Abstract:
An umbilical assembly for supplying power to subsea equipment includes an electrical conductor to convey an electrical current to the subsea equipment. An insulator surrounds the conductor. A support member is positioned between the insulator and the conductor. The support member has either non-magnetic properties or low-magnetic properties because of its material composition. The support member is adapted to connect to a structure at the surface of the sea. The support member supports the weight of the conductor. The supporting of the weight of the conductor by the support member can be to reduce creep typically associated with the conductor supporting its own weight. The support member can be used to hermetically seal the conductor and prevent hydrogen migration along the conductor.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates to supplying electrical power to subsea equipment, and more particularly, to a power umbilical that can be used for supplying electrical power in deepwater and ultra-deepwater applications. 
       BACKGROUND OF THE INVENTION 
       [0002]    In offshore hydrocarbon production, there is typically a structure either a vessel such as a floating production storage and offloading (FPSO) vessel or a platform-i, at the surface of the sea positioned above a production field on the sea floor. There are typically several wellheads that are producing hydrocarbons to be conveyed to the vessel. Moreover, there is often other subsea equipment that requires electrical power to control, regulate, pre-treat, and/or monitor the hydrocarbon production. For example, such equipment can include, but not be limited to, a subsea pump, a subsea compressor, a control or distribution module, a lower marine riser package and blow-out preventer, an electrically submersible pump, a subsea separator, or various types of sensors and communication devices. 
         [0003]    In order to provide such electrical power to the subsea equipment, a power umbilical extends from the structure at the surface of the sea to the field. The power umbilical typically registers with a stab or hub which receives the electrical power and distributes the electrical power through a plurality of control lines to each of the subsea equipment requiring such power. 
         [0004]    Typically, the power umbilical utilizes copper cables as the conductor for conveying such electrical power from the vessel or structure at the surface of the sea to the subsea equipment. It has been observed that for deepwater (more than about 1500 feet depth) and ultra-deepwater (more than about 4000 feet depth), the weight of the copper itself causes deformation in an elongated maimer or “creep” to occur to the copper. Such deformation or creep can ultimately lead to mechanical failure because the copper can become stretched and embrittled. However, even before such mechanical failure such deformation or creep creates losses with the electrical power being transmitted at the hangoff of the structure at the surface of the sea to the subsea equipment. For example, the creep can cause power losses or heat which can be disruptive to the subsea equipment—such as motors for the subsea pumps, electrically submersible pumps, and compressors. Generally speaking, wave disruption of electrical wave is a function of the distance or length the electrical power is being communicated or transmitted (e.g., the length of the conductor) and the magneticity of the materials adjacent the conductor. For small distances, any disruptions due to the magnetic properties of materials around or near the conductor are typically minimal. However, as the distance increases, such disruptions become larger and create a challenge because of the disruptions to the wave form of the electrical current. 
         [0005]    Another problem that has been recognized with prior assemblies is hydrogen migration. For example, such hydrogen formation can occur when there are components comprising zinc within the umbilical. If hydrogen forms within the umbilical, then the hydrogen will try to find a path of least resistance to exit the umbilical. Sometimes the hydrogen is able to find a way through the outer jacket of the umbilical. However, it has also been observed that the hydrogen seeps through the insulators, which can prevent the water from seeping through to the conductors but not the smaller hydrogen molecules, and the hydrogen follows the conductor cables toward the ends of the umbilical. At the ends of the umbilical, the hydrogen typically becomes backed-up and begins to build pressure. When such occurrence is unknown to the operator, the high pressure hydrogen has been known to blow connection the end of the umbilical with an explosion. To prevent such explosions, operators are having to monitor hydrogen migration along the conductor cables, as well as relieving pressure when it reaches a predetermined amount. 
       SUMMARY OF THE INVENTION 
       [0006]    An umbilical assembly for supplying power to subsea equipment includes an electrical conductor to convey an electrical current to the subsea equipment. The umbilical assembly also includes an insulator surrounding the conductor. The umbilical assembly also has a support member, having either non-magnetic properties or low-magnetic properties, positioned between the insulator and the conductor. The support member is adapted to connect to a structure at the surface of the sea. The support member supports the weight of the conductor, 
         [0007]    In the umbilical assembly, the conductor can be a stranded conductor. The stranded conductor can include copper or aluminum cables. When copper cables are used, the supporting of the weight of the conductor with the support member can reduce creep. In the umbilical assembly, the conductor can selected from a type of conductor consisting of a stranded conductor, a solid conductor, and a segmented conductor. 
         [0008]    In the umbilical assembly, the support member can be close-coupled with the conductor. In the umbilical assembly, the support member can also have a textured inner surface that enhances friction between the support member and the conductor. 
         [0009]    In the umbilical assembly, the support member can be stainless steel. In the umbilical assembly, the support member can be AL 4565 alloy stainless steel or Duplex stainless steel. In the umbilical assembly, the support member can be a stainless steel having a chromium content of more than 19 weight percent. In the umbilical assembly, the support member can be a stainless steel having a chromium content of between 22 and 25 weight percent. In the umbilical assembly, the support member can be a stainless steel having a chromium content of more than 25 weight percent. 
         [0010]    In the umbilical assembly, the support member can hermetically seal the conductor and prevent hydrogen migration along the conductor. 
         [0011]    In the umbilical assembly, there can be a plurality of conductors, support members, and insulators extending parallel to each other. The umbilical assembly can also have an outer jacket enclosing the plurality of conductors, support members, and insulators. 
         [0012]    In the umbilical assembly, the umbilical assembly can be adapted to extend to a depth of at least 1500 feet to supply power to the subsea equipment. In the umbilical assembly, the umbilical can also be adapted to extend to a depth of at least 4000 feet to supply power to the subsea equipment. In the umbilical assembly, the umbilical can also be adapted to extend to a depth of at least 10,000 feet to supply power to the subsea equipment. 
         [0013]    Another aspect of the invention is a system for supplying power subsea to subsea equipment requiring electrical power. The system includes a structure associated with hydrocarbon production located at the surface of the sea. The system also includes a conductor extending from the structure toward the sea floor to communicate electrical power from the structure to the subsea equipment. An insulator surrounds the conductor. A support member, having either non-magnetic properties or low-magnetic properties, is positioned between the insulator and the conductor. The support member is connected to the structure at the surface of the sea. The support member supports the weight of the conductor. 
         [0014]    In the system, the support member hermetically seals the conductor and prevents hydrogen migration along the conductor. In the system, the there can be a plurality of conductors, support members, and insulators extending parallel to each other. The system can also include an outer jacket enclosing the plurality of conductors, support members, and insulators. 
         [0015]    The system can also include a subsea distribution module in electrical communication with the conductor and the subsea equipment. The distribution module can selectively distribute electrical power received from the structure to the subsea equipment. 
         [0016]    In the system, the structure can provide power to the subsea equipment, which is positioned on the sea floor and operating in a deepwater environment or in an ultra-deepwater environment. 
         [0017]    In the system, the support member can include stainless steel, and the conductor of electrically conductive cables can have copper cables. The supporting of the weight of the conductor with the support member can reduce creep associated with the copper cables. The conductor call also be a stranded conductor with a plurality of copper cables. 
         [0018]    In the system, the conductor of electrically conductive cables can have cables selected from a group consisting of copper cables, aluminum cables, till, silver, and a conductive alloy. 
         [0019]    In the system, the support member can be close-coupled with the conductor. In the system, the support member can further have a textured inner surface that enhances friction between the support member and the conductor. In the system, the support member can eliminate creep for a predetermined lifetime of a hydrocarbon producing field. 
         [0020]    Another aspect of the invention is a method of supplying electrical power from a structure at the surface of the sea to subsea electrical equipment. The method includes the step of extending a conductor from the structure to the subsea electrical equipment. The method includes the step of surrounding the conductor with an insulator. The method also includes the step of positioning a support member having either non-magnetic properties or low-magnetic properties between the insulator and the conductor. The method includes the step of connecting the support member to the structure. The method also includes the step of supporting the weight of the conductor in order to reduce creep associated with the weight of the conductor with a support member. 
         [0021]    In the method, the step of supporting the weight with the conductor can also include eliminating creep associated with the weight of the conductor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is perspective view of a production facility providing electrical power to subsea equipment with an umbilical made in accordance with the present invention. 
           [0023]      FIG. 2  is sectional view of the umbilical of  FIG. 1  taken along line  2 - 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    Referring to  FIG. 1 , a structure  11  is shown at the surface of the sea. Structure  11  is typically moored to a sea floor  13  by a plurality of mooring lines  15 . While structure  11  is shown as a platform, it will be readily appreciated by those skilled in the art that structure  11  can alternatively be a floating production storage and offloading (FPSO) vessel. In an embodiment of the this invention, sea floor  13  is greater than or equal to 1500 feet deep such that structure  11  is supporting deepwater operations. In another embodiment of this invention, sea floor  13  is greater than or equal to 4000 feet deep such that structure  11  is supporting ultra-deepwater operations. As will be readily understood by those skilled in the art, “deepwater” and “ultra-deepwater” are terms of art which can vary slightly depending upon those you talk with and time. For the purposes of this invention, it is contemplated that these terms shall be as listed above. 
         [0025]    A production riser  17  communicates hydrocarbons produced from a plurality of wellheads  19  to structure  11 . In an embodiment of the invention, there is a plurality of production risers  17  communicating hydrocarbons to structure  11  Risers  17  can receive hydrocarbons directly from a one of wellheads  19 , or alternatively receive hydrocarbons from another subsea collection structure  21  such as a collection manifold or a subsea pump which is in fluid communication with riser  17 . 
         [0026]    A power umbilical  23  extends from structure  11  toward sea floor  13  to provide electrical power to the subsea equipment. As will be readily appreciated by those skilled in the art, power umbilical can also be used for communication and control purposes by including additional lines within power umbilical. In an embodiment of the invention, power umbilical registers with a distribution module  25 . Distribution module  25  receives the electrical power from power umbilical and distributes it to the other subsea equipment, such as wellheads  19  and collection structure  21 , via lines  27 . As will be readily appreciated by those skilled in the art, distribution module  25  could distribute power to a variety of subsea electrical equipment that are not illustrated but are contemplated as part of the present invention. Many such subsea equipment are listed above here in the Background of the Invention. 
         [0027]    Referring to  FIG. 2 , in an embodiment of the invention umbilical  23  includes an outer jacket  29  and an armor package  31  that sealingly protects the internal components of umbilical  2  from the sea water as well as providing a first layer of protection from structural damage, for example resulting from impacts, friction, and bending during deployment. An inner liner or belt  33  is carried within jacket  29  and armor package  31 . Belt  33  provides further protection for the internal components of umbilical  23 , as well as defining an inner or effective diameter of umbilical  23 . 
         [0028]    In an embodiment of the invention, belt  33  carries a tubular lubricant conduit  37  and a communication conduit  39 . Communication conduit  39  preferably carries communications means such as fiber optic lines. Lubricant conduit  37  call provide lubrication fluid to the subsea equipment. Alternatively, or additionally if there are a plurality of lubricant conduits as shown in  FIG. 2 , lubricant conduit  37  can provide hydraulic fluid for use in actuating hydraulically controlled subsea and downhole mechanisms. Belt  33  can also carries carbon fiber rods  41  intermittently spaced therein to increase the longitudinal strength of umbilical  23 , while decreasing the in-water weight as compared to prior umbilicals relying solely upon belt  33 , armor package  31 , and jacket  29  for such strength. 
         [0029]    Umbilical  23  includes a power cable  43  that is also carried within belt  33 . In an embodiment of the invention, there is a plurality of power cables  43 . According to a best mode of the invention, such power cables  43  are symmetrically spaced within belt  33 , with lubricant conduit  37 , communication conduit  39 , and carbon fiber rods  41  embedded in the interstitial spaces or interspatial locations therebetween, as best illustrated in  FIG. 2 . 
         [0030]    According to an embodiment of the invention, power cables  43  include a conductor  45 . Conductor  45  can be a cable or line having an acceptable conductance. For example, copper and aluminum both have conductive properties that are desirable for conveying electrical current. In conventional offshore umbilicals, conductor  45  is a stranded conductor having a plurality of small conductor lines or cables that are bunched or grouped together. In an embodiment of the invention, when conductor  45  is a stranded conductor with a plurality of copper cables, it is contemplated that conductor  45  will be about one-half inch in diameter. With conductor  45  having a one-half inch diameter, umbilical  23  having the components illustrated in  FIG. 2 , for example, would typically have an outer diameter around the circumference of jacket  29  of about three and one-quarter inches, and an inner diameter associated with belt  33  of about 2.22 inches. As will be readily appreciated by those skilled in the art, such dimensions are exemplary based upon the components illustrated in  FIG. 2 , and can vary with an increase in size of conductor  45 , number of power cables  43 , and number of other components such as lubricant conduit  37 , communication conduit  39 , and carbon fiber rods  41 . 
         [0031]    While a single large cable or line (solid conductor) can be used, such a cable or line is generally less flexible and has a shorter operational life before fatigue failure. As will be readily appreciated by those skilled in the art, a segmented conductor is also contemplated as an alternative conductor. In an embodiment of this invention, conductor  45  comprises a stranded conductor having lines that are copper. As will be readily appreciated by those skilled in the art, other conductive metals may be utilized as well. Such alternate conductors may increase the diameter of conductor  45 . While in some situations it may not be desirable to increase the size of umbilical  23  by increasing the size of conductor  45  when using Aluminum (typically doubling in diameter), such an arrangement can decrease the overall weight of umbilical because Aluminum weighs less. Some such alternate conductors, such as aluminum would not experience creep or deformation like copper conductors; however, the increase in diameter to achieve the necessary communication of electrical power may not be beneficial at this time, 
         [0032]    A strength or support conduit member  47  surrounds each conductor  45 . In an embodiment of the invention, support member or conduit  47  is close-coupled with conductor  45  so that support member  47  carries the weight associated with each conductor  45 . In such an arrangement, conductor  45  can be held in place relative to an interior surface of support member  47  by frictional forces due solely from an interference-fit relationship associated with the close coupling. Alternatively, support member  47  may have a textured inner surface to increase frictional forces such that the close coupling of support member  47  does not need to create as much of an interference fit. 
         [0033]    In an embodiment of the invention, support member  47  comprises metal tubing that is seam welded and swaged around conductor  45 . In such an arrangement, support member  47  hermetically seals conductor  45  and therefore prevents the problem of hydrogen migration along conductor  45  as discussed above herein. Alternatively, support member  47  can comprise a plurality of metal members held together by a nonmetallic substrate, similar to an armor package. 
         [0034]    In either embodiment, however, support member  47  should have either non-magnetic or low magnetic properties based upon their material compositions, such as stainless steel. As will be readily understood by those in the art, magnetic properties are typically associated with the presence of iron carbite (Fe3C) in a material. It is preferred if no iron carbite is present, such that support member  47  is non-metallic. However, in the manufacturing processes associated with support member  47 , even stainless steel, a small amount of iron carbite may form. Such formations can be acceptable so long as such formations create only low magnetic properties for support member  47 . Such low magnetic properties are preferably such that there is not a significant disruption of the waveforms associated with the electrical current due to any electromagnetic interference caused by magnetic elements in close proximity to conductor  45 . 
         [0035]    Examples of acceptable non- or low magnetic property stainless steels include “duplex” stainless steel as well as AL 4565 Alloy stainless steel. Duplex stainless steels typically have a mixed microstructure of austenite and ferrite. Typically, during production, the manufacturer aims at producing a 50:50 mix of austenite and ferrite. However, in commercial alloys the mix may be 40:60 respectively. Duplex stainless steels are often characterized by high chromium (19-32 wt. %) and molybdenum (up to 5 wt. %) and lower nickel contents than austenitic stainless steels. AL 4565 alloy stainless steels (UNS S34565) are “superaustenitic stainless steels” which typically have high strength and toughness. AL 4565 alloy stainless steels have a typical material composition of 23-25 wt. % chromium, 5-7 wt. % Manganese, 4-5 wt. % Molybdenum, 0.4-0.6 wt. % Nitrogen, 16-18 wt. % Nickel, less than or equal to 0.01 wt. % Carbon, and the remainder being Iron. 
         [0036]    As will be appreciated bv those skilled in the art, the magnetic properties of a stainless steel typically decrease as the chromium content increase, whereas a 32 wt. % chromium has substantially no magnetic properties. At this time, it is contemplated that a high allow stainless steel having a cluromium content of 19-32 wt. % is acceptable (such as with the AL 4565 stainless steel), as well as 22-25 wt. % with the Duplex stainless steels. As will be readily appreciated by, those skilled in the art, it would also be acceptable to use other such high allow stainless steels such as “Super Duplex” stainless steel, which has at least 25 wt. % chromium. 
         [0037]    In an embodiment of the invention, power cable  43  also includes an insulator  49  that surrounds and encloses both conductor  45  and strength member  47 . Strength member  47  and insulator  49  act together to help to transfer heat from the conductive lines within conductor  45 , as well providing additional protection against sea water. Positioning support member  47  between insulator  49  and conductor  45  is contemplated as helping to accomplish the reduction in the size of the support member  47  as well as allowing support member to carry the weight of conductor  45 . Having support member  47  carry the weight of conductor  45  helps to reduce and/or eliminate the creep or deformation associated with the conductor  45  over a predetermined lifetime of the hydrocarbon producing field (typically twenty (20) years) because the conductor lines are no longer supporting themselves. 
         [0038]    According to an embodiment of this invention umbilical  23  allows structure  11  to provide electrical power to subsea equipment when sea floor  13  is greater than or equal to 1500 feet deep such that structure  11  is supporting deepwater operations. In another embodiment of this invention, umbilical  23  allows structure  11  to provide electrical power to subsea equipment when sea floor  13  is greater than or equal to 4000 feet deep such that structure  11  is supporting ultra-deepwater operations. In yet another embodiment, umbilical  23  allows structure  11  to provide electrical power to subsea equipment when sea floor  13  is greater than or equal to 10,000 feet deep. In each of these embodiments, when support member  47  is a tubular metal conduit that is welded and swaged around conductor  45  conductor  45  is hermetically sealed to prevent the problem of hydrogen migration along conductor  45  as discussed above herein. In each of these embodiments, the weight of conductor  45  is transferred and carried by support member  47 , which helps to reduce and eliminate creep for metal conductors such as copper. 
         [0039]    While in the foregoing specification this invention has been described in relation to certain embodiments and preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to alteration and that certain other details described herein can vary considerably without departing from the basic principles of the invention. For example, umbilical  23  is illustrated as a being catenary type, but may also be vertical or an S-type curve due to buoys (e.g. a “Lazy Wave”). Moreover, the number of power cables  43  can be altered according to specific design requirements. Furthermore, support members  47  can comprise other materials having non-magnetic or low magnetic properties than those specifically provided as examples.