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Client context
A global oil and gas company operating advanced subsea production systems, where reliable power delivery and stability are essential for maintaining safe and continuous operations.
The challenge
The DC-DC Converter Module plays a critical role in subsea systems, ensuring stable power conversion for components such as valve controllers and sensor networks.
As system requirements evolved, the existing module faced growing limitations related to performance, compliance, and component availability.
Increasing power demands introduced challenges in meeting electromagnetic compatibility (EMC) standards, while some key components became obsolete and unavailable. Any upgrade had to preserve compatibility with the existing system architecture and operate reliably in harsh subsea environments, making a full redesign impractical.
What it took to deliver results
To maintain system performance and continuity, the solution needed to:
- improve EMC performance under increased power requirements
- replace obsolete components with modern equivalents
- maintain compatibility with existing subsea systems
- ensure thermal stability and operational reliability
- pass rigorous qualification and compliance testing
The goal was to enhance performance and compliance without disrupting the existing system design.
The solution
A targeted mid-life upgrade approach was implemented to modernize the DC-DC converter while preserving its integration within the existing system. Instead of redesigning the entire module, the focus was on improving key performance areas and addressing component obsolescence.
Advanced EMI suppression and filtering techniques were introduced to ensure compliance with EMC standards, while maintaining efficient thermal behavior. At the same time, obsolete components were replaced with custom-designed alternatives, ensuring continued availability and improved performance.
The upgraded design was validated through simulation and testing to confirm stability and compliance under real operating conditions.
Technology stack:
- LTSpice / PSIM / Power Stage Designer for simulation
- Altium Designer for hardware design
- Custom magnetics manufacturing
- EMC and environmental testing frameworks
How it works
The modernized converter maintains stable power delivery across subsea systems, ensuring consistent operation of connected components.
Enhanced filtering reduces electromagnetic interference, allowing the module to operate within required compliance standards. Custom components ensure long-term availability while maintaining compatibility with the original system design.
Key capabilities:
- Improved EMC performance with advanced EMI suppression
- Replacement of obsolete components with custom designs
- Stable power conversion under increased load
- Compatibility with existing subsea architecture
- Optimized thermal and electrical performance
- Compliance with subsea qualification standards
Impact on operations
The upgrade improved the stability and reliability of power delivery across subsea systems, reducing the risk of failures in critical components. By maintaining compatibility with existing infrastructure, the solution avoided complex integration challenges and minimized operational disruption.
Improved compliance also ensured readiness for future deployments in demanding environments.
Business impact
The solution delivered measurable improvements across key areas:
- Extended product lifecycle, delaying the need for replacement
- Improved compliance, meeting strict EMC and qualification standards
- Reduced operational risk, through stable power delivery
- Avoided redesign costs, by upgrading instead of replacing
- Ensured component availability, through custom replacements
- Enabled future deployments, in demanding subsea environments
The upgraded module provides a reliable and scalable foundation for future subsea systems, allowing the client to continue operating and expanding without major infrastructure changes. The approach can be replicated for other components facing similar performance or obsolescence challenges.
We’ll review your goals, technical constraints, and opportunities to design a solution that fits your organization.
