ORIGINAL EQUIPMENT

MANUFACTURER/TECHNICAL BULLETIN
APPROVAL FORM
Original Equipment Manufacturers (OEM) documents, such as Engineering, Technical and
Product Bulletins, must be reviewed by Transocean to determine their validity and
applicability, prior to distribution within the company.

The attached document has been reviewed to determine its validity and
applicability within Transocean.

Document Ref: A-Z080085 Issue Date: 3-Mar-2003

Subject: DDV, FCR and Cable Connectors
EQUIPMENT: MUX Pod
MANUFACTURER: Shaffer
MODEL: Shaffer Fifth Generation MUX System
PSS Code: JG-439-39
Applies to: Millennium, Pathfinder, Frontier

The document is: Recommendations are:

Not approved for distribution Optional
X Approved for distribution X Mandatory
For information

Actions Required:
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Comments: Follow the maintenance procedures for the AWL-2-FS/MP, AWR-

2/16 FCR or associated cable connector assemblies. We would like to
minimize the wear and damage caused to the FCR and cable by reducing the
number of times the connections are unplugged. The attached procedure
allows for the electronic measurements to be made without unplugging the
cable. We feel some of our failures in the past resulted from disturbing the
connections too often.
Note this document is being re-issued via the formal channels.

Page 1 of 2
 ORIGINAL EQUIPMENT
MANUFACTURER/TECHNICAL BULLETIN
APPROVAL FORM

Note: The plugs and in-line sockets were recently installed in a Millennium SEA in for overhaul
at Shaffer, we are waiting for feedback after a few rig moves to see if this is something that
needs to be done to all three rig's SEAs. These plugs & in-line sockets make it easier to carry
out the attached procedure. We are reluctant to recommend them just yet as we all know that
adding connections to a circuit can also introduce problems as well as resolve them, the
preliminary feedback is good, and we are hopeful that in the near future we will get Shaffer to
issue a product improvement bulletin on this subject. We did share our intentions with all three
rigs in the planning stages. This proposal came from both the Millennium and the Frontier at
the same time. The reason for the plugs was that in order to take the measurements it was
necessary to disconnect wiring, and this has lead to mistakes it the past, that were captured
during tests before running. It is possible to cross the wires anytime they are disconnected if
you are not very careful or use some type of plug system. If we decide to go with the in-line
plugs and sockets we will either re-issue this document or issue one specific to adding the
plugs. By Andy Cates based on information provided by T. Ridgeway.

Reviewed by: T. Ridgway Date: 4-Mar-2004

Approved by: G. Leach Date: 6-Apr-2004
Title: Subsea & Maintenance Location: Houston

Page 2 of 2
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

 Varco Shaffer, Inc. 2003

Copyrighted as an unpublished work
ALL RIGHTS RESERVED
SHAFFER 0464-1 10/05/92 EC # Revision Description Date Rev. Ltr
This work contains the CONFIDENTIAL AND Engineering
Prepared Checked Approved Release Number Date
PROPRIETARY INFORMATION of Varco Shaffer,
Inc. Neither this document nor any information A –Z080085
disclosed herein shall be reproduced in any form,
used, or disclosed to others for any purpose,
JZ DF FLS 70080 3/3/03
including manufacturing, without the express written
permission of Varco Shaffer, Inc.
3/03 3/03 3/03 Title Page
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

1.0 SCOPE

The purpose of this procedure is to detail all of the steps required during the installation
and maintenance of the AWL-2-FS/MP, AWR-2/16 FCR and/or associated cable
connector assemblies.

This procedure is recommended for Transocean only.

2.0 PROTECTIVE APPARATUS

Safety Glasses
Face Mask
Surgical Gloves

3.0 RECOMMENDED LUBRICANTS

Novaguard G624
Novaguard G661
Super-O-Lub
RS 494-124 (Dow Corning 4)

CAUTION:

• DO NOT USE SPRAY LUBRICANTS

• Other silicon sprays may cause swelling in the elastomer compounds used in
the Seacon connectors.

• Application of excess lubricant may prevent the seals from energizing or the
electrical contact from engaging.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 1 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

4.0 MAINTENANCE

These maintenance procedures are required during regular PM schedule, and only
qualified technicians shall perform the procedures.

4.1 Check From Subsea Electronic Assembly (SEA) Check

4.1.1 Ensure that all power is off to prevent any electric shocking or shorting.

4.1.2 Remove the SEA Bell.

4.1.3 Trace all pairs of conductors.

NOTE: Disconnect circuits to be tested from electronics at the point

where the FCR wires are terminated. In some of the recently
overhauled SEAs there are now MIL specification in-line
plug and sockets installed. This together with the
prefabricated plug and terminal strip allow for easier testing
with less possibility for incorrectly re-terminating

WARNING: FCR wires must be disconnected from the first terminal

connection point such that measurements are taken at
the same location each time to ensure consistent
measurements.

4.1.4 Conduct Capacitance measurement between each pair of conductors at 1

kHz and 1 Volt rms. Log the measured results in detail (for future reference).

4.1.5 Conduct Continuity measurement between each conductor to the

Solenoid Shell. If any conductor exhibits continuity, skip to Step 4.1.8.
Log the measured results in detail.

4.1.6 Conduct DC Resistance measurement between each pair of conductors.

The normal conductor DC Resistance should fall in the range of 81 ± 1.5
Ohms. Log the measured results in detail.

4.1.7 Measure the Megger Readings (Insulation Resistance) between each

conductor and Solenoid Shell, with 500 VDC. The IR readings should be
all greater than 50 MegOhms. Log the measured results in detail.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 2 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

4.1.8 If either DCR and/or Megger measurement is out off normal range, trace
the pair of conductors to the corresponding FCR connector.

4.2 De-mating Connector from FCR Check

Only when the measurements are abnormal, then visually inspect the
corresponding FCR(s). If any visual abnormality is sighted, the cable(s) need to
be de-mated from the FCR for further inspection, by following these procedures:

4.2.1 Disengage the locking sleeve by unscrewing and withdraw the outer half
down the cables to allow access.
4.2.2 De-mate each section of the connector individually to avoid undue
stress on the bulkhead.

4.2.3 Grasp the connector by the body between the triangular front and the
rounded endpoint, NOT THE CABLE, and pull out of the bulkhead
ensuring that the direction of pull is in line with the axis of the connector.

CAUTION: The AWR-2/16-FCR Connectors must be handled

correctly in order to avoid damaging the sealing. Avoid
physical shock or bending moments being applied to the
connector.

4.2.4 Ensure that all cables are marked and repeat the process to remove all
cables on FCR.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 3 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

4.3 Cleaning the Connectors Check

4.3.1 Flush the connector mating interfaces with De-ionized Water, if

unavailable clean fresh Tap Water may be used. The use of a washer
bottle/Pump up sprayer with spout will aid this although high-pressure jets
should be avoided.

NOTE: It is the mating interface that needs to be cleaned most

importantly. Flush the mating interfaces (both Cable and
FCR) thoroughly for an extended time, not just outside
surfaces.

4.3.2 Excessive collections of deposited silicone Grease can be removed by

gently wiping with a lint free cloth.

4.3.3 Check inside of sealing pin-sockets of FCR and Cable connectors with
flashlight for any debris deposited there. Clean out the pin-sockets with Q-
tips, if necessary.

4.3.4 The connectors can be dried, if applicable, with dry Nitrogen.

4.4 Inspecting the Connectors Check

4.4.1 Visually inspect the cable for any signs of damage such as cuts or gashes
in the cable itself. Remove and replace any damaged cable with a new
one.

4.4.2 Visually inspect the connectors for any signs of arcing.

4.4.3 Visually inspect the connectors for any signs of corrosion on the Pin(s) or
within the sockets.

4.4.4 Visually inspect the bonding between Pin(s) and rubber boot(s) of the
connector. If there is any suspect of Delamination, check if the rubber
boot can be pulled apart from the Pin.

4.4.5 Remove and replace with new FCR and/or Cable, as necessary.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 4 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

CAUTION: Damages to a cable plug/connector (refer to 4.4.2 to 4.4.4)

are an indication that the mating part (e.g. FCR) may also
be damaged. It is recommended that both cable
plug/connector and FCR (mating pair) be replaced.

4.5 Lubricating the Connectors Check

4.5.1 The lubrication of connectors should be carried out in an area where

debris is minimized to ensure that such debris is not introduced to the
connector.

NOTE: Lubricant to be stored and maintained in clean safe manner.

4.5.2 The lubrication medium advised in Section 3.0 Recommended

Lubricants.

WARNING: Do not use propellant aerosols.

4.5.3 Apply one of the approved lubricants as recommended in Section 3.0.

Lubricate the sealing areas around each of the pin-boots by applying a
thin film of the lubricant, as shown in the image, with a small fine clean
brush.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 5 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

4.6 Mating the FCR Check

4.6.1 It is assumed that at this stage the FCR has been fully checked for
damage and has been lubricated correctly.

4.6.2 The applicable AWR-2/16-MP cable connectors should be grouped

together and the locking sleeve passed over the ends and onto the cables.

4.6.3 As with de-mating, care should be taken to ensure that the connector is
held by its body and inserted in line with the axis of the trailing lead and
perpendicular to the face of the bulkhead. While aligning the connector
ensure that the trailing lead is correctly oriented to prevent mis-mating and
possible damage by imposed stress.

4.6.4 The mating process can now be repeated for the other segments of the
connector.

4.6.5 Lubricate the backs of the pie connector segments to prevent them from
twisting when the locking ring is tightened.

4.7 De-mating Connector from Solenoid Check

Only when the measurements in Section 4.1 are abnormal and there is no
indication of any damage or abnormality following the Visual Inspection of Section
4.4, then the following procedures need to be performed:

WARNING: De-Energize solenoid prior to removing connector.

4.7.1 Disengage the locking sleeve by unscrewing and sliding down the cable to
allow access.

4.7.2 Hold the metal shell body of Solenoid firmly in one hand, grasp the
connector by the body between the round head and the rounded endpoint,
NOT THE CABLE, and pull out of the Solenoid bulkhead ensuring that the
direction of the pull is in line with the axis of the connector to avoid undue
stress.

4.7.3 Clean the connectors following the procedures of Section 4.3.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 6 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

4.7.4 Inspect the connectors following the procedures of Section 4.4.

CAUTION: Damages to cable plug/connector (refer to 4.4.2 to 4.4.4) are an

indication that the mating part may also be damaged. It is
recommended that both mating parts (solenoid and cable
connector) be replaced.

4.8 Megger and Capacitance Readings of Solenoids Check

4.8.1 Measure Continuity between each conductor to the Solenoid Shell. If any
conductor exhibit continuity, skip to Step 4.8.5. Log the measured results
in detail.

4.8.2 Conduct DC Resistance measurement between two conductors. The

normal conductor DC Resistance should fall in the range of 81 ± 1.5
Ohms. Log the measured results in detail.

4.8.3 Measure the Insulation Resistance (IR) of DDV Solenoid between pin #1
and solenoid metal body, and pin #2 and solenoid metal body, using 500
VDC. The IR readings should be all greater than 50 MegOhms. Log the
measured results in detail.

4.8.4 Measure the Solenoid Capacitance between two pins at 1 kHz and 1 Volt
rms. The reading should be no greater than 700 pF (Refer to Shaffer
Field Capacitance Test Procedure: A-X060683 for details). Log the
measured results in detail.

4.8.5 Remove and replace faulty/damaged solenoid with a new one, as

necessary.

4.9 Mating the Solenoid Check

4.9.1 It is assumed that at this stage the connectors are not energized, and they
have been checked for damage and have been lubricated correctly.
(Refer to Section 4.5 for Lubrication Instruction).

4.9.2 As with de-mating, care should be taken to ensure that the connector is
held by its body and inserted in line with the axis of the trailing lead and
perpendicular to the face of the bulkhead. While aligning the connectors

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 7 of 8 Rev. -
 Supercedes:
Shaffer Engineering Standards/Specifications
DDV, FCR AND CABLE CONNECTORS
PREVENTATIVE MAINTENANCE PROCEDURES NEW
FOR TRANSOCEAN ONLY

ensure that the trailing lead is correctly oriented to prevent mis-mating and
possible damage by imposed stress.
4.9.3 Continue to push the trailing lead into the bulkhead until the male
connector face meets the female connector face.

NOTE: Excessive grease may be squeezed out. Remove with a lint

free cloth.

4.9.4 Apply lubricant to the back face of the connector to allow the lock sleeve to
slide on the neoprene smoothly when mating the lock sleeve. Slide the
locking sleeve by hand to engage the thread and spin it down to full
engagement. The back end of cable connector should be held firmly to
prevent connector from turning when the locking ring is tightened.

4.9.5 Anytime the tests are interrupted to change components, the tests need
to be repeated to ensure proper installation, and to verify integrity of
new parts.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A –Z080085
any form, used, or disclosed to others for any
purpose, including manufacturing, without the
express written permission of Varco Shaffer, Inc.
ALL RIGHTS RESERVED
SHAFFER 0464-2 10/05/92 Sheet 8 of 8 Rev. -