�

Customised Offshore Cables

Customised Offshore Cables Subsea Communication and Control

�

Phot

o: Jø

rn A

dde

�

Content

Introduction Innovation Through Experience

Product Categories: ROV Umbilicals ROV Tethers Subsea and Platform Umbilicals Seismic and Oceanographic Cables Fibre Optic Topside Cables Fibre Optic Submarine Cables Electrical and Optical Elements Accessories and Services

Quality Management Quality Management and HSE Nexans Cable Production

05

0608101214151618

2022

�

Phot

o: Jø

rn A

dde

�

Nexans: Innovation through experience

Nexans designs and manufactures special underwater cables. Our cables are known for their robustness and are tested day in and day out in some of the harshest working environments known to man.

Despite the fact that our cables are tried and tested, we continue to innovate, designing and manufacturing better cables, with longer work life, for deeper water depths, for greater and greater distances.

We understand your requirementsWe have designed and built hundreds of umbilicals for remotely operated vehicles (ROV) and have manufactured over ��,000 km of fibre optic subma-rine cable. We design and manufacture cables which operate at 6000m water depths. Our extensive experience is a benefit recognized by our customers.

We transform your needs into a cable designYour specification and our experience, as well as highly specialised technologies available within the company, are the tools which translate your requirements into an operational design.

International experienceOur cables are operational in all parts of the world. Our experience includes large international projects as well as regular delivery to ROV operators. We have logistics and project administration teams in place to accommodate a wide range of customer demands.

Nexans Norway AS at the forefrontThrough development of new tech-nologies qualified through extensive test programs, our aim is to continue to provide our customers with new and better solutions.

6

Applications:Nexans supplies umbilcals to most of the well known ROV operators. Our focus is on continuous improvement and innova-tiveness with respect to our raw materials and manufacturing processes. Our cables are highly dynamic, torque balanced and compact, and are known for their reliability and robustness.

Design:We have designs for the majority of standard ROVs and we develop new designs for specific applications accord-ing to customer specifications.

Steel armoured umbilicals are designed for vehicles commonly used for trenching, ploughing, maintenance, and drill support. This cable is typically designed with a two or three layer torque balanced steel wire armouring and � phase power supply, instrumentation, and fibre optics in a laser welded steel tube. Typical depth rating is �000 to �000m. For deck cables the design is produced with steel tape armouring.

Deep water umbilicals are designed for dynamic deep water applications rated down to 6000 m. The power conductors, fibre optic elements and control conductors are armoured with aramid yarns and covered by a sheath of thermoplastic elastomer which both protects and enables easy termination.

We design for the following ROV vehicles among others: ArgusBoxerCapjetExaminerFlexjetFugro CoreGatorHectorHerculesInnovatorLynxMagnumMakoMarlinMillenniumMRVPL�QuestReconScorpio ScorpionSCVSpiderST�00Triton (XI)

ROV UmbilicalsReliable at any depth

�

Main Design Characteristics:

Typical Characteristics Description Typical range

Electrical signallingOptical signallingPowerPower transferArmouringSheath

Quad/Pair/ TriadSteel tube0.6 – 6.6 kVkVAGalvanised steel/aramidPPE (PP, PE)

0.��mm² to 0.�mm²� – �� fibers SM + MM0.��mm² to 0.�mm²up to �0000.9-�.0 mm–

Main Mechanical and Environmental Characteristics

Typical Characteristics Unit Typical range

Cable outer diameterSafe working loadBreaking strengthOperational depth

mmkNkNmm

�� – 80up to �00

up to �0006000

8

Applications:The alternative to a free swimming ROV is the use of a TMS (Tether Management System) to deploy a ROV to the working depth. Tether cables are used in con- junction with ROV vehicles being deployed from TMS or directly from the surface for smaller ROVs.

We design and manufacture tethers which are characterised by high flexibility, good durability, high strength, neutral buoyancy and minimum drag. The compact and reliable cable core is key to maintaining positive buoyancy even at �000 m water depth.

ROV Tethers Designed for durability

Design:Cables are tailor made for specific applications according to customer specification. A typical design contains a three phase power supply (�00-��0HP), instrumen-tation and conductors; Fibre in a laser welded steel tube encased in a jelly giving internal protection and support for monitoring and video transmission; The cable is armoured with aramid yarn and has typically a TPR (thermoplastic rubber) outer sheath for buoyancy.

9

Main Mechanical and Environmental Characteristics

Typical Characteristics Unit Value

Cable outer diameterWeight in sea water (�.0�� kg/dm³), � barWeight in sea water (�.0�� kg/dm³), �00 barMinimum dynamic bending diameterSafe working loadBreaking strengthOperational depth, maxPower conductors, ROV motorPower conductors, InstrumentationFibre optics

mmkg/kmkg/kmmmkNkNmmm�

mm�

-

�� - �0-�00 - +�0-0 - +��0�00 - 900�-�0�-��0�000�-60.�-���

Phot

o: N

OA

A

�0

Applications:Our design and manufacturing expertise within this product group is well suited to the oil and gas industry’s increasing focus on cost effective operation of installations and increased utilisation of reserves.

Control umbilicals cover applications such as instrumentation, monitoring and control of remotely operated subsea installations from offshore platforms or onshore facilities.

Interplatform and shore to platform cables supply power to offshore install-ations and allow for remote control of unmanned installations.

Main Mechanical and Environmental CharacteristicsDesigns are tailored according to customer needs. The ranges of characteristics given in the table below are indicative only.

Typical Characteristics Unit Typical range

Cable outer diameterSafe working loadBreaking strengthOperational depth, maxPower transferOperating voltageFibre optics

mmkNkNmkVAkV-

�0 – �00up to �00up to �000�000up to �000up to �.�� – �8

Subsea and Platform Umbilicals

Design:The applicable subsea control and oper-ational system determines the character-istics of the umbilical. Power cores, fibre optic elements, steel tubes, hydraulic hoses, coaxial elements, with or without armouring are elements dependent on the application. Signal – electrical Pairs or quads

Signal – optical A selection of maximum 96 single mode and multimode optical fibres protected by a laser-welded steel tube. Up to � steel tubes can be integrated in one FO unit. Power supply Multiple power conductors of varying size from 0.8� to �0 mm�. The voltage rating can be up to ��kV (high voltage umbilicals can be manufac-tured at Nexans Norway’s HV facility).

Sheath Individual sheaths applied over each bundle of elements to ease termi- nation.

Armouring Two or more layers of galva-nised high strength steel wires designed for mechanical protection and torque balance.

Outer protection Polyethylene sheath or yarn protect the amouring against corrosion attack.

Subsea Monitoring Umbilical for BP Thunder Horse Project

Securing value through reliable connections

��

Shore to installation power systems lighting up the North Sea

Phot

o: M

arit

Hom

med

al/

Stat

oil

��

Applications:Nexans is a long time supplier of cables for seismic exploration. We have also expertise with permanently deployed systems for oceanographic, geophysical, and military monitoring systems.

Towed and bottom laid seismic acquisi-tion systems require a wide range of cables. Nexans designs and manu-factures a range of gun cables, sensor cables, riser cables and lead-in cables for subsea seismic operation down to �000 m water depth. Our cable designs are characterised by their mechanical strength, deep-water applications, and durability.

Main Mechanical and Environmental Characteristics

Typical Characteristics Unit Sensor cable

Cable outer diameterSafe working loadBreaking strengthOperational depth, maxOperating voltageFibre optics

mmkNkNmV-

��-80up to �0� up to ��0 �000��0��

Seismic and Oceanographic Cables

Riser / Lead-In

��-��up to �0� up to �80 �000��0��

Air-gun umbilical

6� – 8�up to �0up to �00 NAup to ��00��

Efficient and Effective solutions

Phot

o: P

GS

��

Air-gun cables are used in both towed and bottom laid seismic systems. Typically these cables are steel armoured, compris-ing a central pneumatic hose with power and signal elements laid up around the perimeter. Aramid armouring can be supplied on request.

Sensor cables for permanent and non-permanent bottom laid seismic systems are typically comprised of high perform-ance signal quads and power conductors and optical fibres can be supplied on request. Each cable section has a torque balanced galfan steel wire armouring.

Riser and Lead-in cables correspond-ingly for bottom laid and towed seismic systems are typically comprised of high performance signal quads, optical fibres and power conductors. These cables are heavily armoured with either steel wires or aramid yarns.

Phot

o: w

ww

.woo

dsid

e.co

m.a

u

��

Fibre Optic Topside Cables

Applications:Our fire and mud resistant fibre optic topside cables link platforms to submarine cables. These cables are specially suited for operational and emergency systems on oil and gas platforms and meet the most stringent of IEC requirements.

Design:The Fire Resistant Cable consists of non- combustible materials to ensure oper-ation in a fire situation with temperatures exceeding �000 oC and/or deployment in a mud or chemical containing environ-ments.

Laser welded stainless steel tube protects the fibres and can contain up to �8 fibres in a �.� mm tube and up to 96 fibres in a �.� mm tube.Inner and outer sheath of halogen free flame retardant polyamide and gives the mud/chemical protection designed for �� years lifetime.Armouring of galvanised steel wires helically stranded in one layer.

When safety counts

Phot

o: M

arit

Hom

med

al/

Stat

oil

��

Applications:Our fibre optic submarine cables have been designed specifically for repeater-less systems and have almost unlimited capacity over extremely long distances. Our unrepetered cable family (URC-�) contains a wide range of mechanical design options for various water depths and operational conditions.

Our special submarine jointing tech-nology makes it possible to join long manufactured lengths thus giving unlimited lengths of cable.

Fibre Optic Submarine Cables

Design:We manufacture cables for each specific application using the design elements described below.

Laser welded stainless steel tube comes in � different diameters to hold different fibre counts. Single tube designs offer a maximum of 96 fibres whereas multi-tube designs allow for �8� fibres.

Copper conductors for electrode and power ranging from � ohm/km to �.� ohm/km.

Polyethylene inner sheath covers the steel tube(s) and has a diameter of �0 mm.

Armouring packages include light weight (LW), single armoured (SA), double armoured (DA) and rock armoured (RA) which provide protection during installa-tion and operation.

Outer layer of polypropylene yarn or polyethylene for protection.

Main Mechanical and Environmental Characteristics

Characteristics LW SA

Outer diameter (mm)Cable weight in air (kg/m)Minimum breaking load (kN)Nominal transient tensile strength (kN)Maximum deployment ocean depth (m)Minimum bending diameter (m)

�90.�

60 - ���0 - 60

�000 - �000�.0

�0 - ��0.8 - �.�

�00 - �80�0 - �00

�000 - �000�.0 - �.�

DA

�� - ���.� - �.8

�00 - 6�0��0 - �00

�000 - �000�.� - �.�

RA

��6.�

�00,0�00�00�.�

Decades of experience

Phot

o: M

arit

Hom

med

al/

Stat

oil

�6

Applications:We design and manufacture copper and fibre optic elements for signal and power requirements for integration in large combination umbilicals together with steel tubes or high voltage conductors.

We are known for our ability to produce long lengths of un-spliced cables, and we have developed splicing technology enabling very long final lengths. Our elements are known for their mechanical quality and longevity in the most demand-ing of environments.

Design of Standard Copper Elements:Copper elements are pair and quad configurations of the following sizes: �.�, �.�, �, 6, �0, ��.�, �6 and �� mm². Our cable designs include both

Electrical and Optical Elements

Nexans delivered power and fibre elements to the Danish Horns Rev Windmill Park

armoured and non-armoured elements and incorporate the following special purpose materials:

Insulation of conductors Polyethylene

Fillers in interstices Petroleum jelly and polyethylene to prevent longitudinal water ingress

Inner and outer sheathes Semi- conductive polyethylene and insulating polypropylene

Amouring options include galvanised steel wires, providing high breaking strength and radial protection, aramid yarn for tension relief, or steel tape for both radial protection and electrical shielding

Building blocks for successful operations

��

Physical Characteristics Steel Wires:

QUAD Unit 2.5 mm²

Outer diameterWeight in airWeight in seawaterSafe working load

mmkg/kmkg/kmkN

�8.��00��00.��

4 mm²

�0.68�0�0�0.�

6 mm²

��.8980���0.6

Physical and Electrical Characteristics Copper Elements:The characteristics above are typical for a standard quad design with steel armouring. Final design for each cable is application specific and all relevant characteristics for the cable are docu-mented in a unique technical description.

10 mm²

��.0������0�.0

16 mm²

�6.���6�6���.6

Fibre Optic Elements:Fibre optic elements provide signal and optical communication in an umbilical. Combinations of up to 96 multimode and/or single mode fibres are inserted into one steel tube and covered with a polyethylene sheath, with or without armoured steel wires and an outer poly-ethylene sheath.

Design of Fibre Optic Elements:Fibre optic elements are based on a loose tube design in which the fibres are protected by a laser welded steel tube which is filled with a water blocking com-pound. The hermetically sealed stainless steel tube provides effective protection against excess signal loss in the fibres.

Physical Characteristics of Fibre Optic Elements: The table below shows typical characteristics with single mode fibres. Final values are dependant upon the relevant combination of single mode and/or multimode fibres. The outer diameter can be adjusted to meet customer’s specification. Maximum number of fibres is 96 in a single steel tube design.

Fibre optic, max. 96 off –

G96Fibre Optic elements Nominal Thickness (mm) Nominal Outer Diameter (mm)

G48G24G12G96G48G24G12

0.��

Fibre in steel tube

Inner sheath

0.� 0.� �.� �.0 �.� �.6

�.� �.� �.� �.� 6.� 8.��.� �.�

Armouring, 0.9/�.0 mm

Outer sheath

0.9/�.0 �.� �.� 8.8 �0.8

�.� �.9 �� �� �� ���.� �.�

�8

Accessories and Services

We are continuously developing new products and techniques which comple-ment the operation and installation of our cables.

Applications:Beach joints or standard land splice closures with tap couplers for data feedback.

Branching units allow one cable to be connected to � cables.

Buoyancy elements added to hold a riser cable in a specific geometric configur-ation or to absorb movements between platform and seabed and are tailored to cable characteristics.

Cable anchoring or mechanical fixation of the submarine cable facilitates cable anchoring to a sea bed dead-weight or anchor.

Cable end modules for subsea install-ation and mating of FO connectors.

Cable hang-off to fix or hang a dynamic or static cable off the deck of the plat-form.

Elastomer cable protection is designed for cable and pipeline protection, can be combined with rock dumping, mattressing and trenching.

Optic Distribution Frames (ODF) or patch panel for terminating FO cable, fully equipped with a variety of adaptors and connectors.

Fibre optic submarine joints enable cable sections to be joined for system assembly, installation and repair. The joint box has been qualified for �000 m water depth.

Fibre Optic Termination Unit (FOTU) forms a pressure tight interface between up to three wet mateable fibre optic connectors and up to three FO elements.

Tying your systems together

�9

Graded pull-in terminations, comple-mented with a cable end sealing, hose clamps, heat shrink hose, self amalgamat-ing tape and a wire loop for easy pick-up by ROV.

J-Tube Seals can be supplied to fit all commonly used cable and J-tube dimen-sions. Seals can be supplied to accom-modate two cables.

Remote amplifier box for amplifying optical signals in submarine cables.

Riser cables with torque balanced steel armouring, installation depth �000 m.

Static cables with wide range of armour types and up to �8� optical fibres.

Temperature measurement systems for high voltage installations over long distances.

Topside joint closure or termination kits for FO cables are robust and field proven modular systems of lockable closures made of stainless steel.

Wet mateable connectors to connect � fibre optic cables underwater.

Services:On-site termination and splicing assist-ance by our expert technicians is avail-able in addition to on-site training.

�0

Quality Management and HSE

Research & Development: Nexans has a continuous focus on application- oriented R&D in the form of theoretical studies, test manufacturing, laboratory testing and full scale testing.

This focus has given results. R&D has led to the development of the thin-walled power conductor using semi conductive insulation with the resulting benefits of reduced insulation thickness, more com-pact cables, and smaller outer diameter. Our fibre in a steel tube technology is unique in the industry and provides a more robust cable system, an extended design lifetime and simplifies sealing and termination. New and innovative cable designs demand new termination methods and we have made several advancements within this range of access-ories. Our increasing capabilities within integrated fibre sensor systems build on our many years of experience with fibre optics. Our R&D advances are both customer driven and internally motivated. Our participation in large complex commer-cial projects often demands innovative solutions whereas our internal goals of maintaining our position as a manufac-turer of reliable, robust, and innovative cables motivates our search for improved designs, materials, and manufacturing processes.

Quality Management SystemsWe manufacture high quality cables. To achieve and maintain our quality standards we focus on verification and qualification testing and we test accord-ing to recognised international standards. Our standard internal testing includes mechanical, electrical, and optical testing and we provide additional third party testing upon request.

Our written quality standards cover all aspects of our activities from raw materi-als, process controls and finished product to final documentation. Nexans is ISO 900�, �800� and ��00� compliant.

Our focus on health and safety manage-ment meets the most demanding of external demands by oil and gas oper-ators. All materials are carefully selected with respect to environmental impacts during manufacturing, handling and after service.

Your requirement, our responsibility

��

Phot

o: Jø

rn A

dde

��

Our cable production in Norway was first established in 1915. This Norwe-gian industrial activity later became a part of the Alcatel Group’s world wide activities. In 2000 Alcatel separated its cable division from its other activi-ties and Nexans was born. Today the Nexans Group has operations in over 32 countries and is the world’s leading cable manufacturer.

Nexans Norway AS with headquarters in Oslo has � factories producing for both the Norwegian and international markets and employing over �000 people within its technical and production divisions. Our cable capabilities include power cables, offshore power and signal um-bilicals, customised underwater commu-nication cables, installation and heating cables, and overhead transmission lines.

Our customised underwater telecommun-ication cables are manufactured at our production facility in Rognan, on the coast of northern Norway. This modern plant has a �� year long history of build-ing specialised telecom cables. The plant has access to highly qualified personnel, clean water, stable power supply, and ex-cellent infrastructure such as a deep water harbour, road and rail connections.

Nexans Cable ProductionMade in Norway

Nexans Countries of Operation

��

The world’s only cable production above the Arctic Circle

Phot

o: T

o-Fo

to A

S

��

Lude

ns R

ekla

meb

yrå

/ 18

. apr

il 20

07 /

200

0

Global expert in cables and cabling systems

Nexans Norway AS, Innspurten 9, P.O. Box 6��0 Etterstad, 060� Oslo, Norway. Tel: +�� �� 88 6� 00 – fax: +�� �� 88 6� 0� – www.nexans.no

Nexans Norway AS reserves the right to implement product changes without prior notice.