This application claims the benefit of United Kingdom Application Nos. GB 2103663.7, GB 2103664.5, GB 2103666.0, GB 2103667.8, GB 2103668.6, GB 2103669.4 all filed on 17 Mar. 2021, and all incorporated by reference herein in their entirety.
This invention relates to a subsea, or underwater, connector.
Subsea, or underwater, connectors are designed to operate beneath the surface of the water. Typically, a subsea connector comprises two parts, generally known as plug and receptacle. The receptacle may include one or more conductor pins and the plug may include corresponding plug sockets for the receptacle conductor pins. The connection may be made topside (dry-mate), or subsea (wet-mate) and the specific design is adapted according to whether the connector is a wet-mate or dry-mate connector. Subsea connectors have various applications including power connectors which supply power to subsea equipment, or control and instrumentation connectors which exchange data between different pieces of subsea equipment, or between subsea equipment and topside devices.
In accordance with a first aspect of the present invention, an ROV, diver, or stab, wet mateable connector plug front end housing, the housing comprising a housing front section; a locator mount section; and a seal section axially in series with one another; wherein the housing front section comprises a plug coarse alignment feature on an outer surface of the housing front section, adjacent to a front surface of the housing front section and radially outward of a central axis of the housing; a circumferential groove on the outer surface of the housing front section, axially displaced from and rearward of the coarse alignment feature; wherein the plug coarse alignment feature comprises a bullnose feature; wherein the groove is adapted to receive a latch of an ROV or diver wet-mateable connector receptacle front end housing; and wherein a plug fine alignment feature is formed in the outer surface of the housing front section, aligned with and located radially outward of the central axis of the housing.
The plug front end housing is suitable for any of the ROV, diver or stab wet mateable connectors, with a groove adapted to receive a latch when the front end housing is used for an ROV wet mateable connector, and optionally when used for a diver wet mateable connector, although not for a stab wet mateable connector. However, by standardising features such as the groove, which is there for all the connector types, just not functioning for some, then manufacturing and supply is simplified and overall costs reduced.
The bullnose feature may comprise a series of three truncated cones, the first and third of the cones comprising substantially congruent faces, the first and second cones being joined at their maximum diameter and the second and third cones being joined at their minimum diameter.
The plug fine alignment features may comprise a longitudinal groove forming a keyway.
The plug housing front section may comprise one or more fluid outlets, toward the rear end of the housing front section.
In accordance with a second aspect of the present invention, an ROV, diver, or stab, wet mateable connector receptacle front end housing comprises a housing front section; a locator mount section; and a seal section axially in series with one another; wherein the housing front section comprises a receptacle coarse alignment feature on an inner surface of the housing front section, adjacent to a front surface of the housing front section and radially outward of a central axis of the housing; wherein the receptacle coarse alignment feature comprises a lead in chamfer; the housing further comprising a latch for an ROV or diver wet matable connector, on the inner surface of the housing front section, axially displaced from and rearward of the coarse alignment feature, the latch being adapted to cooperate with a groove of an ROV or diver wet-mateable connector plug front end housing; and a receptacle fine alignment feature formed in the outer surface of the housing front section.
The receptacle fine alignment feature may comprise a through hole.
The receptacle fine alignment feature may further comprise a key mounted in the through hole.
The seal section may comprise one or more barrel seals.
The mounting section may comprise one or more holes, for example through holes, or blind holes, adapted to receive fasteners.
The holes may comprise threaded or smooth inner surfaces.
The fasteners may comprise screws, bolts or pins and the inner surface is adapted accordingly.
The receptacle housing front section may comprise one or more fluid outlets, toward the rear end of the housing front section.
In accordance with a third aspect of the present invention, a wet mateable connector comprises a plug part and a receptacle part; the plug part comprising a plug front end housing according to any preceding claim; a plug front end body comprising electrical pins; a connector plug mount and a connector plug back end housing; the receptacle part comprising a receptacle front end housing according to any preceding claim, a receptacle front end body comprising electrical contacts; a connector receptacle mount and a connector receptacle back end housing.
An example of a subsea connector and associated method in accordance with the present invention will now be described with reference to the accompanying drawings in which:
The drive to reduce overall lifecycle costs, both capital expenditure (CAPEX) and operational expenditure (OPEX), associated with new deep-water oil and gas developments means that improvements to existing designs, manufacturing processes and operation are desirable. Subsea connector systems are desired that have a lower cost, can be relatively quickly and easily installed and that have reduced maintenance requirements, or need for intervention which affects the systems to which they are connected throughout their working life. Thus, connectors which continue to perform without degradation, over a longer period of time, are desirable.
Typically, connectors for different applications may be single or multi-way connectors. For example, a 4-way connector may be used for delivering power, or a 12-way connector for data transfer via a suitable subsea instrumentation interface standard. This may be level 1, for analogue devices, level 2 for digital serial devices, e.g CANopen, or level 3. using Ethernet TCP/IP. Other data connectors, include optical fibre connectors. Wet mateable controls connectors typically have large numbers of thin conductor pins, in order that multiple control signals to different parts of a product can be included in a single control cable. For example, multiple subsea sensors on different pieces of equipment, such as flow sensors, temperature sensors, or pressure sensors each need to have a separate communication path, so that they can be interrogated, monitored and if necessary actuators can be energised, for example to open or close a valve, or to start or stop a pump. Power transmission may be required for the purpose of supplying power to subsea equipment to enable it to operate, for example to close a valve, or drive a pump. Wet mateable power connectors may have a single pin and socket arrangement, or may be multi-way connectors, but typically with fewer, larger, pins than a control or communications connector.
In a subsea wetmate connector comprising a plug and a receptacle in which the receptacle is mounted to already installed equipment or cable, the mating is typically carried out by an ROV or diver, subsea, bringing the plug into contact with the receptacle. With many connector options, such as ROV, diver, or stab wet mateable connectors, each with variations in the bodywork design and interfaces for ancillary components, it is not possible to build to a connector level without knowing the customer's full requirements. If a customer requirement changes, such as the connector type changing, this may result in a rebuild as it may not be possible to configure a fixed ROV connector into a Stab plate connector, for example. With the restrictions imposed by such a design, alterations can be costly and impact delivery schedules as well as product costs.
Conventionally, as illustrated in
Cost pressures on suppliers of subsea connector systems to produce connectors which deliver the same, or better, operational capabilities, at a reduced cost for each product, have largely been addressed to date, by finding a balance between maintaining enough stock to fulfil orders, without overstocking which can result in a large number of components requiring rework if necessary changes are made to a part design. With many variants of connectors available, and with multiple mating methods, for example, the ROV, diver and stab types described above, overheads are kept to a minimum by keeping stock levels relatively low for connector bodies and ancillary components, but as a result, it is difficult to reduce the manufacturing cost per part, as few are made in each batch. As described above, each type of wet mate connector, ROV, stab and diver, has a different body and different parts on those bodies. For example, a latch indicator 8 is provided on an ROV body 6, so that the completeness of the mate can be checked remotely. However, a latch is not needed on a stab plate, as this type of mate cannot be only partially mated because the connectors are positioned on the Stab plate at the correct height so that when the plates are mated, the connectors mate fully. With a diver mate, the plug body has a threaded ring to lock to the receptacle because for a 12 way variant, the accumulative spring force makes it more difficult to mate by hand in the manner that an ROV would. It is also important to control a demate, so that the diver is not injured during the operation. The threaded ring makes the mate easier as well as controlling the demate. ROV and stab mates do not need the threaded ring because ROVs are able to mate with greater force, and there is no risk to personnel during a demate. STAB mate and demate is controlled by the coming together of the plates. The plates are fixed together, and subsequently the connectors cannot move until the plates are parted. The consequence of all these different variants in the components that make up each type of mate body is that it is costly to have all the components in stock, to cover all the options.
The present invention aims to reduce costs and stocking levels, as well as simplifying the supply chain. This problem is addressed by amalgamating all the required features into a single body which can be used by any mate type. As can be better understood from the description hereinafter, a universal interface body for plug and receptacle, having a single front end for all mate types and the same housing body form, or metalwork, is provided. This universal interface may then be customised by adding features to the standard body, if required. This is illustrated in the examples of
Thus, the design provides a standardised plug front end 70 and receptacle front end 80, which are adapted to be configured to the different mate types. The single plug and receptacle bodies incorporate the features needed by any of the mate types, rather than the conventional arrangement of having type specific bodies with only type specific features. The bullnose feature 71, previously only used for an ROV mate is provided as standard for all three connector types as is the fitting for a latch, previously not used for a stab mate. A key and keyway, as well as a mount location towards the rear end of each of the plug and receptacle bodies are provided as standard. For the stab mate, the latch would not be fitted, during assembly, as it is not needed, although the standardised housing is able to take a latch. This avoids unnecessary increases in the part count for the stab mate. Grooves, opening and screws are all put in the same specific places for all mate types. The diameters of various parts of the bodies may be standardised, rather than there being diver, stab and ROV specific body diameters. Although some aspects of the manufacturing may appear to increase costs, the standardisation allows economies of scale that were not possible with the type specific bodies, leading to an overall cost reduction across all the mate types.
The connectors typically comprise a corrosion resistant alloy, suitable for subsea applications, such as stainless steel, super duplex or titanium. Titanium is the most expensive of these. Super duplex has greater mechanical strength than stainless steel, so wall thickness can be reduced relative to a stainless connector or plastics. Typically, the alloy is machined to the desired shape, as the components have tight tolerances, which can be achieved by machining without the need for secondary steps, with their associated delay and cost. Methods such as casting require secondary operations to bring the parts to the required specification, which adds costs to the manufacturing process that are only recovered in high volume products. Production of subsea suitable components is relatively low volume compared to engineering products in general.
For both plug and receptacle, the backend may also be standardised. As illustrated in
By providing a universal interface, and combining the features of ROV, stab plate, and diver mated connectors into one connector housing, components can be purchased in significantly larger quantities than before. By purchasing larger part quantities, price breaks can be met, and the overall connector cost is reduced. By offering a standard interface for the connector bodywork, changes can be accommodated more easily and the impact on lead times can be reduced. A single change to the bodywork, no longer requires updates to multiple assemblies, drawings and associated documentation.
A further simplification is to choose the connector size to house a maximum number of contacts, typically 12 contacts, rather than having series variants of different sizes, such as smaller bodies for 4way, or 7way, than for 12way options. Only as many contacts as are required in the application are used, but each housing can accommodate a body of a size suitable for the maximum number of contacts. Ancillary components may be chosen to fit to the standard bodies, such as latch indicators or ROV cones and flying backshells for ROV Connectors, or stab mounting plates for STAB connectors, enabling the body to be configured in the same way as in any of the existing connector types. By reducing the number of front end assemblies to the minimum required, larger quantities of the connector body metalwork can be stocked, which reduces per item material cost. Reducing variation and standardizing the front ends across the product range, reduces lead times by streamlining processes and optimizing jigs and fixtures.
While the present invention has been described above by reference to various embodiments, it should be understood that many changes and modifications can be made to the described embodiments. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that all equivalents and/or combinations of embodiments are intended to be included in this description.
The foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention disclosed herein. While the invention has been described with reference to various embodiments, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Further, although the invention has been described herein with reference to particular means, materials, and embodiments, the invention is not intended to be limited to the particulars disclosed herein; rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may affect numerous modifications thereto and changes may be made without departing from the scope of the invention in its aspects.
It should be noted that the term “comprising” does not exclude other elements or steps and “a” or “an” does not exclude a plurality. Elements described in association with different embodiments may be combined. It should also be noted that reference signs in the claims should not be construed as limiting the scope of the claims. Although the invention is illustrated and described in detail by the preferred embodiments, the invention is not limited by the examples disclosed, and other variations can be derived therefrom by a person skilled in the art without departing from the scope of the invention.
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2103663 | Mar 2021 | GB | national |
2103664 | Mar 2021 | GB | national |
2103666 | Mar 2021 | GB | national |
2103667 | Mar 2021 | GB | national |
2103668 | Mar 2021 | GB | national |
2103669 | Mar 2021 | GB | national |
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