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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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 3 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 4 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 5 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 6 Chris Plant, Siemens Subsea
Beyond Unit Cost
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 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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 7 Chris Plant, Siemens Subsea
Beyond Unit Cost
Cost Drivers and Project Phases
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 8 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 9 Chris Plant, Siemens Subsea
Design Goals
Beyond Unit Cost
How do we reduce the TCO?
Project Phases
System Design Manufacture
and Testing Deployment
Flexibility in use
cases
Reliability and
robustness
Cross Industry
Standard Compliant
2016-02-03
Unrestricted © Siemens AG 2016 All rights reserved.
Page 10 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 11 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 12 Chris Plant, Siemens Subsea
Design Goals
Beyond Unit Cost
How Do We Reduce the TCO?
Project Phases
System Design Manufacture
and Testing Deployment
Flexibility in use
cases
Minimise Size and
Weight
Cross Industry
Standard Compliant
Reliability and
robustness
2016-02-03
Unrestricted © Siemens AG 2016 All rights reserved.
Page 13 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 14 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 15 Chris Plant, Siemens Subsea
Design Goals
Beyond Unit Cost
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
Cross Industry
Standard Compliant
Reliability and
robustness
2016-02-03
Unrestricted © Siemens AG 2016 All rights reserved.
Page 16 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 17 Chris Plant, Siemens Subsea
Beyond Unit Cost
Minimize Mating Force
2016-02-03
Unrestricted © Siemens AG 2016 All rights reserved.
Page 18 Chris Plant, Siemens Subsea
Beyond Unit Cost
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.
2016-02-03
Unrestricted © Siemens AG 2016 All rights reserved.
Page 19 Chris Plant, Siemens Subsea
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
Minimise Size and
Weight
Electrical Design
Flexibility
Reliability and
robustness
2016-02-03
Unrestricted © Siemens AG 2016 All rights reserved.
Page 20 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 21 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 22 Chris Plant, Siemens Subsea
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
Unrestricted © Siemens AG 2016 All rights reserved.
Page 23 Chris Plant, Siemens Subsea
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:
siemens.com/energy/subsea