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DNV-RP-F401
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FOREWORD
DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life,
property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and
consultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, and
carries out research in relation to these functions.
DNV service documents consist of among others the following types of documents:
Service Specifications. Procedual requirements.
Standards. Technical requirements.
Recommended Practices. Guidance.
The Standards and Recommended Practices are offered within the following areas:
A) Qualification, Quality and Safety Methodology
B) Materials Technology
C) Structures
D) Systems
E) Special Facilities
F) Pipelines and Risers
G) Asset Operation
H) Marine Operations
J) Cleaner Energy
O) Subsea Systems
This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document, and is believed to reflect the best of
contemporary technology. The use of this document by others than DNV is at the user's sole risk. DNV does not accept any liability or responsibility for loss or damages resulting from
any use of this document.
CHANGES
General
This is a new document.
CONTENTS
1.
Introduction............................................................................................................................................ 5
2.
Scope........................................................................................................................................................ 5
2.1 Application................................................................................................................................................5
2.2 Applicable standards.................................................................................................................................5
2.3 Terminology..............................................................................................................................................5
3.
Requirements.......................................................................................................................................... 6
3.1 General construction requirements ...........................................................................................................6
3.2 Conductor..................................................................................................................................................7
3.3 Electrical insulation of core breakdown strength...................................................................................7
3.4 Screen/sheath for prevention water exposure to the insulation system ....................................................7
3.5 Water blocking..........................................................................................................................................8
3.6 Degassing..................................................................................................................................................8
3.7 Longitudinal gas barrier............................................................................................................................8
3.8 Armour......................................................................................................................................................9
3.9 Anchoring of armour.................................................................................................................................9
3.10 Radial compression load carrying capacity ...........................................................................................9
3.11 Flexibility/Compliance .............................................................................................................................9
3.12 Bending radius ........................................................................................................................................10
3.13 Coiling.....................................................................................................................................................10
4.
References............................................................................................................................................. 10
Appendix A. Qualification with Respect to Fatigue................................................................................... 11
A.1 Limitations ............................................................................................................................................. 11
A.2 Definitions.............................................................................................................................................. 11
A.3 Input data ............................................................................................................................................... 12
A.4 Pre-test straining .................................................................................................................................... 12
A.5 Qualification principles.......................................................................................................................... 12
A.6 Qualification based on components ....................................................................................................... 13
A.7 Qualification of complete cable cross section ....................................................................................... 14
A.8 Electrical verification tests..................................................................................................................... 15
Appendix B. Test Methods Fatigue Loading of Complete Cables......................................................... 17
B.1 General................................................................................................................................................... 17
B.2 4-point-bending...................................................................................................................................... 17
B.3 Bending against template....................................................................................................................... 17
Appendix C. Fatigue Testing Detection Techniques .................................................................................. 19
C.1 Metallic materials................................................................................................................................... 19
C.2 Plastic materials ..................................................................................................................................... 20
Appendix D. Estimation of Fatigue Design Curves Least Squares Method ......................................... 22
Appendix E. Estimation of Fatigue Design Curves Incomplete Observations of Number of Cycles to Failure ......................................................................... 23
1. Introduction
This Recommended Practice is to be used as a supplement to ISO 13 628-5 /1/ with regards to electrical power
cables. This ISO standard does not give requirements to such cables on a detailed level. This RP covers
additional requirements for power cables being submerged in seawater at large water depths and/or being
exposed to dynamic excitation, e.g. when suspended from floating production units.
The RP is intended to be used together with /1/. In case of conflict between the ISO standard and this document
the ISO standard shall prevail.
It is a pre-requisite that power cables are designed and fabricated according to existing IEC standards.
2. Scope
2.1 Application
The RP covers electrical power cables, as single cables or integrated in an umbilical in an application covered
by ISO 13 628-5 /1/.
The RP covers cables which comply with IEC 60 502-1 /2/ and IEC 60 502-2 /3/.
The RP applies to cables used for AC power transmission. DC cables are not covered.
Guidance note:
Examples of single cables may e.g. be power supply to direct electrical heating systems for pipelines, main power
supply from shore to floating production units, power supply from floating units to subsea installation etc.
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Guidance note:
The following definition of an umbilical is given in /1/: group of functional components, such as electric cables,
optical fibre cables, hoses, and tubes, laid up or bundled together or in combination with each other, that generally
provides hydraulics, fluid injection, power and/or communication services.
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2.3 Terminology
The terminology used in the document follows the terminology specified in /2/ or /3/:
Alternating current.
Covering consisting of a metal tape(s) or wires, generally used to protect the cable from
external mechanical effects.
Note:
In this RP Armour is used for the components providing the longitudinal strength and
stiffness to the cable.
Conductor:
Part of a cable which has the specific function of carrying current.
Conductor screen: Electrical screen of non-metallic and/or metallic material covering the conductor.
Core:
Assembly comprising a conductor with its own insulation (and screens if any)
DC:
Direct current.
Insulation screen: Non-metallic, semi-conducting layer in combination with a metallic layer applied on the
insulation.
Insulation:
Assembly of insulating materials incorporated in a cable with the specific function of
withstanding voltage.
Oversheath:
Non-metallic sheath applied over a covering, generally metallic, ensuring the protection of
the cable from the outside.
AC:
Armour:
Conducting layer or assembly of conducting layers having the function of control of the
electric field within the insulation.
Sheath:
Uniform and continuous tubular covering of metallic or non-metallic material, generally
extruded. (North America: jacket)
Strand:
One of the wires in a stranded conductor.
In addition the term Water blocking is used for powder, tape, grease, compound, yarn or glue applied under a
sheath or into the interstices of a conductor to prevent water migrating along the cable.
A Barrier sheath, IEC 60 050-461 /6/, having the function of protecting the insulation and its screen from
outside contamination may be specified by the purchaser.
Screen:
3. Requirements
3.1 General construction requirements
3.1.1 Insulation system
The insulation system shall consist of a fully bonded true triple extruded XLPE system (extrusion of conductor
screen, insulation and insulation screen simultaneously). The insulation screen is not required for cables
according to /2/. The use of other insulation system(s) is the subject of agreement between manufacturer and
purchaser.
3.1.2 Conductor
A joint of the entire conductor cross section of the conductor shall not be located in a dynamic part of a cable,
i.e. parts of the cable not resting on the seabed or otherwise prevented from motion.
3.1.3 Armour
Cables shall be balanced with respect to torsion. Un-balanced designs may be used subject to agreement
between manufacturer and purchaser. Test methods and acceptance criteria may have to be modified for unbalanced designs.
3.1.4 Thermal conditions
Cable routing and installation method (e.g. burial, rock dumping, guide tubes etc.) may reduce the heat
transport from the cable. Ancillary equipment like bend stiffeners may act as thermal insulators on the outside
of the cable reducing the heat transport from the cable. Hence, the cable system shall be designed to meet the
worst case thermal loads. The temperature shall not exceed the thermal limitations for any materials in the
power cable.
3.1.5 Longitudinal static strength of cable
The conductor and sheath(s) or screen(s) shall not be taken into account when assessing the longitudinal
capacity of the cable cross section. The strain in the conductor and sheath(s)/screen(s) shall be limited by the
strain in the load carrying elements in the cable cross section.
For applications where it can be shown that it is acceptable that the conductor contributes to the longitudinal
capacity of the cable, e.g. at smaller water depths, the load carrying capacity of the conductor may be taken into
account. In such a case it shall be demonstrated that failure due to creep or any other failure mechanism will
not occur.
A joint of the entire cable cross section shall not be located in dynamic part(s) of a cable, i.e. parts of the cable
not resting on the seabed or otherwise supported.
3.1.6 Fatigue strength of cable.
Cables exposed to dynamic excitation (e.g. cables suspended between floating installations and the sea bottom,
cables exposed to vortex induced vibrations) shall be qualified with respect to fatigue as specified in this
document. For static applications (e.g. cables resting on the sea bed) such qualification is not mandatory.
However, dynamic effects during installation shall be considered.
3.1.7 Hydrostatic strength
The components in the cable cross section shall, when the complete cross section is subjected to an external
hydrostatic pressure not smaller than the larger of 3.5 MPa or the pressure corresponding to the maximum water
depth multiplied by a factor of 1.25, not exhibit any damage that may impair its capacity with respect to
mechanical loads.
Casings (including seals) for cable joints or terminations shall, when subjected to an external hydrostatic
pressure not smaller than the larger of 3.5 MPa or the pressure corresponding to the maximum water depth
multiplied by a factor of 1.5, not exhibit any damage or leakage.
The effect of external hydrostatic pressure on the electrical properties of the cable is handled elsewhere.
DET NORSKE VERITAS AS
3.2 Conductor
3.2.1 Static strength of conductor
The conductor shall be supported in the longitudinal direction of the cable such that failure due to creep is
prevented. This shall be confirmed by calculations based on adequate test data or data available in literature.
The evaluation of creep shall consider the effect of service temperature on the rate of creep. Variations in the
service temperature shall be considered or a conservative approach chosen.
Guidance note:
For cables suspended in large water depths the self-weight of the conductor may induce unacceptable creep in the
conductor if the conductor is not supported.
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3.4.3 Buckling
If not properly supported, bending of a barrier sheath may induce local buckling, particularly for combinations
DET NORSKE VERITAS AS
of thin materials made from material with a large Young modulus (e.g. metallic tubes or foils). Local buckling
shall be prevented.
3.4.4 Corrosion of sheath/screen
The material in the barrier sheath shall be chosen such that it has the sufficient resistance to corrosion
considering the service environment: exposure to sea water, temperature. There shall be no penetration of the
sheath due to corrosion (holes, pits, cracks etc.) during the service life of the cable.
3.4.5 Fatigue strength of barrier sheaths global loads
Barrier sheaths in cables exposed to dynamic loading shall be qualified with respect to fatigue. A procedure for
the qualification of power cables with respect to fatigue is given in Appendix A.
Penetration of the sheath, e.g. a crack, hole etc., shall constitute failure. The safety factor on fatigue life,
determined by calculation or testing, shall not be smaller than 10 unless otherwise agreed between
manufacturer and purchaser.
3.4.6 Fatigue strength of barrier sheath thermal effects/radial expansion
Repeated thermal expansion/contraction of components inside of the sheath may induce fatigue stress in the
circumferential direction. The number of load cycles may be small, but the circumferential strain induced in
the sheath may be relatively large. The number and magnitude of the load cycles shall be specified by the
purchaser as well as the relevant service temperatures.
A satisfactory fatigue life of the sheath shall be demonstrated by recognised methods taking into account
deformation in the non-linear regime of the materials. The design with respect to fatigue shall be based on
fatigue design curves or by direct testing on cable samples. Fatigue design curves shall be determined by testing
at the strain levels that are relevant and be expressed as fatigue life in number of load cycles vs. strain range.
Damage accumulation shall be carried out in accordance with recognised methods.
The fatigue life may alternatively be determined by testing of samples of cable by exposing the cable to heating
cycles while applying the relevant external pressure.
Penetration of the sheath, e.g. a crack, hole etc., shall constitute failure. The safety factor on fatigue life,
determined by calculation or testing, shall not be smaller than 10 unless otherwise agreed between
manufacturer and purchaser.
3.6 Degassing
Cables shall be de-gassed as part of the manufacturing process. The de-gassing procedure is subject to
agreement between the purchaser and manufacturer.
Guidance note:
There is at present no generally accepted procedure for degassing.
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3.8 Armour
3.8.1 Static strength
The allowable utilization factors for load carrying elements for longitudinal loads are specified in Table 3-1.
The utilisation factor shall be taken as the ratio of the applied load to the lesser of the specified minimum yield
strength and 90% of the specified minimum ultimate tensile strength of the steel material in the armour.
For armour of other material than steel the utilisation factors are subject to agreement between the purchaser
and the manufacturer.
Table 3-1 Armour utilisation factors
Utilisation factor
Normal operation
0.67
Installation
0.78
Abnormal operation
1.00
hydrostatic pressure
installation loads, e.g. clamping forces from caterpillar, temporary hang-off
contact forces in chutes
loads from clamps for anchors, buoyancy modules etc.
support reactions, e.g. over mid-water arches.
3.11 Flexibility/Compliance
Possible requirements to the flexibility of the cable shall be clearly stated by the purchaser.
The manufacturer shall specify the flexibility or the bending stiffness of the cable, maximum and minimum,
for different temperatures as agreed with the manufacturer. The flexibility depends on the curvature of the
cable. The flexibility should as a minimum be stated for the minimum bending radius specified by the
manufacturer for installation and service.
DET NORSKE VERITAS AS
3.13 Coiling
Cables which during manufacture, storage or installation may be subjected to coiling shall be qualified in
accordance with /8/.
4. References
/1/ ISO 13628-5. Petroleum and natural gas industries - Design and operation of subsea production systems Part 5: Subsea umbilicals. 2009.
/2/ IEC 60 502-1. Power cables with extruded insulation and their accessories for rated voltages from 1 kV
(Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV
(Um = 3,6 kV). 2009.
/3/ IEC 60 502-2. Power cables with extruded insulation and their accessories for rated voltages from 1 kV
(Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 2: Cables for rated voltages from 6 kV (Um = 7,2 kV) up to
30 kV (Um = 36 kV). 2005.
/4/ IEC 60 228. Conductors of insulated cables. 2004.
/5/ Electra 189. Recommendations for Testing of Long AC Sub-marine Cables with Extruded Insulation for
System Voltage Above 30(36) to 150(170) kV.
/6/ IEC 60 050-461. International Electrotechnical Vocabulary - Part 461: Electric cables. 2008.
/7/ CENELEC HD 605 S2. Electric cables - Additional test methods. 2008.
/8/ Electra 171. Recommendations for Mechanical Tests on Sub-marine cables.
/9/ DNV RP-C203. Fatigue Design of Offshore Steel Structures.
APPENDIX A
QUALIFICATION WITH RESPECT TO FATIGUE
A.1 Limitations
This section covers qualification with respect fatigue loading in the high cycle regime.
Due to the limited strain levels normally expected in service, well known insulation and oversheath materials
with large strain to failures need not be subjected to a qualification procedure. The following materials are
considered to have adequate fatigue strength with respect to mechanical damage:
A.2 Definitions
C
Curvature. C = 1/
Cmax The maximum curvature during one deformation cycle = 1/ min
Cmin The minimum curvature during one deformation cycle = 1/ max
Bending radius. The bending radius shall be assigned a negative and a positive value when bending
occurs to either side of a straight line, see Figure A-1
Umbilical/cable
<0
>0
Figure A-1
Definitions of bending radius sign
static
max
min
max
min
R
R
N
k
ni
D=
i
ni
Ni
Ni
m
The effect of these operations on the mechanical properties shall be represented and/or simulated in a
representative manner, on cable samples or the individual components prior to testing.
Fatigue design curve(s) shall be estimated based on the data using the least squares method (ref. Appendix D).
The design curve shall be given at the mean minus 2 standard deviations in log(N), i.e. representing a 97.5%
probability of survival.
For data for which complete information about the number of cycles to failure is not available (e.g. when testing
complete cross sections) the method given in Appendix E may be applied. The design curve shall represent a
97.5% probability of survival. It is also referred to /9/ that gives a procedure for how to analyse data of this type.
If the number of tested stress levels is sufficiently large the mean and design curves may be divided in more
than one regression line, thus increasing accuracy.
Acceptance criteria
IEC 60 502-2 Sec. 16.2
IEC 60 502-1 Sec. 15.2
IEC 60 502-2 Sec. 16.3
IEC 60 502-2 Sec. 16.4
IEC 60 502-1 Sec. 15.3
C eff =
1/ m
(C i ) m
i =1
(A1)
(C eff ) m N
(A2)
The fatigue load used in the test shall be given by the following equation:
(A3)
The range of curvature and the number of cycles in the test can in principle be chosen arbitrarily as long as the
equation above is fulfilled. However, Ntest shall not be taken smaller than 50 000.
DET NORSKE VERITAS AS
In the preceding tests more than one slope m of the fatigue curve may have been obtained, e.g. it may vary from
component to component. The test condition shall be determined based on the most conservative choice of m.
Post-fatigue electrical tests
The following tests, Table A-2 shall be carried out subsequent to fatigue loading.
Table A-2 POST-FATIGUE ELECTRICAL TESTS
Type of test
Test specification
Electrical
Conductor resistance
IEC 60 502-2 Sec. 16.2
IEC 60 502-1 Sec. 15.2
Partial discharge
IEC 60 502-2 Sec. 16.3
Voltage
IEC 60 502-2 Sec. 16.4
IEC 60 502-1 Sec. 15.3
Mechanical/visual
Verification of cross section
The dimensions of all components in the
cross section shall be verified 1)
Visual inspection of conductor In fatigue loaded area
Visual inspection of sheath
In fatigue loaded area
Dye penetration examination of In fatigue loaded area
sheath
Visual inspection of armour
In fatigue loaded area
wires
Acceptance criteria
IEC 60 502-2 Sec. 16.2
IEC 60 502-1 Sec. 15.2
IEC 60 502-2 Sec. 16.3
IEC 60 502-2 Sec. 16.4
IEC 60 502-1 Sec. 15.3
All measurements to be within specified
tolerances.
No visual defects
No visual defects
No defects
No visual defects
APPENDIX B
TEST METHODS FATIGUE LOADING OF COMPLETE CABLES
B.1 General
Two methods for fatigue testing are considered applicable for testing of complete cable cross sections:
4-point-bend testing
bending against template.
These two methods are described in the following sections.
Alternative methods for applying a fatigue deformation and/or for detecting failure may be accepted subject to
a qualification of the reliability of the method(s) to impart a realistic fatigue deformation and/or to detect
failures(s).
B.2 4-point-bending
The principle for the method is shown in the Figure B-1. The method can be used on both short and long
specimens, but for practical reasons the gauge section will have to be relatively short.
The test set-up can be used for controlled displacement and controlled load and for different R-values.
The curvature of the cable can in principle be determined based on beam theory provided the length of the
specimen is long enough to eliminate end effects. Curvature as a function of displacement of the moving yoke
shall be calibrated. This can be accomplished by instrumenting one or more specimens with e.g. strain gauges
in order to obtain strain level at various positions as a function of yoke displacement. Effects of creep shall be
specially considered.
For long and or slender configurations 4-point-bending may not give sufficient control of the bending radius,
particularly when a tensile preload in the cable is used. Bending against templates may be necessary in such
cases.
Figure B-1
4-point bending
Figure B-2
Bending against former
Figure B-3
Bending against former
APPENDIX C
FATIGUE TESTING DETECTION TECHNIQUES
C.1 Metallic materials
Metallic materials are/may be used in the following components:
conductor core
sheath
screen
armour.
A number of different techniques for detecting defects are available, depending on the component in question.
Detection techniques are discussed below. Common for all or most of the techniques is that they are impossible
to automate or that automation will require a significant effort.
C.1.1 Visual inspection dissection
Destructive detection method
Visual inspection from the outside of components inside the specimen during the course of the test is in
principle impossible, except for the external sheath. Visual inspection can be carried out after the specimen has
been taken apart for access to the component of interest, but this will prohibit further testing of the specimen.
Visual inspection can therefore be used for verifying that a defect has not been formed after a certain number
of cycles, but it will not give any indication of the remaining fatigue life. Or, it can be used to verify that a
defect has been formed, but not exactly at what number of load cycles. These uncertainties could in principle
be mitigated if a reasonably reliable way of back calculating defect growth rates is available. Such methods
may be included in the basis for the qualification.
The result from using visual inspection is illustrated in principle in Figure C-1 below. The cases where a defect
is found or no defect is found upon inspection are shown, the arrows indicating the uncertainty in determining
the true number of cycles to failure. Results of this type will increase the uncertainty in determining a SNcurve.
Examination: no defect
Examination: defect
N
Figure C-1
Presentation of fatigue test results
wires are helically wound and relatively numerous such that a fairly large number of wires have to fail in close
proximity before a detectable change in stiffness occurs.
Similarly, it is questionable whether failure in the core can be detected by this method.
For early detection of fatigue cracks calibration of the detection method is probably required, i.e. the stiffness
as a function of crack size. The sensitivity to small cracks may be low.
Longitudinal cracks, e.g. in longitudinal weld seams, may not be possible to detect by this method due to their
relatively small effect on the stiffness.
C.1.3 Electrical resistance
Non-destructive detection method
Fatigue crack growth in metallic materials will eventually increase their electrical resistance. However, the
sensitivity of this technique may not be sufficiently high for many cable cross sections.
Currents applied to the sheath may pass through the semi-conducting layers under the sheath giving no or very
little appreciable increase in resistance as the length of the damage in the sheath is short, further reducing the
sensitivity of the method. Whether the sensitivity of this method is sufficient or not has to be determined from
case to case.
The resistance of wire screens may not increase appreciably until a large portion of the wires are broken in one
cross section.
The resistance of armour wire could be used as a detection method, provided the individual armour wires are
isolated from one another.
C.1.4 Eddy current
Non-destructive detection method
May be developed for use for detection of fatigue cracks in metal sheaths and screens and armour wires.
Depending on the level of development of the tools early detection of fatigue cracks may be possible. A
significant amount of development and calibration work may be necessary.
Eddy current can not be used, or is difficult to use, for components inside metallic screens or sheaths.
The method may require a significant investment for automating the inspection during testing.
C.1.5 X-ray
Non-destructive detection method
X-ray is a well developed technique for detection of defects in metallic materials. However, the ability of the
technique to discover defects in complete cables, in terms of sensitivity and discrimination between the
different components, has to be demonstrated in each individual case.
The method is not possible to automate.
C.1.6 Leakage
Non-destructive detection method
May tentatively be used for detection of through-wall defects on solid metal sheaths by applying compressed
air on the inside of the sheath. The method requires free passage of air inside and outside of the sheath. This
may not be possible to achieve for all cross section designs.
Armour
APPENDIX D
ESTIMATION OF FATIGUE DESIGN CURVES
LEAST SQUARES METHOD
SN-type fatigue design curves can be expressed on the following form:
log N = log a - m log
(D1)
where:
N
m
a
:
:
:
:
Using the least squares method the constants in the regression curve can be estimated by the following
equations:
n
m=
n (log i ) 2 log i
1
1
log a =
log N i m log i
(D2)
(D3)
where n is the number of data points/test results (log Ni; log i) and:
Ni : number of cycles to failure in test i
i : strain range in test i
The standard deviation s of log N is given by the following equation:
1/ 2
n
2
[log N i (log a m log i )]
s= 1
n 1
(D4)
A fatigue design curve design curve can then be defined by the following equation, based on a 97.5%
probability of survival:
log N = log - m log
where:
log = log a - 2s.
APPENDIX E
ESTIMATION OF FATIGUE DESIGN CURVES INCOMPLETE OBSERVATIONS OF NUMBER OF CYCLES TO FAILURE
The procedure below applies to situation where the exact numbers of cycles to failure for the test specimens
are not known.
SN-type fatigue design curves can be expressed on the following form:
log N = log a - m log
m
a
:
:
:
:
(E1)
(E2)
where:
x
y
A
B
=
=
=
=
log
log N
log a
-m
In case of SN-curves it is often assumed that A is Normal distributed with a constant standard deviation equal
to A. y is then also Normal distributed with a constant standard deviation A and a median value given by E2.
The distribution density function for y is thus given by:
( y A Bx) 2
exp
2 A2
2 A2
f y ( x) =
(E3)
Fy ( x) = f y ( x)dx
Assume that the test observations consist of knf of SN-data (Xnfi;Ynfi) where no failure was observed on
inspection (i.e. the fatigue life is longer than the number of cycles applied in the test) and kf of SN-data (Xf;Yf)
where failure was observed on inspection (i.e. the fatigue life is shorter than the number of cycles applied in
the test).
The likelihood function for a sample including knf observations of non-failed specimens and kf observations
of failed specimens is then given by:
L = Fy (Ynfi ) 1 Fy (Y fi )
k nf
(E5)
kf
Since there is no way to determine E5 analytically, the estimators for A, B and A may be found by maximising
E5 numerically.