Subsea Cable Water Barrier Coating Using Thermal Spraying
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Solution Overview
Problem
Conventional subsea cables use lead sheaths for water barriers, which are wasteful, slow, and dangerous, and the industry seeks alternatives due to environmental concerns, necessitating more efficient and safer methods for forming water barrier layers.
Innovation Solution
Thermal spraying techniques are used to apply metal or polymer coatings to form water barrier layers, allowing for thinner, lighter, and faster cable preparation and repair, enabling the use of alternative materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wiping or lead extrusion methods are used to form water barrier layers, then the water barrier can be formed with traditional materials, but the process is time-consuming, resource-wasteful, and dangerous
Solution Approach 1:
The patent replaces the mechanical lead wiping/extrusion process with a thermal spraying system that deposits metal particles onto the cable surface. This substitution eliminates the need for manual manipulation of molten lead and enables automated, high-speed water barrier formation while maintaining protective effectiveness.
Solution Approach 2:
The patent changes the physical state and application parameters of the water barrier material from molten lead requiring manual wiping to thermally sprayed metal particles that form a coating rapidly. This parameter change enables automated processing and significantly increases production speed while reducing material waste.
2Reliability
If lead wiping method is used to form water barrier layers, then the water barrier can be formed, but the coating is thicker and increases cable weight and bulk
Solution Approach 1:
The thermal spraying process enables precise control of coating thickness and material distribution, creating a water barrier with optimized local properties. The coating can be applied uniformly at controlled thicknesses, providing adequate protection while minimizing unnecessary material and weight.
Solution Approach 2:
Replacing the mechanical lead wiping process with thermal spraying allows for more precise control over coating application, resulting in thinner, more uniform water barrier layers that reduce cable weight while maintaining protective functionality.
3Reliability
If lead wiping method is used to form water barrier layers, then the water barrier can be formed, but the process is resource-wasteful
Solution Approach 1:
The automated thermal spraying system replaces manual lead wiping, enabling precise control over material deposition. This substitution significantly reduces material waste by applying only the necessary amount of coating material without the excessive material use characteristic of traditional wiping methods.
Solution Approach 2:
The thermal spraying process is self-regulating in terms of material deposition, with the coating application automatically controlled by the spray system parameters. This eliminates the material waste associated with manual wiping where experienced technicians are needed to minimize waste.
4Reliability
If lead wiping method is used to form water barrier layers, then the water barrier can be formed, but the process is dangerous for cable engineers
Solution Approach 1:
The patent replaces the dangerous manual process of handling molten lead with an automated thermal spraying system. This substitution eliminates direct human exposure to high temperatures and molten metal, removing the safety hazards associated with traditional lead wiping while maintaining water barrier effectiveness.
Solution Approach 2:
The thermal spraying system acts as an intermediary between the water barrier material and the cable, enabling protective coating application without requiring direct human contact with hazardous materials. This intermediary system preserves worker safety while achieving the same protective function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Thermal spraying provides a time- and resource-efficient method for forming water barrier layers, reducing cable weight and bulk, and enabling quicker cable return to service, while allowing the use of materials other than lead.
Implementation Method 1
forming a water barrier layer that surrounds a length of the cable assembly, wherein the water barrier layer comprises at least one coating of a metal material applied using a thermal spraying technique
Data Source
AI summary
A method for forming a subsea cable or a joint for a subsea cable is provided including providing a cable assembly that has at least a first conductor and a first insulation system surrounding the first conductor and forming a water barrier layer surrounding a length of the cable assembly. The water barrier layer has at least one coating of a metal material applied using a thermal spraying technique. A joint and a subsea cable obtainable by the above method is also provided.