Active Heave Compensated Systems for Cranes and Winches

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Sofia Hafner
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1 Active Heave Compensated Systems for Cranes and Winches LAHC: Linear hydraulic cylinder based system By Arnold Krielen RAHC: Rotating, secondary controlled hydraulic system By Michael Teuteberg The 13 th. North Sea Offshore Cranes & Lifting Conference th. of April The Company What We Stand For Rexroth the world's leading brand that offers all drive and control technologies specialized and integrated. 2 A1 1

North Sea Offshore Cranes & Lifting Conference 15-17 th.

2 The Company History Future through heritage Rexroth creates its power of innovation from its constantlydeveloped knowledge and industrial experience that dates back more than 200 years. In 2001, Bosch Automationstechnik and Mannesmann Rexroth AG were merged to form Bosch Rexroth AG. Robert Bosch GmbH has its origins in the year 1886 the history of Rexroth goes back to the year A11 The Company Within the Bosch Group Bosch Group Revenue 2007: 46.1 billion employees Automobile technology Revenue: 28.2 billion Industrial technology Revenue: 6.2 billion Consumer goods and building services engineering Revenue: 11.7 billion Bosch Rexroth 1) 1) Bosch Rexroth AG (100% Bosch) 4 A10 2

Robert Bosch GmbH has its origins in the year 1886 the history of Rexroth goes back to the year 1795. 3 A11 The Company Within the Bosch Group Bosch Group Revenue 2007: 46.

3 The Company Globally Engaged Sales network in more than 80 countries 67 manufacturing and customizing locations in 25 countries Company owned sales and service locations in 39 countries 5 The Company In contact with customers Multiple entrance levels matching the needs of the customer Projects Modules & Subsystems Components 6 3

service locations in 39 countries 5 The Company In contact with customers Multiple

4 1.Introduction Bosch Rexroth Heave Compensation Systems Total program Linear Passive Heave Compensation LPHC Linear Active Heave Compensation LAHC Rotating Active Heave Compensation RAHC 7 Linear Active Heave Compensation Systems 4

Linear Active Heave Compensation LAHC Rotating Active

5 Intro: Why Active Heave Compensation Phenomena encountered during sub sea installations: Excessive dynamic amplification Uncontrolled take-over from the load Uncontrolled landing on sea bed Difficult ROV assistance Main objectives Reduce idle time Enlarge your window of operation Safeguard equipment and operations 9 Intro: Main Requirements Residual motion less than 10 % High level of accuracy High responsive system Adequate operation modes Smooth transition between modes Significant reduced power consumption Easy adoption in any existing winch system. Integrated system solutions incl. structural & naval engineering Containerized option for multiple use within a fleet 10 5

Requirements Residual motion less than 10 % High level of accuracy High responsive system Adequate operation modes Smooth transition between modes Significant reduced

6 Courtesy SBM & Gusto/MSC 11 Rope scheme for A-frame configuration 12 6

7 Rope scheme for Pedestal configuration Load Load 13 Reduced installed power: Requirement: 175 +/- 3.0 m amplitude & 8 sec period Theoretical net peak power : 3900 kw AHC solution: Passive part compensates the static external load, stores and regenerates energy Active part compensates dynamic effects and losses Installed power : 600 kw A special cylinder configuration required Factor 1:6 14 7

0 m amplitude & 8 sec period Theoretical net peak power : 3900 kw AHC solution: Passive part

8 Passive Friction losses Medium separator Air management system Delay & amplification! Air pressure vessel Air spring Air spring with with energy energy storage storage & regeneration & function function Gas spring effects Dynamic effects Sling slot valve Plunger cylinder 15 MRU Active Passive Control desk Medium separator Air management system Air pressure vessel Servo valve Air spring Air spring with with energy energy storage storage & regeneration & function function Through rod cylinder Sling slot valve Plunger cylinder 16 8

effects Dynamic effects Sling slot valve Plunger cylinder 15 MRU Active Passive Control desk Medium separator Air management system

9 Active Passive C. BR solution & development: Passive and active cylinder integrated Advantages: Enormous reduction in deck space Two in one: less vulnerable Easy to handle Optimal synthesis 17 Simplified scheme of AHC HPAS ICAS Hydraulic Power HPS Control System ICS 18 9

10 Active Passive 700 mt (DF) AHC Courtesy Saipem 19 HPA S Integrated Heave Compensation Cylinder Hydraulic Power ICA S HPS Control System ICS 20 10

11 Active Passive Active Passive Hydraulic Power Unit 2,1 MW HPU HPAS ICAS Hydraulic Power HPS Control System ICS 21 High pressure air management system HPAS ICAS Hydraulic Power HPS Control System ICS 22 11

System ICS 21 High pressure air management system

12 Active Passive HPAS Integrated Control System & MRU ICAS Hydraulic Power HPS Control System ICS Operator Panel 23 Functionality 24 12

13 Functionality Shock Absorber mode at surface load handling Active Heave Compensation mode at hoisting and sub sea operations. Constant Tension mode at touchdown and landing moments Empty Hook mode at connecting and disconnecting Manual mode for maintenance purposes Normal mode (locked)! Smooth transition between several modes! 25 Project execution 26 13

Constant Tension mode at touchdown and landing moments Empty Hook mode at connecting and

14 Project execution: Project portfolio 4 Requirements analysis Requirements are translated into functional specs 4 Concept design 4 Detailed engineering 4 Software design 4 Project management 4 Procurement/Outsourcing 4 Production 4 Installation 4 Commissioning 4 Site management 4 Life Cycle management From scratch to match under one roof 27 Project execution: Simulation A complete dynamic computer simulation is performed and updated during the project: Analyze system behavior Perform parametric studies Simulate mode transitions Simulate extreme / failure cases Validate / optimize components Optimize control system 28 14

scratch to match under one roof 27 Project execution: Simulation A complete dynamic computer simulation is performed and updated during the project: Analyze

15 Project execution: Factory Acceptance Test 700 mt (DF) AHC during FAT Courtesy Saipem In co-operation with GustoMSC 29 Project execution: Facory Acceptance Test Objectives: Test system functions Test all mode transitions Optimize control system parameters 350 mt (DF) AHC during FAT With this final test program, offshore testing & downtime are significantly minimized Courtesy SBM & Gusto/MSC 30 15

functions Test all mode transitions Optimize control system parameters 350 mt (DF) AHC during FAT

16 Project execution: Site Acceptance Test Site acceptance test with testload Courtesy SBM & GustoMSC 31 Project execution: Site Acceptance Test 10 Behavior load without AHC Load under water Ship motion Response of load without AHC Amplitude load in m Behavior load with AHC Load under water Ship motion Time in s Amplitude load in m Response of load with AHC Time in s 32 16

Amplitude load in m 2 0-2 -4 10 8 Behavior load with AHC Load under water Ship motion -6 6-8 4-10 0 10 20 30 40 50 60 70

17 Special heave related applications 33 Special heave related applications Crane compensator 34 17

18 Special heave related applications Deck mating systems Courtesy Hyundai 35 Special heave related applications Active compensated fast lifting system T Courtesy Allseas 36 18

19 Special heave related applications Offshore Access Systems b.m.o. 6 DOF Motion System 37 19

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