmate E/O ConnectorsWetmate E/O Connectors(Equipment in Operation)(Equipment in Operation)

Since 1991: 31,000 Serialized Pieces (Connectors) 5,000 Serialized OFH (Harnesses)

28,000 Electrical — 12,000 ROV 3,000 Optical — 2,900 ROV

Total Operating Hours - 800 Million

April 18, 2023

• Wet Pluggable (Interference type)• Initial Cost: Low• Repair Cost: Replacement• Life expectancy: 7-10 Years• Advantages: Low Cost

• Dry Mateable Submersible• Initial Cost: Medium• Life expectancy: 25-30 Years

• Wet Mateable -Pressure Balanced Oil Filled (PBOF)• Initial Cost: High• Life expectancy: 25-30 Years

Subsea Connectors TypesSubsea Connectors Types

Wet Pluggable Wet Pluggable (Interference type - (Interference type - 1950’s)1950’s)

Dry Mate Submersible (1950’s)Dry Mate Submersible (1950’s)

OIL-FILLED “WET-MATE” (1970’s)OIL-FILLED “WET-MATE” (1970’s)

April 18, 2023

ApplicationsApplications

• Basic Information:• Operating Depth• Component Materials (316ss, Titanium)• Number of Circuits• Operating Voltage (AC/DC) / Amperage• What is the operating voltage for the application?

Common voltages are:• Signal - 10Vdc,24Vdc, Used with sensing equipment

such as pressure, temperature, cameras, etc. • Power – 120vac, 208/240vac, 460vac standard servo

motors for electric valves and power supplies.• High Power – Large Horsepower Motors, Power

distribution Systems

April 18, 2023

Subsea Connector TypesSubsea Connector Types

• Diver Make-up

• ROV Operable

• Stab Plate

• Dry Mate Submersible

April 18, 2023

Types of Subsea Cables:Types of Subsea Cables:

• Multi-conductor Cable –(400M+ Lengths)

• Armoring (Synthetic / Galvanized Steel)

• Pressure Balanced Oil Filled (PBOF) Hose with Wire/Fiber Optic Components – (2-400M Lengths)

April 18, 2023

Attaching the cable to the connector:Attaching the cable to the connector:

• Molding – Polyurethane / Polyethylene

• Field Installable Testable Assemblies• Hose Fittings – JIC / Barb / Integral

Three Basic Types of Cable TerminationsThree Basic Types of Cable Terminations

April 18, 2023

Cable TerminationsCable Terminations• Polyurethane Molding• Initial Cost: Low• Repair Cost: High• Life expectancy: 7-10 Years• Advantages: Inexpensive, Easily adapts to Many Cable Types and sizes.• Limitations: Bonding adhesion to cable jacket and connector shell (delamination) is a

concern, Coatings or Isolation is needed with metal bodied connectors, typically limited to polyurethane jacketed cables. Field repair requires replacement of entire unit.

• Mechanical terminations commonly referred to as FITA’s (Field Installable Testable Assemblies)

• Initial Cost: High• Repair Cost: Low• Life expectancy: 25-30 Years• Advantages: May be assembled and tested on-site. In the event of cable damage

the unit may be disassembled and reinstalled with minimal replacement parts. • Limitations: Typically each unit is designed for a specific cable type. Specialized

installation and or training for installation is highly recommended.

• Fluid Filled Hose Connections.• Initial Cost: Low• Repair Cost: Low• Life expectancy: 25-30 Years• Advantages: Allows for quick cable construction. Wire components may be selected

as needed. Ease of disassembly and assembly if rewiring or repair is needed. Generally a good fit for short run (2Meter to 400Meter) cabling.

• Limitations: Cable lengths are generally limited to 400Meters.

April 18, 2023

Common Questions to ask:Common Questions to ask:

• Connector:• Are there any special considerations (lubrication, maintenance)?• Mating/Demating Force?• Size and Weight?• Materials used/Compatibility with system components?• Common system materials may include Structural Steel, Aluminum,

Stainless Steel, Titanium, and PVC.• Mate/Demate Cycles?• Mate/Demate at depth?• Maximum Operating depth?• System Life Expectancy? (5yr, 10yr, 25+yr)• What factory acceptance test or qualification test will be performed?• Termination:• Has the particular cable been qualified for use with the termination?• Is sealing provided at all cable jacket layers, if so what type? • If the Termination were to flood with water, would the unit still

operate?

April 18, 2023

Other Considerations:Other Considerations:

• When using corrosive materials such as Stainless Steel or Steel are Cathodic Protection Systems utilized such as Zinc Anodes, Sea Water Ground Return or Epoxy Paints?

• Fluid Compatibility• Material Compatibility

Large Scale SystemsLarge Scale Systems

• Ocean NetOcean Net• • NEMO - NEMO - NEutrino MediterraneanNEutrino Mediterranean

ObservatoryObservatory• • NEPTUNE - NEPTUNE - Seafloor InteractiveSeafloor Interactive

ObservatoryObservatory

April 18, 2023

April 18, 2023

Subsea PackageSubsea Package

April 18, 2023

Subsea Branching Unit with ODI Wet-Mate Connection

ODI Wet-Mate Optic Connection

Remote Instrumentation Package with ODI Optical and Electrical Wet-Mate Connections

Ocean Design, Inc.

Steven S. Thumbeck

October 5-8, 2003NIKHEF, Amsterdam

VLV ν T Workshop"Technical Aspects of a Very Large Volume

Neutrino Telescope in the Mediterranean Sea"

Subsea Electric and Optic Connections Allowing for Flexible System Architecture