A joined industry project towards verification and
certification of submarine power cables
Advanced submarine power cable & interconnection forum, Berlin
Wessel Bakker and Frank de Wild
18 June 2014
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DNV GL © 2013
18 June 2014
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Agenda
 Today’s QA/QC and innovation by Wessel Bakker
– Introduction to DNV GL
– Cable life cycle
– Innovation in cable technology
– Product and project certification
 Joint Industry Project by Frank de Wild
– Background
– Consultant view
– Certification view
– Higher goal for the Joint Industry Project
– Description of JIP
– Invitation to potential participants at this workshop
– Q&A
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Introduction Wessel Bakker
 Currently 4 years at DNV GL (former KEMA), Head of Department
in Power System Planning and Project Management & Technical
Services, advisory services in
– strengthening of grids,
– balancing of electrical power supply & demand,
– integration of renewables
– offshore T&D technologies.
 20 years at ABB in Power Generation and Transmission &
Distribution as electrical engineer, project manager of electrical
balance of plant, sales manager, senior account manager of major
utilities and manager of strategy of ABB Benelux.
 President of the Dutch National Committee of CIGRE.
 Delft Technical University, MSc. Electrical Engineering.
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We are a global classification, certification, technical assurance
and advisory company
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In a challenging world we make businesses better prepared
Low carbon energy
Short-term
cost efficiency
Complexity and lack
of global governance
Reliable and
affordable energy
Long-term
competitiveness
Trust and
transparency
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Efficient and fast
Safe
This takes detailed knowledge and diverse domain competence
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Technical and operational challenges…
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Regulatory processes…
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Value chain interdependencies…
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Stakeholder considerations…
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Only by connecting the details can we impact the bigger picture
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We classify, certify, verify and test against regulatory requirements, rules, standards and
recommended practices
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We develop new standards and recommended practices
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We qualify new technologies and operational concepts
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We give expert advice to enhance sustainable business performance
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We call it the broader view
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Reducing uncertainty, increasing safety
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Improving efficiency
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Enabling sustainability
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Building trust
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Industry consolidation
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Global reach – local competence
150
400
100
16,000
years
offices
countries
employees
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Organized to maximize customer value
MARITIME
OIL & GAS
ENERGY
SOFTWARE
CYBERNETICS
RESEARCH & INNOVATION
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BUSINESS
ASSURANCE
Cable life cycle value chain
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Cable life cycle value chain
Feasibility studies
System studies
and Basic design
Decommissioning
Failure analysis
Tender evaluation
Production
and testing
Diagnostics
Installation
Operation & Maintenance
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Submarine cable references examples
 Submarine interconnector projects (different roles):
– NO-NL, UK-NL, UK-IR, UK-Northern Ireland, DK-NL, BE-UK, UK-UK, Caribbean
interconnector, Far East interconnector, 2 more strictly confidential interconnectors
– AC and DC cables, extruded and mass impregnated
 Windfarm export cable / collector cable / offshore facility cable projects:
– Belgium, Netherlands, UK, Germany, Norway, Middle East
– AC and DC cables, single core and three core cables
 Submarine cable conceptual studies
– Studies towards networks at sea, options to connect off shore windfarms to existing
grids
– Several feasibility studies for exceptional interconnectors (strictly confidential)
 Role of DNV KEMA:
– Feasibility studies, conceptual design studies, technical problem solving, innovations
– Independent QA/QC over complete project, risk mitigation
– Safety studies
– Failure investigations
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Innovations in cable technology
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Committed to innovation and foresight
 DNV GL invests 5% of revenue in research & innovation every year,
 we collaborate with industry partners and external experts,
 we share knowledge through standards and recommended practices.
 we provide foresight and initiate competence building and innovation
 we provide specific cable innovation projects
– Extraordinary innovation projects
– Subsea Cable Repair
– Floating Cable
– Innovation Projects
– Dynamic Rating System
– Cable cover thickness monitoring
– Joined Industry Projects
– Smart Cable Guard
– Recommended practice for subsea power cables in shallow water
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Extra Ordinary Innovation Project:
Subsea Cable Repair
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Extra Ordinary Innovation Project:
Floating Cable Concept
Copyright: Per Sverre Wold-Hansen / Softedge
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Innovation Project:
Example: Dynamic rating system
 Typical current as function of time for an
off-shore windfarm export cable
 Conclusion:
– Significant thermal inertness of cable
and environment present
– Leading to significant room for more
current transport, estimated on
average 20% to 35% more current
transport during peaks of 24 hrs in
length
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Innovation project:
Example: Cable cover thickness monitoring
 In case of reduced sand cover over a power cable,
risk on failure due to fishing gear, anchoring,
vibration (if exposed cable in free span) and third
party activities
 Options to monitor exposed power cable
– Regular check with ship logging (sonar)
– known, but how often to be done?
– On-line monitoring with fiber optics
– Check temperature variations with cable loading
with model of cable environment, and
determine thermal capacitance and resistance
– Deduce amount of soil around power cable from
this
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Joint Industry Project
Example: Qualification of Offshore HVDC technology
 Qualification of Offshore HVDC
technology
– 11 partners, offshore as well as
onshore background, and different
practices
– Result of JIP formulated in a
Recommended Practice
– An RP provides an efficient tool to
document Best Practice in an area
where technology changes, and no
international standards are yet
available
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Joint Industry Project
Example: Smart Cable Guard
 Smart Cable Guard (SCG) is a new patented DNV GL award winning ON-LINE
monitoring tool for MV power cables that (with 1 % location accuracy)
– Locates weak spots to prevents outages (Operator can remove weak spots)
– Locates failures to reduces outage times (Operator can perform a faster repair)
 Use up to 36kV (array cable)
 Developed together with 3 partners with DNO background
SCG equipment
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SCG sparks from weak
spot and risk warning
Defect found at weak spot
– failure avoided
February 2014: New recommended practice for subsea power
cables in shallow water renewable energy applications released
Reason for proposal
Disproportional insurance claims related to cables within
offshore wind farms.
Lack of “best practice”, especially for cable system design
and installation.
Industry interest to work with DNV on new guideline (JIP,
15 participants, August 2012 – autumn 2013).
Scope of the proposal
RP was developed in a style which will allow future
updates, expansions and conversion into a standard.
Consequences
A comprehensive guideline freely available to the
industry.
A communication tool for all stakeholders.
A building block for 3rd party verification, complementing
DNV wind turbine and offshore substation guidelines.
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Product and project certification
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High voltage cable testing
Independent testing and certification of medium, high and ultra-high voltage
components used in transmission and distribution power networks
 Largest commercially operated High
Voltage Laboratory in the world
 Specialized in high voltage AC and
HVDC cable testing
 Test bays for PQ tests
 Various trailers for on-site
commissioning testing
 World renowned and fully accredited laboratories, largest short circuit laboratory in the world
 Tests are based on internationally accepted standards (like IEC and IEEE)
 Extreme testing capacity in development for ultra-high power equipment (1200kV) for super
grids
 KEMA Type Test Certificate, Report of Performance
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High power testing
Independent testing and certification of medium, high and ultra-high voltage
components used in transmission and distribution power networks
 No. 1 and largest High Power
Laboratory in the world
 Largest High Power Laboratory in the
Americas
 EUR 70 million investment for extreme
800 kV testing market
 Up to 1200 kV circuit breaker testing
 Unique testing method for large power
transformers
 Complete type test of LV assemblies
 High Power Test Laboratories located in Arnhem, Prague and Chalfont
 Fully accredited Laboratories
 KEMA Type Test Certificate, Report of Performance
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Project certification
Modular service provision for onshore and offshore wind projects based on client’s
needs
 Site specific design conditions
 Site specific design assessment
 Surveillance during production
 Surveillance of transport and erection
 Surveillance during commissioning
 Project certificate
 Periodic monitoring
 Longest history in wind energy
Certification is based upon:
 Own standards/guidelines
 International standards
 Biggest workforce and highly qualified teams
 Various national certification systems
 Avoiding damages/reducing financial
risks/securing investment
 DNV standards and GL guidelines
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 Customer’s specifications
Renewables certification
Accredited certification of equipment (products), services and projects in renewable
energy
 Component certification
 Prototype certification
 Type certification
 Project certification
 Onshore wind
Certification is based upon:
 Offshore wind
 Internationally accepted standards
 Wave and tidal
 Various national certification systems
 Solar/PV
 DNV standards and GL guidelines
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A joint industry project towards verification
and certification of submarine power cables
Advanced submarine power cable & interconnection forum,
Berlin - Germany
Wessel Bakker and Frank de Wild
18 June 2014
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DNV GL © 2013
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SAFER, SMARTER, GREENER
Who am I?
Frank de Wild
• 16 yrs with DNV GL (legacy KEMA)
• Principal consultant
• Leading DNV GL Power cable team in Energy Advisory
• (pre-)design, feasibility, QA/QC, engineering aspects, safety, etc.
• HVAC and HVDC cables
• Land and submarine cables
• Emphasis on current ratings (ampacity)
Active in Cigre SC B1:
• as national member of SC B1
• as convenor of WG B1.35 – current rating
• as convenor of TF B1.53 – cable installation related damage
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Contents
 Introduction
 Background
– Consultant view
– Failure investigations
– Quality assessment / quality control
– Standards and guidelines
– Certification view
 Higher goal for the Joint Industry
Project
 Description of JIP
 Invitation to participate
 Q&A
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Views from our consultants
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Developments around submarine power cables
Number of large cable projects is rising
 Submarine cables to wind farms
 Submarine cables to offshore facilities
 Submarine cable connectors to offshore hubs
 Submarine interconnectors between countries
Demands are increasing
 Cable failure leads to outage of the facility,
and has important impact
 Loading, RAM, EMF requirements are on the rise
 Complexity of solutions is increasing
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Information from failure investigations
‘Failures’ in submarine cables from DNV GL experience:
 We see many failures happening before and after commissioning. Almost all cable
parts are affected, and cable handling is very important
 Various cable systems fail to meet specs before service starts
 During service, cables failures are not uncommon
– External (anchoring, damage)
– Internal (e.g. insulation failures)
When a failure happens:
 During service:
Repair can be time consuming due to difficulty to pinpointing failure & repair
failure
 During testing:
Assessment can lead to redesigning or significant retesting of the cable system,
leading to important project consequences
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Information from failure investigations
Benefit from failures:
 Application of learning cycle
– Failures enable us to learn what is important
– The way back to acceptable situations is defined, often involving special
manufacturing, installation, testing or control procedures
– Further discussions lead the way how to mitigate these failures in the first place
– This information can be used in early phases of other projects
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Cable life cycle value chain
Feasibility studies
System studies
and Basic design
Decommissioning
Failure analysis
Tender evaluation
Production
Diagnostics
Installation
Operation & Maintenance
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Information from QA/QC projects
Quality management in projects
To prevent problems,
DNV GL proposes to include contentwise QA/QC in large cable projects
from the starting phase to the commissioning phase
We do so as a service to the power cable market
Quality management:
1. Definition of the required level of quality
2. Quality Assurance – the process to measure and assure this level
3. Quality Control – Verification whether the quality is according to the defined
quality level
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Quality control during first project stages
Project stage
QA/QC measure
 Project specification
 Review on contents, consistency and
completeness
 Prequalification of supplier
 ISO 9001 audit
 Assessment of standard work procedures
 Assessment of supplier’s experience
 Tender documentation
 Definition of set of functional requirements (FR)
 Definition of responsibilities for functional
requirements, definition of situation when
problems are encountered
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Quality control during project
Project stage
Quality control measure
 Tendering stage
 Bid evaluation on contents, check if FR
can be met
 Engineering phase
 Design review
 Solving design issues
 Check if FR are met
 Manufacturing phase
 Review of test and inspection plans
 Performing tests on assets (also when
not part of IEC)
 Check if FR are tested
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Quality control during project
Project stage
Quality control measure
 Realisation phase
 Review work plans
 Check if realisation is performed
according to work plans
 Check if FR are being met
 Commissioning phase
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 Check if FR can be demonstrably met
Quality control during project
Some important insights:
 Quality levels are defined in the early stages of projects and are affected by the
choices made there. Control actions are especially important in these early project
stages to avoid problems later
 Quality control is about implementing checks (Plan-Do-Check-Act cycle). Most
importantly the functional requirements should be checked
 Actual component testing is a part of quality control, but quality control is much
wider
 Standardized testing is always based on a compromise and is consequently
appropriate for improvement or for additional quality control measures
 For adequate quality control in a project, in-depth technical insight is mandatory
 It would be best to have a single, knowledgeable party performing the quality
control from project start to project finish
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DNV GL experience from QA/QC projects
 Specifications are often not 100% complete or fully adequate
E.g. RAM analysis missing, no definition of optical fibre cable properties, no definition of
traceability of materials, installation requirements incomplete or unverified, tests missing
 Not too much attention to technical risk management and mitigation processes
 Agreements between contract parties give room for uncertain project continuation
in case of failures
 Quality control not always performed, end-client not verifying ITP and QC actions
 Relation between burial depth and failure probability is much more complicated
than e.g. current BPI theory, representative depth measurements are very
difficult
 Problems arise with meeting the functional requirements
(specification) of a project
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Experience with existing standards and guidelines
Available standards, guidelines form a good basis
 IEC 60840, 62067
“Test methods for power cables, but not specifically for submarine cables”
 Cigre TB 490
“Recommendations for testing of long AC submarine cables with extruded
insulation”
However, ‘unclarities’ exist, e.g.
 Development tests are required for special topics for each project, but these are
not often specified / required / communicated
 FO missing in TB 490, interaction between power cable cores and fibre optic cable
is not described nor tested
 Material definition is rather vague:
– In case of changes, cables must have ‘same or similar construction’, and tests
must be repeated if it is likely that a ‘significant effect’ is to be expected
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Existing standards and guidelines
Uncertainties are partly being addressed
 Cigre TB 303
“Revision of qualification procedures for HV and EHC AC extruded underground
cable systems”
Containing a listing of tests currently missing in IEC 60840/62067 (about 30),
primarily with focus on electrical behaviour of underground cables, to the choice
of the user
 DNV RP DNV-RP-J301
“Subsea power cables in shallow water renewable energy applications”
Containing a set of guidelines predominantly on installation of power cables for
offshore windfarms
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Remaining unclarities – consultant’s viewpoint
 What should be inside and outside specifications?
 What should be inside an ITP?
– What tests should be done additional to IEC standards?
– What tests and verification procedures must be applied to FO cables being part
of submarine cables?
 What quality control procedures and verifications should be performed to design,
manufacturing, transportation and installation?
 How to verify that materials which are tested, are actually used in the cable
system delivered, and how to ensure that materials remain traceable through the
manufacturing and installation procedures
 How to verify the risk profile of cable system
after installation (risk vss burial depth)?
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View from our certifiers
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Offshore Wind in the German North and Baltic Sea
Project Certification
 Certification required by authorities
(Federal Maritime and Hydrographic Agency (BSH) according to
“Standard Design of Offshore Wind Turbines”, BSH no. 7005, Version 2007
Submarine cables addressed in section 3.4
often applied in combination with exemplarily given
GL Rules and Guidelines – IV Industrial Services – Part 2 –
Guideline for the Certification of Offshore Wind Turbines, Edition 2012
Submarine cables roughly covered by section 8.10
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Private and confidential
18 June 2014
Offshore Wind in the German North and Baltic Sea
Project Certification
Current certification, test and inspection requirements
 Power core and accessory design / testing according to
IEC 60502 or IEC 60840
 Submarine cable type testing according to CIGRE TB490
(mechanical and electrical testing)
 Current carrying capacity calculation acc. to IEC 60287 in
consideration of installation / risers
 Verification of ITP (Inspection and Test Plan)
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Private and confidential
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Offshore Wind in the German North and Baltic Sea
Project Certification
Current certification, test and inspection requirements
 Evaluation of cable route survey
(locate obstacles, water depth, seabed characteristics)
 Riser and mechanical protection
 Installation and fixation up to termination
 Thermal conductivity of soil (BSH 2K-Criteria)
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Private and confidential
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Offshore Wind in the German North and Baltic Sea
Project Certification
Summary
 -> Lack of definite requirements with regard to product quality assurance
 -> Interfaces between owner, suppliers and contractors are not
adressed and shall be monitored by third party verification
 -> No standard available dealing with sea operations and standardized /
comparable calculation of forces applied to cables during repair, installation and
pull-in
 -> No standard available dealing with the application and qualification of cable
protection systems
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Higher goal
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Higher goal
 To come to an objective and clear reference to define and measure the quality of
an installed submarine power cable
 To improve the quality, and to reduce the chance of failure of the end product: an
installed submarine power cable fulfilling its functional requirements
 To create clarity on how to define and verify the quality of a submarine power
cable
 To create a reference
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Joint Industry Project
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Description of Joint Industry Project
Title
Improving cable quality to reduce risk in
offshore projects
Aim
To reduce risks in new offshore cable projects
By
Defining reference criteria, testing verification and
certification procedures for submarine cable projects
from definition to commissioning
It provides the means to objectively measure the quality of a submarine power
cable project. With that, quality can be monitored and improved, and risks can be
reduced
Yielding a solid basis for verification and future certification of submarine power
cables, bringing definable quality, clarity and transparency
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Description of Joint Industry Project
 Goal to be reached together via a collaborative effort
 Frequent meetings and subject oriented discussions
 Limited project duration
 Ending with a final document, publicly available
We currently seek
 10-15 participating companies representing
different fields in the industry
– Willing to actively contribute to this process
– Willing to pay the participation fee
– Available in October 2014 for the launch meeting of the JIP
DNV GL invites you to joint his initiative!
Interested?
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Please contact [email protected]
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Q&A
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Questions and answers
We believe many failures and project problems can be prevented by creating a
good set of reference criteria for the various phases within submarine cable
projects. Projects will run smoother with it, risks during the project and during
operation will be reduced.
It is better to work towards a set of reference criteria together, than to continue
without it.
Do you agree or not?
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Questions and answers
We currently propose to focus on the complete process from project definition to
commissioning. It enables to balance various criteria in various stages, but it is a
rather large job
Is this there a better way forward?
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Questions and answers
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Thank you for your attention and we look
forward to collaborate with you!
[email protected]
[email protected]
+31 26 356 2854
www.dnvgl.com
SAFER, SMARTER, GREENER
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