Integral multi-master power and communication bus rail system

Description

1 / 38 INTEGRAL MULTI-MASTER POWER AND COMMUNICATION BUS TRACK SYSTEM CROSS-REFERENCE

[0001] This application claims priority over U.S. Provisional Application No. 63 / 486,002, filed February 20, 2023, which is hereby incorporated by reference in its entirety. FUNDAMENTALS

[0002] This section is intended to introduce the reader to various aspects of the art that may be related to various aspects of the present disclosure, which are described and / or claimed below. It is believed that this discussion will be useful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Consequently, it may be understood that these statements will be read in that light, and not as admissions of prior art.

[0003] Hydrocarbon fluids, such as petroleum and natural gas, are obtained from an underground geological formation, referred to as a reservoir, by drilling a well hole that penetrates the hydrocarbon-containing formation.

[0004] As the offshore industry increasingly uses electrical actuation technologies in subsea structures, there is a need for more electrical / electronic interconnectivity between subsea electrical and electronic devices. In subsea applications, various types of infrastructure can be positioned along the seabed and coupled by electrical lines. Subsea electrical trees and subsea structures require a large amount of electrical cabling to supply power to subsea control modules, instruments, sensors, electrical actuators, wireless modems, and other electrical and electronic devices. These devices are generally low-power and interconnected by electrical wires, typically housed in oil-filled hoses for pressure balancing, connected in large oil-filled junction boxes with pressure compensation, and terminated in large, attachable subsea electrical connectors. Petition 870250094622, dated 10 / 16 / 2025, page 9 / 53 2 / 38 complex, with multiple pins. All these components are bulky, difficult to manufacture, and expensive.

[0005] Therefore, it would be useful to be able to power underwater actuators using a reliable, convenient and powerful power system, without the need for electrical cabling or with reduced electrical cabling. SUMMARY

[0006] This summary is provided to present a selection of concepts that are better described below in the detailed description. This summary is not intended to identify key or essential features of the subject matter claimed, nor is it intended to be used as an aid in determining or limiting the scope of the subject matter claimed as set forth in the claims.

[0007] According to some embodiments, the present disclosure refers to a subsea device having a support surface. The system includes a busbar with a plurality of rails coupled to the support surface, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails has an electrically conductive material; and wherein the plurality of loops has a plurality of connection areas. In addition, the system includes at least one insulating layer disposed over the support surface to isolate the plurality of rails. Furthermore, the system includes a control module electrically coupled to the busbar, wherein the control module is configured to electrically couple to a plurality of subsea components by means of the plurality of connection areas.

[0008] According to some embodiments, the present disclosure refers to a system. The system includes a support surface. The system also includes a busbar with a plurality of rails coupled to the support surface, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the loop has Petition 870250094622, dated 10 / 16 / 2025, page 10 / 53 3 / 38 a plurality of connection areas. In addition, the system includes at least one insulating layer arranged on the support surface to isolate the plurality of rails. In addition, the system includes a control module electrically coupled to the busbar. In addition, the system includes a plurality of inductive couplers arranged on at least one insulating layer and electrically coupled to the busbar.

[0009] According to some embodiments, the present disclosure refers to a method. The method includes providing a support surface. The method also includes coupling a busbar to the support surface, wherein the busbar comprises a plurality of rails, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the loop comprises a plurality of connection areas. Furthermore, the method includes electrically coupling the busbar to a control module and wherein the control module is configured to electrically couple to a plurality of subsea components by means of the plurality of connection areas. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The disclosure of the subject matter is further described in the detailed description below and in the accompanying drawings and schematics of non-limiting embodiments of the disclosure in question. The features represented in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in terms of scale or in a somewhat schematic way, and some details of elements may not be shown for the sake of clarity and conciseness. These and other features, aspects and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying figures, in which similar characters represent similar parts throughout the figures, where:

[0011] FIG. 1 is a schematic view of a production system Petition 870250094622, dated 10 / 16 / 2025, p. 11 / 53 4 / 38 submarine having a submarine power system according to an embodiment of the present disclosure;

[0012] FIG. 2 is a schematic view of a submarine power system of FIG. 1 which includes a busbar according to an embodiment of the present disclosure;

[0013] FIG. 3 is a schematic view of a submarine power system of FIG. 1 having a multi-busbar configuration according to an embodiment of the present disclosure;

[0014] FIG. 4 is a schematic view of a busbar rail support system that can be used in the submarine power system of FIG. 1 according to an embodiment of the present disclosure;

[0015] FIG. 5 illustrates an underwater electrical tree having the busbar rail support system of FIG. 4 according to an embodiment of the present disclosure;

[0016] FIG. 6 is a cross-section of an electric underwater tree having the rail support system of FIG. 4 according to an embodiment of the present disclosure;

[0017] FIG. 7 is a cross-sectional view of the busbar rail support system of FIG. 4 having multiple insulating layers according to an embodiment of the present disclosure; and

[0018] FIG. 8 is a front view of the busbar rail support system of FIG. 4 coupled to multiple components according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0019] One or more specific modalities of this disclosure will be described below. The particularities shown in this document serve only as examples and for the purpose of illustrative discussion of the modalities of this disclosure and will be presented with the aim of providing what is considered to be the most useful and easily understandable description of the principles and conceptual aspects of the disclosure. In this sense, there is no Petition 870250094622, dated 10 / 16 / 2025, p. 12 / 53 5 / 38 This attempt to show the structural details of the present disclosure in more detail than is necessary for a fundamental understanding of the present disclosure is flawed because the description provided with the drawings makes it evident to those skilled in the art how the various forms of the present disclosure can be incorporated in practice. Furthermore, in an effort to provide a concise description of these exemplary embodiments, it is not possible to describe all the features of an actual deployment in the descriptive report. It should be noted that in the development of any such deployment, as in any engineering or model project, numerous deployment-specific decisions must be made to achieve the developers' specific objectives, such as compliance with system-related and business-related constraints that will vary from one deployment to another.Furthermore, it should be appreciated that such a development endeavor may be complex and time-consuming, yet it would still be a routine design, manufacturing, and production task for those skilled in the art who have the benefit of this disclosure.

[0020] When elements of various embodiments of the present invention are presented, the articles “a”, “an”, “the” and “said” mean that there is one or more of the elements. The terms “comprising”, “including” and “having” are used in an open manner and therefore should be interpreted as meaning “including, but not limited to”. Furthermore, any use in any form of the terms “connect”, “engage”, “coupling”, “attaching” or any other term describing an interaction between elements means an indirect or direct interaction between the elements described. Additionally, as used in this document, the terms axial and axially generally mean along or parallel to a central geometric axis (e.g., the central geometric axis of a body or door), while the terms radial and radially generally mean perpendicular to the central geometric axis.For example, an axial distance refers to a distance measured along or parallel to the central geometric axis, and a radial distance means a distance measured... Petition 870250094622, dated 10 / 16 / 2025, p. 13 / 53 6 / 38 perpendicular to the central geometric axis. The use of top, bottom, above, below, and variations of these terms is for convenience, but does not require any specific orientation of the components.

[0021] Certain terms are used throughout the description and claims to refer to particular features or components. As will be observed by a person skilled in the art, different people may refer to the same feature or component by different names. This document makes no distinction between components or between features that differ in name but not in function.

[0022] This disclosure relates to a rail support system. In general, the rail support system includes several rails extending along a support surface to form a loop. The loop includes various connection areas where electronic devices can be directly coupled to a power supply or controller. In some embodiments, the rail support system may be implemented as a bus rail support system (e.g., bus support system), and the bus (e.g., to provide power and / or data) includes several rails extending along the support surface to form the loop. As such, the loop includes multiple connection areas (e.g., stationary connection areas) where electronic devices can be electrically coupled to the bus, directly or indirectly.In any case, it should be noted that the description of the “bus rail support system” may apply to the “rail support system,” such as the layout of the rails on the support surface. In some embodiments, the conductive materials may be coupled to one or more inductive couplers. One or more inductive couplers may thus provide power between a host structure and an interface for electrical and electronic devices. In some embodiments, the bus rail support system may be integrated or otherwise coupled to subsea equipment (e.g., hydrocarbon production equipment, injection equipment, etc.). Petition 870250094622, dated 10 / 16 / 2025, page 14 / 53 7 / 38 fluids, carbon sequestration equipment, etc.), which may utilize a relatively large number of electronic devices. In this way, the support surface provides modularity for operations where multiple electronic devices are used, since the support surfaces can provide the user with various areas to organize and / or reorganize the connected electronic devices.

[0023] With the above in mind, FIG. 1 is a schematic view of a subsea system 10 with electrical cables 12 used to transmit information and primary electrical power to various subsea components (e.g., actuators, sensors, etc.). The subsea system 10 may include a subsea hydrocarbon production system configured to extract oil or gas from a subsurface reservoir, a subsea fluid injection system configured to inject fluid (e.g., liquid or gas) into a subsurface reservoir, or any other subsea system associated with subsurface reservoirs. For example, the subsea fluid injection system may include a subsea gas, water, and / or carbon dioxide (CO2) injection system.In certain embodiments, the subsea system 10 may include a subsea tree 14 coupled to a wellhead 16 to form a subsea station 18 configured to extract and / or inject fluids in relation to a subsurface reservoir. For example, the subsea station 18 may be configured to extract formation fluid, such as oil and / or natural gas, from the seabed 20 through the well 22. By another example, the subsea station 18 may be configured to inject CO2 into the subsurface reservoir. In some embodiments, the subsea system 10 may include multiple subsea stations 18 that extract and / or inject fluids in relation to their respective wells 22.

[0024] In embodiments of the subsea system 10 configured for production, after passing through the subsea tree 14, the formation fluid flows through fluid conduits or pipes 24 to a pipe manifold 26. The pipe manifold 26 may connect to one or more flow lines 28 to Petition 870250094622, dated 10 / 16 / 2025, p. 15 / 53 8 / 38 allow formation fluid to flow from wells 22 to a surface platform 30. In some embodiments, the surface platform 30 may include a floating production, storage and offloading (FPSO) unit or a land-based facility. In addition to the flowlines 28 that transport formation fluid away from wells 22, the subsea system 10 may include lines or conduits 32 that supply fluids, as well as carry control and data lines to subsea equipment. These conduits 32 connect to a distribution module 34 which, in turn, couples to subsea stations 18 via supply lines 36. In some scenarios, the platform 30 may be located at a significant distance (e.g., greater than 100 m, greater than 1 km, greater than 10 km or greater than 60 km) from wells 22.As discussed in more detail below, the subsea system 10 (e.g., the subsea tree 14, the subsea station 18, the pipeline collector 26 and / or the distribution module 34) may include a subsea power system (e.g., subsea power bus system) that provides primary and / or secondary power from energy storage units (e.g., batteries, fuel cells or supercapacitors (for initial actuator movement)) via one or more buses to various subsea components (e.g., actuators, sensors, etc.). For example, the subsea power system may be configured to provide secondary power, such as during a loss of primary power from the electrical cables 12, to operate various valves, sensors and other subsea components.Although the subsea system described above is for hydrocarbon extraction, it should be understood that this disclosure may also apply to other types of subsea systems 10, such as subsea injection systems (e.g., subsea gas injection system, subsea water injection system, subsea carbon dioxide injection system).

[0025] FIG. 2 is a schematic view of an embodiment of the submarine power system 50 coupled to the submarine system 10 of FIG. 1. The system Petition 870250094622, dated 10 / 16 / 2025, page 16 / 53 Submarine power system 50 includes a busbar 52 and a plurality of energy storage units 54 electrically coupled to the busbar 52 in a plurality of positions 55 distributed throughout the submarine power system 50. The submarine power system 50 is configured to supply electrical power (e.g., primary and / or secondary power) from the energy storage units 54 via the busbar 52 to a plurality of electric actuators 70 coupled to the respective submarine components 74. In certain embodiments, the busbar 52 includes an electrical busbar and a data busbar that extend to the plurality of energy storage units 54 and the plurality of electric actuators 70. The busbar 52 may include a network or grid of electrical and / or data cables.Busbar 52 may extend for distances of about 5 to 200 meters, or 10 to 100 meters, or another suitable range, depending on the electrical capacity of the energy storage units 54, the power demand of the electric actuators 70, and the electrical losses along the distances. Busbar 52 may include one or more 24 V, 48 V, 72 V, 96 V busbars, or a suitable busbar 52 between 24 V and 800 V or 24 V and 400 V. In certain embodiments, busbar 52 may include multiple power busbars 52 of different voltages. The energy storage units 54 may include any suitable number, size, and electrical capacity of batteries, fuel cells (e.g., hydrogen fuel cells), supercapacitors, or any combination thereof.For example, the number, size and / or electrical capacity of the energy storage units 54 may be based on the number and / or electrical demand of the electric actuators 70, a safety factor to ensure redundant and / or surplus power supply above the maximum amount required for the electric actuators 70, a spatial distribution of the electric actuators 70 and distances on the busbar 52, expected electrical losses on the busbar 52 or any combination thereof. The number, size and / or electrical capacity of the energy storage units 54 are... Petition 870250094622, dated 10 / 16 / 2025, page 17 / 53 10 / 38 discussed in more detail below.

[0026] The subsea power system 50 also includes one or more controllers 56. The controller(s) 56 include a memory 58, a processor 60, instructions 62 stored in memory and executed by the processor 60, and a communication circuit 64. Similarly, each of the energy storage units 54 may include a controller 53, and each of the electric actuators 70 may include a controller 75, wherein the controllers 53 and 75 may include a processor, memory, instructions, and communication circuits. The controllers 56, 53, and 75 may operate independently and / or in combination with each other to facilitate the control of the subsea power system 50 and the operation of the subsea components 74 actuated by the electric actuators 70.For example, instructions 62, when executed by processor 60, allow controller(s) 56 to control the subsea power system 50 to selectively discharge at least one of the plurality of energy storage units 54 through bus 52 to supply power to at least one of the plurality of electric actuators 70 coupled to a respective subsea component 74 of the plurality. Instructions 62, when executed by processor 60, also allow controller(s) 56 to control the subsea power system 50 to selectively charge one or more of the various energy storage units 54 through bus 52 by means of power from a power supply coupled to the electrical cable 12. Controllers 53 and / or 75 may also provide the same or similar control characteristics as controllers 56.

[0027] In the illustrated embodiment, the subsea power system 50 is electrically coupled to the plurality of electric actuators 70 by means of the busbar 52, wherein each of the plurality of subsea components 74 is actuated by one of the respective plurality of electric actuators 70. As discussed above, one or more subsea structures or equipment (e.g., subsea tree, collector, substation, head of Petition 870250094622, dated 10 / 16 / 2025, page 18 / 53 11 / 38 well, etc.) may include a plurality of subsea components 74. The plurality of subsea components 74 may include various flow control equipment, such as valves, pumps, water injection systems, chemical injection systems, or any combination thereof. For example, subsea components 74 may include a variety of valves, such as gate valves, ball valves, blowout preventer assemblies (BOPs), chokes, or any combination thereof. Water and chemical injection systems may also include valves, pumps, flow meters, and other flow control equipment. Subsea components 74 may also include a variety of sensors or monitoring equipment, such as flow meters, temperature sensors, pressure sensors, water sensors, fluid composition sensors, leak sensors, or any combination thereof.However, if primary power is not available when power is needed to operate one or more subsea components 74, the controller(s) 56 will selectively control the subsea power system 50 to provide secondary power from one or more energy storage units 54 via the bus 52 to the appropriate electric actuators 70 to operate the respective subsea components 74.

[0028] Each of the plurality of electric actuators 70 may include electronic components 76, an electric drive 78 and actuator mechanisms 80. The electronics 76 may include power electronics and the controller 75 (e.g., control board, processor, memory, instructions and communication circuits). The electric drive 78 may include a direct current (DC) motor, an alternating current (AC) motor, a servomotor, a linear drive, a rotary drive or any combination thereof. The actuator mechanics 80 may include a transmission, a gear set or gearbox, one or more shafts, a rotary-to-linear converter, a position lock, a position sensor or any Petition 870250094622, dated 10 / 16 / 2025, page 19 / 53 12 / 38 combination of these. In certain embodiments, the electric actuators 70 may use electrical energy to operate in first and second opposite actuation directions, such as in clockwise and counterclockwise rotation directions and / or in forward and backward axial directions. Thus, in an embodiment of the subsea component 74 including a valve, the electric actuator 70 may be configured to use electrical energy to operate the electric drive 78 for opening and closing the valve. In certain embodiments, the electric actuator 70 may exclude a spring or deflection element configured to deflect the actuator in a particular direction, such as spring deflection of the valve towards a normally closed position. Each of the plurality of electric actuators 70 may also include an interface 81 having one or more connectors 82 for independent coupling with each respective electric actuator 70.The connectors 82 may include mechanical connectors and electrical connectors, such as plug connectors, rotational connectors, quick connect / disconnect couplings, or a combination thereof. The plurality of electric actuators 70 may also include integrated harnesses, plug connectors, or a combination thereof, thus enabling each actuator 70 to be recoverable by means of a remotely operated vehicle (ROV) via an ROV interface (e.g., interface 81). In certain embodiments, each of the energy storage units 54 may be packaged with a corresponding electric actuator 70, or in certain embodiments, the plurality of energy storage units 54 may be separated from the plurality of electric actuators 70. In certain embodiments, the plurality of energy storage units 54 are recoverable (e.g., recoverable by ROV) independently of the plurality of electric actuators 70.In some embodiments, the plurality of energy storage units 54 and the plurality of electric actuators 70 are packaged together as a packaged unit or module, wherein the module may be recoverable (e.g., recoverable by ROV) or non-recoverable (e.g., fixedly mounted or permanently installed on a subsea structure). In some. Petition 870250094622, dated 10 / 16 / 2025, page 20 / 53 In the 13 / 38 embodiments, the plurality of energy storage units 54 are recoverable (e.g., recoverable by ROV), while the plurality of electric actuators 70 are not recoverable (e.g., fixedly mounted or permanently installed in a subsea structure). In the illustrated embodiment, the plurality of energy storage units 54 can be removed and replaced while the subsea power system 50 is in operation (e.g., active standby mode).

[0029] In certain embodiments, the subsea system 10 may include an actuation system for the electric actuators 70 and the energy storage units 54 (e.g., batteries) on the busbar 52 of the subsea power system 50 with the components and features described below. The actuation system may be based on a 48 V power busbar system of the subsea power system 50. The actuation system may include dedicated redundant isolated power supplies for charging the battery of actuation systems, e.g., energy storage units 54 coupled to electric actuators 70 via the busbar 52. The subsea power system 50 may include a local subsea power grid for cross-feeding electrical consumers such as the electric actuators 70. The actuation system may include integrated harnesses and plug-in connectors on a subsea mounting base and on the actuator side of the electric actuators 70.Electric actuators 70 may include subsea actuators (recoverable by ROV) with mechanical and electrical quick-connect arrangements, or non-subsea recoverable pluggable electric actuators 70 with energy storage units 54 (e.g., batteries).

[0030] In certain embodiments, the 50-sea subsea power system includes the components and features below. The 50-sea subsea power system may include supercapacitors to support high currents during the initial phase of motor movements (breakdown torque). The supercapacitors may have a voltage rating suitable for the 52 bus, such as, but not limited to, 24 V, 48 V, 72 V, 96 V, or a voltage rating between 24 V and Petition 870250094622, dated 10 / 16 / 2025, page 21 / 53 14 / 38 800 V or 24 V to 400 V. Energy storage units 54 (e.g., batteries) can be actively switched on / off for discharge, and energy storage units 54 (e.g., batteries) can be actively removed and replaced while the system is operating.

[0031] Considering the size of the subsea production equipment structures, the length of the subsea power system 50 in some embodiments may be about 30-50 meters. In certain embodiments, a 24 VDC system may be used to power the bus 52, but it may be challenging to supply sufficient power from an energy storage unit 54 (e.g., battery) to another electric actuator 70 via the power bus 52. In certain embodiments, a higher voltage bus 52 may be used which will provide more efficient power transmission. For example, the bus 52 may be rated at a voltage level of approximately 48 V, 72 V or 96 V up to 400 V, 600 V, 800 V or higher. In certain embodiments, the maximum expected current required on the power bus 52 may be between 30 A and 65 A.

[0032] FIG. 3 is a schematic view of an embodiment of the subsea power system 50 coupled to the subsea system 10 of FIG. 1, further illustrating a multi-bus configuration 51 of bus 52. The subsea power system 50 may include substantially the same features discussed above with reference to FIG. 2, unless otherwise indicated. As illustrated in FIG. 3, the multi-bus configuration 51 has buses 52A and 52B, each coupled to a plurality of energy storage units 54 and a plurality of electric actuators 70. Buses 52A and 52B may be used as redundant buses 52, independent buses 52 for independent power distribution to different electric actuators 70, or other bus-specific control features operating with multiple buses 50. Although FIG.3 illustrates two busbars 52A and 52B; the multiple busbar configuration 51 can include any number of busbars 52, such as 2, 3, 4, etc. Petition 870250094622, dated 10 / 16 / 2025, page 22 / 53 15 / 38 or more buses 50. The buses 52 (e.g., 52A and 52B) in the multi-bus configuration 53 may include an electrical power bus and a data bus (e.g., monitoring and control data bus). For example, the buses 52 may include a plurality of sensors 57 (e.g., one or more sensor types) coupled to the buses 52A and 52B, wherein the sensors 57 may include voltage sensors, current sensors, or other integrity monitoring sensors configured to help track the integrity, a discharge cycle, a charge cycle, or other parameters of the energy storage units 54. The plurality of sensors 57 may include sensor types 1 to M, wherein M is equal to or greater than 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more. The data monitored by sensors 57 are used for monitoring and control of the subsea power system 50 and the subsea system 10, as discussed below.

[0033] The subsea power system 50 has a plurality of energy storage units 54 coupled to busbars 52A and 52B in a plurality of positions 55 distributed throughout the subsea power system 50 and the subsea system 10. The plurality of energy storage units 54 may include a plurality of uniformly distributed energy storage units 54 (e.g., uniformly spaced positions 55), a plurality of non-uniformly distributed energy storage units (54) (e.g., non-uniformly spaced positions 55), or a combination thereof. The positions 55 of the energy storage units 54 may be arranged in a three-dimensional space in the vertical and horizontal directions. The energy storage units 54 and the electric actuators 70 may be arranged in pairs very close to each other, as indicated by the box 77 (e.g., within 0 to 5 meters).For example, one of the energy storage units 54 can be directly coupled to or mounted on (e.g., integrated into) a respective electric actuator 70. However, in... Petition 870250094622, dated 10 / 16 / 2025, page 23 / 53 16 / 38 In certain embodiments, the energy storage units 54 can be distributed throughout the busbar 52 (e.g., busbars 52A and 52B) in a first spatial distribution based on a second spatial distribution of the electric actuators 70, wherein the first and second spatial distributions differ from each other, and the first spatial distribution is configured to provide an improved secondary energy distribution from the energy storage units 54 to the electric actuators 70. In operation, the charging and discharging of the energy storage units 54 are controlled by one or more of the controllers 110, 104, 53 and / or 75.

[0034] In certain embodiments, the subsea power system 50 includes subsea control module(s) 100 (SCM) coupled to one or more subsea structures (e.g., trees, collectors, substations, etc.). The subsea power system 50 may include a plurality of subsea control modules 100 for redundancy and / or independent control of buses 52A and 52B in the multi-bus configuration 51. The subsea control module(s) 100 may each include a subsea electronic module 102 having a controller 104, such as the controller 56 discussed in detail above with reference to FIG. 2. The subsea power system 50 may also include a subsea network or subsea distribution network 106 (e.g., subsea power distribution and communication network) coupled to the subsea control module(s) 100.The submarine distribution network 106 may include distribution hardware such as electrical cables, submarine umbilicals, umbilical termination units, and submarine distribution modules. The submarine power system 50 may electrically and communicatively couple the submarine distribution network 106 with an upper control system 108 by means of one or more umbilicals (e.g., electrical cables 12, submarine telecommunications cables). The upper control system 108 is configured to be mounted on a host structure, such as a surface vessel or a platform. Petition 870250094622, dated 10 / 16 / 2025, page 24 / 53 17 / 38 or a maritime vessel on the water's surface. The upper control system 108 includes a controller 110 with a memory 112, a processor 114, instructions 116 stored in memory 112 and executed by the processor 114, and a communication circuit 118. The upper control system 108 may also be coupled to a main power source 84 to provide primary power to the subsea system 10. In certain embodiments, the main power source 84 may not be a single power source but may also encompass power received via wave energy buoys, offshore wind turbines, and other electrical power sources. Furthermore, the upper control system 108 may include a combination of an energy harvesting system and a communication buoy using satellite communication between the subsea infrastructure and a remote control location.

[0035] The main power supply 84 may include a power generation system, an electrical grid, or a combination thereof. For example, the power generation system may include one or more electric generators driven by a combustion engine, such as a gas turbine engine or a reciprocating piston-cylinder engine. The power generation system may include one or more wind turbines, solar panels, hydroelectric turbines, or other power sources. The main power supply 84 is configured to provide primary power to the subsea system 10 via control by the upper control system 108 (e.g., controller 110) and / or by the subsea control modules 100 and via distribution by the subsea distribution network 106.The upper control system 108 (e.g., controller 110) and / or the subsea control modules 100 can be configured to control a primary power supply from the main power supply 84 to the subsea system 10 to operate various subsea components 74 and / or to the subsea power system 50 to charge one or more energy storage units 54.

[0036] In addition, the upper control system 108 (e.g., Petition 870250094622, dated 10 / 16 / 2025, page 25 / 53 18 / 38 controller 110), the subsea control modules 100 (e.g., controllers 104), the controllers 53 of the energy storage units 54 and / or the controllers 75 of the electric actuators 70 can be configured to monitor operational parameters and control the subsea power system 50 (e.g., charging and discharging of the energy storage units 54) and monitor operational parameters and control the subsea system 10 (e.g., actuation of subsea components 74, such as opening and closing of valves).For example, controllers 110, 104, 53 and / or 75 can be configured to monitor the health, charge cycles, discharge cycles and other parameters of the energy storage units 54, monitor the availability of primary power from the main power supply 84, monitor the power demands to power the electric actuators 70 to operate the subsea components 74 based on various conditions or events (e.g., pressure exceeds limit, component failure, emergency valve closure, etc.) of the subsea system 10, and control the secondary power distribution from the energy storage units 54 via bus 52 (e.g., bus 52A and 52B) based on the various monitored parameters.The health of the energy storage units 54 may include electrical charge level, current level and rate of decline in charge level over time, age, historical discharge and charge cycles, historical diagnostic data, operational data during use to power electrical actuators 70, or any combination thereof. In certain embodiments, the controllers 110, 104, 53, and / or 75 may be configured to communicate with each other in response to various health conditions (e.g., fault, low charge condition, etc.) of the energy storage units 54 to allow for appropriate control response and / or usage intervention. For example, the controllers 53 of the energy storage units 54 may allow self-monitoring and reporting of any health conditions to the controllers 104 and / or 110. The controllers 104 and / or 110 may also... Petition 870250094622, dated 10 / 16 / 2025, p. 26 / 53 19 / 38 perform various monitoring of the energy storage units 54, the electric actuators 70, the busbars 52A and 52B, and other aspects of the subsea power system 50. In certain modes, if a detected health condition is a fault, one of the controllers 53, 104, and / or 110 can trigger an isolation or separation control function, thus isolating or separating the faulty energy storage unit 54 from the busbar 52. Furthermore, if a detected health condition is a low load condition, one of the controllers 53, 104, and / or 110 can trigger a load cycle, thus supplying primary power from the main power supply 84 to the energy storage unit 54 that needs a load.In certain embodiments, the controllers 53 of the energy storage units 54 can communicate with each other, share monitored health information, respond to demands to power the electric actuators 70 to operate the subsea components 74, and agree on control actions (e.g., charge cycle to charge one or more energy storage units 54 and / or discharge cycle to supply power from one or more energy storage units 54 via bus 52). However, any one or a combination of the controllers 110, 104, 53, and / or 75 can be used to provide monitoring and control of the subsea system 10 and the subsea power system 50 using various control processes, as discussed in more detail below.

[0037] The subsea power system 50 (e.g., power bus system) can receive individual energy storage units 54 (e.g., batteries) and regulate the charge / discharge profile of each energy storage unit 54 (e.g., battery). The subsea power system 50 of the disclosure can “regulate” the flow of electrical energy to and from energy storage units 54 (e.g., batteries) and to electrical actuators 70. This can happen automatically or with user intervention. The energy storage units 54 (e.g., batteries) can be equipped with battery firmware. Petition 870250094622, dated 10 / 16 / 2025, page 27 / 53 20 / 38 intelligent, for example, in the controllers 53. In case of failure, the energy storage unit 54 (e.g., battery) can send a message to the subsea control module 100 and disable itself, if necessary, or execute any other pre-programmed algorithms. Any control and status messages regarding the subsea energy system 50 can be sent through the subsea control module 100 to the upper control system 108 (e.g., master control station). It is possible to send individual comments from the upper control system 108 to each energy storage unit 54 (e.g., battery) to execute and monitor functions such as battery health, load cycles, priorities within the network, assignments between batteries and the electric actuators 70 they supply.Energy storage units 54 (e.g., batteries) can communicate with other energy storage units 54 (e.g., batteries) to determine identifier numbers and priorities. It is also useful to avoid cross-charging between energy storage units 54 (e.g., batteries). This function can be overridden by the operator if necessary. In certain embodiments, the subsea power system 50 can be designed so that power flow is permitted only from power sources located in the subsea control module 100 to the energy storage units 54 (e.g., batteries), from the energy storage units 54 (e.g., batteries) to the electric actuators 70, from the energy storage units 54 (e.g., batteries) to the electronic subsea control module 100, and / or from the energy storage units 54 (e.g., batteries) to the subsea sensors 57.The flow of energy from energy storage units 54 (e.g., batteries) to energy storage units 54 can be avoided in certain modes.

[0038] As discussed here, it may be desirable to power at least some of the subsea components (e.g., flow control equipment, chemical injection systems, pumps, systems Petition 870250094622, dated 10 / 16 / 2025, page 28 / 53 21 / 38 water injection and similar) with less or, in some cases, no electrical cabling. Consequently, it may be advantageous to use a support surface that includes a busbar with a loop or that has a surface area sufficient to supply power to several subsea components via an electrical connection formed in different areas of the loop. The support surface can reduce the amount of electrical cabling, or even eliminate electrical cabling for certain subsea components, thus providing more modularity, expandability and / or reliability to operations using subsea equipment (e.g., wellheads, subsea trees, distribution manifolds, substations and similar).

[0039] FIG. 4 is a schematic diagram of a bus rail support system 130 (e.g., power bus rail) that generally provides conductive paths along a surface so that various electronic devices can couple to the control module via the conductive paths in different connection areas. The bus rail support system 130 includes a bus subsystem 132 (e.g., integral bus rail support system, a bus) that includes rails 134. The rails 134 extend to and from the control module 100 to form loops 136. That is, each rail 134 can extend to form a distinct loop 136 that is electrically coupled to the control module 100. Each loop 136 includes a connection area 138 via which electrical components can electrically couple, directly or indirectly, to the control module 100.For example, in some embodiments, indirectly electrically coupled may refer to electrical coupling, with one or more intervening electrical components, such as couplers, inductive couplers and the like. In any case, the handles 136 are coupled to a support surface 140 which generally provides physical structural support for the electrical components and may be coupled to subsea components, as discussed in more detail. Petition 870250094622, dated 10 / 16 / 2025, page 29 / 53 22 / 38 here.

[0040] In general, tracks 134 can be formed of (e.g., composed of, consist of, or consist essentially of) one or more conductive materials. As mentioned herein, “conductive material” refers to a material that has a relatively low resistivity, such as having a resistivity at 20°C less than or equal to 1 x 10⁻³ Ω·m, less than or equal to 1 x 10⁻⁴ Ω·m, less than or equal to 1 x 10⁻⁵ Ω·m, less than or equal to 1 x 10⁻⁶ Ω·m, or less than or equal to 1 x 10⁻⁷ Ω·m. For example, tracks 134 can be made of copper, silver, gold, aluminum, lead, and the like. Rails 134 can be formed on the support surface 140 by various suitable techniques, such as additive manufacturing (e.g., three-dimensional (3D) printing, lithography and the like), material deposition (e.g., chemical vapor deposition, electrochemical deposition, sputtering and the like) or otherwise applied to the support surface 140.For example, the rails 134 can be fixedly and / or integrally coupled to the support surface 140 longitudinally along the rails 134 on the support surface 140. For example, an entire length of each of the rails 134 can be fixedly and / or integrally coupled to the support surface 140. In certain embodiments, the rails 134 can be coupled directly to the support surface 140, for example, by directly connecting the conductive material of the rails 134 to the support surface 140. In some embodiments, the rails 134 can be coupled to the support surface 140 by means of an intermediate layer of adhesive, insulation or other material. In some embodiments, the rails 134 may be formed along a flat surface (e.g., flat surface) of the support surface 140 and / or the rails 134 may be formed and extend longitudinally along respective grooves along the support surface 140.

[0041] As described above, rails 134 form loops 136. As shown, rails 134 have curved corners. In some embodiments, rails 134 have sharp corners or a combination of curved corners and Petition 870250094622, dated 10 / 16 / 2025, page 30 / 53 23 / 38 sharp. It should be noted that the rails 134 may have any suitable shape, such as a rectangular handle (e.g., with sharp corners), a circular handle, an oval handle, or an irregularly shaped handle. Furthermore, the rails 134 are parallel to each other so that the rails 134 do not overlap. Thus, one or more of the handles 136 may be concentric handles (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more concentric handles). In some embodiments, one or more rails 134 may overlap. For example, the rails 134 of a first loop 136 may cross the rails 134 of a second loop 136 at one or more positions or locations along the respective loops 136. In such embodiments, the rails of the first loop 136 and the rails 134 of the second loop 136 may be separated by a suitable insulating material (e.g., electrically insulating layer) to prevent crosstalk or electrical coupling between the first loop 136 and the second loop 136.

[0042] In certain implementations, the support surface 140 may be coupled to or an integral part of subsea equipment, such as a subsea tree, a well, a manifold, a subsea station, or the like. For example, the support surface 140 may include a surface of a structure, a housing, a wall, a floor, a ceiling, a structural support member, or any combination thereof, of the subsea equipment. For example, the support surface 140 may be an integral surface of the subsea equipment, wherein the subsea equipment is constructed of one or more metals suitable for a subsea environment. Thus, the support surface 140 may be a rigid support surface that provides rigidity to the rails 134 on the handles 136 coupled to the support surface 140, structurally supporting and protecting the rails 134 on the handles 136.In contrast to flexible cables, the support surface 140 completely protects the rails 134 in the handles 136, at least on the side of the support surface 140. Furthermore, the support surface 140 can provide a surface area where one or more subsea components can be electrically coupled to the control module 100 in the different connection areas 138, but with a... Petition 870250094622, dated 10 / 16 / 2025, page 31 / 53 24 / 38 reduced amount of wiring to supply power to one or more subsea components. For example, a first subsea component (e.g., a sensor) can be coupled to a first connection area 138, and a second subsea component (e.g., an electric actuator) can be electrically coupled to a second connection area 138. In some embodiments, one or more couplers, such as inductive couplers, can be coupled to each connection area 138. As described in more detail in relation to FIG. 8, the provision of inductive couplers can provide modularity to the support surface 140, making it easier for a user to exchange, change, or otherwise adjust the connection area 138 for a specific subsea component. For example, it may be advantageous to change connection areas 138 for different subsea components based on the space available in a specific connection area 138 to support a specific subsea component.

[0043] In some embodiments, the support surface 140 may be a rigid and substantially flat surface. For example, the support surface 140 may be formed of a substantially rigid material with a Young's Modulus greater than or equal to 100 Mega Pascals (MPa), greater than or equal to 250 MPa, greater than or equal to 500 MPa, greater than or equal to 750 MPa, greater than or equal to 1000 MPa, and so forth. In some embodiments, the insulating material may include rubber, insulating polymers (e.g., polytetrafluoroethylene (PTFE), polyethylene terephthalate (PTE), and the like). In any case, it may be advantageous that at least one insulating layer be provided on the support surface 140 to provide electrical insulation for the conductive material of the rails 134. For example, a first insulating layer may be provided on an upper surface of the support surface 140. In some embodiments, the support surface 140 may be formed using the insulating material.In some embodiments, the support surface 140 may be formed around the handles 136. For example, the support surface 140 may be an insulating polymer that is cured, while the handles 136 are provided within the polymer. Petition 870250094622, dated 10 / 16 / 2025, page 32 / 53 25 / 38 uncured insulator.

[0044] In any case, forming the support surface 140 with the rails 134, electrical or electromechanical devices can be coupled to the rails 134 in one or more connection areas 138. In this way, the busbar rail support system 130 can reduce the probability of crossing or entanglement of cables that can be used in conventional subsea trees for electrical coupling of electrical or power devices. As noted herein, although the above description refers to a busbar rail support system, the description in FIG. 4 can also apply to a rail support system. Furthermore, the descriptions in FIGS. 5-8 can also be applied to the rail support system.

[0045] As discussed herein, the busbar rail support system 130 can be coupled to subsea equipment such as a subsea tree, a well, a manifold, a subsea station, or the like. To illustrate this, FIG. 5 shows an example of a subsea power system 50 or subsea equipment system 150 that includes a subsea power tree 14 with a busbar rail support system 130. In particular, the subsea equipment system 150 includes the subsea power tree 14 coupled to the busbar rail support system 130 that provides power to the electric actuators 154. In general, the electric actuators 154 may include components similar to those described in relation to the electric actuators 68 of FIG. 2. For example, the electric actuators 154 may include the electronics 76 and the electric drive 78. As shown, the electric actuators 154 include an energy storage 54.In some embodiments, the energy storage 54 may be an integrated battery (e.g., integral battery) that manages the energy for the electric actuators 154. As described herein, the inclusion of the integrated battery may advantageously manage the current flow through the rails 134.

[0046] As shown, the electric actuators 154 are electrically coupled to the busbar rail support system 130 by means of a Petition 870250094622, dated 10 / 16 / 2025, page 33 / 53 26 / 38 Inductive Coupler 158. Inductive couplers 158 can be coupled to the busbar rail support system using flexible connections (e.g., sheathed copper wires) or a rigid connection so that the inductive coupler 158 is in a substantially fixed position. Each inductive coupler 158 includes a male coupling portion 160 (e.g., double coil male portion) and a female coupling portion 162 (e.g., double coil female portion). The male coupling portion 160 and the female coupling portion 162 can be selectively coupled with the male coupling portion 160 or the female coupling portion 162 of other inductive couplers 158. For example, subsea components coupled to one portion (e.g., the male coupling portion 160) can be arranged to couple to the complementary portion (e.g., the female coupling portion 162) arranged in different connection areas 138.The male coupling portion 160 can be coupled to the female coupling portion 162 when provided in a coupled position. In some embodiments, the male coupling portion 160 includes pins which, when in a coupled position with the female coupling portion 162, are disposed through at least one insulating layer and in contact with the plurality of rails 134.

[0047] In any case, the electric actuators 154 can supply power to the valves 164. In general, the valves 164 can be any suitable valve of the subsea tree 14, such as low-friction valves, master valves, wing valves, swab valves, flow line isolation valves, chemical injection valves, downhole isolation valves. However, it should be noted that the electric actuators 154 can be used to actuate various components or equipment in the subsea tree 14, as described herein, such as chokes, pressure transmitters, sand detectors, vibration sensors, and flow meters.

[0048] The 14-meter electric tree can consume ultra-low power (e.g., 10-200 Watts). The 130-meter busbar rail support system is Petition 870250094622, dated 10 / 16 / 2025, page 34 / 53 27 / 38 arranged in the electrical tree 14 and provides power to the various components and equipment without the need for pressure-compensated oil-filled hoses housing electrical cables. The electrical tree 14 further comprises a plurality of electric actuators 154 with integral batteries 54 that are in electrical communication with the busbar support system 130 by means of inductive couplers 158. The electric actuators 154 can be used to actuate various components or equipment in the electrical tree, including, but not limited to, low-friction valves, master valves, wing valves, swab valves, flow line isolation valves, chemical injection valves, downhole isolation valves, chokes, pressure transmitters, sand detectors, vibration sensors and flow meters.To reduce the amount of energy to be transferred by the inductive couplers 158, it may be advantageous to provide slow-charging batteries in the device housings. That is, it is now recognized that providing batteries can be useful in cases where devices occasionally have high power consumption to regulate the current within a limiting range. Although the embodiment in FIG. 5 is shown with inductive couplers 158, any other suitable coupler may be used in other embodiments, such as electrical connectors.

[0049] Although only a single support surface 140 is shown, it should be noted that the busbar rail support system 130 may include multiple support surfaces 140. Each support surface 140 may be electrically coupled to another. Furthermore, each support surface 140 may be arranged at any angle so that the support surfaces 140 are perpendicular, coplanar, angularly offset, and so forth, with respect to another support surface 140.

[0050] In some embodiments, the 130 busbar rail support system can be coupled to subsea equipment with one or more integrated subsea components, such as valves. To illustrate this, FIG. 6 is a cross-sectional view of a subsea tree 14 having a system. Petition 870250094622, dated 10 / 16 / 2025, page 35 / 53 28 / 38 busbar rail support 130 with a control module 100. In the illustrated embodiment, the subsea electrical tree 14 includes a conduit 170 that can provide a production flow path 172 for hydrocarbon fluids such as oil and natural gas. As shown, the production flow path 172 is in an upward direction that corresponds to a direction from the wells (e.g., the wells in FIG. 1) to a surface platform (e.g., surface platform 30 in FIG. 1). However, in some embodiments, the conduit 170 can be used to inject fluids into a subsurface formation.

[0051] The subsea tree 14 includes a swab valve 174 and a master valve 176. However, it should be noted that these valves (e.g., the swab valve 174 and the master valve 176) are to be considered non-limiting examples of subsea components. For example, the subsea tree 14 may include other fluid flow devices, fluid injection systems, and other components described herein. In any case, the operation of the swab valve 174 and the master valve 176 is controlled using the actuator mechanics 80 (e.g., the mechanical interface and the gearbox). In general, the actuator mechanics 80 may include features generally similar to those described in relation to FIG. 2.

[0052] In the illustrated embodiment, the mechanics of the actuator 80 of the master valve 176 is controlled by an electric actuator 154. The electric actuator 154 is coupled to the rails 134 by means of an inductive coupler 158. Consequently, the position of the master valve 176 can be adjusted to an open or closed position by the control module 100 by means of energy supplied by the inductive coupler 158. In general, the electric actuator 154 may include certain characteristics of the electric actuator 68 described in FIG. 2. For example, and as shown, the electric actuator 154 may include electronic components 76, an electric drive 78 and an energy storage 54.

[0053] In the illustrated embodiment, the mechanics of the actuator 80 of the cotton swab valve 174 are controlled by an electric actuator 154. The electric actuator 154 is Petition 870250094622, dated 10 / 16 / 2025, page 36 / 53 29 / 38 electrically coupled directly to rails 134. Consequently, the position of the cotton swab valve 174 can be adjusted to an open or closed position by the control module 100 through the direct electrical coupling of the electric actuator 154 to rails 134.

[0054] As described herein, the busbar rail support system 130 may include at least one insulating layer (e.g., electrically insulating layer). To illustrate this, FIG. 7 shows a cross-sectional view of an example of the busbar rail support system 130 corresponding to area 178 shown in FIG. 6. In particular, the enlarged view of part of the busbar rail support system 130 shows a cross-sectional view of the busbar rail support system 130 (e.g., multi-master busbar), comprising a plurality of rails 134 (e.g., electrical conductors or conductor paths) arranged between (e.g., sandwiched between) an upper or outer insulating layer (e.g., upper insulating layer 182) and a lower or inner insulating layer (e.g., lower insulating layer 180).The lower insulating layer 180 and the upper insulating layer 182 surround the rails 134, such that the pins of any connector pierce the upper insulating layer to connect to any of the rails 134. In other words, the lower insulating layer 180 extends directly along (e.g., parallel to) the support surface 140, the plurality of rails 134 extends over the lower insulating layer 180, and the upper insulating layer 182 extends directly along (e.g., parallel to) the lower insulating layer 182 over the plurality of rails 134. In some embodiments, the rails 134 may be formed within a groove of the insulating layers.

[0055] As shown, the rails 134 are coated with a lower insulating layer 180 and an upper insulating layer 182 on the support surface 140. In general, the lower insulating layer 180 and the upper insulating layer 182 can be made of any suitable electrically non-conductive material, including, but not limited to, polymeric and ceramic materials. Petition 870250094622, dated 10 / 16 / 2025, page 37 / 53 30 / 38 In one embodiment, an insulating material surrounding the rails 134 may be used instead of the lower insulating layer 180 and the upper insulating layer 182. In another embodiment, a coil may also be an integral part of the power bus rail panel and located between the lower insulating layer 180 and the upper insulating layer 182 and between two conductors. In another embodiment, the inductive coupler 158 and the rails may be manufactured using novel manufacturing methods such as additive manufacturing methods or 3D printing. The conductors may be made of any suitable conductive material, including but not limited to copper and aluminum. As described in more detail below, the electronic components may include pins that penetrate through one or more insulating layers (e.g., including the upper insulating layer 182) and thus couple to the rails 134.

[0056] Certain embodiments of the disclosure are directed to a method of forming the busbar rail support system 130, such as forming the support surface 140 and / or connecting the electrical components described herein to the support surface 140. The process may include providing a support surface 140. The process may also include coupling a busbar (e.g., the busbar subsystem 132) to the support surface 140. As described herein, the busbar includes a plurality of rails 134, and the plurality of rails 134 extends along the support surface 140 to form a plurality of loops. The plurality of rails 134 includes an electrically conductive material, and the loop includes a plurality of connection areas. In addition, the process may include electrically coupling the busbar to a control module 100.As described herein, control module 100 is configured to electrically couple to a plurality of subsea components via a plurality of connection areas.

[0057] To better illustrate the embodiments of the present disclosure, FIG. 8 shows a perspective view of the busbar rail support system 130 with inductive couplers 158 that electrically couple certain electronic devices to the rails 134 and, finally, to the control module 100. Petition 870250094622, dated 10 / 16 / 2025, pp. 38 / 53 31 / 38 As shown, the bus rail support system 130 includes several rails 134, sensors 190, inductive couplers 158, and an electric actuator 154. In some embodiments, the rails 134 can be paired, so that each pair makes an electrical channel between a first side 192 and a second side 194 of the control module 100. In the embodiment illustrated, the bus rail support system 130 is a three-channel multi-master bus comprising three pairs of buses. For example, the bus rail support system 130 includes a first pair of buses 196, a second pair of buses 198, and a third pair of buses 200 that can be used for power and communication.The first pair of busbars 196 (e.g., a first pair of auxiliary busbars) includes the two outermost rails 134, the second pair of busbars 198 (e.g., a main pair of busbars) includes the two conductors arranged inside the first pair of busbars 196, and the third pair of busbars 200 (e.g., a second pair of auxiliary busbars) includes the two innermost conductors. Although the busbar rail support system 130 in FIG. 8 is a three-channel busbar, any number of channels can be used, for example, a one- or two-channel busbar can be used, or a busbar with four, five, six, seven, eight, nine, ten, eleven, twelve channels or more can be used.

[0058] The 130 busbar support system can use an alternating current (AC) power supply system and be connected on both sides (e.g., the first side 192 (e.g., side A) and the second side 194 (e.g., side B)) to the multi-master capable control module 100. In some embodiments, the control module 100 may include a diplexer and a signal modulator to overlay communication onto the AC power signal.

[0059] The 130 busbar rail support system may include a pair of electrical connectors (e.g., male and female electrical connectors) for high power consumption. For lower power consumption, Petition 870250094622, dated 10 / 16 / 2025, pp. 39 / 53 32 / 38 inductive couplers are used for power transmission. Electrical sensors and actuators for valves (e.g., master valve, swab valve, wing valve, etc.) can be powered by the power bus system via inductive couplers. Each device to be powered by the power bus system will have a unique identifier / address to receive commands from the control module. Each device may have a central processing unit (CPU), read-only memory (ROM), and random access memory (RAM) configured to detect the bus status and execute a pre-programmed workflow to respond to any power, communication, or power and communication issues. Each device may also include electronic components to separate power and communication from the induced signal. Each device may be equipped with the feature of feeding back to the rail system if needed.

[0060] A wide range of devices can be supported, including, but not limited to, electric actuators, flow measuring devices, pressure and temperature sensors, leak detectors, vibration sensors, acoustic sensors, optical devices, long-distance communication devices, wireless modems, downhole equipment, data loggers, etc.

[0061] Each inductive coupler 158 comprises a female double-coil portion and a male double-coil portion. In some embodiments, the inductive coupler 158 may include pairs of first and second coil portions. For example, the first and second coil portions may include (i) a single female coil portion and a single male coil portion, (ii) a female double-coil portion and a male double-coil portion, or a combination thereof. In any case, each portion of the male inductive coupler has at least two coils forming a channel, one connected to the central main bus and one to an external auxiliary bus via pins 202. The external auxiliary bus may be selected for greater Petition 870250094622, dated 10 / 16 / 2025, pp. 40 / 53 33 / 38 Reliability and channel isolation based on assembly orientation — the position of pins 202 defines which coils / channels of the multi-master bus will be used. For example, the master valve sensor and actuator each have male inductive coupler portions comprising two pairs of pins 202 — two arranged in alignment with the second pair of buses 198 (e.g., main bus) and two arranged in alignment with the third pair of buses 200 (auxiliary bus 2). The swab and wing valves also have male inductive coupler portions comprising two pairs of pins 202 — two arranged in alignment with the second pair of buses 198 (main bus) and two arranged in alignment with the first pair of buses 196 (e.g., auxiliary bus 1). Although the embodiment in FIG.Figure 8 may show a male portion of inductive couplers having two pins; it should be noted that other pin counts may be used, including but not limited to three pins, four pins, five pins, or more. In some cases, there may be electronic devices that access only one bus, while in other cases, there may be electronic devices that can access more than one bus. For example, the electronic device coupled to the 130 bus rail support system may be electrically coupled to the first 196 bus pair, the second 198 bus pair, the third 200 bus pair, or any combination thereof.

[0062] Although the embodiment in FIG. 8 is shown with inductive couplers 158, any other suitable coupler may be used in other embodiments, such as electrical connectors (e.g., male and female electrical connectors). Electrical connectors may be used if the power consumption of the host control module is high. Power consumption is expected to be distributed through devices connected to a bus via rails 134. For example, if each device consumes 40 Watts per coil and eight devices are active and demanding power from the bus (e.g., charging the device's internal battery). Petition 870250094622, dated 10 / 16 / 2025, pp. 41 / 53 34 / 38 connected), control module 100 will supply at least 320 Watts to the busbar rail support system 130. This power can be distributed evenly across the busbar system to avoid high electrical loads on one busbar while other busbars (e.g., the first pair of busbars 196, the second pair of busbars 198, or the third pair of busbars 200) are idle.

[0063] Whether inductive couplers 158, electrical connectors (e.g., male and female electrical connectors) or other types of connectors are used, the corresponding connections are made on land before the subsea electrical tree 14 is installed on subsea equipment (e.g., subsea tree, wellhead, substation, manifold, etc.). During installation, the pins of the male portions of the inductive coupler penetrate the upper insulating layer (e.g., shown in FIG. 7) of the busbar rail support system 130 to make contact with the rail conductors 134. It should be noted that in some cases, subsea components may be recoverable subsea components by means of a remotely operated vehicle (ROV) in embodiments where inductive couplers 158 are used for at least a portion of the subsea components, or where inductive couplers are omitted.Consequently, disclosure modalities may include the recovery of a first subsea component with a connector (e.g., a male or female electrical connector) and the replacement of the first subsea component with a second subsea component that has a similar connection (e.g., a male or female electrical connector). Additionally or alternatively, the ROV may be used to swap or exchange the positions of the subsea components on the support surface 140. In this way, the busbar rail support system 130 can provide modularity and flexibility for subsea operations and reduce the need to remove a large number of subsea components from the ocean floor. Petition 870250094622, dated 10 / 16 / 2025, pp. 42 / 53 35 / 38

[0064] The disclosed system incorporates an integrated rail power and communication bus system, a communication signal superimposed on a pair of wires, inductive couplers for low-power transmission and communication, a redundant multi-master bus system, and a novel multi-material fabrication method for a power transmission rail system with inductive couplers. The integrated power bus can be used in a subsea production system, such as subsea production trees, injection trees, carbon injection trees, collector and reinforcement structures, and other subsea structures. The disclosed system reduces risks and eliminates the time-consuming process of connecting and disconnecting electrical connections. The disclosed system also offers high reliability in a compact design, along with reduced equipment and manufacturing costs and a significant reduction in complex wiring schemes.

[0065] The subject matter described in detail above may be defined by one or more clauses, as set forth below.

[0066] A system includes subsea equipment with a support surface. The system also includes a busbar comprising a plurality of rails coupled to the support surface, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the plurality of loops comprises a plurality of connection areas. Furthermore, the system includes at least one insulating layer disposed over the support surface to insulate the plurality of rails. In addition, the system includes a control module electrically coupled to the busbar, wherein the control module is configured to electrically couple to a plurality of subsea components by means of the plurality of connection areas.

[0067] The system of any previous clause, further comprising one or more inductive couplers electrically coupled to a portion of the plurality of connection areas. Petition 870250094622, dated 10 / 16 / 2025, pp. 43 / 53 36 / 38

[0068] The system of any previous clause, in which the rails of the plurality of rails are parallel to each other.

[0069] The system of any preceding clause, in which the plurality of handles comprises a circular handle, a rectangular handle, an oval handle, an irregularly shaped handle, or a combination thereof.

[0070] The system of any preceding clause, in which the plurality of subsea components comprises one or more electric actuators.

[0071] The system of any preceding clause, in which one or more electric actuators comprise an integral battery.

[0072] The system of any preceding clause, in which the subsea components comprise one or more valves, in which one or more electric actuators are configured to adjust a position of one or more valves.

[0073] The system of any previous clause, in which the plurality of subsea components is coupled to the subsea equipment.

[0074] The system of any preceding clause, in which the plurality of subsea components comprises at least one of the following: flow control equipment, subsea fluid injection systems, pumps or a combination thereof.

[0075] The system of any preceding clause, wherein the subsea equipment comprises at least one of the following: a wellhead, a subsea tree, a distribution manifold, a substation or a combination thereof.

[0076] The system of any preceding clause, in which at least one insulating layer comprises a first insulating layer formed integrally on the support surface over the plurality of rails.

[0077] The system includes a support surface. The system also includes a busbar comprising a plurality of rails coupled to the support surface, wherein the plurality of rails extends along the Petition 870250094622, dated 10 / 16 / 2025, pp. 44 / 53 37 / 38 support surface for forming a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the loop comprises a plurality of connection areas. Furthermore, the system includes at least one insulating layer disposed over the support surface to insulate the plurality of rails. Furthermore, the system includes a control module electrically coupled to the busbar. Furthermore, the system includes a plurality of inductive couplers disposed on at least one insulating layer and electrically coupled to the busbar.

[0078] The system of any preceding clause, in which the plurality of inductive couplers comprises a plurality of pairs of first and second coil portions that couple to each other.

[0079] The system of any preceding clause, wherein the plurality of pairs of first and second coil portions comprises a female double coil portion and a male double coil portion, wherein the male double coil portion includes a plurality of pins which, when in a coupled position, are disposed through at least one insulating layer and in contact with the plurality of rails.

[0080] The system of any preceding clause, in which the supporting surface comprises a rigid and substantially flat surface.

[0081] The system of any previous clause, where the support surface is coupled to a subsea tree.

[0082] The system of any preceding clause, further comprising a plurality of sensors, actuators or a combination thereof, electrically coupled to the plurality of rails by means of the plurality of inductive couplers.

[0083] One method includes providing a support surface. The method also includes attaching a busbar to the support surface, wherein the busbar comprises a plurality of rails, wherein the plurality of rails extends along the support surface to form a plurality of handles, wherein the plurality of rails comprises an electrically charged material. Petition 870250094622, dated 10 / 16 / 2025, pp. 45 / 53 38 / 38 conductive; and wherein the loop comprises a plurality of connection areas. Furthermore, the method includes electrically coupling the busbar to a control module and wherein the control module is configured to electrically couple to a plurality of subsea components by means of the plurality of connection areas.

[0084] The method of any previous claim, further comprising coupling a plurality of inductive couplers to a plurality of connection areas.

[0085] The method of any previous claim, wherein the provision of the support surface coupled to the plurality of rails comprises the formation of an insulating layer on the plurality of rails.

[0086] The above discussion is merely illustrative of the principles and various embodiments of the present disclosure. Although certain embodiments have been shown and described, modifications thereof may be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only and are not intended to be a limiting factor. In this sense, the scope of protection is not limited by the description set forth above but is limited only by the claims that follow, in that scope, including all equivalents of the subject matter of the claims. Petition 870250094622, dated 10 / 16 / 2025, pp. 46 / 53

Claims

1 / 3 CLAIMS 1. System, characterized in that it comprises: subsea equipment having a support surface; a busbar comprising a plurality of rails coupled to the support surface, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the plurality of loops comprises a plurality of connection areas; at least one insulating layer disposed over the support surface to insulate the plurality of rails; and a control module electrically coupled to the busbar, wherein the control module is configured to electrically couple to a plurality of subsea components by means of the plurality of connection areas.

2. System according to claim 1, characterized in that it further comprises one or more inductive couplers electrically coupled to a portion of the plurality of connection areas; or in which rails of the plurality of rails are parallel to each other.

3. System according to claim 1, characterized in that the plurality of handles comprises a circular handle, a rectangular handle, an oval handle, an irregularly shaped handle, or any combination thereof.

4. System according to claim 1, characterized in that the plurality of subsea components comprises one or more electric actuators.

5. System according to claim 4, characterized in that one or more electric actuators comprise an integral battery.

6. System according to claim 4, characterized in that the submerged components comprise one or more valves, wherein one or more electric actuators are configured to adjust a position of one or more valves. Petition 870250073193, dated 19 / 08 / 2025, page 19 / 25 2 / 3 7. System according to claim 1, characterized in that the plurality of subsea components is coupled to the subsea equipment; or in which the plurality of subsea components comprises at least one of flow control equipment, subsea fluid injection systems, pumps or a combination thereof; or in which the subsea equipment comprises at least one of a wellhead, a subsea tree, a distribution manifold, a substation or a combination thereof; or in which at least one insulating layer comprises a first insulating layer formed integrally on the support surface over the plurality of rails.

8. System, characterized in that it comprises: a support surface; a busbar comprising a plurality of rails coupled to the support surface, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the loop comprises a plurality of connection areas; at least one insulating layer disposed over the support surface to insulate the plurality of rails; a control module electrically coupled to the busbar; and a plurality of inductive couplers disposed in at least one insulating layer and electrically coupled to the busbar.

9. System according to claim 8, characterized in that the plurality of inductive couplers comprises a plurality of pairs of first and second coil portions that coincide with each other.

10. System according to claim 9, characterized in that the plurality of pairs of first and second coil portions comprises a female double coil portion and a male double coil portion, wherein the male double coil portion includes a plurality of pins which, when in a combined position, are arranged through at least one insulating layer and in contact with the plurality of rails.

11. System according to claim 8, characterized in that the support surface comprises a substantially planar rigid surface; or wherein the support surface is coupled to a subsea tree.

12. System according to claim 8, characterized in that it further comprises a plurality of sensors, actuators or a combination thereof electrically coupled to the plurality of rails by means of the plurality of inductive couplers.

13. A method characterized in that it comprises: providing a support surface; coupling a busbar to the support surface, wherein the busbar comprises a plurality of rails, wherein the plurality of rails extends along the support surface to form a plurality of loops, wherein the plurality of rails comprises an electrically conductive material; and wherein the loop comprises a plurality of connection areas; and electrically coupling the busbar to a control module, wherein the control module is configured to electrically couple to a plurality of subsea components by means of the plurality of connection areas.

14. Method according to claim 13, characterized in that it further comprises coupling a plurality of inductive couplers to a plurality of connection areas.

15. Method according to claim 13, characterized in that providing the support surface coupled to the plurality of rails comprises forming an insulating layer on the plurality of rails. Petition 870250073193, dated 08 / 19 / 2025, p. 21 / 25

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