Modernization and Reverse Engineering of Critical Subsea Power Transformers for Enhanced Reliability and Compliance

The client faces obsolescence and documentation gaps in their existing subsea power transformers, which are vital for controlling subsea operations such as valve control and sensor networks. The outdated components hinder system reliability and increase maintenance costs, risking operational disruptions in harsh subsea environments.

A mid-sized global oil and gas company specializing in subsea production systems, seeking to upgrade aging critical components to extend operational lifespan and meet current standards.

• Reverse engineer existing transformer cores to replicate and improve performance standards in the absence of complete documentation.
• Redesign transformer magnetic cores and chassis to meet modern manufacturing standards and extend operational life.
• Develop custom magnetics and fabricated chassis that seamlessly integrate with existing subsea control systems.
• Conduct rigorous reliability assessments to ensure performance and stability in harsh subsea conditions.
• Deliver a prototype transformer that exceeds the performance and reliability of legacy units, reducing maintenance costs and downtime.

• Reverse engineering module for recreating transformer cores based on available specifications.
• Design tools for optimizing magnetic core geometry to meet current safety and performance standards.
• Customized manufacturing processes for magnetics and chassis fabrication to fit within existing constraints.
• Reliability assessment protocols simulating subsea conditions, including stress testing and environmental validation.
• Prototype development and documentation to facilitate future scaling or upgrades.

• Existing subsea control system interfaces for seamless integration of the upgraded transformer
• Environmental monitoring and testing systems for reliability validation

• Transformer must be compatible with existing dimensions and operational constraints
• Demonstrate performance improvements over legacy units, including enhanced insulation and power isolation capabilities
• Ensure operational stability in harsh subsea conditions with minimal maintenance requirements
• Achieve certification and compliance with industry standards for subsea equipment reliability

The project aims to provide a reliable, cost-effective solution that extends the operational lifespan of critical subsea control components, reduces maintenance and replacement costs, and enhances system stability in challenging environments. The successful upgrade supports future scalability and operational efficiency in expanding subsea oil and gas ventures.