Since the devastating oil disaster in the Gulf of Mexico, safety and environmental protection have become critical issues for the oil and gas industry. Lapp Muller SAS, part of the Stuttgart-based Lapp Group, is particularly involved in this. Through its many years’ experience and excellent reputation, Lapp Müller recently won a contract from the Italian company Breda Energia for a project in conjunction with Gisma and Seacon.
The contract involves the development and production of an underwater cable (umbilical), made up of high-pressure hoses and control cables for opening and closing underwater valves in oil pipelines at depths up to 50 metres off the Mediterranean coast of Egypt.
The cable has been produced in a single length of 900 metres with a tensile strength of nine tons and a total weight of almost six tons. The construction of the cable is impressive. It has a diameter of 71 mm and is filled with two high-pressure hoses for up to 210 bar, as well as special four-wire screened control cables stabilised by a steel cable in the centre of the underwater cable. All components are surrounded by a three-part sheathing layer made up of a polyurethane sheath, extremely strong aramide fibres and an outer polyurethane shielding.
The control cables open and close the giant valves using the high-pressure hoses. The cables are also connected to the controllers and drives that control the position of the valves. The internal logistics alone brought major challenges for Lapp employees as the project had to be completed in less than three months. To complete the job, additional machines had to be rented along with a special crane for loading the three cable drum. Before the underwater cable was approved and delivered, it was tested for a week for safe functioning and reliability by specialists from Seacon.
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