Subsea umbilicals

At the forefront of umbilical technology

Subsea umbilicals

Aker Solutions provides subsea umbilicals for production control and power distribution in the worlds most challenging environments

Subsea umbilicals

Future trends in umbilicals carry with them great industry challenges. It is that future, and the need for sustained technological development, upon which Aker Solutions is focused. Aker Solutions is at the forefront of deepwater, high pressure umbilical technology and is the leading supplier of steel tube umbilicals worldwide. Over the past 15 years we have delivered more than 3 200 kilometres (1 988 miles) to some of the worlds deepest and most challenging fields. Aker Solutions provides cost effective and technically advanced umbilicals, including: Steel tube umbilicals: from basic direct-hydraulic and electro- hydraulic umbilicals to large, integrated service umbilicals Integrated production umbilicals: incorporating actively or passively heated flowline/riser with production control functions Deepwater installation umbilicals: with our carbon fibre technology we can install up to depths of 3 000 metres (9 842 feet) and below We are capable of handling complex projects with long umbilicals, complicated cross-sections (containing a large number of elements), and termination logistics. With state-of-the-art manufacturing facilities located in Norway and the U.S, Aker Solutions has the technology and capacity to service the umbilical requirements of oil companies, subsea development alliances and installation contractors worldwide. Each Aker Solutions umbilical is custom designed per project specification and our teams take pride in meeting our customers expectations of quality umbilicals delivered on time.

Facing industry challenges head on

Subsea umbilicals

custom designed and tuned Smart design solutions

The patented Aker Solutions umbilical concept is designed to separate the individual elements within the patented umbilical while bundling them in a continuous helix with low lay-angle. The PVC profiles in the typical Aker Solutions umbilical have a multipurpose functionality: Extremely good protection for impact loads and from sharp edges Correctly spaces and supports the internal elements in the umbilical cross section Absorbs the impact energy efficiently through elastic deformation Prevents build-up of accumulated radial contact force Supports the tubes from bird-caging even on high compression loads Capable of taking high loads in installation tensioner High cross section lay-out flexibility Internal elements move relative to each other at places where bending occurs, resulting in low frictional effects The low helix lay-angle provides: Limited internal radial force generated at high umbilical tension High torsion stability No need for separate armouring system If increased axial stiffness is required due to high strain, additional helix elements of a suitable material are added to the cross section The umbilical is tuned to meet any water depth or environmental condition by adding weight elements or stiffness elements into the cross section.

Enhanced deepwater dynamic umbilical Aker Solutions patented carbon fibre rod technology increases umbilical axial stiffness for deepwater applications. This technology is used on both steel tube production control umbilicals as well as power distribution umbilicals. Utilisation of this technology allows for increased strength with little affect on overall weight. This provides benefit in terms of reduced structural reinforcement on the host platform, reduced logistical cost, and increased installability.

Subsea umbilicals

Benefits The benefits

Aker Solutions is a market leader in steel tube umbilicals. Advantages: All tubes as well as electrical and fibre optic elements are individually protected and separated by PVC profiles Improved chemical compatibility: super duplex stainless steel is compatible to all commonly used hydraulic fluids and injection chemicals (including methanol) No migration of fluids through the wall of the steel tubing Constant and low tube surface roughness The hydraulic response time and flow resistance will not alter over the years No limit with respect to internal/external line pressure No risk of hose collapse Improved regularity Long continuous umbilical lengths without the need for mid-line joints/splices Fully welded end fittings Excellent corrosion properties of super duplex stainless steel in seawater No separate armouring layers Low weight: weight members may be added if required for seabed stability Improved internal cleanliness Improved crush resistance Technology fit for deep water requirements Standard installation vessels and equipment can be used

Deep-draft quay The Aker Solutions manufacturing facilities allow for direct transfer of subsea production control and power distribution umbilicals to the installation vessels. The Moss facility quay offers eight metres (26 feet) draft, and the Mobile, Alabama, facility quay offers 13 metres (42 feet).

Subsea umbilicals

Manufacturing sites

Moss, Norway Aker Solutions plant in Moss was commissioned in 1993. This state-of-the-art facility is capable of manufacturing large diameter steel tube umbilicals in long, continuous lengths with or without centre lines with an output of 300-500 kilometres per year. Facilities for storage and load-out equipment are available at the deepwater quayside, with equipment including: Automatic welding lines Certified material laboratory Horizontal bundling machine Extrusion line Eight carousels, 11 220 tonnes Installation/transportation of reel handling equipment Qualification testing facility Draft at quay approximately eight metres (26 feet) Quay length 140 metres

Aker Solutions Moss facility

Mobile, Alabama, USA Aker Solutions Mobile facility opened in 2003 and is strategically located to serve the Gulf of Mexico and global markets. The factory, with its high capacity horizontal cabler, has met the challenges of the most aggressive deepwater applications. Characteristics: 300-500 kilometres per year Horizontal bundling machine capable of 21 elements in a single pass Extrusion line and automatic welding Testing facilities which allow for complete system integration testing 13 metre (42 feet) deep-draft quay Complete project management and engineering staff on-site Six carousels, 14 000 tonnes. Includes one portable carousel for umbilical delivery to remote regions

Aker Solutions Mobile, Alabama facility xxxxxxxxxx xxxxxxx

Subsea umbilicals

Test facilities

Aker Solutions two specialist manufacturing facilities are well equipped and staffed. They use state-of-the-art test equipment to ensure that our products meet the high standards of our clients, and of ourselves. Specification: Test equipment to meet complete umbilical qualifications/ verification requirements Crush and bend stiffness testing facilities Full scale and low cycle fatigue testing (with bend stiffeners and bell mouths) High capacity tensile test bench Moss: 30 metre (98 feet) high pull-in test tower on the quay side. The tower has been used for complete umbilical pull-in and hang-off test and can be equipped with a J-tube type pull-in if required

Pull-in test rig Aker Solutions pull-in test tower at the Moss facility

Subsea umbilicals

Umbilical products and systems

Subsea umbilicals

Steel tube umbilical Our umbilicals satisfy both basic direct hydraulic as well as electro-hydraulic umbilicals. Hydraulic, chemical and/or service lines Electrical and/or fibre optic cables Pressure rating of 15 000 psi and above No chemical permeation Long and predictable service life High crush resistance Long continuous manufacturing without transition joints/offshore umbilical connectors The PVC design concept allows for extreme flexibility Carbon fibre may be added to enhance the axial mechanical properties for deepwater service Weight elements may be added to the umbilical allowing the weight to diameter ratio to be tuned for dynamic performance

Integrated production umbilical (IPU) The IPU design is based on proven technology, qualified for both static and dynamic application in shallow and deep water. The design is ideal for contributing to a stronger umbilical and a better protected flow line. The IPU solution reduces complexity of the field layout, as well as cost and time in manufacturing and installation. Incorporation of a coated central gas lift or production flowline of 2 to 10 diameter within an overall umbilical design High voltage conductors for heating and flow assurance with fibre optics for temperature monitoring Insulation, PVC, and electro-hydraulic well control functional elements Outer polyethylene sheath Insulating and protective PVC profiles

Power distribution umbilical (PDU) Our PDU are suitable for both dynamic and static applications to depths of 9 000 feet (2 743 metres). Complete dynamic and electrical analysis Patented PVC profile and construction technique for increased impact and crush resistance Patented carbon fibre rod technology used to enhance axial mechanical characteristics Improved stability compared to conventional armoured power umbilicals

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Subsea umbilicals

Project experience
Client Norsk Hydro Kongsberg Offshore Saipem ABB ExxonMobil/Cameron FMC/Kongsberg Offshore ExxonMobil/Cameron BP Saibos Talisman Kerr McGee Anadarko, Dominion Murphy/Aker Reliance Rashid Petroleum Company GUPCO/BP Helix StatoilHydro Project Troll Oil sgard Satellites Canyon Express Bonga Kizomba A Baobab Kizomba B Rhum Rosa D+E+WI Tweedsmuir

Our project experience is unrivalled in the marketplace. Since 1993, Aker Solutions has produced over 400 umbilicals, totalling approximately 3 200 kilometres. Our projects include:

length (kilometres) 38 173 111 72 22 19 33 51 78 64 40 185 21 159 41 72 59 55

Number of umbilicals 29 16 11 28 5 Yes 2 2 8 3 4 14 7 36 5 1 2 3

Water depth (metres) 350 330 2200 1200 1200 1000 1015 1015 121 1500 2600/1525 2600/2900 1350 0-1200 160 106 828 380

Merganser & Ticonderoga, Red Hawk Atwater Vally, MC 920 Kikeh KG-D6 Development Rosetta Taurt Noonan Vega

Deepest installed umbilical To date, Aker Solutions holds the record for the worlds deepest installed umbilical. Located in the Gulf of Mexico successfully operating in 2 700 metres (9 000 feet) water depth, our carbon fibre enhanced umbilicals are meeting the increasingly challenging requirements of our industry.

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Subsea umbilicals

Aker Solutions provides complete subsea solutions throughout the lifecycle of a development

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Subsea umbilicals

Contact Aker Solutions: Headquarters Snaryveien 36, 1364 Fornebu P.O. Box 94, 1325 Lysaker Norway Tel: +47 67 82 60 00 Fax: +47 67 82 64 00 United Kingdom Howe Moss Ave. Kirkhill Industrial Estate, Dyce Aberdeen AB21 0NA UK Tel: +44 (0)1224 255 000 Fax: +44 (0)1224 255 100 North America 3600 Briarpark drive, Houston Texas 77042 USA Tel: +1 713 685 5700 Fax: +1 713 685 5707 South America Rua da Ajuda, 35-21 andar, Centro Rio de Janeiro - RJ CEP 20.040-915 Brazil Tel: +55 (21) 2122 44 01 Fax: +55 (21) 2122 44 02 Asia Pacific Level 20, Menara HLA No. 3 Jalan Kia Peng 50450 Kuala Lumpur Malaysia Tel: +6 (0) 3 2381 8388 Fax: +6 (0) 3 2381 3560 Australia 4-6 Anderson Place Perth Airport, Western Australia 6105 Tel: +61 (0)8 9262 9300 Africa SONILS OSC Rua 6 - I.L., Boavista, Luanda Angola Tel: +47 51 88 87 00 Fax: +47 67 82 64 00

2009 Aker Solutions All rights reserved. Photo by Pl Laukli www.akersolutions.com/subsea

January 2009