Energy Sector

Application

A leading OEM is developing a range of subsea electrical connector systems for oil and gas and offshore wind. The connectors are used to attach two HV cables together in various locations. These are typically undersea connectors to offshore wind farms and ancillary electrical converting equipment.

TRP produce an assembly comprising multi-layers of different elastomers that perform several functions.

An initial conductive layer ensures electrical conductivity for the connectors and an outer layer provides insulation and protection for the connector. The multi-layer design ensures the custom rubber moulding provides precise electrical field control.

Problem

The customer had an issue with the layers of insulating and conductive materials and needed a clear definition between them. Contamination or delamination between layers could result in electrical breakdown and failures. The initial customer design presented a risk of overflow between layers.

Solution

TRP performed FEA analysis to prove initial concerns that the layers were lifting. We then redesigned the intersecting geometry between the layers to eliminate this delamination. Repeated FEA was then performed to demonstrate improvements through rubber moulding design.

The simulation involved:

• Modelling of the existing profile
• Material characterisation in our in-house laboratory
• Correlation of our basic simulation to our lab testing
• Applying the loads encountered in the moulding process to the profile and observing the resultant stress
• Redesign of profiles
• Analysis of contact pressure and separation between material layers
• Discussion with customer

Initial customer design

Pressure applied to profile.

Loss of contact shown. This is likely to cause functional issues or moulding defects.

TRP-recommended design

Redesigned profile

Pressure applied to profile.

No contact separation for the reduced likelihood of functional issues or moulding faults.

Outcome

TRP achieved a successful redesign for the customer. The shape of the component was changed to allow better processing and more constant and predictable positioning of the different rubber layers. The design was then agreed upon and adopted by the customer.