Chris Plant, Subsea Expo, February 2016 Beyond Unit Cost: Minimising the overall cost of new high power subsea electrical connector systems Answers for energy.
Table of content Introduction 3 What is the TCO? 4 How do we reduce the TCO? 9 Conclusions 26 Page 2
Criticality of subsea electrical connectors Any subsea production system has a large number of electrical interconnections. Subsea Power Distribution increases the demands placed on subsea electrical connectors. Power distribution projects are typically in deeper water and require high voltage and current connectors. Loss of a key interconnection can lead to loss of production from the entire field.. Failure of an interconnection can have the most serious of consequences, particularly in high power applications Page 3
What is the TCO of a subsea connector system? The total cost of ownership (TCO) of a connector system should consider the impact of the connector system on the project costs throughout all project phases: System Design Manufacture and Testing System Deployment Discussions with customers at the start of our new development highlighted how important the TCO is. The costs associated with the connector system through all these phases of the project is the Total Cost of Ownership (TCO) of a connector system Page 4
Cost Drivers and Project Phases System Design These factors affect the design of the project system and can be the hardest to identify and quantify. They often can be engrained into the mindset of the connector and system providers. Cost Driver Large number of connectors Expensive/complex mating tools and intervention methods Cost of protective/test connectors and associated mating equipment Multiple connector systems on a given project Cause Lack of flexibility in connector system High mating force Connector sizes and weights High mating force Lack of suitable connectors Connector electrical capabilities Connectors not qualified to project or industry standard Page 5
Cost Drivers and Project Phases Manufacture and Testing These factors increase the cost of the project by imposing restrictions on the way in which the project is delivered. Cost Driver Modules delayed by availability of connectors Schedule delayed or risk increased waiting for qualification of connectors Additional testing interfaces and/or tests in module Delay to schedule or increase in cost to provide test connectors in module assembly locations Cause Connector harness required to deliver or test modules Connector not qualified to project or operator standard Connector not qualified to be operated at module test voltages Multiple types of test harness required at multiple locations Page 6
Cost Drivers and Project Phases System Deployment The deployment phase of the project is often when issues are discovered, particularly during intervention. Cost Driver High vessel and intervention costs Unexpected interventions Cause High mating force Connector sizes and weights Suitable test/protective connectors Reliability Robustness Page 7
How Do We Reduce the TCO? Project Phases System Design Manufacture and Testing Deployment Minimise Mating Loads Electrical Design Flexibility Flexibility in use cases Minimise Size and Weight Design Goals Reliability and robustness Cross Industry Standard Compliant Design goals are chosen to reduce TCO across multiple project phases Page 8
How do we reduce the TCO? Project Phases System Design Manufacture and Testing Deployment Flexibility in use cases Reliability and robustness Design Goals Cross Industry Standard Compliant Page 9
Flexibility in use cases Quick Connect A new technology which provides the option to mate penetrators to glands at the customers facility. No requirement for any fills (oil, gel, encapsulant) at the module facility. Common Module Interface Utilizes common interface across all connector modules. Provides a framework for quick supply of penetrators with customer specific interfaces. Common Module Interface ready for Quick Connect Page 10
Flexibility in use cases Benefits Allows supply of penetrators separately from harness. Reduce schedule constraints. Simplifies logistics. Allows use of standard test connectors, which can be reused between projects. Provides a method for topside connection between modules without additional connectors. Reduction in time required for site operations. Page 11
How Do We Reduce the TCO? Project Phases System Design Manufacture and Testing Deployment Flexibility in use cases Minimise Size and Weight Design Goals Reliability and robustness Cross Industry Standard Compliant Page 12
Minimize Size and Weight Optimized Electrical Design Investment in dielectric testing of aged materials to characterize the full life of the connector. Design of patented field control systems to optimize field distribution within the connector system. Electrical stresses matched to the results of the materials testing to fully exploit material capabilities. Electrical Testing of Insulation System Concept Page 13
Minimize Size and Weight Benefits Optimized electrical design allows connector size and weight to be minimized. This simplifies mating tools and handling. Field control system minimizes electrical stress in oil and reduces pin length. This reduces the stroke length of a connector pair. Determines requirement for impermeable secondary barrier to provide full electrical performance over the life of the connector at high voltages. Quantifies performance of materials and insulating fluids to allow analysis of connector electrical design early in development. Page 14
How Do We Reduce the TCO? Project Phases System Design Manufacture and Testing Deployment Minimise Mating Loads Flexibility in use cases Minimise Size and Weight Design Goals Reliability and robustness Cross Industry Standard Compliant Page 15
Minimize Mating Force New Shuttle Pin Design Shuttle pin moves backwards into the connector to maintain seal on unmated connector and during the mating process. Existing connector designs typically use a spring loaded shuttle pin leading to a high mating/mated force. Simply scaling an existing design would lead to very high mating/mated force. New patented design removes spring from system. Page 16
Minimize Mating Force Page 17
Minimize Mating Force Benefits Mating force of 45 kv, 1250 A connector lower than a 10 kv, 700 A connector. Complete removal of force which pushes mated connectors apart. Allows mating tools to be smaller and latches to be simpler. Enables ROV mating of large connectors. Enables innovate self-latching ROV mateable protective and test connectors. Page 18
How Do We Reduce the TCO? Project Phases System Design Manufacture and Testing Deployment Minimise Mating Loads Electrical Design Flexibility Flexibility in use cases Minimise Size and Weight Design Goals Reliability and robustness Cross Industry Standard Compliant Page 19
Electrical Design Flexibility Connector design can meet high voltage (45 kv) and high current ( 1250 A) requirements Consideration of circulating screen currents to meet expected requirements based on maximum core current Capabilities incorporated into major connector system modules to maximize commonality Cable, hose and gland can be tailored to lower current applications Page 20 Topside Supply SpecTRON 45 Primary 45 kv Ph-Ph / 277 A SpecTRON 45 Secondary 10 kv Ph-Ph / 1250 A Load 21,65 MVA
Electrical Design Flexibility Benefits Allows connector to be used for multiple applications across a system. Step down transformer primary and secondary Low voltage, high current (compressors) Reduces number of mating tools, test connectors, and protective connectors. Gives system designer more freedom in their system design. Page 21
Conclusions The overall cost of a subsea electrical connector system can be well beyond the unit cost of the connectors themselves. Particularly on high power connections. Subsea power distribution projects will use significantly more high power subsea electrical connectors than other projects. Reducing the TCO of these connector systems requires that the connector manufacturers develops their understanding of the life of the connector and it s impact on other areas of the project. Beyond Unit Cost: Siemens unique approach to connector design Page 22
Thank you! Chris Plant Principal Engineer Siemens Subsea Products (Connectors) Subsea Excellence Centre, Low Mill Business Park, Ulverston, LA12 9EE, UK Mobile: +44 (7921) 244403 E-mail: chris.plant@siemens.com siemens.com/energy/subsea Page 23