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1. Year All Wells Wells less than 2000 Percentage less than 2000 meters meters 2013 5732 wells 5588 wells 97 5 2017 8561 wells 8011 Wells 93 5 Subsea wells worldwide 5053 active subsea wells at end of 2012 d zm e Table 2 and figure 5 gives an overview over areas na hoe RS gor dif f where use of the RITS might be impossible Cuin ER D Bei SEL SEH Dee age e904 Y fi Figure 5 Wells over the world in 2012 Source 1 Other areas 334 wells Table 2 Depths of subsea wells and the deepest existing well in area 2013 Area 0 69 m 70 600 m 601 1500 m 1500 m Deepest Norway 815 wells 20 wells 1100 m British 74 wells 923 wells West Africa 240 wells 617 wells 31 wells Brazil 16 wells 298 wells 445 wells 135 wells Gulf of Mexico 48 wells 229 wells 293 wells 131 wells Asia Pacific 32 wells 297 wells 68 wells The only area in the world where a skid s design limited to 2000 meters may cause a problem 1s in the Gulf of Mexico GoM and in Brazil Although in these fields the majority of subsea wells are still less than 1500 meters deep Based on this analysis the skid s design depth is found sufficient when rated at 2000 meters B Jahnsen 2013 1 2 2 Forecasted Wells tie in and tree on wire RITS is designed as a product to help subsea components that are not signal power wired with the surface In addition to intervention work
2. 34 Force applied from beneath Case 2 MN eese 35 Vertical Impact Load on most exposed corner IMN 35 Vertical Impact Load on exposed element Case 3 MN esses 35 Cassette Configuration CN E EE 37 The buoyancy elements dedicated the cassettes MN sess 39 Adjustments created to fit the cylinder IMN 40 Cylinder mounting ears cassette type one MN eee 41 Mounting of cassette type two note cylinder direction MN 41 Illustration of the Torque Cassette MN seen 42 Maximum buoyance possible inside the torque tool MN 42 The Cylinder Stab Cassette with all the extra components making it work MN 43 The holder cassette IMNT nennen E 44 Direction of cylinder due to cassette type IMN 45 X Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Weight of the components and the total weight of the tool cassette MN 46 Pree stab cassette MN lisis das 46 Hose retrieval system VEN Tora Eege 47 Example of guiding system of flex hoses 200mm MN eere 48 Guid
3. All three items represents persons working together at the same time an not necessarily on the same office on the vessel Figure 3 Illustration of decreasing number of human interactions MN RITS will decrease the number of human interactions since the parking of the ROV requires one RON operator only The manipulator mounted on RITS is operated by the supplier which also results less work for the ROV operator An additional benefit is a closer cooperation between to areas of the industry that during the years has driven apart 1 2 Market for RITS An evaluation of the existing subsea wells is made in order to analyze the potential market for RITS This is required to provide the project with a reasonable technological aim since there are considerable costs related to creating a system that can handle all depths and challenges The development cost can be significantly reduced if the design criteria are limited to handle 80 of the market A successful system can be developed further to handle the entire market This chapter will explain which external mechanisms that will limit the first edition of the RITS 1 2 1 Areas in the world have different sea depths The cost of a skid that can withstand the pressure on the deepest wells of more than 3000 meter can be excessive The marginal cost of larger depths designs increases exponentially due to the increase of external pressure To have manageable cost RITS w
4. Evaluation To prevent the bolts from spinning custom made cuts in the elements are required This ends need a lot welding to be able to fasten bolts Conclusion It requires as much welding as it takes to weld the whole construction Bolt Assembly First Idea is REJECTED Second idea Strategy Use the profiles square geometry to prevent spinning easy to bolt true the sides Evaluation This bolt assembly leads to a higher structure or a smaller inside Conclusion One of the design criteria was to keep RITS as small as possible At this point of the project it is hard to estimate the needed space inside RITS however it is not a good idea to let the bolt connection be dimensioning Bolt Assembly Second Idea is REJECTED Second idea Strategy Adjust the ends without need for welding and make it possible to bolt true the elements A Nc Evaluation This bolt assembly method should be cheap to create however the fastenings between the elements consist of only 3mm thick aluminum It is assumed that this connection will surge which will expose the structure for fatigue Conclusion The fatigue issue is evaluated to unsecure there is not acceptable to loose RITS while operating on 2000 meters depth Bolt Assembly Third Idea is REJECTED Table 11 presents some different bolt assemblies none of them suited for RITS 30 4 4 2 Welded structures T
5. valves handles one supply and one return line there are only three valves needed The three first valves on the figure are planned for a spare hot stab 1f the customer wants three hot stabs and valve four to six is connected the second stab The last three valves are installed to supply the main hot stab with hydraulic Hot Stab 6L REN Figure 65 illustrates the three solenoids required 2 E to operate one 6L hot stab RITS will have the GEI ZEIT KEH ig o pP possibility to handle three hot stabs and as a L result the valve pack will have nine solenoid EIS x x valves The system is explained in Appendix A x Figure 65 Schematic of a standard hot stab Source 36 Pressure 207 Bar Flow 19 ue Manipulator Titan 4 Pressure max 250 Bar Flow Max 95 lpm Pressure 207 Bar Flow Max 36 Ipm Torque Tool ESI Flow various Hot Stab 6 L wer mad Hot Stab6L Clean system HPU at ur us 2o o a at m Ly Clean fluid Figure 66 Copy of Schematics MN 36 FMC Technologies 2010 69 Chapter Eight Control Unit The previous chapters have presented components needed to make RITS work The hydraulic system is designed however a system that controls the hydraulic system is required This chapter will explain how the RITS will be controlled by use of telemetry and other communication component
6. Revision Page no 7 of 23 2 SYSTEM REQUIREMENTS 2 1 SYSTEM COMPONENTS The RITS System shall as a minimum consist of the following equipment e 1 off e 1 off e 3 off e 0 3 off e 3 off e 1 off e 1 off e 1 off e 1 off e 1 off e 0 1 off e At least 1 off 2 2 ROV Torque Tool API 17D size 1 4 ROV Hydraulic Power Unit HPU Different Cassettes 5 options Stab 6 Line 345 Bar with hoses Kystdesign 6L Compensators Parker F11 10 pump Parker F11 10 motor Surface Control Unit SCU Manipulator Titan 4 Pall filter 9050 RCU remote control unit Oceaneering Topside monitor s SYSTEM CONFIGURATION The RITS shall be flexible with regard to the configuration required for the various Intervention Tools when used for different applications Dock up to fixed API 17D interface instead of using grabber manipulator Require a adjusted API 17D interface bucket on the subsea unit Operate ROV panels with the FMC operated manipulator Provide an option for a pre programmed manipulator Easier access of special tools can bring three tools at the time Hydraulic systems by use of a hot stab gt Mechanical systems by use of torque tools or other tools from the tray gt Bring other tools e g LAOT Linear Actuator Override Tool 100040011 or 100049598 The RITS system is divided into two main parts one system operating the hot stabs and the other system handles everything else It r
7. The configuration of the RITS will ensure that the RCU will be compatible with the other systems due to signal and electricity but even so it will require separate lines 7 4 Control system Hierarchy The RCU of the torque tool has its own system while the rest of the control units will be controlled through the CDB placed in the electricity can A consequence is that two signal lines and two electric lines are required when a torque tool is installed ROV Auxillary 110 VAC ms Guy Kat Manipulator Ko EH erg CHE GREN A Xin Eme Ii Mn exime Figure 72 Hierarchy of control units MN E Oceaneering 2009 73 7 5 Signal The CDB is capable to handle four control cards as long as the signal is RS 485 RS 485 is a protocol to handle signals The CDB will communicate with one master signal transfer to from topside Signals sent to the CDB are transferred further to the PWM16 s that operates the solenoids Table 25 Signal configuration Valve Tool Valve Component Function Lines pack DC Lil 41 1st Hot stab spare Supply A Drain B L12 Ist line t r Drain A Supply B DC2 121 41 1st Hot stab spare Supply C Drain D L22 2nd line t r Drain C Supply D DC3 L31 41 1st Hot stab spare Supply E Drain F L32 3rd line t r Drain E
8. e Safety Relief Valve Normally there is a safety relief valve connected to the supply line As the HPU will be activated as long as RITS is active it is required flow on the clean side A pump will apply more and more pressure until something breaks to avoid that the pressure gets to high there is a by pass solution that opens when RITS operate without using the HPU The relief valve will open at 228 Bar and the system is protected xg All lines are closed ge Ln L L L 3 One Solenoid Open NM E Se E Sl ud gt ji aL ea UL A P CV Es oft i bar 96 Sensors There are sensors installed to be able to monitor the system It is required to know that the signals that are sent from the HMI makes an action down inside RITS which is important for the hot stabs since it applies pressurized fluids into a system The sensors are installed on the piping and are sending electric signals with different voltage The each specific voltage represents one bar Traditional sensors are normally sending a voltage between 4 and 16 mA A voltage of 4 mA means 0 Bar while 16 mA means the highest value the sensor can measure e g 690 Bar The measurements in between is presented by a linear equation between these two values Voltage converted to pressure 97 Appendix B Hot Spots ANSYS is
9. 030 ge 5 E 14 erg erg 010 0 008 le 20 0 01 SEH lt 01 a 14 Forbehold om trvkkfeil og rett til endrine av m l Table 5 Measurements of Sylinderteknikk cylinders source 7 Figure 18 The cylinder used in RITS MN 19 3 6 Torque Tool A torque tool is the wrench used subsea Most subsea tasks are performed by the manipulator e g operation of ROV handles The torque tool performs more advanced task as mechanical override of failed valves or to mechanically power up a motor or a pump It is also required to connect disconnect Multi Quick Connectors MQC which is a common task since the MQC has more restricted life cycle than the XTs The torque tool has an API 17D interface receptacle which is useful since all the special tools will have a true API 17D interface option ref chapter 5 3 The torque tool exists in several different sizes RITS will use the most common the 2700 NM with 2000MM motor Table 6 System requirements needed to meet FMC customers needs Mechanical Data Length 600mm Width 360mm Diameter 300mm Weight in Air 39 kg Weight in Water 30 kg Torque Range 2700 Nm Hydraulic Data Pressure 200 Bar Flow 36 l min Fluid ISO VG22 Shell Tellus or equal General Data Axial Force on latches 3000 N Max Water depth 3000 meters Figure 19 Torque Tool with ROV handle Figure 19 illustrates a torq
10. 16 It is important that the design prevents the locking pin to turn during operation which may happen due to vibrations during operation Pins to avoid that the cylinder turn cause of vibration Figure 17 Locking mechanism for the cassettes MN The manipulator lift the cylinder 5 mm up and then turn the handle 90 degrees it is not possible to pull to long since the geometry of the pin is designed in a way that prevents the pin to be pulled more than 10 mm Subsea cylinders adjustment There are strict requirements to equipment used subsea and there are a few suppliers approved to deliver hydraulic cylinders to FMC Sylinderteknikk is an FMC approved supplier and because of that their cylinders are used in RITS Their expertise and long experience ensures the requirements due to corrosion pressure limitations and other demands of the subsea business are met It is required a special corrosion protection ring on the stem The ring will increase the length of the cylinder housing with approximately 25 mm Table 5 does not include the extra 25 mm protective ring extensions and needs to be added when selecting the cylinder size 7 Hydex Sylinderteknikk 2014 17 3 4 Force capacity of the cylinder The force the cylinder needs to overcome is quite small The strength is calculated by the piston area multiplied by the fluids pressure The smallest standard cylinder from Sylinderteknikk with enough stroke len
11. 37 5 2 The Cassette Design There are a few design requirements that count for all cassettes 1 Equal size to fit in the same guiding system 2 Approximately the same weight It is an advantage that the people handling RITS can switch between the cassettes without concerning about the center of gravity 3 Mounting system which way the cylinder is mounted Equal Size The size of the cassettes is dependent on the outer dimensions of RITS while the size of the skid was determined by size of the tools The height was dimensioned to allow space for the largest tool the torque tool The length of the cassettes is slightly increased to make space for additional buoyancy and also to make the cylinders fit It results in cassette outer measurements of 230x360x600 Equal Weight The cassettes are designed in the same material as RITS aluminum 6082 T6 to avoid galvanic corrosion The cassettes will be filled with syntactic foam in all hollow areas to make the cassettes buoyant in water The plate elements consist of two aluminum plates with room for syntactic foam in between the resulting in a sandwich construction that makes the cassettes both lighter and stronger see figure 31 There is not necessarily enough room for buoyancy to make the cassette neutral in water The tools inside the cassettes will increase the weight and to compensate this weight dedicated areas for extra buoyancy elements are created in the structure chapt
12. Figure 65 Schematic of a standard hot stab Source 201 69 Figure 66 Copy of Schematics MN iino pe moet Eibach eed ei aeeess 69 Figure 67 Picture of a valve pack from Innova Source 21l eee 70 DEreure 05 PWM TG Source KEE 71 Figure 69 Control card for Titan 4 Source 201 71 Figure 70 CDB from Innova Source A0 72 Figure 71 Model of the RCU from the OMM Source All 73 Figure 72 Hierarchy of control units MN Lec aiiod 73 Figure 73 Concept drawing of the HMITMNT AAA 75 Figure 74 Speed Sensor Source 31 ue ceo aeo ba ius 77 Figure 75 Pressure sensor Source 42 iti tete ehe cdaanaiovanddesnaccesesopesdeadouradeecs T Pipure 76 Th puoyancy package 5 oda A pdt el ages 80 Figure 77 Example of the last buoyancy element may look MN sees 80 Figure 78 Adjusted Elements aue tl M redo at lent ais 81 Figure 79 How the thruster will work true RITS Source 40 and MN 82 Figure 80 How to adjust CoG MN eee teret aee darse Re e eo EEGENEN Ce 83 Figure 81 Examples of bolts CADIZ BMC oerte eoo ee een ep tena ee deeg 84 Frouress 2 Fastening r 84 Tables Table 1 Percentage well less than 2000 meters ita id ve c piede 6 Table 2 Depths of subsea wells and the deepest existing well in area GLUES een Cn ee 6 Table 3 Planned forecasted wells and depths that are increasing most in percentage 2 able dC vimder Iengtliscss eoe I tete d
13. Supply F DC4 141 41 2nd Hot stab spare Supply A Drain B L42 1st line t r Drain A Supply B DCS L51 2nd Hot stab spare Supply C Drain D L52 de 2nd line t r Drain C Supply D DC6 Lol 41 2nd Hot stab spare Supply E Drain F L62 3rd line t r Drain E Supply F DCH L71 41 3rd Hot stab spare Supply A Drain B L72 Ist line t r Drain A Supply B DC8 L81 41 3rd Hot stab spare Supply C Drain D L82 2nd line t r Drain C Supply D DC9 L91 3rd Hot stab spare Supply E Drain F l 3rd Line ur 5 L92 Drain E Supply F DC10 L101 Hot Stab API Activate hot stab L102 solution Pull back hot stab DC11 Lill 40 1st cylinder Activate Tray 1 L112 Closes Tray 1 DC12 L121 Yo 2nd cylinder Activate Tray 1 L122 Closes Tray 1 DC13 L131 2 3rd cylinder Activate Tray 1 L132 Closes Tray 1 DC14 L141 49 Locking dogs Locks RITS to buckets by use of locking dogs L142 Releases RITS The table shows the signal list for the RITS This table is the basis from where a control screen and the software for the control system is created 74 Chapter Nine Graphic User Interface The GUI also called HMI is the screen that allows the operator to send information to the control system The panel built up of switches that will open or close hydraulic lines that activate the hydraulic lines and the operation given in table 25 will be done A GUI for the RITS is shown in fig 73 The Configuration section of the control sc
14. equipment while main purpose with the last one is to provide RITS with loose tools There will be designed five different cassettes all with different capabilities There is space for three cassettes on the RITS at the time so the customer can choose which of the five alternatives they need for the exact operation 5 1 Modes of operations Few systems in the subsea business are module based Normally there is a new special design to every project even if a similar project is developed earlier The RITS design should be modified to a system that is more flexible All the different tools will be installed in the cassettes and the customer should be able to choose which tools they need The manipulator should also be a part of customer package choice By defining the cost of each piece a flexible module system is created and the customer can pay due to their need however it is recommended to have the manipulator installed at all times to maintain the flexibility ROV There is only possible to install one torque cassette and one cylinder SE stab cassette at the time It is decine d because the control system limited ystem db it is not enough hydraulic components to handle more than Manipulator Titan 4 em one of these components at the time EE Figure 29 Cassette Configuration MN mr x ii ES Tool Cassette Holder Cassette Torque Cassette Cylinder Stab Free Stab Cassette Cassette lt y
15. if corrosion is considered a problem If the aluminum structure should be too weak steel or expensive solutions as titan would be replacement alternatives Buoyancy elements are needed to make RITS buoyant in water FMC guidelines demands ROV tools to not exceed 50 kg under water Tools that are heavier than 50 kg will cause a dysfunctional ROV and prevent the RITS from improve the present subsea technique From a subsea intervention point of view tools heavier than 50 kg is called ROT remotely operated tool and is another kind of equipment than what RITS are supposed to be To meet the requirement from FMC RITS cannot exceed 50 kg in water Chambers filled with air could make the RITS more buoyant An air filled system must stand an outer pressure on 2000 meters sea depth to avoid breaking the air chambers and require a thicker and heavier layer of material The material called BMTI or Syntactic Foam has proved to stand a sea depth level of 3000 meter The Syntactic Foam SF3000 could be blasted into different profiles to improve the buoyancy ref table below Normally Syntactic Foam is delivered in elements that are easy to customize Mat Web 2014 Phone call with DIAB Norway 24 Table 9 Important capabilities for Syntactic Foam Properties Metric Values Weight in air 495 kg m Seawater Buoyancy 30 2 kg block Block size 57 liters Depth rating 3000 meters The buoyancy element
16. product This unit will be customized by Innova due to the system requirements Table 24 Electric Can Source FMC Per Olaf Tangen Weight in air 11 kg Weight in water 2 3 kg Material Aluminum 082 T6 Hard Interface Burton 5506 2008 Power input 88 264 VAC 47 63 Hz Power output 24 VDC Power rating 500W The info given on the transformer is taken from a previous FMC project The power input has a wide range which makes it compatible with the RCU s In addition to make the system less complicated it will contain the CDB to protect it from the external pressure Innova 2014 72 7 3 RCU Remote Control Unit for the torque tool The RCU described here is installed when the torque cassette are needed The torque system is an Oceaneering product The RCU is the control unit for the torque tool and is delivered with control HMI software It is the kind of system that will be designed for the rest of the components however the RCU will only be able to control the torque tool inside the torque cassette while the other system needs to operate several units RCU facts Depth rating 3000 meters Max Pressure 250 bar Max flow 95 Ipm Weight in air 30 kg Electricity 90 132 VAC Telemetry RS 232 or RS 485 Figure 71 Model of the RCU from the OMM Source 41 This system requires separate signal and power lines to be able to operate The hydraulic will be supplied from RITS on the Tellus side
17. DH parameters dh from the DH parameters dh a i alpha id 1 theta i xv np array 1 0 0 zv np array 0 01 1111 T x AngleAxis2T zv dh item i 3 s Trans2T dh item i 2 zv i AngleAxis2T xv dh item i 1 Trans2T dh item 1 0 xv return T def AngleAxis2T r theta The homogeneous trasformation matrix T of a rotation theta about r 102 S Skew r R np cos theta np matrix np eye 3 np sin theta S 1 np cos theta r r T T np matrix np eye 4 T 0 3 0 3 R copyO return T def Trans2T p The homogeneous transformation matrix T of a displacement p T 2 np matrix np eye 4 T 0 3 3 2 p copyO return T def Skew 1 The skew symmetric for of a vector S np matrix 0 r 2 r 1 r 2 0 r 0 r 1 r 0 O 1D return S def ForwardKin dh q Forward kinematics for revolute joint manipulator Inputs dh Matrix of DH parameters q Vector of joint variables q Outputs J Geometric Jacobian Te Homogeneous transformation matrix of manipulator dhf dh copy Note Must use copy dhf dh makes dhf and dh the same variable Insert joint variable in DH vectors dhf 0 3 dhf 0 3 q print dhf 0 3 Homogeneous transformation matrices for each link TO1 LinkDH2T dhf 0 T12 LinkDH2T dhf 1 T23 LinkDH2T dhf 2 T34 LinkDH2T dhf 3 T45 LinkDH2T dhf 4 T56 LinkDH2T dhf 5 Homogeneous matrices from frame to each link frame
18. FMC Technologies 2007 67 Compensator volumes A similar excel sheet as the one presented for the dirty side is set up for the compensator volume on the clean side of the system The calculations estimate a compensator volume of 7 45 liters but without any spare capacity for failures It means that one 6 liters compensator as used on the Tellus side is too small There are larger compensators than 6 liters however there could be an advantage to keep compensators of equal size Knowing that the reservoir will be empty by one flush to sea by the 7 valve there is desirable to increase the reservoir with a few liters Installing two 6 liters compensator provides a volume of 12 liters which seems like a satisfying volume for RLWI and many other subsea projects It makes it possible to keep the operation going even if some fluid is lost by one flush to sea The estimation is not accurate however there is difficult to make exact volume estimation for a random project Figure 64 Compensators placed in a rack MN and source 30 Compensators of equal size can be installed in a rack which is easier for the people that shall assemble RITS 68 7 3 3 Valve Pack The valve pack on the HPU side of RITS hydraulic system has nine valves of the same ref figure 66 The nine Wandfluh BM4D32 G24 M55 M33 controls three hot stabs Each hot stab requires three valves One valve to each pair of line and since the 3 position solenoid
19. The hydraulic system is completely filled when RITS is lowered in the water which includes the fluid lines Since the hydraulic lines are not yet designed an estimation of volumes of the lines are made based on experience from previous FMC projects In the calculation for the RITS compensator length of 4 meter and an inner diameter of 4 mm is estimated The RCU has its own compensating system and does not need any extra expansion option while the Titan 4 needs an extra volume of 2 2 liters Sich Data for each Force off component cylinder Assumed fluid in hydraulic lines P crop Tubo tength Pressure drop Tube volume SAA A FIF F3 EXC EC EE CONES 23 OS EZ IX B EIE E Z ZJE 0 00 0 00 10 000 A131 Ttan 4 0 01 2201 000 1401 0 00 of oof 0 00 0 00 60 000 Total exted volume 3 30 Density Oil type Shet Thallus 32 900 kg Total retract volume 0 00 Aver expansion coaffcient at 20 100 deg C TI tideg C Erik Bakkevig KystDesign AS Volume difference 130 o with 25 deg at surface and 2 at seabed 0 deg at ship deck and 5 deg at seabed ne 27 dog C 210 bar VOLUME COMPENSATOR CALCULATIONS Safety factor m FOR SUBSEA MPU OR ROV HPU Estimated compensator Total actuator voluma Total piping volume vo d u me VOLUME COMPENSATOR CALCULATIONS FOR VALVE PACK TOTAL FLUID VOLUME COMPENSATED VOLUME 4 20 de Max voluma change by de
20. The temperature in the motor cannot exceed 80 degrees 9 1 1 Sensor Signals to surface The sensors will be connected to the PWM16 installed in valve pack 1 and the signals will be routed true the CUTE and up to the hardware topside HMI The position of the sensors varies some components are developed with sensor possibilities while other sensors needs to be installed on the piping or custom made flanges Each PWM16 can handle five sensors and there are two of them in valve pack 1 It is preferable that the sensor signal is 4 20 mA 76 Fluid Level Sensor The 6L compensators from Kystdesign are delivered with a level sensor integrated To activate the sensor a signal coupling to the PWM16 will be required Speed Sensor The motor is the most charged component and needs monitoring The motor has an option for mounting a speed sensor of the shaft This sensor is useful since it also makes it possible to calculate the flow of the hydraulic oil in the clean and dirty system by use of the formulas in Gr Speed Sensor ource presented in chapter 7 2 4 and 7 3 1 Pressure Sensor The pressure sensor is essential to have control over the system and to alert failure A pressure sensor in front of the motor is required to be able to estimate the motor power There will also be inserted pressure sensors on the clean fluids one on the supply line and one on the return Figure 75 Pressure sens
21. Ti ForwardKin dh gh Increment from Ti to Tf to Tf dp np array 0 2 0 2 0 2 ry np array 0 1 0 1z np array 01 101 11 D Tf Ti Trans2T dp AngleAxis2T ry np pi 6 AngleAxis2T 1z np pi 6 q0 qh copyO qf InverseKin dh Tf q0 print qf qf 0 5591 1 1805 1 4447 1 7900 2 0085 1 1492 wow print 105 MC EnergySystems FMC Kongsberg Subsea Appendix D RITS Specification ROV Intervention Tool Skid RITS Document type Doc no SPC 0000031472 Specification Page 10f23 Status Change no Date Version Revision In preparation THE This document is the property of FMC Kongsberg Subsea AS and is not to be reproduced or disclosed to any party without the written consent of FMC Kongsberg Subsea AS ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 2 of 23 TABLE OF CONTENTS Section Page 1 INERODUCTION E 4 Lol PURPOSE ia aia 4 IAE AA A 4 1 3 ABBREVIATIONS D 5 ld REFERENCES tna a a a a aa esti ai 5 2 SYSTEM REQUIREMENTS cui 7 21 SYSTEM COMPONENTES a a 7 2 2 SYSTEM CONFIGURATION srusio e E EEEE ARE E 7 GE WT TR E RT 8 2 3 1 Subsea System E 8 2 3 2 Topside System e EE 9 3 FUNCTIONAL REQUIREMENTS iria ida 10 Si GENERAL DATA tilapia le 10 3 2 TARGET MECHANICAL DATA sia 10 3 21 RITS a 11 3 3 H
22. Triton XLX Slingsby Other ROV systems not contained in the list may also be suitable host systems The physical requirements for the ROV and handling deployment system are as follows e The minimum through frame lift capacity of the ROV is 1 000 kg e The ROV A frame and handling system must be able to handle an additional weight in air and through the splash zone of 600 kg for RITS e The height of the A frame must be able to accommodate RITS height of approximately 350 mm plus 400 mm to install and remove the ROV MC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 18 of 23 4 1 2 Hydraulic Interface The hydraulic motor driven pump shall be supplied with hydraulic fluid directly from the host WROV The clean fluid reservoir will be filled before every operation due to what system that will be operated The requirements for the hydraulic supply are as follows e Valve Packs 2 off 4 3 bi directional control valves with closed centre position e Fluid Mineral oil Shell Tellus 22 or equivalent e Maximum supply pressure 207 bar 3 000 psi above ambient e Minimum flow requirement at 207 bar 20 LPM e Minimum oil compensation 6 liters e ROV interface connections Supply Custom depends of the ROV Return Custom depends of the ROV 4 1 3 Electrical Interface RITS shall be supplied with electrical power and control signals directly from the electrical system on the host W
23. an API 17D to be applied in an attempt to standardize the interface Subsea systems are installed with override functions Common for Figure 6 Model of an API 17D p size 1 4 MN those overrides is that they require a special tool as e g a hot stab or torque tool To ensure a proper access for the tools a solution where all the special tool interfaces are installed inside an API 17D interface is selected The API 17D has three standardized sizes The most suitable size for RITS is the API 17D 1 4 the dimensions of the interface are given in figure 6 The interfaces are built in workshops which causes a free material selection It is preferred to use the same material as the rest of RITS to avoid galvanic corrosion The front may be installed with a rubber element to decrease the impact forces of the landing Figure 7 API 17D drawing modified from FMC archive MN 9 2 2 API17D interface Bucket The API 17D interface require modifications on the ROV panel The ROV panel is the unit where all ROV handling and override mechanisms are placed Many ROV panels are installed with API 17D interfaces however they are installed in a way that may cause problems for RITS If RITS should dock on an existing interface bucket the ROV and the manipulator will be disabled because of no working space To avoid this problem a new API 17D interface bucket needs to be installed To little working space Adju
24. and invers kinematics To avoid going deep into this expressions a simplified explanation is considered enough for this study Here only the principles are briefly described as the software are fully developed and delivered with the Titan 4 and a RITS operator will only be an ordinary user The forward kinematics needs an input of the angles in all joints at every time step The forward kinematics output is the grippers position in 3D space represented by a 4x4 matrix that gives the rotation and position It is possible to interpolate a 4x4 matrix and when the interpolation is executed it is possible to add a value to the existing 4x4 matrix This new matrix is the first step on the way to the end position Inverse kinematic will then produce new joint angles and the manipulator moves The joint angles are presented as a 6x1 vector Forward kinematic will produce a new 4x4 matrix and a new interpolated value can be added By performing this process enough times the manipulator will finally be at the end position Rotation and position on end effector Tx Ty Tz Xx Forward Kinematics p lx Ty ny an eae New position Tx Ty noz 4x4 matrix Ax4 matrix 0 0 0 1 Inverse kinematic Figure 45 Kinematics explanation of the robotics MN 51 6 1 2 Visual Components Visual Components VC is the software that performs the kinematics calculation In addition to the calculation it has a good application
25. factor to be added the weight of the skid The weight of the skid is approx 600 kg ZMGW in air The safety factor DF design factor is the greatest of following calculations DF 2 5 or DF 1 4 0 8 x V 50 MGW DF 2 5 or DF 1 63 Lifting force DF x MGW x9812 14715 N The bolt is dimensioned to handle heavier skid than the RITS as a result only the structure will require an analysis in ANSYS to verify to be within the requirements Table 28 Rejected Interface Connection 250 00 150 00 Fastening Points Requirements Stress Max 250 MPa Aluminum No requirements should be functional Stress 303 9 MPa NOT ACCEPTED Deformation 5 4 mm NOT ACCEPTED The first attempt of the lifting rods was not solid enough The width elements were simply to long which resulted in too much deformation and too much stress in the fastening of the width element see red tag on stress figure 85 It is possible to shorten the length of the element that bend by installing an element perpendicular on the middle of the beam It will reduce the spread of the element In addition the rods in front were moved one beam a head 0 00 500 00 1000 00 mm 250 00 750 00 Fastening Points Requirements Stress Max 250 MPa Aluminum No requirements should be functional Stress 70 3 MPa ACCEPTED Deformation 0 16 mm ACCEPTED Hot Spot see Appendix B Table 2
26. get deeper Tree on wire is a method that first of all is used on deep wells while tie in is a work performed on all depths The calculation in table 3 exemplifies a high percentage increase in deep wells yet the number of wells will still be lower than the wells less than 2000 meters Knowing from table 2 that the deepest wells are over 3000 meters deep it is assumed that the cost of calculating RITS with a 3000 meter design will be expensive This information gives an indication that RITS may be more suited to handle tie in and intervention than tree on wire however it the depths are less than 2000 meters RITS still an option 1 3 Working class ROVs The size of the ROVs will determine the size of RITS as the large ROVs will not have any difficulties carrying a small skid while the smallest ROVs will have a max allowable size of RITS Skid structure which are larger than the ROV are problematic as they are exposed to hits from the sides The table below presents the ROVs commonly used in the offshore industry Table 4 Overview of common ROV s sizes with operational depths over 2000 meters WROV type and supplier Width Length Height Weight HD ROV 1 7 meter 2 5 meter 1 9 meter 3700 kg Schilling UDH ROV 1 9 meter 3 meter 2 meter 52770 kg Schilling Centurion QX 200 1 7 meter 2 5 meter 1 7 meter 2500 kg Subsea 7 Centurion QX 300 1 7 meter 2 5 meter 1 7 meter 290
27. hydraulic supply drain hoses Many components like e g valve actuators on a XT use a hot stab to operate A female shape connector will fit the hot stab and provide a hydraulic connection to the valve actuator There are O rings separating each port to ensure that the fluid will be added the correct line d Hot stab Check Valve Hose The fluid supply are controlled by a valve pack as in RITS The stab is open to the return tank line when the solenoid valve is in neutral position The check valves 50 psi will prevent the water from entering into the tool The system is compensated which means that the pressure will be the same in the water and inside RITS The check valves will on the other hand allow the 207 bar pressure through when the valve is switched to active mode It is an advantage that the check valves are installed as close to the hot stab as possible to avoid too much water in the lines 95 Check Valves gt h A check valve is a spring loaded ball that will be installed in the piping As long as the force of the L a flow is weaker than the spring no fluid will pass however when the pressure increases the flow will go true This technique is used in the hot stab system but HOU also in other parts of RITS as well It is frequently used to control the direction of the f flow Pa B e
28. in addition to API 17D However there are no indications of the API 17D interface being too weak since the present solution with a more instable grabber manipulator are able to perform subsea operations The grabber manipulator is furthermore not capable of providing a fixed stand for robotics and it cannot provide any space for a HPU system or a torque tool The ROVs that are used today require two manipulators and the ROV industry will still develop ROVs with two manipulators independent of RITS Since the ROV will have two extra manipulators available it should be possible to make the position solid by use the grabber manipulator on the ROV and an API 17D interface It will require cooperation between the supplier of the subsea equipment and the ROV operator however the result of a rigid and fixed position will open for new possibilities in subsea operation RITS is equipped with its own Titan 4 manipulator and one may ask why the manipulator of the ROV is not used It is possible but every ROV has its own geometry which will interfere with the fixed position and standard VC programming are therefore lost If the owner of RITS shall pre program the system it is an advantage that the Titan 4 installed on RITS are used The new docking method opens for a market of new technical solutions The robotics illustrated in this thesis will be one of the many new features provided by RITS Videos from subsea operations reveal that it is chall
29. in air 2 kg Space for one of these per cassette decrease the weight by 1 9 kg each Weight in air 1 7 kg Table 13 An overview of which cassettes and the use of elements Cassette 1 2 3 Weight reduced Weight in air Tool Cassette Holder Cassette 1 1 9 kg 1 7 kg Torque Cassette 1 2 1 10 9 kg 10 1 kg Cylinder Stab Cassette 1 2 1 10 9 kg 10 1 kg Free Stab Cassette 1 1 9kg 1 7 kg The table reveals how many elements the different cassettes will need It is based on an evaluation of the weight of the tool combined with the cassettes Excel Buoyancy calculation 39 5 3 The Cassettes Type One with an API interface The cassettes have tracks and holes to make it fit the structure In front it is hole made to fit the API 17D interface On the other side there is a hole created to make room for the hydraulic and electric lines The lines connect the cassettes to the structure where the control units are postioned These traces and holes makes it possible to create a standard cassette structure and buoyancy Figure 31 Adjustments created to fit the cylinder MN The most challenging customization are the tracks to make the cylinder fit the cylinder is the same as presnted in chapter 3 The tracks in the cassette will have extra 75mm applied in the front to adjust the cylinder to be fastened to the mounting ears in the structure The type
30. is developed in six different sizes The capacity of the motor is depending of the flow on Tellus side of the system It is an advantage that the motor is not working at max speed at all time to reduce wear and tear The larger motors will give the same volume and pressure to a lower speed than the small motors To select the most suitable pump it will be a trade off between low speed and low weight which is two abilities that work against each other The flow on the Tellus side of the hydraulic system is dependent of the component with the lowest max flow For the RITS it is the manipulator that needs a flow of 19 liters per minute lpm It results in a total system requirement of approx 20 Ipm When the flow is given it is possible to pick the most suitable pump size Volumetric efficiencies Basic formulas for hydraulic motors Flow q D displacement cm rev n shaft speed rpm n volumetric efficiency Dxn g qz 1000 xn Vmin Torque M Ap differential pressure bar M DXAPXMm Nm between inlet and outlet 63 nnm Mechanical efficiency 1000 2000 3000 4000 5000 my Overall efficiency Speed rpm Power P n MX Nam _QXAPxnm Tee M Figure 60 Volumetric efficiency Source 31 Figure 59 Basic formulas for hydraulic motors Source 31 RPM is calculated by the formula in figure 60 Table 22 represents the results of the calculation In the table it is possible to choose the most suitable mo
31. line numbers and be simple to use and understand 14 The cassette configuration on the HMI will be set according to the cassettes configuration in RITS The system will be tested on a test stand before the launching process MIC technologies Doc no SPC 0000031472 Version 00 Revision Page no 10 of 23 3 FUNCTIONAL REQUIREMENTS The functional requirements of the RITS are as follows 3 1 GENERAL DATA Bem mm Design water depth 2000 meter Maximum landing force 20000 N 20kN 3 2 TARGET MECHANICAL DATA OI Rovsan J ooo mmm 7 MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 11 of 23 3 2 1 RITS The functional requirements of the RITS are as follows The hydraulic power supply in the RITS shall be suitable for operation using mineral oil Shell Tellus 22 or equivalent supplied from the ROV All components are powered by this system except from the Hot Stab that is powered by the motor pump HPU system The hydraulic power unit HPU shall be supplied with water based fluid Marston Bentley HW443 or equivalent filled topside Each line to the Hot Stab 6 Line 345 Bar shall be fitted with a 50 psi check valve to prevent the loss of hydraulic fluid from the system when disconnected The pressure compensators shall have a low level indicator and alarm to the control of the HPU system and the ROV system In addition there is a spe
32. main idea is to replace the present grabber manipulator on the ROV with a new and more solid interface connection It will provide a more rigid position which will make the operation subsea easier A rigid system will open for other features Figure illustrates the main idea of RITS create some new situations that will open for new system for subsea use Main Idea Enabled by Additional features Existing M hydraulic system Tool Cassettes API Docking Receptacle Pre Programmed Manipulator Fixed position Figure 1 New systems provided by the docking interface on RITS MN 1 1 The RITS idea RITS will be designed with an API 17D interface which will provide the skid with a more stable position on the subsea equipment Combined with the manipulator it opens for an opportunity to pre program the manipulator to do tasks automatically This pre programming can be planned before the ROV goes subsea while the day rate is running The manipulator mounted on RITS is operated by the supplier of the equipment that shall be installed The manipulator provides the same flexibility as the solution used today A new pre programmed option will be possible because of a fixed docking point by using the API 17D interface RITS will carry special tools in cassettes that can be activated by using cylinders This is an advantage since the present technology requires the ROV to collect the tools from other locations such as onboard o
33. maintenance on existing wells RITS can be useful for new installation of XTs Both tree on wire and tie in operations are subsea tasks that can benefit from using RITS Tree on wire is an installation of a XT without the marine riser which is a continuous pipe from the platform down to the seabed Since the riser is not installed it is challenging to communicate with the XT down on seabed To be able to operate the XT a ROV is frequently used Installations like this require the ROV to handle the landing of the XT in addition to connecting the communication line afterwards Umbilical Tie in operations are in a similar non commuting state as the tree on wire Tie in means the operation to plug connect the production line to the XT It has been developed systems to make this operation easier however all of them are heavily dependent of the ROV Table 3 is a result of the information provided in Figure 4 overview of depths of wells however separated into percentage increase of forecasted wells due to depth Table 3 Planned forecasted wells and depths that are increasing most in percentage Area 0 600 m 601 1500 m 1501 2000 m 2000 m 2013 existing wells 3642 wells 1695 wells 25 wells 144 wells 2014 8 8 96 16 5 96 29 5 96 67 4 96 2015 8 6 96 9 5 96 24 9 32 96 2016 7 4 96 9 3 96 24 4 96 34 6 96 2017 5 3 96 6 8 96 22 96 29 9 The table points out a tendency that the wells in the future will
34. np matrix np_mat Returns Kinematic chain joint values based on the target matrix def OnInverse kinobj global qh if FirstCall OnFinalize print OnInverse target kinobj Target printMatrix target Convert to numpy Tf vcMatrix2Numpy target print Tf q0 kinobj Joint Values Create numpy array from q0 np array q0 reshape 6 1 qf InverseKin DH_PARAMS Tf qh kinobj JointValues qf return True def OnRebuild OnFinalize def OnFinalize print OnFinalize global FirstCall global DH_PARAMS 101 global LO1X LO1Z L12X L23X L34X L45X L56X FirstCall False comp getComponent LO1X comp L01X LO1Z comp L01Z L12X comp L12X L23X comp L23X L34X comp L34X L45X comp L45X L56X comp L56X DH PARAMS _ SetDHParams print DH_PARAMS def printMatrix mat Usefull utility function for printing matrix value for Vec in mat N mat O mat A mat P print 3 3g1 3 3g1 3 3g1 3 3gm Vec X Vec Y Vec Z Vec W nun def SetDHParams global qh global LO1X L01Z L12X L23X L34X L45X L56X Might be errors here Initialize DH parameters dh and the zero position gh of the URS robot dh np matrix LO1X np pi 2 LO1Z 0 L12X 0 0 0 L23X 0 0 0 L34X np pi 2 0 0 0 np pi 2 0 O np pi 2 0 0 L45X L56X 0 return dh qh def LinkDH2T dh i The homogeneous transformation matrix T of link i with
35. oil Shell Tellus Oil 32 Filtrations 3 microns 10 microns absolute Electric Data Input Power 24 VDC Power consumption incl solenoid 6W start 12W run Slave arm current draw 1 875A at 24VDC General Data Max Water depth 4000 meter Table 20 Data for Titan 4 The Titan 4 will be installed on the top front of the RITS The manipulator will during transport be in a position where the ROV protects the manipulator from direct hits Kinematics for Titan 4 2 Schilling Robotics 2012 49 Figure 44 Measurement of Titan 4 Source 24 Table 21 Kinematics for Titan 4 6 revolute joints and joint lengths Lik a aa wa 1 121 mm n 2 195 mm Ou 2 851 mm OQ5 3 483 mm O3 4 13mm u2 or 5 n 2 O5 n 2 6 193 0mm 74 0 mm Oe Source Robotics book 50 6 1 Kinematics Visual Components and Python Programming The main challenge to operate a manipulator automatically is to create an expression between the angles in the joint and the coordinates in the 3D space The manipulator gripper will get the information to move to a given coordinate however the issue is what joint angles that give these coordinates Each joint will need a separate angle and to make it a bit harder there are several different angles that can achieve the same coordinate for the gripper at the end 6 1 1 Kinematics The tools solving these problems are called forward
36. one cassettes are installed with the interface receptacle to be able to dock on to subsea equipment Some of the type one cassettes have additional capabilities because of integrated tools Cassettes of this kind have similar structure and a standard buoyancy package Table 14 Standard Cassette type 1 weights Weight in Air Weight in Water Cassette structure 6 044 kg 3 8 kg Standard Buoyancy Package 3 3 kg 3 6 kg 40 Cassette type one is fastened on the mounting ears in front of RITS This is because type one cassettes will be exposed for the impact load when the ROV tries to park RITS The impact load will be calculated later on however the design direction of the cylinder used are explained in the cylinder chapter 3 1 3 The structure is designed with mounting ears illustrated in Figure 32 The cylinders on the cassettes are adjusted to fit into those ears Figure 32 illustrates the first 800 mm in front of the structure of RITS MES Figure 32 Cylinder mounting ears cassette type one MN This is the main difference between the two cassette types Chapter 3 1 3 Cylinder Position explains the main idea of the placement of the cylinders that will handle the impact load of parking RITS The cassettes type two has other limitations due to strength and functionallity the reason is explain in chapter 5 4 The Cassette Type Two however the conclusion is a cylinder mounted in op
37. pin in the receptacle that will be pushed into a fitting hole in the interface bucket RITS will be totally fastened as long as the pin is pushed inside the bucket This system is standard on the API 17D interface however the locking dog pin is not always installed The system on figure 10 is actually an Oceaneering invention but by implementing a dedicated hydraulic line to the locking dogs in RITS will make this system possible for all the interfaces As figure 10 is illustrating the locking dog has a spring installed The purpose of this Tool body Latch Latch dog cylinder Spring 6041 o O ring O ring 85s ER If the locking dogs are not installed the Figure 10 Locking dog assembly Source 4 spring is to retrieve the locking pin if the system loses its power It is a safety Piston mechanism that makes it possible for the ROV to pull away in an emergency situation hydraulic lines will be plugged with a blind flange In addition to a solid extended bucket it is possible to install a system that mechanically informs when the locking dogs are installed The locking dogs will push a pin out and the camera on the ROV will be able to verify the status of the connection Figure 11 The spring loaded locking dog pin MN Oceaneering 2009 11 Chapter Three Tools RITS will be designed with tool packages called cassettes The cassettes will contain the API interface an
38. syntactic foam and one without All calculations are performed with the structure without foam because it is the weaker of the two profiles It means that the analysis made for the first profile will apply for the filled profile since it weigh less in water and is stronger The area of the cross section is width x height area gt 50 3 x 2 x 50 3 x2 19 36mm 0 001936m Pcs Length Total length Volume Buoyancy Height 14 0 25 m 3 5m 0 0068 m 3 6 kg Width 10 1 45m 14 5 m 0 028 m 14 84 kg Length 4 2 7 m 10 8 m 0 021 m 11 13 kg Table 27 Calculation of buoyancy in the structure Calculated on behalf of volume multiplied by buoyancy density A filled profile would have decreased the weight by approx 30kg and this may be handy if a heavy tool should be wanted for a specific project The idea of filling the profile was to reduce the weight of the structure As the buoyancy issues where solved se next chapter without a filled structure the first edition of RITS will consist of a profile without syntactic foam 79 10 1 1 The Buoyancy Elements Four buoyancy elements are required to make RITS function they are presented in chapter 10 2 2 They will not alone provide enough buoyancy to make RITS neutral in water Therefore to make the system buoyant all the empty spaces between the cassettes will be filled with foam elements in addition to the edges of the structure I
39. the ROV is supposed to perform The different cassettes all contain different tools and since an HPU is installed even a hot stab cassette is possible This study indicates that the cassettes the manipulator and the HPU system developed will work The docking system however needs extensive testing before RITS can be produced If the docking gives satisfying results during the tests all the required documentation and design specifications are presented The docking solution is the component making all the other systems possible The RITS should therefore be able to improve the working situation for the ROV operations IV Sammendrag De fleste undervannsinstallasjoner har egne systemer for installasjon I situasjoner hvor dette er umulig eller mekanismen feiler er det eneste hjelpemiddelet en ROV Dette gj r ROVen avgj rende for undervannsoperasjoner Utfordrene arbeidsforhold pa havbunnen gj r undervannsoperasjoner vanskelige Denne rapporten vil presentere et nytt verkt y som vil forbedre arbeidsposisjonen til ROVen verktgyet er kalt RITS Rov Intervention Tool Skid RITS er laget ved hjelp av normale undervannslgsninger hvor hovedideen er basert pa en ny tilkoblings metode Denne faste tilkoblingen vil sikre en solid kobling mellom ROVen og ROV panelet pa komponenten under vann Koblingen som brukes er en API 17D kobling og planen er at denne vil sikre roligere arbeidsforhold nede pa havbunnen Den nye oppdaterte kobling
40. to illustrate this VC will be able to give the Titan 4 all its needed joint angles to complete a movement VC has a database for a number of different manipulators however Titan 4 was not included in this database The Titan 4 what to be implemented manually which required a new geometric model new kinematics and so on The picture in figure 46 is capable to simulate the whole operation and by adding the subsea unit in the figure it is possible to illustrate exact operations in detail 3 3DAutomate 2014 SPI fle C Users norstemD File Edt View Simulation Report Tools Help HMM Lm Dip e su ver LL e mre j 1 m a j 15 Deelt 7808557200 162780727906 2 050195 Me 0o 5425 4 Figure 46 Screen shot of Visual Components 1 Is the function that defines the point the manipulator should move to A new point in the movement are set by manually move the manipulator to the wanted position and then push the 1 button and a new point in the movement of the manipulator is created 2 Illustrates the point that the manipulator shall pass through during the programmed motion 3 The kinematics are presented in box 3 The values in this box can be programmed in to the Titan 4 software and the manipulator is then ready for a new step movement 52 6 1 3 Python The biggest challenge to make a fully working Titan 4 in VC was to implement the kinematics New kinematic was created for
41. transducers and a stable reference voltage for potentiometer type sensors The embedded controller and supporting electronic components shall be qualified for operation at an external pressure of 300 bar The qualification shall be accomplished by documenting correct operation of the electronics while cycling the external pressure from 0 bar to 300 bar A minimum of 10 cycles is considered necessary to adequately demonstrate long term tolerance to the specified external pressure MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 16 of 23 3 5 3 Camera and Light Control System Camera and light is operated from the ROV All operation will happen in front of the ROV 3 5 4 Surface Control Unit The Surface Control Unit shall provide the control signals to control the hydraulic functions and display the monitored values in metric units from various sensors installed on RITS It shall be based on a laptop PC with a GUI software providing input to all tool functions and display of all monitored values and status diagnostics information The RCU and the Titan 4 will use suppliers software linked true RITS normal GUI when they shall operate The Surface Control Unit shall be able to operate in the following modes e Software master mode In this mode the GUI software is the control system master and all control system functions are controlled and monitored from the software e Simulator mode e Th
42. usable hot stab a special clean system is needed inside RITS Systems that provide clean fluids are called a Hydraulic Power Unit HPU It is a system that can make a secondary system flow without mix fluids The schematic will show what components that are needed inside the RITS to make a clean fluid system possible See Appendix A for a detailed explanation of a hot stab and how it is works 10 FMC Technologies 2010 22 Chapter four The Structure design The structure will protect all the sensitive tools inside RITS with its frame It is important that the structure is designed so that it will not expose the manipulator or other tools To work as intendant it is important to choose the right material form and profiles of the pieces that become the structure Subsea equipment is exposed to some of the most corrosive environments in the world even if the oxygen level is low down on seabed Equipment stored on the vessels is particularly exposed to corrosion It is problematic that equipment like RITS is exposed for seawater and then be stored on deck where the oxygen level is high Another material sensitive factor is the weight Offshore equipment should be easy to handle Waves and wind makes lifting operations dangerous therefore it is important to keep weight as low as possible In addition to the issues mentioned above costs are an important factor There are many materials that fulfill the environmental challen
43. with open center 20 LPM 5 USGM 200 bar The valve pack shall satisfy the following requirements Material selection and protective coating shall be suitable for long term immersion in seawater to a depth of 2 000 metres 1 A prime consideration in the choice of materials and design shall be to minimise weight and size consistent with fulfilling the functional requirements 2 All ports and internal passages in the valve block shall be designed to accommodate the maximum flow for each circuit with minimum pressure drop 3 External hydraulic connections shall be designed to suit BSP hydraulic fittings 4 A pressure relief valve shall be installed as an over pressure safety valve for the main HPU system The valve shall be manually adjustable and at least allow adjustment within the range 160 bar to 400 bar 5 A pressure transducer shall be installed in the valve pack to monitor the inlet hydraulic supply pressure 6 A temperature transducer shall be installed as a safety mechanism for the HPU motor MC Technologies Doc no SPC 0000031472 Version 7 8 00 Revision Page no 15 of 23 Drain and bleed ports shall be installed in positions that allow air to be vented from the enclosure and fluid drained from the enclosure when installed either with the valve block oriented vertically or horizontally The compensation system shall ensure that at least 0 5 bar over pressure is maintained in the compens
44. 0 kg Subsea 7 ACV 1 9 meter 3 4 meter 2 meter Subsea 7 Hercules 1 85 meter 2 05 meter 2750 kg Subsea 7 Quantum 2 meter 3 58 meter 2 meter 5350 kg Subsea 7 Diablo 2 04 meter 2 65 meter 1 82 meter 3050 kg Subsea 7 Demon 1 83 meter 2 95 meter 2 meter 3500 kg Subsea 7 Magnum Plus 2 59 meter 1 85 meter 3060 kg Oceaneering Maxximum 1 83 meter 3 048 meter 1 85 meter 4850 kg Oceaneering Millenium Plus 1 68 meter 3 3 meter 1 92 meter 3990 kg Oceaneering Triton XTR 1 7 meter 2 5 meter 1 7 meter 3600 kg Slingsby Oceaneering 2013 Subsea 7 2013 Technologies 2013 G Tech 2013 8 Chapter Two RITS Interface The RITS interface unit is the component that shall ensure a rigid and stable position The present ROV systems require a 5 function grabber manipulator that is operated manually by personnel topside The grabber manipulator will grab the ROV handles mounted on the subsea installation This operation is challenging because of movement in the sea and poor 2D visibility The idea is to replace the manipulator with a connector that allows RITS to dock onto the subsea equipment and keep the ROV in a defined stable position resulting in faster and more accurate operation 2 1 API 17D interface The American Petroleum Institute has developed various standards for use by the petroleum industry The API 17D is the standard describing the most common connector interface FMC guidelines demand that
45. 002 28 4 4 Assembling the structure There are different ways to assemble a square profile into a structure Subsea structures are normally welded together FMC wanted other options than welding to be considered Bolted and welded structures are discussed in this chapter while glue and other assemble methods has been considered too unsecure innovative and will not be further discussed 4 4 1 Bolted structures The main advantage with bolting a structure is to make it easier to replace broken pieces The challenge is to get the structure solid enough Important concerns for design of a bolted construction are e A bolted structure needs to be designed in a way that allows the bolts to fasten into the profiles since profile is hollowed it will not be possible to fasten bolts on the ends e It is a challenge to bolt the structure in a way that prevents the square profiles to turn around They need a fastening system that makes them stay in the same position at all times e The system needs to provide a solid connection to prevent stress issues as fatigue e The bolt assembly should not increase or decrease the size of the structure Figure 23 Example of a skid structure MN The table on next page presents the most realistic bolt connections They are evaluated according to the criteria listed above 29 First idea Strategy Make the bolt assembly as similar as possible to a welded solution uw E
46. 1030 770 7 6396 x Object Weight in air 4 2 Corrosion Corrosion is an everyday problem for all equipment stored nearby the sea The problems are worst in the splash zone where the sea water frequently splashes over the materials where access to oxygen is good The salt water makes the environment more corrosive since salt creates an ionized bridge that leads to galvanic corrosion between different rated steels Storing the equipment inside where the humidity is lower than outside will decrease the rate of corrosion Down on seabed there is less oxygen and the corrosion rate is lower than in splash zone though it does not mean that the environment is good for RITS Aluminum has a low Poisson number which makes it frequently used as an anode for higher valued materials Low weight and acceptable strength also makes it a good material choice for RITS The corrosion problem is handled by avoiding material with high Poisson number combined with regular maintenance The idea is to build RITS in aluminum without using a not ionizing material between RITS and the ROV Experience will show whether it will be enough to prevent RITS from corrode If not it is possible to install anodes or other corrosion protectors during the regular maintenance RITS will be topside very often therefore corrosion is not considered as a significant problem Experience from FMC intervention and tool department is that corrosion on tools seldom causes an
47. 2 Version 00 Revision Page no 13 of 23 3 4 ELECTRICAL SYSTEM The electrical system will be guided true an electric transformer can Mode of operation Electrical power supplied from the WROV via an electric Can or direct to the RCU only for if the Torque Cassette is mounted Electrical supply to RITS Power supply The electrical system on the WROV shall have sufficient power to run the RCU and the two valve packs inside RITS ROV Auxillary 110 VAC PESE E ek Tu ADDITA ETC ps prom lar amm Lef ke RT lanzrenrn STS Tis ao Sel sees To SIETE sores eres OU CTS KETI axa A XM NEEDS e XT ski Aal es XI TIT ns dcs Figure 4 Control system MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 14 of 23 35 CONTROL SYSTEM 3 5 1 Control System General Requirements 3 5 2 Subsea Hydraulic Control Unit The compensated valve pack shall include the following items e Compensated enclosure e Hydraulic valves and components e Imbedded Controller and driver electronics e Pressure transducers e Connectors and penetrations e Compensation unit s Valve Pack on ROV side of hydraulic system 4 off 4 3 way Type NG3 solenoid valve with open centre 20 LPM 5 USGM 200 bar 1 off 4 2 way Type NG3 solenoid valve with open centre 20 LPM 5 USGM 200 bar Valve Pack on ROV side of hydraulic system 9 off 4 3 way Type NG3 solenoid valve
48. 7 2 2 FheCassette EE EE 38 Dies Cassette e e EE 39 35 4 The Cassettes Type One with an API interface iii 40 5 4 The Cassette type two for Tool Carerg eene enne enne 45 X Hose Cassette stater A ag 48 Chapter Six Manipulator st t 49 6 1 Kinematics Visual Components and Python Programming eese 51 6 1 1 Ee 51 6 12 Vis al EENEG 32 G L3 Tis EE 53 6 1 4 Example of robotics on a RLWI stack cuina 53 Chapter Seven Hydraulic Systemi e eegene As 54 Ta Hydraulic Schematic EE 55 7 1 1 Valves used in the RITS Schematics eeeeeeseeeeeseeeseseesseseresressererssresseseresresse 56 VII 7 2 ROV hydraulic system Tellus System coperte eene ere 59 7 2 1 Filter EEN 59 T22 AE COMPENSADA 61 7 2 3 Valve Pack 2 valve pack for the dirty system sse 62 124 Th hydraulic motor unless nad 63 13 The Clean system HPU SySUIT side oa eerta eh era e ERR a exe erae EE ideada dias 65 E Sr Ne Mer EE 65 732 Th tl an side compensator trio 67 Las e E 69 Chapter Eight Control Unit iiie a edente Ae RR Ada NENNEN 70 TA Valve pack Control Systems viniste a Pee EA 70 FEL c AS PA AAA e ee a 71 A KE E RS A TS 71 7 1 3 CUTE Communication Distribution Board 12 Dee e EE 12 7 3 RCU Remote Control Unit for the torque tool eene 73 TA a Hera C ys sues od odes dee as eb o a 73 D CM PE ee EE 74 Chapter Nine Graphic User Interface eee eter keete Egeter
49. 75 OU SSPUSODS ui ores ede AE ea e e ote a eee ds 76 9 1 1 Sensor Signals to eg E 76 Chapter Ten ET e EE E 78 10 1 Buoyancy in the structure profiles ua ec decedat ea epond cus 79 10 1 The B oyancy Bleser enee 80 10 1 2 Adu WEE EE 81 10 1 3 Precaution of buoyancy element positioning eene 82 VIII A e EE E 83 Chapter Eleven Interface tothe ROV usina dd 84 Chapter Thirteen DISCUSSION oque cei s A ca 87 Chapter Fourteen C EE EE 90 Bibliography de 91 DEIER idas 95 Appendix A Hot Stab EE 95 Appendix B Hot Spots EE 98 Appendix C Visual Components Programming Python Script ooooocononccnoncccnnncncnonncnnnnos 99 Appendix E Project Progress iei eM eet dba esa t EE 129 Figures Sources market with MN gt Created by M Norstebg spring 2014 Figure 1 New systems provided by the docking interface on RITS MN neeesser 2 Figure 2 Components in RITS MN usina EEN 3 Figure 3 Illustration of decreasing number of human interactions MN 4 Figure 4 Graph that illustrates numbers of wells in the world by depth source 1 5 Figure 5 Wells over the world in 2012 Source I eter teen ete reete nn ente eee 6 Figure 6 Model of an API 17D size 14 MN Tesco dir rei 9 Figure 7 API 17D drawing modified from FMC archive MN eeens 9 Figure 8 Extended interface bucket capability IMNT A 10 Figure 9 An extended API bucket MN Vas 10 Figure 10 Lockin
50. 9 Approved Interface Connection The buoyancy elements are not adjusted however it is a small adjustment which will not change the total buoyancy more than acceptable It will be compensated by adding an extra cm of syntactic foam on the adjusting element To avoid galvanic corrosion the bolt should be treated with a primer max 50u thick due to FMC guidelines Typical zinc rich epoxy or aluminum pigmented epoxy and lubricated with Tectyl 506 86 Chapter Thirteen Discussion The main aim for this thesis is to improve the operational situation for the ROV by presenting a new docking solution The new docking solution should be more solid ridged and fixed than the present grabber manipulator while at the same time maintaining the flexibility RITS will be able to provide such a system however the quality of the parking stand is essential to make RITS effective An unstable parking stand will cause difficulties for the operators since the fixed position will be lost All the other features RITS will provide are depending on a solid connection that creates a fixed position towards the ROV panel For example will a few cm offset be crucial for the pre programmed manipulator s movements The idea of RITS is based on a design with an API 17D interface which resulted in no evaluation of other interface units As the system is fully depending on a solid interface connection it could be a good idea to search for other options
51. MC Technologies FMC Technologies 2006 2 inch M3000 Valve Kongsberg FMC Technolgies FMC Technologies 2006 Acetal Polymer 20 Percente PTFE Kongsberg FMC Technologies FMC Technologies 2007 7 inch M3000 valve Kongsberg FMC Technologies FMC Technologies 2010 OMM Subsea Intervention Tie In ROV Tool Stab 6L 207 Bar Standard Document 5th Rev F ed Kongsberg FMC Technologies FMC Technologies 2010 Product Data Sheet Torque Tool 2700 NM API 17D Class4 4th rev D ed Kongsberg FMC TEchnologies Foss M 2014 Hoses Interview 5 Mai 2014 Huco Dynatork 2013 Flexible Coupling Hertfordshire Huco Engineering Industries Ltd Hydex Sylinderteknikk 2014 KM DVL serie standard sylindere mobil kvalitet sf risk opplagring Online Available at http hydex no S ylinderteknikk did 9106345 Accessed 15 February 2014 91 Hydex Sylinderteknikk 2014 Subsea Sylindere Online Available at http hydex no S ylinderteknikk aid 9078836 Accessed 5 Mars 2014 Innova 2014 CUTE Stavanger Innova Technology Innova 2014 Hydraulic Valve Pack Stavanger Innova Technology Innova 2014 PWM 16 Stavanger Innova Technologies i Tech 2013 Centurion HD Online Available at http www interventiontechnology com en cms user_files File ROVs Centurion_HD 281 29 pdf Accessed 6 September 2013 i Tech 2013 Centurion OX Online Available at http www interventiontechnology com e
52. MIO operates eight 4 3 solenoid valves It has a depth rating on 3000 meters and Figure 68 PWM 16 Source 38 communicates with both a RS 232 and a RS 485 standard 7 1 2 Titan 4 Control system Titan 4 is an advanced system with the control card integrated inside the manipulator However there is an issue to be customized as the control card needs a communication board Figure 69 Control card for Titan 4 Source 39 38 Innova 2014 Schilling Robotics 2012 71 7 1 3 CUTE Communication Distribution Board The system will have several PMW16 control cards A master communication distribution board CDB is required The CDB supplied from Innova can handle four different control cards which is exactly the number of PWM16 s and Titan control card on the RITS Size 160x100x12mm Electrisity 12DC 24VAC optional Telemetry 1 off RS 232 or 4 off RS 485 Figure 70 CDB from Innova Source 40 It is designed to be installed in an enclosure without any depth rating Instead of designing a special container for the CDB it is planned to integrate it in an electric transformer package 7 2 Electricity Can All the control cards solenoid valves and the distribution board require 24 VAC Installing a transformer will make the system less complicated since it reduce the customization of all the control units Innova has developed systems like this earlier however there is not a standard
53. NTNU Trondheim Norwegian University of Science and Technology ROV Intervention Tool Skid RITS Development of a new ROV tool Magnus Norstebg Subsea Technology Submission date June 2014 Supervisor Olav Egeland IPK Co supervisor Dan Lindkjglen FMC Technologies Norwegian University of Science and Technology Department of Production and Quality Engineering Magnus Ngrstebg NTNU IVT Master s thesis in Subsea Technology Development of the ROV Intervention Tool Skid RITS A design report Trondheim June 2014 Supervisor NTNU Olav Egeland Supervisor FMC Technologies Dan Lindkjglen Norwegian University of Science and Technology Faculty of Engineering and Technology IVT Department of Production and Quality NTNU Trondheim Norwegian University of Science and Technology Oppgave tekst 1 Design a ROV Skid called RITS equipped with a torque tool hot stab manipulator and a tool tray 2 Create the documentation FMC Technologies normally require for a project Except documents that explain additional equipment like test units and transport units 3 Present at least one example of how the robotics can improve subsea operation with its increased accuracy The rest of the pre study report is implemented in the SPC Appendix D the progress reports are added as appendix E Declaration I Magnus N rsteb hereby declare that this dissertation is all my own work and the s
54. ROV via oil filled interconnecting cables with wet mateable connectors In addition video signals from cameras on the ROV shall be routed back to the WROV for transmission to the surface The requirements for the electrical power communications and video interface are as follows Interface ROV Requirement Electrical Power 110 120 VAC Electric Interface Burton 5506 2008 RCU Interface probably the same Data Interface Serial line RS485 half duplex The electrical system on the WROV shall have sufficient power to run all lights and cameras in addition to RITS MIC technologies Doc no SPC 0000031472 Version 00 Revision Page no 19 of 23 5 MATERIALS AND CORROSION PROTECTION 5 1 MATERIAL SELECTION Material selection shall be as follows Part Description Material Type Material Fam Structural Framework Framework Structural Framework Aluminium AA 6082 T6 AA Aluminium AA 6082 76 T6 NORSOK Machined Parts Aluminium AA 6082 T6 NORSOK M CR 120 R2 Polymer Parts Parts Hydraulic Piping and POM aa 316L LM 1025 Fittings Cylinders Structural Steel Hydex Sylinderteknikk 5 2 SURFACE TREATMENT Surface preparation coating application inspection testing and repair shall be in accordance to the following Part Description System Cathodic Protection Tool frame Raw aluminium anodes If M interfaces Primer max 50u zinc rich epoxy or A pigmented epoxy Tecty
55. T02 TOI T12 T03 TO2 T23 T04 T03 T34 TOS T04 T45 Homogeneous transformation matrix for manipulator Te TOS TS6 Rotation axes z0 np array 0 0 111 103 zl TO1 0 3 2 z2 TO2 0 3 2 z3 T03 0 3 2 z4 T04 0 3 2 z5 T05 0 3 2 Position vectors pO np array 0 0 01 pl TO1 0 3 3 p2 TO2 0 3 3 p3 T03 0 3 3 p4 T04 0 3 3 p5 T05 0 3 3 Position vector of manipulator pe Te 0 3 3 Blocks of position part of geometric Jacobian JOO Skew z0 pe pO J01 Skew z1 pe p1 J02 Skew z2 pe p2 J03 Skew z3 pe p3 J04 Skew z4 pe p4 JOS Skew z5 pe p5 Geometric Jacobian J np bmat JOO JO1 JO2 JO3 JO4 JOS zO z1 z2 z3 z4 z5 return J Te def InverseKin dh Td q0 Inverse kinematics using inverse geometric Jacobian Inputs dh DH parameter matrix Td Commanded homogeneous transformation matrix q0 Initial value for q Outputs Solution q Rd Td 0 3 0 3 qk q0 copy for count in range 1 5 Jk Tk ForwardKin dh qk print Jk Rk Tk 0 3 0 3 Re Rd Rk T ep Td 0 3 3 Tk 0 3 3 Rotation error is the r sin theta vector eo 1 2 np array Re 2 1 Re 1 2 Re 0 2 Re 2 0 Re 1 0 Re 0 1 e np bmat ep eo K 1 dq K np matrix np linalg inv Jk e qk qk dq 104 return qk Main program Initialize URS robot parameters dh qh SetDH UR5 Ji
56. TO 6Z PAM wey nueg SE vTTO 67 PIM vTTO OZ VOW YOM jo adoos e EI E VI ZO TO eS PTTO 07 VOW uoday Apmisaid Ch z PT 90 OT 9n1 PT TO OZ VOW SIS9UL JO J915 amp T T 60 50 TO 8Z vz Oz 91 t 80 VO O 92 C 81 v1 OT 90 zO 6 Sz tz ZT Et 60 SO TO Sz Iz Zt T 60 S0 TO 82 vZ Oz 9t CT o unreo vt AeWwSz rien vr Jdvsz vLJdvvT VI JENTE vLJEWZT vLJeWEO rail roi reel gg apon ssa2apaig sium pex SUIEN YSE LO 129
57. YDRAULIC SYSTEM a dete aR d On tat TE TEE 12 3 4 ELECTRICAL SYSTEM EE 13 33 CONTROLS YS CEI sar 14 3 5 1 Control System General Requirement eese 14 E A S bsea Hydraulic Control Unit E 14 3 5 3 Camera and Light Control System ia 16 23 8 Surface Control BE 16 4 INTERFACE REQUIREMENTS ss is 17 421 1 Mechanical BitetIdee oncesi EE Sood o EE eR 17 41 2 KEE 18 4 1 3 El ctrical Ditetl AUR iii 18 3 MATERIALS AND CORROSION PROTECTION eere nennen 19 51 MATERIAL SELECTION conil 19 345 SURFACE TREATMENT eeehe aaa eege 19 5 3 FABRICATION E 19 5 4 IDENTIFICATION AND TRACEABILITY AAA 19 5 5 PACKING STORAGE AND PRESERVATION cccoicccoccniconacconnenioninccnnnccnnnanicnnan 19 6 TEST REQUIREMENTS EE 20 61 UNIT CUA NA E 20 6 1 1 Factory Acceptance Test urnas a 20 62 Ce EECH ei iniri state dci 21 7 DOCUMENTATION E 21 7 INTERMEDIATE DOCUMENTATION FROM SUPPLIER TO SIBI 21 Tu FINAL DOCUMENTATION E 22 MIC Technologies Doc no SPC 0000031472 Version Figure 1 Figure 2 Figure 3 Figure 4 00 Revision Page no 3 of 23 FIGURES ROV Intervention Tool Skid RITS Control System Overview model of RITS Hydraulic Schematics Control system MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 4 of 23 1 INTRODUCTION 1 1 PURPOSE The purpose of this document is to form the basis for detail des
58. a motor and the motor is interconnected by a shaft and a coupling to the pump shaft of the clean system This system is called Hydraulic Power Unit HPU The fluid that runs in the HPU system depends of what kind of system the tool e g a hydraulic hot stabs is specified to operate with It is usually specified oil and can be mineral oil as well as water based oil Tellus 32 oil Viscosity 32 sST Density 900 kg m Clean Fluids The main reason to use mineral oil is to make XT stay subsea for 20 years To meet these demanding conditions there are strict requirements for these systems and where especially the solenoid valves demands clean fluid To avoid problems as bacteria growth inside the control units a mineral oil are demanded There are several different types of mineral oil that varies due to supplier of the XT typically mineral fluid frequently used is Oceanic HW443 25 Shell 2008 54 Ba 19 qeis 10H SMOUEA MOJ4 seg LOT DINSSDIS SMOUEA 2011 seg 02 NSS 001 anbsoy wd ag xe MOa 4eg 02 saunssaug pue 103e nde wd Gt mold seg LO NSS Hydraulic Schematics 7 1 NOY NIN OISIA ur P9389 19 sogeuroauosg gp IMZA CM e m 9 Ge Pny uea TL kee GH te mm m m m in GET 10yesuaduo gt a G IE un v to as ma TEN AUR AUR VIS an un zeny ten zm rem em tm Wd S6 Xe 0011 109 OSZ xeui ounssaag fidH 1591 AOH N
59. ab 18 Table 5 Measurements of Sylinderteknikk cylinders source 7 eese 19 XII Table 6 System requirements needed to meet FMC customers gees 20 Table T Into Gk EE 22 Table 8 AT6082 T6 material features oie Egeter eege 24 Table 9 Important capabilities for Syntactic Foam sse 25 Table 10 Square Profile measurements in millimeters MN eene 28 Table 11 presents some different bolt assemblies none of them suited for RITS 30 Table 12 All tables is stress and deformation analysis of structure eese 36 Table 13 An overview of which cassettes and the use of elements esses 39 Table 14 Standard Cassette type 1 weights ed ea I etaed AeEee 40 Table 15 Weight of all the components and the total weight of the torque cassette 42 Table 16 Weight of all the components and the total weight in the cylinder stab cassette 43 Table 17 Weight of the components and the total weight of the cassette s 44 Table 18 Weight of all the components and the total weight if the cassette 46 Table 19 Weight of all the components and the total weight if the cassette 47 Table 20 Datator Titan EE 49 Table 21 Kinematics for Titan 4 6 revolute joints and joint lengths ooonnoccnnncccinncccnnnncn n 50 Table 22 Abili
60. al if the advantage of a rigid position subsea will regain the cost of the tools 89 Chapter Fourteen Conclusion The focus area of this thesis was the design of a ROV tool that could improve the working situation subsea The technological challenges have all been solved and there have not been found any reason to believe that the unit should not work as intended There are however found two elements that determine the plans of further development e The high RITS costs must provide high return on the investment by more efficient subsea operations e Testing of the docking solution must prove a ridged solid and fixed stand making it possible to use robotics in an efficient way The conclusion is simply there is no theoretical reason that RITS will fail but it requires extensive testing and a thorough evaluation of the cost aspect concerning the design 90 Bibliography B Jahnsen 2013 Subsea Wells Worldwide Asker B Jahnsen DIAB Group 2013 Meterial Solution for buoyancy insulation and impact protection for subsea applications Sweden DIAB Group DIAB Group 2014 Syntactic Foam meet specific deoth and buoyancy down to 10 000 meters Online Available at http www diabgroup com en GB Products and services Core Material S yntactic Accessed 15 February 2014 DnV 2011 Portable Offshore Units 2 7 3 ed Oslo Det Norske Veritas FMC Technologies 2002 1 2 175 Gate Valve Kongsberg F
61. all has provided a bypass system that opens when the flow cannot pass true the filter The contingency system for the locking dogs makes sure that the RITS always will be able to disconnect and turn back topside to clean the filter without expose the system for danger This contingency system and a regularly access of maintenance makes the bypass system unnecessary To reduce the risk of clogged filter it will be cleaned regularly maybe as often as between every RITS operation Bypass valve Full flow low inertia bypass valve mounted in the filter head between inlet and outlet port Operation is independent of clogging indicator Instant response to limit AP across element during cold starts and flow surges Fluid flow clear of the element when in bypass mode Fully supported element construction for out to in flow High collapse strength and filtration integrity Uniform diffused flow Ultipor H elements Ultipor III filter media Unique composite structure Graded pore construction Po inert inorganic fibres with Ga corrosion protected steel 969 endcap and core Gei Removal ratings 20 2 5 5 7 12 and 22 Gei micrometres where 21000 o to ISO 16889 ac aes Optional visual and electrical differential pressure indicating devices Accurate and reliable indication of the need for element service Sampling port Sampling via the differential pressure indicator port for sampling withou
62. analysis software which calculates the actual forces on the structure To be able to put the forces on the correct position there is added small areas to the model These small areas make ANSYS over analyze It results in greater forces than what actually appears The figure below illustrates the problem Red areas are the max forces The calculation calculate a pressure of 242 81 MPa yet the stress areas are connected the point where the forces are put To be sure that the calculation is correct the results was controlled by manual calculations It is a static calculation and is W 7600 mm Johannesen 2002 L the length from the elements fastening to where the force are applied P t w P P may typical be P but it will vary from case to case due to the actual situation The manual calculations revealed that the high values appeared on the units created to fasten the force The tags added the hot spot is the actual max force controlled manually and combined with the analysis in ANSYS 98 Appendix C Visual Components Programming Python script from vcPythonKinematics import import vcMatrix import vcVector from math import import numpy as np Define the amount of joints and their names JOINT COUNT 6 JOINT NAMES III J2 J3 J4 J5 J6 qh np array 0 0 0 0 0 0 print qh global FirstCall DH_PARAMS global LO1X L01Z L12X L23X L34X L45X L56X Firs
63. andardized aluminum 6082 T6 profile size The tools inside the RITS will be installed with customized cassettes designed to slide to the operating position The cassettes will be guided on traces in the structure and square profiles will make this guiding easier Table 10 Square Profile measurements in millimeters MN Properties Metric Values Aluminum area 2 91 cc Illustration of profile Inner area 0 001963 mm WEE per meter 7 86 kg m wo per meter 6 1308 kg m E Pressure capacity E depth rating unlimited as long there are holes in the profile Areal Moment 7600 mm The strength of the structure can be calculated by use of NX and ANSYS If the profile should be too weak a second solution of the same profile is presented Square profile 50x50x3 Frame filled with buoyancy Syntactic Foam A profile filled with buoyancy syntactic foam will create a sandwich effect between the upper and lower part of the profile This kind of profiles is known for being very strong Syntactic foam inside the profile makes the structure lighter The choice between the two profiles will be determined in chapter 10 1 Buoyancy due to need for buoyancy elements Syntactic foam may solve the issue by filling the profile however from an economical point of view it is not ideal since the process of filling a structure with foam increases the cost 17 Smith Stal 2014 dd Johannesen 2
64. ated enclosure at an external ambient pressure of 300 bar An external pressure gauge shall be supplied to monitor the compensation pressure The hydraulic valves and components selected for the valve pack shall be standard off the shelf catalogue items from a generally recognised manufacturer and available on a world wide basis The preferred vendor is Wandfluh but functionally equivalent components from other vendors are acceptable An embedded controller shall control the various hydraulic valves and collect data from sensors installed in the valve pack and sensors located external to the valve pack T O Type Quantity Application Digital PWM Out 28 Hydraulic valve solenoid or proportional valve control Digital In 1 Electric Can connected a Communication Distribution Board 0 Water Ingress Detection installed in valve pack Pressure sensor Analogue Input 4 16 mA supply pressure HPU analogue input supply pressure and HPU return pressure Speed Sensor O A In motor pump In motor pump shaft 4 16mA 4 16mA 9 10 11 Interface circuitry shall be included to provide current drive for the hydraulic valve solenoids and the proportional valve solenoids The electrical power available for the controller and drive electronics is 24 VDC at 15 Amps The drive circuitry shall be capable of simultaneously driving 10 solenoid coils without overload Interface circuitry shall be included to provide power to the pressure
65. be consumed when the hot stabs overrides subsea valves By evaluating the most common valves used for subsea installations it is possible to calculate a dimensioning volume Table 23 Summary over consumption of fluids required to operate override a system Component MI cut Explanation Source Displacement Kiot 0 No consumption of fluids to run a motor since all the fluid will be flowing back to RITS o Displacement volume for override different volume 33 YY SPOL between each side of the piston Displacement volume for override different volume 34 a Nave POL between each side of the piston Displacement volume for override different volume 35 T Vale inn between each side of the piston the displacement volume for an actuator is often the difference of the actuator stem on the stem side of the piston In an override situation the return fluid will flow into RITS and the only fluid consumption is the volume of the stem on stem side of the cylinder One of the subsea installations RITS will handle is the Riserless Light Well Intervention stack RLWI Stack For the RITS the capacity of this operation is used to calculate the capacity The RLWI stack has two 7 valves four 2 valves and two 1 2 valves In addition some spare compensator volume is added to handle e g failures that cause leakages etc a 7 valve will flush 7 4 liters 33 FMC Technologies 2002 FMC Technologies 2006 35
66. be fully balanced in air The launching system of the ROV is assumed strong enough to handle this imbalance or special lifting sling will be designed for each project A lifting sling will by use of different lengths be able to neutralize the imbalance of the skid in air during transportation Figure 80 How to adjust CoG MN 83 Chapter Eleven Interface to the ROV The ROVs are normally capable to adjust the fastening interfaces as long as the interface guide rod is of standard size The interface used on the RITS is the same as used on the CAT12 that is a new intervention skid under development The ROV will be guided on the top of the guide rods On the upper part of the guide rod there is a hole A pin inside the ROV will be thread inside this hole and keep the RITS fastened This is performed topside om Ob 1 1 SEE DETAIL 588 6 SEE DETAIL B Figure 81 Examples of bolts CAD12 FMC The bolts are quite large compared with the aluminum elements in the structure It requires a platform to mount the fastening guiding rods The guiding rods is defined as lifting point of the skid which results in a new calculation from DnV 2 7 3 to confirm that the structure are strong enough Figure 82 Fastening Rods 84 The guiding rods will be checked due to the force needed to handle the RITS during operation DnV 2 7 3 chapter 3 5 require a safety
67. creasing temperatura Assumed air volume at surface Max volume reduction by decreasing temperature 0 09 dm3 Total deka volume Assumed ai volume at surface 0 05 dm3 Theoretical volume 055 and Theoretical volume 0 14 dm3 Recommended safety factor 1 50 Recommended safety factor 1 50 RECOMMENDED COMPENSATOR VOLUME 5 86 dm3 tres 0 83 dm3 tres FOR RETURN LINE COMPENSATOR RECOMMENDED COMPENSATOR VOLUME 0 21 dm3 pres Figure 55 Explanation of compensator volume estimation Excel appendix C MN Kystdesign 61 The Excel Sheet in figure 55 shows the compensator volume calculation By implementing the cylinder data it is possible to calculate the difference in fluid consumed for the cylinder when it is pulled in versus pulled out The calculation is made in an Excel datasheet which is added in the source list The result reveals a required compensator volume of 5 85 liters Kystdesign has a compensator of 6 liters active volume which fits the demands for the RITS 6 liter compensator Length w sensor 588 mm Width 0246mm Weight air 11 3 kg Weight water estimated 7 2 kg Material POM Figure 56 Data and picture of the compensator Source 28 7 2 3 Valve Pack 2 valve pack for the dirty system Since RITS consists of two separate hydraulic systems it contains two valve packs To make the system less complicated it has been decided that each system will have its own valve pack to avoid contaminat
68. d both in air and in water with valve pack and compensator filled with oil Correct marking of the equipment Correct marking of individual components piping cables and terminal blocks 6 2 SYSTEM QUALIFICATION The System Qualification of the ROV Deployed ICS shall consist of two system tests e System Test ST on land e Shallow Water Test SWT Both tests shall be carried out in accordance with the Client s requirements and written procedures approved by FKS if applicable 7 DOCUMENTATION The Document Schedule shall be an appendix to the purchase order 7 4 INTERMEDIATE DOCUMENTATION FROM SUPPLIER TO CLIENT The equipment supplier shall make the following documentation available to the client throughout the course of the project Order Confirmation Execution plan General assembly drawings The drawings and documents shall include parts lists envelope dimensions and interface information Factory acceptance test procedures MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 22 of 23 7 2 FINAL DOCUMENTATION The following documents shall be submitted to the client subsequent to delivery of the equipment in accordance with the document schedule General Arrangement GA drawings Piping and Instrumentation diagrams P amp ID Interconnection diagrams Wiring diagrams Hydraulic schematics Component list Spare parts list Detail drawings necessary to sho
69. d the special tools The tools in the cassettes will be protected inside RITS during transportation subsea and a cylinder will activate the cassette by push it in operational position This chapter will explain the cylinders that activate the tool cassettes and a brief explanation of the special tools inside the cassettes 3 4 Cylinders RITS need three cylinders to be able to activate all three cassettes It is important that the cylinder can withstand the design depth determined to be 2000 meters depth Hydraulic cylinders exist in all sizes A combination of available space and need of strength will determine which type of cylinder that is applicable for RITS The diameter of the piston and the hydraulic pressure acting on the piston determines the strength of the cylinder It means that the needed force can be important when determining the cylinder size however it is preferable to use a small cylinder to reduce the weight of the skid The required strength for the cassette cylinders in RITS is limited Their only purpose is to push the cassettes in addition to withstand the forces applied when RITS connects the interface bucket The idea is to design the skid with a lock mechanism that will reduce the forces on the cylinder when connected It decreases the demands for strengths which reduce the size of the cylinder The cylinder shall handle the friction between cassette and structure while the locking mechanism should
70. e breaking point of what is manageable on deck even by use of lifts The total weight of 600 kg should not be a problem since the lifts handling the ROV during the launching process are strong RITS will not increase the weight of the complete unit more than approximately 10 20 It means that the handling and launching of the ROV will not be changed significantly whether RITS is carried or not It is the behavior in water that is the uncertain part of this design The whole system weighs less than 50kg in water and RITS is designed to allow the ROV thrusters to operate freely The ROV with RITS attached should behave well still the behavior of RITS will need testing The testing of RITS behavior in water may be conducted simultaneously as the testing of the docking solution The theory indicates that the system as it is designed should work as intended As many of the challenges regarding RITS are solved there have never been set any cost limitations in this project The advantage of systems built without cost limitations is that they usually will work but they will also be expensive It all comes down to evaluating the price up against the cost savings RITS will provide by making the subsea work more efficient There is no doubt that the capabilities of RITS are useful easy access of tools and supplier handled manipulator The cost of the tools is on the other hand quite high especially the manipulator A pilot version of RITS will reve
71. e locking dog system will activate the dogs in all three interface receptacles however if one of the cassettes are installed without API 17D interface the hydraulic line will be installed with a blind flange This blind flange is mounted topside when the cassette configuration is installed Lower panel controls valve pack one DC1 DC9 in table 25 The switches will open a supply line and a return line in one of the hot stabs Which one is depending of what the operator want It will be tested onboard of the vessel to avoid wrong couplings etc Sensor panel upper right panel is installed to be able to monitor the system There are important to know the status inside the skid when it is in operation In addition to prevent damage it may reveal the reason for any malfunction The RITS and the tools are expensive and therefore a panel showing the system status will be required to manage a safe and secure operation 9 1 Sensors The numbers of sensors that are required inside RITS are limited In addition to monitor the level in the compensators it is important to know the pressure on both sides of the hydraulic system dirty and clean The flow is also an important factor to monitor and the motor has an opportunity to install a shaft speed transducer This makes it possible to calculate the flow on both sides of the hydraulic system The last transducer that is required is a temperature transducer to make sure that the motor will not break
72. ecided by the size of the smallest ROV The skid should not be bigger than the smallest ROV allows because it will increase the chance of hits towards the structure The shortest and less wide ROVs are market in table 1 and result in a skid footprint size of 1550 x 2700 mm 300 mm is added to the length to make space for the manipulator The skid will be mounted under the ROV with the risk of being exposed to hits from under The skid height needs to have enough space for the tool package all the special tools are installed inside an API 17D interface receptacle It is assumed that the tools do not need any more space than the interface receptacle To be on a safe side a few millimeters are added to reduce potential complications later on The dimensional tool height is determined to be 250mm and the skid structure will build 50mm on both the lower and upper frame This gives a total height of 350mm The skid s outer frame dimensions is 1550x2700x350mm Figure 24 The Structure of RITS MN 32 4 6 Strength of structure There is important to verify that RITS are solid enough to operate subsea and can handle the impact load while the ROV will park upon existing subsea equipment This calculation will be performed in ANSYS by use of the 3D model presented in chapter 4 5 RITS is built by 50x50x3 profiled aluminum 6082 T6 and the model created is fully compatible for a strengthen analysis in ANSYS The CAD software needs material stre
73. ed senor on the shaft between the motor and the pump There is installed three pressure sensors in the system on the motor supply line on the pump supply line and the pump return line de P See 4 M d r Figure 4 model of RITS MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 12 of 23 vorrma 3 3 HYDRAULIC SYSTEM The hydraulic system design shall include all the components necessary to operate the various subsystems The hydraulic system will incorporate the following design requirements Hydraulic supply to RITS Design pressures above ambient for hydraulic system Supply pressure 207 bar 3 000 psi Maximum working pressure WP 207 bar 3 000 psi Test pressure 1 5 x WP 310 bar 4 500 psi Maximum flow at working pressure 20 LPM 5 3 USGM Fluid ROV Tellus VG22 or equal Hydraulic Power Unit Powered by the Parker F1 1 10 motor pump unit separate fluid from RITS Hydraulic fluid Mineral Oil Transeoacic or equal Cleanliness requirement NAS 1638 Class depending off operated system Supply pressure 207 bar Maximum flow at working pressure 18 6 bar Hydraulic interface 6L Hot Stab Number of hot stabs possible 3 at the time normally less Manipulator Torque Tool Hot Stab 6L Hot Stab 6 L Figure 3 Hydraulic Schematics MIC Technologies Doc no SPC 000003147
74. eft side is put on Then the circulation will turn the other way and close the cylinder Electricity applied on Solenoid closed right side and cylinder Return Li Return Line In Line In Line Figure 49 4 3 Solenoid valves spring loaded MN 56 4 3 solenoid valve A 4 3 solenoid valve means a valve with 4 ports that has 3 different position like the solenoids presented in figure 49 This kind of solenoid is suited to handle double acting cylinders and hot stabs Wandfluh BM4D32 G24 M55 M35 is the solenoid valve that will be used inside RITS It is a 4 3 spring electric valve In the normal position like it is drawn in the schematics it is closed but if an electric voltage is applied the valve switches over and a circulation starts If power is lost the springs will force the valve back to closed position It is a contingency mode and the hydraulic flow stops A simplified version of the BM4D32 G24 M55 M35 is used for the locking dogs This kind of valve is a 4 2 spring solenoid valve The 4 2 solenoid valve is used in situations where there are no need to change the direction of the flow The spring inside the locking dog cylinder will force the locking dog back Solenoid operated spool valve 4 2 way impulse valve e 4 3 way with spring centred mid position NG3 Mini 4 2 way with spring reset Qaa 15 l min p 350 bar max Figure 50 Picture of solenoid valve Solenoid operated sp
75. en apner et marked av nye potensielle l sninger hvor blant annet forh ndsprogrammerte manipulatorer vil forbedre undervannsarbeidet Roboteknikk gj r dette mulig og er et verkt y som er mye brukt i landindustrien Mangelen pa faste punkter har f rt til at roboteknikk har vert lite brukt under vann Med den nye oppkoblingsmetoden kan derimot roboteknikk tas i bruk ogsa i undervannsbransjen og et eksempel pa hvordan dette kan gj res er vist i oppgaven En manipulator krever et hydraulisk system Slike systemer kan enkelt oppjusteres til a handtere flere komponenter De hydrauliske systemene krever kontrollenheter koblet til en skjerm om bord i fart yet p havoverflaten Siden disse systemene allerede er laget kan andre undervannsverktgy ogs installeres i RITS Verktgyene plasseres i standardiserte kassetter RITS vil kunne h ndtere tre kassetter av gangen mens det finnes fem forskjellige alternativer n r det kommer til kasser Kunden velger de kassettene som passer best for den planlagte operasjonen RITS inneholder et HPU system som muliggj r bruk av en Hot Stab som er et viktig verkt y under vann Studien viser at teknologien som far kassetter manipulator og HPU system til a virke er tilfredsstillende Det er ingen grunn til tro at RITS ikke skulle fungere Likevel er tilkoblingsmetoden og RITS sine bevegelse i vann upr vd Skulle testene av disse to tingene v re tilfredsstillende er all annen dokumentasjon klargjort og RITS
76. enging to operate subsea units because of poor 2D 87 visibility and movement in the sea These troubling working conditions cause longer operations which results in higher costs Since the ROV is the only component that can operate on 2000 meters depth it leads to a stressful situation for the ROV operators It would be an advantage that the operation could be performed in a non stressful situation RITS will be able to provide a solution that makes this possible Visual Components illustrates how easy it is to pre program the manipulator By using the simulation mode integrated in the HMI a safe and controlled operation can be tested before the ROV is subsea To be certain that the system operates as intended it is possible to make a preview test on a test stand onshore Compared with the present subsea operation RITS will require more planning The industry is used to dealing with problems as they appear whereas RITS needs to identify the problems before the ROV goes subsea The process of implementing this in an already established and conservative industry may be difficult however the benefits of planned work would gain profit for the suppliers since the operation will be more efficient If something unexpected should happen RITS will be able to control the manipulator manually It will function as a contingency solution if anything should happen in addition to involving the supplier of subsea equipment to a greater extent It bene
77. er 5 2 1 The weight and volume measurements of all cassettes are performed in NX the buoyancy is calculated in Excel Different mounting system The two different cassette types have different methods for mountening the cylinders and for fastening to RITS Cassette type one is fastened on the mounting ears in front of RITS This is because type one cassettes will be exposed to the impact load when the ROV parks RITS The second cassette type does not have the same requirements due to strength and they will not be functional unless the cylinder is mounted in the opposit direction chapter 5 4 38 5 2 1 Cassette Buoyancy The areas in front of the structure where the cassettes are installed will prevent too much variation of the center of gravity CoG The calculation of buoyancy is the volume of the elements multiplied with the floating capacity of syntactic foam the volume is measured in NX while the calculation is performed in excel a document added the source list The dedicated elements are located over and under the structure in the front The right combination of these three alternatives will make the cassettes equally weighted Figure 30 The buoyancy elements dedicated the cassettes MN Bouyancy elements for cassettes in structure Space for one of dices per caselia tdecrenee tie weight by 4 7kgl p A Weight in air 4 4 kg Space for two of these per cassette decrease the weight by 2 2 kg each Weight
78. erface Handbook Design Guidelines 1st A ed Kongsberg FMC Technologies Schilling Robotics 2012 Schilling Robotics Titan 4 Manipulator System Position Controlled 4 Km Submersible 2nd rev B ed Davis CA FMC Technologies Shell 2008 Shell Tellus Oil S 32 Oslo EcoOnline Smith Stal 2014 Lagerkatalog page 66 Online Available at http www smithstal no SmithStaal Produkter lagerkatalog smithstal no pdf Accessed 15 Mars 2014 Subsea 7 2013 Demon Online Available at http www interventiontechnology com pt cms user_files File RO Vs demon pdf Accessed 6 September 2013 93 Subsea 7 2013 Diablo Online Available at http www interventiontechnology com pt cms user_files File ROVs diablo pdf Accessed 6 September 2013 Subsea 7 2013 Hercules Online Available at http www interventiontechnology com en cms user_files File ROVs Hercules 28 1 29 pdf Accessed 6 September 2013 Technologies F E 2013 Forum Energy Technology Online Available at http www f e t com our_products_technologies subsea solutions rovs work class Accessed 6 September 2013 Wandfluh AG 2012 Pressure Relief Valve Screw in Cartridge Frutigen Wandfluh Wandfluh 2006 NG3 Mini Fruitgen Wandfluh 94 Appendices Appendix A Hot Stab A hot stab is a hydraulic interface tool with many ports Each port has its own piping and control solenoid valve which is connected the
79. esults in control systems and two hydraulic systems however both systems are operated from the same HMI MIC Technologies Doc no SPC 0000031472 Version 2 3 00 Revision Page no 8 of 23 SPECIFIC REQUIREMENTS 2 3 1 Subsea System Requirements The requirements of the subsea components of RITS are as follows 1 2 3 4 5 6 7 8 9 10 11 RITS shall be launched and deployed by Work Class RON WROV The skid shall be made neutrally buoyant in seawater by means of removable buoyancy elements And with a weight in water less than 50 kg RITS shall be transportable in the water at the maximum operating depth on 3000 meters RITS shall be powered from the ROV with control signals routed from the surface via the ROV control system The electrical and hydraulic interfaces shall be industry standard and compatible with a WROV The RITS structure shall provide the mechanical interface for mounting the RITS beneath the WROV The structure shall be compatible with the common WROV systems in current use The mounting system shall have a flex system to decrease the impact load The interfaces shall be industry standard API 17 D size 1 4 Special intervention tools shall fit inside the API 17D size 1 4 interface includes hot stab ol and Torque Tool tool tray will have a separate system The Intervention Tool inside shall be powered from the ROV s auxiliary valve pack The hydrau
80. etermined by the weight of the structure and the tool in addition to standard buoyancy elements It results in an extra cassette buoyancy alternative is implemented that reduces the weight in water by 10 9 kg 42 Cylinder Stab Cassette The cylinder stab cassette is a custom made solution where the hot stab is installed inside an API 17D interface It requires a special design of the hot stab interface on the subsea installation The system works by using an extra cylinder that can push an extended hot stab through the API receptacle A guiding system with a rail and tractor is integrated in the cassette to secure a proper guiding POM Rail Weight air 3 4 kg Weight water 1 kg Aluminum Train Weight air 1 2 kg Weight water 0 8 kg Weight air 8 5 k zB AVR Weight air 5 5 kg Weight water 4 5 79 API 17D interface 5kg Weight water 5 3 kg Modified Hot Stab increasted length kg ao a Cylinder stroke length 182mm Weight air 5 kg Weight water 2 5 kg Figure 36 The Cylinder Stab Cassette with all the extra components making it work MN The components needed to push the hot stab makes this unit similarly weighted as the torque cassette The structure is a bit modified which results in a higher weight in addition it results in a lower buoyancy effect By using extra buoyancy calculated in chapter 5 2 1 it is possible to lower the weight in water to 2 4 kg which is app
81. fits the subsea industry with improved cooperation between the ROV providers and the equipment suppliers The suppliers will be able to design a more ROV friendly unit which will result in a safer and more efficient subsea operation To be able to design improved systems there should not be an obstacle that the special tools are hard to provide The hydraulic control system inside RITS will be able to handle several different kinds of special tools by using conventional technology which makes it possible to create standard size tool cassettes The use of the tool cassettes requires strict working procedures by the ROV operator It is a more complicated operation than to just pick up the tool and put it into the interface however the present solution does not either provide easy access of tools Normally it requires a longer travel to the surface or to a tool basket on the seabed to pick up the right tools The improved access to the tools provided in RITS would make those trips unnecessary In order to maintain the flexibility RITS is designed in a way that it also allows handling of tools in the normal way handling of lose tools 88 At this point RITS seems like a unit without disadvantages however there is one issue that is not in favor of RITS All the features in RITS require space and thereby increase the weight of the ROV when a RITS is carried The heaviest cassette is the torque cassette with a weight of 63 kg It is on th
82. g dog assembly Source Al 11 Figure 11 The spring loaded locking dog pin MN eee 11 Figure 12 Simplified how the Cylinder works Source ol 14 IX Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Cylinder with two fastening rings source 6 ooooonnconnnccnonoconcnonancnoncnononananona corn ncnnos 14 Solution for mounting of cylinder beneath the structure MN 15 Guiding system of POM MN ico rite Seege O ee 16 Locking cylinder for the cassettes IMNT AA 16 Locking mechanism for the cassettes TMNT AAA 17 The cylinder used m RITS MN Tacita qe tanen nep aer erroe Po do bind 19 Torque Tool with ROV handle id A at 20 A 6 Line Hot Stab both inside and outside Source 10 21 An extended hot stab customized to fit inside an API 17D MN and Source 10 21 Examples of syntactic foam source 14 eren eren eerte etn nnn 25 Example of a skid structure MN etit ien eerta Pee tete ent n bagno donan rede 29 The Structure o RIES MN 5i iei ee eoe eee tere eer tee eret er eoe e ee te etel ences 32 Horizontal Impact Load and impact position Case 1 MN
83. ges however they usually are expensive The cheapest material commonly used for equipment in similar environment as RITS is Aluminum 6082 T6 This chapter explains the material choices for the structure Further different solutions for how to assemble the structure are discussed 4 1 RITS material choice Steel is a normal choice of material because of the strength and the experience from many other subsea projects There is a design goal to keep RITS as small as possible to make the ROV moveable Steel is heavy which require more buoyancy elements to make RITS neutral in water Buoyancy elements are quite big and exclude the steel solution since it will increase the size of RITS 23 Al 6086 T6 is an aluminum quality commonly used for equipment moved up and down in the sea The prices are acceptable and the strength is within the wanted range Table 8 Al 6082 T6 material features Properties Metric Values Density 2 1 g cc Hardness Vickers 95 Tensile Strength Yield Wall thickness less than 5mm LL Tensile Strength Ultimate Wall thickness less than 5mm ane Thermal Conductivity 170 W m K Aluminum meets the design requirements to RITS Aluminum is ranked low in the galvanic series which makes it vulnerable for galvanic corrosion connected to most other metals An advantage with RITS is easy access for maintenance and an objective is to create RITS into a structure that easily can be changed
84. gth is the 30 cylinder aredyiston X pressurey Strength of Cylinderarial direction II x 0 0152 x 207 x 10 14 625 N Using POM guiding and the locking mechanism for the cassettes the cylinder of 030 is strong enough The capacity of the cylinder is that strong that there is no point of calculate the friction The friction will be reduced because of the guiding system however the cylinder is strong enough to relive the cassettes locking mechanism when the impact force appears 3 5 Cylinder Lengths RITS will need four cylinders to be able to perform the task it is designed for Three of the cylinders will be installed to push the cassettes into operational mode and back to transport mode The last cylinder is needed for the cylinder stab cassette Common for all cylinders is the limited stroke lengths which are restricted to push the length of the interface 181mm given in figure 7 measurements of the interface receptacle Table 4 Cylinder lengths A length 25mm Stroke OD outer IN Total Length of stem length diameter Diameter length Tray Cylinder 203 mm 181 mm 040 50 030 384mm Hot Stab Cylinder 203mm 181 mm 040 50 030 384mm Extra length to customize the cylinder for subsea use ref Terje Grimsrud Sylinderteknikk 18 3 5 1 The RITS cylinders 30 35 40 253 E 5 m n EE NNNM NEN NEN NE o pas pro os mmm COR mm PCS 035 030 S 040 nm 025
85. h needed is 200 mm which is the length the cassettes will move x Min Diameter outer 1155mm 200mm 2n x 5 431mm The figure shows the principle to achieve flexible hydraulic lines By letting the hose move freely between the guiding walls the hose will be able to move 200 mm without any stretching The stiffness in the hose will ensure a controlled movement which means that the hose will increase or decrease it diameter in a secure way The guiding system will be installed in an enclosure built up of two gratings and side Figure 42 Example of guiding walls where the hose freely may move and bend The hose will system of flex hoses 200mm MN be protected with an outer wear protection from TESS Figure 43 Guiding of the hoses will be arranged between two gratings MN 2 Foss 2014 and TESS catalogue 2014 48 Chapter Six Manipulator Titan 4 is a recommended manipulator from Schilling Robotics Schilling Robotics is the main supplier of manipulators for the subsea industry and the Titan 4 is their most successful invention The control unit is inside the manipulator it only require power and signal cables connected to be able to operate Titan 4 is the natural choice of manipulator for the RITS Mechanical Data Length 1922mm Width Diameter Weight in Air 100 kg Weight in Water 78 kg Hydraulic Data Pressure 207 Bar Flow 19 Ipm Fluid
86. handle the parking forces As a result small cylinders will be strong enough for RITS and results in the desired low constructional weight 12 Pneumatic cylinder In an attempt to reduce the weight of the construction an idea of using a pneumatic cylinder was presented Since there is no pneumatic system in the RITS system the idea was to fill the pneumatic cylinder with oil The idea was rejected pretty fast since there are very strict requirements for subsea cylinders and reconstruct and re certificate a pneumatic cylinder to be operated with oil as a hydraulic cylinder would be very demanding Pneumatic cylinders have stricter requirements as the compressed gas will have explosive behavior Additionally they operate with a working pressure less than 30 bar which result in need to fine tune pressures by a few bars Cylinders in RITS should be reliable and robust and Sylinderteknikk warned for mechanical problems if the design was dependent controlling with of fine tuned pressures Hydraulic cylinder The hydraulic cylinders are commonly used subsea as hydraulic units are reliable and powerful The cylinder needs to operate on the same fluid as the rest of the components These components are operating on oil To avoid complications with the fluids and pressure it is natural to pick a hydraulic cylinder for the cassettes The main reason to seek other solutions than hydraulic cylinders was the concern regarding weight The req
87. he cassette will be able to open and the manipulator can pick out the tools inside Figure 38 Direction of cylinder due to cassette type MN A simple solution is to mount the cylinder on the mounting ears behind the cassette The tool carriers will merely bring tools subsea and are not designed to handle any impact loads because they do not have any API interface As a result the Cylinder Position presented in chapter 3 1 3 will not apply for cassette type two RITS are designed with two different tool carriers and there is not possible to create a standard cassette structure or buoyancy profile The cassette structure will nevertheless be filled with as much syntactic foam as possible 45 The tool Cassette Structure w buoyancy Weight of cassette structure Buoancy Volume Figure 39 Weight of the components and the total weight of the tool cassette MN The tool cassettes have a unique and simple design which is suited for this cassette only The aluminum structure is heavier than the other cassettes since there is no need for hole to make the API 17D interface fit however it is partly compensated with more space for buoyancy There is no tooling other than the structure itself The cassette weight is 1 kg in water Table 18 Weight of all the components and the total weight if the cassette Free Stab Cassette Structure w buoyancy Figure 40 Free stab cassette MN Weight i
88. he most common method to assemble a structure is by welding As the bolt assemblies were found inappropriate welding came out as the most ideal assembly method A welded structure allows an easier fastening of profiles perpendicular on each other The welds are solid and usually stronger than the material in the elements The welding will additionally provide a more adjustable geometry than a bolted connection since it is easier to fasten welded elements in any direction Many details on the structure in addition to joining the elements require welding It is details as fastening of the cylinder and mounting of the instruments inside RITS Non destructive tests NDT of all the welded joints are required to control that the welds are properly made The NDT methods for weld joints are x ray or ultrasound and the documentation that follow welded joints are more complicated than for a bolt connection The documentation is considered a disadvantage of welding since it requires a welding procedure which is developed by FMC and the operator welding RITS When the documentation procedure is developed it can be used for all welds which make the process smoother Welding of aluminum require another technique than for steel which must be documented through a separate procedure Except for that welding of aluminum elements is not considered a problem 31 4 5 Outer Dimensions of RITS The footprint length and width of the structure is d
89. ic components cleanliness check e External pressure test of the control system components e Functional test of all the tool functions This test shall be carried out several times to verify acceptable design requirements e Final inspection to verify dimensional tolerances and weight etc The hydraulic systems on RITS shall be pressure tested to 1 5 x design pressure The acceptance criteria for the pressure test shall be a maximum 2 pressure drop over 15 minutes under stable temperature conditions The equipment supplier shall provide documentation to verify the fluid cleanliness level of the hydraulic system equal or better than that specified above at the time of delivery The subsea controller enclosure and a minimum of five solenoid valves shall be tested for correct operation at an external test pressure of 200 bar A successful test shall be accomplished by documenting correct operation of the electronics during cycling of the external pressure from 0 to 200 bar 10 times During the last cycle the pressure shall be maintained for a minimum period of 10 hours Correct operation of the solenoids shall be determined by reading the input to the subsea controller MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 21 of 23 The following shall be checked during the final inspection e External and internal dimensions e Interface dimensions e Weight data Parts to be used subsea shall be weighe
90. ign fabrication and testing of the ROV Intervention Tool Skid RITS The purpose of the RITS is to improve ROV intervention assignments Installation testing and retrieval of subsea equipment depending of intervention tools are the main aim for RITS RITS is intended to reduce the ROV operational time consumption by improving the working condition without reducing the present flexibility This specification will provide the information and requirements necessary for the detailed design and manufacture of the system The vendor is encouraged to propose alternative solutions to those specified in this document if these can be justified on the basis of improved functionality or can be shown to contribute to a more cost effective solution It is expected that any changes proposed be fully justified and must satisfy the functional requirements established in this specification 1 2 SCOPE This document provides the requirements and design data for the RITS The scope of this document is to define the following e System Requirements e Functional Requirements e Interface Requirements Material Selection and Corrosion Protection e Documentation e Outline Operational Procedures FP MC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 5 of 23 1 3 ABBREVIATIONS The following abbreviations are used in this document DC Direct Current FKS FMC Kongsberg Subsea AS GUI Graphical User Interface HMI H
91. ill be no forces applied at this point 15 3 2 Guiding System POM Polyoxymethylene is a plastic material widely used to protect equipment from dirt and scratches in the subsea industry The RITS project will use POM to reduce the friction between the cassettes and the structure In addition to lower the friction it will secure a proper guiding of the cassettes The combination of a proper guiding and an optimal position of the cylinder will secure a reliable handling of the cassettes POM is a low cost material It is softer than the aluminum which makes the wear and tear to appear on the component easiest to replace The POM will be fastened to the structure by clips or bolts Figure 15 Guiding system of POM MN 3 3 Brackets locking mechanism The most critical situation for the cylinder is the impact forces when the interface receptacle is pushed into the interface bucket To avoid that the cylinder will handle all the forces a locking mechanism for the cassettes is installed There are several different methods to lock a cassette RITS will use a simple and mechanical solution since the manipulator can be programmed to do the locking automatically The system consists of a half cylinder with a handle on top The cylinder allows the cassettes to slide freely in one osition but when the cylinder is turned 90 degrees the P y 8 Figure 16 Locking cylinder for the cassettes cassette will be locked MN
92. ill be designed to operating conditions for wells depths down to 2000 meters The table and graph below provides an overview of all the subsea wells in the world The data is taken from Quest Subsea Database and shows existing and forecasted wells until 2017 wen Development in number of active subsea wells 10 000 4 CAGR for period 2013 2017 is 9000 8567 11 1 pa 8 000 6 000 ECH i _ 2523 2363 E mi 2162 m 2000 m 5 000 tm O 7 1974 J m 1500 2000 m mies a 1695 4000 4 J E 600 1500 m 3362 T 22 1381 90 Ges 1131 T283 TORUM 3000 5 H 1 4 i L L H L 4622 4866 2000 4 H i 3964 4304 3642 3262 2929 3058 2587 2769 1000 2423 I I I 0 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Year Source Quest Subsea Database Feb 2013 Last revision BJ 13 Dec 2013 Figure 4 Graph that illustrates numbers of wells in the world by depth source 1 B Jahnsen 2013 Figure 4 illustrates the depths of the existing and forecasted subsea wells in the world Even if the deep wells seem to increase the main market is wells less than 2000 meters Experiences by FMC engineers show that the expenses of going deeper than 2000 meters usually cost more than it is worth The table below confirms that a design depth on 2000 meters covers more than 90 of the market Table 1 Percentage well less than 2000 meters
93. ing conditions makes the ROV operations difficult This report will present a new tool called RITS ROV Intervention Tool Skid created to simplify these subsea operations The RITS system is developed by utilizing conventional subsea technology only The main idea is to introduce a fixed docking solution It will ensure a rigid and fixed position between the ROV and the ROV panels The docking receptacle an API 17D will secure a completely locked connection to the subsea unit From this rigid position the operator may perform the work without any disturbance of the water flow The locked position provides new opportunities for the ROV it opens for pre programmed control of the manipulator and other tools Robotics technology is frequently used in the onshore industry however lack of fixed positions has previously excluded robotics subsea This is changed by the new docked position and an example of a pre programmed manipulator will be presented as a part of this thesis A manipulator requires a hydraulic system which can be designed to operate more than one manipulator The hydraulic systems are controlled by an embedded control unit connected to a computer with a control screen HMI The extra capacity of the hydraulic system is used to operate special tools which are installed inside cassettes RITS will be able to carry three cassettes at the time and the customer can choose between five cassettes depending of what kind of operation
94. ing of the hoses will be arranged between two gratings MN 48 Measurement of Titan 4 Source 241 50 Kinematics explanation of the robotics MN eene 51 Screen shot of Visual CORDOLDETILS ied Deseo sube pov deeg ien gedd er 52 Simullatedexample E 53 Schematics created in Visio MN 55 4 3 Solenoid valves spring loaded IMNT A 56 Picture of solenoid valve Solenoid operated spool valve 57 Drawing from previous FMC project FMC eene 57 Wandfluh BM4D32 G24 M55 M35 Schematic on the left MN 58 A pressure relief valve Source 20 la da 58 Picture of pall 9050 taken from the datasheet provided from Pall source 29 60 Explanation of compensator volume estimation Excel appendix C MN 61 Data and picture of the compensator Source 28 eese 62 The valve pack two with 5 solenoids IPMCT eere 62 Picture of a F11 Motor Pump Source ii A eases acess 63 Basic formulas for hydraulic motors 00 0 eee ceeseceececeeeeeceeeeeceeeeeceeeecseeeenteeeenaees 64 Volumetric efficiency Sources viii risa 64 Pump formulas from the Parker catalog Source 31 sess 65 Shaft connection between the motor and the pump MN and Source 31 66 Huco multibeam aluminum Source 30 sess 66 Compensators placed in a rack MN and source 201 68 XI
95. ion of the cleanest system The valve pack on Tellus side will handle the solenoids that operate the cylinders The RCU and Titan 4 have integrated hydraulic control system from the suppliers which are connected to a valve pack on Tellus side built up of 4 pcs 4 3 Wandfluh BM4D32 G24 M55 M35 3 pcs are to activate the trays while the last is installed to handle the cylinder stab cassette 1 pcs 4 2 Wandfluh to activate locking dogs in the API 17D Figure 57 The valve pack two with 5 solenoids FMC 62 7 2 4 The hydraulic motor The motor is installed provide the HPU side with power to run a pump to avoid contamination of the clean fluid HPU systems are developed in many different versions where clean fluids are required The HPU system used inside the RITS is custom made for the RITS even if the principle is taken from previous FMC projects One of the most common motors for HPU system in use is the Parker F11 The Parker F11 handles pressure over 207 bars in addition to be able to supply RITS with the needed flow It is a great advantage that it is small and that it is used subsea before Model F11 010 Max Pressure 305 bar Displacement 9 8 cm rev Flow max 110 Bar Max rpm 10200 Max depth used subsea when connected a compensator system Weight in air 7 5kg Weight in water Figure 58 Picture of a F11 Motor Pump Source 31 Parker 2013 63 Determination of the motor size The F11
96. ional mode 1 operation mode 2 operation mode s ES al E The API interface are in operational mode de A lot of forces applied on cylinder l D E emm Li E E all o 6 a The API interface are in transport mode No forces applied on cylinder 1 transport Mode 2 transport mode Figure 14 Solution for mounting of cylinder beneath the structure MN A cylinder is strongest when the stem is pulled inside the cylinder When the stem is pulled fully out it will be exposed for force from the sides As a result there is a risk that the stem will bend It is possible to calculate how much force that can be applied before the stem breaks As figure 14 illustrates will the cylinder be mounted in the opposite direction of what may seem as the natural way to protect the stem The idea is to apply the highest forces on the cylinder when the stem is pulled in as solution number 2 illustrates When the stem is pushed out the interface receptacle is hidden inside RITS and will not be exposed for radial forces In the position with the stem pulled in it is easy to calculate the capacity of the cylinder When the stem is pulled in the there is no need to be concerned about the limited stem capacity which means that full strength of the cylinder can be estimated area of stem multiplied by working pressure It will not be necessary to calculate the capacity of the stem at full stroke since there w
97. is mode mimics the behaviour of the subsea hydraulic controller When connected to the communication link the topside controller will believe that it is talking to the subsea hydraulic controller The user can set the value of simulated limit switches and analogue sensors Commands sent from topside will be visualised in the simulator GUI page e Configuration mode Setting of all the user configurable options I O mapping interlocks scaling etc Settings are downloaded to the surface controller s permanent flash memory Diagnostic mode Display of all raw and scaled values in the system Display of communication error and timeout counters oP VIC Technologies Doc no SPC 0000031472 Version 00 Revision THE 4 INTERFACE REQUIREMENTS The interface towards subsea equipment is an API 17D interface 4 1 1 Mechanical Interface The ROV Interface Frame provides the mechanical interface between the WROV and RITS The Interface Frame s shall be designed for the Work ROV Systems in common use Page no 17 of 23 The Work ROV Systems considered to be suitable for deployment of RITS are listed below WROV HD ROV Schilling UDH ROV Schilling Centurion QX 200 Subsea 7 Centurion QX 300 Subsea 7 ACV Subsea 7 Hercules Subsea 7 Quantum Subsea 7 Diablo Subsea 7 Demon Subsea 7 Magnum Plus Oceaneering Maxximum Oceaneering Millenium Plus Oceaneering Triton XTR Slingsby
98. it HPU and ensure that the fluids are not mixed All the systems inside RITS are dimensioned to handle a pressure of 207 Bar The components are more different when it comes to flow demand The flow represents the speed of action and the unit with the lowest flow capacity will be the dimensioning A result is that some units may become a bit slower yet the work will still be done since the pressure which represents the strength is the same The system will have its own compensator to protect RITS if the compensating system inside the ROV fails A filter is installed as a precaution to avoid unnecessary dirt in the RITS system 7 2 4 Filter As for all the components the external pressure at 2000 meter depth is the first demand to be fulfilled for the filter In addition a 3 micron filter is needs to clean the fluid to meet the manipulator demands Pall Norway recommended a filter called 9050 The filter 9050 can handle pressure from both outside and inside up to 700 bars which is a lot more than needed Pall is a large supplier of subsea filters and is frequently used by FMC for other subsea projects Of standardization reasons within FMC they are the chosen supplier for filters also for RITS 2 Pall Corporation 2002 59 Contingency solution for the filter The filter will after a period of time be filled with dirt and reduce the performance of the RITS If the filter should be clogged between service intervals P
99. klar for operasjon Likevel henger alt p om hovedideen med ny tilkoblingsmetode fungerer godt i virkeligheten Contents IDBIOVIGUDIIS eegene 1 Chapter One Introduction ue ita ta Rad Y Ue dx qo ned a ke cand EE 2 ch et KEE b ct cS 3 LI2 Need tor RUES A dite etae eri tod D dt aa pdt tad 4 1 2 Market for AN KEE 5 1 2 1 Areas in the world have different sea depths see 5 1 2 17 Forecasted Wells tie in and tree on wire 7 1 3 Working class ROVS sccsscavecsceesscceientenyantvsnsuacassaveisaiajenccuaunsces aE EAE EE S 8 Chapter Dwo RITS Interest Ae ade aed diet eee Oates 9 ANE WEA eG e EE 9 E ER E 10 2 3 Lhelocking dOos E EE 11 Chapter Three KEEN 12 AS e op auae pU etui ite nested dea i dum ei mu ea da 12 Sell Double actine Ee aere o teft din 14 3S4 GEN e WEEN 14 39529 A position e dM 15 3 2 Guiding System ii id 16 3 3 Brackets locking MAA aden a da tdi une dus 16 3 4 Boree capacity or the cylind r iocus eto Oque ia 18 3J A O 18 2 3 Ll hedelDs cylinders EE 19 3 6 Torque Tool WEE 20 Suh A Ae e Ae 21 3 7 1 Two hot stab ENEE 22 UE EEN Structure EE 23 Al SEDES material te 23 42 WC OPO STON S o EE 26 AO E EE 27 44 Assembling the structure siii iio atando raise 29 AAT Bolted s ctutes u ia a 29 ADS Welded SUS So 31 43 Quier Dimensions of RIES latin 32 AO Strength SUE ee 33 47 Strength analysis aa di 36 Chapter Five The Cassettes usina 37 SE UModes OLPC al italia 3
100. l 506 5 3 FABRICATION All fabrication installation inspection and DE of structural steel and pressure containing equipment shall be conducted in accordance with NORSOK M CR 101 and M CR 601 5 4 IDENTIFICATION AND TRACEABILITY Identification and traceability shall be conducted in accordance with FKS Document Identification and Traceability F3 5 5 PACKING STORAGE AND PRESERVATION Packing storage and preservation shall be conducted in accordance with FKS Document Standard and Instructions for Packing Protection and Preservation F4 MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 20 of 23 6 TEST REQUIREMENTS RITS shall be subjected to a test programme in order to demonstrate that the design will satisfy all specified requirements and perform satisfactorily in service The test program shall be divided into Unit Qualification and System Qualification as outlined below 6 1 UNIT QUALIFICATION 6 1 1 Factory Acceptance Test The individual components RITS shall be subjected to a Factory Acceptance Test FAT to verify that the equipment complies with the requirements of this specification and the applicable regulations standards and codes The FAT is to be carried out in accordance with written procedures provided by the supplier and approved by FKS The minimum requirements for the FAT are e Pressure test of hydraulic system and components e Flushing of hydraul
101. lic interfaces shall be compatible with the existing interfaces on the subsea equipment with no modifications In situations where the interface does not fit the necessary task will be operated by the manipulator mounted on the RITS In the event of equipment failure the RITS shall be designed with a fail safe open mechanism on the locking dogs on the API connectors and can be retrieved by means of a suitable backup system i e pulled in by the umbilical The RITS shall not be installed with cameras and lights Light and visual will be supplied by the ROV system Facilities shall be provided for emergency lifting of the RITS for recovery to the surface in the event of equipment failure The system shall enable the retrieval installation procedure to be aborted at any stage of the operation in the event of equipment failure Design of the system shall be such that operation with only one WROV MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 9 of 23 2 3 2 Topside System Requirements The requirements of the topside components of the RITS are as follows 12 The Surface Control Unit SCU shall provide the operator interface for control and monitoring of RITS during operation Control and feedback signals shall be routed via the ROV control system and RITS 13 The SCU shall have a graphical user interface GUI with separate graphics The graphic shall depict the tool layout with the hydraulic
102. n Air Weight in Water Cassette structure 7 65 kg 4 8 kg Buoyancy in structure 3 5 kg 3 8 Weight of cassette structure Buoancy Volume The free stab cassette is more customized than the others The cassette structure is without any front so it is possible to reach the hot stab The modified structure requires a different buoyancy package than the other cassettes and the structure will therefore be of different weight 46 Table 19 Weight of all the components and the total weight if the cassette Weight in Air Weight in Water Cassette structure 7 0 kg 4 4 kg Tool Weight 4 5kg 3 5 kg Buoyancy in structure 2 5 kg 2 7 Structure cassette buoyancy 10 1 9 kg A structure dedicated buoyancy element is installed to keep the weight of the cassettes approximately equal It results in a weight in water of 3 3 kg which is within acceptable tolerance compared to the weight of the other cassettes In addition the free stab cassette will need more flexible hoses since it will be pulled out by the manipulator The manipulator will handle the free stab by pulling it out from RITS and into the position on the ROV panel as illustrated in the upper illustration of figure 41 Hose for free stab The first idea to handle the flexible requirements of the hose was to install a hose reel however a hose reels are not tested for subsea To avoid complications with the reel another system was developed By in
103. n cms user files File ROVs Centurion QX 300 Se ries 281 29 pdf Accessed 6 September 2013 i Tech 2013 Quantum Online Available at http www interventiontechnology com en cms user_files File ROVs Quantum_Spec_Sheet pdf Accessed 6 September 2013 Johannesen J 2002 Tekniske Tabeller 2 ed Oslo Cappelens Forlag A S Kystdesign Hydraulic Compensators Haugesund Kystdesign Mat Web 2014 Aluminum 6082 T6 Online Available at http www matweb com search DataSheet aspx MatGUID fad29be6e64d4e95a241690f1f6e leb7 amp ckck 1 Accessed 2 February 2014 92 Measurments Specialities 2012 MSP300 Fremont Measurements Specialities Oceaneering 2009 Remote Control Unit Stavanger Oceaneering Oceaneering 2009 ROV Tools Torque Tool Cl 1 4 Kongsberg FMC Oceaneering 2013 Magnum Plus Online Available at https www oceaneering no products and services rov operations work rovs magnum plus aspx Accessed 6 September 2013 Oceaneering 2013 Millennium Plus Online Available at https www oceaneering no products and services rov operations work rovs millennium plus aspx Accessed 6 September 2013 Pall Corporation 2002 9050 9051 Series Filter Assembly England Pall Parker 2013 Hydraulic Motor Pump Catalogue Hy30 8249 UK Trollhattan Sweden Parker Reinert S Lindkjolen D amp Youkhana R K 2013 SPC60099795 Subsea Intervention Tie In ROM Int
104. n the vessel or in a basket on the seabed Manipulator Structure H POM uH e Cassette needed to make Cylinder _ the system work Fastened beneath the cassettes Interface Figure 2 Components in RITS MN 1 1 2 Need for RITS Bad visibility flowing water and old systems makes the ROV operation difficult inefficient and time consuming and it leads to high costs for the installation company The new docking system will provide a solution that can solve this issue A solid parking allows the ROV to be more accurate and apply more force on the installation in addition to improve the working situation for the operator The present ROV operations require two skilled ROV operators One operator keeps the ROV in place with the grabber manipulator while the other operates the equipment This arrangement makes the operators dependent on each other in addition to communicate with the equipment experts the suppliers The equipment engineers know how the installation should be handled An efficient operation is therefore depended on good communication between at least three people which not necessarily are sitting in the same room Figure 3 illustrates the present solution that requires three people while the right side only need two Suppi stallation ini The installer konvo Grabber manipulator Operator Manipulator Supplier installation info APT 170 Interface replaces grabber manipulator 7
105. ngth as input which is 250 MPa for aluminum 6082 The model in ANSYS will be market with a color code if the forces on the structure overstep 250 MPa ANSYS does the analysis knowing the structure and material of RITS However there is a challenge to calculate the applied forces on RITS Det Norske Veritas standard DnV_No 2 7 3 Portable Offshore units describe the force that applies on subsea structures The forces presented in DnV 2 7 3 are the actual forces added safety factors The actual weight of the structure and the landing speed of RITS need to be determined before the safety factors can be calculated The most significant weight of RITS is the ROV mounted on the top of the structure The figures in table 1 3 inform that a common ROV weigh approximately 5000 kg even though the interface receptacle will be designed with a rubber element on the end to reduce the impact load The interface between RITS and the ROV will have some flex resulting in that the actual impact weight is estimated to 75 of 5000 kg The landing speed is presented in a FMC document FMC SPC60099795 Intervention Tie In ROV Interface Handbook Design Guidelines based on experiences from previous FMC projects The handbook assumes a realistic impact speed to be 0 5 m s The speed combined with the impact weight gives the actual impact force of Impact Weight 5000kg x 0 75 Impact Load Impact Weigth x Speed x g 5000 x 0 75 3750 kg Impact L
106. oad 3750kg x 0 5 x 9 81 18393N 12 DnV 2011 Reinert et al 2013 29 DnV 2 7 3 Impact load for strength analysis RITS is a Portable Offshore Unit less than 25 ton and with a high risk ref DnV standard 2 7 3 that makes it a R45 class unit This risk classification gives the opportunity to calculate impact forces that can be inserted in ANSYS Horizontal impact The force that will be the basis towards RITS in horizontal direction is given in chapter 3 6 1 in DnV 2 7 3 The test in CREO will be performed by inserting the calculated horizontal impact load Furr perpendicular to the structure Fyr is the greatest of following factors see table 5 2 in DnV 2 7 3 Fhir 2 5 x Impact Load or Fhir Impact load x 1 4 0 8 x V 50 MGW Fhir 2 5 x 18393 or Fhir 18393 x 1 4 0 8 x V Fhir 45982 N or Fhir 27449 N The horizontal impact load will be applied on the front of the structure on one of the longest elements with a force of Fhi 45982 N x 0 08 Fhi 3678 N Figure 25 Horizontal Impact Load and impact position Case 1 MN 34 Vertical impact There are two scenarios that need to be fulfilled due to vertical impact All actual forces are applied at one corner It is a possible scenario when RITS is put down on ground This force is already calculated and is the same as impact load 18939 N Figure 26 Force applied from beneath Case 2 MN The second scenario is
107. ool valve Figure 34 shows what a single valve look like while figure 36 shows the function principle of the same solenoid There are several solenoids and to protect them they will be placed together inside a valve pack as illustrated in figure 35 Installing them in a row inside a valve pack makes it easier to design the control system for the valves Figure 51 Drawing from previous FMC project FMC 27 Wandfluh 2006 57 The main reason to pick the BM4D32 G24 M55 M35 is because of the ability to handle the external pressure at 2000 meters depth Figure 52 illustrates two different 4 3 spring loaded solenoid valve Both valves have the possibility to control the direction of the flow in addition to equalize the flow Figure 52 Wandfluh BM4D32 G24 M55 M35 Schematic on the left MN The BM4D32 G24 M55 M35 is more suited to handle the pressure at 2000 meters depth because of the way it stays in neutral position This kind of valve keeps the cylinder in position by applying the same flow and pressure on both sides of the piston The result is a fully compensated system The left illustration on figure 36 will not provide the cylinder with a auto compensating system as leakages may result in that the piston moves uncontrolled which is a major problem to handle on 2000 meters depth The cylinder illustrated below requires a compensating system and that makes the BM4D32 G24 M55 M35 the best choice of solenoid
108. or Source 42 line It is to control that the safety relief valve and the other mechanisms do not fail The pressure sensors are installed on the piping The sensors on the inlet line should be rated 0 400 Bar while the one on the HPU return line does not need to be rated higher than 0 50 Bar The reason is presented in Appendix A and has something to do of the way a hot stabs work relief valve and check valves Temperature Sensor In an overload situation the first component in the HPU that going to fail is most likely the motor It is the component that is most heavily charged The motor has a max design temperature of 80 degrees in the supply line To avoid protect the pump a temperature sensor is installed on in the piping in front of motor The required range of the sensor will be 0 100 degrees C The temperature sensor looks similar to the pressure sensor on figure 74 i Measurments Specialities 2012 77 Chapter Ten Buoyancy The purpose of the buoyancy elements is to make sure the RITS weight is less than 50 kg in water At this point all the main components are installed and it is possible to calculate a weight of RITS in water without buoyancy elements Installation of foam elements will decrease the weight in water while it will increase the weight in air Consequently it is desirable to use as less foam as possible primary to avoid a heavy construction in air while securing that the weight in water i
109. ote The check valves on the hot stab are not implemented in this drawing See Appendix A 55 7 1 1 Valves used in the RITS Schematics The schematic reveals the components that will make RITS work The electric power control signals and the hydraulic power are provided by or transferred through the ROV The electrical power and signals comes from topside through the umbilical to the ROV while the hydraulic power comes from a tank in the ROV RITS will not consume any fluid since the system is a closed circuit and cause of that return all fluid taken from the ROV Solenoid Valves A solenoid valve is a control valve for the hydraulic lines that activates the cylinders or the special tools The solenoid valve best suited for subsea use need to handle high external pressure and have the ability to be reliable operated from the surface maybe 2000 meters away Figure 49 is illustrating how a solenoid is working The figure to the left is showing the solenoid valve in normal position There are springs on each side of the solenoid valve forcing the cylinder in the normal position when the solenoid not is powered When electricity is put on the solenoid valve will overcome the spring force and the core with the valve openings will move By putting on electricity on the right side the fluid will circulate in a direction that extends the cylinder picture in the middle If the stem of the cylinder shall be pulled back electricity on the l
110. ources of information and material I have used have been fully identified and properly acknowledged as required II Acknowledgment I would like to thank all of those who have helped me through the process of writing this dissertation First of all I would like to thank my supervisor Olav Egeland and Dan Lindkjglen for their guidance and helpful tips while supporting me through the process of finalizing this dissertation Thanks to Per Olaf Tangen for help with technical issues and Lars Thingelstad for help with Visual Components I want to credit the Norwegian University of Science and Technology in Trondheim for making it possible to combine university studies and an athlete career with Drammen Handballklubb at top national level In a unique way NTNU facilitates for Master of Science studies during a sports career A special thanks to Mr Jan Erik Tangen who has been my contact with the university in this respect Additionally I would like to thank my text controllers Monique Lier Nes Atle Ngrstebg and Sidsel Ngrstebg for their patience love and support throughout this period I could not have done this without them II Executive Summary Most subsea installations have their own integrated control and automation systems In cases where this is impossible or the mechanism fails the only unit that can handle such problems is the ROV This makes the ROV essential for subsea intervention However challeng
111. pe required It makes the foam element flexible without being too heavy and solid Many ROVs have a thrusters mounted in the middle of the system which should be taken into consideration when installing the foam elements RITS will not have any buoyancy in the middle section simply to allow the main thrusters on the ROV to work Figure 79 How the thruster will work true RITS Source 40 and MN http www oilandgasonline com doc rov industry getting down to the challenge of 0001 date 28 5 14 82 10 2 Centre of Gravity CoG Handling and lifting of the equipment is simplified with a balanced structure During the design phase it is difficult to estimate the exact center of gravity since the piping usually is not designed before the unit is in the workshop The piping will change the CoG which makes it unnecessary to calculate the exact CoG The various cassettes will have a weight difference of approx 1 5 kg which also will change the CoG The components inside the RITS are strategic positioned to avoid too big variations of the CoG which means that the heaviest components are placed on each side of the center line This tactic will reduce the fine tuning of the CoG in the assembly phase of the project Example of this is that the heavy manipulator is installed diagonally with the compensators and the pump motor RITS will be adjusted to be neutral in water by use of buoyancy elements which not necessarily means it will
112. pocite direction and fastened in the mountings ears behind H ge gt Figure 33 Mounting of cassette type two note cylinder direction MN 41 Torque Cassette Figure 34 Illustration of the Torque Cassette MN The Torque Tool is hidden behind the buoyancy elements figure 33 Behind the foam elements it looks like presented in the tool chapter chapter 3 figure 19 The ROV handle is not installed in the cassette since there is no need for it and it will cause extra weight The Torque Cassette is the heaviest of the cassettes since there is not sufficient space for buoyancy elements to make it neutral in water Consequently it will determine the weight of the other cassettes Table 15 Weight of all the components and the total weight of the torque cassette Weight in Air Weight in Water Cassette structure 6 044 kg 3 8 kg Tool Weight ref chapter 30 kg 30 kg Standard Buoyancy Package 3 3 kg 3 6 kg Extra Buoyancy 14 6 kg 15 6 kg Structure cassette buoyancy See chapter 5 2 1 0 10 9 kg Figure 35 Maximum buoyance possible inside the torque tool MN Figure 24 shows how much syntactic foam that is possible to fill in the Torque Cassette in addition to the standard buoyancy package The volume is 29418040 mm which results in a weight in water reduction of 15 6 kg The lowest weight possible for the Torque Cassette will be 3 8 kg This weight is d
113. reen panel is installed to make the system flexible It is a tick off selection system that will activate other panels the will pop up to the right The switches will be grey until the box on the configuration panel is ticked off It is important that the tick off reflects the current tool equipment of RITS if not the HMI will activate wrong lines This has to be tested and checked on a test stand before RITS goes subsea The manipulator and the RCU have their own system By push their buttons a new HMI picture will appear and is the suppliers HMI If there is enough screens topside the manipulator should have its own HMI active at all times 0 In Out In Out Fail Temp c D Cassette 81 eec GC Flow Ipm 1 2 1 82 2 Pressure bar Pressure bar ROV side HPU side HPU side ELE e m In Out Fail 6L 6L D assette eoo MES mem vw 9 x In Out Fail Cassette 3 e 0 Pressure __ bar 1 5L LSL 1 5L itical Critical Critical In ba Out Locking dog In Out Fail erc RUM tow chu Low Volume d LE D ou In Out Fail D Cylinder Stab eed 1 2 3 x FOO we COO weer BOX Cylinder Stab seme LILILI OOO Free Stab ZOo A co m zoo Defines which stab gt Figure 73 Concept drawing of the HMI MN 78 The Upper right left panel controls valve pack two DC10 DC14 in table 25 There are five switches that allow the cylinders and the locking dogs to be operated Th
114. roximately the same as the weight of the torque cassette Table 16 Weight of all the components and the total weight in the cylinder stab cassette 43 Weight in Air Weight in Water Cassette structure 6 22 kg 3 92 kg Tool Weight 22 52 kg 13 kg Buoyancy in structure 3 3 kg 3 6 kg Structure cassette buoyancy See chapter 5 2 1 0 10 9 kg Holder Cassette The holder cassette will not have any function except from parking RITS onto the interface bucket The structure will still be built in the same way as the rest of the cassettes type one Figure 37 The holder cassette MN with a standard buoyancy package and standard aluminum profile The cylinder underneath has a maximum stroke length of 181mm which is restricted to only push the interface out To be able to get access inside the holder cassette an extra stroke length will be required figure 37 illustrates the problem Since stem is pulled completely inside the cylinder housing when cassette edge and the structure edge are aligned there will be no access to the inside of the cassette It results in a cassette that will not be able to carry any tools The cassette type two is more suitable in cases where a tray should be required the holder cassette must be installed to provide the API 17D docking option The most likely usage for the holder cassette is when two type two cassettes are need The holder cassette is easy to make buoyant becau
115. s 7 1 Valve pack Control Systems A valve pack is custom designed RCU for the rest of the system in RITS except for the torque tool The solenoid valves are positioned in a row with a control card PWM16 on top This control card is called an embedded control unit and controls which solenoid valve that will opens the hydraulic line e The control card will send an electric signal toa magnet that will overcome the spring force inthe solenoid e The solenoid valve will only open the hydraulic line that it is connected to e The electricity and the hydraulic lines will at all times be connected to the valve pack just waiting for signal to be activated Figure 67 Picture of a valve pack from Innova Source 37 37 Innova 2014 70 7 1 1 PWM16 Control Card The signals from the computer topside will end up in the PWMI106 This is the unit that applies power to the solenoids valves that opens the hydraulic lines The hydraulic system will be active at all times and the control card will decide what line that is open The solenoid valves presented in chapter 7 1 1 allows the flow go in both direction which means one line to supply and one to tank return It signals are sent to the other side of the solenoid valve it will switch and the circulation will go reverse direction This is how the operator can control the cylinder to go out or pull back in The PWM16 operates 16 individual 24 VDC loads It means that one PW
116. s are solved In addition to handle the change of volume of the fluid it applies an extra fluid reservoir The clean fluid can be filled into the system before the operation subsea starts and because of that the customer will have completely control of the fluid type and cleanness 7 3 1 The Pump A motor uses the hydraulic flow to power a shaft while a pump circulates the fluids by use of the power from the shaft As the same calculation applies for the pump it will be an advantage to use the same pump as the motor The RPM is given in table 12 1969 By using the formula for q in table a flow for the HPU side is given The flow on the HPU dirty side of the system has a flow of 18 6L Basic formulas for hydraulic pumps Flow q D q l min D displacement cm rav x volumetric oliin n volumetric efficiency Torque M AP differential pressure bar mM _DXAp Nm between inlet and outlet 63 X Tm my mechanical efficiency i m Overall efficiency Power m n n X Mihm P kW Figure 61 Pump formulas from the Parker catalog Source 31 65 The coupling between motor and pump It is difficult to mount the shafts exactly aligned The misalignment will expose o rings and seals for forces and tear Figure 62 illustrates the effect To decrease the tear a flexible coupling will be installed between the shafts to reduce the alignment problem A flex coupling makes also service easier If one of
117. s can be customized into the shapes that are needed by use of glue and saw The Syntactic Foam is also quite hard and can be used on the outside of RITS combined with the aluminum structure Syntactic foam is normally used on ROVs and the foam elements are seldom more protected than figure 23 illustrates Figure 22 Examples of syntactic foam source 14 Acetal Polymer POM is a hard plastic material normally used as protection for flanges and seals RITS will use POM elements for tasks that do not require any strength A typically area for POM will be the chambers where the tool cassettes will be placed The material will have a deformation of 196 at 4500 psi equal to 300 bar This is within acceptable range for the POM elements and should not cause any trouble for RITS If it should be too tight for the guiding system it is easy the grind the POM 15 DIAB Group 2014 14 DIAB Group 2013 15 FMC Technologies 2006 25 Aluminum weight in water Archimedes law tells that weight of components in water is calculated to be Weigth in water Weight object Weight of displaced fluid This can be changed to a simpler and more usable equation Object Density Water Density GE x Object Weight in air Object Weight in water The density of salt water is approx 1030 kg m and the density of aluminum is 2700 kg m it makes it possible to calculate a percentage to calculate the aluminum weight in water 2700
118. s ket below 50 kg Table 26 Weight of the components in RITS 1 Measurements made in NX 2 From Datasheets gt see source for each component 3 Assumption cause lack of information assumed to consist of aluminum factor 63 ref ch 4 1 1 5 kg for the cassettes final adjustment will be performed in a test pit Weight Per piece Pcs Weight in sum Component In air In water In air In Water Structure 55 kg 34 7 kg 1 55 kg 34 7 kg Filter 12 7 kg 8 kg 1 12 7 kg 8 kg Titan 4 100 kg 78 kg 1 100 kg 78 kg RCU 30 kg 17 kg 1 30 kg 17 kg Compensator gt 11 3 kg 7 1 kg 3 33 9 kg 21 3 kg Valve Packs 3 25 kg 2 kg 1 3 25 kg 2 kg Valve Pack 2 gt 5 85 kg 3 7 kg 1 5 85 kg 3 7 kg Cylinder 7 5kg 2 5 kg 3 20 kg 7 5 kg Transformer 11 kg 2 3 kg 1 11 kg 2 3 kg Pump Motor 2 7 5 kg 4 7 kg 2 15 kg 9 4 kg Grid 13 kg 8 19 3 39 kg 24 6 kg Cassettes Std Cassettes Varies 3 8 kg 3 varies 11 4 kg Locking pins 1 2 kg 0 75 kg 6 7 2 kg 4 5kg The RCU is not implemented in the calculation since 1t will not be installed at all times The RCU is also stripped for all protective covers because the buoyancy elements will provide extra protection see VP RCU element in chapter 10 1 2 78 10 1 Buoyancy in the structure profiles In chapter 4 3 it was discussed that the structure could be constructed by use of two optional profiles one filled with
119. se of the available space inside however it is preferable to install the buoyancy in the dedicated structure areas to keep low weight of the cassette in air The extra needed buoyancy should be installed in the structure and not inside the cassette since it will make the handling of the cassettes on deck easier It is a strategy that applies for all the cassettes Table 17 Weight of the components and the total weight of the cassette Weight in Air Weight in Water Cassette structure 6 044 3 8 kg Tool Weight 8 5 kg 5 3kg Buoyancy in structure 3 3 kg 3 6 kg Structure cassette buoyancy See chapter 5 2 1 0 1 9 44 5 4 The Cassette type two for Tool Carriers The main purpose of the cassette type two is to bring special tools subsea It function as a tray and will not be installed with the API 17D interface The lack of the API 17D interface requires a different fastening of the cylinders Normally the cassettes with API interface are in operational mode when the cassette edge is aligned with the structure edge the API will then be pushed 181 cm out in operational mode The same stroke lengths apply for cassettes type two and there will be no access of the tools inside A different setup is therefore required for the cassette type two cylinders When the cylinder is mounted in the original direction gt there is not possible to push the cassette longer than By turning the cylinder t
120. similar manipulators as used in VC and in the NTNU course TPK4170 Robotteknikk The coding was done in Python and the software for the manipulator is able to calculate the joint angles and the end effectors position The kinematics seems to work and the coding is shown in Appendix D 6 1 4 Example of robotics on a RLWI stack The illustration application in VC is a useful tool to present robotics and its abilities As an example video simulation of the RITS working with a URS manipulator is presented The video may be found in the source folder following this thesis It is called URS simulation RLWI panel Figure 47 Simulated example in VC 53 Chapter Seven Hydraulic System RITS has two hydraulic systems because of stricter requirements of clean fluids into a XT This demands a separate system since the fluid the ROV provides does not meet such requirements RITS is powered from the ROV s auxiliary valve pack which is called dirty valve pack Most tools are able to operate on ROV Fluid however an extra filter is often installed to reduce the wear on the systems The fluid supplied from the ROV is in most cases ordinary hydraulic oils as e g very often a Tellus oil from Shell and the dirty fluid side is therefore often by slang called Tellus hydraulic side at least in within the FMC The clean system is driven by a motor pump solution which avoid the fluids from being mixed The dirty system powers
121. similar the horizontal impact 3678 N however it will be applied to the weakest point of RITS The weakest point of RITS is on the longest element which is one of the elements going perpendicular on the length of the structure Figure 28 Vertical Impact Load on exposed element Case 3 MN The results from the analyses are presented on the next page 35 4 7 Strength analysis Case 1 Requirements Stress Max 250 MPa Aluminum No requirements should be functional Stress 21 11 MPa ACCEPTED Deformation 0 3 mm ACCEPTED Hot Spot see Appendix B for explanation Case 2 Requirements Stress Max 250 MPa Aluminum No requirements should be functional Stress 147 5 MPa ACCEPTED Deformation 0 14 mm ACCEPTED Case 3 Requirements Stress Max 250 MPa Aluminum No requirements should be functional Stress 130 8 MPa ACCEPTED Deformation 2 mm ACCEPTED Hot Spot see Appendix B for explanation Table 12 All tables is stress and deformation analysis of structure 36 Chapter Five The Cassettes The cassettes are an important part of RITS almost all the capabilities in RITS are in the cassettes There are two types of cassettes one with an API 17D interface and one without the API 17D interface The main purpose of the first type is to be able to dock on to subsea
122. siy wou suoneiaap jueoubis Aue usaq jou sey asay ued siy 0 anp pawwopad usaq seu Oom IV Progress Report Appendix E Gannt Chart A T T SO 97 Vol VT vO SC VOW 5yse1 pa ejop 40 IWN Em Sat SCLC VIVOZCUDS VI vO SQ uns neuimps 2119913 SE o SCLC FIT UNS VI vO 90 UNS INEW YI yneip H SE ec 97 vTPO 90 UNS PT EO PZ LOW Wun amod SE sc 97 vTPO 90 UNS FCEOEZ UOW un jonuo SE zx PTEO EZ UNS vTEO ZT VOW squauodwos urew amnis E 9c LV8T vIvO ZZ UNS FC EO CT YOW suoppuny pue s3umesg KH sc PTEO EO UON pTZOTO18S NS El e PT EO 9T UNS FC ZOE VOW Joye ndiuew ee E TCOC6T vTZO EZ Uns FC ZOO VOW saapurlA SE z PTZOOTUON pPTZOTO1eS Aea 1001 ee EI oV VIZOOTUON pTZOTO18S 1001 anbsoy SE o PTZOOT YON PT Z0 TO 1eS eis 10H e EI et 7 PTEO 9TUNS pTZO TO WS eds OH St vT EO ST ung pTZO TO APS suod y Wd Su a ST vT90 0T an PTSO 9 VOW pensqy pue uoisnpuo SE gt VI PTSO SZ UNS pT SO ZT VOW Voissnosig S EI St 8 L VESOTI UON VT EO ZT VOW s3umesg DE vt CI PT POET UNS pT EO TE UON 9J6M JOS U 59NOQOY SUR JO adwexg uy ge EI EL TI pTEQOE UNS pTEO PZ Ve suauodwo ENSIA ui pawwes3osd SE 7 PT EO HT Vol VTEO ZT UOW sonewaury EN Hu VI PO ET UNS FC EO CT UON sonoqoy a or L 8 vTUPO ET UNS PTEO ZT LOW vopeuejdx3 Aajquiassy Se 6 9 PTEOLTUOW vL EO vO 9n uonnios une SE 2 9 PTEOZOUNS pTZO 9T uns uoneuejdx3 1uauoduio SE PTZO 9T UNS pTZO TO18S uon npoziut SE S Froot ant pTZOTO IPS voday NNIN El s T ZO TO 8S VT
123. stalling an elastic band to the hose it will be pulled back as illustrated on figure 41 Max pulling length 2 x middel grating 2 x 750mm 1 5 meter Figure 41 Hose retrieval system MN The elastic band is connected the hose and will pull the hose in A disadvantage is that it will be pulled back if the manipulator loses its grip The advantage is that a system like this is not woundable for deep water 47 5 5 Hose Cassette hydraulic supply All the cassettes will be moved from operational to transport mode several times to allow such a system a flexible connection of hydraulic hoses will be required Hoses are normally strong with respect to pressure from inside however hoses have a tendency to collapse if the external pressure gets much higher than the outside pressure Hoses applicable for 200 Bar external pressure is quite stiff because they consist of several layers of steel The hose recommended from TESS Kongsberg was the TESS 5040 It meets all the requirements for the RITS It handles external pressure of 200 bar internal pressure of 300 Bar and it is capable to supply enough flow The only challenge with this hose is the minimum bend diameter of 360mm The bend diameter is demanded to ensure that the hose will not break and the diameter will be central in the flex system required for the cassettes Formula for Circumferece 2nr 360 Circumferece min inner circle 2n x 1155mm Extra lengt
124. sted working space for each ROV Panel Figure 8 Extended interface bucket capability MN The extended bucket is important to make RITS functional and it is a critical unit to secure the new connection method The ROVs are installed with thrusters that can make the ROV neutral weighted The principle with extended interface buckets will need testing before RITS can be tried in operation yet the grabber manipulator method make it work with a less rigid system It is an indication of that the API 17D method should work ES Figure 9 An extended API bucket MN The API 17D interface buckets are commonly used on several subsea projects They are as the receptacle created in many different materials while the size is standardized Figure 9 illustrates an API 17D interface bucket and an example of how the buckets may be extended to satisfy the demands of RITS The strength requirements will depend of the ROV model and will require a separate dimensioning for each specific project 10 2 3 The locking dog system The API 17D interface will ensure that RITS has a steady position during the operation still there is a chance that RITS will fall out of the interface To avoid this problem a locking system are implemented between the bucket and the receptacle Figure 6 reveals two holes that seem without purpose Those two holes are actually important for the locking system and are called locking dogs A locking dog is a
125. t breaking lines Mounting Variety of head mountings for installation versatility Pipe mounting or top manifold options available Positive sealing Unique positive sealing interface using standard O rings Figure 54 Picture of pall 9050 taken from the datasheet provided from Pall source 29 The exact model is called 9050SKH where the H specifies the fluid that the filter will clean A Pall 9050 filter cleans the system to at least 3 microns and handles 700 bar inner and outer pressure and meets the requirements for the RITS 60 7 2 2 The compensator The compensator on the Tellus side of the RITS hydraulic system will compensate the fluid volume variations for all the components A compensator is a tank that adjusts the volume by use of a spring and because of that equalizes the pressure when the fluid consumption of the tools etc varies Other volume variations are caused by change of volume that occur due to change of temperature and change of external pressure The compensator principle is a simple but it is still challenging to calculate the size of the compensator In addition to handle the variations of the fluid volume due to physical changes the calculations also must include the variations of fluid consumed during operation works like a fluid reservoir Consumption is typically fluid needed to handle the cylinders The cylinder consumption is related to different volume on each side of the piston
126. t leaves a buoyancy area of 353441427 mm NX measurements Which lead to a weight calculation of the buoyancy elements density of syntactic foam Area x Density air water Weight Weight in Air 0 353m x 4954 175 kg Weight in Water 0 353m x 530 187 kg The structure with buoyancy In water 208kg 187 kg 21 kg In air 320 kg 175 kg 22 5 kg 517 5 kg Figure 76 The buoyancy package The weight in water is less than 50 kg without the piping included Second element will be installed to avoid complications if the piping and other extra elements is heavy The design of this element will be determined during the assembly Figure 76 is an example of an element that is supposed to be installed to balance RITS when it is tested in a test pit This element is called adjustment element because it adjust the imbalance and compensates the potential extra weights applied during installation Weight in water 21 kg Weight in air 22 5 k Figure 77 Example of the last buoyancy element may look MN 80 10 1 2 Adjusted elements The buoyancy elements need to allow piping to be installed Some customization is also required to make space for valve packs and RCU Piping Element VP RCU Element Manipulator Element Figure 78 Adjusted Elements Rare Element is mounted on the rare end of the RITS A hole is made to provide access to the system inside without need to dismo
127. tCall True Init kinematic object information def OnInitKinObject kinobj pass Returns the amount of joints this kinematics handles def OnGetJointCount return JOINT_COUNT Returns the indexed joint names def OnGetJointName index return JOINT_NAMES index Constraints kinematic solutions to show only valid choices def OnConstrainParams kinobj return True Relaxes kinematics solutions to show all choices def OnRelaxParams kinobj return True Returns Kinematic chain target matrix value based on joint values def OnForward kinobj print OnForward global DH_PARAMS 1f FirstCall OnFinalize qmag np array kinobj JointValues reshape 6 1 99 q qmag np array 0 0 0 0 0 0 print q J T ForwardKin DH_PARAMS q print T m Numpy2vcMatrix T kinobj Target m return True def Numpy2veMatrix mat T np ravel mat s T 0 0 m vcMatrix new N m N N X T 0 N Y T 4 N Z T 8 m N N O m 0 O X T 1 O Y T 5 O Z T 9 m O O A m A A X T 2 A Y T 6 A Z T 10 mA A P m P P X T 3 P Y T 7 P Z T 11 m P P return m def vcMatrix2Numpy mat np_mat np eye 4 N mat N O mat O 100 A mat A P mat P np_mat 0 0 np_mat 0 1 np_mat 0 2 np_mat 0 3 np_mat 1 0 np_mat 1 1 np_mat 1 2 np_mat 1 3 np_mat 2 0 np_mat 2 1 np_mat 2 2 np_mat 2 3 N X O X SCH NY O Y return
128. the parts either the pump or the motor has to be taken out the other may stay by only dismounting the coupling Figure 62 Shaft connection between the motor and the pump MN and Source 31 Flex coupling Huco Dynatorc is a common flex coupling suited to connect two shafts together There is no air filled chambers in the construction and it is made of aluminum which reduces the chances for galvanic corrosion L b Ga E ex 5 B 5 A L x52 33 SERE 22 223 Material Aluminum Max rpm 5000 rpm Max torque 140 Nm Temp range 40 140 C Figure 63 Huco multibeam aluminum Source 30 Huco Dynatork 2013 66 7 3 2 The clean side compensator The compensator in the HPU has two important purposes It needs to compensate the external pressure on the clean fluid system and contains the extra fluid needed to operate external subsea units by use of hot stabs RITS is designed as a tool carrier for many different projects It makes it challenging to calculate an exact volume for the compensator In most cases all fluid are transferred back to the RITS through the return lines however mineral and water based fluids are sometimes accidentally released to sea Assuming that all the fluids usually will be returned to RITS gives the minimum capacity of the compensator Another assumption is that powering up a pump or motor will not consume any fluid The fluid will first of all
129. ties for Parker F11 motor sizes Source 29 eee 64 Table 23 Summary over consumption of fluids required to operate override a system 67 Table 24 Electric Can Source FMC Per Olaf Tangen eere 12 Table 25 Srenal e E EE 74 Table 26 Weight of the components in RIIT 78 Table 27 Calculation of buoyancy in the structure esee 79 Table 28 Rejected Interface Connections ue ende eie ee deed eee a pedes 85 Table 29 Approved Interface C OnlBOlOTL micro EEUU TUE 86 XIII Abbreviations API American Petroleum Institute CDB Communication Distribution Board CoG Center of Gravity FMC Food Machinery Corporation GUI Graphic User Interface HMI Human Machine Interface NTNU Norwegian University of Science and Technology NDT Non Destructive Testing RCU Remote Control Unit RITS ROV Intervention Tool Skid RLWI Riserless Light Well Intervention ROV Remotely Operated Vehicle VC Visual Components WROV Working Class ROV XT Christmas Three Chapter One Introduction The purpose of the new ROV Intervention Tool Skid RITS is to improve subsea intervention Subsea intervention in this context is the tooling making subsea installation operation and maintenance possible under water By definition all hands on activities made by the ROV and its tools is subsea intervention It does not include inside bore operation The
130. tor Table 22 Abilities for Parker F11 motor sizes Source 29 F11 size Weight Displacement Flow Volumetric effectiveness RPM 005 4 7 kg 4 9 cm rev 20 Ipm Assumed 0 97 3959 rpm 012 8 2 kg 12 5 cm rev 20 Ipm Assumed 0 96 1536 rpm See figure 30 A shaft speed of approx 2000 rpm is assumed the small motor will produce a higher RPM on 201 min it results in a higher volumetric effectiveness The smallest pump works at too high speed to stand required wear resistance The biggest that are calculated works at a lower speed which decreases the volumetric effectiveness As a result too much power is lost From these considerations the most suiting motor is the F11 010 with a weight of 7 5 kg 64 7 3 The Clean system HPU system The clean hydraulic power unit is necessary to make RITS capable to work with hot stabs Many subsea installations are installed with hot stab interfaces to power up a motor or override a valve etc where the fluid used for the hot stab gets in contact with the fluid of the subsea fixed installation All these systems have different tolerances for cleanness of fluids and they are usually significant stricter than a Tellus oil and a 3 microns filter The clean oil must also be compatible with the oil in the subsea installation To control the cleanness of the system a separate reservoir is needed By installing a compensator on the HPU side of the system two issue
131. ue tool The ROV handle the orange grip will be removed for RITS use The torque tool is the only tool that has locking dogs integrated from the supplier The locking dog system planned for RITS is a copy of the torque tool system i FMC Technologies 2010 2 Oceaneering 2009 20 3 7 Hot Stab It can be challenging to operate all the valves one by one In cases like that a hot stab becomes in handy The purpose of a hot stab is to apply pressurized fluid into a subsea installation through a number of ports The ports send high pressured fluid to open or close integrated valves in the subsea installation The advantage with the hot stab is thus that it can operate several valves at the time When the stab gets connected it opens one or several supply lines and return lines to operate valves In addition to override scenarios the stab can use its external fluid to operate motors pumps Pressurized fluids are also used to check that connections are properly tightened by adding a hot stab to the RITS it becomes more useful also for tie in projects The number of function depends of how many lines the stab has RITS will use 6 lines 345 bar hot stabs which can handle three valves 3 supply lines and 3 return lines Figure 20 A 6 Line Hot Stab both inside and outside Source 10 While the torque tool normally has API 17D interface connection the hot stab does not have any standardized interface connection but are normall
132. uirements of RITS cylinders are limited and results in a low weight component Sylinderteknikk weighted a 30 cylinder 250 mm long to 2 5kg which means that the cylinder is a light component compared to other units inside RITS It is not worth the risk to choose a pneumatic cylinder to reduce the weight by 1 kg Information and recommendation from meeting with Sylinderteknikk Terje Grimsrud date 28 02 14 13 3 1 1 Double acting cylinder A double acting cylinder has two hydraulic lines connected to Sylinderteknikk the cylinder house one each side of the piston The cylinder is operated by filling fluid on one side of the piston When one side is filling up the other side will drain and the piston and stem will move Double acting means that both sides of the piston can Figure 12 Simplified how the be filled Single acting cylinders are often installed with a spring Cylinder works source 6 to force the stem back into start position when the pressure is bled off 3 1 2 Fastening method The cylinder on figure 12 is a double acting cylinder with OccmHB 0 a flange connection Figure 13 is showing a double acting with two rings These two types are identical when it er on n ya Comes to size and strength but the fastening methods are SZ AAA SN different The position and space inside RITS will Figure 13 Cylinder with two fastening determine what fastening method that is the best choice rings so
133. uman Machine Interface HPU Hydraulic Power Unit ICS Intervention Control System LPM Litre minute MQC Multi Quick Connect Plate N A Not Applicable OBSROV Observation Class Remotely Operated Vehicle RITS ROV Intervention Tool Skid ROT Remotely Operated Tools ROV Remotely Operated Vehicle SCU Surface Control Unit SPC Design Specification FKS Document WROV Work Class Remotely Operated Vehicle 1 4 REFERENCES Industry Standards and Codes NORSOK U CR 008 Subsea Colour and Marking DnV 2 7 3 Portable Offshore Units R3 AS 4059 Cleanliness Requirements of parts used in Hydraulic Systems Maximum Contamination Limits R4 NS 3471 Projecting of Aluminium Constructions Calculation and Dimensions ISO 13628 2000 Petroleum and Natural Gas Industries Design and Operation of Subsea Production Systems Remotely Operated Vehicle ROV Interfaces MIC Technologies Doc no SPC 0000031472 Version 00 Revision Page no 6 of 23 To ROV Control System MN x Manipulator Titan 4 Ke Surface Control Unit n 1 j ea ee Te IS e es I TE TE Ti cu E SU ved LIE fI IN L ios d d Be E m ae ESTT ppi 8 feu NE E j G LG J Tool Cassette Holder Cassette Torque Cassette i as q Cylinder Stab Fee Stap Cassette Cassette Figure3 ROV Intervention Tool Skid RITS Control System Overview oP VIC Technologies Doc no SPC 0000031472 Version 00
134. unt the ROV on top Piping Element is mounted between the machinery in the end it is installed to protect the machinery from the ROV thruster water flow An important factor is holes for piping and hoses to be able to supply the cassettes with signal and power VP RCU element is mounted behind the cassettes As for the piping element it is installed with holes for piping In addition it has dedicated areas for the smallest valve pack and the RCU The mounting of RCU and valve pack 2 needs to be in the front to be able to provide the hoses with a flexible length solution see chapter 5 5 Manipulator Element is the element holding the manipulator This element is as big as possible to oppose the weight of the manipulator The modification on this element is adjusted to make space for piping hose control and power supply 81 10 1 3 Precaution of buoyancy element positioning All the components inside the RITS are mounted on a grating It makes it easier to install the components and it allows water to pass true The purpose of letting water true the construction is to make the RITS easier to operate in water To keep the operational advantage it is important to not stop the water flow by installing the foam elements on the top of the structure The buoyance elements are produced in 150 mm tick plate with some variations in length and width By use of glue and saw it is possible to customize these plates into almost exactly the sha
135. urce 6 i RITS is designed with a double acting cylinder with two rings as fastening method the reason is presented in chapter 3 1 3 Safe fail close or safe fail open A safe fail close system is often used in situations where cylinders need to go to lock during failure It is performed by installing a spring on one side of the piston This contingency mechanism will not be required for the cylinders activating the cassettes It is not critical if RITS will not be able to pull the cassettes in during transport it will only require a more careful transportation The contingency spring solution is illustrated on the locking dogs system It is required for the locking dogs because RITS will not be able to pull back if the dog pins are activated The contingency mode has to be designed for the solenoid valve system in a way that allows the fluid to drain 6 Hydex Sylinderteknikk 2014 14 3 1 3 Cylinder position A cylinder consists of cylinder housing and a steel stem Steel is a strong material but it is still quite flexible when the construction is thin The most suitable cylinder is small and therefore the stem is thin To avoid problems with that the stem bends or get overloaded the cylinder must be mounted to give as low unnecessary loads as possible Mounting of Cylinder seen from beneath The cylinder is weak when the stem is long watch the stem lenghts and note that solution 2 has a short stem in operat
136. valve Pressure Relief Valve The pressure relief valve is installed to protect the system A WANDFL UH for pressure peaks The valve is connected the return line A _ Pressure relief valve Ny Screw in cartridge Pilot operated and when a peak appear it will open and drain the overload e Qaa 100 l min p 400 bar Py max 350 bar This valve will open a line from the supply line to the Figure 53 A pressure relief valve Source 28 tank if the pressure gets too high and the system is protected The relief valve installed on the HPU side of the system has a more active function The valve will open as long as the hot stabs are closed See more information in Appendix A Hot Stab 2 Wandfluh AG 2012 58 7 2 ROV hydraulic system Tellus system The Tellus system of the RITS is powered from the ROV It is the main power system for all components in RITS however it is not clean enough to risk spill of fluid into the other hydraulic systems The Tellus system of RITS is the part that can operate with the same fluid as the ROV It is units as the cylinders the torque tool require a RCU remotely control unit and the Titan 4 manipulator The hot stab system is the only component that needs cleaner fluid The hot stab system is operated by a motor on the Tellus side of the hydraulic system The motor powers a pump that makes the clean fluids run Systems like this are called a Hydraulic Power Un
137. w locations of spares parts Software documentation including top level flow diagram and commented source code Hardware documentation including assembly drawings of printed circuit boards with component lists and wiring diagrams Data sheets for major components hoses cables etc Technical Description Operation and Maintenance Manual including packing and preservation procedure FAT report including a cleanliness report All documents shall be delivered as hand copies and in electronic format 13 DOCUMENTATION FOR OPERATION The following Documentation for Operation DFO shall be supplied by the client for the RITS Control System Equipment User Manual USM including Technical description and data Transportation and storage Preservation and maintenance Equipment Hook up and Function Test HFT MC technologies Doc no SPC 0000031472 Version 00 Revision Page no 23 of 23 8 DRAWINGS Ka D 040 1100 60 1550 taleg E Ayuo ysiuty Ajuo uonesng A HEEL SACU geg 3 Ajc ues Pa ASE jenueiw e BuO SALI eujaix3 35818014 Ges Aeununsjenuew A A ueunung aapzeu mmm sysey jeuayg i aupa ammm noy A euiuins jene 3UOSSJIN 3AR2EU fe Asewuns polola mmm Asewwns auo PTTO 6Z PAM seg uds ddwryey nueg nalosy ysel Ods uone yrseds 24 au ur eeus ureu ay ue jueuiubisse au ul pazuaw jdwu s odes pnis eid y jo jse1 ay uejd
138. y problem Corrosjons bok 26 4 3 Profile of structure It is important to select the right profile of the aluminum beams for the structure The following four criteria need to be fulfilled The profile should all be mass produced to avoid extra cost The profiles need to withstand corrosion under severe conditions It is difficult to calculate the different profiles ability to withstand corrosion since this is a matter of experience Advanced profiles will corrode faster because of the tendency to trap salt water inside the structure however the advanced profiles may benefit of a stronger profile at a lower weight The profiles should allow easy guiding of the cassettes This is a challenge for advanced profiles which make them not competitive A structure with a square cross section is an easy design that allows cassettes to glide upon It is also easy to calculate the strength of such profile The profiles need to withstand the external pressure at sea depth of 2000 meters A square hollow profile is weaker towards outer pressure since it will trap air inside By use of hollow profiles it is important to equalize the pressure by creating holes in the structure The holes will equalize the pressure on both side of the element 27 Square profile 50x50x3 without any substance in the middle A square profile with the dimensions 50x50x3 is selected for the structure The dimension 50x50x3 is chosen because it is a st
139. y put in operating position by a manipulator arm For RITS a new solution is proposed where the hot stab is installed to an API 17D interface It requires some modification of the normal 6L hot stab though there will not be any change of function it will simply be a bit longer than the normal Figure 21 An extended hot stab customized to fit inside an API 17D MN and Source 10 21 3 7 1 Two hot stab Cassettes solutions To increase the flexibility of RITS it will have a cassette providing a loose hot stab It means a hot stab that can be operated by the manipulator The hot stab system requires more adjustment than the other tools however to be able to handle existing XT s this unit is required as existing subsea installations not are designed to handle a hot stab true a API 17D interface Table 7 Info of a hot stab Mechanical Data Length 438 mm Width various Diameter 140 mm Weight in Air 4 5kg Weight in Water 3 5kg Hydraulic Data Pressure 207 Bar design 380 Bar Flow 30 Ipm Fluid oil Depending of external system General Data Max Water depth 2500 meter Hydraulic interfaces Hydraulic hoses 7 16 x 20 JIC Clean system Hydraulic Power Unit A hot stab applies fluid into external systems Subsea system usually have strict requirements due cleanness to fluids RITS is powered by the ROV auxiliary valve pack which consist of dirty fluid Tellus To insert a

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