The transportable inline heave compensator is an installation tool designed to compensate vertical heave motion during sensitive installations/lifts of payloads in an offshore environment. The vertical heave source is typically induced by swells that cause floating objects, like installation vessels and barges, but not limited thereto, to move vertically up and down. The transportable inline heave compensator is designed to operate in air and in water. The transportable inline heave compensator is an inline tool that combines the principles of spring isolation and may be used with an active cylinder control in order to generate an efficient compensation effect
The tool can operate like a traditional gas-over-hydraulic fluid spring-dampening device if the active control malfunctions. During offshore construction, high and heavy structures are to be lowered by expensive working ships with big cranes of high carrying capacity. The structures have to be lifted from fixed or floating objects and be placed on either fixed or floating locations, topside or subsea. Irregular movements of working ships, barges and supply vessels generated by swell and wind can be increased a lot by the crane boom, so that even with average swell it is difficult or impossible to carry by the crane sensitive structures during violent ship and crane movements and to lower them subsea. Since daily costs of operation with working ships are very high, each delay causes enormous additional costs. Therefore, a strong demand exists to perform respective works also in less favourable weather and with average swell without damaging the structures to be moved. The prior art compensation devices, such as crane mounted active heave compensators, have a very high capital cost and have several weaknesses, where the biggest ones are, no mobility, insufficient splash zone crossing performance, fatigue of wire rope, lack of passive backup systems, high power demand and lack of models for heavy lifts.
Many prior art passive (PHC) and active (AHC) heave compensators exist, like e.g. US 20080251980, US 20150362039, US 20080105433. The main difference between the invention and traditional PHC units is that the invention uses a drum fitted with one or more rope means as the length extension means, while a traditional PHC uses a hydraulic actuator as the length extension means. Compared to AHC, one of the differences between the prior art and the invention is for example that the transportable inline heave compensator is a transportable compensator for inline use with a passive backup system to go subsea with the payload being installed. Traditional active compensators often do not have a passive backup system and always stay topside on a vessel.
U.S. Pat. No. 3,743,249 A describes an apparatus for maintaining a constant tension in a cable. The apparatus comprises a cylinder/piston assembly, a drum, spirally shaped to keep the tension in the cable independent of the position of the piston, and a rack and a pinion as a means for converting longitudinal displacements of the piston into rotation of the cable drum.
GB 2187159 A, describes a lifting apparatus with sheave blocks and compensators connected to one of the sheave blocks to prevent transmission of motions, as wave motions, from the block to carried load. A fluid actuated booster piston-cylinder assembly is interconnected with the compensator to permit greater loads to be carried for the same range of movement of the compensator.
US 2015/129529 A1 describes a marine lifting apparatus with active heave compensation including a main chassis, a drive assembly with a lifting column comprising a gear rack, a pinion, and a motor. A control circuitry is commanding the drive assembly to cause the lifting column to translate on the heave motion detected by a sensor.
Compared to AHC, one of the differences between the prior art and the invention is for example that the transportable inline heave compensator is a mobile compensator for inline use with a passive backup system to go subsea with the payload being installed. Traditional active compensators often do not have a passive backup system and always stay topside on a vessel.
The main disadvantages of the prior art are: high capital binding in permanently installed (i.e. not mobile) equipment which is often only needed a few weeks per year, high installation costs, high maintenance costs (especially related to fatigue in crane steel wire rope), poor splash zone crossing performance due to fast dynamics, poor performance for short wave periods due to fast dynamics, poor resonance protection, high power demand and lack of existing models for heavy lifts.
The main features of the present invention are given in the independent claim. Additional features of the invention are given in the dependent claims.
The transportable inline heave compensator is basically a passive heave compensator which traditionally is an inline tool, with an optional added active component to increase the performance. The transportable inline heave compensator consists of one or more actuators connected to one or more gas accumulators, which might be double acting accumulators, which is further connected to one or more gas tanks.
The transportable inline heave compensator is naturally depth compensated and allows for efficient usage of available pumps for active actuator control. Influences like temperature variations and load variations are handled by the active compensation system.
Active control of the actuator is used to compensate for heave motion. The active control is controlled by sensors, where the most important ones are the piston position or drum angle sensor, the accelerometer and the wire rope speed sensor, i.e. via a computer, which able compensator to increase or reduce gas pressure in tanks and accumulators individually by use of i.e. control valves, gas boosters, pressure intensifiers etc. Information about the wire rope speed is transferred to the compensator via wireless signals while the compensator is in air and via acoustic transmission while it is submerged.
The transportable inline heave compensator can operate in several different modes with variable stiffness and damping with or without active control of the actuator and with or without active control of the pressure levels in the various gas volumes. The transportable inline heave compensator is energy efficient due to the fact that passive part of the compensator carries the entire load of the payload weight and the actively controlled hydraulic motors(s) only have to compensate for gas compression effects and friction, which typically is maximum 15% of the force compared to static force, and usually much less. Energy regeneration is also used so that only friction as well as oil leakage and mechanical losses in the hydraulic pump contributes to the energy consumption. When active control of the actuator is not required the transportable inline heave compensator may use the active system to charge the internal battery pack. Further, acoustic communication subsea and wireless communication topside allow for control and monitoring of the compensator, on-board sensors allow the user to verify performance after a lift is concluded.
The invention has the following advantages compared to the prior art; MOBILE construction, lower cost for same capacity, as good performance for long wave periods and better performance for short wave periods, excellent splash zone crossing performance, well-suited for resonance protection, reduced wear of the steel wire rope, low energy consumption, reduced lifting height requirement, no upending required.
The main features of this patent application, which are new compared to previous applications:
The new actuator design allows for horizontal construction of the compensator, which gives two large benefits. One, the elongation of the compensator can be long without increasing the effective vertical length of the compensator. Two, troublesome upending of the compensator from horizontal position on the vessel deck to vertical position (hanging in the crane hook) is removed as it is ready to go when lifted straight up from the vessel deck. It also worth noting that a very simple, effective and cheap passive depth compensation can be used with this actuator design. The improved gas accumulator design allows for simpler construction at a lower cost compared to prior art.
The following section will describe how a transportable inline heave compensator (100) according to the present invention works during different phases of an offshore subsea lift. One possible application is shown, where it is assumed that a payload (101) is initially on a barge (103) next to an installation vessel (102), as shown in
There are different requirements to functionality during the different phases of the lifting operation. During the first phase, which is lifting of the payload (101), that is located on a floating barge (103), from a floating vessel (101), it is beneficial if the transportable inline heave compensator (100) can compensate motion in such a way that the relative motion between the lower part of the transportable inline heave compensator (100) and the barge (103) deck is zero, except for winch spooling. This functionality requires three things:
The first requirement is handled by a wireless MRU (105), short for motion reference unit, placed on the barge (103) deck, preferably close to the payload (101). The second requirement is either handled by an accelerometer inside the transportable inline heave compensator (100), or by a MRU (104) located on the vessel (102) or in the crane. The final requirement is normally given by the crane computer, and is transferred wirelessly while in air, or via acoustic signals when submerged, to the transportable inline heave compensator (100).
Based on the information above the computer integrated into the transportable inline heave compensator (100) is able to control the actuator (10) in such a way that the relative motion between the lower part of the transportable inline heave compensator (100) and the barge (103) deck is close to zero while the crane winch is not spooling out wire rope. The computer will take spooling into account, to not cause any lag for the crane operator.
After successful connection and lifting of the payload (101) from the barge (103) deck, the payload (101) has to cross the splash zone (i.e., the border between air and sea), where different requirements apply. This phase is characterized by fast dynamics, where unpredictable forces from slamming and buoyancy occurs and is best suited for a passive heave compensator, which the transportable inline heave compensator (100) basically is. Active actuator (10) control is turned off, stiffness and damping is adjusted to the best possible settings by use of control valves (CV). During the actual crossing of the splash zone, the actuator (10) equilibrium position tends to move towards the inner position, due to buoyancy forces acting on the payload (101). This effect is compensated by adjusting the internal gas pressure in one of the following ways:
The adjustment is performed automatically by the on-board computer based on changing equilibrium position of the actuator (10).
At a certain distance after crossing the splash zone, the transportable inline heave compensator (100) will often switch to a softer setting with less damping. This is done to prevent resonance in the lifting arrangement. If the passive system alone is not enough to avoid resonance, then the actuator (10) can either be locked by closing control valves or actively controlled by the computer to prevent resonance.
Drop in temperature during transport from shallow waters to deeper waters influence the equilibrium position of the actuator (10). The water temperature often tends to decrease as the transportable inline heave compensator (100) is lowered into deeper waters. This affects the actuator (10) equilibrium due to the fact that the gas pressure in all gas volumes are reduced due to lowered temperature. The transportable inline heave compensator (100) compensates this either by transferring gas under higher pressure from one of the tanks to the gas accumulator (30) via control valves or from a tank under lower pressure to the gas accumulator (30) via the gas booster (160) or pressure intensifier (141) and control valves (CV). The second and often most important effect is the increasing water pressure.
During the final phase of the lifting operation, which is the landing phase, the active actuator (10) control is again enabled, either by acoustic commands, water pressure triggering or by an ROV, to ensure that there is minimal relative velocity between the lower end of the transportable inline heave compensator (100) and the seabed (106). The on-board computer uses the on-board accelerometer, the position sensor (90) or drum angle sensor (91) as well as acoustically transmitted signals from the vessel (102) about wire rope spooling to actively control the actuator (10) to a high degree of accuracy and without crane operator lag. The water pressure sensor (indirectly measures distance) can also be used in improving the control signal.
The energy source for the compensator can be either a battery pack or an energy source on the vessel connected to the compensator via an umbilical.
The sketches or figures shown are intended to show the principles of the invention, wherein numerous variations with a number of accumulators and tanks can be utilized in order to get the same results
According to one embodiment of the invention a transportable inline heave compensator comprises minimum one drum, minimum one first actuator, consisting of a cylinder and a piston located inside the cylinder and adapted for reciprocation with respect thereto, minimum one rack and pinion, linking together the drum and the first actuator piston, and converts the rotational motion of the drum and pinion to linear motion of the rack and first actuator piston. The embodiment further comprises bearing means for the drum to allow rotation of the drum, structure means/framework linking the bearing means to the first actuator, which are immovable relative to each other, minimum one first accumulator, fluidly connecting the first actuator at either the rod side or the piston side, minimum one rope means connected to the drum in one end and a connection device in the other end and minimum one second connection device attached to either of; a rope means or a fixed point on the compensator.
An accelerometer (92) can measure the position of the transportable inline heave compensator (100), which position is affected by the movement of the vessel (102), Drum angle sensor(s) (91) can measure the movement of the payload (101). If the payload (101) is not at rest, the means for hydraulic fluid transportation (180) will either push or brake the piston (42) in the second actuator (40), so that the net movement of the payload (101) will be zero. Communication means (145) transfers signals from the vessel about crane winch spooling to the transportable inline heave compensator (100), so that such effects can be quickly incorporated into the actions of the means for hydraulic fluid transportation (180).
The transportable inline heave compensator (100) can comprise a sensing arrangement or means, such as for example at least one drum angle sensor (91), shown with alternative placements in
When the payload (101) at the barge (103) is connected to the transportable inline heave compensator (100), the torque acting on the drum (16) is increased to almost carry the load (about 90% of static weight) of the payload (101). When desired by the crane operator, a fast pressure increase can be performed to quickly lift (i.e. Faster than normal crane speed) the payload (101) from the barge (103) in order to reduce risk of contact between the barge (103) deck and the payload (101) after lift-off, the pressure increase is performed by injecting gas from a second tank (T2) or by using the means for hydraulic fluid transportation (180). The barge (103) is then relocated, and the payload (101) is ready to cross the splash zone. During the splash zone crossing phase, the transportable inline heave compensator (100) is operating in a passive mode, with no active control of the drum (16), except for equilibrium adjustments (wanted equilibrium angle (or “stroke”) is pre-set) due to environmental disturbances, such as increased buoyancy and/or changing temperature. After crossing the splash zone, the stiffness of the transportable inline heave compensator (100) is reduced by connecting a first tank (T1). This is crucial to provide good resonance protection. During the lowering phase, the pump (180) can be used to charge an energy source (144), adapted for supplying the transportable inline heave compensator (100) with power, by utilizing the hydraulic fluid flow in the transportable inline heave compensator (100). The equilibrium angle (or “stroke”) of the drum (16) is maintained by a means for gas transportation (140) that adjusts the pressure of the different gas volumes in the transportable inline heave compensator (100). The landing phase mode is either activated based upon water depth or activated by a ROV (the ROV turns a switch on the transportable inline heave compensator (100)). During this phase, the heave motion of the payload (101) will be close to zero, and it can safely be installed. The heave motion is partly compensated by the passive spring (i.e. A gas volume in the first accumulator (30), and a gas volume in the first tank (T1)), and partly by the means for hydraulic fluid transportation (180), transferring fluid in and out of the second actuator (40) via the pressure intensifier (170).
Transportable inline heave compensator (100) is provided with connection devices (19) for suspending the compensator (100) from a load bearing device and a connection device (19) for a carrying a payload (101), The compensator (100) is comprising a passive heave compensator part and possibly an active heave compensator part, and is provided with a sensor arrangement, where the compensator (100) further comprises at least one actuator (10) that is horizontally oriented in operation and comprises an actuator piston rod (13) with a horizontally stroke indirectly connected to a rope means (18), with indirectly it is understood that it is not directly connected to the piston rod but connected via an element that is connected at the end of the piston rod, either at a sheave or to a drum that is in connection with the piston rod via a rack and a pinion, where the rope means (18) at an end, via a connection device (19), such as a padeye, is connected to at least one of; a vessel (102) at the sea surface or a payload (101), incorporating a curved device/device with a curved surface where rope means is suspended to for converting the vertical movements of vessel (102) or payload (101), to horizontal movements of the actuator piston rod (13) compensating the load (101). The transportable inline heave compensator (100) comprises an active part which is self supported and not connected to the vessel (102). With self supported is to be understood that the compensator has an active part which not have to be coupled to the vessel.
A means for gas transportation (140), consisting of a pressure intensifier (141), connected to a pump (142), connected to a motor (143), connected to an energy source (144), is used to transport gas between the first accumulator (30), the first tank (T1), the second tank (T2) and the surroundings. The means for gas transportation (140) enables transport of gas even when there is a negative differential pressure. Valve means (CV6, CV5, CVB2) are used to control gas flow in and out of the means for gas transportation (140). Drum angle sensor(s) (91), which may be located in one or both of the actuators (10, 40), the first accumulator (30) or on the drum (16) is used to measure the “stroke” of the transportable inline heave compensator (100) as a function of the angle of the drum (16).
The actuator (10) consists of an active actuator cylinder (20) and a passive actuator cylinder (11), that are collinear with each other as well as horizontal.
The active actuator cylinder (20) comprises a first hollow piston rod (21), connected to a first piston (23), a second hollow piston rod (24) connected to a second piston (22), where the second hollow piston rod (24) and the second piston (22) are mounted concentrically inside the first hollow piston rod (21) and fixed to one end of the active actuator cylinder (20). The active actuator cylinder (20) has three separate volumes, designated V3, V4 and V5. V3 is located between; the inside of the first hollow piston rod (21), the inside of the second piston rod (24), the top of the second piston (22) as well as the end of the actuator cylinder (20) and is filled with hydraulic fluid. V4 is located between; the inside of the first hollow piston rod (21), the outside of the second piston rod (24), the bottom of the second piston (22) and the first piston (23) as well as the end and inside diameter of the actuator cylinder (20) and is filled with a low pressure gas (including vacuum). V5 is located between; the outside of the first hollow piston rod (21), the top of the first piston (23) as well as the end and inside diameter of the actuator cylinder (20) and is filled with a hydraulic fluid.
The passive actuator cylinder (11) comprises a third piston (12) connected to a piston rod (13) and has two volumes, designated V1 and V2, where V1 is on the piston side and V2 is on the rod side. The volumes are filled differently, depending on if the passive actuator cylinder (11) is working in tension or compression mode, where V1 is filled with hydraulic fluid and V2 is either filled with oil or filled with low pressure gas (including vacuum) when working in compression mode and where V2 is filled with hydraulic fluid and V1 is either filled with oil or filled with low pressure gas (including vacuum) when working in tension mode. At least one of the two volumes is connected to a gas accumulator (30).
The active and passive actuator cylinders (11, 20) have equal stroke length, the piston rods (13, 21) are joined together and should preferably have the same diameter to cancel water pressure effects. In the joint area between the piston rods (13, 21) a set of actuator sheaves (25, 26) are mounted.
The actuator further contains framework (80) joining the two actuator cylinders (10, 20) together in a stiff connection. The framework (80) may partly consist of tanks and accumulators to reduce weight. The framework (80) is further fitted with connection device (19) used to connect the transportable inline heave compensator (100) to a crane, or similar, located on a vessel (102), where the connection device (19) may be located in the centre of gravity of the transportable inline heave compensator (100) or at other locations as shown in
The transportable inline heave compensator (100) further features a sensing means adapted for measuring the vertical motion of the transportable inline heave compensator (100), one or more sensing means adapted for measuring the pressure in one or more volume, a computer adapted for controlling the pump (P), the gas booster (160) and the control valves (CV) based on input from the sensing means, communication means adapted to transfer signals between the vessel (102) and the transportable inline heave compensator (100), preferably with acoustic communication while subsea and wirelessly while in air and either a battery pack or an umbilical cable for energy supply.
Decrease in temperature and increase of water pressure is handled by the transportable inline heave compensator (100) in different ways:
The actuator (10) consists of minimum two actuator cylinders (11), each with an actuator piston (12) and an actuator rod (13) connected to the actuator piston (12) in one end and a horizontal sheave (25) in the other end, a framework (80) locking the actuator cylinders in position relative to each other as well as providing support for the sheaves (27) and acting as a support for the-transportable inline heave compensator (100) when not in use (i.e. Placed on the vessel deck), at least two rope means (18) (i.e. Wire rope, fibre rope, chain, belt or similar) attached to a fixed point (e.g. Framework (80)) in one end and connected to the payload (101) in the other end and being reeved over the actuator sheaves (25) and the other sheaves (27), connection device (19) used for connecting the-transportable inline heave compensator (100) to the crane and to the payload (101) via connection device (19) attached to a framework (80) attached to the minimum two rope means (18). The actuator cylinders (11) have two volumes each, the first volume (V+) is used for extending the actuator rod (13), and the second volume (V−) can be used for e.g. Active depth compensation or end damping. The first volume (V+) is normally connected to double acting gas accumulator(s) and is normally filled with oil.
When tension is applied to the rope means (18) a force will act on the actuator rod (13) via the actuator sheave (25) which in turn will be transferred to the first volume (V+) as pressure via the actuator piston (12). The figure shows a rope means (18) configuration which gives double the movement of the rope means (18) compared to the actuator cylinder (11) stroke. This can be increased by increasing the number of rope means (18) falls. Also the force acting on the actuator cylinder (11) is twice of the force in the rope means (18).
The actuator (10) consists of minimum two actuator cylinders (11), each with an actuator piston (12) and an actuator rod (13) connected to the actuator piston (12) in one end and an actuator sheave (25) in the other end, a framework (80) locking the actuator cylinders in position relative to each other as well as providing support for the sheaves (27), at least two rope means (18) (i.e. Wire rope, fibre rope, chain, belt or similar) attached to a fixed point (e.g. Framework (80)) in one end and connected to the payload (101) in the other end and being reeved over the actuator sheaves (25) and the other sheaves (27), connection device (19) used for connecting the transportable inline heave compensator (100) to the crane. The actuator cylinders (11) have two volumes each, the first volume (V+) is used for e.g. Active depth compensation or end damping, and the second volume (V−) is used to retract the actuator rod (13). The second volume (V−) is normally connected to double acting gas accumulator(s) and is normally filled with oil.
When tension is applied to the rope means (18) a force will act on the actuator rod (13) via the actuator sheave (25) which in turn will be transferred to the second volume (V−) as pressure via the actuator piston (12).
The transportable inline heave compensator (100) further features a sensing means adapted for measuring the vertical motion of the transportable inline heave compensator (100), one or more sensing means adapted for measuring the pressure in one or more volume, a computer adapted for controlling the pump (P), the gas booster (160) and the control valves (CV) based on input from the sensing means, communication means adapted to transfer signals between the vessel (102) and the transportable inline heave compensator (100), preferably with acoustic communication while subsea and wirelessly while in air and either a battery pack or an umbilical for energy supply.
Number | Date | Country | Kind |
---|---|---|---|
20160909 | May 2016 | NO | national |
20161987 | Dec 2016 | NO | national |
20162072 | Dec 2016 | NO | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/NO2017/050135 | 5/26/2017 | WO | 00 |