DESIGN PREMISE

CABLE TERMINATION & DYNAMIC ACCESSORIES

Project Name: EolMed

Client: Ideol
JDR Job Reference Number: 108549
JDR Document Number: 108549-DP-001

Rev Date Reason for Issue Issued Checked Approved

00 16 Mar 2021 Issue for Tender K. Verillis TJ. Kho D. Yap

CONFIDENTIALITY STATEMENT
The information contained within this document is strictly confidential and is the property of JDR Cable Systems Ltd. JDR Cable Systems Ltd is also
the owner of all other rights in this document (including, but not limited to copyright, trade secrets and design rights). No use or disclosure is to be
made, neither the whole nor any part of this document may be reproduced, stored in or transmitted in any form by any means (electronic,
mechanical, reprographic, recording or otherwise) without prior written permission of JDR Cable Systems Ltd. JDR Cable Systems Ltd does not
give you permission to use or retain this document if you do not agree to these conditions.
© 2021 JDR Cable Systems Ltd. All rights reserved

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Contents

Revision History ...................................................................................................................... 4

1 Introduction ........................................................................................................ 5
1.1 Abbreviations and Definitions ................................................................................... 6
1.2 Codes and Standards ............................................................................................... 7
1.3 Units of Measure ...................................................................................................... 8
1.4 References ............................................................................................................... 8

2 Scope of Supply................................................................................................. 9
2.1 Cables ...................................................................................................................... 9
2.2 Topside Accessories ................................................................................................ 9
2.3 Dynamic Accessories ............................................................................................... 9
2.4 Ancillary Accessories ................................................................................................ 9

3 General Design Inputs..................................................................................... 10

3.1 Environmental Inputs .............................................................................................. 10
3.2 Cable Configuration ................................................................................................ 10

4 Topside Accessories ....................................................................................... 11

4.1 Pull-in Head ............................................................................................................ 11
4.2 Hang-off Assembly ................................................................................................. 14
4.3 Disconnection & Abandonment Kit ......................................................................... 16
4.4 Electrical Terminations ........................................................................................... 17
4.5 Fibre Optic Termination Boxes ............................................................................... 19
4.6 Cable Cleats ............................................................. Error! Bookmark not defined.

5 Dynamic Accessories ...................................................................................... 20

5.1 Dynamic Bend Stiffener and Latch Mechanism Assembly ..................................... 20
5.2 Buoyancy Modules ................................................................................................. 25
5.3 Touchdown Protection Jackets ............................................................................... 26
5.4 Cable Tether/Hold-back Solution ............................................................................ 27

6 Ancillary Accessories ..................................................................................... 30

6.1 Reel for Main IAC and Spare cable length ............................................................. 30

APPENDIX A - Example Hang-off Assembly Drawing ......................................... 31

APPENDIX B - Example Flexible Pull-in Assembly Drawing .............................. 33

APPENDIX C - Example T-connector Datasheet .................................................. 36

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APPENDIX D - Example Array Cable Transition Box .......................................... 39

APPENDIX E - Example of JDR Fibre Optic Splice Box Drawing ....................... 41

APPENDIX F - Example of Cable Cleat Datasheet .........Error! Bookmark not defined.

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Revision History
Issue Date Reason for Issue
00 16 Mar 2021 Issue for Tender – Initial Release for ITT2

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1 Introduction
EolMed – Gruissan Floating Offshore Windfarm, is the development of a pre-commercial floating wind
farm of 33MW, 66kV, situated 18km off Gruissan coast in the Mediterranean Sea. The farm consists of
here V164 10MW floating wind turbines from MHI Vestas Offshore Wind, each connected to a floating
hub by inter-array cables.

JDR have been asked to provide a proposal for the supply of dynamic inter-array submarine power
cable lengths and associated accessories required to export the power from the wind turbine generators
to the floating hub.

This document outlines the design premise for the mechanical and electrical cable accessories
proposed for this project which includes design inputs that will be used covering methodologies,
assumptions made during the initial design and functional specifications for all proposed cable
accessories.

Note: All parameters specified for the accessories offered with this tender is subject to confirmation
after the Dynamic Analysis is performed. The details are based on typical assumptions on the
environmental conditions and must be assessed by the Customer on the suitability for installation as
well. Any changes may result in a variation to prices.

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1.1 Abbreviations and Definitions
Abbreviation Description
AC Alternating Current
BS British Standard
BIMEP Biscay Marine Energy Platform
BSR Bend Stiffener Relief
CCW Counter-Clockwise
CG Cumberland Grip
CW Clockwise
DBSC Diverless Bend Stiffener Connector
DC Direct Current
DNV GL Det Norske Veritas Germanischer Lloyd
EN European Norm
FEA Finite Element Analysis
FEH Floating Electrical Hub
FO Fibre Optics
FWT Floating Wind Turbine
HV High Voltage
ISO International Standards Organization
JDR JDR Cables Systems
MBL Maximum Breaking Load
MBR Minimum Bend Radius
N/A Not applicable
PU Polyeurethane
TBC To be confirmed
DVE Verband der Elektrotechnik, Elektronik und Informationstechnik e.V.

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1.2 Codes and Standards
International Standard Number Document Title
ISO 9001:2015 Quality Management Systems - Requirements
Test Requirements on Accessories for use on
Power Cables od Rated Voltage from 1,6/6(7,2)kV
DIN VDE 0278-629-1:2009
up to 20,8/36(42)kV – Part 1: Cables with extruded
insulation
Environmental Conditions and Environmental
DNV-RP-C205
Loads
DNV-RP-B401 Cathodic protection design
DNV-RP-H103 Modelling and analysis of marine operations.
DNV-RP-J301 Subsea Power Cables In Shallow Water
DNV-RP-F401 Electrical Power Cables In Subsea Environments
BS EN 10204: 2004 Metallic Products - Types of inspection Documents
Bushings above 1 kV up to 52 kV and from 250 A
BS EN 50180: 2015 to 3,15 kA for liquid filled transformers. General
requirements for bushings
Plug-in type bushings above 1 kV up to 52 kV and
from 250 A to 2,50 kA for equipment other than
BS EN 50181: 2010
liquid filled transformers

Petroleum And Natural Gas Industries -- Design

ISO 13628-5 And Operation Of Subsea Production Systems --
Part 5: Subsea Cable’s
Zinc Coatings – Guidelines and recommendations
ISO 14713-1:2009 for the protection against corrosion of iron and steel
structures.
NORSOK M-501 Surface Preparation and Protective Coating

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1.3 Units of Measure
Unit Description
Te Metric Ton – mass
Kg Kilogram – mass (1 Te=1000 kg)
m Metre – length
mm Millimetre – length (1m=1000mm)
N Newton – force (kg x g (9.81m/s2))
Pa Pascal - pressure / Stress (N/m2)
A Ampere – electrical Current
Deg / º Degrees – angle
MW Megawatts – power (1MW = 1x106 W)
MVA Mega voltage-amps – power

1.4 References
Documents relevant to Employer specifications, proposed cable design and qualification reports for
accessories are referenced below:

Client Document No JDR Document No Document Title

A-A-IA-EE-SP-01,
N/A « IAC » cables specification
Rev05C

N/A STD-DR-029-003 48-hour Installation Seals Qualification Report

6-month Abandonment Seals Qualification
N/A STD-DR-029-019
Report
66kV Al Cable with NKT T-connectors
N/A PD087-QR-003
Qualification Report
150 mm2 Copper 36/60~69(72.5) kV Subsea
N/A 108549C
Cable Cross Sectional Drawing

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2 Scope of Supply
JDR has provided the following list of cable and accessories as part of the scope of supply. Each
accessory is listed as a base case options for the client’s consideration. Information and datasheets for
the listed accessories that JDR has considered have also been included.

2.1 Cables
Cross Section Description
108549C 150 mm2 Copper 36/60~69(72.5) kV Subsea Cable

2.2 Topside Accessories

 Pull-in / Termination and Hang-off Assembly (I-tube on FWT & J-tube on FEH) :
o Pull-in head & Cable End Caps
o Hang-off
 Electrical termination:
o T-connectors
o Array cable transition box (ACTB)
 Fibre optic termination:
o Patch panel / Splice box
 Cable cleats
 Disconnection and abandonment kit

2.3 Dynamic Accessories

 Dynamic bend stiffener and latch mechanism assembly

 Buoyancy modules
 Touchdown protection
 Hold back clamp / Tether

2.4 Ancillary Accessories

 Reel for main IAC cables

 Reel for spare cable

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3 General Design Inputs
3.1 Environmental Inputs
In order to perform a preliminary design, a number of environmental inputs are required. Most of these
inputs were assumed unless specified from client’s document referenced above:

Parameter Value
Design life 25 years
Maximum design water depth 60 m
Maximum ambient air temperature 30°C
Maximum ambient water temperature 25°C
Solar radiation Assumed not exposed
Maximum conductor short-circuit 20 kA per 1 second (specified)
Maximum screen short-circuit 6.7 kA per 0.3 second (assumed)

Table 3-1: Environmental Parameters

3.2 Cable Configuration

The simplest configuration assumed will be a lazy wave, however a tethered wave or more complex
double-S may be required if the combination of site conditions are not appropriate for a simple
configuration. The cable configuration shall be confirmed upon outcome of Dynamic Analysis.

Figure 3-1: Example Tethered Lazy-wave cable configuration

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4 Topside Accessories
The topside accessories consist of pull-in head and hang-off assemblies for securing the cable on the
platforms prior to termination. A typical pull-in head is a stubby design. However for potentially tighter
bends, there is an alternative flexible pull-in head design which can be proposed. The base case
assumed for our offer is based on a stubby pull-in head. If the pull in loads are low enough, a simpler
Chinese finger grip can also be used. JDR can discuss the most suitable option depending on the
installation conditions and final structure design.

4.1 Pull-in Head

4.1.1 Stubby Pull-In Head Assembly (Base Case)

A pull-in head assembly, comprised of a stubby pull-in head, an armour body and bend strain relief is
utilised to for pull-in of the submarine power cable during the cable installation.

Within the armour body provides the power cable armour wires are spread out and potted using wirelock
resin. The resin provides a means for transferring axial tensile loads from the power cable armour to
the armour body and through to the pull-in head.

The pull-in head incorporates a pad eye suitable for a Shackle for fitment of the pull-in shackles and
messenger wires during the cable pull-in.

A bend strain reliever is in place to provide bend protection to the power cable at the entrance to armour
body. The design of the pull-in assembly ensures that it shall be free from snagging points to facilitate
pull in of the power cable.

Figure 4-1: Typical Stubby Pull-in Head Assembly

The following table details typical technical specifications of the stubby pull-in assembly:

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 Parameter Client Specification
Material Carbon steel
Proof water depth 100 m
Safe working load 10 Te
To be confirmed upon FWT termination and tail
length requirement eg. Disconnection and re-
termination. Note that price for this item will be
provisional at this stage.
Length
If a long tail length is necessary, the pull-in head
needs to be replaced with a flexible pull-in head
as proposed in next section below.
The armour body will be fitted and potted at our
facility with sufficient cable tail length for testing
prior to cable pull-in (TBC)
Installation The pull in head and cable caps will be fitted
offshore prior to pull-in.
Following pull-in the cable will be cut behind the
pull-in head, stripped and terminated.

Table 4-1: Parameters assumed for stubby pull-in head

4.1.2 48-hour Installation End-caps & Seals (within the pull-in head)

Figure 4-2: Typical Installation End-caps / Seals

JDR installation end-caps and seals are designed to provide water ingress protection to the cable
components for up to 48-hours in wet storage during installation activities. These can be installed in
factory or on board vessel prior to installation of cable grips for cable pull-in operation. They have been
type tested with JDR subsea cable according to qualification report STD-DR-029-003. If a longer wet
storage period is required, the 6-month abandonment end-caps may be installed in place of these
installation end-caps.

Parameter Description

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 Operating Temperature -10 to +35 °C
Maximum Operating Depth 60 m
Rated Abandonment Duration Up to 48 hours

Table 4-2: Installation end-caps & seals operating parameters

End-caps are essentially maintenance free during its abandonment lifetime and shall be removed
following installation. No further operation or maintenance is expected.

4.1.3 Flexible Housing & Pull-In Assembly (Alternative)

JDR can alternatively offer a flexible pull-in assembly paired with abandonment end-caps for tighter
bends or disconnection operation and prolonged abandonment. See section 4.3 for more details.

Figure 4-3: Typical flexible pull-in assembly

The proposed pull-in assembly consists of a lower module for direct interface with the armour body
(which will have been installed during hang-off installation), followed by a flexible housing for cable tail
lengths, and finally the pad-eye for connection to messenger wire. Please see Appendix B for example
flexible pull-in assembly drawings.

During a disconnection operation, the 6-month abandonment seals and flexible pull-in assembly shall
be installed directly on to cable ends and armour body. The hang-off split flanges are then removed and
BSR latch disengaged to allow cable to be disconnected from the WTG platform and abandoned. The
cable-end can then be retrieved and pulled in to position again following its abandonment period.

This particular flexible pull-in assembly includes the following features:

 Can be designed to meet specific cable diameter and tail length requirements
 Flexibility of assembly suits J-tubes with multiple tight bend profiles, without compromising
cable Minimum Bend Radius.
 Limited pulling load due to design selection of the body.

The following table details typical technical specifications of the flexible pull-in assembly:

Parameter Description

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 Carbon Steel (Modules)
Material
Polyeurethane PU / Kevlar (Carcass Body)
Proof water depth (m) 60
Maximum working load (kN) 35
The pull in head may be installed topside prior to
Installation
abandonment.
Table 4-3: Provisional pull-in head parameters

4.2 Hang-off Assembly

The hang-off assembly offered consists of a potted armour body and split flanges.

The potted armour body comes from the pull-in head assembly from Section 4.1.1 above and it features
a circumference groove to allow interface with the split hang-off flange installed above the J-tube top
flange upon cable pulling.

Split hang-off flange

I-tube / J-tube
Armour body
top interface

Figure 4-3 Typical assembled hang-off split-flanges (Outlined I-tube on left & armour body on right)

Once the permanent armour body is installed, the temporary lifting rings are used to hold the tension of
the cable so the temporary hang-off clamp can be removed. The armour body is then lowered and
secured to the top of the I-tube via the split hang-off. The split hang-off flanges are designed to be fitted
directly on to a circumferential groove of the armour body, and bolted interface with the I-tube/ J-tube
top flange. Please see Appendix A for example permanent hang-off assembly drawings.

The armour body shall remain within the assembly for the duration of the specified design life or until
disconnection is required. The hang-off flanges can be designed to meet specific I-tube or platform
interfaces and feature earth lead connections between the two hang-off plates and to the armour body.

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The following table details typical technical specifications of the hang-off flanges:
Description Parameter
Material Carbon Steel S355
Flange Interface Designed to meet platform interface
Earthing Connections M12-M12 35mm2 Braid Lead
Hang-off Load TBC
Sealing To 1 bar TBC
Environment Unprotected topside environment (salt spray); (assumed)

Table 4-3: Parameters for proposed cable hang-off

4.2.1 Proposed Pull-in and Installation Strategy

The armour body may be pre-terminated on to cable ends together with the pull in head above and the
dynamic bend stiffener, latch mechanism (see Section 4.3 below) prior to load-out. This can be done
either on the installation vessel or cable manufacturing facility during cable spooling on the dedicated
reel with partitions for respective end termination.

At this stage, all the cables are delivered onto a single reel unterminated. For this case, the end
termination will need to be prepared and installed by the Installation Contractor during installation.

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4.3 Disconnection & Abandonment Kit
The following kits are proposed to allow for a controlled cable disconnection and abandonment program,
should the turbine maintenance purpose be required.

4.3.1 6-month Abandonment End-caps & Seals

Figure 4-4: Typical Abandonment End-caps / Seals

JDR abandonment end-caps are designed to protect cable ends and prevent water ingress for a
prolonged sea-bed abandonment during installation (due to adverse weather conditions etc.). These
are installed over cable tail ends and within the pull-in assembly prior to seabed abandonment. They
have been type tested with JDR subsea cable and rated for an abandonment period of up to 6-months
according to qualification report STD-DR-029-019.

Parameter Description
Operating Temperature -10 to +35 °C
Maximum Operating Depth 60 m
Rated Abandonment Duration Up to 6 months

Table 4-4: Abandonment end-caps & seals operating parameters

End-caps are essentially maintenance free during its abandonment lifetime and shall be removed
following installation. No further operation or maintenance is expected.

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4.4 Electrical Terminations

4.4.1 T-connectors

T-Connectors are designed to connect the cable core to gas insulated

switchgear and other equipment using CENELEC bushing type F (1250 A)
specified up to 72.5 kV. Please see Appendix C for further specifications.

NKT CB72 T-Connectors have been type tested with JDR 66kV Al cable in
accordance with IEC 60840: 2011 and CIGRE TB490 as described in
qualification report PD087-QR-003.

The following parameters have been used as the basis of our offer. All values
specified are nominal and shall be confirmed during detailed design. JDR
reserves the right to offer alternative suppliers or designs pending detailed
design, provided they comply with the employers’ requirements with a similar Figure 4-12: HV T-
connector
level of qualification.

Table 4-5: Electrical T-connector parameters

Parameter Description
Voltage 72.5 kV
Maximum Current 1250 A if installed with type F bushing
Interface Type (Bushing) Type ‘F’ CENELEC EN 50180&81
Conductor material Copper or Aluminium
T-Connector Insulating Material Silicone Rubber
Screen Wire
Lugs Mechanical
Piggy Backed Offered for the FES platform, not for the FTW end.
Copper Wire Metallic screen shall be formed into earth lead.
Bonding / Earthing Requirements
Cable lug included.
Capacitive Test Point Yes

T-Connectors are essentially maintenance free. It is however recommended that inspections be

performed periodically throughout its operational lifetime.

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 4.4.2 Array Cable Transition Box / Cabinet (FES)

Figure 4-5: Customised solution to fit four 72kV cables connected into one Cable Transition Box

For termination off all the power cables at the floating buoy end, JDR can supply NKT customized Cable
Transition Box (ACTB) or cabinets. As shown in figure above, one side of the cabinet allows piggyback
connection for two array cables, whilst the other side allows piggyback connection of the third IAC and
export cable. The routing of the cable tails are yet to be defined and the stand design for the cabinet
shall be further discussed.

The cabinets are made of non-corrosive material. Figure above shows a typical cabinet arrangement
for two ends of the 72kV subsea cable. This solution can be customized to suit the functional and space
requirements. Please see Appendix D for example drawing.

Table 4-6: Provisional Array Cable Transition Box (ACTB) Parameters

Parameter Description
Supplier NKT
Model KT484D-66 series
Voltage 66 kV
Nominal current rating 1250 A
Material Enclosure: GRP Glass fiber reinforced polyester resin (halogen free)
Screws / metal parts: Stainless steel
Connector screw type rating 30 kA, 5 sec (TBC)
Nominal withstand lighting 325 kV +/- 10 x 1.2/50µs (TBC)
impulse voltage
IP rating IP 54
Cable Screen Wire
Stands Not included and requires further discussion about routing of the
cable and the cabinet’s position at the floating buoy.

Array cable transition box / cabinets are essentially maintenance free for the life of the product.

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4.5 Fibre Optic Termination Boxes
Fibre optic ends may be capped or terminated into a splice assembly which will be secured initially
within the pull in-head, pulled topside, and re-terminated into a fibre optic patch box which is either wall
or frame mounted on the FWT platform or within the floating hub. The connection type shall be specified
during detail design. Pigtails (within splice box) can be provided for both the incoming and outgoing
cables.

Figure 4-6: Typical Fibre Optic Splice Cassette Assembly (left) and FO Patch Box (right)

The junction box shall provide protection to IP66 as a minimum. The splice box will be suitable for re-
entry without the use of specialist tools. Please see Appendix E for example assembly drawing.

A typical splice box will come with following components:

Table 4-7: Typical FO Splice Box Components List

Item Description
1 HellermannTyton fibre management system C/W with Cassettes (TBC)
2 Armoured Gland
3 Non-Armoured Gland
4 Earth Studs
5 Constant force Spring
6 SC-UPC Simplex Adaptor SM (TBC)
7 SC Single Mode 2-metre Pigtails (TBC)
8 Internal Earth Terminal

Fibre optic splice boxes are essentially maintenance free. It is however recommended that inspections
be performed periodically throughout its operational lifetime.

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5 Dynamic Accessories
5.1 Dynamic Bend Stiffener and Latch Mechanism Assembly
The Diverless Bend Stiffener Connector (DBSC) latch assembly consists of a male and female sub-
assembly. The female sub-assembly shall be bolted / welded to the shoe bend at the bottom-end of the
I-tube on the floating structure and the male sub-assembly shall be installed on the cable end. The
purpose of this system is to:

 Secure cable at the I-tube bottom opening upon cable pull-in when both assemblies engage.
 Remain engaged during normal operational conditions.

Figure 5-1: Example DBSC Latch assembly female part (top), male part (bottom)

5.1.1 Female DBSC Latch Sub-Assembly

The female DBSC latch sub-assembly will be bolted to the bottom of the floating structure J-tube prior
to installation. It features the latching mechanism responsible for engaging/securing the male latch
assembly in place during installation.

The female latch assembly is designed to:

 Bolt onto the existing I-tube or J-tube to form part of the structure.
 Allow passage of the pull-in and hang off arrangement, as well as the male DBSC latch
mechanism up the I-tube and prohibit movement out of the I-tube under normal operation.

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 Figure 4-5 – Example Female DBSC Latch Assembly

The structure can be corrosion protected with anodes welded onto the main body as shown above.

5.1.2 Male DBSC Latch Sub-Assembly

The male DBSC latch sub-assembly components shall be installed on the cable at the factory/vessel.
This sub-assembly is designed to engage onto the female DBSC latch mechanism during cable pulling.

The male DBSC can come with an automatic end fitting release system, to provide interventionless
installation into the female DBSC, followed by interventionless release of the end fitting from the end
fitting from the male DBSC once latched; for this instance it would be the pull in head.

Figure 4-6 – Typical Male DBSC Latch Sub-Assembly

The bottom flange of the male part is used for mounting a dynamic bend stiffener if necessary.

5.1.3 Dynamic Bend Stiffener

The latch mechanism comes with a dynamic bend stiffener. The Bend Stiffeners ensure that cable
bending does not exceed the minimum bend radius as specified by the client. Dynamic Bend Stiffeners
maximize the fatigue life of the cable by minimizing cable movements caused by the environmental
loads. They are designed according to the Tension-Angle plots output during Dynamic Cable System
Analysis.

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 Figure 5-7: Typical Dynamic Bend Stiffener

As shown in Figure above, the bend stiffener consists of a conical body with a reinforced base section.
There is also a central axial opening so as to allow for the passage of the cable. The conical body is
manufactured as a homogenous flexible component using engineered polyurethane (PU) elastomers,
selected for their material properties and excellent fatigue resistance.

The base section is reinforced by an internal steelwork assembly which assists with the transmission of
loadings to the adjacent structure. This will be fabricated from high strength carbon steel. The base
section incorporates an end flange. It is this part which will allow the stiffener to be connected to the
adjacent male latch assembly as shown in the section above.

Parameter Value
Dynamic Bend Stiffener Overall Length 2.2 m*
Internal Bore To suit cable diameter
Base Diameter TBC
Tip Diameter TBC
Approx. Weight in air (kg) ~600
Design Life (years) 20

Table 5-4: Provisional parameters for dynamic bend stiffener

* In absence of any dynamic analysis data available for the project, JDR have assumed a 2.2 m bend
stiffener. On receipt of dynamic analysis results, JDR would be happy to amend the offer to suit the
results of your analysis.

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 5.1.4 Dynamic Bend Stiffener Tip Clamp

Figure 5-2: Dynamic Bend Stiffener with tip clamp

A tip clamp is fitted onto the cable to prevent the assembly from sliding down the cable during
installation. As the cable is pulled up through the I-tube, the tip clamp supports the male latch sub-
assembly, until the male and female components of the latch assembly engage and is secured. A typical
tip clamp is designed to hold a minimum load of 2 tonnes without slipping of the cable.

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 5.1.5 Installation Phases

Table below describes the installation phases for the components of the dynamic bend stiffener and
latch mechanism assembly.

Phase Location Components

 Female Latch Assembly (FLA) and latch mechanism
assembled, trial fitted and verified.
Pre-Load Out Onshore
 FLA welded on to bottom-end of J/I-tube.

 Male Latch Assembly (MLA)/BSR flange and BSR are

fitted to desired cable position prior to deployment on
vessel (may be installed pre-loadout on individual
Post-Load Out /
Offshore / Vessel cable drums if pre-terminated option is opted for).
Pre-Installation
 BSR tip clamp installed to hold the assembly in
position during cable pulling.

 Cable pull-in – guide through I-tube, engagement of

Offshore / FWT latch mechanism accordingly.
Installation
Structure  Removal of BSR tip clamp – diver required.

Table 5-1: Dynamic Bend Stiffener and Latch Mechanism Assembly Installation Phases

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5.2 Buoyancy Modules

Figure 5-3: Typical buoyancy modules:

Buoyancy modules are used to add buoyancy to the cable and provide a catenary between the turbine
and the seabed preventing unwanted forces to be applied to the turbine by the cable.

The modules offered are manufactured using micro-spheres and macro-spheres held in an epoxy resin
matrix and the complete syntactic foam core would be contained within tough, durable, rotationally
molded, symmetrical moldings with strap recesses allowing simple assembly with the supplied straps
and fasteners. The modules also incorporate convection channels where appropriate to ensure high
riser temperatures are not transmitted to the modules.

The design consists of the integral clamp modules which addresses the issues that are endemic to the
attachment of buoyancy modules to risers, flow line and cable pipes:

 Ovality and variability of the nominal diameter,

 Riser bend radii and high rates of change of these radii,
 Long service lives, subsea, without intervention or maintenance.

The integral clamp will comprise interface pads that will act as the friction interface between the module
and the cable. JDR has supplied integral clamps of this design for other installations and they have
proved very successful.

The integral clamp reduces the number of components required to be installed, the buoyancy module
moulding is designed to fit specified cable diameter, and is secured by Kevlar Straps and Super Duplex
Axis Bars. The clamping force is generated directly through the module and into the interface friction
pads by the straps. Provisional parameters for the buoyancy modules are presented below:

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Table 5-2: Provisional parameters for buoyancy modules

Parameter Value

Uplift per buoyancy module (kg) 290 kg - TBC subjected to dynamic analysis

Number of modules per set 22 - TBC subjected to dynamic analysis

Length of module (m) TBC during dynamic analysis

Depth rating 60 m

* In absence of any dynamic analysis available for the project, JDR have assumed a 22 x 290 kg uplift
Bouyancy Modules. On receipt of dynamic analysis results, JDR would be happy to amend the offer
to suit the results of your analysis.

5.3 Touchdown Protection Jackets

Touchdown protection is provided in order to protect the cable from abrasion of the seabed. The
protection is installed on the cable over a predefined section (TBC from dynamic analysis; assumed
40m) prior to being over boarded.

The touchdown protection consists of split tubular half shells which are made from a marine grade
polyurethane elastomer to provide impact protection and abrasion resistance. Each shell unit will be
secured with corrosion resistant locking bands.

Figure 5-4: Typical touchdown protection assembly

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Figure above shows a typical design of touchdown protection duct with the following features:

 Coverage length per set (TBC from dynamic analysis)

 Stiffness built to suit required bend stiffness upon dynamic analysis
 Lead inserts can be included within assembly for ballast upon dynamic analysis output
(subject to additional costs)
 Maintenance free upon installation

Table 5-3: Provisional parameters for touchdown protection

Parameter Value

Coverage 40 m - TBC subjected to dynamic analysis

Depth rating 60 m

* In absence of any dynamic analysis available for the project, JDR have assumed a 40 m coverage.
On receipt of dynamic analysis results, JDR would be happy to amend the offer to suit the results of
your analysis.

5.4 Cable Tether/Hold-back Solution

If a tethered lazy wave is identified from global dynamic analysis, a cable hold-back solution would be
necessary. The purpose of the cable hold back solution is to prevent cable at the touch down location
from drifting or dragged together with the floating structure at extreme conditions. The hold back system
also helps dampen the oscillatory movement of the cable at touch down location during service.

5.4.1 Vertical Hold Back

When a vertical hold back solution is required upon completion of cable Dynamic Analysis, the system
below can be opted for. The system consists of the gripping component onto the cable, connected to
an anchor/base via a tether rope. When this vertical hold back solution is opted for, the horizontal hold
back above will not be required for the system.

5.4.1.1 Cumberland Grip

For the vertical hold back, the bend limiting device takes the form of a Cumberland Grip (CG). This
assembly provides a fixed gripping location on the cable and over-bend protection, supporting the cable
both sides of the anchor structure. The Cumberland Grip utilises a combined split friction grip and bend
protection unit in one single polyurethane casting, which prevents the cables either side of the holdback
position from bending to their minimum bend radius during the operational life of the cable.

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 Figure 5-5: Typical Cumberland grip

The tapered profile provides a calculated reduction in bend protection from the central root area,
outwards towards the tip section. The bore size is designed undersize to provide a gripping action along
the entire length of the polyurethane casting. The proposed Cumberland grip is designed to hold 10 Te
axial load. The design will be optimised during detailed design if greater gripping capacity is required
from Dynamic Analysis output.

The grip is attached to the cable along its length using a number of ‘split line fasteners’ identified in
Figure above. The carrier ring and yoke are both manufactured from carbon steel and painted to
NORSOK M-501 system7. The carrier ring and yoke are both ‘split’ to allow for quick assembly during
cable deployment. The yoke is free to rotate on the carrier ring during assembly and can be attached
to a tether line during system assembly.

If the Cumberland Grip design is not suitable for the application, a customized clamp design can be
an alternative gripping component if required.

5.4.1.2 Tether Line

The tether line can be provided in two different form, either high strength braided rope or stud link chains
rated to required hold back tension. The tension requirement is subjected to the output of the Dynamic
Analysis.

5.4.1.3 Anchor/ Clump Weight

JDR is considering concrete/steel clump weight as the anchor of the vertical holdback system. It
consists of a steel plate or cylindrical based, designed to required anchor load. See Figures below. A
wide base skirt may be attached to the bottom of the clump weight to provide seabed stability and
anchor suction support. The base case of this clump weight is preliminary defined to be 10 Tonne. The
weight and design is subjected to the output from the cable system dynamic analysis.

Cast iron clump weight may be considered if greater holdback capacity is required and also if a rocky
terrain is foreseen at holdback location. Table below shows preliminary specification of both options.

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Steel/ Concrete Clump Weight Cast Iron Clump Weight/ Sinker

- steel frame: mild steel, painted - material: cast iron

- in a form of rectangular plate or cylindrical - flat, smaller footprint on the ground
- anodes for corrosion protection over design life - painted and specified to last required weight
- lifting eyes for handling and deployment until the end of design life

- only suitable for sand and mud seabed terrain - suitable for rock terrain

- not suitable for rock terrain - lifting eyes for lifting and deployment

- take up for deck space during installation - take up less deck space installation

Table 5-4: Clump weight descriptions and comparison

Figure 5-6: Example Concrete filled cylindrical clump weight (left) and cast iron sinkers (right)

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6 Ancillary Accessories
6.1 Reel for Main IAC and Spare cable length
Cable reel(s) have been offered for the storage, transportation and installation of the cable lengths. The
primary function of the reel is to allow for installation the main cable during installation campaign.
Whereas for the spare cable, a section of installed subsea power cable is damaged beyond repair and
requires replacement.

Figure 6-1: Typical Cable Reel – For Information only

Cable reels are individually designed to hold the required length of specific cable and weight. The reels’
barrels are designed to ensure the static minimum bend radius of each cable is not compromised. The
reels are designed to be lifted using a spreader beam and manufactured with sea-fastening and lifting
points for transportation. Each reel is supplied with a suitable cradle for lifting with the reel.

Table below presented the proposed cable reel dimensions to house for both all main cable lengths and
spare cable length respectively. Reel design and dimensions shall be confirmed during detailed design
phase.

Situation Drum Specification

For all 3 main cable lengths (unterminated) 7.2m (H) x 5.6m (L), Belly diameter = 4.0m
For spare cable length (unterminated) 5.0m (H)) x 4.0m (L), Belly diameter = 3.0m

Table 6-1: Example of Spare Reel Dimensions – For Information only

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APPENDIX A - Example Hang-off Assembly Drawing

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APPENDIX B - Example Flexible Pull-in Assembly Drawing

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APPENDIX C - Example T-connector Datasheet

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APPENDIX D - Example Array Cable Transition Box

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APPENDIX E - Example of JDR Fibre Optic Splice Box Drawing

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