Steven S. Thumbeck

1. Subsea Electric and Optic Connections Allowing for Flexible System Architecture Steven S. Thumbeck VLV ν T Workshop "Technical Aspects of a Very Large Volume Neutrino Telescope in the Mediterranean Sea" October 5-8, 2003 NIKHEF, Amsterdam

2. Subsea 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.

3. Subsea Connectors • WHO SHOULD USE SUBSEA CONNECTORS? • Not everyone • Only when the value of the component exceeds its cost should it be considered.

4. Subsea 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?

5. Subsea 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.

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

7. Subsea Connectors

8. Reliability • 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

9. Wetmate Electrical and Optical Connector Components • Electrical Connectors • Conductor and contact band arrangement • Optical Connectors • Ferrule and split sleeve arrangement High reliability components repackaged for subsea applications.

10. Wetmate E/O Connectors(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

11. Subsea Connectors Types • 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

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

13. Dry Mate Submersible (1950’s)

14. OIL-FILLED “WET-MATE” (1970’s)

15. Applications • 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

16. Subsea Connector Types • Diver Make-up • ROV Operable • Stab Plate • Dry Mate Submersible

17. 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)

18. Attaching the cable to the connector: Three Basic Types of Cable Terminations • Molding – Polyurethane / Polyethylene • Field Installable Testable Assemblies • Hose Fittings – JIC / Barb / Integral

19. Cable 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.

20. 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?

21. 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

22. Large Scale Systems • Ocean Net • NEMO - NEutrino Mediterranean Observatory • NEPTUNE - Seafloor Interactive Observatory

24. Subsea Package

25. Ocean Design, Inc. Subsea Branching Unit with ODI Wet-Mate Connection ODI Wet-Mate Optic Connection Remote Instrumentation Package with ODI Optical and Electrical Wet-Mate Connections

26. Subsea Electric and Optic Connections Allowing for Flexible System Architecture Steven S. Thumbeck VLV ν T Workshop "Technical Aspects of a Very Large Volume Neutrino Telescope in the Mediterranean Sea" October 5-8, 2003 NIKHEF, Amsterdam