Dynamic Deep Water Power Cables/
Power Umbilicals
Jon Arne Hll
Nexans Norway AS
Introduction
Background:
More infrastructure at the sea bed requires electric power
and hydraulic service
And in deeper waters 3000 m.
Nexans Dynamic Deep Water Power Cable qualification
program:
3000 m water depth
Development both for 3 phase AC systems and coaxial for use
in DEH and DC
According to DNV OSS 401 Technology Qualification
Management
Failure mode no.1: Mechanical failure of the copper conductor
Dynamic cables - examples
Power umbilical DEH Riser One flowline
Interplatform XLPE 145 kV AC DEH Riser Two flowlines
Qualification Basis
Vessel and configuration data:
The cable is assumed
suspended in a lazy wave
configuration from a semi-
submersible vessel at 3000 m.
The cable dynamics are
limited by a bend stiffener at
the I-tube exit.
Concept Selection
Copper (Cu)
300
Stress [MPa]
250
200 Rp02 @ 2900 m
150
100
50 Non-linear @ 1300 m
95 mm2 Cu conductor 0
0 0,2 0,4 0,6 0,8 1
with XLPE insulation Elongation [%]
Additional effects that must be accounted for:
Dynamics.
Creep.
Fatigue.
Cu needs reinforcement at 3000 m water depth.
Concept Selection
Selected cable concept :
Protective sheath
Steel armour layers to relieve
the conductor stress
Inner sheath for armour
bedding
Power phases
Profiles for transmission of
contact forces
Test cables
Lay-angle - One concept 3 designs
Power Armour
phase layers
Cable 1 Low High
Cable 2 Medium Medium
Cable 3 High Low
Qualification status
An optimized prototype cable designed for
dynamic application at 3000 m water depth is
manufactured, with 95 mm2 conductors
The design is based on calculation tools verified by
actual conductor and cable testing
Conductor fatigue properties have been
established
Dynamic analysis has been performed and verified
by full scale testing
Full scale qualification testing performed in-house
Ready for delivery
Use of the development
Jack and St Malo field
GoM, 7000 ft Water depth
Qualification, testing and delivery of Power
Umbilicals for subsea pumps
Qualification and testing of large 630 mm2
Power Cable
Jack and St Malo Power Umbilicals
Armoured design (strength carrier)
2 x 3 36kV 95mm2 Power Cores
3 x 16 Single mode Fiber Cables
2 x 2kV Copper Quads 10mm2
1 x 4 Single Mode Fiber for temperatur and
strain measurment/monitoring.
Status Jack and St Malo Power Umbilicals
2 Year Engineering Study
2 Year Qualification Program including production
of prototype length and full scale testing of
complete system
Delivery of 2 x 21 km Delivery lengths
630 mm2 LDPCU Cable system
No.
Function Off Dimension Design Requirement
Design power = 28.0
MVA
@ 34.5 kV
MV Power Design voltage = 36
Supply 3 630mm2 3-phase, symmetrical kV
Single-mode,
4 fibres armoured Wavelength =
FO, strain 2 OD = 10 mm ITU-T G.652.D 1310-1550 nm
Single-mode,
16 fibres unarmoured Wavelength =
FO, signal 2 OD = 10 mm ITU-T G.652.D 1310-1550 nm
630 mm2 LDPCU Cable system status
Engineering Study
Qualification Program including production of
prototype length and full scale testing of
complete system
Final report presented to Client
Summary Protection of conductor in a
Dynamic Power Cable
1. Optimize lay angles
2. Calculate that proper conductor stress relief is achieved by
a verified FEM tool
3. Establish the conductor fatigue properties taking into
account the non-linear stress-strain behavior of copper and
internal friction between the wires
4. Improved input and evaluation of effects of friction
5. Perform dynamic analysis based on the established and
improved fatigue curve
6. Design is qualified according to ISO-13628-5
