IMCA LIFTING & RIGGING SEMINAR Ropes for Offshore Heavy Duty - - PowerPoint PPT Presentation

Thursday, 27th September 2018

IMCA LIFTING & RIGGING SEMINAR Ropes for Offshore Heavy Duty Applications & Integrity Management

Matteo Ducceschi

Lifting & Rigging Seminar

Thursday, 27th September 2018

TOPICS

Introduction Ropes & Comparison Maintenance Approaches Conclusions

Thursday, 27th September 2018

TOPICS

Introduction Ropes & Comparison Maintenance Approaches Conclusions

4 Thursday, 27th September 2018

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INTRODUCTION Background

For EPCI Contractors…

• In the medium-long term offshore market scenario the focus will be on the subsea

field development segment

• SURF

developments are moving to ultra-deep waters and typical topside processes are being relocated onto the seabed

• Tighter capital discipline enhances the search for flexibility, cost-efficiency and

for optimized project schedule

• Subsea deployment and laying capabilities are pushed to their technological

limits and innovative solutions are being invest igated and developed by the market players to overcome present technological showstoppers

… ropes are becoming more and more crucial

5 Thursday, 27th September 2018

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INTRODUCTION Applications, Needs and Alternatives

Applications

• Heavy duty subsea deployment
• Pipeline abandon and recovery
• Heavy lifting
• Mooring

Needs

• Higher SWL / Lower SF
• Low paying load reduction with water depth increase
• Low impact on existing / chartered assets (and equipment)

Alternatives

• Large diameter steel wire ropes
• Multi-fall / multi-cable steel wire rope systems
• Heavy duty fibre ropes
• Parallel fibre cables
• Hybrid rope concept
• Combined rope systems
• Improved and modern IMR approaches

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INTRODUCTION Areas of Improvement

Rope Design Rope Equipment IMR Approach Rope Based System

Predictive Maintenance CBM Preventive Maintenance

DIGITAL ENABLED SOLUTIONS PRODUCT DEVELOPMENT SYSTEM DEVELOPMENT

Fibre Cables Fibre Ropes S teel Wire Ropes Hybrid Ropes Multi-fall S ystems Hybrid S ystems Fibre Rope S ystems

Thursday, 27th September 2018

TOPICS

Introduction Ropes & Comparison Maintenance Approaches Conclusions

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ROPES & COMPARISON Considered Constructions and Materials

Steel Wire Rope

• Non rotating
• WS

C core

• S

teel

• S
• cket termination, …

Fibre Rope

• Braided rope
• HMPE
• Eye termination, …

Fibre Cable

• Parallel fibres
• HMPE
• Thimble termination

Continuous Parallel Fibre Yarns Thimble Thimble Core Wire Strand Rope Rope Strand Yarn Fibre

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10 20 30 40 50 60 150 300 450 600 750 900 1050 Weight [kg/m] MBL [ton]

Weight in Water vs MBL

Wire Rope Fibre Rope Parallel Fibre Cable

ROPES & COMPARISON Mechanical Properties Comparison

40 50 60 70 80 90 100 110 120 130 150 300 450 600 750 900 1050 Diameter [mm] MBL [ton]

Diameter vs MBL

Wire Rope Fibre Rope Parallel Fibre Cable 10 20 30 40 50 60 Wire Rope Fibre Ropes Parallel Fibre Cable Linear Weight [km/m]

Weight comparison @ 1000 tons MBL

W in Air W in Water

Note for any kind or rope: weight doesn’ t consider socket s, shackles, t himbles, or any

• t her connect ion component .

… however a comparison merely based on rope mechanical properties would return only rough information about applicability on different field application …

10 Thursday, 27th September 2018

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Steel Wire Rope Fibre Rope Parallel Fibre Cable Weight

Specific weight (7.85 kg/ dm3) Specific weight (0.9-1.5 kg/ dm3) depending on fibres material S ame specific weight of fibre ropes (due to base materials)

Diameter

High fill factors warrant low diameters Rope construction lead to higher diameters S ame diameter of steel wire ropes (due to manufacturing process)

Length

No technical limits No technical limits Limited to EW plant length 150 m

Temperature Resistance

Up to ab. 100° C Up to ab. 70-90° C (depending on fibres material) Up to ab. 70-90° C (depending on fibres material)

Cyclic Load Resistance

CBOS condition can be managed CBOS condition still critical for temperature build-up Infinite fatigue life under axial loading

Chemical Resistance

Corrosion issues on marine/ subsea envionment UV impact and water absorption (not for HMPE) can be managed UV impact and water absorption (not for HMPE) can be managed

Spool-ability

Typical D/d ratio 18-20 Typical D/d ratio up to 30 Not spoolable under tension

ROPES & COMPARISON Technology Benchmark

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ROPES & COMPARISON A Real Case: OIE Carrier Mooring Ropes

The Offset Installation Equipment carrier has been designed to intervene in case

• f

blow

• ut

event when no vertical access is possible

Weight Length Temperature Resistance Chemical Resistance Spool-ability Steel Wire Rope Fibre Rope Parallel Fibre Cable

A spoolable, light and temperature resistant fibre rope was finally selected

Thursday, 27th September 2018

TOPICS

Introduction Ropes & Comparison Maintenance Approaches Conclusions

13 Thursday, 27th September 2018

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MAINTENANCE APPROACHES Trends and Comparison

Maintenance has evolved from a corrective process, performed aft er a funct ional failure, t o a preventive activity where it ems are maint ained according to a time-schedule based on t he assumpt ion that a component has a defined lifet ime. However, estimat es of lifet ime have large uncertaint ies. In order to reduce t he uncert aint y condition-based maintenance, based on t he assessment of asset condit ion, emerged enabling also more sophist icat ed predictive approaches.

Downtimes System Reliability Repair Costs Risks Spare Parts Maintenance Effectiveness Operative Life On-site Maintainers Productivity

Preventive Maintenance Condition-Based Maintenance Predictive Maintenance Corrective Maintenance

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MAINTENANCE APPROACHES Rules & Regulations Ropes Integrity Management

Third Parties Requirements

• ISO

4309:2010 and API-RP-9B: est ablishes general principles for t he care and maint enance, and inspect ion and discard of st eel wire ropes used on cranes and hoist s

• IMCA-SEL-022: provides guidance on t he element s of an IMR syst em required t o achieve

an accept able level of ongoing safet y for t he use of wire ropes in a marine environment

• DNVGL-ST-E407: provides t he st ruct ure for assuring t hat rope based deployment and

recovery syst ems will funct ion as int ended unt il discarded

Internal Requirements

• Dedicated

Work Instructions, complement ary

• r

narrowing t he above ment ioned st andards, can be put in place providing inst ruct ions t o ensure t he correct condition of wire ropes by periodic inspect ions and maint enance on-board OCVs

General Note

• It has to be not iced t hat DNVGL-ST-E407 and IMCA-SEL-022 opens t o a continuous

monitoring and predictive approaches for wire rope monitoring, while ot her above ment ioned standards mainly reflect a preventive maintenance approach

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MAINTENANCE APPROACHES Focus on Construction Vessels

An Offshore Construction Vessel is a complex system, which ropes need different maintenance strategies depending on their usage, criticality and also associated capital and operating expenditure.

Pipeline A&R Deck & subsea Cranage Mooring AHC subsea deployment Lifeboat cranage

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MAINTENANCE APPROACHES Adopt, Adapt, Improve Philosophy

• Three

possible complementary and incremental strategies can be adopted depending

• n

technology maturity, application and equipment specificity,

• perations associated risks:
• Adopt methods, procedures and regulations that have proved so sound in the past ;

suitable for standard equipment and operations (e.g. on deck lifting)

• Adapt

them to the changing needs of the t imes, depending on the scenario peculiarities (e.g. heavy lifting for offshore modules installations)

• Wherever possible, improve them t o cope with all those specific and peculiar cases

not covered by available methodologies (e.g. ultra deep water deployment with large diameter heave compensates steel wire ropes)

Technology Maturity Standard Application Equipment specificity Associated Risks

ADOPT ADAPT IMPROVE

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MAINTENANCE APPROACHES Wire Rope Monitoring System

Rope Fatigue Monitoring System*

• Records and logs the accumulated number of bending cycles along the

entire rope length and life

• Returns for

each rope meter the number

• f cycles the rope has

experiences and the equivalent percentage of rope fatigue life

Machine Vision System

• Monitors the wire rope geometry along the entire rope length
• Returns information about the rope geometry in terms of diameter,
• vality and spikes

Temperature Monitoring Vision System

• Monitors the wire rope temperature at the exit point of the fixed

sheave of the AHC

• Returns the rope and the sheave temperatures

Data Sharing

• Data are shared with WRMS specialist of the Maintenance and Upgrade

Technical S ervice, Vessel Asset Managers and maintenance surveyor

* Deeply presented in 2016 IMCA rope workshop

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PRESENT & FUTURE IMR APPROACHES Further Developments

Predictive Tools

• Data driven predictive tools are under

development based

• n semi-

empirical models and on opportunities related to digital technologies (e.g. bid data management, machine learning, … )

Operations Automation

• Higher level of automation and support to operators in st andard lifting and

rigging operat ions are pursued aiming at increasing unmanning of the

• ffshore

installation activit ies and vessels and a subsequent safety enhancement

Thursday, 27th September 2018

TOPICS

Introduction Ropes & Comparison Maintenance Approaches Conclusions

20 Thursday, 27th September 2018

This document is property of Saipem S.p.A. who will safeguard it s right according t o t he civil and penal provisions of t he law. The content of this document is confidential and cannot be disclosed wit hout S aipem S .p.A. writ t en aut horizat ion.

CONCLUSIONS General Outcomes

• Ropes and related systems and technologies are becoming more

and more crucial for an offshore EPCI contractor

• Different rope technologies, alternative to steel wire ropes, are

available on the market and can be effectively adopted depending

• n the application
• Beside

rope technologies also IMR procedures are under improvement exploiting also digital technology

• pportunities

aiming at increase operations safety and efficiency

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matteo.ducceschi@ saipem.com davide.rossin@ saipem.com