Subsea Electrical Connector Leak-Proof Sealing Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Subsea electrical connectors frequently fail due to exposure to underwater currents and saltwater, leading to leakage and connectivity issues, especially in applications like subsea pumps where elimination is impractical.
Innovation Solution
A subsea electrical connector design featuring molded seals, an interference fit pin/receptacle seal, and angled seating surfaces, along with automatic alignment and secure fastening mechanisms to prevent improper connection and ensure leak-proof performance under severe conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If subsea electrical connectors are used to connect cables in subsea applications, then electrical connection is enabled, but the connector fails with high frequency due to underwater currents and saltwater exposure
Solution Approach 1:
The connector is divided into separate male and female components that can be assembled onshore and then connected subsea. This segmentation allows the sealing interfaces to be protected from direct saltwater exposure during connection, reducing the harmful effects of saltwater and currents on the sealing surfaces.
Solution Approach 2:
A cable connector assembly acts as an intermediary component between the cable and the subsea environment. The connector includes sealing elements and protective structures that mediate between the electrical connection function and the harsh subsea conditions, preventing saltwater ingress while maintaining electrical connectivity.
2Reliability
If subsea electrical connectors are eliminated to avoid failure, then connector failures are reduced, but cable handling and installation become extremely difficult due to cable weight and motor size
Solution Approach 1:
The electrical connection system is segmented into modular components (cable connectors, motor connectors, cable assemblies) that can be prepared separately onshore. This allows the heavy cable and motor to be handled in manageable sections during installation, improving ease of operation while maintaining system reliability through proper sealing design.
Solution Approach 2:
The cable connectors are assembled and sealed onshore before subsea deployment. This preliminary action allows the sealing interfaces to be protected from saltwater exposure during the difficult cable handling and installation operations, enabling easier operation during installation while maintaining reliability during subsea operation.
3Ease of manufacture
If traditional connector designs are used, then manufacturing is simpler, but sealing performance fails under stress from ocean currents
Solution Approach 1:
The sealing design incorporates dynamic elements that can accommodate movement and stress from ocean currents. The connector includes flexible sealing elements and stress-relief features that maintain sealing performance under dynamic loading conditions while remaining manufacturable using standard processes.
Solution Approach 2:
The connector utilizes composite construction with different materials optimized for specific functions: sealing materials for water tightness, structural materials for current resistance, and conductive materials for electrical connection. This composite approach maintains ease of manufacture through modular assembly while achieving superior seal performance under current stress.
Data Source
AI summary
A subsea electrical connector for connecting a first cable and a second cable. A first insulator has an outer face, possibly an inner face, and a pin portion transverse to the outer face. A second insulator has a mating outer face, an inner face, and a pin receptacle. At least one face seal ring is positioned between the first insulator outer face and the second insulator outer face. At least one pin seal ring is positioned between the pin portion and the pin receptacle. Preferably, an interference fit is provided between the pin and pin receptacle. A preferred seating angle seal has an angled surface adjacent the end of the pin portion and within the pin receptacle. First and second electrical connectors are mounted within the first insulator and the second insulator. The first and second metal electrical connectors each have a socket for receiving the first and second cables. A preferred embodiment includes receptacles for the fasteners with stop members, which limit the relative rotation to align the fasteners with the receptacles.