Underwater connectors are very essential and complex components of deep-sea engineering equipment and their design and manufacture have apparent multidisciplinary characteristics. Wet-mateable connectors (WMCs) represent the highest level of technology in this field, and only a very few countries in the world can produce WMCs. So, WMCs are likely to be a constraining factor to some maritime powers that might try to achieve breakthroughs in this field, constraining the innovation-driven development of deep-sea equipment. This paper gives a detailed overview of underwater connectors, both electrical and optical. First, the background of underwater connectors is introduced, and then the main available commercial off-the-shelf (COTS) products are described. Next, the new concept of functional units is proposed by the authors to help readers to have a better understanding of underwater connectors. Then, the basic theories of design are introduced according to different functional units, covering the aspects of electrical/optical connection, pressure-balanced oil-filled (PBOF) technology, penetrable self-sealing, aligning and locking structures. Finally, some discussions and conclusions are presented. This paper aims to reveal the secrets of key technologies used in underwater connectors, especially in WMCs.

Underwater wet-mateable connectors have been widely used to reduce the cost and the time of installation, maintenance and reconfiguration in many fields, such as the oil and gas (O&G) industry, offshore renewable energy (ORE), and undersea observatories. In the past few years, the authors’ group has made some efforts in developing wet-mateable connectors. This paper presents a methodology for designing and testing a wet-mateable electrical connector. First, an innovative wet-mateable electrical connector with dual-bladder pressure-balanced oil-filled (PBOF) technology is proposed. Second, the generalized equations of differential pressure are derived. Then, a procedure of thermal-electric-structure (TES) coupling simulation is proposed, and a series of finite element analysis (FEA) involving coupled multi-field problems is conducted, including thermal-electric coupling analysis, static structural analysis, and dynamic analysis. Finally, a prototype of the proposed connector is developed successfully, and its electrical performance is verified by the online test in a hydrostatic pressure environment with an ocean depth of 3000 m, which has reached the leading level in China. This paper is the first discloser on wet-mateable connectors in the aspects of design, theory, simulation and testing, which might be helpful to many ocean scientists in developing countries who are technically blocked or could not afford the high cost.

The fast development of deep-ocean engineering equipment requires more deep-ocean pressure chambers (DOPCs) with a large inner diameter and ultra-high-pressure (UHP). Using the pre-stressed wire-wound (PSWW) concept, cold isostatic pressing (CIP) chambers have become a new concept of DOPCs, which can provide 100% performance of materials in theory. This paper aims to provide a comprehensive design process for a practical metal-made CIP chamber. First, the generalized design equations are derived by considering the fact that the cylinder and wire have different Young’s moduli and Poisson’s ratios. Second, to verify the theory and the reliability of the CIP chamber, the authors proposed a series of FEA models based on ANSYS Mechanical, including a two-dimensional (2D) model with the thermal strain method (TSM) and a three-dimensional (3D) model with the direct method (DM). The relative errors of the pre-stress coefficient range from 0.17% to 5%. Finally, the crack growth path is predicted by using ANSYS’s Separating Morphing and Adaptive Remeshing Technology (SMART) algorithm, and the fatigue life is evaluated by using the unified fatigue life prediction (UFLP) method developed by the authors’ group. This paper provides a more valuable basis to the design of DOPCs as well as to the similar pressure vessels than the previous work.