DEP SPECIFICATION

MEDIUM VOLTAGE, 6kV (Um = 7.2kV) to 30kV (Um = 36kV),

POWER CONDUCTORS FOR DEEPWATER UMBILICALS

DEP 37.80.02.35-Gen.

February 2011

DESIGN AND ENGINEERING PRACTICE

© 2011 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.
 DEP 37.80.02.35-Gen.
February 2011
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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global
Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference
international, regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice to be applied by Shell
companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such
facility, and thereby to help achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at
each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by
these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI
disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or
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All administrative queries should be directed to the DEP Administrator in Shell GSI.
 DEP 37.80.02.35-Gen.
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TABLE OF CONTENTS
PART I INTRODUCTION AND GENERAL REQUIREMENTS...............................................4
1. INTRODUCTION ........................................................................................................4
1.1 SCOPE........................................................................................................................4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4
1.3 DEFINITIONS .............................................................................................................4
1.4 CROSS-REFERENCES .............................................................................................5
1.5 COMMENTS ON THIS DEP .......................................................................................5
1.6 DUAL UNITS...............................................................................................................5
2. GENERAL REQUIREMENTS.....................................................................................6
2.1 GENERAL ...................................................................................................................6
2.2 SCOPE OF WORK .....................................................................................................6
2.3 PROJECT DOCUMENTS ...........................................................................................6
PART II AMENDMENTS AND SUPPLEMENTS TO IEC 60502-2..........................................7
1 SCOPE........................................................................................................................7
4.2 INSULATING COMPOUNDS......................................................................................7
5 CONDUCTORS ..........................................................................................................7
6.1 MATERIALS................................................................................................................7
7 SCREENING...............................................................................................................7
8 ASSEMBLY OF THREE CORE CABLES, INNER COVERINGS, AND FILLERS .....8
9 METALLIC LAYERS FOR SINGLE-CORE AND THREE-CORE CABLES................8
12.1 LEAD SHEATH ...........................................................................................................8
16.1 GENERAL ...................................................................................................................8
16.2 ELECTRICAL RESISTANCE OF CONDUCTORS.....................................................8
17.1 GENERAL ...................................................................................................................9
18 TYPE TESTS, ELECTRICAL......................................................................................9
18.2 CABLES OF RATED VOLTAGE 3.6/6 KV HAVING UNSCREENED
INSULATION ............................................................................................................10
19 TYPE TESTS, NON-ELECTRICAL ..........................................................................10
19.12 OIL IMMERSION TEST FOR ELASTOMERIC SHEATHS ......................................10
19.14 FLAME SPREAD TEST ON SINGLE CABLES ........................................................10
19.15 MEASUREMENT OF CARBON BLACK CONTENT OF BLACK
POLYETHYLENE (PE) OVERSHEATHS.................................................................10
19.18 DETERMINATION OF HARDNESS OF HARD ETHYLENE PROPYLENE
RUBBER (HEPR) INSULATION ...............................................................................10
19.19 DETERMINATION OF THE ELASTIC MODULUS OF HEPR INSULATION ...........10
19.22 WATER PENETRATION TEST ................................................................................10
ANNEX A Fictitious calculation method for determination of dimensions of protective
coverings...................................................................................................................11
ANNEX B Tabulated continuous current ratings for cables having extruded insulation and
a rated voltage from 3,6/6 kV up to 18/30 kV ...........................................................11
ANNEX C Rounding of numbers................................................................................................11
PART III REFERENCES .........................................................................................................12

APPENDICES
APPENDIX 1 PROJECT DOCUMENTS................................................................................13
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PART I INTRODUCTION AND GENERAL REQUIREMENTS

1. INTRODUCTION

1.1 SCOPE
This new DEP specifies requirements and gives recommendations for the manufacture of
medium voltage (MV) power cores with extruded solid insulation from 6 kV up to 30 kV for
use in subsea umbilical applications.
This DEP is based on IEC 60502-2. Part II of this DEP amends, supplements and deletes
various clauses/paragraphs of IEC 60502-2. Clauses of IEC 60502-2 that are not
mentioned in this DEP remain applicable as written.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production. This DEP may
also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process should be
implemented; this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Abbreviations
FAT Factory Acceptance Test
HEPR Hard Ethylene Propylene Rubber
ITP Inspection and Test Plan
MRB Manufacturing Record Book
MOC Management of Change
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February 2011
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MV Medium Voltage
PE Polyethylene
PVC/B Polyvinyl Chloride
QP Quality Plan
TDR Time-Domain Reflectometry

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in
(Part III).

1.5 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at standards@shell.com, using
the DEP Feedback Form. The DEP Feedback Form can be found on the main page of
“DEPs on the Web”, available through the Global Technical Standards web portal
http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

1.6 DUAL UNITS

In this DEP, the International System of units (SI) shall be understood to prevail over US
Customary (USC) units. USC units are provided in brackets following the SI units for
information.
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2. GENERAL REQUIREMENTS

2.1 GENERAL
Part II of this DEP amends, supplements and deletes various clauses/paragraphs of
IEC 60502-2. Wherever reference is made to IEC 60502-2, it shall be understood to mean
IEC 60502-2 as amended/supplemented by this DEP.
For ease of reference, the clause numbering of IEC 60502-2 has been used throughout
Part II of this DEP. Clauses of IEC 60502-2 that are not mentioned in this DEP shall remain
applicable as written.

2.2 SCOPE OF WORK

Project specific variables such operational life, operating environment, water depth, rated
voltages and current etc shall be specified in the Project Scope of Work of the Purchase
Order to the MV power core manufacturer.

2.3 PROJECT DOCUMENTS

Manufacturer/Supplier shall prepare a Project Document Register in accordance with the
Project Scope of Work and shall include the documents and drawings listed in (Appendix 1)
of this DEP for all elements of scope awarded to Manufacturer/Supplier.
Manufacturer/Supplier may propose a Project Document Register that differs in document
or drawing titles or in structure providing the register encompasses the required
deliverables.
Manufacturer/Supplier shall submit a register of all non project specific internal
manufacturing procedures and specifications to Principal and permit review on site of all
documents (written in English) and audit of the manufacturing procedures at any time
during the project execution.
Manufacturer/Supplier shall issue a project specific Inspection and Test Plan (ITP) for
Principal’s review and approval. The ITP shall include for all manufacturing stages:
• Principal specification reference
• Manufacturing procedure reference
• Inspection/test procedure reference
• % or proportion of items inspected
• Inspection/test frequency
• Acceptance criteria
• Retest criteria and procedure (if applicable)
• Rework procedure (if applicable)
• Type and content of paperwork completed prior to release
Additional specific content to be included in the Quality Plan shall be identified in the
Project Scope of Work or on the Purchase Order.
The Quality Plan or a separate project specific document shall capture sub-supplier quality
surveillance and receipt inspection and testing. Receipt inspection and handling of fluids
and Principal free-issued items shall also be addressed.
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PART II AMENDMENTS AND SUPPLEMENTS TO IEC 60502-2

1 SCOPE
Replace 1st paragraph of this subsection with:
This part of IEC 60502 shall apply to the construction, dimensions, and test requirements of
power cores with extruded solid insulation from 6 kV up to 30 kV for use in subsea
umbilicals. Fabrication of the cores into an umbilical is covered by DEP 37.80.02.36-Gen
Replace 2nd paragraph of this subsection with:
The risk of radial and longitudinal water ingress shall be considered and tests conducted on
samples that have been exposed to seawater at rated pressure. Cable designs with
barriers claimed to prevent water ingress shall be tested to verify their effectiveness. Water
penetration testing included in IEC 60502 shall be adapted to provide the appropriate
hydrostatic pressure to which the power cores will be exposed in normal operation and/or
during umbilical repair, post installation.
Delete 3rd paragraph of this subsection

4.2 INSULATING COMPOUNDS

Add to this subsection:
Polyvinyl Chloride (PVC/B) insulation shall not be used for subsea cables.
Add to this subsection, table 2, b) Thermosetting:

Tree retardant cross-linked polyethylene TR-XLPE

5 CONDUCTORS
Add to this subsection:
Alternative conductor materials and alloys may also be considered where specific
mechanical properties are required. However, these alternative materials shall be
subjected to a rigorous qualification testing program to demonstrate suitability for the
application (e.g. corrosion resistance, tensile strength, fatigue life). The qualification testing
program shall require Principal approval.
Where stranded conductors are used, all interstices shall be filled with a water blocking
material to prevent longitudinal water migration such that the cable may be repaired post
installation (the effectiveness of this longitudinal water blocking shall be tested – section
19). This water blocking material shall not have a detrimental effect on the contact
resistance of any crimp contacts made to the conductors.

6.1 MATERIALS
Add to this subsection:
Polyvinyl Chloride (PVC/B) insulation shall not be used for subsea cables.
XLPE insulation shall be dry cured; preference should be given to manufacturers who
subject their cores to long curing periods at elevated temperatures.
Cores without an impermeable, radial water barrier shall use EPR or tree-retardant XLPE
rather than plain XLPE – water swelling compounds or tapes underneath lapped metallic
screens do not constitute an impermeable, radial water barrier

7 SCREENING
Replace 1st paragraph of this subsection with:
Each core shall have an individual metallic layer.
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February 2011
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8 ASSEMBLY OF THREE CORE CABLES, INNER COVERINGS, AND FILLERS

Add to this subsection:
If required, the assembly of three-core cables shall be specified by the Umbilical
Manufacturer as listed in the Project Scope of Work.
Subclauses 8.1 thru 8.3 shall not apply.

9 METALLIC LAYERS FOR SINGLE-CORE AND THREE-CORE CABLES

Add to this subsection:
The Project Scope of Work shall specify which metallic layer (a-d) shall be used.
Note: Only option c) will provide an impermeable radial barrier to water and gas ingress to keep the insulation
‘dry’.

12.1 LEAD SHEATH

Add to this subsection:
Lead shall not be used for dynamic umbilical sections due to its low fatigue resistance

16.1 GENERAL
Add to this subsection:
Additional routine tests shall include insulation resistance (IR) profiles and time-domain
reflectometry (TDR).
IR measurements shall be made between the conductor and metallic screen at 5 kV DC for
a period of 10 min for cables rated less than 15 kV Uo and at 10 kV for cables rated greater
than 15 kV Uo. Measurements shall be made using an automatic tester and downloaded to
an electronic storage device. From the electrical data, an IR profile shall be produced
showing the insulation performance over the 10 min test period. IR readings shall be
greater than 10 GΩ-km after 10 min. The conductor shall then be discharged through the
test unit to capture the dielectric discharge (DD) value.
After grounding each conductor for sufficient time [approximately five (5) times the duration
for which the test voltage was applied], a stepped IR measurement shall be made between
the conductor and metallic screen. The applied voltage shall be increased in five equal
increments (at 2 min intervals, for a total test duration 10 min) up to the final test voltage of
5 kV DC for cables rated less than 15 kV Uo and 10 kV for cables rated greater than 15
kV Uo.
A TDR trace shall be obtained for each conductor from both ends. The width of the pulse
shall be sufficient to allow the complete conductor length to be scanned. The graphs
produced shall detail all the major points such as the start and finish of the conductors, any
splices, and any NCR/anomaly locations. The cable length of each conductor shall be
recorded to allow the propagation velocity to be calculated for each cable.
All equipment shall be calibrated and within certification prior to commencement of
production and testing. All testing parameters are subject to Principal approval.

16.2 ELECTRICAL RESISTANCE OF CONDUCTORS

Replace the 4th paragraph of this subsection with:
For copper conductors, the DC resistance of each conductor at 20 ºC shall not exceed the
appropriate maximum value specified in IEC 60228. For conductors of other material,
Manufacturer/Supplier shall advise the maximum DC resistance at 20 ºC. This resistance
value shall be subject to Principal approval.
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17.1 GENERAL
Add to this subsection:
Additional sample tests shall include tests for capacitance and inductance per unit length.
A sample of completed cable [10 m (33 ft) length minimum, dependent on the sensitivity of
the test equipment] shall be measured for its capacitance per unit length. The capacitance
between the conductor and screen shall be measured at fixed frequencies as stated in the
Manufacturer/Supplier’s quality plan and written specifications.
A sample of completed cable [10 m (33 ft) length minimum, dependent on the sensitivity of
the test equipment] shall be measured for its inductance per unit length according to the
Manufacturer/Supplier’s quality plan and written specifications.

18 TYPE TESTS, ELECTRICAL

Add to this subsection:
Additional testing shall be required to prove and qualify the design and final manufactured
product for deepwater, subsea dynamic service. The Manufacturer/Supplier shall prepare a
qualification program to objectively demonstrate the suitability and reliability of the power
core for deepwater static or dynamic applications for all operational parameters and design
requirements listed in the Project Scope of Work.
As a minimum, the following elements shall be addressed in the qualification program:
• Radial water penetration (refer to CIGRE Working group 21.02, Electra 189)
• Axial water penetration, where conductors are exposed to seawater at rated
pressure, simulating operation following a subsea repair (refer to CIGRE Working
group 21.02, Electra 189)
• Accelerated ageing (following a period of exposure to seawater at rated pressures)
• Dynamic movement
• Internal/cabling friction
• Hydrostatic pressure
• Squeezing
• Environmental elements
The Manufacturer/Supplier shall propose the manner in which insulation integrity shall be
determined. As a minimum, this shall include partial discharge testing, electrical
breakdown testing, and IR profile.
18.1.1 Sequence of Tests
Add to this subsection:
The tan δ measurement (b) shall not be required.
After the voltage test (e), the testing sequence shall include the following:
IR profile test per comments and requirements listed in (16.1).
Hyperbaric tests in accordance with project data sheet requirements.
18.1.3 Bending Test
Replace the 3rd paragraph of this subsection with:
The diameter of the test cylinder shall be:
25 (d +D) ± 5 % for single-core cables
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18.2 CABLES OF RATED VOLTAGE 3.6/6 KV HAVING UNSCREENED INSULATION

This section shall not apply.

19 TYPE TESTS, NON-ELECTRICAL

Add to this subsection:
As a minimum, the following elements shall be addressed in the qualification program
(qualification criteria shall be defined within the project’s scope or work document):
• Tensile strength of cable conductors
• Fatigue failure of cable conductors and metallic layers (defined in section 9)
• Ultimate yield strength of cable conductors
• Fretting of conductor wires
• Longitudinal and radial water penetration at rated hydrostatic conditions (refer to
CIGRE Working group 21.02, Electra 189)

19.12 OIL IMMERSION TEST FOR ELASTOMERIC SHEATHS

This section shall not apply.

19.14 FLAME SPREAD TEST ON SINGLE CABLES

This section shall not apply.

19.15 MEASUREMENT OF CARBON BLACK CONTENT OF BLACK POLYETHYLENE (PE)

OVERSHEATHS
This section shall not apply.

19.18 DETERMINATION OF HARDNESS OF HARD ETHYLENE PROPYLENE RUBBER

(HEPR) INSULATION
This section shall not apply.

19.19 DETERMINATION OF THE ELASTIC MODULUS OF HEPR INSULATION

This section shall not apply.

19.22 WATER PENETRATION TEST

Replace this subsection with:
Water penetration tests shall be proposed by the Manufacturer/Supplier that suitably
represents the long-term exposure of the power cores at maximum water depth and
operating temperature as listed in the project data sheet. Core samples shall be
preconditioned through heating cycles, to ensure that they have experienced the
anticipated thermal expansion expected during normal operation, prior to performing the
penetration test. Water penetration shall be considered for both radial and longitudinal
directions. The test and criteria are subject to Principal approval.
 DEP 37.80.02.35-Gen.
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ANNEX A Fictitious calculation method for determination of dimensions of protective coverings

This annex shall not apply.

ANNEX B Tabulated continuous current ratings for cables having extruded insulation and a rated
voltage from 3,6/6 kV up to 18/30 kV
This annex shall not apply.

ANNEX C Rounding of numbers

This annex shall not apply.
 DEP 37.80.02.35-Gen.
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PART III REFERENCES

In this DEP, reference is made to the following publications:

NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS
Deepwater Umbilical Manufacturing Specification DEP 37.80.02.36-Gen.
Deepwater Umbilical Transportation and Installation DEP 37.80.03.30-Gen.
Specification
Deepwater Subsea Controls, Power, and Chemicals DEP 37.80.03.31-Gen.
Distribution Hardware Installation Specification
INTERNATIONAL STANDARDS
Conductors of insulated cables IEC 60228
Cables for rated voltages from 6kV (Um = 7,2 kV) up to 30 IEC 60502-2
kV (Um = 36 kV)
Issued by:

International Electrotechnical Commission

3, rue de Varembé
P.O. Box 131
CH - 1211 Geneva 20
Switzerland
OTHER PUBLICATIONS
Recommended for testing of long ac submarine cables with CIGRE WG 21.02,
extruded insulation for system voltage above 30 (36 to 150 ÉLECRA No. 189
(170) kV
 DEP 37.80.02.35-Gen.
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APPENDIX 1 PROJECT DOCUMENTS

The following project documents shall be included in the Manufacturer/Supplier project

document register:

A.1 ELECTRIC CABLES

• Cable Qualification Test Reports
• Electric cable mechanical properties and transmission characteristics
• Conductor core joint qualification
• Insulation repair qualification
• Quality Plan (QP) Electric Cable (QP for each cable size/type)
• Electric cable performance characteristics
• Electric cable mechanical properties
• Cable Cross Section Drawing (for each cable size/type)

A.2 CABLE DESIGN/TEST

• Cable Design Specification and/or Technical Data Sheet include
• Cable construction materials and physical properties
• Performance values of elements
• Including dissection report detailing specimen and element condition at the end of the
testing

A.3 CABLE MANUFACTURE/FACTORY ACCEPTANCE TEST (FAT)

• Intermediate Test Procedures/Reports
• Factory Acceptance Test Procedure/Report
• As-Built Length Log

A.4 QA/QC INSPECTION

• Quality Surveillance Plan (for sub-contract materials)
• Receipt Inspection Check List for Free Issue Materials
• Receipt Inspection Check List for Sub-Contracted Materials