HYDRO GROUP PLC DEFENCE CAPABILITY Represented by: Web: www.nord-tech.dk Mail: post@nord-tech.dk Tel.: +45 6591 9802
Contents 1. Introduction... 3 2. Hydro Group Profile... 4 3. Hydro Group defence solutions... 6 3.1 HRS connectors (Hydro Bond Rubber Seal)... 9 3.2 HDM connectors (Hydro Bond Deck Mate)... 10 3.3 HPS penetrators (Hydro Bond penetrator series)... 11 3.4 Fibre Link penetrator... 12 3.5 Moulding and Encapsulation... 12 3.6 Subsea optical and electrical cables... 14 4. Hydro Group experience... 15 4.1 South Korean Aerospace Research Institute (KARI) - Aerostat cable... 16 4.2. Kongsberg Acoustic range - Optical and electrical cable and connector harness... 16 4.3 Thales Optronic Systems non-hull penetrative optronic mast - SDM connectors... 16 4.4 QinetiQ Heavy tow cable... 17 5. Tests and Qualification... 18 2
1. Introduction Hydro Bond Engineering was formed in 1982 by a team of experienced engineers who envisage the potential to develop subsea technology in the North Sea. Offshore oil explorations had not long started and the arduous conditions of underwater engineering projects necessitate specialist capabilities from specialist companies. Hydro Bond Engineering was such a company. However, the nature of the projects was increasing in complexities; the customer portfolio was growing so in 1987 Hydrocable Systems was created. Initially based in Arbroath and relocated to its current site 1991; Hydrocable Systems joined with Hydro Bond Engineering and operate under the holding company of Hydro Group plc. Each company specialises in two business streams; Hydro Bond Engineering limited designs, manufacture and support subsea optical and electrical connectors, penetrators, assemblies, and terminations and Hydrocable Systems limited designs, manufactures and support subsea optical and electrical cables, tethers and umbilical s. Together they provide the complete solution. In essence a total solution to complex problems is achievable from one company. Today, Hydro Group plc employs 71 full time direct staff, and has business representation in key geographical areas. Due to its fast pace growth and demand to increase its product portfolio the Group has recently moved to a new state of the art purposed-built facility. Its customer base include all blue chip and major operators and contractors in both domestic and international subsea makets. 3
2. Hydro Group Profile Hydro Group specialises in the design and manufacture of subsea and harsh environment electrical and optical connectors, penetrators, cable assemblies and terminations. With 28 years experience. Hydro Group plc is a market leader in providing solutions for subsea applications in both domestic and international markets. We are at the forefront in the development of subsea technologies, with involvement from prototype concept through to design, manufacture and project management, supplying the whole package, including umbilical cables electrical and optical connection systems for data, power and signal transmission. We provide solutions to a number industry sectors: Defence Oil & Gas Oceanographic Diving Marine Renewable Energies Our scope of work includes: Hydro Bond Engineering: Design, manufacture and delivery of: Submarine Pressure Hull Glands Penetrators NPT, UNF, DDC, Fibre Optic Connectors Deck Mateable, Underwater Mateable, & Non Magnetic Terminations Optical, Kevlar, Wire Armour, Hybrid Connectors Offshore Installation & Termination, Moulding Polyurethane (P.U), Polyethylene (P.E), P.V.C., Hytrel, Neoprene. Miniature connectors. EXD rated connectors Sensors Junction boxes Cable Termination & Moulding Moulding kits Pressure Testing to 10,000 PSI / 6860 MSW / 689 BAR Project management Hydrocable Systems: Design, manufacture and delivery of: Fibre optic cables Diver Communication cables ROV Tether cables Cat 5 Cables Mini TV cables Push Rod Cables Halogen Free Cables Armoured Cables Buoyant Cables Kevlar Strain Cables Towed Arrays Range Cables Towed Sonar Cable Thin Wall Conductor Cables Welding Cables Production Control Cables Completion Control Cables 100 Meters MOQ 4
Certification Hydro Group plc holds the certification approval to ISO 9001:2008 to design and manufacture of subsea electrical and optical connectors, electrical pressure hull penetrators, associated subsea electrical cable terminations, installation of electrical and optical connectors, specialist underwater and harsh environment electrical and optical composite cables, tethers and umbilical s. Headquarters: Hydro Group plc Hydro House, Claymore Avenue Aberdeen Science & Energy Park Bridge of Don Aberdeen, AB23 8GW Scotland, UK Tel. +44(0)1224822996 Fax.+44(0)1224825142 Email. sales@hydrogroup.plc.uk Web. www.hydrogroup.plc.uk 5
3. Hydro Group defence solutions Hydro Group specialise in the customised design and manufacture of subsea optical electrical connectors, cables and penetrators whilst continuing to invest in product development to further expand our product offering. We have highlighted some of the most popular ranges. Please feel free to visit our website www.hydrogroup.plc.uk for our complete range of products and additional technical information. 1. Submarine pressure hull gland 2. Submarine & surface vessel water tight bulkhead gland (WTB) 3. Submarine & surface vessel fibre optic junction box (FOISB) 4. Submarine closed loop degaussing system connectors 5. Submarine stator monitoring connection system 6. Submarine countermeasures (specially screened) firing system, connection system 6
7. Submarine non penetrative mast communication connector system 8. Submarine non penetrative mast dynamic control connector system 9. Submarine outboard fibre optic connection system 10. Submarine flank array sonar system connection system 11. Submarine tether communication system 12. Helicopter dipping sonar quick release connection system 13. Surface vessel bow sonar connection system 7
14. Surface vessel towed active and passive array sonar system 15. Mine hunter ROV tether and connection system 16. Autonomous underwater vehicle (AUV) Fibre optic and electrical connection system 17. Subsea vertical array detection system connection system 18. Subsea multi influence & acoustic test range connection system permanent 19. Subsea multi influence & acoustic test range connection systems mobile 8
3.1 HRS connectors (Hydro Bond Rubber Seal) Hydro Bond underwater mate able rubber sealing connectors are designed for diver depth but when mated can be used in deep sea applications down to 2440 MSW. Each contact, cable and connector housing is chemically bonded into a synthetic rubber matrix. This prevents water ingress to the cable cores even when the fix ring is fully engaged and prevents the connector from being over tightened. When mated underwater, electrical isolation between contacts is achieved by means of individual rubber conical sealing arrangements. When the connector is mated, water is initially forced out of the tubes. When the mate is complete, the individual tubes will have sealed, retaining some of the water inside, but completely isolated from one another. Disengagement is made easy by the fix ring which jacks the connectors apart. Typically this connector has been used for submarine closed loop degaussing systems, general outboard connection of submarines, offshore range systems and hardware. HRS HRS Electrical Mechanical Pin density 1 to 70 contacts Material Stainless steel, Titanium Aluminium, Silicon Bronze, Nickel Aluminium Bronze Voltage rating Up to 3300 Volts RMS Shell sizes Available in 5 shell sizes Current Up to 750 Amps O ring seal NI 70 Mate and de-mate use How many cycles Environmental Water depth rating 2440 MSW standard (6,900 MSW upon request) Temperature ratings -20 C to + 60 C Submerged design life 25 years Termination options Fully water blocked Mechanical strain termination Oil filled P.U. / P.E. moulding 9
3.2 HDM connectors (Hydro Bond Deck Mate) The HDM series has standard configurations with high density electrical paths for submarine tether communication systems, subsea multi influence & acoustic test range connections permanent or mobile, ROV communications module applications, 4 pin high voltage / high current for hydraulic power unit (HPU) applications, Optical Fibre paths for communications or video, coaxial paths for video or combinations of all the above. It is rated to 3,450 MSW as standard and with a 6,900 MSW option to meet most ocean floor applications. HDM HDM HDM titanium / fibre Optic HDM fibre optic Electrical Mechanical Pin density 3 to 73 contacts Material Stainless steel, Titanium, Aluminium, Silicon Bronze, Nickel Aluminium Bronze, Inconel Voltage rating Up to 4500 Volts RMS Shell sizes Available in 7 shell sizes Current Up to 95 Amps O ring seal NI70 Partial discharge <10 pc (3.3 kv options) Mate and de-mate use >500 cycles Fibre Optic Environmental Fibre optic- single mode 9/125 µm Water depth rating 3,450 MSW standard (6,900 MSW upon request) Fibre optic- multi mode 50/125 : 62.5/125 Temperature ratings -20 C to + 60 C Typical insertion loss 0.5 db per mated pair Submerged design life 25 years Termination options: Fully water blocked Mechanical strain terminations Oil filled 10
3.3 HPS penetrators (Hydro Bond penetrator series) P.U/ P.E moulding Hydro Group plc electrical penetrators are designed for deep sea applications and navy dive systems. These are used for passing electrical energy through the pressure boundaries of underwater vehicles and equipment. Several of the designs are Lloyds, DNV and ABS approved and has been specifically designed to withstand both gas and hydrostatic pressure. Pressure blocking within the penetrator is achieved by using a hard and tough non-conductive insert through which solid conductors are passed. Each individual insert is pre-tested to 5,000 psi before being wired and assembled into the penetrator housing. Peripheral sealing of the insert is affected by means of viton rubber 'O' seals. HPS right angle penetrator HPS right angle penetrator HPS in line penetrator HPS right angle penetrator Electrical Mechanical Pin density 1 to 55 contacts Material Stainless steel, Titanium Aluminium, Silicon Bronze, Voltage rating 500 Volts RMS (typical) Fixings NPT, smooth bore, flanged Current Up to 150 Amps O ring seal Viton Conductor tails 0.5mm² to 70 mm² Shear notch For diving bell application Environmental Water depth rating Up to 1500 MSW unmanned 455 MSW manned Temperature ratings -20 C to + 60 C Submerged design life 25 years Certification DNV R/2004, Lloyds & ABS witness testing 11
3.4 Fibre Link penetrator Hydro Fibre Link deep field penetrator can operate at 3000 MSW (310 Bar). The design and construction of the optical fibre penetrators can be limited due to the cable design and construction. The Hydro Fibre Link deep field penetrator is most suitable for sea bed ploughs, ROV, MUX systems and deep sea platforms. Fibre-Link Fibre-link Mechanical Material Stainless steel (as standard), Titanium and Aluminium (optional) Fibre Optic Fibre optic- single mode 9/125 µm O ring seal NI70 (standard) Fibre optic- multi mode 50/125 : 62.5/125 µm Typical insertion loss 0.5 db Depth rating 3000 MSW (310 bar) 3.5 Moulding and Encapsulation The L 100 Encapsulation Rubber which Hydro Bond use for moulding cable splices and over moulding connector housings is polyurethane rubber. This particular material is heat cured with diamine base compound to form polyurethane rubber outstanding physical properties. L 100 should not be confused with cold setting and hot setting polyester based urethanes since these materials have vastly inferior water resistant properties. L 100 rubber has excellent water and oil resistant properties. The long term water resistant of L 100 has been fully investigated over a period of 10 years and these results (see below) show that the material does not appreciably degrade. In addition, our company has first hand practical knowledge of the successful use of L 100 in subsea applications over the past 28 years! Hydro Group specialise in chemically bonding the L 100 rubber to metal and other elastomers. We can bond to the most conventional cable sheath material such Neoprene Hytrel, Nitrile, Polyurethane, Hypalon, EPR, etc 12
Assembly being removed from mould tool P.U junction box sample 13
3.6 Subsea optical and electrical cables Hydrocable Systems designs and manufactures a range of cables suitable for use underwater and in harsh environments. Our extensive knowledge of materials and engineer applications combine to manufacture high quality products. Applications include: Cables for videos Data transmission Communications Power Instrumentation ROV Cable plough Trenchers Armoured ROV tether Range Composite Flat power Fibre optic High Voltage Strain Bearing High grade materials such as are used in manufacture to produce cables with superior abrasion resistance, flexibility and reliability Polyurethane EPR Hytrel TPR Megalon Polyethylene Cross-linked The composition of our cables may vary widely: Multi-conductor to give optimum usage for various video and camera type. Twisted screened pairs, triples and quads with foil screening for communication and signal. Insulation compounds suitable for high voltage and various power applications. Sheathing compounds and braids for various mechanical and environmental requirements. The vast majority of our cables are customised to client s specification; however we keep on stock some of our most popular ranges in a variety of lengths. 14
Stock cable Stock cable Stock conductor cores Stock conductor cores In addition to popular cable configurations customer designs are offered to suit specific customer requirements. As part of its specialized service Hydrocable Systems alongside Hydro Bond Engineering can also provide complete cable assemblies, harnessing, terminations, splicing and encapsulation of electrical / fibre optic connectors. Our cables can be terminated to our own connectors or any other third party connector. Most of our cables comply with the majority of International standards and British specification standards. They are also tested in each and every stage of the manufacturing process. Please refer to the section Test and Qualification below for further clarification on the tests conducted in all our cables. 4. Hydro Group experience Hydro Group has participated in a number of defence and other high profile projects for the past 30 years. Our customer portfolio includes major subsea contractors and operators in both domestic and international markets. Below is a list of the 4 projects. 15
4.1 South Korean Aerospace Research Institute (KARI) - Aerostat cable Project: Hydro Group was contracted by the South Korean Research Institute (KARI) to design and manufacture a lightweight cable for their aerostat project. An aerostat is effectively a tether balloon that remains aloft through the use of buoyant lighter than air gases. It is used primarily in military and surveillance operations. The project took 3 years of research and development between KARI and Hydro Group. Solution supplied: The aerostat envelope required a lightweight cable and connectors for an operational height of 4000 ft. The lightweight cable consisted of an aramid braided strength member for strength, fibre optics for data and camera systems. The 10 ton breaking snatch load on a small diameter lightweight cable made it very challenging to manufacture and qualify. Aerostat Hydro Cable Systems CS1955 4.2. Kongsberg Acoustic range - Optical and electrical cable and connector harness Project Hydro Group was contracted by Kongsberg to design and manufacture a cable and connector harness to be fitted to an acoustic range for the Turkish navy. Solution supplied The acoustic range required 25 assemblies of armoured cable, terminated to HG deck mate connectors (HDM). The connector assembly incorporated strain terminations with the armour electrically insulated from the connector shell. The requirement was for the assembly to take a load bearing of 2.8 tonne approx for a towed acoustic range. Third party connectors were also terminated to some of the assemblies and modified to improve through life service. FAT test well conducted, shipping was to military standard MIL STD-129P. Assemblies ranged from around 200 meters up to 2,850 meters in length. Acoustic range HG optical & electrical assembly 4.3 Thales Optronic Systems non-hull penetrative optronic mast - SDM connectors 16
Project HG was contracted by Thales Optronic Systems to design and manufacture special hybrid deck mate connectors for the non-penetrative mast to be installed in BAE Astute submarine program. Solution supplied A non hull-penetrating electronic imaging system, which incorporates a broad range of multi spectrum sensors, support for high sensitivity wide band RF sensors and advanced signal and image processing technology. The system required a full cable and connector subsystem for integration and interface of the mast to the PHG (pressure hull gland). The subsystem met all operational requirements to provide a fully flexible cable interface under all dynamic operating conditions and meet all functional requirement at full submarine dive depth. Non-penetrative optronic mast HG hybrid deck mate connectors 4.4 QinetiQ Heavy tow cable Project HG was contracted by QinetiQ to supply a heavy tow cable, associated strain termination and cable harnesses for their Variable depth sonar system. Solution supplied The 660m long contra helical steel wire armour heavy tow body sonar cable was designed to be towed behind a war ship hunting for submarines. The acoustic dampening braid on the outer of the umbilical is used for reducing the vortex and increasing coefficients whilst being towed at 20 knots plus. Incorporated within the design was a weak link to enable safe release of the sonar system and ensure ship safety. The parameters for the design were that the release force was 176.5 kn plus or minus 10 % The cable breaking strength was 300 kn plus or minus 20 kn. Electrical and optical tests were also conducted while a 10 tonne load was applied to the cable strain terminations. Hydrostatic test to 500 metres was conducted as part of the requirement. QinetiQ tow sonar HG Tow cable 17
5. Tests and Qualification Routine Test and Factory Acceptance Test are a vital part of our business. As standard practice we perform a number of tests throughout the manufacturing process of our connectors, cables, assemblies and penetrators. For our connectors, connector assemblies and penetrators we can perform: Insulation test Continuity test Mate and de-mate test Sealing test Optical test Explosion proof test Temperature test Hydrostatic test o 1 hydrostatic pressure vessel up to 2000 psi / 1372 MSW / 137.90 bar o 1 hydrostatic pressure vessel up to 3250 psi / 2229 MSW / 224 bar Helium test o 1 helium pressure vessel up to 5000 psi / 3430 MSW / 344.74 bar Hydraulic test o 1 oil pressure vessel up to 5000 psi / 3430 MSW / 344.74 bar o 1 oil pressure vessel up to 10000 psi / 6860 MSW / 689 bar Hydrostatic pressure vessel Assembly testing For our cables, tethers and umbilical s we can perform Capacitance test Loop resistance test Impedance test Attenuation test Noise test Insulation resistance test High voltage test Conductor resistance test Low resistance test Dimensional height gauge test Tensile test Pull test Flash test 18
We can also do third party qualification to meet customer s required standards. 19