Bulkhead connector modification for seawater use over extended periods

Difficulty was experienced with bulkhead connectors when these were used over a one year period in equipment on the Arctic sea bed. Failures occurred after periods ranging from three to eleven months. Four instrument packages, each fitted with seven XSG-BCL plastic bulkhead connectors, were recovered and examination showed that all the connectors leaked to some extent. In the case of some of the connectors carrying the battery power, the positive pins were corroded off completely. A modification in the form of an enclosure surrounding the connector is now used. This is completely filled with liquid vaseline after the connection is made. This system has now been used on over fifty connectors, of which only one has leaked and that leakage was minor. The cause of this failure is now under investigation and tests are at present being conducted to eliminate a recurrence, using an alternative filler.