ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE...2. FIBER ROPE FOR SUBSEA INSTALLATION. Subsea capacity...
Transcript of ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE...2. FIBER ROPE FOR SUBSEA INSTALLATION. Subsea capacity...
ULTRA-DEEP SUBSEA CRANEWITH FIBER ROPE
HUISMAN EQUIPMENT
IMCA CONFERENCE AMSTERDAM
27-09-2018
HUISMAN - EQUIPMENT
Table of content
1. Introduction fiber rope
2. Fiber rope for subsea installation
3. Huisman subsea crane with fiber rope
4. Huisman fiber rope research
5. Summary
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1. INTRODUCTION
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1. INTRODUCTION FIBER ROPE
More than 10 years fiber rope development Huisman
Research Spooling system Heat development Rope lifetime Subsea block stability Rope selection End connection Rope monitoring
Applications Round slings Stays Tuggers
Subsea installation system
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1. INTRODUCTION FIBER ROPE
Stays Stays for super flyjib in 2012 to reduce weight and increase handling speed Fibremax with Teijin Technora fibre
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1. INTRODUCTION FIBER ROPE
Fiber rope on crane tuggers
Increased safety: Lighter Less stiffness Easier handling
Increased handling speed: Lighter Lower bending stiffness Torsion free
Maintenance, inspection and transport: Not sensitive to corrosion No need for lubrication Easy inspection On-board in-line splicing possible
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1. INTRODUCTION FIBER ROPE
Benefits fiber rope compared to steel wire rope Increased subsea capacity due to buoyancy of the rope Not sensitive to corrosion No lubrication required Can be inspected internally Torque free Lower weight to ease handling and transport Repair of mid rope sections by splicing Lower (axial) stiffness
Disadvantages fiber rope compared to steel wire rope Maximum operational temperature is 70oC (HMPE) Lower bending lifetime More sensitive to abrasion, sharp edges Low friction (e.g. traction winch systems) Low radial stiffness and lack of shape (e.g. cutting-in and-stick slip on winch)
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2. FIBER ROPE FOR SUBSEA INSTALLATION
Subsea capacity fiber and steel rope
Deploy 150mt in air at 4km of water depth
350mt crane using steel wire rope
150mt crane using fiber rope
Fiber rope results in
reduced power consumption during AHC
a smaller crane
smaller vessel size
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2. FIBER ROPE FOR SUBSEA INSTALLATION
Torque properties fiber versus steel rope Steel wire rope will rotate when loaded
Protrusion of the rope
Lower block instability
Fiber rope is torque neutral
Allows multi-fall operation
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Torque neutral fiber rope
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Low-spin steel wire rope
3. HUISMAN FIBER ROPE CRANE
Huisman design philosophy
Treat fiber rope as an asset and ensure operation is safe and reliable
Limit fiber rope temperature during heave compensation
Maximum operational temperature of the rope is 70oC (HMPE)
Rope temperature increases significantly when heave compensated
Rope cooling will be part of the safety system
Fiber rope is treated as an asset
Maximize Lifetime of the valuable fiber rope
Bending lifetime is halve that of steel wire rope
A reduced operational rope temperature and smaller diameter increases the rope lifetime
Avoid heave compensation on the fiber rope
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3. HUISMAN FIBER ROPE CRANE
Hybrid fiber rope crane
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Features Rope transfer to improve lifetime of fiber and steel rope Single line operation with steel and fiber rope
No heave compensationon fiber rope winch
Heave compensationon steel wire rope winch
Sheave notRotating during AHC
Sheave rotatingbut water cooled
SheaveRotating during AHC
Rope spacer for block stability during subsea operation
Patent pending11
Single line operation with steel wire rope to increase lifetime fiber rope
3. HUISMAN FIBER ROPE CRANE
Hybrid fiber rope crane
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Fiber rope
Steel wire rope
Connection fiber and wire rope
Steel wire rope winchFiber rope winchwith cover for UV protection
Dual fall block
Slip-less traction winch (with cover)
Storage winch
SpoolerPatent pending
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3. HUISMAN FIBER ROPE CRANE
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Fiber and steel wire rope have their unique benefits
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Topic Fiber Rope Steel Wire RopeDeepwater lowering + +Remaining capacity at deepwater + +/-Corrosion resistance + -Inspection + +/-In-line splice + -Torque free + +/-Heave compensation / heat resistance - +Price of rope (CAPEX & OPEX) - +Rope fatigue lifetime - +Resistance to sharp corners - +Proven technology - +
3. HUISMAN FIBER ROPE CRANE
Topic Fiber Rope Steel Wire Rope Huisman HybridDeepwater lowering + + +Remaining capacity at deepwater + +/- +Corrosion resistance + - +Inspection + +/- +In-line splice + - +Torque free + +/- +Heave compensation / heat resistance - + +Price of rope (CAPEX & OPEX) - + +Rope fatigue lifetime - + +Resistance to sharp corners - + +/-Proven technology - + +
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Dual fall crane combines the benefits of fiber and steel wire rope
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4. FIBER ROPE RESEARCH
Huisman research fiber rope for subsea installation Huisman started research in fiber rope in 2006 Varying test equipment developed for testing fiber rope Integration of the fiber rope into the crane system to manage rope temperature and
lifetime
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4. FIBER ROPE RESEARCH
Hoist system - multi-layer spooling of a fiber rope
Tension variations results in:
cutting-in
stick slip resulting in shock loading
Special spooling techniques are very sensitive to errors
Fiber rope lifetime on drum with high tension is lower than steel
Jacketed rope does not improve spooling behavior with a direct winch
Storage winch with constant tension is the most robust solution
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Traction winch design Heat due to slip is negligible if traction winch is designed for the fiber rope
Groove design depends on rope properties Torque is controlled per drum
The drums function as a heat sink for the fiber rope and has a much larger cooling capacity than air
Traction winch optimized for fiber rope based onstandard and proven design
4. FIBER ROPE RESEARCH
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4. FIBER ROPE RESEARCH
Fiber rope has a limited operating temperature
Maximum operational rope temperature of HMPE is 70oC
At 70oC the fiber rope has lost more than 20% of its strength
Bending lifetime of a fiber rope reduces a factor of 2 per 20oC increase
Limited margin with an environmental temperature of 45oC
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Rope failure due to overheating
Source: Samson Ropes
Measurement of rope temperature
Rope core temperature can be 20oC higher than exterior rope temperature during heave compensation
Inaccuracy temperature sensors is +-5oC
Location temperature sensor is not necessarily the hottest spot on the rope’s exterior
Heave compensation using fiber rope not preferred
4. FIBER ROPE RESEARCH
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Limits and accuracies Temperature
Temperature limit (HMPE) 70oC
Sensor inaccuracy +-5oC
Temperature difference with rope core 20oC
Inaccuracy location of measurement +-5oC
Temperature limit measurement by sensor 40oC
Rope temperature control Rope temperature easily exceeds 70oC temperature limit during heave compensation
Significant active cooling measures required which will be part of the crane’s safety system
4. FIBER ROPE RESEARCH
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4. FIBER ROPE RESEARCH
Block rotation with steel wire rope Steel wire rope will induce torque when loaded Twist in the rope will generate a torque on the
lower block Sea current on the load and block
Rope spacer field proven for steel wire rope Fiber rope is torque neutral due to its braided
construction Easier to prevent twisting for fiber rope
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4. FIBER ROPE RESEARCH
Rope usage monitoring
Determines the consumed lifetime of the steel and fiber rope
based on the actual usage
Optimization of the steel and fiber rope lifetime using auto
transfer
3D Rope vision system (patent pending)
Reconstruction of the rope section along the complete rope
Measurement of the rope profile diameter, fluffiness, etc.
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SUMMARY
Subsea operation with fiber rope Full crane capacity at water depth Corrosion and lubrication free fiber rope In-line repairs of the rope for increases lifetime or increased rope length
Slip-less traction and storage winch No risk of cutting-in of the fiber rope No-stick slip effects on winch during large tension variations Robust spooling pattern Limited heat development Improved rope lifetime Storage winch and sheave will be covered for UV protection
Non-jacketed rope Internal and external visual inspection possible Higher strength Easier to splice No relative motion between jacket and load bearing material
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SUMMARY
Heave compensation on steel wire rope winch No heat build-up in fiber rope No active cooling required and is no part of safety system Significant increase lifetime of valuable fiber rope Rope lifetime optimized by rope transfer steel wire and fiber rope
Dual fall operation Torsion free fiber rope Smaller rope diameter increasing lifetime, easing handling, reducing
cost Single line fiber rope to double the water depth (without AHC)
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