Part 1: Umbilical Cable — What Functional Units Can Be Integrated?

Three Core Functional Modules

Electrical Conductors:

Medium/High Voltage AC or DC power to supply subsea pumps, compressors, valves, and other equipment. The design of these conductors depends on the voltage rating (typically Low Voltage such as 400V/690V, Medium Voltage like 3.3kV/6.6kV/11kV, or even higher), current capacity, and phase configuration (AC or DC). The conductors must utilize special insulation materials (e.g., XLPE, EPR) and a watertight structure to withstand the long-term high-pressure subsea environment.

Fiber Optic Units:

Single-mode/Multi-mode fibers for high-speed data/video transmission and real-time control signal communication. 

ROV Umbilical Cord with Tubes:

Hydraulic Lines: Transmit hydraulic power to operate subsea valves and actuators.

Chemical Injection Lines: Deliver corrosion inhibitors, hydrate inhibitors (e.g., methanol), demulsifiers, etc., to ensure flow assurance.

Gas Lift/Injection Lines: Used for enhanced oil recovery.

Part 2: How to Customize a ROV multiple Umbilical Cable?

Step 1: Requirements Definition & Engineering

Define: Water depth, route length

Determine: Required functional types and quantities (number of electrical, optical, and fluid conduits; tube diameters; pressure ratings).

Analyze: Environmental loads (waves, currents, seabed topography, temperature, corrosivity), installation method (cable-lay vessel, tensioner requirements), and operational conditions (dynamic fatigue, hydrostatic pressure, mechanical wear).

Step 2: Design & Analysis

Structural Design: Determine the arrangement of components (helically stranded, parallel), armor layers (for tensile, compressive, and torsional strength), and sheathing materials (for corrosion, abrasion, and hydrogen-induced cracking resistance).  Consider requirements such as flame retardancy and longitudinal water blocking.

Analyses: Perform mechanical analysis (tension, bending, fatigue), thermodynamic analysis (effect of electrical conductor heating on fluids and fibers), and fluid dynamics analysis (vortex-induced vibration during installation and operation).

Step 3: Material Selection & Manufacturing

Conductor material (copper, aluminum), fiber optic type, steel tubes (carbon steel, duplex/super duplex stainless steel), polymer sheaths (HDPE, XLPE, polyamide), armor wires (galvanized, phosphatized).

Manufacturing processes: seamless welding of steel tubes, redundant protection for fibers, and precise control during stranding/laying up of layers.

Step 4: Testing & Verification

Factory Acceptance Testing: Electrical tests (voltage withstand, partial discharge), hydraulic tests (pressure, leakage), and mechanical tests (tension, bending, fatigue).

Step 5: Installation, Operation, Maintenance & Decommissioning

Briefly mention the criticality of installation and the concept of predictive maintenance based on monitoring data.

Learn more about our specialized umbilical cables.

For a detailed design guide or preliminary technical discussion, please feel free to contact us via email at:inquiry@rouline.com

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© 2024 RouLine. The article "Core Functional Modules of Umbilical Cable and Key Considerations for Customized Engineering Design" is an original technical publication of our company. No individual or organization may reproduce or use this article for commercial purposes without prior authorization.

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Article Information

Author: RouLine

Source: Knowledge

Original Link: https://www.rouline.com/subsea-rov-umbilical-cable-functional-modules-custom-design-guide-n.html

Publication Date:  31st Dec., 2025

To Learn More

If you have requirements for custom underwater equipment cables or wish to obtain more technical documentation, please contact us via our official website at www.rouline.com or by email at inquiry@rouline.com.