High Horsepower Subsea 14

Diamould Ltd 1

EuALF 28-Feb-08

Development of a downhole wet-mateable Power

Connector for the worlds first wireline retrievable

ESP system

Stuart Parkinson

Product Line Manager Instrumentation and Fibre Optics

Diamould Ltd

Diamould Ltd 2

EuALF 28-Feb-08

Developed during 2002 for Shell

5kV x 125A single-phase downhole wet connector

Receptacle connector installed permanently downhole for life of well

Plug connector mounted in pump module which is retrievable

Seapower-01

Diamould Ltd 3

EuALF 28-Feb-08

Seapower-01

Plug connector downwards facing

Receptacle connector upwards

facing

Angular profile for debris control

Diamould Ltd 4

EuALF 28-Feb-08

Seapower-01 Technical Challenges

Mechanical and electrical packaging within 1.9" diameter

Elimination of electrical stress within connector - 10 years downhole

Environmental conditions and effect upon product functionality

Debris management

Elimination of fluid ingress

High quality injection mouldings without air voids

Connector mating sequence and alignment

Diamould Ltd 5

EuALF 28-Feb-08

High quality void free injection mouldings

Use of Moldflow at design stage and PD testing at FAT stage

Seapower-01 Technical Solutions

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Elimination of electrical stresses

Solution - electrical FEA and use of metallized surfaces

Aim to achieve smooth electrical field and stress below 3kV/mm

Seapower-01 Technical Solutions

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Principles used on Seapower-01 have been carried through to future

power developments

Design validation using electrical FEA and Moldflow - reduces

iterations at qualification level

Focus on quality at component and assembly level

Developed the metallization theory to new field smoothing

techniques at higher voltages

Seapower-01 Summary

Diamould Ltd 8

EuALF 28-Feb-08

Development and field trials of a High Power

Connector system for deepwater ESP applications

Adam Kendall

Product Line Manager Power and Hydraulic Connectors

David Bissett

Lead Designer for Seapower-02

Diamould Ltd

Diamould Ltd 9

EuALF 28-Feb-08

8kV x 220A 3-Phase Wet-Mate Connector

Seapower-02

Tubing

Hanger

Receptacle

Connector

Diamould Ltd 10

EuALF 28-Feb-08

Seapower-02 Receptacle Connector

Previous Technology:

1. Exposed male Contacts; corrosion and potential contamination or

damage to male Insulators can result

2. Male Contacts are not guided; can bend

Technological Advancements:

Pressure compensating, enclosed oil system around male

Contacts

Male Pins are positively located in a moving Wiper Plate, limiting

deflection

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EuALF 28-Feb-08

Seapower-02 Plug Connector


3. Debris around end of male Pin Contact introduces contaminants

during connector mating


A Capture Lip Seal in the Shuttle Pin holds water and debris

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EuALF 28-Feb-08

Seapower-02 Plug Connector

Capture Lip Seal

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Seapower-02 Mating Connectors


4. Stress gradient through front Connector Plate can induce surface

tracking


Front sealing system in male Wiper Plate (Receptacle Connector)

forms seal with front of mating Plug Connector during mate & de-

mate, reducing voltage field stress levels

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EuALF 28-Feb-08


Flange Mounted Receptacle Mating ROV Plug

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5. Contact stack-up tolerance is restrictive; often a dead-length

(i.e. zero)


Sliding Contact design improves stack-up capability (+/- 0.5 for

Seapower-02) and voltage field

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Seapower-02 Features


6. No electrical stress control for Insulators passing through metallic

housings, resulting in high discharge levels


Insulators passing through bulkheads are Metallized, preventing

discharge, particularly around O-ring grooves where trapped air is

prevalent

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Metallized

Contact Insulator

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7. Cable termination design is also prone to discharge


New Termination Sleeve system incorporates bonded field smoothing tube and pressure compensation element

Use of multiple layer moulding techniques, with different compounds and dissimilar relative permittivity values, to encourage electrical stress grading (smoothing of field)

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EuALF 28-Feb-08


Termination Sleeve and bonded field smoothing tube

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Grommet Seal (an example of multiple layer moulding)

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Seapower-02 TH Receptacle Connector


8. Lower TH termination to ESP cable is vulnerable in the event of

downhole rapid gas decompression


Cable Boot Seal is adequately supported / constrained by

Housing and Support Plate to prevent permanent damage;

successfully passed 2,000psi pressure drop over 2 minutes

Diamould Ltd 22

EuALF 28-Feb-08

Rapid Gas Decompression

Damage to ESP cable outer

jacket and TH Connector

elastomer components

Gas damage to outer jacket of

ESP cable; internal view detailing

gas ingress bubbles

What can go wrong?

Diamould Ltd 23

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9. No metal sealing barrier inside TH Connector; elastomer O-rings with PTFE back-up rings between Contact Insulator and Connector Housing


Contact Insulators have integral metallic stress control collar,which is EB welded into connector housing; successfully passed PR2 testing to API-6A, under varying conditions of pressure and temperature

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View of Contact Insulators

detailing stress control

collars and electron beam

welds; acts as PR2 gas

barrier

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Seapower-02 TH Dry-Mate Plug Connector


Field installable lower TH dry-mate plug connector, with pre

vacuum gel-filled sealing and pressure compensation system;

cable termination can be performed offshore and is repeatable

Diamould Ltd 26

EuALF 28-Feb-08

Seapower-02 TH Dry-Mate Plug Connector

Lower TH dry-mate Plug Connector terminated to ESP Cable

Is capable of accommodating flat and round ESP cables, up to

size 2/0 AWG

Diamould Ltd 27

EuALF 28-Feb-08

Petrobras Installations

Jubarte &

Golfinho field

trials (permanent

installations);

mudline is at

around 1,500m

water depth

Diamould Ltd 28

EuALF 28-Feb-08


Custom-built long-neck

ROV Tree Cap

Connectors, Power and

Instrumentation,

successfully deployed

on the Jubarte 6 field

Diamould Ltd 29

EuALF 28-Feb-08


Jubarte 2 Vertical

Connection Module

prior to deployment

offshore

Diamould Ltd 30

EuALF 28-Feb-08

Thank you!

Should you have any queries, do not hesitate to contact:

Adam Kendall, Product Line Manager

David Bissett, Lead Designer for Power Connectors

Mike Winfield, Sales & Marketing Manager

Please go to www.diamould.com

High Horsepower Subsea 14

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