Deepwater Umbilical Challenges in Brazil and Worldwide

In the past all umbilicals were made of thermoplastics, used mainly for transport of hydraulic fluids to open or close valves, with separate hoses connecting to each valve on a subsea tree. As the deepwater production increased, concerns over possible failures on thermoplastic umbilicals mounted, triggering the development of the steel tube umbilical. Efficiency and reliability are the keys for deepwater umbilicals.

The modern subsea umbilical used by the O&G industry provides transmission of electric and fiber optic signals, electrical power, hydraulic fluids, and injection of chemical fluids from the surface to the seabed through electric and/or fiber optic cables encased in thermoplastic and/or steel tubes. Umbilical technology faces major challenges posed by the structural loads that umbilicals must sustain without failing, when deployed in deepwater O&G plays.

Many different kinds of specialized subsea equipments that make up subsea systems require umbilicals. These can be BOPs, Trees, Manifolds, Separation and Processing units, ROVs, Hybrid AUV/ROVs, to name but a few.

Subsea systems are vital for deepwater O&G exploration and production. Umbilicals are the link through which remote command and control signals from the surface reach deepwater subsea systems. They are also the link between ROV support vessels and the ROVs that inspect and make some interventions in subsea systems.

As subsea system go into increasingly deeper waters, umbilicals are exposed to higher pressures and more structural stress caused by longer lengths and hazardous conditions, such as strong deepwater currents. Steel and thermoplastic umbilicals have greatly evolved over the last decade, increasing in strength, size, capabilities and durability. New technologies are almost constantly being researched in order to keep up with the demands placed on umbilicals.

The major deepwater O&G markets in the world, such as Brazil, WA and the GOM, are greatly dependant on umbilicals in order to undertake the E&P necessary to develop these deep and ultra-deep reservoirs. In Brazil, with the ongoing increase in both production and exploration efforts in the deep pre-salt frontier, umbilicals are arguably in greater demand than anywhere else. All we need to remember is that the Brazilian O&G production is expected to skyrocket within the next 9 years, reaching an estimated volume of more than 6 billion boe by 2020, incredibly, tripling the present production. A true modern day oil boom, where a substantial amount of the major new reservoirs are located in deep or ultra-deep waters, with many of the huge, newly discovered pre-salt reservoirs such as Tupi (Lula) and Libra, dependant on subsea systems located at over 2000 meters (6,600 feet) below sea level.

Oceaneering Umbilical Solutions

(Formerly Multiflex, and part of Marine Production Systems do Brasil Ltda.)

OUS is one of only three companies manufacturing umbilicals in Brazil (the other two being MFX and Prysmian). Oceaneering´s state of the art facility in Niteroi, across the bridge from the city of Rio de Janeiro, comprises a total area of 35,000 m², with 10,000 m² solely dedicated to manufacturing. It currently has substantial umbilical manufacturing capacity and is currently executing a massive capital investment plan designed to more than double its umbilical manufacturing capacity. This will further improve its capabilities to produce the heavier deepwater umbilicals, increase usable space, expand infrastructure to augment growth, expand its Qualification Facility, and build a dedicated Tests and Services facility, all currently planned to be complete by the end of this year. The fact that they have one of only three umbilical manufacturing plants in the country gives them a major advantage over their global competitors when disputing Petrobras tenders, as the amount of local content in equipment purchased by the national operator is a very important criteria, when determining equipment tender victors.

Oceaneering is also the only major subsea umbilical manufacturer in Brazil that produces the full range of pump, thermoplastic hose, steel tube, hybrid, electric and fiber optic umbilicals, These are produced at all of its  in its three worldwide locations; Brazil, US and in the UK.

Mr. G. Scott Reynolds, Vice President and General Director of Marine Production Systems do Brasil, the Brazilian branch of Oceaneering International, was kind enough to answer some question questions for me.

What are some of your major deepwater umbilical projects in Brazil and Worldwide? What kind of materials are we using for these projects?

 Oceaneering Umbilical Solutions Brazil (OUSB) has provided a wide variety of types of umbilicals for a range of Petrobras projects in multiple fields, including for the first production well in Tupi (Lula) and the massive global contract for Santos, Campos and Espírito Santo basins.  They have also provided umbilicals and services to Devon, Chevron, and other multi-national oil companies in Brazil, including a joint effort by both the US and Brazil facilities for Shell’s BC-10 block; and are also currently supplying the umbilicals for OGX’s Waimea project.  Umbilicals provided contained power cables, signal cables, fiber optics, thermoplastic hoses, steel tubes, multiple extrusion layers, armoring, or any other component required to meet the customer’s needs.

What new technologies are you developing for different types of umbilicals used in the O&G Industry?

As Petrobras goes into deeper and deeper water, increasing internal and external hose pressures are a big industry challenges, calling for development of thermoplastic hoses that can withstand internal operating pressures of 10 to 15,000 psi and are collapse resistant to external pressures equivalent to 3000m water depth. Additionally, the deep water umbilicals are heavier and are being suspended over greater depths, therefore greatly increasing the suspended weight, causing potential separation issues between internal components and outer sheaths.  OUSB’s Engineering COE (Center of Excellence) is currently working on these issues, as well as others, to introduce new designs, products, and manufacturing techniques to the market.  OUSB is the only umbilical manufacturer in Brazil to have its own complete and self-contained qualification facility, thereby greatly decreasing development expense and lead-time.

Additionally, Oceaneering’s Umbilical Solutions’ Central Engineering Group out of the UK is working on a variety of umbilical technology challenges on a global scale.

How do regulations and environmental concerns affect the development of new umbilical technology?

OUSB is committed to complying with all Brazilian environmental regulations and to protecting the environment and community in which it operates. Its facility incorporates all needed infrastructure to meet or exceed all applicable regulations.

OUSB exceeds local content regulations and uses Brazil-based suppliers for every possible application, from the supply of manufacturing machines to the umbilicals’ components and materials.

How do you envision the future demand in Brazil and Worldwide for subsea and deepwater umbilicals?

Petrobras subsea umbilical demand is expected to quadruple over the next five years, as they further explore and produce out of Brazil’s pre-salt areas. This demand will stretch the total available umbilical capacity in Brazil, though Oceaneering Umbilical Solutions’ two other plants in the US and UK stand ready to support Brazil’s umbilical needs if called upon.

With three global plants and a central engineering development group, OUS is well positioned to provide world-class umbilical manufacturing and services to meet their Global and Brazilian customers’ needs.

Important Note:  Oceaneering is also the largest provider of ROVs in Brazil and the world, and offers other O&G products and services under its Brazil incorporation name; Marine Production Systems do Brasil, Limitada (MPS). Its Oceaneering Umbilical Solutions facility is located in Niterioi. Its ROV facility and Training Center is located in Macaé, along with its Rotator and Deepwater Technology Solutions businesses.  MPS will be opening a new headquarters, with administration and sales support, in downtown Rio (near Petrobras) in June.

Claudio Paschoa