Steven S. Thumbeck October 5-8, 2003 NIKHEF, 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

June 18, 2015 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.

June 18, 2015 Subsea Connectors WHO SHOULD USE SUBSEA CONNECTORS? Not everyone Only when the value of the component exceeds its cost should it be considered.

June 18, 2015 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?

June 18, 2015 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.

June 18, 2015 Subsea Connectors This staged deployment method will minimize risks and safety concerns during operations in the event of severe weather conditions.

June 18, 2015 Subsea Connectors

June 18, 2015 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

June 18, 2015 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.

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 Million

June 18, 2015 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: Years Wet Mateable -Pressure Balanced Oil Filled (PBOF) Initial Cost: High Life expectancy: Years Subsea Connectors Types

Wet Pluggable (Interference type ’s)

Dry Mate Submersible (1950’s)

OIL-FILLED “WET-MATE” (1970’s)

June 18, 2015 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

June 18, 2015 Subsea Connector Types Diver Make-up ROV Operable Stab Plate Dry Mate Submersible

June 18, 2015 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)

June 18, 2015 Attaching the cable to the connector: Molding – Polyurethane / Polyethylene Field Installable Testable Assemblies Hose Fittings – JIC / Barb / Integral Three Basic Types of Cable Terminations

June 18, 2015 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: 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: 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.

June 18, 2015 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?

June 18, 2015 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 Systems Ocean Net NEMO - NEutrino Mediterranean NEMO - NEutrino Mediterranean Observatory Observatory NEPTUNE - Seafloor Interactive NEPTUNE - Seafloor InteractiveObservatory

June 18, 2015

Subsea Package

June 18, 2015 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, 2003 NIKHEF, 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