Patent Application
20110006150
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The field of this invention of that of umbilical reels which store and handle hose and/or electric and/or fiber optic control lines for deepwater offshore service. These reels typically pay out these lines, called umbilicals, and mechanics clamp the umbilical to a drilling riser or other pipe string being run to the seafloor. The actual weight of the umbilical is typically supported once it leaves the reel and in the water by the riser or pipe to which it is clamped. Typically these reel units have to be closely monitored to insure that excessive tension which can destroy the umbilical is not encountered as it is being deployed or in the event of unexpected movement of the riser or pipe to which it is clamped.
When the drilling riser or other pipe string is lowered, an operator will rotate the spool to allow umbilical to be paid off in accordance with the downward movement of the riser or pipe. In some cases, the motor can be left in the take up mode, and the umbilical simply be pulled off the spool against a relatively constant torque provided by the motor power.
The spool portion of a reel can typically be locked into position by the brakes, the motor, or a manual locking pin. A danger to the umbilical or reel can occur in the event that the drilling riser or other pipe string to which the umbilical is attached is lowered while the reel spool is locked in position. The reel spool can be locked in position because someone forgot to release the locking pin, the brakes are set, or the motor is locked. When this happens, an umbilical worth hundreds of thousands of dollars can be destroyed by the excessive tension and personnel can be injured.
Alternately, if the riser and umbilical are being deployed and the air pressure which runs the reel is lost, the failsafe brakes will automatically lock creating a chance that excessive tension will destroy the umbilical before the condition is recognized.
A slip clutch has sometimes been added to the reel to allow the spool to turn when a relatively fixed preset tension limit on the umbilical is exceeded. The spool holds several layers of umbilical and as successive layers of umbilical are deployed the spooling diameter decreases and this effect causes the tension on the umbilical to increase because the preset torque remains fixed. As offshore services are required in deeper water the length of umbilical deployed from the reels increases and this causes the diameter differential between a fully loaded spool and a fully deployed spool to increase thus multiplying the maximum tension on the umbilical during deployment. A fixed preset torque which provides a tension of 1,000 pounds on the umbilical when the spool is fully loaded can vary to over 3,000 pounds when the spool is nearly empty.
The object of this invention is to provide a method for automatically controlling the slipping torque on a motorized offshore reel to provide a constant tension on an umbilical as it is being deployed.
A second object of the present invention is to provide a method of counting the revolutions of the spool during the umbilical deployment, determining the current radius to the cable being deployed, and automatically controlling the slipping torque in a fashion to maintain a constant tension limit on the umbilical.
A third object of the present invention is to utilize said means for automatically controlling slippage torque to apply maximum torque in an emergency.
Another object of the present invention is to provide means to calibrate the slipping torque on the reel in actual field conditions.
Reel 14 is positioned on the deck 16 of vessel 1 with umbilical 18 extending over pulley or sheave 20 and going down the side of the riser 5. Riser 5 is a series of jointed pipes and as they are sequentially connected and lowered into the ocean to lower the blowout preventer stack 7, clamps 22 secure the umbilical 18 to the drilling riser 5. The riser 5 and blowout preventer stack 7 may weigh as much as 650,000 lbs. When lowered with the umbilical 18 attached, if the rotation of the reel 14 is stopped, the full 650,000 lb. load can be put on the umbilical, destroying it. An even worse consequence is that the pulley or sheave 20 can be pulled down from its mounting and injure personnel on the deck.
Referring now to
Motor 38 is shown with gear 40 (shown through the motor for clarity) engaging the outer gear profile 42 on the perimeter of main disk 34. Gear 40 and the outer gear profile 42 are positively engaged such that if the motor 38 does not turn, the main disk 34 cannot rotate. Alternately, the connection between the motor and the main disk can be by roller chain and sprocket profiles, as is well understood in the industry. A motor torque controller 43 is located next to the motor 38 which adjusts the air pressure to the motor 38 as the spool 32 rotates to maintain a relatively constant tension on the umbilical 18 as the umbilical 18 leaves the reel 14.
Brake assemblies 44 and 46 are caliper or disk brake assemblies which are spring loaded to engage when air pressure is released. If the air pressure is released from these brakes, the brakes will close and the main disk 34 will not rotate about the centerline of spool 32.
Spool 32 rotates on main bearings 48. Panels 50, 52, and 54 provide valves for remote control functions at the end of the umbilical. Levelwind 56, as will be seen in
Locking pin 60 is engaged in locking pin socket 61 which is fixed to leg 62 of the reel frame 30. Locking pockets 63 are provided on the side of spool 32 for engaging locking pin 60 to positively stop the rotation of the spool 32. When locking pin 60 is an instrumented load pin, it can be engaged and give a positive reading of the torque output of the motor.
Locking pin 65 is engaged in locking pin socket 66 which is fixed to the motor mount 67 on the frame 30. One or more holes 68 are drilled through the main disk 34. When locking pin 65 is engaged in a hole 68, the main disk 34 will not rotate. When locking pin 65 is an instrumented load pin, it can be engaged to give a positive reading of the slipping force when the umbilical 18 is pulled, as long as the brakes 44 and 46 are released and the motor 38 is allowed to free wheel.
Referring now to
Referring now to
Pressure in pressure port 88 controls the air pressure in the chamber 89 which acts against the conical springs 85 to reduce the friction load on the brake pads 80 and 82. This allows the friction grip on the main disk 34 to be reduced when a lower slipping load is desired.
Pressure in pressure port 90 controls the air pressure in chamber 91 to increase the friction load of brake pad 80 onto main disk 34 and therefore of main disk 34 onto brake pad 81. This allows the friction grip on the main disk 34 to be increased when a higher slipping load is desired.
Bolts 92 attach bracket 93 to bracket 94 in a portion in front of and behind the cylinder 87 (not shown). Slots 95 allow for position adjustment of bracket 93 relative to bracket 94 in a first direction. Bolts 96 bolt bracket 94 to the side flange 78 of the spool. Slot 98 allows for adjustment of the slip clutch assembly 36 along the surface of the side flange 78 of the spool generally in a direction 90 degrees to the adjustment allowed by slots 95.
Referring now to
With specific input information on the diameter of spool 32, the width of spool 32 and the diameter of umbilical 18, the row number of the current umbilical being paid off, the number of umbilical wraps on that row, and the desired tension, the computer 102 can calculate the pressure for port 90 required to generate the desired torque. The computer 102 will read the current pressure as indicated on the pressure transducer 104 and compare it to the desired pressure.
The computer 102 will then either send an electronic signal to open the vent valve 110 to reduce the pressure in port 90 or pressure increase valve 106 to increase the pressure to match the desire. Alternately, a pressure regulator as is well understood in the industry may be controlled to maintain the desired pressure in port 90 to produce the required torque on the spool 32 to keep the umbilical 18 tension stable.
If an emergency occurs and emergency shut down button 112 is pushed, it will lock brake pads 80 and 82 on the main disk 34 by putting pressure into port 88 on therefore on the opposite side of the piston 84. This will have the air pressure loading adding to the conical spring 85 loading for an increased friction loading on the main disk 34.
Referring now to
As a real life example, the problem will be demonstrated in terms of a desired umbilical tension of 1000 lbs., an outer radius 116 of 45 inches, and inner radius 118 of 15 inches, a slip clutch assembly radius 120 of 30 inches, area of piston 84 energized by air is 1.5 sq. in. rig air supply will be at least 120 p.s.i., and a sliding coefficient of friction of 0.3.
The torque generated by the umbilical on the full reel is 45 inches times 1,000 lbs. or 45,000 in-lbs. The total resisting force on the slip assemblies will be determined by 45,000 in-lbs./30 inches or 1,500 lbs. Sliding friction is calculated by the normal force (perpendicular to the surface) time the coefficient of friction. This means that the total normal force will need to be 1,500 lbs./0.3=5,000 lbs. The normal force is divided up between four slip clutch assemblies with friction on two sides each, so the individual required normal force is 5,000 lbs./8=625 lbs. This means that the conical springs 85 as seen on
The torque generated by the umbilical on a nearly empty reel is 15 inches times 1,000 lbs. or 15,000 in-lbs. The total resisting force on the slip assemblies will be determined by 15,000 in-lbs./30 inches or 500 lbs. This means that the total normal force will need to be 500 lbs./0.3=1,666 lbs. So the individual required normal force is 1,666 lbs./8=208 lbs. As the conical springs 85 as seen on
The reel is shown with 9 wraps presently on the outer layer. It will start with zero pressure in port 88 and 90, and then after 9 revolutions of the reel it will increase the pressure in port 88 slightly to compensate for the slight smaller radius on the second layer of umbilical wraps. Twenty one wraps later, it will adjust again as it goes to the next layer.
A similar process happens on the motor torque controller 43, except that it must sense the rotation of the spool 32 from its stationary position on the frame. Based on its determination of the current level of the umbilical on the spool 32, it will adjust the pressure supplied to the motor to give a constant tension on the cable at a lower value than the slip tension, i.e. 750 lbs.
In this way the slip tension and motor tension can be at a desired constant value which are relatively close to one another for maximum equipment and personnel safety.
Referring now to
The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
