Umbilical

The present invention relates to an umbilical comprising a number of fluid pipes, electric wires and/or optical conductors, filler material located at least partially around and between the fluid pipes and the wires/conductors and they are collectively gathered in a twisted bundle by means of a laying operation, a protective jacket that encompasses the fluid pipes, the wires/conductors and the filler material, and at least one load carrying element predetermined located in the cross section of the umbilical, optionally that one or more fluid pipes constitute load carrying elements.

The invention also relates to a method of manufacturing the umbilical of the introductory said kind, as expressed in the ingress of the following independent claim 12.

It is to be noted that the invention finds use in both the more traditional umbilical and the relatively newly suggested power umbilical, i.e. an umbilical that is able to transfer large amounts of electric power between the sea surface and equipment located at the sea bed. This application relates to the more traditional umbilical, while the power umbilical is subject to a separate patent application filed on the same day as the present application. It is further to be noted that the present umbilical primarily is intended to be used for static purposes and its tensional capacity is first of all required during the deployment thereof, subsequently to be resting more or less stationary on the sea bed.

The traditional way to perform the laying operation of several elongate elements is for example shown in NO 174 940 (WO 93/17176) and NO 971984. When looking into the figures in the first document, in particular figure 1, the machinery normally required to manufacture such umbilical is shown. As shown, the machinery is complicated, space demanding, voluminous, and accordingly very cost intensive. In addition, due to the size, the machinery necessarily needs to be stationary, i.e. be located in a large facility, preferably close to a harbour.

The machinery necessarily needs to have these dimensions in order to fulfil its functions, namely be able to wind the elongate elements together into a bundle that

extends helically in the longitudinal direction thereof having a predetermined laying length, typically 1,5 to 15 meters per revolution, depending on intended application.

It has been a distinct desire from the industries to be able to manufacture an umbilical by use of considerably simpler machinery. In addition there is a desire to have a mobile facility that can produce the umbilical at the site, or close to the site where the umbilical is to be installed. How to enable this, in consideration of the premises above? Some regards have been necessary to take, and in particular the ability of the umbilical to take up and withstand tensional loads. This is discussed below.

When such a bundle of elongate elements are subjected to tensional loads, for example during deployment on deeper waters, the twisted, or wound, elements will tend to "straighten out" or "twist open". It is the load carrying elements in the cross section that are dedicated to take up the tensional loads. The load carrying elements can be pipes, steel wires or elements made of composite material, either in the form of individual composite rods distributed on the cross section or rods gathered in bundles. An example of composite material is carbon fibre.

With the now proposed solution for the laying operation of the umbilical, which simplifies the manufacturing process substantially, the load carrying elements will not necessarily be able to fulfil their function, namely be able to transfer substantial loads, or tensional loadings. They will, as indicated above, only tend to straighten out. However, such a new solution will require only a very simple machinery of manufacture compared with the traditional ones. So all the desires set forth above will be fulfilled. But as one will understand, a new problem is created - how to enable the load carrying function?

This is an acknowledged problem and in this respect we refer to US patent 6,472,614 in the name Coflexip. In column 1, from the middle of the page and down, it is indeed described that the elements of the umbilical normally (traditionally) are wound together in the well known S-Z configuration, which means that it is wound alternating with shifting direction. Further it is described that since the S-Z configuration cannot

withstand substantial tensile stress without unwinding (as described above), additional layers of armouring (steel or Kevlar, for example) must be wound counter helically around this bundle to take up the tensile stress. The armouring consists of a plurality of steel wires or rods placed side by side with small pitch relative to the longitudinal axis of the umbilical.

In order to teach how this umbilical typically looks like, the US patent tells that this is disclosed in API (American Petroleum Institute) specification 17E, "Specification for Subsea Production Control Umbilicals", in particular pages 42, 43 and 44. Abstracts from this are shown in figures 7-8 and are marked with "prior art". It is further stated in US patent 6,472,614, at the bottom of column 2, that there is no standard for steel tube umbilicals at this moment, but that it will come. This we understand as a confirmation of that the pipes that are shown on page 43 of the specification 17E are thermoplastic pipes - and not steel pipes as the present invention relates to.

Such is also included to illustrate the traditional way of thinking when it comes to S-Z laying (winding) combined with load carrying. This requires armouring rods that are helically wound (not S-Z) in at least two layers and each layer is wound in opposite directions to each other in order that they shall be able to act as the load carrying elements in the cross section.

As far as we know, no one has until this date carried out S-Z laying (winding) of the steel pipes in an umbilical, just because they perform the load carrying function and will, by applying axial loads of some magnitude, tend to straighten out (unwind), just as described in said US patent 6,472,614. In addition the steel pipes naturally are inherently rigid by nature and consequently intractable to handle in such a laying operation.

Another problem with this type of subsea umbilicals has been that pipes and cables need to be spliced relatively frequently, perhaps every 500 meters. This results in a substantial number of joints if lengths of several tenths of kilometres are to be supplied.

Every single splicing operation is time consuming. In complicated cross sections of the umbilical, it may take a couple of days to perform such a splicing operation.

Thus a challenge has been prevailing in the task to be able to manufacture substantial lengths of umbilicals having complicated cross sections and with fewer splices than before; in brief achieve a more continuous and effective production. Similarly, as before, it is a demand that the umbilical can be coiled up on carousels or reels for shipping and transportation purposes.

In accordance with the present invention an umbilical of the introductory said kind is provided, which is distinguished by the fact that the fluid pipes, the wires/conductors, the filler material and possibly the at least one load carrying element, are alternately laid, i.e. by continuously alternating direction, in the entire or part of the longitudinal extension of the umbilical, combined with that the laid bundle is kept fixed substantially torsion stiff by the protective sheath, possibly with the addition of a strength band, or tape, which is helically wound about the bundle just internal of the protective sheath.

It is to be understood that the strength band, or tape, can be varied according to which depths the umbilical is to be deployed, or, actually, may be omitted completely. At small depths the strength band can be one simple ribbon, strip or tape just to keep the bundle together until the outer sheath is extruded thereon. When the depth become deeper it may be necessary with a steel band that is wound around the bundle. A detailed explanation appears from the text below.

According to the idea of the invention, the present umbilical is designed in such a way that the wounded elements are prevented from unwinding, in spite they are S-Z wound. This is achieved in that: a) the twisted elements are in engagement with the filler profiles which fully or partly encloses the twisted elements b) the umbilical is sufficiently torsional stiff to counteract the torque that the load carrying elements generates under axial tension c) the inner friction counteracts that the elements unwinds.

By this new way to lay umbilicals, so called S-Z laying, combined with an outer sheath and/or strength band or tape, the above described is achieved. Said in a different way, engagement of filler profiles in combination with the torque rigidity of the umbilical and internal friction counteracts that the S-Z laid bundle unwinds when the elements are put into tension. For umbilical applications where the tensional capacity of the S-Z laid elements is sufficient to take up the tension within the umbilical, it means that armouring is not necessary. The described umbilical immobilizes the steel pipes and the remainder elongate elements of the cross section both with regard to radial motion, axial elongation and torsion, and at the same time the steel pipes are able to fulfil their duty as load transferring elements in spite of their sinus configuration.

In addition, simpler and less comprehensive production machinery that requires less space and has lower cost, is achieved. It is also considered to be possible to make a mobile facility for direct use in the proximity of actual fields that are developed. It is further to be understood that to wind for example common electric conductors, or wires, by means of S-Z winding is commonly known. But to design and manufacture an S-Z laid umbilical where the components are able to take load, has never been done before, just as umbilicals having S-Z laid steel pipes has never before been manufactured.

In a suitable embodiment the strength band, or the tape, is helically wound about the bundle in two or more layers, laid in opposite directions. Further the strength band, or the tape, can be helically wound about the bundle by relatively short laying length, like 0,1 to 0,5 meter.

The strength band can be of metallic material, like steel, lead or aluminium. Alternatively the strength band can include fiber armoured ribbon, fiber armoured ribbon with friction liner and textile ribbon, where the fibre armoured ribbon can be reinforced with aramid fiber, carbon fiber, glass fiber and other synthetic materials.

As one will understand, the nature of the strength band regarding strength, rigidity and how tight it is applied to the bundle, is used to increase/decrease the torsion stiffness,

which in turn influence on the load carrying capacity of the umbilical. In brief one can say that the more deep waters the umbilical is to be deployed, the more torsion stiffness is required.

It is to be understood that the laying of the fluid pipes, the wires/conductors, filler material and possibly other load carrying elements can alter direction at irregular intervals, while in another alternative embodiment it may alter direction at regular intervals.

In a typical embodiment, as one can recognize today, the laying will take place over approximately one half to three revolutions before it alters direction and is laid a corresponding number of revolutions in opposite laying direction before it once more alters direction.

In one embodiment the umbilical includes one or more separate layers with load carrying elements as outer layer that is located just within the sheath. These load carrying elements in each layer are, however, laid in a traditional way in a continuous helix in the same direction in the entire length extension of the umbilical. This will almost be as shown in said API standard, figures 7 and 8.

Preferably the load carrying elements can be light weight rods of composite material and/or steel string or steel wire and/or fiber rope and/or polyester rope and/or aramid threads. This finds its application when the depth exceeds a certain value. Then one will take into use carbon rods, for example, in order to increase the axial stiffness with minimum increase of the umbilical weight.

In order to increase the torsional stiffness of the umbilical, the filler material can be designed such that longitudinal grooves or flutes are formed that the material in the outer sheath are penetrated into when the material is extruded thereon. This will create friction creating means that increases the torsional stiffness of the umbilical. This will further ensure that no relative rotation between the outer sheath and the filler material takes place.

When strength band is used the strength band is wound by a certain distance between each winding such that a gap is formed between each winding in order to achieve the above said penetration of the sheath material into the groove during the extruding operation.

According to the present invention also a method of the introductory said kind is provided, which is distinguished in that the fluid pipes, electric wires/conductors, the filler material and possibly the at least one load carrying element are alternating laid, i.e. by constantly shifting direction, in the entire or part of the longitudinal extension of the umbilical and that the or each load carrying element either is centrally or peripheral located during the manufacture, and that the laid bundle is retained substantially torsional stiff by applying the outer protective sheath, possibly by the addition of a strength band, or a tape, that is helically wound about the bundle after said laying operation is complete and before the protective sheath is applied.

The strength band, or the tape, can be wound in a helix about the bundle in two or more layers laid in different directions. The strength band, or the tape, can be helical wound about the bundle with relatively short laying length, such as 0,1 to 0,5 meter. The laying can be performed with alternating direction at irregular intervals, alternatively at regular intervals. The laying operation can typically take place over an area from approximately one half to three revolutions before the direction thereof changes.

In one embodiment one or more separate layers of load carrying elements can be applied as outer layer inside the sheath, said load carrying elements in each layer are laid continuous in a helix in the same direction in the entire longitudinal extension of the umbilical.

In one embodiment the filler material can be configured such that longitudinally extending grooves or flutes are formed, and the material that forms the outer sheath is extruded onto the pipe bundle and penetrates into the grooves, to create the friction making means to increase the torsional stiffness of the umbilical.

When strength band is used, the strength band, or tape, can be wound thereon by some certain distance apart between each winding such that a gap exists between each winding and the extruded material is enabled to penetrate into the grooves.

With the new way of laying the umbilical, a new type of laying machine that is considerably simpler than the previously used machines is contemplated. The laying operation can take place by means of oscillating motions rather than the traditional rotating motions, rotations of the huge bobbins that carries the cables, pipes and filler material.

This means that the fluid pipes, the wires/conductors, the filler material and possibly other load carrying elements can be supplied differently than with the previous machine, which implies that the production equipment can be differently organized. By continuous laying in one direction with the huge bobbins, in addition to that they rotate about their own axis, are also brought to continuous, timed rotation about the longitudinal axis of the umbilical in order to obviate torsional stresses within the elongate elements that are fed out of the bobbins. These potential torsional stresses will by the new laying method only arise in small extent since the laying direction is shifting all the time. Those torsional stresses that build up in one direction are in turn relived when the laying direction changes and diminish towards zero again. Thus the huge bobbins do not need to rotate about the longitudinal axis of the umbilical, but can remain stationary. This simplifies the machine very significant. So significant that one can easily contemplate to construct a mobile facility where the umbilical can be produced proximate to where the umbilical is to be installed.

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

Fig. 1 shows a cross sectional view through a first embodiment of the umbilical according to the present invention with fiber tape being wound around the bundle of elongate elements,

Fig. 2 shows a cross sectional view through a variant of first embodiment of the umbilical shown in figure 1 having steel band wound around the bundle of elongate elements,

Fig. 3 shows a cross sectional view through another variant of first embodiment of the umbilical shown in figure 1 having longitudinally extending grooves in the filler material that are filled with sheath material, Fig. 4 shows a cross sectional view through a second embodiment of the umbilical according to the present invention with fiber tape being wound around the bundle of elongate elements,

Fig. 5 shows a cross sectional view through a variant of the second embodiment of the umbilical shown in figure 4 having steel band wound around the bundle of elongate elements,

Fig. 6 shows a cross sectional view through another variant of the second embodiment of the umbilical shown in figure 4 having longitudinally extending grooves in the filler material that are filled with sheath material,

Fig. 7 (prior art) shows extracts from API (American Petroleum Institute) specification 17E, figure D-2 that shows schematically a S-Z laid cable and laying machine,

Fig. 8 (prior art) also shows extracts from API (American Petroleum Institute) specification 17E, figures E-I and E-2 that show typical umbilicals having thermoplastic pipes laid in this way.

Two embodiments of the umbilical cross sections shown in the figures 1-6 will now be described, each having three variants. It is to be understood, however, that many embodiments and variants are within the scope of the appended claims. For the detailed construction of the traditional umbilical and how it is manufactured, reference is given to the previously mentioned WO 93/171776.

The umbilical according to figure 1 is basically constructed of the following elements: a bundle of elongate elements consisting of inner and outer channel elements 2, 3, for

example of polyvinyl chloride (PVC), electric conductors/wires 7, optical conductors 8 and metallic fluid pipes 4, 5, 6, normally made of steel, that are laid together into said bundle. The bundle is kept together and in place by a strength band, in this variant according to figure 1, fiber ribbon 9 that is wound circumferentially around the bundle before an outer sheath 1, for example made of polyethylene (PE), is extruded onto the bundle.

As an illustrating example of the dimensions we talk about here, without thereby being considered as limiting, the diameter of the umbilical can, as an example, be 107mm. The wires 7 can have a complete cross sectional area of 22mm ² and the optical conductors can have an outer diameter of 12mm. The steel pipes 4 can be 12,5 mm and the pipes 5, 6 can have 18mm as outer diameter. The umbilical can have a net weight (empty) of 152 N/m and designed tensile capacity of 233kN and strength at rupture of 416kN.

The inner and outer channel elements 2, 3 are lying at least partly around and between the fluid pipes 4, 5, 6 and are typically made as rigid, elongate, continuous elements of plastic material. The fluid pipes 4, 5, 6, the wires 7, the conductors 8 and filler material 2, 3 are alternating laid, i.e. having ongoing changing direction, in the entire or part of the longitudinal extension of the umbilical. In addition the laid bundle is kept substantially torsional stiff by the protective sheath 1 by having the addition of a strength band in the form of a fiber ribbon 9 that is helically wound around the bundle immediate inside the protective sheath 1.

The umbilical according to figure 2 is a variant of that shown in figure 1 and most of the elements are the same and are denoted with the same reference numbers. However, it is to be noted that the strength band now is a metal band which is given the reference number 10 replacing the fiber ribbon shown in figure 1. This variant will normally be used when the deployment shall take place in deeper waters. The way in which it is bundled and wound together corresponds to the variant described above. As an example, without thereby being limiting, the metal band 10 in a typical embodiment can

have a thickness of 0,8mm and be wound in two layers and applied with tension in the band 10.

The umbilical according to figure 3 is another variant of that shown in figure 1 and most of the elements are the same and are denoted with the same reference number. However, it is to be noted that the strength band now is a tape only, which is given the reference number 12 and has, actually, only a temporary function. This is to keep the bundle of elongate elements together until the outer sheath 1 of polyethylene is extruded onto the bundle. Further, longitudinally extending grooves 11 are made in or between the outer channel elements 3. This is done to be able to extrude the sheath material 1 into the grooves to lock the outer sheath 1 to the outer channel elements 3 or increase the friction therebetween in order to ensure sufficient torsional stiffness. To be able to extrude the sheath material into the grooves 11, the tape 12 is wound circumferentially by a predetermined space between each winding such that the sheath material can penetrate into the grooves 11. The way in which the umbilical is bundled and wound together corresponds to the variants described above.

Figure 4 shows a second main embodiment of the umbilical having somewhat smaller cross section. Most of the elements from the embodiment according to the figures 1-3 are the same and are denoted with the same reference number with the addition of a mark'. The umbilical according to figure 4 is as before basically constructed of the following elements: a bundle of elongate elements consisting of inner and outer channel elements 2\ 3', for example of polyvinyl chloride (PVC), electric conductors/wires T, possibly optical conductors and metallic fluid pipes 4', 5', 6\ normally made of steel, that are laid together into said bundle. The bundle is kept together and in place by a strength band, in this variant according to figure 4, fiber ribbon 9' that is wound circumferentially around the bundle before an outer sheath 1 ', for example made of polyethylene (PE), is extruded onto the bundle. The way in which it is bundled and wound together corresponds to the variants described above.

The umbilical according to figure 5 is a variant of that shown in figure 4 and most of the elements are the same and are denoted with the same reference numbers. However, it is

to be noted that the strength band now is a metal band which is given the reference number 10' replacing the fiber ribbon shown in figure 4. This variant will normally be used when the deployment shall take place in deeper waters. The way in which it is bundled and wound together corresponds to the variant described above.

The umbilical according to figure 6 is still another variant of that shown in figure 4 and most of the elements are the same and are denoted with the same reference numbers. However, it is to be noted that the strength band now is a tape only, which is given the reference number 12' and has, actually, only a temporary function. This is to keep the bundle of elongate elements together until the outer sheath 1 ' of polyethylene is extruded onto the bundle. Further, longitudinally extending grooves 11 ' are made in or between the outer channel elements 3'. This is done to be able to extrude the sheath material 1' into the grooves to lock the outer sheath 1' to the outer channel elements 3' or increase the friction therebetween in order to ensure sufficient torsional stiffness. To be able to extrude the sheath material into the grooves 11 ' the tape 12' is wound circumferentially by a predetermined space between each winding such that the sheath material can penetrate into the grooves 11'. The way in which it is bundled and wound together corresponds to the variants described above.

Figure 7 and 8 show extracts from API (American Petroleum Institute) specification 17E, "Specification for Subsea Production Control Umbilicals", in particular pages 42 and 43. Figure 7 shows schematically in the lower view an S-Z laid, or oscillatory laid umbilical. The upper figure shows totally schematic how the machinery for this type of laying is contemplated. Figure 8 shows two variants of umbilicals that can be laid in this way, then as mentioned with thermoplastic fluid pipes.