The present invention relates to a machine for SZ closing/laying of an umbilical/power umbilical comprising a plurality of elongated elements, which elongated elements are different regarding transversal cross section, material, function and in number.

Typically such elongated elements constitute one or more among the following traditional components of an umbilical/power umbilical: power cables for transfer of vast amounts of electric power, fluid pipes of same or different transversal cross sectional dimensions, electric wires for control purposes etc, optical conductors, filler material in the form of stiff or rigid elongated elements which are laying at least partly around and between the other elongated elements, such as the fluid pipes, the power cables and the wires/conductors, and possibly one or more load carrying elements predetermined located within the transversal cross section of the umbilical, or power umbilical, such as steel wire or carbon rods, individually or gathered into bundles. However, several of the elements may be similar to each other. Thus it is to be understood that it is not that important which type of elements that are closed together, but the way this is performed and how the machine which is able to perform this is constructed, which is the new and inventive.

Accordingly the present invention also relates to a method for SZ closing/laying of an umbilical/power umbilical by means of a machine as defined above.

A well proven closing machine which over a long period of time is used for production of classic umbilicals, i.e. of the type which are helically twisted about its longitudinal axis, is briefly described and illustrated in fig. 1-5 in WO 93/17176 (NO 174 940). Another type of closing machine, in particular used for SZ closing of cables, is schematically illustrated in fig. 7 of WO publication 2008/075965. As far as we know this represents the state of the art.

One object with the present invention is to design a closing/laying machine which is substantially simplified relative to the voluminous and kind of complicated laying machines available today. Besides, it is a desire to be able to design such a machine to be mobile, i.e. be able to move the machine from place to place without too comprehensive and complicated operations.

This is achieved with a machine of the introductory said kind which is distinguished in that the laying machine is arranged in the following component sequence when viewed in the pulling direction starting at an entry end: a first die which receives and gathers a first set of elongated elements substantially rectilinear from respective supplies of elongated elements, a static second die which receives and gathers a second set of elongated elements substantially rectilinear from respective supplies of elongated elements and close these together with the first set into a gathered bundle, at least one supporting means which keeps the gathered bundle radially in place; a revolving device able to revolve the bundle torsional back and forth in an SZ oscillating way, and a tape or band wrapping apparatus which immediate after the revolving device applies band or tape circumferentially onto the SZ laid bundle of elongated elements.

Thus the enormous revolving carousels carrying a plurality of bobbins which in turn revolves about their bobbin axis, is avoided. See fig. 1-5 of WO 93/17176. These conditions are substantially improved with the machine shown in fig. 7 of WO 2008/075965. However, such a machine is primarily designed for manufacture of existing cables during common cable production, but the principle was proposed used to manufacture the SZ closed umbilical according to WO 2008/075965. However, one has still not arrived there, other than that this umbilical is manufactured in shorter test lengths. The now suggested closing/laying machine is indeed constructed for full scale production of continuous lengths of umbilicals of very different transversal cross section profiles, which also includes power umbilicals of the nature shown in WO 2008/075964.

Normally the elongated elements will be one or more among the following traditional components in an umbilical/power umbilical: power cables for transfer of vast amounts of electric power, fluid pipes, electric wires, optical conductors, filler material in the form of stiff elongated plastic elements (PVC) which are laying at least partly around and between the power cables and the wires/conductors, and one or more load carrying elements predetermined located in the transversal cross section of the umbilical or power umbilical.

One type of load carrying elements is carbon rods having embedded strength fibres. They have equally large axial strength as steel, but 10% of the weight only. The actual force that each carbon rod transfers is approximately 3% of its load capacity only. It is the axial stiffness that is created within the umbilical that is crucial. The umbilical is close to be without elongation when it is SZ closed and external strength band is wrapped around.

Conveniently, the means that provides for the pulling action of the umbilical through the machine can be one or more sets of caterpillar tracks.

Preferably the machine includes turning mechanisms which is able to alter the direction of the advanced elongated elements.

Preferably the machine includes means that applies a protective sheath which envelops the respective elongated elements that may be included in a dedicated umbilical/power umbilical.

In a preferable embodiment the revolving means that performs the closing action, may revolve one revolution per approximately 10 meters of umbilical length.

Further, a method of the introductory said kind is provided, which is distinguished in that the method includes introduction of a first set of elongated elements into the entry end of the closing/laying machine and into a first die which receives and gathers the respective elongated elements substantially rectilinear from respective supplies of elongated elements, that a second set of elongated elements is advanced to a second, static die and is merged with the first set of elongated elements advanced from the first die, that all the elongated elements are introduced into the static, second die and are closed into a bundle of elongated elements, that the bundle after the closing thereof, is further advanced to one or more supporting means which keeps the bundle radially in place, that the bundle is further advanced to a revolving device which revolves the bundle torsional back and forth in an SZ oscillating way, and that a tape or band is circumferentially applied onto the SZ closed/laid bundle of elongated elements.

Conveniently the umbilical is pulled through the machine by one or more set of caterpillar track means.

Preferably, a protective sheath that envelops the respective elongated elements that may be included in a dedicated umbilical/power umbilical, is applied subsequent to the wrapping of a band or tape.

Other and further objects, features and advantages will appear from the following description of preferred embodiments of the invention, which are given for the purpose of description, and given in context with the appended drawings where:

Fig. 1 shows in perspective view a closing/laying machine according to the invention, Fig. 2a-2f show encircled details of the machine shown in fig. 1, Fig. 3 shows a top view of a closing/laying machine according to the invention, and Fig. 4 shows an elevation view of a closing/laying machine according to the invention.

With reference to fig. 1 a machine 1 for SZ closing of an umbilical 10 or power umbilical is generally shown. The umbilical is made up by a plurality of elongated elements 10a- 1Oe which are different with regard to transversal cross sectional form, material, function and in number. Typically such elongated elements will be one or more among the following traditional components of an umbilical/power umbilical: power cables for transfer of vast amounts of electric power, fluid pipes, electric wires, optical conductors, filler material in the form of stiff elongated plastic elements, often of PVC, and one or more load carrying elements predetermined located in the transversal cross section of the umbilical or power umbilical. The filler material will normally be located at least partly around and between the power cables and the wires/conductors. One type of load carrying elements is carbon rods having embedded strength fibres. They have equally large axial strength as steel, but 10% of the weight only. The closing/laying machine 1 is assembled in a particular way and the individual components that are to provide for particular functions are arranged in a defined order. In that end of the closing machine 1 where the finished umbilical 10 exits, a number of caterpillar tracks means 2 are located, here shown three similar units, which are able to pull the umbilical 10 through the closing machine 1. The caterpillar tracks means 2 are such arranged that two sets of elongated belts 2a are facing each other and sandwiches the umbilical 10 therebetween. At the same time the belts 2a are driven in an endless path and thus pull the umbilical 10 through the closing machine 1. The two sets are equipped with means that provides for adjustable pinch force against the umbilical 10.

At the opposite end of the machine the elongated elements 10a- 1Of that the umbilical 10 is to be assembled of, are fed into the closing machine 1. Each individual elongated element 10a- 1Of departs from respective supply, typically a bobbin 11, or a reel, onto which the element 1 Oa- 1 Of is stored.

The closing machine 1 will typically be elevated from ground level L in order to have space for a large number of bobbins 11, or reels, having large diameter and capacity, possibly two in height. The closing machine 1 is located on a platform 12, something like a gangway, having a hand rail 13. The platform 12 is standing on columns 14 which in turn are founded to the base or ground L.

The closing machine 1 is described further according to a defined component order when viewed in the pulling direction and starting from an entry end. A first die 3 is placed on a pedestal 3a projecting from the platform 12. The first die 3 has an opening 3b which receives and gathers a first set of elongated elements 10a- 10c from respective supplies 11 of elongated elements. The elongated elements 1 Oa-I Oc readily extend aslant from the bobbins 11 and towards the closing machine 1. A turning mechanism 15 for each elongated element 10a- 1Oe is arranged adjacent to the first, die 3. Each turning mechanism 15 ensures that the direction in which an elongated element is advanced from the bobbins 11 is converted into a substantially rectilinear motion, and without any torsional twisting towards the opening 3 b of the die. From the turning mechanism 15 and towards the opening 4b all actual elongated elements 10a- 1Oe extend in parallel.

A second die 4 is also placed on a pedestal 4a projecting from the platform 12. The second die 4 is static and has an opening 4b which receives and gathers a second set of elongated elements 1 Od- 1Of from respective second supplies 16 of elongate elements 1 Od- 1Of. Also this time the elongated elements 1 Od-I Of readily extend aslant from the bobbins 16 and towards the closing machine 1. Another turning mechanism 17 for each elongated element 1 Od- 1Of is arranged close to the second die 4. Each turning mechanism 17 ensures, as before, that the direction in which an elongated element is advanced from the bobbins 16 is converted into a substantially rectilinear motion, and without torsional twisting towards the opening 4b of the die 4. From the turning mechanism 17 and towards the opening 4b all actual elongated elements 1 Od- 1Of extend in parallel and now in parallel with the elongated elements 10a- 10c extending from the first die 3.

In the static die 4 all the elongated elements 10a- 1Of are closed together into a bundle 18 and where the bundle 18 subsequent to the closing together extends substantially rectilinear and without any internal torsional twist. The stabilizing, static die 4 has an opening 4b which is complementary to the external shape of the closed together bundle 18. In practise, this means that the external shape of the bundle 18 has longitudinal grooves or splines which have a corresponding shape in the die opening 4b. This is because the die 4 shall be able to retain the umbilical against torsional rotation.

From the die 4 the now closed together bundle 18 is advanced to one or more supporting means 5, here shown a number of five, which are able to retain the bundle 18 radially in place, also when exposed for torsional forces. Each supporting means 5 is placed on a pedestal 5a projecting from the platform 12. The support means 5 has an opening 5b which is arranged with a number of peripherally placed rollers 5 c which is abutting against the surface of the bundle 18 and keeps the bundle 18 radially in place. From there the bundle 18 is advanced further to a revolving device 6. The revolving device 6 is also located on top of a pedestal 6a projecting from the platform 12. The revolving device 6 has an opening 6b which also is complementary to the external shape of the closed together bundle 18. This will tell that the internal shape of the opening 6b has longitudinal splines or grooves. This, because the revolving device 6 shall be able to twist the umbilical while it is passing through the opening 6b. Simultaneously, the umbilical 1 is retained against torsional rotation by the static die 4. This means that torsional twisting can take place between the revolving device 6 and the static die 4 only. The revolving device 6 that ensures the closing action will normally revolve one turn per approximately 10 meter of umbilical length, without thereby being a limitation. However, a long laying length is to prefer in many situations, particularly with regard to twisting during axial loads.

Subsequent to the revolving device 6 a tape or band wrapping apparatus 7 is arranged, which immediately after the revolving device 6 applies band or tape circumferentially onto the SZ closed/laid bundle 18 of elongated elements 10a- 1Of. The band wrapping apparatus 7 is also placed onto a pedestal 7a projecting from the platform 12. The band wrapping apparatus 7 has an opening 7b which the closed together bundle 18 passes through and further on to a caterpillar tracks means 2.