Polar umbilical cable

Abstract

The invention relates to the technical field of umbilical cables, and discloses a polar umbilical cable which comprises a basic function unit module, an electromagnetic heating system and a temperature monitoring control system, the electromagnetic heating system is composed of an induction coil, a function driving unit and an electromagnetic shielding layer, and the induction coil is arranged between outer armor layers in a penetrating mode; the induction wire is a copper-based alloy enameled wire which is high in conductivity, resistant to high temperature and corrosion and appropriate in magnetic conductivity, and electromagnetic shielding layers are arranged on the inner side of the induction coil and the outer side of the armor layer to prevent stray magnetic fields generated in the electromagnetic heating process from leaking outwards. The cable is integrated with a real-time monitoring and control system, temperature data of part of point positions can be collected in real time and transmitted to a central controller through a temperature sensor embedded in the cable body, overall temperature distribution is restored based on an umbilical cable temperature distribution model, and the system adjusts a heating strategy according to the temperature distribution state to stabilize the temperature of the umbilical cable within a set interval. And the operation and maintenance cost and the fault risk are greatly reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of umbilical cables, in particular to a polar umbilical cable. BACKGROUND

[0002] With the continuous development of offshore oil exploitation technology, the underwater production system plays an increasingly important role in the development of deep-sea oil and gas fields. As a key component of the underwater production system, the umbilical cable undertakes the task of transmitting hydraulic pressure, power, control signals, chemical agents, etc. in connecting the upper facilities and the underwater production system. However, with the advancement of the underwater production system to deep-sea areas, the design of the umbilical cable faces many technical challenges, especially the polar umbilical cable used in extremely cold environments. Low temperature causes the material to gradually harden, and the lower the temperature, the higher the hardness. When the temperature exceeds a certain low temperature, the umbilical cable cannot be bent or moved by human power, affecting normal use of the product, and the risk of structural cracking increases.

[0003] The patent application with publication number CN109754935A discloses a multifunctional armored umbilical cable for underwater equipment, which comprises an umbilical cable main body and an armor layer wound outside the umbilical cable main body. The armored umbilical cable main body comprises an outer insulating layer, an optical fiber unit, a main wire, an inner insulating layer, and a filler between the main wire and the inner insulating layer. A plurality of auxiliary wires and a central filler are provided in the inner insulating layer. The gap between the plurality of auxiliary wires and the inner wall of the inner insulating layer is filled with an inner insulating layer filler. The plurality of main wires are wrapped outside the inner insulating layer, and the gap between the main wires and the outer wall of the inner insulating layer is filled with a filler between the main wires and the inner insulating layer. The outer insulating layer is wrapped outside the plurality of main wires, and the gap between the plurality of main wires and the inner wall of the outer insulating layer is filled with a grounding wire and an optical fiber unit.

[0004] The design of this prior art lacks an effective temperature monitoring and control mechanism, making it difficult to monitor temperature changes in real time and thus unable to adjust temperature control strategies in a timely manner.

[0005] Therefore, a new technical solution is needed to solve the above technical problems. SUMMARY

[0006] The purpose of the present application is to provide a polar umbilical cable that integrates a real-time monitoring and control system. Through the temperature sensors embedded in the cable body, temperature data at some points can be collected in real time and transmitted to the central controller. According to the temperature fluctuation law of the polar environment, the heating strategy can be adjusted in advance, greatly reducing the operation and maintenance cost and the risk of failure.

[0007] The technical solution adopted by the present application is: The utility model provides an arctic umbilical cable, including basic function unit module and electromagnetic heating system, temperature monitoring control system, the electromagnetic heating system is by inductive coil, function drive unit and electromagnetic shielding layer are composed, inductive coil is arranged between outer armor layer, inductive coil is copper base alloy enameled wire of high conductivity, high temperature resistance, corrosion resistance and suitable magnetic permeability, function drive unit adopts high performance insulated gate bipolar transistor module to build ground power drive circuit, sets up electromagnetic shielding layer in inductive coil inside and armor layer outside, blocks the stray magnetic field produced in electromagnetic heating process and leaks outward, avoids the electromagnetic interference to surrounding electronic equipment, communication system and marine biological environment.

[0008] Through adopting the above structure, the electromagnetic heating system in the device is based on electromagnetic induction phenomenon, when the alternating current passes through the inductive coil which is wound around the outer armor steel wire of the umbilical cable, the high frequency alternating magnetic field is generated. Since the armor steel wire is usually made of steel material with good magnetic conductivity, the magnetic lines of force in the alternating magnetic field can easily penetrate the armor steel wire, according to the law of electromagnetic induction, the induced current, namely the eddy current, is generated in the armor steel wire. The eddy current converts the electric energy into heat energy under the action of the resistance of the armor steel wire, so that the armor steel wire is rapidly heated. Since the heat is directly generated in the armor steel wire, it is not necessary to conduct through the external heating body, so that the heat loss in the transmission process is greatly reduced, and the heating efficiency is significantly improved.

[0009] Preferably, the temperature monitoring control system includes an optical fiber unit arranged in the cable, the end of the optical fiber is connected with a distributed optical fiber temperature demodulator, the temperature demodulator adopts a PT100 temperature sensor, and the measurement range is-200 DEG C~600 DEG C.

[0010] Through adopting the above structure, when the device is used, the collected temperature data is fed back to the central control system in real time, and the overall temperature distribution is converted based on the measured temperature data through the umbilical cable temperature distribution model.

[0011] Preferably, the basic function unit module includes a power unit, a control unit, a pipe unit, a filling unit, an armor layer and a sheath layer, the power unit, the control unit, the pipe unit and the filling unit are twisted to form a cable core, and the cable core is coated with the armor layer and the sheath layer.

[0012] Preferably, the power unit is used for transmitting electric energy, the pipe unit is used for conveying fluid, and the filling support part is used for maintaining the roundness of the umbilical cable.

[0013] Preferably, the armor layer is formed by winding a plurality of armor steel wires at a spiral angle, and the armor layer is coated with a sheath layer made of high-density polyethylene material.

[0014] Preferably, the inductive coil is arranged in the gap between the armor steel wires of the armor layer, alternating current is passed through the inductive coil, and heat is generated in the armor steel wire by electromagnetic heating effect, so as to regulate and control the overall temperature.

[0015] Preferably, the inductive coil is arranged inside the outer armor steel wire of the armor layer, AC power is passed through the inductive coil, and heat is generated in the armor steel wire by using the electromagnetic heating effect, so as to regulate the overall temperature.

[0016] By adopting the above structure, the number of turns, wire diameter and winding mode of the inductive coil are accurately designed according to the outer diameter size of the umbilical cable, the specification of the armor steel wire and the required heating power, the uniformity of heating is ensured, for the umbilical cable with a larger diameter, a multi-layer segmented winding structure is adopted, the magnetic field distribution is optimized, the coupling effect of the magnetic field and the armor steel wire is enhanced, and the armor steel wire can be uniformly heated.

[0017] Compared with the prior art, the present application has the following beneficial effects: 1、The cable integrates a real-time monitoring and control system, through the temperature sensor embedded in the cable body, part of the point temperature data can be collected and transmitted to the central controller in real time, based on the umbilical cable temperature distribution model, the overall temperature distribution is restored, the system adjusts the heating strategy according to the temperature distribution state to stabilize the umbilical cable temperature in the set interval, which greatly reduces the operation and maintenance cost and fault risk.

[0018] 2、The cable of the present application integrates an optical fiber unit in the umbilical cable, which can feedback the temperature of the umbilical cable in real time, the temperature monitoring and control system receives the temperature data and compares it with the preset temperature threshold, adjusts the current size and frequency of the electromagnetic heating system according to the control algorithm, and maintains the temperature in a stable range.

[0019] 3、When the cable of the present application is used, the number of turns, wire diameter and winding mode of the inductive coil are accurately designed according to the outer diameter size of the umbilical cable, the specification of the armor steel wire and the required heating power, the uniformity of heating is ensured, for the umbilical cable with a larger diameter, a multi-layer segmented winding structure is adopted, the magnetic field distribution is optimized, the coupling effect of the magnetic field and the armor steel wire is enhanced, and the armor steel wire can be uniformly heated. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 The electromagnetic heating system of the present application is shown in the figure; Figure 2 The temperature monitoring and control system of the present application is shown in the figure; Figure 3 The structure of embodiment 1 of the present application is shown in the figure; Figure 4 The structure of embodiment 2 of the present application is shown in the figure.

[0021] 1, inductive coil; 2, electromagnetic shielding layer; 3, armor steel wire; 4, optical fiber unit; 5, power unit; 6, control unit; 7, pipe unit; 8, filling unit; 9, sheath layer. DETAILED DESCRIPTION Example 1

[0022] like Figures 1-3 As shown, this embodiment provides a polar umbilical cable solution based on electromagnetic heating and temperature monitoring and control system. The electromagnetic heating system consists of an induction coil 1, a functional drive unit and an electromagnetic shielding layer 2. The functional drive unit is an external drive circuit, and a high-performance insulated gate bipolar transistor module is used to build a power drive circuit. This circuit can quickly respond to instructions issued by the control system, accurately adjust the frequency and amplitude of the alternating current output to the induction coil, and thus flexibly and accurately control the heating power of the electromagnetic heating device, which is not reflected in the umbilical cable structure diagram of this embodiment. The induction coil 1 is interspersed between the armored steel wires 3 of the umbilical cable. The induction coil is made of copper-based alloy enameled wire, and the conductor is twisted into multiple strands of single wire. The cross-sectional diameter is 5mm and the cross-sectional area is 19mm. 2 , an induction coil is arranged every 2 to 3 armored steel wires, for a total of 12. The winding direction and spiral angle of the induction coil 1 are consistent with the armored steel wire 3 of the layer in which it is located, and it is wound in a clockwise direction with a winding angle of 15°. An electromagnetic shielding layer 2 is set inside and outside the induction coil 1, and a metal material with high magnetic permeability is selected to prevent the stray magnetic field generated during the electromagnetic heating process from leaking outward, thereby avoiding electromagnetic interference to surrounding electronic equipment, communication systems and marine biological environments. The initial ambient temperature is -20°C, the initial alternating current frequency of the induction coil 1 is 50Hz and the amplitude is 200A. Under the action of the designed electromagnetic heating system, simulation calculations show that the average temperature of the umbilical cable cross section increases by about 15°C.

[0023] The optical fiber temperature monitoring system in this embodiment includes three single-mode optical fiber units 4, each optical fiber adopts G.654.E type optical fiber with a transmission rate of 10Gbps. The temperature monitoring optical fibers are arranged from the inside to the outside. Figure 3 The end of the optical fiber is connected to a distributed optical fiber temperature interrogator, which uses a PT100 temperature sensor with a measurement range of -200°C to 600°C.

[0024] The collected temperature data is fed back to the central control system in real time. Based on the measured temperature data, it is converted into an overall temperature distribution using the umbilical cable temperature distribution model. The control system pre-sets a temperature threshold range of 0°C to 30°C. When the monitored temperature falls below 0°C, the control system issues a command to the electromagnetic heating system. The electromagnetic heating system's functional drive unit increases the current or frequency of the induction coil 1, accelerating the heating of the armored steel wire 3 and rapidly raising the umbilical cable temperature. When the temperature approaches or reaches the set upper limit, the control system reduces the output power of the electromagnetic heating system to maintain the temperature within a stable range.

[0025] The umbilical cable of the embodiment includes, in addition to the electromagnetic heating system and the temperature monitoring and control system, functional units such as the power unit 5, the control unit 6, the pipe unit 7, and the filling unit 8 for maintaining the roundness of the umbilical cable, the reinforcing structural steel wire 3, and the sheath layer 9. The types and quantities of the functional units are designed according to the requirements of the use scenarios of the umbilical cable. In the embodiment, there are three power units 5, three control units 6, and seven pipe units 7. The armor layer is made of 26 steel wires 3 with a diameter of 5 mm, which improves the tensile and impact resistance of the umbilical cable. The sheath is made of high-density polyethylene material, which enhances the external impact resistance and water resistance of the umbilical cable. Embodiment 2

[0026] As shown in Figure 1 , 2 , the structure diagram of Embodiment Two is shown. The polar umbilical cable of the embodiment includes an electromagnetic heating system composed of an induction coil 1, a functional driving unit, and an electromagnetic shielding layer 2. The functional driving unit is an external driving circuit, which is constructed by using a high-performance insulated gate bipolar transistor module. The circuit can quickly respond to the instructions sent by the control system, accurately adjust the frequency and amplitude of the alternating current output to the induction coil, and thus flexibly and accurately control the heating power of the electromagnetic heating device. The structure diagram of the umbilical cable of the embodiment is not embodied. The difference from Embodiment One is that the induction coil 1 is arranged on the inner side of the outer armor steel wire 3. The induction coil 2 is made of copper-based alloy enameled wire, the conductor is twisted by multiple single wires, the cross-sectional diameter is 5 mm, the cross-sectional area is 19 mm 2 , it is arranged in a ring shape, the twisting direction is opposite to that of the armor steel wire 3, that is, counterclockwise, the twisting angle is 15°, and there are 23 wires. The electromagnetic shielding layer 2 is arranged on the outer side of the armor layer and the inner side of the induction coil layer, and is made of a metal material with high magnetic permeability, so as to block the leakage of the stray magnetic field generated during the electromagnetic heating process, and avoid causing electromagnetic interference to the surrounding electronic equipment, communication systems, and marine biological environment. The initial ambient temperature is -20℃, the initial alternating current frequency of the induction coil 1 is 50Hz, and the amplitude is 200A. Under the action of the designed electromagnetic heating system, the average temperature of the cross section of the umbilical cable is increased by 20℃ through simulation calculation.

[0027] The optical fiber temperature monitoring system in the embodiment includes three single-mode optical fiber units 4. Each optical fiber is of the G.654.E type, and the transmission rate is 10Gbps. The temperature monitoring optical fibers are arranged in the Figure 3The end of the optical fiber is connected with a distributed optical fiber temperature demodulator, which uses a PT100 temperature sensor and has a measurement range of -200℃~600℃. The collected temperature data is fed back to the central control system in real time, and the overall temperature distribution is converted based on the measured temperature data through the umbilical temperature distribution model. The control system pre-sets a temperature threshold range of 0℃~30℃, and when the monitored temperature is lower than 0℃, the control system will issue an instruction to the electromagnetic heating system to increase the current or frequency of the induction coil 1 through the functional driving unit of the electromagnetic heating system to accelerate the heating speed of the armored steel wire 3, so that the temperature of the umbilical cable rises quickly; when the temperature approaches or reaches the set upper limit temperature, the control system reduces the output power of the electromagnetic heating system to maintain the temperature within a stable range.

[0028] In addition to the above electromagnetic heating system and temperature monitoring and control system, the umbilical cable of the embodiment further includes functional units such as power unit 5, control unit 6, pipe unit 7, and enhanced structure armored steel wire 3, sheath layer 9 from the inside to the outside. The types and quantities of functional units are designed according to the use scene requirements of the umbilical cable, and in the embodiment, there are two power units 5, two control units 6, and four pipe units 7. The armored layer uses 50 armored steel wires with a diameter of 5mm to improve the tensile and impact resistance of the umbilical cable, and the sheath uses high-density polyethylene material to enhance the external impact resistance and water resistance of the umbilical cable.

[0029] The present application, by arranging the induction coil to perform electromagnetic induction heating on the armored steel wire, and designing the number and alternating current of the induction coil according to the temperature conditions in the polar environment, realizes uniform heating of the armored steel wire, effectively solves the problem of uneven heating of traditional umbilical cables, improves the heating efficiency and product performance; the built-in temperature monitoring optical fiber is used for online temperature monitoring, and the real-time control mechanism of adjusting the current size of the induction coil is combined with the temperature results to realize accurate monitoring and regulation of the temperature of the umbilical cable, effectively avoiding the problem of material hardening caused by too low temperature in the polar environment, and ensuring the flexibility and normal use of the product.

[0030] The above-described embodiments are merely preferred embodiments of the present application and do not limit the scope of the present application. Without departing from the design spirit of the present application, various modifications and improvements to the technical solutions of the present application made by those skilled in the art should be included in the protection scope determined by the claims of the present application.

Claims

1. A polar umbilical cable, comprising a basic functional unit module, an electromagnetic heating system, and a temperature monitoring and control system, characterized in that: The electromagnetic heating system consists of an induction coil, a functional drive unit and an electromagnetic shielding layer. The induction coil is interspersed between the outer armor layers. The induction wire is a copper-based alloy enameled wire with high conductivity, high temperature resistance, corrosion resistance and suitable magnetic permeability. The functional drive unit adopts a power drive circuit constructed with a high-performance insulated gate bipolar transistor module. An electromagnetic shielding layer is arranged on the inside of the induction coil and the outside of the armor layer to prevent the stray magnetic field generated during the electromagnetic heating process from leaking outward, thereby avoiding electromagnetic interference to surrounding electronic equipment, communication systems and marine biological environments.

2. The polar umbilical cable according to claim 1, characterized in that: The temperature monitoring and control system includes an optical fiber unit arranged in a cable. The end of the optical fiber is connected to a distributed optical fiber temperature demodulator. The temperature demodulator uses a PT100 temperature sensor with a measurement range of -200°C to 600°C.

3. The polar umbilical cable according to claim 1, characterized in that: The basic functional unit module includes a power unit, a control unit, a pipe unit, a filling unit, an armor layer, and a sheath layer. The power unit, the control unit, the pipe unit, the filling unit and the optical fiber unit are twisted together to form a cable core, which is covered with an armor layer and a sheath layer in sequence.

4. The polar umbilical cable according to claim 3, characterized in that: The power unit is used to transmit electrical energy, the pipe unit is used to transport fluid, and the filling support component is used to maintain the roundness of the umbilical cable.

5. The polar umbilical cable according to claim 1, characterized in that: The armor layer is formed by winding multiple layers of armor steel wires at a spiral angle, and the outside of the armor layer is covered with a sheath layer made of high-density polyethylene material.

6. The polar umbilical cable according to claim 5, characterized in that: Induction coils are inserted into the gaps between the armored steel wires of the armor layer. Alternating current is passed through the induction coils, and electromagnetic heating effect is used to generate heat in the armored steel wires, thereby regulating the overall temperature.

7. The polar umbilical cable according to claim 5, characterized in that: An induction coil is arranged inside the outer armor steel wire of the armor layer, and alternating current is passed through the induction coil to generate heat inside the armor steel wire using the electromagnetic heating effect, thereby regulating the overall temperature.

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