GISMA 10 Series, Handling Instructions Manual

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Page 2: ...7 2 5 Connector Handling 13 7 2 6 Test Port 14 7 2 7 Pressure Balanced Oil Filled Hose PBOF 14 SUBSEA CONNECTORS SERIES 22 16 7 3 1 General 16 7 3 2 Live Mate Demate 16 7 3 3 Protection of receptacle s pin contacts 17 7 3 4 Removal of Marine Growth and Calcareous Deposits 17 7 3 5 Connector Handling 17 7 3 6 Mounting dimension 18 7 3 7 Sealing spare parts 19 SUBSEA CONNECTORS SERIES 34 23 7 4 1 Ge...

Page 3: ... receptacle s pin contacts 34 7 7 4 Removal of Marine Growth and Calcareous Deposits 34 7 7 5 Cleaning process for ferrules 35 7 7 6 Connector Handling 35 SUBSEA CONNECTORS SERIES 80 37 7 8 1 General 37 7 8 2 Live Mate Demate 37 7 8 3 Protection of receptacle contact pins 38 7 8 4 Removal of Marine Growth and Calcareous Deposits 38 7 8 5 Diver Mate Connectors 38 7 8 6 Stab Plate Connectors 40 7 8 ...

Page 4: ...manufactured primarily from materials such as stainless steel 1 4404 1 4571 316L 316Ti marine bronze CW307G and titanium Grade 5 and as such are designed to withstand harsh saliferous environments However the connector insulator and exposed parts are susceptible to mechanical damage if not adequately protected Dust caps are fitted to all GISMA connectors before transport but can be fitted with POM...

Page 5: ... should be below 75 Very moist or very dry conditions should be avoided The connectors should be protected from sunlight and artificial light with a high ultra violet content The connectors should not be allowed to come into contact with solvents oil greases or any other semi solid materials If storage time is longer than 2 years outer o rings have to be replaced prior to installation 6 Jumper han...

Page 6: ...nector shall have the following periodic maintenance checks Examine the connector for signs of damage Check the locking sleeve these shall be tight if loose refer to assembly instruction for torque values where appropriate SUBSEA CONNECTORS SERIES 10 7 1 1 General The series 10 sizes 1 to 7 range of connectors has been developed for long term reliable signal and low power control system applicatio...

Page 7: ...asures must be taken Test connectors or free touchable connectors with metal shell must be connected to the earth conductor The series 10 range of connectors can be supplied either singularly or as part of a harness assembly All series 10 connectors require the following acceptance tests during termination Mating test Insulation Resistance test High Voltage test Continuity test Cable terminations ...

Page 8: ... fill the conical seal cavities with grease see drawing below Greasing ensures that the two elastomer Insulators in the conical seals can slide perfectly into its final position and thus best seal After 5 underwater matings the connector must be greased again applies only to series 10 For greasing the GISMA connectors Grease EK2 is specified The corresponding compatibility of this Grease is with a...

Page 9: ...s of the receptacles pressure hull penetrators and the through bulkhead receptacles e g with GISMA FETT LP 430 strongly recommended at stainless steel and titanium threads Dirty connectors to be purged with GISMA foam cleaner SCHAUMREINIGER Allow three minutes to react In case of strong dirt repeat the procedure Then rinse with clean water Following rinse with the enclosed cleaning liquid SPÜLLÖSU...

Page 10: ...tightening the locking sleeve with the one hand simultaneously feed in the connector with the other Mating After tightening the locking sleeve by hand screw it into the receptacle fitting using corresponding wrenches If the locking sleeve is designed with a safety screw tighten it For defined clamping torque refer to GISMA document Torque overview Cathodic Protection Stainless steel 1 4404 1 4571 ...

Page 11: ... 4x90 36 17 7 11 28 32 6 2 26 5 H8 27 5 0 3 40 51 12 M5 6x60 39 19 2 11 28 35 6 3 32 H8 33 5 0 3 48 59 12 M5 6x60 46 22 2 15 26 41 6 4 36 5 H8 37 5 0 3 52 63 12 M5 6x60 51 24 7 16 26 46 6 5 47 H8 49 5 0 3 67 78 12 M5 6x60 69 32 7 24 25 62 6 6 56 H8 59 5 0 3 77 88 17 M5 6x60 78 39 2 14 25 75 6 7 85 H8 88 0 3 112 126 28 M8 6x60 71 91 H8 94 0 3 122 142 17 M8 6x60 Mounting holes for standard flange an...

Page 12: ...rease the mounting hole and the supporting surface with corrosion preventing fluid for example Fluid Film as a minimum If the connectors are to be left unmated in seawater for any length of time pressure watertight protective caps must be used to protect the contacts Over exposure will increase the risk of corrosion damage or marine growth on the contact surfaces of the pin contacts This could lea...

Page 13: ... hour In addition the thermoplastic materials have good resistance to Citric Acid Other acid cleaners such as 50 Acetic Acid should not be used as they may cause deterioration of the elastomeric materials Chiselling and abrasive methods are not recommended Use of a water jet is acceptable but the jet should not be directed onto the pins at the front and onto any elastomer part like insulators and ...

Page 14: ...idered by the customer 7 2 6 Test Port Series 16 receptacles are equipped with test ports according to API specification 16D The integrity of the sealing of the mating and flange area could be tested The test ports should be sealed by the provided test port sealing plugs at all times For testing the sealing plugs will be replaced by a test port adapter and a test pressure pump will be connected vi...

Page 15: ...7 2008 Rev Index Z From 29 07 2020 Copyright by GISMA GmbH Page 15 of 44 Picture boot seal fastening set Fill the oil reservoir entirely with oil by a syringe Make sure the oil can t drain until the hose system is completely filled with oil GISMA will supply boot seal material specimen Viton for oil compatibility check on request ...

Page 16: ...ss coupled with a mating connector or fitted with a pressure watertight protective cap in order to prevent electrolytic damage to the contacts when exposed to sea water All mild steel sealing interfaces shall be inlayed with Inconel 625 or similar where no additional protection can be provided This is to prevent localised pitting of the interface If not possible grease the mounting hole and the su...

Page 17: ...d not be directed onto the pins at the front and onto any elastomer part like insulators and bootseals NOTE Keep the connector mated at any cleaning operation 7 3 5 Connector Handling Installation instruction for jam nut receptacles bulkheads and pressure hull penetrators The flange and mounting hole has to be manufactures according VG 85 519 or customer design The mounting hole and the supporting...

Page 18: ...0 39 0 05 39 0 05 0 25 39H7 H8 27 40 85 40 90 41 1 1 30 4 3 70 39 0 05 39 0 05 0 25 39H7 H8 27 40 85 40 90 26 43 41 1 1 30 4 4 85 54 0 05 54 0 05 0 25 54H7 H8 26 5 40 85 27 43 56 1 1 37 9 5 85 54 0 05 54 0 05 0 25 54H7 H8 28 40 85 27 43 56 1 1 37 9 7 105 72 0 05 72 0 05 0 25 72H7 H8 33 7 40 85 74 1 1 47 4 Mounting holes for standard pressure hull penetrators Please contact our design department fo...

Page 19: ... 241 268 255 285 199 227 250 147 280 ATTENTION all details are approximately measurements 7 3 7 Sealing spare parts Replaceable O rings and profile sealing rings on pressure hull penetrator We offer a customised sealing package to our customers Please contact our sales department for suitable selection Based on the part number you will get information and a quotation about the right set immediatel...

Page 20: ...be greased again For greasing the GISMA connectors Grease EK2 is specified The corresponding compatibility of this Grease is with all elastomers used in GISMA insulating sealing elements given At the same time this product has excellent properties The grease EK2 is not conductive By mating the GISMA connector the contact forces applied mean the grease is completely displaced from the contact area ...

Page 21: ...m grease to prevent losses Left Ungreased insulator Right greased insulator Picture grease filling of plug Lightly grease the locking threads of the receptacles pressure hull penetrators and the through bulkhead receptacles e c with GISMA FETT LP 430 strongly recommended at stainless steel and titanium threads Dirty connectors to be purged with GISMA foam cleaner SCHAUMREINIGER Allow three minutes...

Page 22: ...tion of O rings the general guidelines for O ring assembly have to be taken into account Mainly the correct installation e g position cleanness and greasing with GISMA FETT EK2 have to be ensured In case that the O rings carrying assemblies are installed for more than 2 years to a structure and then will be disassembled we generally recommend to replace the O rings We recommend changing the O ring...

Page 23: ...ng testing UNDER NO CIRCUMSTANCES should a foreign object such as a screwdriver test probe or crocodile clip be used as a test connection as this could damage the seals and insulation Such actions will invalidate the warranty of the connector Attention The customer is responsible for the safe operation of the connectors and cable systems All necessary protective measures must be taken Test connect...

Page 24: ...ermoplastic materials have good resistance to Citric Acid Other acid cleaners such as 50 Acetic Acid should not be used as they may cause deterioration of the elastomeric materials Chiselling and abrasive methods are not recommended Use of a water jet is not acceptable NOTE Keep the connector mated at any cleaning operation 7 4 5 Connector Handling The mounting hole and the supporting surface must...

Page 25: ...will only be installed once our experience shows the estimated lifetime may be double For operating temperatures between 5 C to 40 C longer lifetimes can be expected Defective clamps to be replaced Alignment Put the plug onto the receptacle Twist the connector until the keyway locks into place While tightening the locking sleeve with the one hand simultaneously feed in the connector with the other...

Page 26: ...during testing UNDER NO CIRCUMSTANCES should a foreign object such as a screwdriver test probe or crocodile clip be used as a test connection as this could damage the seals and insulation Such actions will invalidate the warranty of the connector Attention The customer is responsible for the safe operation of the connectors and cable systems All necessary protective measures must be taken Test con...

Page 27: ...ic materials have good resistance to Citric Acid Other acid cleaners such as 50 Acetic Acid should not be used as they may cause deterioration of the elastomeric materials Chiselling and abrasive methods are not recommended Use of a water jet is not acceptable NOTE Keep the connector mated at any cleaning operation 7 5 5 Connector Handling The mounting hole and the supporting surface must be clean...

Page 28: ... only be installed once our experience shows the estimated lifetime may be double For operating temperatures between 5 C to 40 C longer lifetimes can be expected Defective clamps to be replaced Alignment Put the plug onto the receptacle Twist the connector until the keyway locks into place While tightening the locking sleeve with the one hand simultaneously feed in the connector with the other Mat...

Page 29: ...or or fitted with a pressure watertight protective cap in order to prevent electrolytic damage to the contacts when exposed to sea water All mild steel sealing interfaces shall be inlayed with Inconel 625 or similar where no additional protection can be provided This is to prevent localised pitting of the interface If not possible grease the mounting hole and the supporting surface with corrosion ...

Page 30: ...n the plug 7 6 4 Removal of Marine Growth and Calcareous Deposits To remove calcite growth topside or subsea from GISMA connectors a solution of 50 Citric Acid is recommended All seawater exposed elastomeric materials in GISMA connectors have been fully tested against 50 Citric Acid and are compatible for duration of 1 hour In addition the thermoplastic materials have good resistance to Citric Aci...

Page 31: ...th a further dry stick also under rotating movements 7 6 6 Connector Handling Pre Mating Check The connector that is to be joined must be free of dirt and foreign matter Attention For hybrid connectors eg fibre optic and coax combined it is necessary to ensure that only the region of the O ring must be greased Fibre optic and coaxial contacts must be kept absolutely free from grease to prevent los...

Page 32: ...efined clamping torque refer to GISMA document Torque overview for series 10 22 35 40 Cathodic Protection Stainless steel 1 4404 1 4571 comparable to 316L 316Ti marine bronze CW307G or titanium grade 5 diver mate connectors must be connected to the CP Cathodic Protection system at all times Super Duplex stainless steel connectors should be isolated from the CP system to reduce the possibility of h...

Page 33: ...itted with a pressure watertight protective cap in order to prevent electrolytic damage to the contacts when exposed to sea water All mild steel sealing interfaces shall be inlayed with Inconel 625 or similar where no additional protection can be provided This is to prevent localised pitting of the interface If not possible grease the mounting hole and the supporting surface with corrosion prevent...

Page 34: ...n the plug 7 7 4 Removal of Marine Growth and Calcareous Deposits To remove calcite growth topside or subsea from GISMA connectors a solution of 50 Citric Acid is recommended All seawater exposed elastomeric materials in GISMA connectors have been fully tested against 50 Citric Acid and are compatible for duration of 1 hour In addition the thermoplastic materials have good resistance to Citric Aci...

Page 35: ...th a further dry stick also under rotating movements 7 7 6 Connector Handling Pre Mating Check The connector that is to be joined must be free of dirt and foreign matter Attention For hybrid connectors eg fibre optic and coax combined it is necessary to ensure that only the region of the O ring must be greased Fibre optic and coaxial contacts must be kept absolutely free from grease to prevent los...

Page 36: ...efined clamping torque refer to GISMA document Torque overview for series 10 22 35 40 Cathodic Protection Stainless steel 1 4404 1 4571 comparable to 316L 316Ti marine bronze CW307G or titanium grade 5 diver mate connectors must be connected to the CP Cathodic Protection system at all times Super Duplex stainless steel connectors should be isolated from the CP system to reduce the possibility of h...

Page 37: ...of the receptacle s pin contacts This could lead to damage to the seals and insulation within the socket contacts Plugs do not require full pressure watertight protective cap for protection GISMA advise the fitting of POM caps to protect plugs against marine growth It is good practice to always fit the protective cap when a connector is unmated topside prior to deployment to provide mechanical pro...

Page 38: ...cid Other acid cleaners such as 50 Acetic Acid should not be used as they may cause deterioration of the elastomeric materials Chiselling and abrasive methods are not recommended Use of a water jet is acceptable but the jet should not be directed onto the shuttle pins at the front of the plug as this could result in a risk of water being forced through the primary seals 7 8 5 Diver Mate Connectors...

Page 39: ...ter keyway locator Cathodic Protection Stainless steel 1 4404 1 4571 comparable to 316L 316Ti or titanium grade 5 stab plate connectors must be connected to the CP Cathodic Protection system at all times If the connector is designed with a fixed flange and screw mounting an additional CP connecting would not be required Super Duplex stainless steel connectors should be isolated from the CP system ...

Page 40: ...g the receptacle connector should be checked for debris The connectors have been designed to accommodate sand and silt contamination however large pieces of debris should be removed using a water jet Prior to mating a visual inspection has to be done Pin contacts have to be straight and without any damages Cathodic Protection Stainless steel 1 4404 1 4571 comparable to 316L 316Ti or titanium grade...

Page 41: ...ngagement Pre Mating Checks Before mating the receptacle connector should be checked for debris The connectors have been designed to accommodate sand and silt contamination however large pieces of debris should be removed using a water jet Prior to mating a visual inspection has to be done Pin contacts have to be straight and without any damages Mating The ROV mateable plug is assembled with GISMA...

Page 42: ... or titanium grade 5 stab plate connectors must be connected to the CP Cathodic Protection system at all times If the connector is designed with a fixed flange and screw mounting an additional CP connecting would not be required Super Duplex stainless steel connectors should be isolated from the CP system to reduce the possibility of hydrogen embrittlement Mating forces standard configuration Size...

Page 43: ... for GISMA connectors HI 2007 001 Document replaces MV 2000 020 MV 2000 030 and MV 2005 011 First issue 15 07 2008 Rev Index Z From 29 07 2020 Copyright by GISMA GmbH Page 43 of 44 7 8 8 Mounting hole for flange receptacle ...

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