Modular Feedthrough Connector for Subsea Pressure Testing
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Solution Overview
Problem
Subsea wet-mate connectors face challenges in pressure testing due to rapid gas decompression issues, which can damage elastomeric diaphragms and require costly replacement, often necessitating the omission of pressure tests or using workarounds that compromise reliability.
Innovation Solution
The subsea plug connector is designed with multiple, separable sections using cold separable joint elements, allowing the plug front end to be removed during pressure testing without compromising pressure retention, and assembled topside before deployment, utilizing cold connections like screw threads, spring latches, or flexible joints for easy assembly and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure testing is performed on subsea wet-mate connectors, then connector reliability is improved, but elastomeric diaphragms are damaged due to rapid gas decompression
Solution Approach 1:
The connector is divided into separate sections: a pressure-testable section (receptacle and part of plug body) and a non-pressure-testable section (front end with elastomeric diaphragm). This segmentation allows pressure testing to be performed on the robust metallic portions without subjecting the delicate elastomeric diaphragm to damaging rapid decompression, thereby maintaining both reliability and protecting vulnerable components.
Solution Approach 2:
The front end containing the elastomeric diaphragm is extracted or removed from the pressure testing process. The connector is designed so that the front end can be separated or excluded from the pressure test zone, allowing the main body to be thoroughly tested while the sensitive diaphragm remains protected from harmful rapid gas decompression.
2Object-affected harmful factors
If pressure testing is omitted to protect elastomeric diaphragms, then diaphragm damage is avoided, but connector reliability cannot be verified
Solution Approach 1:
The testing process is segmented into two parts: the pressure-testable metallic sections undergo comprehensive pressure testing to verify reliability, while the non-pressure-testable front end with the elastomeric diaphragm is protected from testing. This allows reliability verification of the critical pressure-bearing components without exposing the diaphragm to damaging conditions.
Solution Approach 2:
Different parts of the connector have different testing requirements. The metallic body portions are designed for pressure testing to verify reliability, while the front end with the elastomeric diaphragm is designed with local quality characteristics that make it suitable for protection rather than pressure testing. This local differentiation allows simultaneous achievement of reliability verification and diaphragm protection.
3Ease of manufacture
If the connector is designed as a single integral unit, then manufacturing is simplified, but replacement of damaged parts requires complete connector replacement
Solution Approach 1:
The connector is segmented into modular sections (front end, middle section, rear end) that can be manufactured separately and assembled. This segmentation enables selective replacement of only the damaged portion rather than the entire connector, significantly reducing repair costs and complexity while maintaining manufacturing efficiency through standardized modular components.
Solution Approach 2:
The modular design allows the intact portions of the connector to be recovered and reused after only the damaged section is replaced. Instead of discarding the entire connector, the functional sections remain in service, reducing waste and replacement costs while maintaining ease of manufacture through standardized modular units.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A subsea plug connector part (9) for a subsea wet-mateable connector comprising a receptacle connector part (8) and a plug connector part (9), the plug connector part comprising a plug back end (11), a plug front end (13) and an interface (12). The interface comprises a first cold separable joint element (20) at one end. The plug front end (13) comprises a second cold separable joint element (18). The first cold separable joint element (20) and second cold separable joint element (18) are adapted to join the interface (12) to the plug front end (13).