Hardware
Oil & Gas
UK

Mid-life Upgrade for DC-DC Converter

Ensuring power conversion and maintaining stability in subsea components

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About the client

Our client, a global leader in the oil and gas industry, required an upgrade to their existing DC-DC Converter Module used in subsea power systems. This module is critical for power conversion and maintaining stability in subsea components such as valve controllers and sensor arrays. Its performance directly impacts the efficiency and safety of underwater operations, making its reliable function essential in harsh subsea environments.

Business challenge

The project faced several key technical challenges:

EMC Compliance: As the power requirements of the module increased, the challenge of passing electromagnetic compatibility (EMC) tests grew more complex. Design changes has to be confirmed to to comply with industry standards.
Obsolescence Removal: Some of the existing components were obsolete and no longer in production. This required custom redesigns to replace these parts while maintaining or improving overall system performance.

Team composition

Power Electronics Engineer
Simulation Engineer
Electronics Design Engineer
EMC Engineer
QA Engineer

Our solution

To overcome these challenges, we adopted a multi-pronged approach:

EMC Optimization: Balancing thermal performance and EMC compliance was a significant challenge. We introduced advanced filtering solutions to suppress EMI and ensure that the module met all necessary EMC standards. This allowed the module to pass rigorous EMC testing while preserving optimal thermal management.
Custom Component Manufacturing: To address obsolescence, we designed and manufactured custom replacements for outdated components. This ensured that the new module met the latest operational standards without requiring a full redesign of the entire system.

Technologies used in this project

Power Electronics: LTSpice, PSIM, Power Stage Designer
Design Tools: Altium Designer
Testing and Compliance: EMC and Environmental Testing, Custom Magnetics Manufacturing

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Value we added

The mid-life upgrade enhanced the performance and longevity of the DC-DC Converter Module. Additional EMI suppression solutions ensured the module passed stringent EMC and Q1 qualifications, and the project successfully passed Q2 tests at the SEM level. These improvements extended the product’s lifecycle and ensured compliance for future deployments in challenging subsea environments.

Future perspective

This upgrade positions the client for continued success in subsea operations, as the improved module design increases reliability and extends operational life.