Dynamic Deep Water Power Cables/

Power Umbilicals

Jon Arne Häll

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