New subsea umbilical plant uniquely serves Asia-Pacific market
Paul Gahm, JDR Cable Systems Inc.
Demand for subsea production umbilical systems in the Asia-Pacific region is projected to increase substantially during the next three years (2007-2009) according to a major energy industry publisher that views it as the fastest-growing region in the world.
To leverage this growth, the Umbilicals Systems business unit of UK-based JDR Cable Systems Ltd. will open a strategically-located Thailand manufacturing plant in fall 2006 to serve this burgeoning market.
In addition to being well-situated geographically, this site possesses local manufacturing capabilities in three key areas:
• Subsea production umbilicals, including full termination and hardware. Dynamic and static double-armored production control umbilicals for remote control of subsea trees.
• Subsea power cables, including specialty composite cables. Dynamic and static applications, with voltages up to 33 kV, including fiber optics and terminations for topside and subsea systems.
•Workover umbilical packages, including umbilical and reeler packages. IWOCS and THRT umbilicals for ultra deepwater applications, for pressures up to 15,000 psiwp and temperatures up to 275 °F, fiber optics and electrical arrays, and reeler packages to customer specifications.
Integrated manufacturing
JDR will supply the hydraulic hose and electric cable components from its ISO 9001-certified manufacturing facility in the UK to the new Thailand plant, where assembly and integration of these critical components into complete umbilical systems will take place. The Thailand plant’s highly trained local work force is supervised by a relatively small number of experienced expatriates, with ongoing training provided in accordance with the industry standards.
JDR’s HSE and quality management systems cover all aspects of design, manufacture, and operations. This combination of providing the critical core components from the UK, coupled with the highly skilled local workforce and state-of-the-art manufacturing equipment in Thailand, puts project-critical umbilical systems in close proximity to major subsea field developments in this region.
One of JDR's umbilical reels.
JDR’s Umbilical Systems manufacturing facility, part of the company’s “Center of Excellence,” is located in Littleport, England. This facility provides the company’s R&D, engineering, project management, manufacturing, highly specialized testing, and supply of critical components to JDR’s facilities located in Thailand and Houston, Texas (USA).
The Asia-Pacific facility
JDR’s new Thailand manufacturing plant is located at the Thai Naval Base at Sattahip at the northern tip of the Gulf of Thailand, 150 mi south of Bangkok, and 1,300 km from Singapore by sea. Beginning with a lease signed in spring of 2006 with the Bangkok Dock Co., which manages ports for the Royal Navy, the Thailand plant will supply long-length, subsea production umbilicals, and associated products.
JDR's new Thailand subsea umbilical plant.
Manufacturing long-length umbilicals requires specialized manufacturing equipment, customized assembly and integration processes, and deepwater quayside access to allow load-out of large umbilical reels. The new facility will incorporate all of these requirements.
Braided hose and signal cables will be shipped to JDR Thailand from JDR’s UK factory. Asian-sourced items will typically include galvanized armor wire sheathing, steel termination components, and delivery/installation reels.
Housed in a 100 m-by-100 m plant, this manufacturing operation will have close access to 400-metric ton heavy-lift cranes and a 12-m deep quayside for direct load-out to installation vessels and/or freight lines.
Specialized manufacturing equipment, including an armoring line, cabling machine, and large extruders, is currently being installed, with plant commissioning scheduled for 3Q 2006 to allow first product deliveries to be scheduled for 4Q 2006.
When transpooling is not required, 500-ton rated cranes will lift reels from quayside to the vessel.
Fast, cost effective supply to the Asia-Pacific region significantly reduces the logistics challenges experienced by operators for decades. By utilizing a modern facility with deep quayside access and a highly-skilled local work force, JDR will be able to deliver to operators in the Asia-Pacific region custom-engineered umbilical systems and complete a global loop of supply and service capabilities.
This facility expansion was planned and brought into operation as a natural outgrowth of JDR’s established presence as an experienced manufacturer of critical service umbilical, cable and termination applications, all through in-house manufacturing capabilities.•
