Minimising the overall cost of new high power subsea electrical … · 2016-02-09 · •The overall cost of a subsea electrical connector system can be well beyond the unit cost

Unrestricted © Siemens AG 2016 All rights reserved. Answers for energy.

Beyond Unit Cost: Minimising the overall cost of

new high power subsea electrical connector

systems

Chris Plant, Subsea Expo, February 2016

2016-02-03

Unrestricted © Siemens AG 2016 All rights reserved.

Page 2 Chris Plant, Siemens Subsea

Table of content

• Introduction 3

• What is the TCO? 4

• How do we reduce the TCO? 9

• Conclusions 26

2016-02-03



Beyond Unit Cost

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

2016-02-03



Beyond Unit Cost

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

2016-02-03



Beyond Unit Cost

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 Cause

Large number of connectors Lack of flexibility in connector system

Expensive/complex mating tools and

intervention methods

High mating force

Connector sizes and weights

Cost of protective/test connectors and

associated mating equipment

High mating force

Lack of suitable connectors

Multiple connector systems on a given

project

Connector electrical capabilities

Connectors not qualified to project or

industry standard

2016-02-03



Beyond Unit Cost


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 Cause

Modules delayed by availability of

connectors

Connector harness required to deliver

or test modules

Schedule delayed or risk increased

waiting for qualification of connectors

Connector not qualified to project or

operator standard

Additional testing interfaces and/or

tests in module

Connector not qualified to be operated

at module test voltages

Delay to schedule or increase in cost

to provide test connectors in module

assembly locations

Multiple types of test harness required

at multiple locations

2016-02-03



Beyond Unit Cost


System Deployment

The deployment phase of the project is often when issues are discovered,

particularly during intervention.

Cost Driver Cause

High vessel and intervention costs

High mating force

Connector sizes and weights

Suitable test/protective connectors

Unexpected interventions Reliability

Robustness

2016-02-03



Design Goals

Beyond Unit Cost

How Do We Reduce the TCO?

Project Phases

System Design Manufacture

and Testing Deployment

Cross Industry

Standard Compliant

Minimise Mating

Loads

Flexibility in use

cases

Design goals are chosen to reduce TCO across multiple project phases

Reliability and

robustness

Minimise Size and

Weight

Electrical Design

Flexibility

2016-02-03



Design Goals

Beyond Unit Cost

How do we reduce the TCO?

Project Phases



Flexibility in use

cases

Reliability and

robustness

Cross Industry

Standard Compliant

2016-02-03



Beyond Unit Cost

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

2016-02-03



Beyond Unit Cost

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.

2016-02-03



Design Goals

Beyond Unit Cost


Project Phases



Flexibility in use

cases

Minimise Size and

Weight

Cross Industry

Standard Compliant

Reliability and

robustness

2016-02-03



Beyond Unit Cost

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

2016-02-03



Beyond Unit Cost

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.

2016-02-03



Design Goals

Beyond Unit Cost


Project Phases



Minimise Mating

Loads

Flexibility in use

cases

Minimise Size and

Weight

Cross Industry

Standard Compliant

Reliability and

robustness

2016-02-03



Beyond Unit Cost

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 .

2016-02-03



Beyond Unit Cost


2016-02-03



Beyond Unit Cost


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.

2016-02-03



Design Goals

Beyond Unit Cost


Project Phases



Cross Industry

Standard Compliant

Minimise Mating

Loads

Flexibility in use

cases

Minimise Size and

Weight

Electrical Design

Flexibility

Reliability and

robustness

2016-02-03



Beyond Unit Cost

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

Load

21,65 MVA

SpecTRON 45 Primary

45 kVPh-Ph / 277 A

SpecTRON 45 Secondary

10 kVPh-Ph / 1250 A

Topside Supply

2016-02-03



Beyond Unit Cost

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.

2016-02-03



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

2016-02-03



Beyond Unit Cost

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:

[email protected]

siemens.com/energy/subsea

mailto:[email protected]

Documents

Minimising the overall cost of new high power subsea electrical … · 2016-02-09 · •The overall cost of a subsea electrical connector system can be well beyond the unit cost