The HYDRALIGHT Part Number System can now be found on SEACON’s website. This can be viewed on the HYDRALIGHT products page.
HYDRALIGHT Optical Underwater Mateable Connector Part Number System
The expansion of SEACON’s UK facility began in January 2013 and was completed by July. 8,000 square feet over two stories was added to the building bringing the total square footage of SEACON (europe) Ltd to 32,000. The new build provides a larger stores area, expanded machine shop, new termination and oil filling workshop plus additional space for future growth.
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SEACON (europe) LTD, Great Yarmouth, Norfolk, England
SEACON’s facility in El Cajon, CA, USA also expanded this year with 800 square feet being added to the Sales department. This additional space will also provide room for the growing Project Management and Engineering departments.
SEACON El Cajon, California, USA
In addition SEACON Advanced Products, LLC, of Bellville, TX, USA also underwent growth to their manufacturing plant which included a new 8,550 square foot (285 foot long) Subsea Jumper building which is now fully complete and operational allowing for increased jumper capacity and shorter lead times.
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SEACON Advanced Products LLC, Bellville, Texas, USA
The draw has taken place for the Fortnum and Mason ‘Vintner’ Christmas Wine Hamper and the lucky winner was Danny Watkins of Buckleys.
SEACON would like to congratulate Danny and thank everyone who took the time to enter. In the meantime we wish you a Merry Christmas and a Happy New Year!
Track records have been added to SEACON’s website datasheet page, available in PDF download, under the SEACON Advanced Products, LLC section. These track records give details of units sold and in operation along with other details including applications.
The track records are available for
To view SAPL track records please visit our datasheets page available here.
Please visit our events page to see the forthcoming shows that SEACON will be exhibiting at in 2014.
SEACON Feature in Scandinavian Oil & Gas Magazine – Subsea Electrical and Fibre-Optic Distribution System Integrator
While SEACON is well-known for its highly successful connector solutions and cabled assemblies, in recent years the company has been expanding its capabilities to support the ever growing subsea power and communications distribution market. With primary focus around its qualified underwater-mateable optical and electrical connectors and Pressure Balanced Oil Filled (PBOF) hose conduit, SEA CON has developed a suite of products to provide customers with complete optical and electrical distribution system solutions. In addition to its own product baseline, SEACON also integrates third-party sensors and connectors into the distribution system assemblies.
A key technology within a distribution system is the PBOF hose conduit with industry-standard MKII hose fittings. This elastomeric (such as rubber) conduit not only provides protection for the electrical/fibre-optic lines within a compensating fluid, but also allows external pressure to freely communicate with the interior oil volume, equalising the pressure in the assembly. The stresses and strains encountered during ROV operations are controlled via longitudinal strength members that provide the strength and also limit elongation of the hose.
Jumper Assemblies – hose conduit with optical or electrical connectors at either end
Key elements in both optical and electrical distribution systems are:
• Jumper Assemblies – Hose conduit with optical or electrical connectors at either end.
• Distribution Harness – Can have multiple “legs” with either connectors or sensors terminated to the end of each leg.
• Umbilical Termination Assemblies – Provide the interface between the optical or electrical element of the umbilical and SEACON wetmate connector(s).
• Cable Hang-Offs – Specially designed cable strength member terminations that provide support for the individual cable elements at the top side of some umbilical cables.
• Abandonment Caps or Connectors – When the top side of an umbilical needs to be abandoned subsea for a period, these provide watertight protection of the umbilical cable.
Although many design features make these products successful, highlights for Jumper Assemblies/Distribution Harnesses include:
• Integral fibre management system within the hose to mitigate excessive movement or forces applied directly to the internal fibres or small wire terminations.
• Allow for multiple optic and electrical conductor configurations over shorter lengths, negating the requirement to purchase expensive custom cables.
• Easily repairable in the field.
For Umbilical Termination Assemblies, features of note include:
• Multiple configurations enable interfacing with incoming individual or multiple-cable elements and single or multiple PBOF hose exits.
• Proven and testable penetrators between 1 atmosphere and pressure – compensated chambers.
SEACON 2013 Jumper Assembly Activities
Providing reliable and qualified products is only one prerequisite for being a successful vendor in this market. Another major element is servicing those products. SEACON has succeeded by providing products and services to its global customers primarily from three strategically located regional bases: SEACON Advanced Products LLC (SAPL) Bellville, Texas, USA; SEACON Europe (SCE), Great Yarmouth, United Kingdom; and SEACON Precision Subsea, Notodden, Norway. These locations provide equal capabilities for integration of optical or electrical distribution systems.
While SEACON’s experience in optic integration is well known, the narrative below highlights some recent changes in SEACON’s support for electrical distribution systems.
The Electrical Distribution Group (EDGe) has been formed to fill a need in the subsea electrical distribution market. With an increasing need for a fast turnaround on Electrical Flying Leads (EFLs), umbilical terminations, sensor harnesses and similar equipment, SAPL has added engineering, sales, and technician personnel, as well as inventory to increase capacity for meeting customers’ expanding delivery needs.
SAPL understands the need to support legacy projects in the Gulf of Mexico and around the world. The company has the ability, knowledge and expertise to integrate third-party connectors, sensors and equipment to be used in the subsea theatre.
SAPL recently purchased its fifth pressure vessel for the Bellville, Texas, manufacturing and test facility to increase throughput of Factory Acceptance Test requirements for subsea distribution equipment. The pressure vessel is housed in a new, 285-foot-long building, purpose-built for jumper production. The building allows SAPL to expand its jumper capacity, which can now dedicate more resources for assembly of electrical and optical systems as well as EFLs, Optical Flying Leads (OFLs), harnesses and miscellaneous other assemblies.
SAPL constantly strives to improve and expand its product lines. Its goal is to provide not only standard products but also customised solutions for customers with everchanging requirements. SAPL is ISO-certified and is committed to providing quality products that meet and/or exceed customer expectations. SAPL is also dedicated to providing a safe and healthy working environment for its employees around the world, and encourages the same health and safety conscious actions in their everyday lives.
Quick-fit hose terminations
SCE has been manufacturing hybrid jumper assemblies for over 15 years, supplying a number of OEMs throughout the offshore industry, and currently ships 800 to 900 assemblies per year. Used extensively in the oil and gas market, these assemblies are employed in a variety of applications including subsea trees and electronic modules, and blowout preventers. In addition, optical jumpers are used on ROVs for both military and civilian applications including cameras and high-speed data transfer.
All assemblies are manufactured under SCE’s stringent quality control system. Jumpers are divided between optic and electric hose workshops for termination where experienced technicians begin the assembly process. Upon passing an initial inspection, the jumpers undergo final assembly and helium leak testing before oil filling and final inspection.
Driven by customer demand, SCE has consistently developed and improved the assembly and manufacture of these items by incorporating a number of innovations.
These improvements include:
• Optic termination methods to cope with increased depth requirements.
• Reverse pressure rating for the connector inserts.
• “Distributor type” boot sealing on the electrical terminations to provide complete integrity in the event of damage to the jumper hose.
• Development of a quick-fit hose termination system.
SCE’s expertise, consistent quality, and excellent delivery track record (for example, currently 95% on time with a leading subsea control system OEM) have led to orders from a number of new clients, including requests for termination of third-party components. To meet this demand, SCE recently opened a new dedicated jumper workshop at their facility in Great Yarmouth.
Recent manufacturing developments include the purchase of a hydraulic hose crimp swager and delivery of a new hydrostatic test chamber, which will facilitate testing of complete jumper assemblies and electronic distribution junction boxes down to 8,500 psi. Jumpers can be supplied in either connector-to-connector or connector-to-penetrator configuration. Splitter boxes are also available for multiple hose breakouts.
Dedicated jumper production facilities
SEACON Precision uses qualified components, processes, and test methods in compliance with standards such as ISO13628-6 as well as customer specifications. These represent some of the most challenging requirements in the industry. SEACON Precision’s Notodden, Norway, facility produces jumpers and harness systems for sensor systems, subsea battery units, electronics and instrumentation. In addition, it manufactures subsea umbilical terminations.
Although electrical jumpers have been well-understood in the industry for at least 30 years, SEACON Precision has added innovations by integrating glass-to-metal hermetic seals, with additional
protection barriers, terminated with Ethernet wiring to achieve a robust, highly reliable, copper based broadband link on the seabed.
Applications for electrical jumpers are typically:
• Power and Ethernet communications distribution network through an umbilical between Subsea Router Modules (SRMs) and electro-hydraulically operated Subsea Control Modules (SCMs) for Christmas trees and manifolds. These solutions are now being provided on several “Fast Track” projects on the Norwegian shelf. The company also supplies the fibre-optic jumpers and umbilical terminations to the same projects – resulting in the entire power and communication system for these subsea installations, from the surface to the seabed, including both electrical (power) and fibre-optic (communications) components.
• Cables and connectors for pressure and temperature transmitters, and multi-phase, turbine, and Venturi flowmeters. These are present on miscellaneous permanently installed subsea oil and gas production equipment such as Christmas trees, manifolds, and pig receivers.
SEACON Precision’s hyperbaric test chamber has an inside diameter of 1 meter and depth of 3 meters. It features electric and fibre-optic feed-through penetrators in the lid and cooling coils for low-temperature tests. It tests electrical jumpers that will be used to ocean depths to 3,000 metres, equivalent to 300 bar pressure and tested to 150% of that pressure.
SEACON worldwide is committed to actively supporting its customer base in the subsea power and communications market through optical and electrical jumper assemblies and umbilical terminations designed to operate at full ocean depth. This is achieved through both the expertise described in this article, and the capability and products available through SEACON’s other divisions located in El Cajon, California, USA; Tijuana, Mexico; and Rio de Janeiro, Brazil.
An ‘Open House’ was held on Wednesday 4th December, 2013 at SEACON’s new Encapsulating & Molding facility. The event was well attended with customers being given a tour of the new workshop followed by product demonstrations and a BBQ lunch.
The new facility located in the west Houston area, opened in the Summer of this year to better serve our expanding market and develop even greater levels of support both to the Gulf Coast region and internationally by specializing in short order custom assemblies and carrying increased stock of our most popular connectors.
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For more details please contact us at
1718 Fry Road, Suite 250,
Houston, TX 77084,
Tel: +1 (281) 394-0216
Read about SEACON’s New Encapsulating and Molding Facility as featured in this month’s December issue of Subsea and Offshore Service Magazine.
To read the full article please download the PDF available here… SEACON Feature in Subsea & Offshore Service Magazine
Dave Pye, SEACON’s Renewable Energy Business Development Manager gave a presentation at the International Tidal Energy Summit held in London, the UK from 26th to 27th November, titled ‘Lowering the Cost of Connection – Innovative Hybrid Electro-Optic Connector’.
MARINE ENERGY SUBSEA HUB – Low Cost Retrievable Hub for the Wave and Tidal Sector
OVERALL CONCEPT – INITIAL SCHEMATIC
To improve the viability of tidal & wave projects a subsea connection hub solution is required to reduce CAPEX, OPEX and increase availability. Current options of surface piercing platforms or heavy hubs are unsuitable & too expensive.
SEACON (europe) Ltd’s involvement in the project centres on the production of a HYBRID wet-mateable connector incorporating both high power electrical and optical fibre elements.
The aim of the SEACON project is to reduce the present cost of the separate electrical and fibre optic connectors by a significant amount.
Wet-mate electrical connectors are presently available from 4 or 5 suppliers with ratings up to 11kVAC and 400 amps or more.
Wet-mate optical connectors are presently available from a similar number of suppliers with fibre counts up to 48.
Configurations of both types include Diver mate / ROV mate and Stab plate.
To date however no HYBRID medium voltage connector has been designed and qualified to include both elements.
The environment in which these products have to survive and function is far more severe than deep water. Factors affecting performance and service life include :
a. Corrosion. Shallower deployments often result in warmer waters. High tidal flows will refresh the oxygen content in the water.
b. Marine Growth / biofouling. Again the above factors greatly increase the rate of marine growth.
c. Cyclic pressure. Wave effect can impose cyclic pressures. At a mean water depth of 50 metres, a 5 metre wave would vary the pressure from 30 to 50 psi at irregular intervals. This is not
significant in deep water.
d. Cyclic power level. In Tidal applications the power generated will vary from zero to maximum twice per day. Wave applications could generate random power levels.
e. Scour and material deposition.
Corrosion and biofouling examples :
CORROSION AND BIOFOULING TESTING
SEACON have commissioned PLYMOUTH MARINE LABS to carry out a long-term corrosion and biofouling test on various material samples.
The frame was installed by EMEC at their FALLS OF WARNESS site in late September 2013 and will be retrieved for initial examination in 6 months time.
Materials fitted to the frame include 4 metallic and two non-metallic discs, up to 10 of each type.
THE NEW PRODUCT
The product under development by SEACON as part of the TSB-funded project will have the following ratings and design features :
1. Electrical rating will be 6.6kV (u) and 250 amps per contact. 4 electrical contacts will be provided to allow for one to be used as an earth if necessary. This will allow the connector to be used on generators up to 2.5MW at 6.6kV.
2. Minimum of 4 fibre-optics. Low insertion loss (0.5db max) and single or multi-mode.
3. Stab-plate and ROV-mate variants.
4. Materials selected for maximum corrosion resistance and resistance to marine growth.
LOWERING THE COST
The aim of the project is to reduce the cost of the connectors and connection system requirements significantly. We will aim to achieve this in a number of ways:
a. Combining the two elements into one connector will mean only one set of shell components is required.
b. The “real-estate” required on the hub or generators is greatly reduced.
c. Careful material selection will result in extended lifetime and hence reduced maintenance or retrieval requirements.
d. Use of proven electrical and optical elements.
e. Provision of automatic protection for the pin half of the connector will remove the need for expensive dummies and their fitting and removal.
f. Standardised testing, in particular FAT. Here we would encourage a JIP to be set up to determine these requirements.
g. IEC TC-114: Marine energy – Wave, tidal and other water current converters.
The standards produced by TC 114 will address:
• System definition
• Performance measurement of wave, tidal and water
• Current energy converters
• Resource assessment requirements, design and survivability
• Safety requirements
• Power quality
• Manufacturing and factory testing
• Evaluation and mitigation of environmental impacts
This TSB-funded project has a timescale of 2 years. The project was initiated in February 2013 hence is scheduled to be complete in February 2015.
The connector will be completed before that date in order for it to be incorporated into the Hub.
SUMMARY & CONCLUSIONS
The product will have a rating of 6.6kV (u) and 250 amps (4-pins). Optically it will contain a minimum of 4 fibres with insertion losses of less than 0.5db. Initial depth rating will be at least 100 metres, probably more.
The aim of the SEACON element of the project is to produce a Hybrid Opto-Electric Wet-Mate connector at around 50% of the cost of two separate connectors. ROV and Stab-plate versions will be designed.
The design will incorporate materials and design features to minimise the effect of marine growth and corrosion.
As the cost of connectors is a very significant part of the overall system cost, it is hoped that this project will go a long way towards helping with the necessary cost reductions required by the Marine Renewable Energy industry.
As SEACON continues to expand its capabilities into the ever growing subsea distribution market, so too does the investment in our manufacturing facilities and equipment in order to support this growth. SEACON Advanced Products, LLC., (SAPL) of Bellville, Texas, USA has been undergoing an expansion program since March of this year which includes a new 8,550 square foot (285 foot long) Subsea Jumper building which is now fully complete and operational and houses a new pressure vessel 9ft 2 inches deep with a 30 inch inner diameter, certified to 10,000 psi/689 bar which will increase jumper capacity and shorten lead times.
With primary focus around our own highly successful and reliable underwater mateable optical and electrical connectors and our qualified Pressure Balanced Oil Filled (PBOF) hose conduit, SEACON has built up a suite of products to provide customers with complete optical and electrical distribution system solutions. In addition to our own product baseline, SEACON is also able to integrate third party products into distribution system assemblies.
One of the key technologies within SEACON’s distribution systems is the Pressure Balanced Oil Filled (PBOF) hose conduit with MKII hose fitting. This elastomeric (rubber) conduit provides not only protection for the electrical fiber optic lines within a compensating fluid, but allows the sea pressure to freely communicate with the interior oil volume, equalizing the pressure in the assembly. The stresses and strains encountered during ROV operations are controlled via longitudinal strength members that not only provide the strength, but also limit the elongation of the hose.
The key elements in both optical and electrical distribution systems are:
· Jumper Assemblies – Hose conduit with optical or electrical connectors at either end
· Distribution Harnesses – These can have multiple ‘legs’ with either connectors or sensors terminated to the end of each leg
· Umbilical Termination Assemblies – These provide the interface between either the optical or electrical element of the umbilical and the wet-mate connector(s)
· Cable Hang-Offs – These are specially designed cable strength member terminations that provide support for the individual cable elements at the top side of some umbilical cables
· Abandonment Caps or Connectors – Where the top side of an umbilical needs to be abandoned subsea for a period, these provide a watertight protection from flooding of the umbilical cable
There are many design features that make these products successful including:
Jumper Assemblies/Distribution Harnesses
· Integral fiber management system within the hose to mitigate excessive movement or forces applied directly to the internal fibers
· Integral cable management for Ethernet cabling within the hose to mitigate excessive movement or forces applied directly to the small wire terminations
Umbilical Termination Assemblies
· Proven and testable penetrators between 1 atmosphere and pressure compensated chambers
For more information please contact firstname.lastname@example.org