Hardware, Software
Oil & Gas
UK

Mid-life Upgrade for SEM Power Transformer

Modernization of a critical component in subsea control systems

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About the client

Our client, a leading global player in the oil and gas sector, specializes in subsea production systems. They approached us to manufacture and modernize a Subsea Electronics Module (SEM) Power Transformer, a critical component in subsea control systems. This component is responsible for delivering power and isolating key control mechanisms, including valve controllers and sensor networks, used for managing subsea operations.

Business challenge

The project presented multiple technical challenges:

Obsolescence Issues: The original transformer core, an essential part of the SEM Power Transformer, was no longer in production. This required us to reverse-engineer the core based on its original parameters to ensure that it met or exceeded the performance standards of the legacy system.
Inadequate Documentation: Documentation for the original design was incomplete, posing difficulties in both the replication and modernization processes. We had to meticulously recreate missing technical documentation, ensuring precision in the transformer design.
Custom Redesign and Manufacturing: To meet modern operational needs and improve system longevity, we needed to redesign the magnetic core and chassis, upgrading components while maintaining the original design’s dimensions and operational specifications.

Team composition

Power Electronics Engineer
Electrical Engineering Technologist
QA Engineer

Our solution

To tackle these challenges, we implemented a phased approach:

Reverse Engineering and Core Redesign: Using the available specifications, our engineers reverse-engineered the original transformer core. We optimized the core design to meet current manufacturing standards, ensuring it matched the electrical insulation and power isolation capabilities required for underwater valve controllers and sensors.
Custom Manufacturing: We developed custom magnetics for the transformer and fabricated the chassis to fit within the original SEM design. By leveraging advanced manufacturing techniques, we ensured that the newly designed transformer would fit seamlessly into the subsea control systems.
Reliability Assessment and Upgrade: Once the core and components were redesigned, we carried out a rigorous reliability assessment to ensure that the transformer would perform as expected in harsh subsea environments. The upgraded transformer met or exceeded the operational stability of the previous design.

Technologies used in this project

Custom Magnetics Manufacturing
Reverse Engineering

How about repeating the /success/ of our clients?

Value we added

By reverse-engineering and upgrading the SEM Power Transformer, we enabled the client to avoid the high costs of developing a completely new subsea power control system. Our solution:

Resolved the obsolescence issues by delivering a modernized transformer core with improved performance.
Delivered a prototyped SEM Power Transformer that met the stringent requirements of subsea operations, ensuring power isolation and reliability.
Provided a cost-effective solution that extended the life of their existing subsea production system.

Future perspective

This successful mid-life upgrade provides the client with a reliable solution that can be integrated into future subsea projects. As subsea oil and gas operations continue to expand, having scalable, reliable, and easily upgradable equipment like the SEM Power Transformer is essential. The solutions we provided ensure that the client can maintain operational efficiency and safety in subsea environments for years to come.