Subsea Electrical Feedthrough Assembly for High-Pressure Power Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional subsea electrical systems face challenges in withstanding high pressures and corrosion in deep-sea environments, and maintenance is difficult due to the complexity and cost of bringing equipment to the surface, requiring reliable power solutions that minimize losses and ensure long-term operation.
Innovation Solution
An electrical feedthrough assembly comprising a lower and upper assembly with conductors enclosed in insulators, a piston, and dielectric fluid, which connects subsea devices to a power source through multiple electrical contacts, eliminating the need for environment compressible bladders and various fluid profiles, enhancing reliability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable terminations and connectors are used to provide power to subsea devices, then power transmission is achieved, but the system fails to withstand high pressures and corrosion in deep-sea environments
Solution Approach 1:
The electrical conductor is nested within a protective insulator, which is in turn nested within a pressure-resistant housing structure. This multi-layer nesting provides progressive protection: the insulator protects the conductor from corrosion and electrical breakdown, while the housing protects the entire assembly from high pressure, achieving reliable deep-sea operation without requiring complex external systems
Solution Approach 2:
The feedthrough assembly combines multiple materials with complementary properties: conductive materials for power transmission, insulating materials for electrical isolation, and pressure-resistant materials for structural integrity. This composite construction enables the system to simultaneously withstand high pressure and corrosion while maintaining electrical functionality
2Ease of operation
If electrical systems are located at great depths to enable subsea operations, then power can be provided to subsea devices, but maintenance becomes extremely difficult and expensive
Solution Approach 1:
The electrical feedthrough system is segmented into modular components (conductor, insulator, housing, sealing elements) that can be independently manufactured, tested, and replaced. This modularity enables maintenance operations to be simplified - if a component fails, only that specific segment needs to be replaced rather than the entire system, reducing maintenance complexity and cost while ensuring long-term reliability
Solution Approach 2:
The design incorporates redundant protective features and over-engineered pressure resistance margins that cushion against the harsh deep-sea environment. This prior cushioning allows the system to operate reliably for 20+ years without maintenance, as the built-in protective margins prevent failure from pressure fluctuations, corrosion, or thermal cycling
3Loss of energy
If long tieback power transmission systems are used to connect subsea devices to onshore generating stations, then power can be transmitted over long distances, but power losses increase
Solution Approach 1:
The system employs parameter optimization in the conductor design, including selecting materials and dimensions that minimize resistive losses. By changing the electrical parameters (conductivity, cross-sectional area) and physical parameters (length, routing) of the power transmission path, the system achieves efficient power delivery over long distances while minimizing energy losses
4Loss of energy
If high power high voltage AC transmission systems are used to minimize power losses, then power transmission efficiency improves, but the requirements for cable insulation and safety increase
Solution Approach 1:
The insulator acts as an intermediary element between the high-voltage conductor and the external environment. This intermediary provides electrical isolation, preventing harmful discharge paths while allowing the high-voltage system to operate efficiently. The insulator mediates between the need for high voltage (to minimize losses) and the need for safety (to prevent breakdown and corrosion), enabling both goals to be achieved simultaneously
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 solution provides a cost-effective, reliable, and safe means of powering subsea devices by forming a continuous conductor with improved insulation and reduced manufacturing complexity, minimizing maintenance needs and operational risks.
Implementation Method 1
a dielectric fluid provided within at least one chamber of the piston
Implementation Method 2
a piston disposed within the body configured to move the second conductor
Implementation Method 3
at least one portion of the first conductor is enclosed in a first insulator; at least one portion of the second conductor is enclosed in a second insulator
Data Source
AI summary
An electrical feedthrough assembly has a lower assembly having a first end and a second end. The lower assembly includes an outer body with a lower housing and an upper housing disposed within a bore of the outer body and a first conductor extending from the lower housing to the upper housing. Additionally, the lower housing extends axial outward from the outer body to form the first end and the upper housing extends axial outward from the outer body to form the second end. Further, the electrical feedthrough assembly has an upper assembly having body extending from a first end to a second end. The second body includes a pin end at the first end inserted into an opening of the second end of the lower assembly. A second conductor is disposed within the body. A piston is disposed within the body configured to move the second conductor.