Deepwater Tests of Wet Mateable Electrical and Hydraulic Connectors
Authors: Johnson Donald W. , Henkener Jerry , Volkert Bruce 
Published: October 2008

Southwest Research Institute performed a test program on electrical and hydraulic connectors for use in deep water environments. Four electrical and six hydraulic connectors were tested under the direction of DeepStar 300 committee. Make/break forces, allowable misalignment, sealing, and power carrying capabilities were evaluated under conditions simulating 6000 feet of sea water. This paper describes the test fixture and procedure developed for the program and presents the test results in general to show the state of readiness of electrical and hydraulic connectors for deep water service.

Introduction

The DeepStar program is a cooperative industry project developedby Texaco to examine deep water subsea production systems for installation in the Gulf of Mexico. This testing project was awarded to Southwest Research Institute (SWRI) by the DeepStar 300 committee. Four electrical and six hydraulic connected were tested. The participating vendors were:

Electrical Connector VendorsLockheed - Martin, Challenger MarineHawke Cable Glands LimitedTronic Electronic Services LimitedOcean Design Incorporated

Hydraulic Coupler VendorsNational Coupling Company, IncorporatedCooper Oil Tool Division of Cooper IndustriesSnapTite IncorporatedCad Kurt Walther GMBH & Company, KGStaubli, Hydraulic and Pneumatic DivisionKvaemer FSSL Incorporated

The 300 committee would like to thank each of the connector vendors for donating their time and materials to this program. Without their contributions the program could not have been accomplished.

The test program was intended to demonstrate the capability of currently available electrical connectors and hydraulic couplers to operate at the DeepStar Operating Conditions. this required developing a test fixture and appropriate test procedures. The 300 committee anticipates that participating DeepStar oil companies will use the information gained in this program for future control system designs. A further intent of the program was to make a test fixture and procedures available to industry beyond DeepStar. The test fixture and procedures developed in this program are available for use in the future for qualification tests for a specific deep water installation or to assist manufacturers in developing new products and improving existing ones.

Program Findings and Recommendations

This section relays the findings and recommendations generated in the CTR A305/306 test program. At the most basic level, it must be understood that this program was not a qualification program. Therefore it should not be concluded that some connectors 'passed' DeepStar while others 'failed.' The connectors were of different designs for different applications. Each was tested to criteria established by the individual manufacturer rather than against a uniform standard.

Secondly, it must be understood that the DeepStar test procedures reflect the need of an equipment manufacturer to design his equipment to be a suitable host to the electrical or hydraulic connectors that are necessary for the functioning of an overall system.