HUISMAN EQUIPMENT IMCA CONFERENCE AMSTERDAM 27-09-2018 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE HUISMAN - EQUIPMENT
1. INTRODUCTION 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 2 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 3 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
1. INTRODUCTION FIBER ROPE Stays Stays for super flyjib in 2012 to reduce weight and increase handling speed Fibremax with Teijin Technora fibre 4 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 5 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 70 o C (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) 6 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 7 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 Low-spin steel wire rope Torque neutral fiber rope 8 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
3. HUISMAN FIBER ROPE CRANE 9 ULTRA-DEEP SUBSEA CRANE WITH FIBER 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 70 o C (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 10 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
3. HUISMAN FIBER ROPE CRANE Single line operation with steel wire rope to increase lifetime Sheave Hybrid fiber rope crane Rotating during AHC fiber rope Heave compensation on steel wire rope winch No heave compensation on fiber rope winch Rope spacer for block Sheave not stability during subsea Rotating during operation AHC Features Sheave rotating Rope transfer to improve lifetime of fiber and steel rope but water cooled Single line operation with steel and fiber rope Patent pending 11 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
3. HUISMAN FIBER ROPE CRANE Hybrid fiber rope crane Steel wire rope winch Fiber rope winch with cover for UV protection Slip-less traction Steel wire rope winch (with cover) Connection fiber and wire rope Fiber rope Storage winch Dual fall block Spooler Patent pending 12 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
3. HUISMAN FIBER ROPE CRANE Fiber and steel wire rope have their unique benefits Topic Fiber Rope Steel Wire Rope Deepwater 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 - + 13 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
3. HUISMAN FIBER ROPE CRANE Dual fall crane combines the benefits of fiber and steel wire rope Topic Fiber Rope Steel Wire Rope Huisman Hybrid Deepwater 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 - + + 14 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 15 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 16 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
4. FIBER ROPE RESEARCH 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 on standard and proven design 17 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
4. FIBER ROPE RESEARCH Fiber rope has a limited operating temperature Maximum operational rope temperature of HMPE is 70 o C At 70 o C the fiber rope has lost more than 20% of its strength Bending lifetime of a fiber rope reduces a factor of 2 per 20 o C increase Limited margin with an environmental temperature of 45 o C Rope failure due to overheating Source: Samson Ropes 18 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
4. FIBER ROPE RESEARCH Measurement of rope temperature Rope core temperature can be 20 o C higher than exterior rope temperature during heave compensation Inaccuracy temperature sensors is +-5 o C Location temperature sensor is not necessarily the hottest spot on the rope’s exterior Heave compensation using fiber rope not preferred Limits and accuracies Temperature Temperature limit (HMPE) 70 o C +-5 o C Sensor inaccuracy Temperature difference with rope core 20 o C +-5 o C Inaccuracy location of measurement 40 o C Temperature limit measurement by sensor 19 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
4. FIBER ROPE RESEARCH Rope temperature control Rope temperature easily exceeds 70 o C temperature limit during heave compensation Significant active cooling measures required which will be part of the crane’s safety system 20 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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 21 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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. 22 ULTRA-DEEP SUBSEA CRANE WITH FIBER ROPE
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