Composite deepwater dynamic hose umbilical cable and preparation method thereof

Abstract

The invention discloses a composite deepwater dynamic hose umbilical cable and a preparation method thereof, and relates to the field of umbilical cables, the composite deepwater dynamic hose umbilical cable comprises a power cable, the outer wall of the power cable is provided with a first XLPE insulating layer, and the outer wall of the first XLPE insulating layer is provided with a functional layer. According to the composite deepwater dynamic hose umbilical cable and the preparation method thereof, the power cable is arranged in the center of the whole body and can bear main tensile force, and the three-core sounding hose, the air pipe and the water pipe which are low in strength are distributed on the periphery, so that the situation that the hose unit yields firstly under the tensile force and cannot bear the tensile force is avoided. Through the arrangement of the galvanized steel wire armoring and the Kevlar fiber braid layer, mechanical complementation can be formed, the tensile strength is improved compared with that of a traditional single-layer armoring, the nylon rope filling bodies and the special-shaped filling strips are adopted for filling, the roundness of the whole cross section can be optimized, the number of cabling units is reduced, and the manufacturing complexity is reduced.

Description

Technical Field

[0001] The present invention relates to the field of umbilical cables, and in particular to a composite deepwater dynamic hose umbilical cable and a preparation method thereof. Background Art

[0002] The umbilical cable is a multifunctional composite deep-sea cable that integrates power transmission, signal control, fiber optic communication, and hydraulic / chemical agent delivery. It is mainly used to connect surface facilities (such as offshore platforms and ships) with underwater production systems (such as underwater oil trees and ROV robots). It is the lifeline of deep-sea oil and gas exploration and development and underwater equipment operation and maintenance. Its function is similar to that of a human umbilical cord, and it achieves stable transmission of energy, signals and materials through multi-channel integration.

[0003] Existing deepwater umbilical cables have the following disadvantages: the metal armor in the umbilical cable is heavy and prone to corrosion; the hose unit is prone to yield failure; the dynamic fatigue life is insufficient, and deep-sea damage cannot be quickly repaired, resulting in its tensile strength, fatigue resistance, vibration resistance, corrosion resistance and maintenance costs cannot be guaranteed when used in extreme deep-sea environments.

[0004] Therefore, it is necessary to propose a composite deepwater dynamic hose umbilical cable and a preparation method thereof to solve the above problems. Summary of the Invention

[0005] The main purpose of the present invention is to provide a composite deepwater dynamic hose umbilical cable and a preparation method thereof, which can effectively solve the problems in the background technology.

[0006] To achieve the above object, the technical solution adopted by the present invention is:

[0007] A composite deepwater dynamic hose umbilical cable, comprising a power cable, wherein an outer wall of the power cable is provided with a first XLPE insulation layer, and an outer wall of the first XLPE insulation layer is provided with a functional layer;

[0008] The functional layers include a copper tape shielding layer, a three-core sounding hose, an air pipe, a water pipe, a polyester binding tape, a galvanized steel wire armor, a Kevlar fiber braided layer, a signal transmission unit, a Kevlar fiber braided mesh, a PA11 lining, a stainless steel wire braided layer, a PUR outer sheath, an anti-torsion layer, a conductive coating, a self-repairing layer, an anti-biological attachment layer, and a detection marker tape.

[0009] Preferably, the inner cavity of the power cable and the copper tape shielding layer is filled with a nylon rope filler, the inner cavity of the copper tape shielding layer is installed with a communication cable, the outer wall of the communication cable is installed with an HDPE sheath, and the communication cable is spirally twisted around the power cable and installed on the outer wall of the power cable.

[0010] Preferably, a high-density polyethylene sheath is installed on the outside of the air pipe, water pipe and three-core sounding hose, the high-density polyethylene sheath is installed on the outside of the communication cable, and the inner cavity of the high-density polyethylene sheath is filled with special-shaped filling strips.

[0011] Preferably, there are two groups of three-core sounding hoses, each group of three-core sounding hoses has three hoses, the air pipes and water pipes are symmetrically distributed on the outside of the communication cable, and the air pipes and water pipes are arranged alternately.

[0012] Preferably, the polyester binding belt is installed on the outside of the high-density polyethylene sheath, the galvanized steel wire armor is installed on the outside of the polyester binding belt, the Kevlar fiber braided layer is installed on the outside of the galvanized steel wire armor, and the signal transmission unit is installed on the outside of the Kevlar fiber braided layer.

[0013] Preferably, the signal transmission unit includes a copper conductor, a second XLPE insulation layer and an aluminum-plastic composite shielding layer.

[0014] Preferably, the Kevlar fiber mesh is installed on the outside of the signal transmission unit, and the elastic silicone is filled in the inner cavity of the Kevlar fiber mesh. The Kevlar fiber mesh and the elastic silicone are used to dynamically compensate the power cable.

[0015] Preferably, the PA11 lining is installed on the outside of the Kevlar fiber woven mesh, the stainless steel wire braided layer is installed on the outside of the PA11 lining, the PUR outer sheath is installed on the outside of the stainless steel wire braided layer, the inner side of the anti-torsion layer is embedded with spiral stainless steel wire, and the anti-torsion layer is installed on the outside of the PUR outer sheath.

[0016] Preferably, the conductive coating, self-repairing layer and anti-biological attachment layer are all coated on the outside of the anti-torsion layer, the conductive coating is used to reduce the signal loss of the power cable, the self-repairing layer is polyurethane containing microcapsules, which is used to automatically release polyurethane to repair the anti-torsion layer after damage, the anti-biological attachment layer is a silicon-based antifouling coating, the detection mark band is a fluorescent strip and an RFID chip, and a balancing hole is opened on the outside of the anti-torsion layer for balancing the internal and external water pressure of the power cable.

[0017] A method for preparing a composite deepwater dynamic hose umbilical cable comprises the following steps:

[0018] S1: The power cable adopts the copper conductor stranding process. The conductor is twisted into a multi-strand structure after annealing. The outer layer is extruded with a first XLPE insulation layer. The optical fiber unit of the communication cable adopts a loose tube structure with built-in water-blocking yarn filling. The copper tape shielding layer is covered by a longitudinal wrapping process. The outer layer is extruded with HDPE sheath. A conductive coating is applied between the copper tape shielding layer and the HDPE sheath to reduce signal loss.

[0019] S2: The three-core sounding hose adopts a three-layer co-extrusion process. The inner lining layer is made of PA11 material and is formed by melt extrusion; the middle reinforcement layer is braided with stainless steel wire; the outer sheath is extruded with thermoplastic polyurethane, and the surface is laser engraved with a pressure resistance mark;

[0020] S3: The air and water pipes are formed by a rotary extrusion process, with polyester binding tape, galvanized steel wire armor and Kevlar fiber braid wrapped synchronously;

[0021] S4: The power cable is fixed to the central axis of the cabling machine. The communication cable, air pipe and water pipe are wrapped around the power cable in a spiral twisted manner. The nylon rope filling body and special-shaped filling strip are filled to the corresponding position.

[0022] S5: A signal transmission unit is composed of a copper conductor, a second XLPE insulation layer and an aluminum-plastic composite shielding layer, which is installed on the Kevlar fiber braided layer. Elastic silicone is installed on the Kevlar fiber braided mesh. The spiral stainless steel wire is embedded in the inner cavity of the anti-torsion layer. The Kevlar fiber braided mesh is installed on the signal transmission unit. The PA11 lining, the stainless steel wire braided layer and the PUR outer sheath are installed on the Kevlar fiber braided mesh in sequence. The conductive coating, the self-healing layer and the anti-biological attachment layer are coated on the anti-torsion layer. The detection marker tape is installed on the anti-torsion layer. Based on this, the preparation of a composite deepwater dynamic hose umbilical cable is completed.

[0023] Compared with the prior art, the present invention provides a composite deepwater dynamic hose umbilical cable and a preparation method thereof, which has the following beneficial effects:

[0024] 1. This composite deepwater dynamic hose umbilical cable and its preparation method can withstand the main tensile force by placing the power cable at the center of the whole, while the lower-strength three-core sounding hose, air pipe and water pipe are distributed on the periphery, which can prevent the hose unit from yielding first when subjected to tension. The galvanized steel wire armor and Kevlar fiber braided layer can form mechanical complementarity, and the tensile strength is improved compared to traditional single-layer armor. The use of nylon rope filler and special-shaped filling strips for filling can optimize the roundness of the overall cross-section, reduce the number of cable units, and reduce manufacturing complexity.

[0025] 2. This composite deepwater dynamic hose umbilical cable and its preparation method, by installing elastic silicone in a Kevlar fiber braided mesh, combined with an anti-torsion layer and spiral stainless steel wire in its inner cavity, can reduce bending stress concentration and extend the overall fatigue life. The self-repairing layer containing microcapsules can release repair agents when the microcapsules rupture after damage, thereby improving the overall repair rate and reducing the frequency of deep-sea maintenance. The conductive coating can shield electromagnetic interference and reduce signal loss. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic structural diagram of the present invention as a whole;

[0027] Figure 2 is a cross-sectional view of the present invention;

[0028] Figure 3 It is a structural schematic diagram of the signal transmission unit of the present invention;

[0029] Figure 4 This invention Figure 2 Enlarged view of point A in the middle.

[0030] In the figure: 1. Power cable; 2. Nylon rope filling body; 3. First XLPE insulation layer; 4. Functional layer; 5. Copper tape shielding layer; 6. Communication cable; 7. HDPE sheath; 8. Three-core sounding hose; 9. Air pipe; 10. Water pipe; 11. Special-shaped filling strip; 12. Polyester binding tape; 13. Galvanized steel wire armor; 14. Kevlar fiber braided layer; 15. Signal transmission unit; 16. Copper conductor; 17. Second XLPE insulation layer; 18. Aluminum-plastic composite shielding layer; 19. Kevlar fiber braided mesh; 20. Elastic silicone; 21. PA11 lining; 22. Stainless steel wire braided layer; 23. PUR outer sheath; 24. Anti-torsion layer; 25. Spiral stainless steel wire; 26. Conductive coating; 27. Self-healing layer; 28. Anti-biological attachment layer; 29. ​​Detection marking tape. DETAILED DESCRIPTION

[0031] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0032] Example 1:

[0033] like Figure 1-Figure 4As shown, a composite deepwater dynamic hose umbilical cable includes a power cable 1, the outer wall of the power cable 1 is installed with a first XLPE insulation layer 3, the outer wall of the first XLPE insulation layer 3 is installed with a functional layer 4, the functional layer 4 includes a copper tape shielding layer 5, a three-core sounding hose 8, an air pipe 9, a water pipe 10, a polyester binding tape 12, a galvanized steel wire armor 13, a Kevlar fiber braided layer 14, a signal transmission unit 15, a Kevlar fiber braided mesh 19, a PA11 liner 21, a stainless steel wire braided layer 22, a PUR outer sheath 23, an anti-torsion layer 24, a conductive coating 26, a self-repairing layer 27, an anti-biological attachment layer 28, and a detection marker tape 29. The inner cavity of the power cable 1 and the copper tape shielding layer 5 is filled with Nylon rope filling body 2, a communication cable 6 is installed in the inner cavity of the copper tape shielding layer 5, and a HDPE sheath 7 is installed on the outer wall of the communication cable 6. The communication cable 6 is spirally twisted around the power cable 1 and installed on the outer wall of the power cable 1. The air pipe 9, water pipe 10 and three-core sounding hose 8 are installed with a high-density polyethylene sheath on the outside. The high-density polyethylene sheath is installed on the outside of the communication cable 6. The inner cavity of the high-density polyethylene sheath is filled with a special-shaped filling strip 11. There are two groups of three-core sounding hoses 8, and each group of three-core sounding hoses 8 has three. The air pipe 9 and water pipe 10 are symmetrically distributed on the outside of the communication cable 6. The air pipe 9 and water pipe 10 are arranged alternately. The polyester binding tape 12 is installed on the outside of the high-density polyethylene sheath. Galvanized steel wire The armor 13 is installed on the outside of the polyester binding tape 12, the Kevlar fiber braided layer 14 is installed on the outside of the galvanized steel wire armor 13, the signal transmission unit 15 is installed on the outside of the Kevlar fiber braided layer 14, the signal transmission unit 15 includes a copper conductor 16, a second XLPE insulation layer 17 and an aluminum-plastic composite shielding layer 18, the Kevlar fiber braided mesh 19 is installed on the outside of the signal transmission unit 15, and the elastic silicone 20 is filled in the inner cavity of the Kevlar fiber braided mesh 19. The Kevlar fiber braided mesh 19 and the elastic silicone 20 are used to dynamically compensate the power cable 1, the PA11 lining 21 is installed on the outside of the Kevlar fiber braided mesh 19, and the stainless steel wire braided layer 22 is installed inside the PA11 The outside of the lining 21, the PUR outer sheath 23 is installed on the outside of the stainless steel wire braided layer 22, the inner side of the anti-torsion layer 24 is embedded with a spiral stainless steel wire 25, the anti-torsion layer 24 is installed on the outside of the PUR outer sheath 23, the conductive coating 26, the self-repairing layer 27, and the anti-biological attachment layer 28 are all coated on the outside of the anti-torsion layer 24, the conductive coating 26 is used to reduce the signal loss of the power cable 1, the self-repairing layer 27 is a polyurethane containing microcapsules, which is used to automatically release polyurethane to repair the anti-torsion layer 24 after damage, the anti-biological attachment layer 28 is a silicon-based anti-fouling coating, the detection mark band 29 is a fluorescent strip and an RFID chip, and a balancing hole is opened on the outside of the anti-torsion layer 24 to balance the internal and external water pressure of the power cable 1.

[0034] By placing the power cable 1 at the center of the whole, it can withstand the main tensile force, while the three-core sounding hose 8, air pipe 9 and water pipe 10 with lower strength are distributed on the periphery, which can avoid the hose unit yielding first when subjected to tension. The galvanized steel wire armor 13 and Kevlar fiber braided layer 14 are set to form mechanical complementarity, and the tensile strength is improved compared with the traditional single-layer armor. The use of nylon rope filler 2 and special-shaped filling strips 11 for filling can optimize the roundness of the overall cross-section, reduce the number of cable units, and reduce the manufacturing complexity. By installing elastic silicone 20 in the Kevlar fiber braided mesh 19, combined with the anti-torsion layer 24 and the spiral stainless steel wire 25 in its inner cavity, the bending stress concentration can be reduced and the fatigue life of the whole can be extended. The self-repairing layer 27 containing microcapsules can release the repair agent when the microcapsules rupture after damage, thereby improving the overall repair rate and reducing the frequency of deep-sea maintenance. The conductive coating 26 can shield electromagnetic interference and reduce signal loss.

[0035] Example 2:

[0036] A method for preparing a composite deepwater dynamic hose umbilical cable comprises the following steps:

[0037] S1: The power cable 1 uses a copper conductor stranding process. The conductor is twisted into a multi-strand structure after annealing. The outer layer is extruded with a first XLPE insulation layer 3. The optical fiber unit of the communication cable 6 adopts a loose tube structure with built-in water-blocking yarn filling. The copper tape shielding layer 5 is covered by a longitudinal wrapping process. The outer layer is extruded with a HDPE sheath 7. A conductive coating is applied between the copper tape shielding layer 5 and the HDPE sheath 7 to reduce signal loss.

[0038] S2: The three-core sounding hose 8 adopts a three-layer co-extrusion process. The inner lining layer is made of PA11 material and is formed by melt extrusion; the middle reinforcement layer is braided with stainless steel wire; the outer sheath is extruded with thermoplastic polyurethane, and the surface is laser engraved with a pressure resistance mark;

[0039] S3: The air pipe 9 and the water pipe 10 are formed by a rotary extrusion process, and the polyester binding tape 12, the galvanized steel wire armor 13 and the Kevlar fiber braid 14 are wound synchronously;

[0040] S4: The power cable 1 is fixed to the central axis of the cabling machine, the communication cable 6, the air pipe 9 and the water pipe 10 are wrapped around the power cable 1 in a spiral twisted manner, and the nylon rope filling body 2 and the special-shaped filling strip 11 are filled to the corresponding positions;

[0041] S5: The copper conductor 16, the second XLPE insulation layer 17 and the aluminum-plastic composite shielding layer 18 form a signal transmission unit 15, which is installed on the Kevlar fiber braided layer 14, the elastic silicone 20 is installed on the Kevlar fiber braided mesh 19, the spiral stainless steel wire 25 is embedded in the inner cavity of the anti-torsion layer 24, the Kevlar fiber braided mesh 19 is installed on the signal transmission unit 15, the PA11 lining 21, the stainless steel wire braided layer 22, and the PUR outer sheath 23 are installed on the Kevlar fiber braided mesh 19 in sequence, the conductive coating 26, the self-repairing layer 27 and the anti-biological attachment layer 28 are coated on the anti-torsion layer 24, and the detection marker tape 29 is installed on the anti-torsion layer 24. Based on this, the preparation of a composite deep-water dynamic hose umbilical cable is completed.

[0042] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A composite deepwater dynamic hose umbilical cable, comprising a power cable (1), characterized in that: The outer wall of the power cable (1) is provided with a first XLPE insulation layer (3), and the outer wall of the first XLPE insulation layer (3) is provided with a functional layer (4); The functional layer (4) comprises a copper tape shielding layer (5), a three-core sounding hose (8), an air pipe (9), a water pipe (10), a polyester binding tape (12), a galvanized steel wire armor (13), a Kevlar fiber braided layer (14), a signal transmission unit (15), a Kevlar fiber braided mesh (19), a PA11 lining (21), a stainless steel wire braided layer (22), a PUR outer sheath (23), an anti-torsion layer (24), a conductive coating (26), a self-repairing layer (27), an anti-biological attachment layer (28), and a detection marker tape (29).

2. The composite deepwater dynamic hose umbilical cable according to claim 1, characterized in that: The inner cavities of the power cable (1) and the copper tape shielding layer (5) are filled with a nylon rope filler (2), the inner cavity of the copper tape shielding layer (5) is installed with a communication cable (6), the outer wall of the communication cable (6) is installed with a HDPE sheath (7), and the communication cable (6) surrounds the power cable (1) and is twisted in a spiral and installed on the outer wall of the power cable (1).

3. The composite deepwater dynamic hose umbilical cable according to claim 1, characterized in that: The air pipe (9), water pipe (10) and three-core sounding hose (8) are externally installed with a high-density polyethylene sheath, the high-density polyethylene sheath is installed externally on the communication cable (6), and the inner cavity of the high-density polyethylene sheath is filled with a special-shaped filling strip (11).

4. The composite deepwater dynamic hose umbilical cable according to claim 3, characterized in that: There are two groups of three-core sounding hoses (8), each group of three-core sounding hoses (8) has three hoses, the air pipes (9) and water pipes (10) are symmetrically distributed outside the communication cable (6), and the air pipes (9) and water pipes (10) are alternately arranged.

5. The composite deepwater dynamic hose umbilical cable according to claim 4, characterized in that: The polyester binding belt (12) is installed on the outside of the high-density polyethylene sheath, the galvanized steel wire armor (13) is installed on the outside of the polyester binding belt (12), the Kevlar fiber braided layer (14) is installed on the outside of the galvanized steel wire armor (13), and the signal transmission unit (15) is installed on the outside of the Kevlar fiber braided layer (14).

6. The composite deepwater dynamic hose umbilical cable according to claim 5, characterized in that: The signal transmission unit (15) comprises a copper conductor (16), a second XLPE insulation layer (17) and an aluminum-plastic composite shielding layer (18).

7. The composite deepwater dynamic hose umbilical cable according to claim 1, characterized in that: The Kevlar fiber braided mesh (19) is installed outside the signal transmission unit (15), and the elastic silicone (20) is filled in the inner cavity of the Kevlar fiber braided mesh (19). The Kevlar fiber braided mesh (19) and the elastic silicone (20) are used to dynamically compensate the power cable (1).

8. The composite deepwater dynamic hose umbilical cable according to claim 1, characterized in that: The PA11 lining (21) is installed on the outside of the Kevlar fiber braided mesh (19), the stainless steel wire braided layer (22) is installed on the outside of the PA11 lining (21), the PUR outer sheath (23) is installed on the outside of the stainless steel wire braided layer (22), a spiral stainless steel wire (25) is embedded in the inner side of the anti-torsion layer (24), and the anti-torsion layer (24) is installed on the outside of the PUR outer sheath (23).

9. The composite deepwater dynamic hose umbilical cable according to claim 8, characterized in that: The conductive coating (26), the self-repairing layer (27), and the anti-biological attachment layer (28) are all coated on the outside of the anti-torsion layer (24); the conductive coating (26) is used to reduce the signal loss of the power cable (1); the self-repairing layer (27) is polyurethane containing microcapsules, which is used to automatically release polyurethane to repair the anti-torsion layer (24) after damage; the anti-biological attachment layer (28) is a silicon-based antifouling coating; the detection marking band (29) is a fluorescent strip and an RFID chip; and a balancing hole is opened on the outside of the anti-torsion layer (24) to balance the internal and external water pressures of the power cable (1).

10. A method for preparing a composite deepwater dynamic hose umbilical cable, using the composite deepwater dynamic hose umbilical cable according to any one of claims 1 to 9, characterized in that: The following steps are included: S1: The power cable (1) adopts a copper conductor twisting process, and the conductor is twisted into a multi-strand structure after annealing treatment. The outer layer is extruded with a first XLPE insulation layer (3). The optical fiber unit of the communication cable (6) adopts a loose tube structure with built-in water-blocking yarn filling. The copper tape shielding layer (5) is covered by a longitudinal wrapping process, and the outer layer is extruded with a HDPE sheath (7). A conductive coating is applied between the copper tape shielding layer (5) and the HDPE sheath (7) to reduce signal loss. S2: The three-core sounding hose (8) adopts a three-layer co-extrusion process, the inner lining layer is made of PA11 material, which is formed by melt extrusion; the middle reinforcement layer is braided with stainless steel wire; the outer sheath is extruded with thermoplastic polyurethane, and the surface is laser engraved with a pressure resistance mark; S3: The air pipe (9) and the water pipe (10) are formed by a rotary extrusion process, and the polyester binding tape (12), the galvanized steel wire armor (13) and the Kevlar fiber braid (14) are wound synchronously; S4: The power cable (1) is fixed to the central axis of the cabling machine, the communication cable (6), the air pipe (9) and the water pipe (10) are wrapped around the power cable (1) in a spiral twisted manner, and the nylon rope filling body (2) and the special-shaped filling strip (11) are filled to the corresponding positions; S5: A copper conductor (16), a second XLPE insulation layer (17) and an aluminum-plastic composite shielding layer (18) are formed into a signal transmission unit (15), which is installed at the Kevlar fiber braided layer (14), an elastic silicone rubber (20) is installed on the Kevlar fiber braided mesh (19), a spiral stainless steel wire (25) is embedded in the inner cavity of the anti-torsion layer (24), the Kevlar fiber braided mesh (19) is installed at the signal transmission unit (15), a PA11 lining (21), a stainless steel wire braided layer (22) and a PUR outer sheath (23) are installed in sequence at the Kevlar fiber braided mesh (19), a conductive coating (26), a self-repairing layer (27) and an anti-biological attachment layer (28) are coated on the anti-torsion layer (24), and a detection marker band (29) is installed at the anti-torsion layer (24). Based on this, a composite deepwater dynamic hose umbilical cable is prepared.

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