Competence centre for submarine technology

The Halden plant is Nexans' competence centre for submarine power cables as well as interplatform cables and umbilicals for the offshore industry.

Modern facilities
The factory is equipped with modern facilities for the manufacturing of steel tube umbilicals and composite cables for the offshore market, including two vertical lay-up machines able to accommodate a large number of drums and baskets. A special feature of the plant is the turntables used for the storage of semi-finished products between processes and the large turntables located outside the factory used for the storage of finished cables. From this selfpowered outdoor turntables – with diameters of 30 metres and a storage capacity 35,000 tons – an entire cable length can be transferred directly to a laying vessel equipped with a similar turntable. From this factory we have supplied cables in continuous lengths of up to 145 km, at a weight of 6,300 tons.
 

  • Paper-insulated cables
    The Halden plant is especially equipped for producing long paper-insulated and heavy submarine power cables. The plant is currently able to produce cables with conductors up to 2,500 mm2, for voltages up to 765 kV. 
  • XLPE-insulated cables
    The vertical production line for XLPE cables is installed in a tower over 100 metres high. The extrusion line is a completely closed system for submarine cables up to 420 kV. Nexans is able to manufacture continuous lengths of XLPE cabels of factory joints. Applying controlled factory joints on the phases, the maximum length is only limited by the storage and laying vessel capacity. 
  • DEH cables
    Nexans has pioneered the development of DEH technology in  partnership with Norwegian operators and research organisations. The world’s first installation of a DEH system took place in 2000 for Statoil’s Åsgard oil and gas field on the Norwegian continental shelf, where it is used to heat the flowlines in order to prevent hydrate formation. Since Åsgard, Nexans has delivered more than 200 km of  DEH cables. 
  • Umbilicals
    Nexans introduced the first steel tube umbilical in 1993, and the first dynamic steel tube umbilical in 1995. The company has supplied more than 2,400 km of umbilical altogether such as umbilicals for 2,300 m waterdepth for Shell`s NaKika project. The umbilical delivered for Statoil’s Snøhvit field includes the 145 km long main umbilical from land to submarine and represents a record-breaking length. Nexans has  a totally integrated umbilical operation, covering everything from engineering and steeltube welding to qualification testing and hook-up.

Research and development
Research and development are carried out on a comprehensive range of sub-marine power cables and umbilicals. Important R&D activities are:

  • Deep waters
    Dynamic and static umbilicals and power umbilicals for deep waters. 
  • Insulations systems
    Insulation systems for HVDC and HVAC submarine cables, paper lapped and extruded polymeric.

Halden plant in Norwyay

The plant was built in order to produce the 120 km 350 kV Skagerrak cables in the early 1970´s. Since its erection, it has continuously been enlarged and upgraded in order to accommodate developments in the field of paper insulated high-voltage AC and DC cables, high-voltage XLPE (crosslinked polyethylene)-insulated cables, composite cables, pipeline heating cables and umbilicals for the offshore industry.


Milestones
The plant has supplied cables to a number of projects representing milestones in submarine cable technology, among them:
  • the first 250 kV DC cables across the Skagerrak Sea
  • the first 525 kV AC cables between   Vancouver Island and mainland British Columbia, Canada
  • the first 400 kV DC cables 
  • the first steel tube umbilicals
  • the first 420 kV XLPE AC Submarine cable system for Ormen Lange
  • the first direct electrical heating systems for offshore pipelines
  • 400 kV AC cable at a maximum water depth of 830 m
  • the first Integrated Return Conductor (IRC) HVDC cable - between Scotland and Northern Ireland