Deepwater umbilical cable and manufacturing method thereof

Abstract

The deepwater umbilical cable comprises a body, the body comprises an inner core layer, an outer core layer and an outer protection layer from inside to outside, an inner core layer sheath is arranged at the joint of the inner core layer and the outer core layer, outer core layer anti-skid teeth are arranged on the side, close to the outer core layer, of the inner core layer sheath, and an outer core layer sheath is arranged at the joint of the outer core layer and the outer protection layer. The invention further discloses a manufacturing method of the deepwater umbilical cable, the manufacturing method comprises the steps that a stranded forming medium-voltage power cable unit is prepared, the outer core layer anti-skid teeth face the outer core layer, a stranded forming outer core layer is prepared, the outer core layer anti-skid teeth face the outer core layer, the outer core layer anti-skid teeth face the outer core layer, and the outer core layer anti-skid teeth face the outer core layer. The inner armoring anti-skid teeth face the armoring layer, and the outer armoring anti-skid teeth face the armoring layer. The invention provides a deepwater umbilical cable which is stable in structure and not prone to deformation and a manufacturing method of the deepwater umbilical cable.

Description

Technical Field

[0001] The present invention relates to the field of umbilical cables, and more specifically to a deep-water umbilical cable and a manufacturing method thereof. Background Art

[0002] With the gradual development of offshore oil and gas fields in China towards deep water and marginal oil fields, the application of underwater production systems in China is becoming increasingly widespread, and the consumption of umbilical cables supporting them has increased sharply. However, ordinary umbilical cables lack the laying conditions for deep and far seas, with low structural stability, weak anti-hydrostatic pressure ability and axial stiffness performance. During the application process in deep and far seas, they are easily deformed by ocean currents and high pressures, making it difficult to meet the laying standards. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a deep-water umbilical cable with stable structure and not easily deformed and a manufacturing method thereof.

[0004] The technical solution adopted by the present invention to solve the above problems is that a deep-water umbilical cable includes a body. The body includes a medium-voltage power cable unit, a low-voltage power cable unit, an optical cable unit and a steel pipe unit. The body includes an inner core layer, an outer core layer and an outer protective layer from inside to outside. The inner core layer includes the medium-voltage power cable unit. The outer core layer includes the low-voltage power cable unit, the optical cable unit and the steel pipe unit. The outer protective layer includes an armor layer and an outer sheath. An inner core layer sheath is provided at the connection between the inner core layer and the outer core layer. An outer core layer anti-slip tooth is provided on the side of the inner core layer sheath close to the outer core layer. An outer core layer sheath is provided at the connection between the outer core layer and the outer protective layer. An inner armor anti-slip tooth is provided on the side of the outer core layer sheath close to the outer protective layer. The outermost layer of the outer protective layer is provided with an outer sheath, and an outer armor anti-slip tooth is provided on the inner side of the outer sheath.

[0005] Compared with the prior art, the advantages of the present invention are as follows: In the umbilical cable, there are multiple conveying units including a medium-voltage power cable unit, a low-voltage power cable unit, an optical cable unit, and a steel pipe unit. The mechanical properties of each conveying unit are different. In particular, the differences in structural strength, size, and surface roughness cause different changes in each conveying unit when being disturbed after shaping, resulting in different degrees of deformation and offset between each conveying unit, thus destroying the structural stability of the umbilical cable. The inner core layer of the present invention only includes a medium-voltage power cable unit, and its structure has good stability. The deformation under interference and extrusion is unified and not likely to cause differential changes. While there are many types of conveying units in the outer core layer, deformation differences are likely to occur, resulting in offset phenomena and affecting the structural stability of the umbilical cable. Therefore, the structural design of anti-slip teeth in the outer core layer is added to increase the grasping force on each conveying unit in the extrusion state to avoid the offset of the conveying unit and ensure the structural stability. At the same time, the anti-slip teeth in the outer core layer are formed by extrusion molding, and the tooth gaps in the anti-slip teeth in the outer core layer can provide the extrusion deformation space for the anti-slip teeth in the outer core layer to provide deformation buffering for the outer core layer and the inner core layer, reducing or even avoiding the deformation between the outer core layer and the inner core layer. The outer sheath is the main compressive layer, and the stability of its structure directly affects the service stability of the umbilical cable. If the structure of the armor layer deforms, it will directly cause the direct damage of the umbilical cable. Therefore, the structural stability of the armor layer needs to be importantly protected. The inner armor anti-slip teeth and the outer armor anti-slip teeth are designed for the inner layer and the outer layer of the armor layer respectively to increase the grasping force on the armor wires in the inner layer and the outer layer of the armor layer to avoid the offset of the armor wires and ensure the structural stability of the armor layer, thus ensuring the compressive capacity of the armor and making it not easily deform, and further ensuring the use safety of the umbilical cable in the deep and far sea area.

[0006] As an improvement of the present invention, the outer core layer further includes a convex filling strip and a circular filling strip. The steel pipe unit includes a large-diameter steel pipe and a small-diameter steel pipe. The low-voltage power cable unit, the large-diameter steel pipe, and the circular filling strip have the same diameter. The small-diameter steel pipe has the same diameter as the optical cable unit. The two sides of the convex filling strip are recessed for fixedly connecting with the small-diameter steel pipe or the optical cable so that the small-diameter steel pipe and the optical cable are fixed to the outer core layer. The outer layer of the low-voltage power cable unit is provided with low-voltage cable anti-slip teeth. Through this improvement, the large-diameter steel pipe and the circular filling strip are produced according to the wire diameter of the low-voltage power cable unit, and the small-diameter steel pipe is produced according to the wire diameter of the optical cable unit. Then, through the design of the convex filling strip, the small-diameter steel pipe and the optical cable unit are thickened so that the placement thickness of the small-diameter steel pipe and the placement thickness of the optical cable unit are the same as the wire diameter of the low-voltage power cable unit, thereby ensuring the thickness consistency of each conveying unit of the outer core layer. When forming the outer core layer, a standard circle can be formed on the cross-section of the outer core layer, so that the outer core layer has stronger compressive resistance and structural stability. The design of the low-voltage cable anti-slip teeth can not only cooperate with the anti-slip teeth of the outer core wire without meshing. As long as they are kept in close contact, they can play a role in fixing the low-voltage power cable, preventing the low-voltage power cable from sliding, and ensuring the use stability of the low-voltage power cable. At the same time, other conveying units of the outer core layer in contact with the low-voltage power cable can also obtain the grasping force of the low-voltage cable anti-slip teeth, maintaining the use stability. That is, the anti-slip teeth of the outer core layer enhance the structural stability of the outer core layer in the radial direction, while the low-voltage cable anti-slip teeth increase the structural stability of the outer core layer in the circumferential direction.

[0007] As an improvement of the present invention, the medium-voltage power cable unit includes three groups of three-core medium-voltage power cables and one group of three single-core medium-voltage power cables arranged dispersedly. The three groups of three-core medium-voltage power cables are designed to be evenly arrayed circumferentially. One single-core medium-voltage power cable is placed outside the connection of any two adjacent groups of three-core medium-voltage power cables. Filler strips are filled in the gaps of the inner core layer. The three medium-voltage power cables in the three-core medium-voltage power cable are stranded and formed in the positive direction along the axis of the three-core medium-voltage power cable. The stranding pitch diameter ratio of the three-core medium-voltage power cable is not greater than 12. The three groups of three-core medium-voltage power cables and the three single-core medium-voltage power cables are stranded and formed in the reverse direction along the axis of the body. The stranding pitch diameter ratio of the medium-voltage power cable unit is not greater than 11, and the stranding pitch diameter ratio of the three-core medium-voltage power cable is not equal to the stranding pitch diameter ratio of the medium-voltage power cable unit. Through the above improvement, during the stranding and forming process, unilateral stranding is carried out. Therefore, when there is an opposite stranding force, the stranding force will be weakened, resulting in the phenomenon of loose stranding. By setting the stranding direction of the three-core medium-voltage power cable to be opposite to the stranding direction of the medium-voltage power cable unit, not only can the axial stiffness performance be enhanced, but also the influence of external forces can be balanced. When the external force causes loose stranding of one of the three-core medium-voltage power cables or the medium-voltage power cable unit, it will form a tight stranding effect on the other, thus balancing the overall structural performance. The design that the stranding pitch diameter ratio of the three-core medium-voltage power cable is not greater than 12 and the stranding pitch diameter ratio of the medium-voltage power cable unit is not greater than 11 is because the smaller the stranding pitch diameter ratio, the higher the stranding density, so as to ensure the stranding strength of the three-core medium-voltage power cable and the medium-voltage power cable unit, which is applicable to the harsh marine environment in the deep sea area. The stranding pitch diameter ratio of the three-core medium-voltage power cable is not equal to the stranding pitch diameter ratio of the medium-voltage power cable unit. When the external force causes loose stranding of both the three-core medium-voltage power cable and the medium-voltage power cable unit at the same time, such as axial force, it can make the degree of looseness of the three-core medium-voltage power cable and the medium-voltage power cable unit form a difference and cannot form loose synchronously, thereby increasing the difficulty of loosening, and also playing a role in increasing the stranding strength and axial stiffness performance of the medium-voltage power cable unit.

[0008] As an improvement of the present invention, the outer core layer is stranded and formed in the positive direction along the axis of the body. The stranding pitch diameter ratio of the outer core layer is not greater than 10, and the stranding pitch diameter ratio of the medium-voltage power cable unit is not equal to that of the outer core layer. Through this improvement, since the stranding direction of the outer core layer is opposite to that of the medium-voltage power cable unit, not only can the axial stiffness performance be enhanced, but also the influence of external forces can be balanced. When the external force causes stranding looseness in one of the outer core layer or the medium-voltage power cable unit, it will form a stranding and compressing effect on the other, thus balancing the overall structural performance. The design that the stranding pitch diameter ratio of the three outer core layers is not greater than 10 is because the smaller the stranding pitch diameter ratio, the higher the stranding tightness, so as to ensure the stranding strength of the outer core layer, which is applicable to the harsh marine environment in the deep sea area. The stranding pitch diameter ratio of the outer core layer is not equal to that of the medium-voltage power cable unit. When the external force causes stranding looseness in both the three outer core layers and the medium-voltage power cable unit at the same time, such as axial force, it can make the degree of looseness of the outer core layer and the medium-voltage power cable unit different, and they cannot form looseness synchronously, thus increasing the difficulty of looseness, and also playing a role in increasing the overall stranding strength and axial stiffness performance of the umbilical cable.

[0009] As an improvement of the present invention, the outer core layer sheath is provided with outer core layer sheath hole grooves. Through this improvement, in the high-pressure environment of the deep sea, the umbilical cable is prone to the phenomenon of diameter reduction under compression. For the stranded structure, the radial diameter reduction will only enhance the stranding tightness. However, for the outer core layer sheath, if there are no outer core layer sheath hole grooves, the reduced-diameter outer core layer sheath will appear a structure of extrusion protrusion, thus destroying the roundness of the outer core layer sheath, and further destroying the structural stability of the umbilical cable, resulting in the easy damage of the umbilical cable. Through the design of the outer core layer sheath hole grooves, a diameter reduction space is provided to avoid the phenomenon of extrusion protrusion and ensure the water pressure resistance of the outer core layer sheath.

[0010] As an improvement of the present invention, the outer sheath is provided with outer sheath hole grooves. Through this improvement, in the high-pressure environment of the deep sea, the umbilical cable is prone to the phenomenon of diameter reduction under compression. For the stranded structure, the radial diameter reduction will only enhance the stranding tightness. However, for the outer sheath, if there are no outer sheath hole grooves, the reduced-diameter outer sheath will appear a structure of extrusion protrusion, thus destroying the roundness of the sheath, and further destroying the structural stability of the umbilical cable, resulting in the easy damage of the umbilical cable. Through the design of the outer sheath hole grooves, a diameter reduction space is provided to avoid the phenomenon of extrusion protrusion and ensure the water pressure resistance of the outer sheath.

[0011] As an improvement of the present invention, the outer core layer sheath hole grooves and the outer sheath hole grooves are respectively arranged on two sides of the axis away from each other. Through this improvement, the outer core layer sheath hole grooves and the outer sheath hole grooves are arranged in a misaligned manner at the maximum angle, reducing the deviation of the umbilical cable structure balance to ensure the structural stability and structural strength of the umbilical cable.

[0012] A manufacturing method of a deep - water umbilical cable for manufacturing a deep - water umbilical cable, the steps are as follows:

[0013] S1: Prepare a stranded medium - voltage power cable unit;

[0014] S2: Wrap an inner core layer sheath around the outer layer of the medium - voltage power cable unit, and the outer core layer anti - slip teeth on the inner core layer sheath face the outer core layer;

[0015] S3: Prepare a stranded outer core layer;

[0016] S4: Wrap an outer core layer sheath around the outer layer of the outer core layer, and the inner armor anti - slip teeth on the outer core layer sheath face the armor layer;

[0017] S5: Prepare a stranded armor layer;

[0018] S6: Include an outer sheath around the outer layer of the armor layer, and the outer armor anti - slip teeth on the outer sheath face the armor layer.

[0019] Compared with the prior art, the advantages of the present invention are as follows: In the umbilical cable, there are multiple conveying units including a medium - voltage power cable unit, a low - voltage power cable unit, an optical fiber cable unit, and a steel pipe unit. The mechanical properties of each conveying unit are different. Especially the differences in structural strength, size, and surface roughness make the changes of each conveying unit different when being disturbed after shaping, resulting in different degrees of deformation and offset between each conveying unit, thus destroying the structural stability of the umbilical cable; There are many types of conveying units in the outer core layer, and deformation differences are likely to occur, resulting in offset phenomena and affecting the structural stability of the umbilical cable. Therefore, the structural design of the outer core layer anti - slip teeth is added to increase the grasping force of each conveying unit in the extrusion state to avoid the offset of the conveying unit and ensure the structural stability. At the same time, the outer core layer anti - slip teeth are formed by extrusion molding, and the tooth gaps of the outer core layer anti - slip teeth can provide the extrusion deformation space for the outer core layer anti - slip teeth to provide deformation buffer for the outer core layer and the inner core layer, reducing or even avoiding the deformation of the outer core layer and the inner core layer; The outer sheath is the main compressive layer, and the stability of its structure directly affects the use stability of the umbilical cable. If the structure of the armor layer deforms, it will directly cause the direct damage of the umbilical cable. Therefore, important protection needs to be carried out on the structural stability of the armor layer. The inner armor anti - slip teeth and the outer armor anti - slip teeth are designed for the inner layer and the outer layer of the armor layer respectively to increase the grasping force of the armor wires in the inner layer and the outer layer of the armor layer to avoid the offset of the armor wires and ensure the structural stability of the armor layer, thus ensuring the compressive ability of the armor and being not easy to deform, and further ensuring the use safety of the umbilical cable in the deep - sea area.

[0020] As an improvement of the present invention, in step S1, the following steps are included:

[0021] S1.1: Prepare the medium-voltage power cable in the three-core medium-voltage power cable;

[0022] S1.2: Strands the three-core medium-voltage power cable in the positive direction along the axis of the three-core medium-voltage power cable, the stranding pitch diameter ratio is not greater than 12, and fills the first filling strip in the gap of the three-core medium-voltage power cable;

[0023] S1.3: Wrap the outer layer of the three-core medium-voltage power cable with a nylon water cloth tape to shape the three-core medium-voltage power cable;

[0024] S1.4: Prepare a single-core medium-voltage power cable;

[0025] S1.5: Strands three groups of three-core medium-voltage power cables and three single-core medium-voltage power cables in the reverse direction along the axis of the body, the stranding pitch diameter ratio is not greater than 11, and fills the second filling strip between the three-core medium-voltage power cable and the single-core medium-voltage power cable, and the stranding pitch diameter ratio in step S1.2 is not equal to the stranding pitch diameter ratio in this step;

[0026] In step S3, the following steps are included:

[0027] S3.1: Prepare the low-voltage power cable in the low-voltage power cable unit;

[0028] S3.2: Take four low-voltage power cables and strand them in the reverse direction along the axis of the low-voltage power cable unit, the stranding pitch diameter ratio is not greater than 10;

[0029] S3.3: Wrap the outer layer of the low-voltage power cable unit with a copper-plastic composite tape;

[0030] S3.4: Extrude and form low-voltage cable anti-slip teeth on the outer layer of the copper-plastic composite tape;

[0031] S3.5: Distribute the low-voltage power cable unit, large-diameter steel pipe, circular filling strip, and convex filling strip fixedly connected with the optical cable unit or small-diameter steel pipe evenly along the circumference;

[0032] S3.6: The outer core layer is stranded and formed in the positive direction along the axis of the body, and the stranding pitch diameter ratio is not greater than 10. Through the above improvement and the design of steps S1.1 - S1.5, during the stranding and forming process, unilateral stranding is carried out, which will cause the stranding force to weaken and the stranding to become loose when there is an opposite stranding force. By setting the stranding direction of the three-core medium-voltage power cable opposite to that of the medium-voltage power cable unit, not only can the axial stiffness performance be enhanced, but also the influence of external forces can be balanced. When the external force causes stranding looseness in one of the three-core medium-voltage power cable or the medium-voltage power cable unit, it will form a stranding and compressing effect on the other, thus balancing the overall structural performance. The design that the stranding pitch diameter ratio of the three-core medium-voltage power cable is not greater than 12 and the stranding pitch diameter ratio of the medium-voltage power cable unit is not greater than 11 is because the smaller the stranding pitch diameter ratio, the higher the stranding density, to ensure the stranding strength of the three-core medium-voltage power cable and the medium-voltage power cable unit, which is applicable to the harsh marine environment in the deep sea area. The stranding pitch diameter ratio of the three-core medium-voltage power cable is not equal to that of the medium-voltage power cable unit. When the external force causes stranding looseness in both the three-core medium-voltage power cable and the medium-voltage power cable unit at the same time, such as axial force, it can make the looseness degrees of the three-core medium-voltage power cable and the medium-voltage power cable unit different, and they cannot form looseness synchronously, thus increasing the difficulty of loosening, and also playing a role in increasing the stranding strength and axial stiffness performance of the medium-voltage power cable unit. Through the design of steps S3.1 - S3.6, by setting the stranding direction of the outer core layer opposite to that of the medium-voltage power cable unit, not only can the axial stiffness performance be enhanced, but also the influence of external forces can be balanced. When the external force causes stranding looseness in one of the outer core layer or the medium-voltage power cable unit, it will form a stranding and compressing effect on the other, thus balancing the overall structural performance. The design that the stranding pitch diameter ratio of the outer core layer is not greater than 10 is because the smaller the stranding pitch diameter ratio, the higher the stranding density, to ensure the stranding strength of the outer core layer, which is applicable to the harsh marine environment in the deep sea area. The stranding pitch diameter ratio of the outer core layer is not equal to that of the medium-voltage power cable unit. When the external force causes stranding looseness in both the outer core layer and the medium-voltage power cable unit at the same time, such as axial force, it can make the looseness degrees of the outer core layer and the medium-voltage power cable unit different, and they cannot form looseness synchronously, thus increasing the difficulty of loosening, and also playing a role in increasing the overall stranding strength and axial stiffness performance of the umbilical cable.

[0033] As an improvement of the present invention, in step S5, the armor layer is wound with four layers of carbon fiber filaments, and the winding directions of adjacent two layers of carbon fiber filaments are opposite. Through this improvement, the structural strength of the armor layer is ensured by the winding of the four layers of carbon fiber filaments. At the same time, the design that the winding directions of adjacent two layers of carbon fiber filaments are opposite can not only enhance the axial stiffness performance, but also balance the influence of external forces. When the external force causes the twisting and loosening of two of the carbon fiber filaments, it will cause the effect of twisting and compressing the two layers of carbon fiber filaments, thereby balancing the overall structural performance. At the same time, in terms of materials, the carbon fiber filaments have better toughness than traditional steel wires and are not easily bent and broken, enabling the umbilical cable to operate safely and stably in the deep sea. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 is a schematic diagram of the overall cross-sectional structure of the present invention.

[0035] Figure 2 is a schematic diagram of the cross-sectional connection structure of the inner core layer of the present invention.

[0036] Figure 3 is a schematic diagram of the cross-sectional connection structure of the outer core layer of the present invention.

[0037] As shown in the figure: 1. Inner core layer, 1.1 Medium-voltage power cable unit, 1.1.1 Three-core medium-voltage power cable, 1.1.2 One-core medium-voltage power cable, 1.2 Filler strip, 2. Outer core layer, 2.1 Low-voltage power cable unit, 2.1.1 Low-voltage cable anti-slip teeth, 2.2 Optical cable unit, 2.3 Steel pipe unit, 2.3.1 Large-diameter steel pipe, 2.3.2 Small-diameter steel pipe, 2.4 Convex filler strip, 2.5 Circular filler strip, 3. Outer protective layer, 3.1 Armor layer, 3.2 Outer sheath, 3.2.1 Outer armor anti-slip teeth, 3.2.2 Outer sheath hole groove, 4. Inner core layer sheath, 4.1 Outer core layer anti-slip teeth, 5. Outer core layer sheath, 5.1 Inner armor anti-slip teeth, 5.2 Outer core layer sheath hole groove. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0038] The embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0039] As Figure 1As shown in the figure, a deep-water umbilical cable includes a body. The body includes a medium-voltage power cable unit 1.1, a low-voltage power cable unit 2.1, an optical cable unit 2.2, and a steel pipe unit 2.3. The body includes an inner core layer 1, an outer core layer 2, and an outer sheath layer 3 from the inside out. The inner core layer 1 includes the medium-voltage power cable unit 1.1. The outer core layer 2 includes the low-voltage power cable unit 2.1, the optical cable unit 2.2, and the steel pipe unit 2.3. The outer sheath layer 3 includes an armor layer 3.1 and an outer sheath 3.2. An inner core layer sheath 4 is provided at the connection between the inner core layer 1 and the outer core layer 2. An outer core layer anti-slip tooth 4.1 is provided on one side of the inner core layer sheath 4 close to the outer core layer 2. An outer core layer sheath 5 is provided at the connection between the outer core layer 2 and the outer sheath layer 3. An inner armor anti-slip tooth 5.1 is provided on one side of the outer core layer sheath 5 close to the outer sheath layer 3. The outermost layer of the outer sheath layer 3 is provided with an outer sheath 3.2. An outer armor anti-slip tooth 3.2.1 is provided on the inner side of the outer sheath 3.2. An outer core layer sheath hole groove 5.2 is provided on the outer core layer sheath 5. An outer sheath hole groove 3.2.2 is provided on the outer sheath 3.2. The outer core layer sheath hole groove 5.2 and the outer sheath hole groove 3.2.2 are respectively provided on two sides away from the axis center.

[0040] As Figure 2 shown in the figure, the medium-voltage power cable unit 1.1 includes three groups of three-core medium-voltage power cables 1.1.1 and one group of three single-core medium-voltage power cables 1.1.2 arranged dispersedly. The three groups of three-core medium-voltage power cables 1.1.1 are designed in a circumferential uniform array. One single-core medium-voltage power cable 1.1.2 is placed outside the connection of any adjacent two groups of three-core medium-voltage power cables 1.1.1. The gaps of the inner core layer 1 are all filled with filling strips 1.2. The three medium-voltage power cables in the three-core medium-voltage power cable 1.1.1 are twisted and formed in the positive direction along the axis of the three-core medium-voltage power cable 1.1.1. The lay ratio of the three-core medium-voltage power cable 1.1.1 is not greater than 12. The three groups of three-core medium-voltage power cables 1.1.1 and the three single-core medium-voltage power cables 1.1.2 are twisted and formed in the reverse direction along the axis of the body. The lay ratio of the medium-voltage power cable unit 1.1 is not greater than 11, and the lay ratio of the three-core medium-voltage power cable 1.1.1 is not equal to the lay ratio of the medium-voltage power cable unit 1.1.

[0041] As Figure 3As shown, the outer core layer 2 further includes a convex filling strip 2.4 and a circular filling strip 2.5. The steel pipe unit 2.3 includes a large-diameter steel pipe 2.3.1 and a small-diameter steel pipe 2.3.2. The low-voltage power cable unit 2.1, the large-diameter steel pipe 2.3.1, and the circular filling strip 2.5 have the same diameter. The small-diameter steel pipe 2.3.2 and the optical cable unit 2.2 have the same diameter. The two sides of the convex filling strip 2.4 are used for fixedly connecting with the small-diameter steel pipe 2.3.2 or the optical cable so that the small-diameter steel pipe 2.3.2 and the optical cable are fixed on the outer core layer 2. The outer layer of the low-voltage power cable unit 2.1 is provided with low-voltage cable anti-slip teeth 2.1.1. The outer core layer 2 is stranded and formed along the positive direction of the axis of the body. The stranding pitch-diameter ratio of the outer core layer 2 is not greater than 10, and the stranding pitch-diameter ratio of the medium-voltage power cable unit 1.1 is not equal to that of the outer core layer 2.

[0042] As Figures 1-3 shown, a manufacturing method of a deep-water umbilical cable for manufacturing a deep-water umbilical cable is as follows:

[0043] S1: Prepare the stranded and formed medium-voltage power cable unit 1.1;

[0044] S1.1: Prepare the medium-voltage power cable in the three-core medium-voltage power cable 1.1.1;

[0045] S1.1.1: Take 14 copper wires of 2.60 mm, arrange them in the order of 4 + 10, and conduct concentric stranding with the axis of the medium-voltage power cable. The stranding direction of the inner layer is the positive direction, and the stranding direction of the outer layer is the reverse direction, that is, 4 copper wires are stranded in the inner layer and 10 copper wires are stranded in the outer layer, which also has the effect of enhancing the axial stiffness performance and balancing the influence of external forces;

[0046] S1.1.2: The stranding pitch and tolerance of the inner layer are 140 ± 15 mm, and the stranding pitch and tolerance of the outer layer are 160 ± 15 mm;

[0047] S1.1.3: Pour water-blocking glue between the copper wires;

[0048] S1.1.4: Extrude and mold the shielding layer, insulation layer, and insulation shielding layer of the medium-voltage power cable through a three-layer coextrusion process. The nominal thickness of the shielding layer is 0.8 mm, the nominal thickness of the insulation layer is 4.5 mm, and the nominal thickness of the insulation shielding layer is 0.8 mm. Set the body temperature to 45°C - 115°C, the line speed to 13.8 m / min, the crosslinking degree to 87.5%, the preheating temperature in front to 90°C, the temperature of the expansion tube to 200°C, Z1 to 425°C, Z2 to 410°C, Z3 to 390°C, Z4 to 375°C, Z5 to 365°C, Z6 to 355°C, Z7 to 345°C, and Z8 to 340°C; the rotational speed of the extrusion screw for the shielding layer is 17.36 rpm / min, the rotational speed of the extrusion screw for the insulation layer is 20.17 rpm / min, the rotational speed of the extrusion screw for the insulation shielding layer is 28.82 rpm / min, and the three-layer coextrusion equipment is conventional equipment;

[0049] S1.1.5: Wrap a semiconductive water-resistant tape with a nominal thickness of 0.5 mm;

[0050] S1.1.6: Wrap a copper tape with a nominal thickness of 0.1 mm and a width of 40 mm;

[0051] S1.1.7: Wrap a semiconductive water-resistant tape with a nominal thickness of 0.5 mm;

[0052] S1.1.8: Through an extruder, set the body temperature to 120°C - 185°C, the production speed to 10 - 15 m / min, and extrude an MDPE protective layer with a nominal thickness of 4.3 mm on the outside;

[0053] S1.2: Strands the three-core medium-voltage power cable 1.1.1 in the positive direction along the axis of the three-core medium-voltage power cable 1.1.1, with the stranding pitch diameter ratio not greater than 12, and fills the gaps of the three-core medium-voltage power cable 1.1.1 with the first filling strip;

[0054] S1.2.1: Take a special PVC sheath material with high strength and high hardness, and extrude and manufacture the first filling strip on an extruder, set the extrusion temperature to 155°C - 185°C; the extrusion speed to 10 m / min - 15 m / min;

[0055] S1.3: Wrap a nylon water cloth tape with a nominal thickness of 0.3 mm and a width of 60 mm around the outer layer of the three-core medium-voltage power cable 1.1.1. When wrapping, control the wrapping pitch of the wrapping machine to 35 mm and the rotational speed of the wrapping head to 220 r / min to shape the three-core medium-voltage power cable 1.1.1;

[0056] S1.4: Prepare a single-core medium-voltage power cable 1.1.2;

[0057] S1.4.1: Take 14 copper wires of 2.60 mm, arrange them in the pattern of 4 + 10, and conduct concentric stranding with the axis of the medium-voltage power cable as the center. The stranding direction of the inner layer is forward, and the stranding direction of the outer layer is reverse, that is, 4 copper wires are used for stranding in the inner layer and 10 copper wires are used for stranding in the outer layer, which also has the effect of enhancing the axial stiffness performance and balancing the influence of external forces;

[0058] S1.4.2: The stranding pitch and tolerance of the inner layer are 140 ± 15 mm, and the stranding pitch and tolerance of the outer layer are 160 ± 15 mm;

[0059] S1.4.3: Inject water-blocking glue between the copper wires;

[0060] S1.4.4: Conduct extrusion molding of the shielding layer, insulation layer, and insulation shielding layer of the medium-voltage power cable through a three-layer co-extrusion process. The nominal thickness of the shielding layer is 0.8 mm, the nominal thickness of the insulation layer is 4.5 mm, and the nominal thickness of the insulation shielding layer is 0.8 mm. Set the body temperature to 45°C - 115°C, set the line speed to 13.8 m / min, the crosslinking degree to 87.5%, the preheating temperature in front to 90°C, the temperature of the expansion tube to 200°C, Z1 to 425°C, Z2 to 410°C, Z3 to 390°C, Z4 to 375°C, Z5 to 365°C, Z6 to 355°C, Z7 to 345°C, Z8 to 340°C; the extrusion screw speed of the shielding layer is 17.36 rpm / min, the extrusion screw speed of the insulation layer is 20.17 rpm / min, the extrusion screw speed of the insulation shielding layer is 28.82 rpm / min, and the three-layer co-extrusion equipment is conventional equipment;

[0061] S1.4.5: Wrap a semiconductive water-blocking tape with a nominal thickness of 0.5 mm;

[0062] S1.4.6: Wrap a copper tape with a nominal thickness of 0.1 mm and a width of 40 mm;

[0063] S1.4.7: Wrap a semiconductive water-blocking tape with a nominal thickness of 0.5 mm;

[0064] S1.4.8: Through the extruder, set the body temperature to 120°C - 185°C, the production speed to 10 - 15 m / min, and extrude an MDPE protective layer with a nominal thickness of 5 mm on the outside;

[0065] S1.5: Use three three-core medium-voltage power cables 1.1.1 and three single-core medium-voltage power cables 1.1.2 to conduct reverse stranding and forming along the axis of the body. The stranding pitch-diameter ratio is not greater than 11, and a second filling strip is filled between the three-core medium-voltage power cable 1.1.1 and the single-core medium-voltage power cable 1.1.2, and the stranding pitch-diameter ratio in step S1.2 is not equal to the stranding pitch-diameter ratio in this step;

[0066] S1.5.1: Select a special PVC sheath material with high strength and hardness, and extrude the second filling strip on an extruder. Set the extrusion temperature at 155°C - 185°C; the extrusion speed at 10 m / min - 15 m / min;

[0067] S1.5.2: After stranding, wind a layer of nylon water tape with a nominal thickness of 0.3 mm around the outer layer. The rotation speed of the winding head of the winding machine is 230 r / min;

[0068] S2: Wrap the inner core layer sheath 4 around the outer layer of the medium-voltage power cable unit 1.1. The outer core layer anti-slip teeth 4.1 on the inner core layer sheath 4 face the outer core layer 2; the nominal thickness of the inner core layer sheath 4 is 5.0 mm, made of HDPE material, produced by an extruder. Set the body temperature at 135°C - 175°C, and the production speed at 6 m / min - 10 m / min;

[0069] S3: Prepare the stranded and formed outer core layer 2;

[0070] S3.1: Prepare the low-voltage power cable in the low-voltage power cable unit 2.1;

[0071] S3.1.1: Select 7 copper wires of 1.67 mm, arranged in 1 + 6, and perform forward concentric stranding around the axis of the low-voltage power cable;

[0072] S3.2.1: Extrude HDPE insulation with a thickness of 1.0 mm on the outer layer of the stranded copper wires. Use an extruder, control the body temperature at 125°C - 175°C, and the production speed at 25 - 35 m / min;

[0073] S3.2: Select four low-voltage power cables and perform reverse stranding and forming around the axis of the low-voltage power cable unit 2.1. The stranding pitch diameter ratio is not greater than 10;

[0074] S3.3: Wrap a copper-plastic composite tape with a nominal thickness of 0.06 mm around the outer layer of the low-voltage power cable unit 2.1;

[0075] S3.4: Select an MDPE sheath material with a nominal thickness of 1.8 mm, use an extruder, control the body temperature at 120°C - 180°C, and the production speed at 20 - 30 m / min, and extrude and form low-voltage cable anti-slip teeth 2.1.1 on the outer layer of the copper-plastic composite tape;

[0076] S3.5: Distribute the low-voltage power cable unit 2.1, large-diameter steel pipe 2.3.1, circular filling strip 2.5, and convex filling strip 2.4 fixedly connected with the optical cable unit 2.2 or small-diameter steel pipe 2.3.2 evenly along the circumferential direction;

[0077] S3.5.1: Prepare the optical cable unit 2.2;

[0078] S3.5.1.1: Bundle eight optical fibers and fill the gaps between the optical fibers with ointment.

[0079] S3.5.1.2: Take a 316L stainless steel pipe with a thickness of 0.2 mm and wrap it around the outside of the optical fibers.

[0080] S3.5.1.3: Use an extruder, set the body temperature to 125°C - 175°C, and the production speed to 30 - 40 m / min, and extrude an HDPE sheath with a thickness of 1.1 mm outside the stainless steel pipe.

[0081] S3.5.1.4: Take a phosphated steel wire with a nominal diameter of 1.6 mm, use a steel wire armoring machine, with a wrapping pitch of 65 mm, and wind and wrap it on the outer layer of the HDPE sheath.

[0082] S3.5.1.5: Use an extruder, set the body temperature to 125°C - 175°C, and the production speed to 30 - 40 m / min, and extrude an HDPE sheath with a nominal thickness of 1.7 mm on the outer layer of the phosphated steel wire armor.

[0083] S3.5.2: Prepare the steel pipe unit 2.3.

[0084] S3.5.2.1: Take a small-diameter steel pipe 2.3.2 made of a bidirectional non-magnetic stainless material, use an extruder, control the body temperature at 120°C - 180°C, and the production speed at 20 - 30 m / min, and extrude an HDPE sheath on the outer layer of the small-diameter steel pipe 2.3.2.

[0085] S3.5.2.2: Take a large-diameter steel pipe 2.3.1 made of a bidirectional non-magnetic stainless material, use an extruder, control the body temperature at 120°C - 180°C, and the production speed at 20 - 30 m / min, and extrude an HDPE sheath on the outer layer of the large-diameter steel pipe 2.3.1.

[0086] S3.5.2: Prepare the convex filling strip 2.4. Take a special PVC sheath material with high strength and high hardness and extrude it on an extruder. Set the extrusion temperature to 155°C - 185°C; the extrusion speed to 10 m / min - 15 m / min.

[0087] S3.5.3: Prepare the circular filling strip 2.5. Take a special PVC sheath material with high strength and high hardness and extrude it on an extruder. Set the extrusion temperature to 155°C - 185°C; the extrusion speed to 10 m / min - 15 m / min.

[0088] S3.6: Take four low-voltage power cable units 2.1, three optical cable units 2.2, three large-diameter steel pipes 2.3.1, three small-diameter steel pipes 2.3.2, five convex filler strips 2.4, and three circular filler strips 2.5 and twist them into shape along the positive direction of the axis of the body. The lay ratio shall not be greater than 10.

[0089] S4: Wrap an outer core sheath 5 around the outer layer of the outer core layer 2. The inner armor anti-slip teeth 5.1 on the outer core sheath 5 face the armor layer 3.1. Use an extruder to extrude chloroprene rubber. The body temperature is controlled at 65°C - 75°C, the production speed is 8 - 10 m / min, the air pressure is 12 - 14 bar, and the outer core sheath 5 with a nominal thickness of 5.0 mm is formed.

[0090] S5: Prepare the twisted and formed armor layer 3.1. Take carbon fiber filaments with a nominal diameter of 5.0 mm and wind them using a wire armor machine. The armor layer 3.1 is wound with four layers of carbon fiber filaments, and the winding directions of adjacent two layers of carbon fiber filaments are opposite. The lay pitch is 2000 mm ± 100 mm.

[0091] S6: Include an outer sheath 3.2 on the outer layer of the armor layer 3.1. The outer armor anti-slip teeth 3.2.1 on the outer sheath 3.2 face the armor layer 3.1. Use an extruder to extrude chloroprene rubber. The body temperature is controlled at 65°C - 75°C, the production speed is 8 - 10 m / min, the air pressure is 12 - 14 bar, and the outer core sheath 5 with a nominal thickness of 15.0 mm is formed.

[0092] Through the design of a deep - water umbilical cable and its manufacturing method, by using the designs of the anti - slip teeth 4.1 of the outer core layer, the anti - slip teeth 2.1.1 of the low - voltage cable, the anti - slip teeth 5.1 of the inner armor, and the anti - slip teeth 3.2.1 of the outer armor, the structural strength and structural stability of the outer core layer 2 and the armor layer 3.1 are increased. Under the influence of severe underwater ocean currents, it is not easy for relative sliding to occur between the components inside the umbilical cable, thus avoiding the phenomenon of damage to the components inside the umbilical cable caused by relative sliding; by using the designs of the outer sheath holes 3.2.2 and the outer core layer sheath holes 5.2, when the umbilical cable is installed underwater, it will not cause extrusion deformation damage to the cable body due to the imbalance of internal and external water pressures of the umbilical cable, thereby improving the water - pressure resistance of the umbilical cable and ensuring the safety of the umbilical cable during use; through the design that the inner - layer stranding direction of the copper wires in the medium - voltage power cable is opposite to the outer - layer stranding direction of the copper wires in the medium - voltage power cable, the stranding direction of the three - core medium - voltage power cable 1.1.1 is opposite to the stranding direction of the medium - voltage power cable unit 1.1, the stranding direction of the medium - voltage power cable unit 1.1 is opposite to the stranding direction of the outer core layer 2, the stranding direction of the copper wires in the low - voltage power cable is opposite to the stranding direction of the outer core layer 2, and the winding directions of adjacent two layers of carbon fiber filaments are opposite, all effectively improve the axial stiffness of the umbilical cable, balance the influence of external forces. At the same time, in terms of materials, carbon fiber filaments have better toughness than traditional steel wires and are not easily bent or broken, enabling the umbilical cable to operate safely and stably in the deep and far - reaching sea, thus meeting the laying conditions of the deep and far - reaching sea.

[0093] The above is only an illustration of the best embodiment of the present invention, but it should not be construed as a limitation of the claims. The present invention is not limited to the above embodiments, and its specific structure allows for changes. All changes made within the protection scope of the independent claims of the present invention are within the protection scope of the present invention.

Claims

1. A deepwater umbilical cable, characterized in that: The invention comprises a main body, wherein the main body comprises a medium-voltage power cable unit (1.1), a low-voltage power cable unit (2.1), an optical cable unit (2.2) and a steel pipe unit (2.3); the main body comprises an inner core layer (1), an outer core layer (2) and an outer sheath (3) from the inside to the outside; the inner core layer (1) comprises a medium-voltage power cable unit (1.1); the outer core layer (2) comprises a low-voltage power cable unit (2.1), an optical cable unit (2.2) and a steel pipe unit (2.3); the outer sheath (3) comprises an armor layer (3.1) and an outer sheath (3.2). ), an inner core layer sheath (4) is provided at the connection between the inner core layer (1) and the outer core layer (2), an outer core layer anti-slip teeth (4.1) are provided on the side of the inner core layer sheath (4) close to the outer core layer (2), an outer core layer sheath (5) is provided at the connection between the outer core layer (2) and the outer protective layer (3), an inner armor anti-slip teeth (5.1) are provided on the side of the outer core layer sheath (5) close to the outer protective layer (3), an outer sheath (3.2) is provided on the outermost layer of the outer protective layer (3), and an outer armor anti-slip teeth (3.2.1) are provided on the inner side of the outer sheath (3.2).

2. A deepwater umbilical cable according to claim 1, characterized in that: The outer core layer (2) further comprises a convex filling strip (2.4) and a circular filling strip (2.5); the steel pipe unit (2.3) comprises a large-diameter steel pipe (2.3.1) and a small-diameter steel pipe (2.3.2); the low-voltage power cable unit (2.1), the large-diameter steel pipe (2.3.1) and the circular filling strip (2.5) have the same diameter; the small-diameter steel pipe (2.3.2) and the optical cable unit (2.2) have the same diameter; the grooves on both sides of the convex filling strip (2.4) are used to be fixedly connected with the small-diameter steel pipe (2.3.2) or the optical cable so that the small-diameter steel pipe (2.3.2) and the optical cable are fixed to the outer core layer (2); and the outer layer of the low-voltage power cable unit (2.1) is provided with low-voltage cable anti-slip teeth (2.1.1).

3. A deepwater umbilical cable according to claim 1, characterized in that: The medium-voltage power cable unit (1.1) comprises three groups of three-core medium-voltage power cables (1.1.1) and one group of three dispersedly arranged single-core medium-voltage power cables (1.1.2). The three groups of three-core medium-voltage power cables (1.1.1) are designed in a uniform array along the circumferential direction. The outer side of the connection between any two adjacent groups of three-core medium-voltage power cables (1.1.1) is used to place a single-core medium-voltage power cable (1.1.2). The gaps in the inner core layer (1) are filled with filling strips (1.2). The three-core medium-voltage power cables (1.1.1) The three medium-voltage power cables are twisted in the forward direction along the axis of the three-core medium-voltage power cable (1.1.1), and the twisted pitch-diameter ratio of the three-core medium-voltage power cable (1.1.1) is not greater than 12. The three groups of three-core medium-voltage power cables (1.1.1) and three one-core medium-voltage power cables (1.1.2) are twisted in the reverse direction along the axis of the body, and the twisted pitch-diameter ratio of the medium-voltage power cable unit (1.1) is not greater than 11, and the twisted pitch-diameter ratio of the three-core medium-voltage power cable (1.1.1) is not equal to the twisted pitch-diameter ratio of the medium-voltage power cable unit (1.1).

4. A deepwater umbilical cable according to claim 3, characterized in that: The outer core layer (2) is twisted and formed along the axis of the body, the twisted pitch ratio of the outer core layer (2) is not greater than 10, and the twisted pitch ratio of the medium-voltage power cable unit (1.1) is not equal to the twisted pitch ratio of the outer core layer (2).

5. The deepwater umbilical cable according to claim 1, characterized in that: The outer core layer sheath (5) is provided with an outer core layer sheath hole groove (5.2).

6. A deepwater umbilical cable according to claim 5, characterized in that: The outer sheath (3.2) is provided with an outer sheath hole groove (3.2.2).

7. A deepwater umbilical cable according to claim 6, characterized in that: The outer core layer sheath hole groove (5.2) and the outer sheath hole groove (3.2.2) are respectively arranged on two separate sides of the axis.

8. A method for manufacturing a deepwater umbilical cable, characterized in that: The steps for manufacturing a deepwater umbilical cable according to any one of claims 1 to 7 are as follows: S1: preparing a twisted medium voltage power cable unit (1.1); S2: The inner core layer sheath (4) is wrapped around the outer layer of the medium voltage power cable unit (1.1), and the outer core layer anti-slip teeth (4.1) on the inner core layer sheath (4) face the outer core layer (2); S3: preparing a twisted outer core layer (2); S4: wrapping an outer core layer sheath (5) on the outer layer of the outer core layer (2), with the inner armor anti-slip teeth (5.1) on the outer core layer sheath (5) facing the armor layer (3.1); S5: preparing a twisted armor layer (3.1); S6: The outer layer of the armor layer (3.1) includes an outer sheath (3.2), and the outer armor anti-slip teeth (3.2.1) on the outer sheath (3.2) face the armor layer (3.1).

9. The method for manufacturing a deepwater umbilical cable according to claim 8, characterized in that: Step S1 includes the following steps: S1.1: Prepare the medium voltage power cable in the three-core medium voltage power cable (1.1.1); S1.2: The three-core medium-voltage power cable (1.1.1) is twisted in the forward direction along the axis of the three-core medium-voltage power cable (1.1.1), with the twisting pitch ratio not greater than 12, and the first filling strip (1.2) is filled in the gap of the three-core medium-voltage power cable (1.1.1); S1.3: Wrap nylon water cloth tape around the outer layer of the three-core medium-voltage power cable (1.1.1) to shape the three-core medium-voltage power cable (1.1.1); S1.4: Prepare a medium voltage power cable (1.1.2); S1.5: Three groups of three-core medium-voltage power cables (1.1.1) and three single-core medium-voltage power cables (1.1.2) are twisted in reverse along the axis of the main body, and the twisted pitch-diameter ratio is not greater than 11, and a second filling strip (1.2) is filled between the three-core medium-voltage power cables (1.1.1) and the single-core medium-voltage power cables (1.1.2), and the twisted pitch-diameter ratio of step S1.2 is not equal to the twisted pitch-diameter ratio of this step; Step S3 includes the following steps: S3.1: Prepare the low-voltage power cable in the low-voltage power cable unit (2.1); S3.2: Take four low-voltage power cables and twist them in reverse direction along the axis of the low-voltage power cable unit (2.1) to form a twisted cable. The twisted cable pitch ratio is not greater than 10. S3.3: Wrap the outer layer of the low-voltage power cable unit (2.1) with a copper-plastic composite tape; S3.4: Extrusion molding low voltage cable anti-slip teeth (2.1.1) on the outer layer of the copper-plastic composite tape; S3.5: The low-voltage power cable unit (2.1), the large-diameter steel pipe (2.3.1), the circular filling strip (2.5) and the convex filling strip (2.4) fixedly connected with the optical cable unit (2.2) or the small-diameter steel pipe (2.3.2) are evenly distributed along the circumference; S3.6: The outer core layer (2) is twisted in the forward direction along the axis of the body, and the twisting pitch ratio is not greater than 10.

10. The method for manufacturing a deepwater umbilical cable according to claim 8, characterized in that: In step S5, the armor layer (3.1) is wound with four layers of carbon fiber filaments in total, and the winding directions of two adjacent layers of carbon fiber filaments are opposite.

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