Subsea Clamping Cylinder - Bosch Rexroth

RE 08144Edition: 2020-07Replaces: 2020-06

RE 08144, Edition: 2020-07, Bosch Rexroth AG

Content

Introduction 2Main Features 2Subsea Umbilicals, Risers and Flowlines System 2Product Description 2Working Principle – Storage 3– Commissioning 3– Clamping Process 4– Decommissioning 4Integration– Hydraulic controlled 5– Electrically controlled 5

Subsea Clamping Cylinder

Technical Information

Special Features 6Advantages 6General Technical Data – System Specifications 7– Subsea Condition 7Interface 7Subsea Clamping Cylinder ― At a Glance 8Further Information 8

2/8 Technical Information | Subsea Clamping Cylinder

Bosch Rexroth AG, RE 08144, Edition: 2020-07

Introduction

The Subsea Clamping Cylinder (SCC) is a hydraulic-mechanic system that is utilized to protect Subsea Umbi-licals, Risers and Flowlines (SURF) from wear, caused by dynamic loads. It finds use wherever a constant clamping force has to be maintained for long service time without the need of a continuous energy supply.Especially designed for Bend Stiffener Connections (BSC) of SURF systems, Subsea Clamping Cylinders from Rexroth can be used in seawater for a duration of up to 25 years.This patented clamping solution includes a mechanic locking system and a set of mechanic springs inside the cylinder. The clamping force can be adjusted during the installation process and can be maintained throughout the lifetime. A power supply is only required during the positioning and the initial clamping. Once this process is completed, no power is required throughout the designed service life.

Main Features

The clamping system is based on mechanical components without the need for regular maintenance. Energy is only required for the adjustment of the position and clamping force during commissioning and decommissioning. After the clamping force is adjusted hydraulically, the system is mechanically locked and the power supply can be discon-nected.The clamping force is maintained in a pre-defined range throughout the service time by the compression of a spring package inside the actuator. Thus, the system reacts instantaneously to changes of the load that might for example be induced by waves, impacting the floating production system.

Subsea Umbilicals, Risers and Flowlines System

Riser systems provide the connection between the Sub-sea Production System on the seabed and the Floating Production Systems, such as FPSO and FLNG. The Riser system shall be a reliable and stable equipment while providing a certain degree of flexibility in order to compensate for any vessel movements that might be caused by environmental forces like wind and waves. Loads caused by unexpected movements can create wear and tear on stiff joints in Riser systems and possibly cause material fatigue and the need for early replacement. The objective of the Subsea Clamping Cylinder is to avoid the wear of clamping connection, securing the productiv-ity for long-time and protecting high value equipment. The clamping process of the SCC is controlled automati-cally using fluid-power. This eliminates the manual inter-vention and hazardous work environments for divers.

Retractioncylinder

Springpackage

Safetylock

Extensioncylinder

Guide pin

Product Description

The clamping cylinder is a combination of a hydraulic cylinder, a safety lock and a spring package assembly.The movement and initial clamping is achieved by the means of a hydraulic cylinder and fluid power. After the clamping force is adjusted to the individual requirements of the clamping connection, the mechanic locking system of the actuator can be enabled. As soon as the position of the actuator is locked in place, the spring package allows the clamping force to react to external forces. After the safety lock is enabled, power can be removed from the system, which maintains the clamping force throughout the entire lifetime of a Riser system. The safety lock can be released and actuated by hydraulic power as often as required for clamping applications. This might be during maintenance or during decommissioning at the end of the system life cycle.

Subsea Clamping Cylinder | Technical Information 3/8


Working PrincipleSt

orag

e

▶ Storage at seabed –up to 2 years at depth of 3,000 m ▶ In this state, the cylinders shall be retracted with safety lock engaged (as delivered by manufacturer) ▶ No energy supply required

▶ Movement and clamping controlled by hydraulic power

Pressure @ port A

Pressure @ port B

Pressure @ port K

Pressure @ port L

Extending

Clamping

Initiate safety lock

Complete safety lock

pressure increase

pressure decreased

A

LKB Extend cylinder by providing hydraulic fluid to chamber A

A

LKB Cylinder builds up clamping pressure by increasing hydraulic pressure in the chamber A

B K L

A

Safety lock is positioned by providing hydraulic pressure in chamber K

B K L

A

Safety lock is blocked by reducing the hydraulic pressure in chamber A

Now, commissioning is finished, the power supply can completely be deactivated and disconnected.

Com

mis

sion

ing

120

100

80

60

40

20

00 50 100 150 200 250 300

Cla

mpi

ng fo

rce

[%]

Hyd

raul

ic p

ress

ure

[MPa

]Time [s]

clamping force

locking pressure

clamping pressure



▶ Clamping process at depth of up to 300 m ▶ No energy supply required ▶ Automatic load adjustment within clamping system

Pressure @ port A

Pressure @ port B

Pressure @ port K

Pressure @ port L

Keep locked

pressure increase

pressure decreased

A

LKBClamping cylinder is installed with nominal force by reducing the pressure in chamber K (final state = clamped)

Working Principle

Throughout the clamping process, the system reacts to external loads by adopting the clamping force accord-ingly. The patented clamping solution does not require an external energy supply, the clamping force within a BSC is automatically shared between all clamping cylinders.For example, if any load is induced from the floating equipment, forces will be generated inside the clamping connection. Due to the design of the clamping cylinders from Rexroth, the force, generated by the spring package will automatically adjust accordingly, to generate a safe clamping connection.

Cla

mpi

ng P

roce

ss

▶ Release of safety lock and movement controlled by hydraulic power

Pressure @ port A

Pressure @ port B

Pressure @ port K

Pressure @ port L

Energize clamping cylinder

Release safety lock

Retracting

pressure increase

pressure decreased

A

LKB First increase the hydraulic pressure in chamber A

A

LKB Release safety lock by providing hydraulic pressure in chamber L

A

LKB Release the cylinder clamping force by reducing the pressure in chamber A and L

A

LKB Retract the cylinder by pressurizing chamber B

Dec

omm

issi

onin

g

120

100

80

60

40

20

00 20 40 60 80 100 120

Cla

mpi

ng fo

rce

[%]

Hyd

raul

ic p

ress

ure

[MPa

]

Time [s]

clamping force

unlocking pressure

clamping pressure

120

100

80

60

40

20

0300

Cla

mpi

ng fo

rce

[%]

Cla

mpi

ng c

ompr

essi

on [

%] clamping force

spring compression



x

F

P

x

F

P

Q p

Integration: hydraulic controlled

Subsea clamping cylinders can be driven by topside hydraulic equipment. As hydraulic power is only required, when an actuation has to be performed, all hydraulic lines can be disconnected, once the clamping process is completed.

Control panel

Sensors

Power unitRiser

Hook Hook

SCC SCC

Customer interface

Bosch Rexroth basis

Bosch Rexroth advanced

Electric line

Hydraulic line

Integration: electrically controlledIn addition to hydraulic operation, the Subsea Clamping Cylinders can be extended with a subsea hydraulic power unit. The hydraulic fluid is kept in a safe, enclosed environment and only electric signals are exchanged with topside equipment. The actual clamping force, pressures and clamping positions can be closely monitored throughout the service life of the clamping system.

Sens

ors

Customer interface

Bosch Rexroth basis

Bosch Rexroth advanced

Electric line

Hydraulic line

Riser

Sens

ors

S-HPU

Control panel

Hook Hook

SCC SCC



Special Features

Due to the mechanical clamping of the actuator, the hydraulic system doesn’t have to be pressurized to pro-vide the nominal clamping force for the entire service time. Therefore, the risk of a contamination of seawater by hydraulic fluid is minimized. Furthermore, the actuator is designed with environmental friendly fluid that is proven in different subsea systems by Bosch Rexroth.The clamping force of the cylinders can be adjusted during the initial hydraulic clamping process. In the combination with a wide selection of cylinder sizes and spring capacities, the clamping force can specifically be optimized for every individual application.The robust design of the system allows storage at the seabed (up to 3,000 m) for up to two years. Even after a storage at seabed, the system can be used for clamping operations at depth of 300 m for up to 25 years. Optional, the system can be provided with 3.1 or 3.2 certificates from a specified classification society.

Advantages

For the integration in existing BSC Interface, the mount-ings can be modified, based on customer requirements. Compared to traditional systems, the Subsea Clamping Cylinders allows remote and fully automated operation. It withstands the harsh subsea environment and doesn’t require continuous maintenance throughout the designed service life of up to 25 years.By allowing fully remote operation of the clamping cylin-ders, no manual intervention is required, enabling the full scope of benefits of diverless bend stiffener connectors. The system protects your workers, the environment and your equipment.The innovative working principle of maintaining clamping force minimizes the wear and tear of the Riser system by reducing the forces, induced by external loads. The system allows the constant clamping force, combined with a load balancing between all clamping cylinders in a system.

The spring package will automatically react to forces, induced into the clamping connection. Various additional options are available upon request. They reach from integrated subsea hydraulic power units (HPU) to additional electric or wireless sensor-packages in order to monitor the clamping force and position of the actuator.In conclusion, the system enables potential for cutting down cost during commissioning and maintenance by enabling remote operation and reducing wear and tear of bend stiffer systems.On request, the reliable system of Subsea Clamping Cylinders can be used for any clamping application. It is engineered in a way that it is not only suitable for SURF-systems but allows use in any clamping application not just in a marine or offshore setting but on land too. Clamping force for a lifetime.

SurgeYaw

Pitch

RollHeaveSway

The picture above shows what happens when a multi-direc-tional load reaches the risers systems, causing a Pitch or Roll movement. In this case, one cylinder might be compressed by connection plates, where the opposite cylinder might be released. In this case, the springs will push back the com-pressed cylinder, sharing this higher load with the released cylinder. This avoids an over-stress of a single unit, increas-ing the overall system reliability.



System specifications

Operating pressure Max. 500 bar (during commission and decommission)0 bar during normal operation (no power supply needed to hold clamp force)

Hydrostatic pressure test 750 bar

Hydraulic interface 4 x G1/4”

Mechanic mounting interface Trunnion fixture or according to customer specifications

Mechanic hook interface Round flange at head end or according to customer specifications

Max. length Depending on selected variant

Max. outer diameter Depending on selected variant

Stroke min. Depending on selected variant

Force variants From 20 to 120 to (6 types at 20 to steps)max. load = 120 % of nominal load for a short period of time

Service time 25 years

Subsea condition

Environment Subsea Sea water (salt) with possible dirt particles

Hydraulic fluid Environmental friendly with certificate for oil & gas subsea applications

Water depth 0 m (min) to 300 m (max) (operation) 0 m to 3,000 m (storage max. 2 years)

Deployment velocity (laying down and lift up) Max. 5 m/s (effect in pressure: 0.5 bar/s)

Enclosure IP 68 for water depth (see above)

Resistance to salt spray 1,000 h according to ISO 9227 (DIN 50021)

Protective coating NORSOK standard subsea painting

Operating temperature 4 °C to 40 °C (according to API 17F, ISO 13628-6)

Storage / Transport temperature -18 °C to 50 °C (according to API 17F, ISO 13628-6)

System set-up ▶ Typically 6 cylinders connected in parallel ▶ Recommended for use under cathodic protection

General Technical Data

Interface

The hydraulic and electric interface can be modified according to specific requirements. An example can be found in the following graphic:

Guide pin

Extend clamping cylinder (G1/4“)

Release safety lock (G1/4“)

Engage safety lock (G1/4“)

Retract clamping cylinder (G1/4“)



Bosch Rexroth AGIndustrial HydraulicsZum Eisengießer 197816 Lohr am Main, Germany Telephone +49 (0) 93 52 / 40 30 [email protected] www.boschrexroth.com/SUBSEA

© All rights reserved to Bosch Rexroth AG, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.The data specified above only serve to describe the product.No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

Subsea Clamping Cylinder ― At a Glance

Advantages

▶ Clamping continuously for up to 25 years ▶ Designed for subsea operation and storage ▶ Highly reliable, mechanical clamping system ▶ Automatically adjusts to any multi-direction load ▶ No power supply required after clamping

Options Fields of application

Further information

MarineBrochure R999001175www.boschrexroth.com/marine

SubseaBrochure R999000122www.boschrexroth.com/subsea

OffshoreBrochure R999000257www.boschrexroth.com/offshore

ATEX, IECEx, Explosion-proofBrochure R999000373 / 317www.boschrexroth.com/atex

Cylinderwww.boschrexroth.com/cylinder

▶ Customized mechanical interfaces ▶ Subsea hydraulic power units ▶ Advanced monitoring packages

▶ Subsea ▶ Onshore ▶ Offshore

Subsea Clamping Cylinder - Bosch Rexroth

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