Subsea Conductor Contact Tip With Compressible Sleeve
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Solution Overview
Problem
Existing subsea contact tips for connecting electrical conductors are not suitable for use with ROV tools, often resulting in uneven surfaces and water accumulation due to their design, which fails to meet interface tolerance requirements and is not adapted for underwater environments.
Innovation Solution
A smooth male contact tip design featuring a tapered sleeve and contact tip with a compressible section, where the contact tip's inner surface compresses the sleeve to securely engage the conductor, providing a seamless transition and minimizing water accumulation, utilizing materials like Alloy 625 or bronze alloys for connection elements and copper for the sleeve and tip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional crimping ferrule or contact sleeve is used above sea level, then the conductor tip can be prepared for jointing, but the surface becomes deformed and uneven, failing to meet interface tolerance requirements
Solution Approach 1:
The contact tip is divided into two separate components: a sleeve that receives the conductor and a contact tip portion that interfaces with the connector. This segmentation allows each component to be optimized independently - the sleeve can be crimped for secure conductor attachment while the contact tip portion maintains a smooth, precision-machined surface for interface compatibility
Solution Approach 2:
Different parts of the contact tip assembly have different surface qualities tailored to their specific functions. The sleeve portion has a crimped, textured surface for mechanical grip on the conductor, while the contact tip portion has a smooth, precision-finished surface for electrical and mechanical interface with the connector, ensuring both secure attachment and interface tolerance compliance
2Reliability
If a subsea connector contact with gripping fingers is used, then the conductor can be secured, but the diameter is considerably larger than the cable, creating an uneven surface and open spaces for water accumulation
Solution Approach 1:
The sleeve is inserted into the contact tip portion, creating a nested configuration where the conductor-securing sleeve is contained within the smooth-diameter contact tip. This nesting allows the gripping function to be maintained while the outer diameter is controlled by the contact tip portion, ensuring a flush interface with the connector and eliminating open spaces where water could accumulate
Solution Approach 2:
The sleeve acts as a flexible element that can be compressed by the contact tip portion to grip the conductor securely. This flexible component allows for reliable conductor securing through deformation and compression, while the rigid contact tip portion maintains a precise outer diameter that matches the connector interface, preventing water ingress
3Ease of operation
If a contact tip designed for ROV tool installation is used, then underwater installation is enabled, but the structure must be simplified for ROV manipulation
Solution Approach 1:
The contact tip assembly is segmented into a sleeve and a contact tip portion that can be assembled in sequence. This segmentation allows the sleeve to be prepared on the conductor first, followed by attachment of the contact tip portion, creating a modular assembly that is easier to manipulate and install with ROV tools compared to a single complex integrated component
Solution Approach 2:
The sleeve is pre-assembled onto the conductor end before the contact tip portion is attached. This preliminary action simplifies the overall installation process by separating the conductor preparation step from the final connector interface step, allowing each to be optimized and executed independently during ROV-operated subsea installation
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
The design allows for secure, seamless engagement of conductors by ROV tools, ensuring a smooth surface transition and minimizing water ingress, suitable for subsea environments and in situ repair of direct heating cables, while maintaining structural integrity and ease of assembly.
Implementation Method 1
the contact tip comprises a tapered surface inside the opening adapted to compress the compressible section of the sleeve when the contact tip surrounds the sleeve
Data Source
Figure 1~3
Figure 4
Figure 5a~6
AI summary
Conductor contact comprising a sleeve (2) with an opening adapted to receive a free end (1) of a conductor, a contact tip (3) with an opening (35) adapted to receive the sleeve (2), wherein the sleeve (2) comprises a tapered outer surface (21) on a compressible section surrounding said opening, wherein the contact tip (3) comprises a tapered surface inside the opening adapted to compress the compressible section of the sleeve when the contact tip surrounds the sleeve (2), and an outer smooth surface (34).