Subsea Electrical Voltage

Governing document Classification: Internal

Subsea Electrical High Voltage Connector Assemblies

Project development (PD) Technical and professional requirement, TR2313, Final Ver. 1, valid from 2011-07-05

Owner: Chief Engineer

Validity area: Corporate technical and professional requirements/All locations/All value chains/Offshore

Governing document Subsea Electrical High Voltage Connector Assemblies

Classification:Internal

Project development (PD), Technical and professional requirement, TR2313, Final Ver. 1, valid from 2011-07-05

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1 Objective, target group and provision........................................................................................................................... 3 1.1 Objective .............................................................................................................................. 3 1.2 Target group ......................................................................................................................... 3 1.3 Provision .............................................................................................................................. 3

2 Requirements........................................................................................................................................................................ 3 2.1 Operational conditions ............................................................................................................ 3 2.2 Ratings................................................................................................................................. 4 2.3 Design Analysis ..................................................................................................................... 4 2.4 General requirements ............................................................................................................. 5 2.5 Connectors ........................................................................................................................... 6 2.6 Penetrators ........................................................................................................................... 7 2.7 Jumpers/cable pigtails ............................................................................................................ 7 2.8 Seals ................................................................................................................................... 8 2.9 Material Requirements ............................................................................................................ 8 2.10 Test Requirements ................................................................................................................. 9

3 Factory acceptance tests ................................................................................................................................................11 3.1 Acceptance Test Sequence Requirements............................................................................... 11 3.2 Helium Tightness Control Test ............................................................................................... 11 3.3 Contact Resistance Test (CR test) .......................................................................................... 12 3.4 Partial Discharge Test (PD test) ............................................................................................. 13 3.5 Operations and Hyperbaric Tests ........................................................................................... 13 3.6 High Voltage Test (HV AC test) .............................................................................................. 14 3.7 Shell Continuity Test............................................................................................................. 14 3.8 Screen Continuity Test.......................................................................................................... 14 3.9 Insulation Resistance Test..................................................................................................... 14 3.10 Static pressure test (penetrators)............................................................................................ 15

4 Qualification tests..............................................................................................................................................................16 4.1 Trending of test results ......................................................................................................... 16 4.2 Qualification Test Sequence Requirements .............................................................................. 16 4.3 Critical component testing ..................................................................................................... 17 4.4 Prototype Manufacturing Acceptance Tests.............................................................................. 17 4.5 Electrical and Thermal Qualification Tests - connectors.............................................................. 17 4.6 Electrical and Thermal Qualification Tests – penetrators ............................................................ 18 4.7 Electrical Short Circuit Qualification Tests ................................................................................ 18 4.8 Hyperbaric Qualification Tests................................................................................................ 19 4.9 Pressure Cycling Tests – penetrators ...................................................................................... 20 4.10 Mechanical and Environmental Stress Tests ............................................................................ 21 4.11 Hyperbaric Long Term Qualification Test - connectors ............................................................... 23 4.12 Long Term Pressure Cycling Qualification Tests – penetrators .................................................... 24 4.13 Flooded hyperbaric long term qualification tests - connectors...................................................... 25 4.14 Flooded hyperbaric long term qualification tests - penetrators ..................................................... 25 4.15 Dismantling and Examination................................................................................................. 26

5 Definitions and abbreviations ........................................................................................................................................27 5.1 Definitions........................................................................................................................... 27 5.2 Abbreviations ...................................................................................................................... 28 5.3 Changes from previous version .............................................................................................. 29 5.4 References ......................................................................................................................... 30




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1 Objective, target group and provision

1.1 Objective

The objective of this document is to present requirements for design, fabrication, qualification and testing of connector assemblies, to be applied in project development work within the area of subsea technology. The document specifies detailed requirements which are not covered by TR1232 and TR3127, including their referenced standards. The document is valid for all connector assemblies with rated voltages Um in the range 3.6 Um 36 kV.

1.2 Target group

The target group for this document is personnel involved in project planning, project execution, modifications and operation of subsea installations.

1.3 Provision

This document is provided for in

- TR3070: Subsea technology, technical requirements and standards

2 Requirements

2.1 Operational conditions

The connector assemblies shall meet the following minimum operational requirements: 1. Maximum operational water depth: 3000 m 2. Steady state power frequency range: 15 – 100 Hz 3. External operating temperatures: -5 to +20 0C (sea temperature in service) 4. Internal1) operating temperature: -5 to +60 0C 5. Handling temperatures: -10 to +40 0C 6. Storage temperatures: -25 to +60 0C

1) Internal = inside housing to which the connector assembly is attached.

Specified temperature ranges do not take into account the heat developed by the connector assembly itself. Environmental and operational conditions other than the ones specified above shall be clearly specified in the project design basis (e.g. rated frequency for compressor motors).




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2.2 Ratings

2.2.1 Voltage rating

The values of Um of connector assemblies shall be chosen from the standard values of the highest voltage for equipment, as defined in IEC 60038. The following rated voltages shall be used: Uo/U (Um) = 1.8/3 (3.6) – 3.6/6 (7.2) – 6/10 (12) – 8.7/15 (17.5) – 12/20 (24) – 18/30 (36) kV.

2.2.2 Current ratings

The rated current Ir of connector assemblies should be chosen from the standard values specified in IEC 60059. The following values should be used: 100 – 200 - 250 – 315 – 400 – 500 – 630 – 800 – 1000 – 1250 – 1600 – 2000 – 2500 A. Rated current shall normally be specified for rated frequency in seawater at 20 deg C. For connector assemblies operating at other conditions, the rated current and corresponding operational ambient conditions shall be clearly specified in the data sheet. For penetrators and bulkhead mounted connectors, rated current may be given by operational conditions in the tank/housing to which it is mounted; these conditions shall be clearly specified in the data sheet. Maximum allowable current for operation at other conditions (e.g. lower sea water temperature, in air for system testing, other frequencies etc.), shall be given for information. Unless otherwise specified, the standard value of the rated thermal short-time current, Ith shall be 15 times Ir, tth being 1 s. Unless otherwise specified, the standard value of the rated dynamic current shall have an amplitude of the first peak equal to 2.5 times Ith.

2.2.3 Differential pressure rating (Design pressure)

Pressure retaining components (penetrators, bushings, bulkhead mounted connectors etc.) should be categorised and qualified to standardized pressure classes, in accordance with ISO 10423 as given below: 138 bar (2000 psi), 207 bar (3000 psi), 345 bar (5000 psi), 690 bar (10000 psi), 1035 bar (15000 psi) or 1380 bar (20000 psi).

2.3 Design Analysis

The connector assemblies shall be subject to a design analysis covering as a minimum: 1. Electrical, thermal and mechanical finite element analysis, covering qualification test and operational

conditions. The analysis shall include worst case loads (test, storage, handling, installation/retrieval and operation) including fault scenarios. The analysis should also include possible nonlinear and time dependent material properties. The analysis shall verify that the worst case loads do not exceed electrical, thermal or mechanical limitations for any material.

2. Design analysis shall include calculations to verify suitability of the pressure compensating system. The analysis shall include test, storage, transportation, installation/retrieval and operational conditions. Any hysteresis shall be included.




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3. The material properties and limitations used in the analysis shall be identified and documented based on qualified, recognised and repeatable fabrication processes, also applicable for bonding between materials.

4. The design shall be subject to a Design Failure Mode Effect and Criticality Analysis.

2.4 General requirements

The connector assemblies shall meet the following requirements: 1. The connector assembly shall be designed for a service life time of 25 years. 2. The connector assembly shall be designed as maintenance free throughout design service life. 3. The connector assembly shall be designed for minimum one year storage onshore and for minimum

one year storage subsea, in addition to the specified design service life. 4. Designed and capable of meeting project specific needs and operational requirements. 5. All parameters outside the envelope of previously qualified designs shall be presented, and shall also

include parameters regarded as not relevant. Qualification tests shall be performed if any relevant parameters are outside the envelope of a previously validated connector assembly design, such as operational conditions, design including new materials, assembly routines or production processes.

6. Minimum two water sealing barriers between sea water and electrical conductors/live parts shall be included. Each barrier shall be testable during qualification testing; at least one barrier shall be testable during FAT.

7. All cable terminations shall include an electric field controlling device, in order to ensure control of the electrical field stresses.

8. For XLPE cable terminations, the maximum conductor temperature in this interface shall be 65°C in order to limit the softening of the XLPE insulation.

9. It shall be possible to refurbish the connector assembly following retrieval, e.g. provisions shall be made for replacing critical parts (e.g. renewing dielectric fluid or replacing seals) each time the connector assembly is retrieved. Preferably, the refurbishment should be performed on the offshore vessel.

10. Unless otherwise specified, dummy connectors shall be possible to energize to minimum rated voltage, also allowing IR testing. If applicable, contacts shall be wired/shorted within the dummy connectors.

11. Differential pressures (hysteresis during pressurization/depressurization) between pressure compensated areas and pressure vessel shall be tested and verified, in order to document the compensating suitability at various depths (may be performed as discrete tests). Compensated areas shall also be documented as suitable for storage and transportation at the specified temperature ranges.

12. Operational changes in pressures and tolerance to rapid gas decompression (RGD) shall be documented, if applicable. If sealing or insulating materials are affected by the service environment, the RGD resistance shall be documented after long term exposure to this environment.

13. The fabrication processes and relevant procedures (eg. assembly, connection and locking) shall be qualified, recognized and demonstrated as repeatable.

14. Wet mate parts of a connector assembly with Um > 12 kV should be designed as an electrically clean environment mating type.

15. Rotational forces, vibrations, tensions, compressions or any other environmental effect, or a combination, shall not impair the function or quality of the connector assembly, throughout design service life.

16. Strain relief means for securing sheaths, screens and armour shall be incorporated in design - to verify mechanical and electrical suitability.

17. Connector assemblies should have measures for grounding of housings and cable screens. 18. The cable termination shall prevent longitudinal transport and pressure buildup from gas and water

between strands within a conductor, between the insulation system and a phase sheath and between




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the interstices of a multicore cable. The capability to withstand internal pressure shall be better or equal to what the cable can resist.

2.5 Connectors

2.5.1 General requirements

The following requirements apply to all types of connectors: 1. Rated number of matings (without maintenance) shall be specified for connectors and should be

minimum 50. If the connector assembly is intended used as part of a control system, the rated number of matings should be minimum 90.

2. The electrical contacts shall be robustly constructed and should be gold plated. The electrical contacts shall not be capable of physical contact with the contacts of the opposing connector assembly half during primary engagement of the connector assembly, to ensure that the electrical contacts are not exposed to any primary alignment forces.

3. Designed as capable of vertical, tilted and horizontal operation, including mating and demating. 4. Designed with clearly visible indications of correct rotational and axial alignment prior to and during

mating. The connector assembly shall also have self-evident means to indicate that the connector assembly is fully mated; i. e. a positive fully mated indication shall be part of design.

5. Designed with a robust locking mechanism to prevent accidental or vibration-induced demating or malfunction. The connector assembly shall have self-evident means to indicate that the locking mechanism is fully locked, i.e. a positive fully locked indication shall be part of design.

2.5.2 Wet mateable connectors

Additional requirements for wet mateable connectors: 1. Designed as capable of installation/retrieval at subsea depth by ROV/ROT. Further reference is made

to TR1231. 2. Designed to accept calcium deposits, marine growth and debris without jamming, and without

interfering mating, demating and operation. 3. Designed for operation within the presence of sand and silt, and tolerant to silt and fine sand deposits

(eg. mating areas, housing and locking mechanism). The connector assembly design shall not be suscepticle to sand particles during mating or demating.

4. The connector assembly shall be designed for water-jet cleaning of marine growth in the mated condition, or with a protection cap assembled. The potential risks of performing this water jetting shall be clearly defined and documented.

5. The connector assembly shall be designed for acid cleaning with citric acid and brushed with a purpose made ROV brushing tool to remove calcium growth. Applicable limitations shall be specified, e. g. maximum concentrations and durations when using citric acid.

6. Unprotected parts of the connector assembly shall be protected immediately after subsea demating, and shall remain protected until subsea mating. Water-jetting or acid cleaning may be performed on unmated connector halves just prior to subsea mating if dirt or calcite deposits are present (if not prohibited by connector user manual).

7. If an ROV operated system is selected, personnel from an ROV company shall be involved in engineering and testing of the tooling system. Operational simulations (3-D) should be used as part of engineering and development. The need for a shallow water test shall be evaluated and a recommendation presented to Company. The performance of such test is optional, pending on Company decision.




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2.5.3 Dry mateable connectors

Additional requirements for dry mateable connectors: 1. Dry mateable connectors shall be suitable for mating/demating in harsh offshore conditions, i.e. in a

humid and salt atmosphere. 2. The mating interface volume should be oil filled and pressure compensated. 3. Means for testing seals between the connector halves after mating shall be included.

2.6 Penetrators

2.6.1 General requirements

The following requirements apply to all penetrators: 1. The penetrator connection seal should include two sealing barriers. If only one penetrator connection

seal is used, this shall be metallic. Each barrier shall be separately testable during qualification testing; at least one barrier shall be testable during FAT. The pressure integrity barriers and water blocking methodology shall be approved by Company.

2. The materials used shall be compatible with the gas or fluid inside the compartment, at the specified temperature range.

2.6.2 Penetrators for pressure compensated housings

Penetrators used in pressure compensated housings shall be designed for a differential pressure in the range –10 to +10 bar in the specified temperature range.

2.6.3 Penetrators subject to differential pressure

Requirements for penetrators which are exposed to differential pressure above what is normally seen for pressure compensated assemblies: 1. Components intended for differential pressure service shall be designed and tested mechanically

according to the design code applicable to the part to which it is mounted. If not specified, ISO 10423 should be used as a reference, where PSL 3G should be the level of technical quality/documentation.

2. Applicable temperature range shall be clearly specified and related to the pressure rating requirements.

2.7 Jumpers/cable pigtails

1. Jumper cables shall have mechanical protection in addition to the cable outer sheath. If oil filled hoses are used, the hoses should generally not be used as pressure compensation for connectors/ penetrators (i.e. not share oil volume).

2. Jumper cables should have a tension strength element included in order to avoid tensional forces in the cables.

3. The jumper, pigtail and interfacing parts of the connector assembly shall be stable after complete installation subsea and throughout design service life, either by design or by other measures. VIV or stability analysis and resulting protection or design changes shall be performed, if necessary.

4. Electrical cables should in general be designed and type/FAT tested in accordance with IEC 60502-2. Cable sheath shall be included.




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2.8 Seals The connector assemblies shall meet the following requirements:

1. In general all connector assemblies shall incorporate minimum two water sealing barriers between seawater and electrical conductors/live parts. The seals shall be independently installed (different seal surfaces). Each barrier shall be testable during qualification testing; at least one barrier shall be testable during FAT.

2. Seals shall be of subsea field proven type and designed and qualified for continuous subsea operation for all operating conditions.

3. Materials used shall be compatible with all applicable interfacing materials and fluids, also if one sealing barrier should fail.

4. The sealing components of the connector assembly shall not deform the cable insulation or the outer semi-conductive layer in such a way as to lower the electric or mechanical strength of the cable.

5. Cable outer sheath can be considered as one sealing barrier. 6. The principle with two water sealing barriers is applicable also to dummy connectors (main

connector disconnected). 7. Seals exposed to process gas/fluid in normal operation shall be metallic. 8. Use of test ports for testing of seals should be minimized. Where test ports are introduced, careful

consideration shall be made in order not to introduce new potential leakage paths and reduce the main seals integrity level. Preferably seal test ports should be plugged and sealed by welding after use.

9. Supplier shall demonstrate that the sealing system fulfills the design life time of the connector assembly. Any diffusion shall be quantified and it shall be verified that the diffusion rates are acceptable.

2.9 Material Requirements

The connector assemblies shall meet the following requirements: 1. The connector assembly shall consist of proven materials and components, which are qualified and

suitable for relevant equipment, applications and environments. 2. Norsok standard M-001 should be used as reference standard for materials selection and testing. 3. TR3101 shall be used for fasteners. 4. The polymeric materials used for sealing and/ or insulation shall be compatible with the service

environment. The compatibility shall be documented according to requirements and test methodology given in Norsok standard M-710 when exposed to the applicable service fluids.

5. If compatiblity tests reveal material changes that may affect the electrical performance or sealing capability, relevant tests as defined in chapter 4 shall be repeated after equally long time service environment exposure.

6. Each connector assembly and its individual parts shall be documented as 100 % traceable, enabling comparison and rectification on similar connector assemblies. Hence, materials, manufacturing records and recording of test results shall ensure full traceability for each connector assembly. The materials shall be delivered with certificates type 3.1 according to EN 10204.

7. Barrier materials exposed to process gas/fluid in normal operation should be inorganic. 8. The composition of all metallic components shall be verified by positive material identification (PMI)

according to Contractors procedure. The PMI shall be performed as late as possible in the assembly process and the result documented.

9. All testing and traceability documentation shall be available for review upon request. Testing performed to other standards than mentioned above may be acceptable, based on comparative qualification between the applicable standards.




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10. Qualification testing of new materials, new combination of materials or bonding between materials shall be performed. New is defined as new material grade or materials not used in similar equipment, application and/or environment. The qualification program and acceptance criteria shall be presented to Company for acceptance prior to testing.

11. The connector assembly shall be compatible with relevant and interfacing fluids/materials as per operational requirements, throughout design service life.

12. The connector assembly shall be designed to either be cathodically protected or made of a sea water resistant material. In the latter case, the connector assembly shall be electrically isolated from the CP system. After assembly, the electrical bonding contact or insulation, respectively, shall be measured and documented.

13. Any dielectric oil shall be carefully selected, also considering density relative to water, such that potential migration and/or ingress of water do not gather in critical areas within the connector assembly – leading to reduction of service life.

14. New non-metallic sealing and barrier materials, new combination of materials or bonding between materials shall be tested and qualified to prove the ability to withstand the thermal, electrical and mechanical stresses it may be exposed to. The test program should typically include, but not be limited to, the following:

Compatibility tests Disc bursting tests (for insert moulding materials, e.g. epoxy) Bonding tests

The test program and acceptance criteria shall be based on Norsok standard M-710.

15. The materials selection report shall be presented to Company for acceptance, before construction of connector assemblies commences.

2.10 Test Requirements

2.10.1 General test requirements

1. Test procedures and acceptance criteria shall reflect the conditions, interfaces and environment during operation, installation and recovery/re-installation plus all temporary phases. The design limits should as far as possible be determined through testing, both to establish the actual safety factors and to verify the nominal values (software calculations).

2. Test procedures with unambiguous test setup sketches and test descriptions shall be developed based on this specification. A section in each test procedure shall describe the HSE hazards and the HSE measures taken to reduce the hazards. Previously performed tests shall be documented as compliant to this specification. Any deviations shall be listed and presented.

3. Test personnel shall be documented as technically competent and trained to perform the applicable tests, where competence also includes HSE aspects during testing.

4. The necessary amount of prototype connector assemblies and test accessories shall be provided, resulting from this specification. Furthermore, the prototype connectors should be manufactured from verified fabrication processes, enabling repeatable serial production with similar quality. Such validation shall be presented to Company for acceptance.

5. Findings from the critical componenent testing (ref. section 4.3) shall be incorporated into the design prior to build and test of the prototype.

6. The same connector assembly should be used throughout qualification testing without refurbishment. Alternatively, it shall be validated that testing of several connector assemblies or discrete testing of subassemblies provides the same confidence level as one connector assembly throughout qualification testing. Such validation shall be presented to Company for acceptance.




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7. The prototype connector assemblies used for qualification testing shall be purpose built, i.e. shall not be used subsea after qualification testing, unless agreed with Company.

8. The cable termination shall be included in the penetrator qualification tests, where applicable. 9. The wet test equipment shall be outfitted as specified in section 2.10.2. 10. When wet tests in simulated worst case seawater is specified, the simulated worst case seawater shall

be as specified in section 2.10.3. Composition of the simulated worst case seawater and even distribution of particles within the pressure vessel shall be verified prior to and after testing.

11. Dismantling and examination as per section 4.15 should be performed when deemed necessary, pending on the detailed qualification test program.

2.10.2 Wet test equipment requirements

The wet test equipment shall meet the following requirements: 1. The pressure vessel shall be outfitted such that the simulated worst case seawater can be circulated

during testing, to ensure that the composition and particles remain evenly distributed within the pressure vessel - when relevant.

2. Pressurization and depressurization rate capability within the pressure vessel should be minimum 20 bar/minute. Measures should be made to avoid ice forming during depressurization.

3. An externally controlled connector assembly mating device shall be installed within the pressure vessel, where the mating device shall be operable at the specified test conditions. The connector assembly half which is designed to move shall be positioned in the mating device. The mating device shall enable repeated mating and demating of connector assemblies. Worst case angles, maximum misalignment tolerances and measurement of forces may be performed dry or as a separate test at ambient pressure.

4. Sensors as required shall be included in the test setup, to monitor the applicable parameters, e.g. pressures and temperatures. Sensors should also enable measurements of differential pressures between pressure compensated areas and pressure vessel, and forces resulting from mating/demating and locking/unlocking - if not performed as discrete tests.

2.10.3 Simulated worst case seawater requirements

The simulated worst case seawater shall meet the following requirements: 1. Salinity to be approx. 35000 ppm (sea salt plus mains water) containing approximately 1.5 per

cent weight sand and silt. 2. The distribution of particle size shall be approximately flat between 2-500 microns. Typically 1%

river silt (2-50 microns) and 0.5% builders’ soft and sharp sand (50-500 microns) may be used. 3. The composition and temperature of the seawater shall be established, recorded and verified prior

to testing, and circulation shall be provided and maintained during testing - when relevant.




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3 Factory acceptance tests

3.1 Acceptance Test Sequence Requirements

The factory acceptance test sequence shall be as follows: 1. Helium tightness control test. 2. Contact resistance. 3. Shell continuity. 4. Screen continuity. 5. PD test to 1.73 x Uo (< 10 pC). 6. Operations and Hyperbaric tests. 7. Static pressure test (penetrators). 8. Contact resistance. 9. PD test to 1.73 x Uo (< 10 pC). 10. PD test to 2.5 x Uo (< 50 pC). 11. HV AC test to 2.5 x Uo (hold time 30 min.). 12. PD test to 1.73 x Uo (< 10 pC) For delivery connectors, number of mate/demate operations during FAT shall be recorded and part of final documentation. This log shall be maintained during subsequent system test activities (SIT etc) up until commissioning and start-up.

3.2 Helium Tightness Control Test

3.2.1 General

The objective of the helium tightness control test is to verify that all sealing barriers are correctly fitted during assembly and do not leak. The required two independent sealing barriers shall be tested during assembly, where a helium tightness control shall be carried out to verify the intended sealing functions. The test procedure shall be supported with drawings where each sealing barrier is defined. The vacuum technique as outlined in section 3.2.2 shall be used for tightness control. If the vacuum technique can not be used due to the design solution, the sniffer technique as outlined in section 3.2.3 may be considered acceptable for tightness control. However, the sniffer technique has a much lower sensitivity - such that reliable and quantitative results may reveal challenging to obtain. Note: Correct use of Helium vacuum techniques will reveal a single seal leakage almost immediately,

after a short period of Helium purging (typically << 1 min.). If Helium is exposed for longer periods (typically > 5 min.), diffusion through soft materials (seals, membranes, non-metallic parts) may take place - which would then complicate the interpretation of test results. The test procedure should cater for diffusion effects, and the test equipment supply/return lines should be short – contributing to a successful test performance. When testing across a double/multi seal barrier or double/multi string welded seam, a leak indication will be delayed - and it could be very difficult to discriminate a leak from diffusion.




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3.2.2 Vacuum technique

Helium shall be applied so that it swamps one side of the sealing barrier/termination chamber to be tested. Helium leakages shall be sensed on the other side of the sealing barrier/termination chamber with a mass spectrometer - having an accuracy better than 1·10-9 mbar·l/s. Temperature and pressure shall be continuously recorded. An outline procedure/sequence should be as follows:

Connect the test equipment on one side of the sealing barrier/termination chamber to be tested, and let the test equipment run until the background helium level indication is stable - and low enough to allow reading in the acceptance criteria range.

Purge helium systematically at the other side of the sealing barrier/termination chamber to be tested, where it shall be assured that helium fully surrounds each seal.

The mass spectrometer helium rate before and after each purging shall be recorded. Acceptance criteria: The reading shall not increase with more than 5·10-8 mbar·l/s during purging with helium.

3.2.3 Sniffer technique

If the sniffer technique shall be used for tightness control in a serial production, measures to prevent a varying helium to air ratio in the test room/area should be performed. Company shall accept if the sniffer technique can be used for tightness control purposes. A clear reasoning and a procedure should then be provided, outlined as follows:

The sealing barriers/termination chamber to be tested should be entirely wrapped (to gather leakages). The sniffer probe should be positioned inside the wrapping at relevant locations (as and where required).

There shall be a verified calibration procedure for each sniffer test, i. e. for each sealing barrier/termination chamber to be tested. When developing each calibration procedure, an acceptable sniffer signal shall be documented. Due to the uncertainty related to this sniffer test method, a safety factor of minimum 10 should be applied on the sniffer signal - to account for inaccuracies.

The acceptance criteria shall be based on a documented analysis for each case/design solution that is tested.

3.3 Contact Resistance Test (CR test)

The objective of the test is to determine the resistance of the connector assembly contacts. The contact resistance shall be measured at each contact interface during assembly. The resulting total resistance (cable termination to cable termination) shall also be measured – for all connector assemblies. The values measured during prototype manufacturing acceptance tests and the initial test after manufacturing shall be used as references, for all subsequent tests. The CR test shall be performed in accordance with IEC 61238-1. The current used shall be minimum 10 % of the rated current, however not lower than 10 A. Any subsequent increase in contact resistance shall be explainable. Acceptance criteria: Maximum 20 mV (rms) voltage drop across each contact interface at rated current (extrapolation acceptable). Similar (within ± 10%) resulting total resistance (cable termination to cable termination) for identical designs. This also applies to multipin connector assemblies.




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3.4 Partial Discharge Test (PD test)

The objective of the test is to determine that the PD level for the connector assembly is below the acceptance criteria, and hence verify the insulation quality of the connector assembly. The partial discharge test shall be performed in accordance with IEC 60270 and IEC 60885-2. The test shall be performed on each circuit with the voltage applied between the cable conductor (pin) and the earthed metallic screen and housing, with all other circuits earthed. This procedure shall be repeated on each circuit. Acceptance criteria: PD level < 10 pC @ 1.73 x Uo PD level < 50 pC @ 2.5 x Uo

3.5 Operations and Hyperbaric Tests

The objective of the test is to verify correct operation of each production connector assembly, at the specified conditions. Conductive tapped water is required. If applicable, jumper hose pressures shall be recorded both pre and post hyperbaric testing. Prior to, during and after hyperbaric testing, the following parameters shall be tested and recorded. Contact resistance, as per section 3.3. Shell continuity, as per section 3.7 (prior to and after hyperbaric testing, as a minimum). Screen continuity, as per section 3.8 (prior to and after hyperbaric testing, as a minimum). Insulation resistance (IR), as per section 3.9. Step Pressure

1. Prior to or during hyperbaric testing, mechanical fit-up tests shall verify that applicable forces needed to mate/demate and lock/unlock the connector assembly at all applicable conditions are within the defined envelope for each applicable force. The needed forces shall be thoroughly tested and reported, which also apply for rotational and axial alignment tolerances and indications (mating and locking).

2. Prior to hyperbaric testing (in dry conditions), perform tests as listed above. 3. After filling and soaking for 1 hour, perform tests as listed above. 4. Pressurize from ambient pressure to 1.1 x HP. 5. Hold at 1.1 x HP for 1 hour and perform tests as listed above after the hold period. 6. Demate-mate at 1.1 x HP and perform tests as listed above after the demate/mate (wet mate

connectors only). 7. Depressurize from 1.1 x HP to ambient pressure. 8. Hold at ambient pressure for 1 hour. 9. Demate-mate (at ambient pressure) (connectors only)

10. Perform tests as listed above. Table 1: Sequence of Operations and Hyperbaric Tests Pressurization and depressurization rate should be minimum 20 bar/minute. Hold time after each pressurization or depressurization should be minimum 5 minutes. Acceptance criteria: The forces measured during the operation tests shall be within the defined envelope. The connector assembly electrical performance as specified above shall remain within specification and




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without reduction throughout testing. Jumper hose pressure shall not be reduced throughout testing. Acceptance criteria given in referenced sections shall also be met.

3.6 High Voltage Test (HV AC test)

The objective of the test is to verify the insulation level of the connector assembly. The test shall hence verify the electrical withstand level of the connector assembly and prove the ability to withstand the electrical stresses it is exposed to. The HV AC test shall be performed in accordance with IEC 61442 and 60060-1. The test shall be performed on each circuit with the voltage applied between the cable conductor (pin) and the earthed metallic screen and housing, with all other circuits earthed. This procedure shall be repeated on each test circuit. Test voltages and durations shall be as specified in the various test sequences in this specification. Acceptance criteria: No breakdown or flashover shall occur.

3.7 Shell Continuity Test

The objective of the test is to determine the resistance between connector assembly metallic housings, intended to provide electrical continuity when mated. The test shall be performed in accordance with IEC 61238-1. Acceptance criteria: Maximum 100 mV voltage drop across each contacting interface at the maximum expected current. If no current is specified, 10 A shall be used.

3.8 Screen Continuity Test

The objective of the test is to determine the resistance between the power cable screen and the connector assembly, intended to provide electrical continuity (defined path for charging/fault currents). The test shall be performed in accordance with IEC 61238-1. The total resistance between the power cable screens on each side of the connector assembly shall also be measured. Acceptance criteria: Maximum 30 mV voltage drop across each contacting interface at the maximum specified current. If no current is specified, 20 A shall be used.

3.9 Insulation Resistance Test

The objective of the test is to detect any insulation resistance (IR) changes throughout hyperbaric testing. The insulation resistance against earth shall be measured on each electrical contact individually, where other electrical contacts and conductive parts are earthed. A DC megger with 2500 V test voltage should be used for testing. For connector assemblies with Um above 7.2 kV, the measurement shall be performed with 5000 V DC. The insulation resistance shall be recorded after 1 and 10 minutes. Acceptance criteria: IR > 10 GΩ (stable reading) after 10 minutes. Recording shall be performed at 1 and 10 minutes.




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3.10 Static pressure test (penetrators)

This test is applicable to penetrators only. The objective of the test is to verify correct operation of each penetrator at the specified conditions. Conductive tapped water is required. If applicable, jumper hose pressures shall be recorded both pre and post pressure testing. Prior to, during and after the pressure testing, the following parameters shall be tested and recorded: Contact resistance, as per section 3.3. Insulation resistance (IR), as per section 3.9.

Step Pressure 1. Prior to differential pressure testing (dry conditions), perform tests as listed above. 2. After installation in pressure tank, filling and soaking for 1 hour, perform IR test 3. Pressurize from ambient pressure to 1.5 x DP 4. Hold at differential test pressure for 3 minutes 5. Release pressure to ambient 6. Pressurize from ambient pressure to 1.5 x DP 7. Hold for 15 min, perform IR test after 1 min. 8. Release pressure to ambient, perform IR test after 1 min. 9. Hold at ambient pressure for 1 hour, perform IR test. 10. Perform He Leak test as per section 3.2

Table 2: Sequence of Static pressure Test Pressurization and depressurization rate should be minimum 20 bar/minute. Test shall be performed for differential pressure in both directions (internal –ambient, ambient-internal), as applicable. Acceptance criteria: No leakage/no pressure drop (any drop in pressure shall be explainable). Acceptance criteria given in referenced sections shall also be met.




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4 Qualification tests

4.1 Trending of test results

In order to detect any deterioration of the component during the test programme, the following parameters shall be trended through the complete test programme:

- Contact resistance (voltage drop) - Insulation resistance - PD Inception voltage (as applicable)

Temperature correction shall be performed when applicable. Results shall be presented in tables and graphically as part of the final test report.

4.2 Qualification Test Sequence Requirements

The test sequence should be as listed below. 1. Critical component testing 2. Prototype manufacturing acceptance tests 3a. Electrical and thermal qualification tests - connectors 3b. Electrical and thermal qualification tests – penetrators 4. Electrical short circuit qualification tests 5. Hyperbaric qualification tests 6. Pressure cycling tests – penetrators 7. Mechanical and environmental stress tests 8a. Hyperbaric long term qualification tests- connectors 8b. Long term pressure cycling qualification tests - penetrators 9a. Flooded long term qualification tests – connectors 9b. Flooded long term qualification tests – penetrators 10. Dismantling and examination Note A: Dismantling and examination as per section 4.15 should be performed when deemed

necessary, pending on the detailed qualification test program and number of prototype connector assemblies, with reference to section 2.10.1 (test requirement nos. 4 and 5).

Note B: CR, IR and PD tests at the start of a new test sequence are not necessary if already performed

at the end of previous sequence. If dismantling of a connector assembly has been performed, the below listed tests shall be performed prior to starting the next test sequence.

Contact resistance. Insulation resistance. PD test to 1.73 x Uo. PD test to 2.5 x Uo. HV AC test to 2.5 x Uo (hold time 1 hour). PD test to 1.73 x Uo.




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4.3 Critical component testing

The objective of the critical component testing is to verify the most critical part/components in a new design by testing on a component/sub-assembly level prior to building and testing a full prototype. This will increase the probability of succesfull qualification testing. Contractor shall, for all new designs, identify “critical” components (also ref section 2.4.4). These may represent extension of current technology, new materials, new bonding between materials, new geometries etc. Based on a risk assessment of the new design, a test program for the “critical” components/sub-assemblies shall be proposed. The crititcal component testing shall be successfully completed before the design is frozen and the first prototype built.

4.4 Prototype Manufacturing Acceptance Tests

The objective of the test is to verify that the connector assembly used for qualification testing is free from manufacturing defects. The outline test specification and sequence are as follows: 1. Helium tightness control test, as per section 3.2. 2. Static pressure test, as per section 3.10 (penetrators only) 3. Contact resistance, as per section 3.3. 4. Insulation resistance as per section 3.9 5. PD test to 1.73 x Uo, as per section 3.4. 6. PD test to 2.5 x Uo, as per section 3.4. 7. HV AC test to 4 x Uo (hold time 1 hour), as per section 3.6. 8. PD test to 1.73 x Uo, as per section 3.4. Acceptance criteria given in referenced sections shall be met.

4.5 Electrical and Thermal Qualification Tests - connectors

The objective of the tests is to verify the ability of the connector assembly to handle electrical load changes with and without hyperbaric pressure. Information about capability for operation in air will also be determined. A temperature rise test at rated current and frequency shall be performed before the thermal cycling commences, in order to determine the highest local temperatures within the connector assembly. Temperature detectors shall be assembled where the highest local temperatures are expected. The temperature rise test shall be conducted until the temperature is stable, i.e. maximum 1 degrees Celsius temperature variation over a duration of 1 hour. Then the current shall be increased to reach a stable temperature 5-10 degrees Celsius above steady state temperature at rated current. The measured current shall be recorded and used in the thermal cycling test described below. The test shall be performed

- in air at ambient temperature and - in the relevant operational environment (fluid, gas..) at the maximum ambient temperature. This

figure shall be used as basis for the thermal cycles test. The outline test specification and sequence are as follows:




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1. Temperature rise test 2. Thermal cycles x 15 without hyperbaric pressure (ambient). 3. Thermal cycles x 15 at 1.1 x HP. 4. Contact resistance, as per section 3.3. 5. Insulation resistance test as per section 3.9 6. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 7. PD test to 1.73 x Uo, as per section 3.4. Thermal cycling: The connector assembly shall be installed in conditions corresponding to the actual ambient media and the worst case operational thermal conditions. The connector assembly shall be heated by passing the current (as determined by the temperature rise test in operational conditions) through the conductor. A voltage of 2.5 x Uo shall be applied during the test. When the conductor temperature has reached a stable value, 5-10 degrees Celsius above the temperature the connector assembly will have when running at maximum rated operational current, it shall be kept at this temperature for at least 2 hours. The connector assembly shall then be cooled down to maximum 10 degrees Celsius above ambient temperature. The total duration of each thermal cycle shall be minimum 8 hours. Reference is made to IEC 60502-4 and IEC 61442 (heating cycle curve). Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. Acceptance criteria given in referenced sections shall also be met.

4.6 Electrical and Thermal Qualification Tests – penetrators

Penetrators shall undergo a similar thermal qualification test as described in 4.4 above, but with the following test sequence: 1. Temperature rise test (in air). 2. Thermal cycles x 15 with no differential pressure. 3. Thermal cycles x 15 at 1.5 x DP (internal - ambient). 4. He leak test as per section 3.2. 5. Insulation resistance as per section 3.9. 6. Thermal cycles x 15 at 1.5 x DP (ambient - internal). 7. He leak test as per section 3.2. 8. Insulation resistance as per section 3.9. 9. Contact resistance as per section 3.3. 10. HV AC test to 2.5 x Uo (hold time 1 hour) as per section 3.6. 11. PD test to 1.73 x Uo as per section 3.4. Acceptance criteria: The penetrator electrical performance as specified above shall remain within specification and without reduction throughout testing. Acceptance criteria given in referenced sections shall also be met.

4.7 Electrical Short Circuit Qualification Tests

4.7.1 General

The objective of the tests is to ensure that the connector assembly is able to withstand the maximum calculated short circuits in the system without degradation or damage.




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The outline test specification and sequence are as follows: 1. Contact resistance, as per section 3.3. 2. PD test to 1.73 x Uo, as per section 3.4. 3. Thermal short circuit, as per section 4.6.2. 4. Dynamic short circuit, as per section 4.6.3. 5. Contact resistance, as per section 3.3. 6. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 7. PD test to 1.73 x Uo, as per section 3.4. Unless otherwise specified, the standard value of the rated thermal short-time current, Ith shall be 15 times Ir, tth being 1 s. Unless otherwise specified, the standard value of the rated dynamic current shall have an amplitude of the first peak equal to 2.5 times Ith. Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No degradation or damages shall be observed. The acceptance criteria given in referenced sections shall also be met.

4.7.2 Thermal short circuit tests

The objective of the test is to ensure that the connector assembly is able to withstand the maximum calculated short circuits in the system without degradation of the conductor contacts or insulation material. The test methods shall be as relevant in IEC 61442. One end shall be connected to the test generator and the other end to a short circuiting bar. Maximum short circuit temperature for the materials shall be defined, eg. 250 degress Celcius for XLPE insulated cables. The connector assembly shall be subjected to two short circuits.

4.7.3 Dynamic short circuit tests

The objective of the test is to ensure that the connector assembly is able to withstand the maximum calculated short circuit currents in the system without degradation or damages to the sealing barriers due to mechanical forces. The test is project specific and only relevant if the peak current is > 80 kA (single phase) and 63 kA (three phase). The test requires a three phase assembly as installed subsea, to be regarded as a valid test. The test methods shall be as relevant in IEC 61442. One end shall be connected to the test generator and the other end to a short circuiting bar. The waveform shall be recorded. The connector assembly shall be subjected to two short circuits.

4.8 Hyperbaric Qualification Tests

The objective of the tests is to ensure that the connector assembly is able to withstand the maximum number of surface recoveries without degradation or damage. The test requirements are as per section 2.10.




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The outline test specification and sequence are as follows: 1. Contact resistance, as per section 3.3. 2. Insulation resistance, as per section 3.9. 3. PD test to 1.73 x Uo, as per section 3.4. 4. Demate/mate (connectors only). 5. Pressure cycling x 15 (from ambient pressure to 1.1 x HP). 6. Repeated demate/mate x 30 at 1.1 x HP (wet mate connectors only). 7. Repeated demate/mate x 10 at ambient pressure (dry mateable connectors only). 8. No mating (penetrators only) 9. Pressure cycling x 15 (from 1.1 x HP to ambient pressure). 10. Demate/mate (connectors only). 11. Contact resistance, as per section 3.3. 12. Insulation resistance, as per section 3.9. 13. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 14. PD test to 1.73 x Uo, as per section 3.4. Pressurization and depressurization rate should be minimum 20 bar/minute. Hold time after each pressurization or depressurization should be minimum 5 minutes. Pressure compensated areas: The pressure compensated areas within the connector assembly may be qualified as part of this test, or discrete tests should be performed. Repeated demate/mate: Correct operation of the connector assembly at specified worst case angles/speed/misalignment

during mating and demating shall be demonstrated, where the maximum misalignment tolerances, speed and mating forces shall be established in advance.

Correct operation of the locking mechanism shall be demonstrated. The locking mechanism shall be checked for correct operation/position both in locked and unlocked position.

All reasonable attempts to mate and lock the connector assembly with various worst case angles/speed/misalignment shall be performed.

All applicable forces needed to mate/demate and lock/unlock the connector assembly at all applicable conditions shall be thoroughly tested and reported.

As described in section 2.10.2, worst case angles, maximum misalignment tolerances and measurement of forces may be performed dry or in a water filled pool at ambient pressure. Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No leakage, degradation or damages shall be observed. The acceptance criteria given in referenced sections shall also be met. The forces measured from mate/demate and lock/unlock operations shall be within the limitations of the installation method intended used.

4.9 Pressure Cycling Tests – penetrators

This test is applicable to penetratrors only. The objective of the test is to demonstrate that the penetrator is capable of handling varying pressure loads at the worst case operational conditions. The penetrator shall be installed at actual operational conditions (media and temperature) during the test.

1. Contact resistance, as per section 3.3. 2. Insulation resistance, as per section 3.9. 3. PD test to 1.73 x Uo, as per section 3.4.




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4. Pressure cycling x 30 (from ambient pressure to 1.5 x DP). Hold time for each cycle shall be 5 minutes.

5. Insulation resistance as per section 3.9 shall be measured every 5th cycle. 6. Contact resistance, as per section 3.3. 7. Insulation resistance, as per section 3.9. 8. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 9. PD test to 1.73 x Uo, as per section 3.4. 10. He leak test as per section 3.2

The above specified test sequence shall be performed twice, with differential pressure applied in different directions (internal – ambient, ambient - internal). Acceptance criteria: No leakage/no pressure drop during hold time (any pressure drop shall be explainable). The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No degradation or damages shall be observed. The acceptance criteria given in referenced sections shall also be met.

4.10 Mechanical and Environmental Stress Tests

4.10.1 General

The objective of the tests is to ensure that the connector assembly is able to withstand the mechanical and environmental stresses it may be exposed to, without degradation or damage. The outline test specification and sequence are as follows: 1. Contact resistance, as per section 3.3. 2. PD test to 1.73 x Uo, as per section 3.4. 3. Thermal shock test, as per section 4.9.2. 4. PD test to 1.73 x Uo, as per section 3.4. 5. Impact/shock test, as per section 4.9.3. 6. PD test to 1.73 x Uo, as per section 3.4. 7. Vibration tests, as per section 4.9.4. 8. PD test to 1.73 x Uo, as per section 3.4. 9. Cleaning and spillage test, as per section 4.9.5. 10. Contact resistance, as per section 3.3. 11. PD test to 1.73 x Uo, as per section 3.4. 12. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 13. PD test to 1.73 x Uo, as per section 3.4. 14. PD test to 2.5 x Uo, as per section 3.4. 15. Dismantling and examination Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No degradation or damages shall be observed. The acceptance criteria given in referenced sections shall also be met.

4.10.2 Thermal shock test

The objective of the test is to verify that the connector assembly is able to withstand thermal shocks, without degradation or damage.




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The connector assembly shall be tested in unmated condition, at atmospheric pressure. High Temperature x 3: The temperature shall be raised to 60 degrees Celcius and maintained for a period of four hours. The connector assembly shall then be rapidly cooled by immersion in water, which shall have a temperature between 0 and 5 degrees Celcius. Water volume shall be sufficient to ensure a rapid cooling. Allow the connector assembly to return to ambient room temperature. Low Temperature x 3: The temperature of each assembly shall be lowered to -25 degrees Celcius and maintained for a period of four hours. The connector assembly shall then be rapidly heated by immersion in water, which shall have a temperature between 0 and 5 degrees Celcius. Water volume shall be sufficient to ensure a rapid heating. Allow the connector assembly to return to ambient room temperature.

4.10.3 Impact/shock test

The objective of the test is to verify that the connector assembly is able to withstand an accidental force or impact, without degradation or damage, typically from an ROV or during transport/assembly. Apply a 5 kN force (minimum) to the connector assembly (mated connector pair or penetrator), in as many directions as possible. The force shall be applied rapidly (within 1 second) and shall be applied three times in each direction (minimum). A free fall test shall be performed in accordance with IEC 60721-3-2 Table 5 Class 2M2. The floor shall be hard, typically as for a transport compartment. For connectors, the test shall be performed both with a mated connector assembly and with unmated connector halves.

4.10.4 Vibration test

The objective of the test is to verify that the connector assembly is able to withstand vibrations, without degradation or damage. As a minimum, vibration tests shall be based on all vibration sources acting on the connector assembly, including relevant interfaces which may cause amplification or dampening, and where a safety margin ≥ 5 shall be catered for. The tests shall be performed such that amplifications built-up over time are registered, where gravity and mounting position also shall be catered for. The outline test specification is as follows: 1. Sweep test of 25 mm/s in the frequency range 5 - 190 Hz, in all directions (X-Y-Z). The 25mm/s is

based on worst case level vibrations (normally 5 mm/s) and that a safety margin of 5 normally is used for accelerated vibration testing.

2. Sweep test of 3 g acceleration in the frequency range 190 - 1000 Hz. 3. Four shock tests at 30 g 11 ms half sine in each of the six directions. 4. Endurance testing to prove calculated fatigue properties, where the test procedure shall reflect

design service life. A fatigue level safety margin of 2.5 is in accordance with Wøler S-N curves (see figure below).




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Example of S-N (Wøler) curve

0

100

200

300

400

500

600

700

800

900

1,E+01 1,E+02 1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08 1,E+09 1,E+10Number of cycles (-)

Str

ess

leve

l (M

pa)

Example S-N curveVibration during test (5 times operational level)Maximum vibration during operation

Figure 1: Wøler S-N curve

Acceptance criteria: 1. No resonances with amplification > 10 in the frequency range 5 - 1000 Hz. 2. No fractures or visible signs of fatigue induced cracks. 3. No signs of fretting, deterioration of seals or seal leakages. 4. No reduction in pretension of mechanical parts.

4.10.5 Cleaning and spillage test

The objective of the test is to verify that cleaning of marine growth, calcium or accidental spillage of chemicals can be performed topsides or subsea, without degradation or damage. The ability to withstand short time exposure to the applicable fluids shall be demonstrated, and maximum exposure limitations shall be specified. Mated connector assembly (dry test): Expose the connector assembly with 50% citric acid for one hour, and then wash the connector assembly with a metal brush with vigour as expected for a purpose built subsea ROV washing and brushing tool. Typical fluids the mated or unmated connector assembly may be exposed to are hydraulic fluids (Brayco, Oceanic or Transaqua), glycol, methanol or diesel. It shall be documented if there is any need to clean these fluids from the connector assembly, and/or specify exposure limitations and cleaning methods/tools (both topsides and subsea cleaning methods).

4.11 Hyperbaric Long Term Qualification Test - connectors

The objective of the tests is to ensure that the connector assembly is able to withstand long term service at operational conditions, without degradation or damage. Conductive tapped water is required. The outline test specification and sequence are as follows:




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1. Contact resistance, as per section 3.3. 2. Insulation resistance, as per section 3.9. 3. PD test to 1.73 x Uo, as per section 3.4. 4. Demate/mate. 5. Long term pressure test at elevated temperature and 1.1 x HP. 6. Demate/mate x 30 (wet mate connectors only). 7. Demate/mate x 10 at ambient pressure in the middle of the pressure/temperature hold period (dry

mateable connectors only) 8. Contact resistance, as per section 3.3. 9. Insulation resistance, as per section 3.9. 10. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 11. PD test to 1.73 x Uo, as per section 3.4. Pressurization and depressurization rate should be minimum 20 bar/minute. The elevated temperature shall primarily be determined from material limitations as defined in the material selection report. However, the design analysis results shall also be evaluated when determining the elevated temperature. The test duration shall be determined from the selected elevated temperature, and shall reflect the specified design service life using the Arrhenius method. Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No degradation or damages shall be observed. The acceptance criteria given in referenced sections shall also be met.

4.12 Long Term Pressure Cycling Qualification Tests – penetrators

The objective of the tests is to ensure that the connector assembly is able to withstand long term service at operational conditions, without degradation or damage.

1. Contact resistance, as per section 3.3. 2. Insulation resistance, as per section 3.9. 3. PD test to 1.73 x Uo, as per section 3.4. 4. Static pressure test, as per section 3.10. 5. Long term pressure cycling test to 1.1 x DP at elevated temperature. 6. Static pressure test, as per section 3.10. – with 24 hours hold time instead of 15 min. 7. Contact resistance, as per section 3.3. 8. Insulation resistance, as per section 3.9. 9. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 10. PD test to 1.73 x Uo, as per section 3.4.

The above specified test sequence shall be performed twice, with differential pressure applied in each direction (internal – ambient, ambient - internal). Minimum 50 pressure cycles shall be performed in each direction. Pressurization and depressurization rate should be minimum 20 bar/minute. Hold time after each pressurization or depressurization should be minimum 5 minutes. The elevated temperature and number of pressure cycles shall primarily be determined from material limitations as defined in the material selection report. However, the design analysis results shall also be evaluated when determining the elevated temperature. The test duration shall be determined from the selected elevated temperature, and shall reflect the specified design service life using the Arrhenius method.




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Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No leakage, degradation or damages shall be observed. Any pressure drop during the hold time shall be explained. The acceptance criteria given in referenced sections shall also be met.

4.13 Flooded hyperbaric long term qualification tests - connectors

The objective of the tests is to ensure that the connector assembly is able to withstand long term service at operational conditions with the outer water sealing barrier to sea removed, without degradation or damage. Conductive tapped water is required. The outline test specification and sequence are as follows: 1. Contact resistance, as per section 3.3. 2. Insulation resistance, as per section 3.9. 3. PD test to 1.73 x Uo, as per section 3.4. 4. Demate/mate. 5. Long term pressure test at elevated temperature and 1.1 x HP. 6. Demate/mate x 10 (wet mate connectors only) 7. Demate/mate x 2 at ambient pressure in the middle of the test program (dry mateable connectors

only). 8. Contact resistance, as per section 3.3. 9. Insulation resistance, as per section 3.9. 10. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 11. PD test to 1.73 x Uo, as per section 3.4. Pressurization and depressurization rate should be minimum 20 bar/minute. Hold time after each pressurization or depressurization should be 5 minutes. This test should be performed with the cable(s) intended used in the project, if possible. If the connector assembly is of an electrically clean environment mating type, the number of repeated mate/demate cycles may be reduced to 3 (subject for Company acceptance). If the connector assembly is intended used as part of a control system, the number of mate/demate cycles shall be minimum 30. Acceptance criteria: The connector assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No degradation or damages shall be observed. The acceptance criteria given in referenced sections shall also be met.

4.14 Flooded hyperbaric long term qualification tests - penetrators

The objective of the tests is to ensure that the penetrator assembly is able to withstand long term service at operational conditions with the outer water sealing barrier removed, without degradation or damage. Conductive tapped water is required. The inner barrier shall be exposed to the applicable fluid or gas resulting from a removed outer barrier. The outline test specification and sequence are as follows:

1. Contact resistance, as per section 3.3. 2. Insulation resistance, as per section 3.9.




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3. PD test to 1.73 x Uo, as per section 3.4. 4. Static pressure test as per section 3.10. 5. Long term pressure cycling test to 1.1 x DP at elevated temperature. 6. Static pressure test as per section 3.10. – with 24 hours hold time instead of 15 min. 7. Contact resistance, as per section 3.3. 8. Insulation resistance, as per section 3.9. 9. HV AC test to 2.5 x Uo (hold time 1 hour), as per section 3.6. 10. PD test to 1.73 x Uo, as per section 3.4.

The above specified test sequence shall be performed twice, with differential pressure applied in each direction (internal – ambient, ambient - internal). Minimum 50 pressure cycles shall be performed in each direction. Pressurization and depressurization rate should be minimum 20 bar/minute. Hold time after each pressurization or depressurization should be 5 minutes. This test should be performed with the cable(s) intended used in the project, if possible. Acceptance criteria: The penetrator assembly electrical performance as specified above shall remain within specification and without reduction throughout testing. No leakage, degradation or damages shall be observed. Any pressure drop during hold time shall be explained. The acceptance criteria given in referenced sections shall also be met.

4.15 Dismantling and Examination

The objective of the dismantling and examination is to detect any degradation or damage to the connector assembly, resulting from qualification testing. The connector assembly shall be dismantled and examined, typically as follows: 1. Damages, carbon deposits or wear. 2. Accumulation of solids on critical interface areas. 3. Contamination of dielectric fluids (sampling shall be near where particles will naturally deposit). 4. Change in material properties. Acceptance criteria: 1. No damages or carbon deposits shall be observed. Wear shall be evaluated as acceptable. 2. Accumulation of solids shall not interfere the mating or locking operation of the connector assembly. 3. Water, salt and silt content of fluid filled enclosures to be quantified and the supplier shall assess the

impact of this upon the operation of the connector assembly over its lifetime. 4. Insulation resistance and conductivity of dielectric fluid samples to be quantified. Any change in

material properties shall not interfer the operation of the connector assembly throughout design service life.




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5 Definitions and abbreviations

5.1 Definitions

Arrhenius method A method for prediction of design service life, assuming single failure mechanisms.

Cable termination Device fitted to the end of a cable to ensure electrical connection with other parts of the system and to maintain the insulation up to the point of connection

Clean Environment Seawater expelled from compartment and compartment cleaned

Company Statoil ASA Connector assembly Wet and dry mateable connectors, penetrators and cable

terminations, also including jumper cables or cable pigtails between subsea components – or any combination of these

Connector Fully insulated termination permitting the connection and the disconnection of a cable to other equipment

Design pressure Maximum differential pressure that a penetrator can work with at worst case operating conditions. Two figures shall be specified, for differential pressure in both directions; internal-ambient and ambient-internal.

Dummy Connector Fully insulated device allowing connection to a connector half for protection when unmated. Normally no cable is attached to the dummy connector, internal connnection between phases may however be established to allow continuity testing.

Dry mateable connector Connector designed to be submerged in sea water, but connected/disconnected in topside environment only.

Factory Acceptance Tests Shall demonstrate quality and repeatability of each connector assembly, to ensure that the connector assembly subjected to qualification tests is representative for the manufactured connector assemblies

High Voltage Um > 1.2 kV AC Hydrostatic pressure Hydrostatic pressure corresponding to the design water depth. Jumper cable Cable connection terminated at each end to either a connector

or penetrator. Penetrator Device that enables one or several conductors to pass through

a partition such as a wall or a tank, and insulates the conductors from it; the means of attachment (flange or fixing device) to the partition forms part of the penetrator. Penetrators include bulkhead mounted connector assembly components. Bushing is an alternative commonly used term.

Penetrator connection seal Seal between the penetrator body/flange and the wall/tank/housing to which the penetrator is attached. The penetrator connection seal may also constitute a water sealing barrier.

Qualification Tests Shall demonstrate that a connector assembly type is suitable for the intended purpose. If any relevant parameter are outside the envelope of a previously validated connector assembly design, qualification tests shall be performed

Rated current, Ir Maximum r.m.s. value of current which the connector assembly




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can carry continuously at rated frequency in seawater at 20 deg C

Rated dynamic current Id Peak value of a current that the connector assembly withstands mechanically

Rated thermal short-time current r.m.s. value of a symmetrical current which the connector assembly withstands thermally for the rated duration (tth) immediately following continuous operation at rated current and frequency, with maximum temperatures of ambient sea water/operational media

Water sealing barrier Part of a connector assembly that prevents intrusion of seawater into the connector assembly internals.

Wet mateable connector Connector designed to be submerged in sea water, and can also be connected/disconnected in submerged condition.

5.2 Abbreviations

AC Alternating Current CP Cathodic Protection CR Contact Resistance DFMECA Design Failure Mode Engineering and Criticality Analysis DP Design Pressure FAT Factory Acceptance Test g Acceleration due to Gravity HSE Health, Safety and Environment HV High Voltage (Um > 1.2 kV AC) HP Hydrostatic Pressure IEC International Electrotechnical Commission IR Insulation Resistance ISO International Organization for Standardization PD Partial Discharge PMI Positive Material Identification PSL Product Specification Level rms Root Mean Square RGD Rapid Gas Decompression ROT Remotely Operated Tool ROV Remotely Operated Vehicle TR Technical Requirements Uo Rated power frequency voltage between a conductor and earth or metallic screen for

which the connector assembly is designed U Rated power frequency voltage between conductors for which the connector assembly is

designed Um Maximum value of the “highest system voltage” for which the connector assembly may

be used VIV Vortex Induced Vibration WR Work process Requirements XLPE Cross-Linked PolyEthylene




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5.3 Changes from previous version

This document replaces TD0153 ver. 1.01. This document is structured differently, as both design and test requirements have been specified separately for connectors and penetrators. The following main changes apply (sub-sections not specified since document has been re-structured): Chapter Change from TD0153

2 Maxium external operating temperature reduced from 30 0C to 20 0C 2 Internal operating temperature range defined (-5 to +60 0C) 2 Standard voltage, current and differential pressure ratings specified. 2 Maximum 65 °C specified as maximum conductor temperature for XLPE

cable terminations 2 Tolerance to RGD specified, as applicable 2 Minimum number of matings without maintenance specified for connectors 2 Field controlling device required for all cable terminations 2 Requirements for penetrator connection seals included 2 Seals exposed to process gas/fluid in normal operation shall be metallic 2 Barrier materials exposed to process gas/fluid in normal operation should be

inorganic. 2 Findings from critical component testing to be implemented in the design prior

to build and test of prototype 3 In general, final electrical test specified to be PD test 3 New Helium tightness control test specified 3 CR acceptance criteria modified to include voltage drop only 3 More stringent PD acceptance criteria at 2.5 Uo (50 pC) 3 Test voltage for IR test increased for connector assemblies with Um above

7.2 kV 3 Static pressure test included for penetrators 4 Trending of CR, IR and PD inception voltage during the qualification test

programme specified 4 Separate test specifications for connectors and penetrators where applicable. 4 Critical component testing included 4 Requirements for drop test changed, now to be in accordance with IEC 4 Vibration test requirements changed 4 Flooded tests specified to be long term tests




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5.4 References

EN 10204 Metallic products – types of inspection documents IEC 60038 IEC standard voltages IEC 60059 IEC standard current ratings IEC 60060-1 High-voltage test techniques. Part 1: General definitions and test requirements IEC 60270 Partial discharge measurements IEC 60502 Power cables with extruded insulation and their accessories IEC 60502-4 Test requirements on accessories for cables IEC 60721-3-2 Guidance for the correlation and transformation of environmental condition classes of

IEC 60721-3 to the environmental tests of IEC 60068 – Transportation IEC 60885-2 Partial discharge test IEC 61238-1 Compression and mechanical connectors for power cables IEC 61442 Test methods for accessories for power cables ISO 10423 Wellhead and christmas tree equipment Norsok M-001 Materials selection Norsok M-503 Cathodic Protection Norsok M-650 Qualification of Manufactures of Special Materials Norsok M-710 Qualification of non-metallic sealing materials and manufactures TR0042 Surface preparation and protective coating TR1231 Subsea intervention systems TR1232 Subsea umbilicals and cables TR3070 Subsea technology, technical requirements and standards TR3100 Materials Technology, Technical requirements and standards TR3101 Fasteners TR3127 Submarine AC power cables WR1622 Technology qualification

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Subsea Electrical Voltage