U.S. patent application number 15/604139 was filed with the patent office on 2017-09-07 for self-adjusting reel assembly apparatus, system and method.
This patent application is currently assigned to Reel Power Licensing Corp.. The applicant listed for this patent is Benton Frederick Baugh. Invention is credited to Benton Frederick Baugh.
Application Number | 20170254160 15/604139 |
Document ID | / |
Family ID | 57504608 |
Filed Date | 2017-09-07 |
United States Patent
Application |
20170254160 |
Kind Code |
A1 |
Baugh; Benton Frederick |
September 7, 2017 |
SELF-ADJUSTING REEL ASSEMBLY APPARATUS, SYSTEM AND METHOD
Abstract
The present invention is a computer controlled reel apparatus,
system and method of using same that may generally maintain
constant tension on a reel umbilical.
Inventors: |
Baugh; Benton Frederick;
(Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Baugh; Benton Frederick |
Houston |
TX |
US |
|
|
Assignee: |
Reel Power Licensing Corp.
Oklahoma City
OK
|
Family ID: |
57504608 |
Appl. No.: |
15/604139 |
Filed: |
May 24, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15177603 |
Jun 9, 2016 |
9689215 |
|
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15604139 |
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62174348 |
Jun 11, 2015 |
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62174363 |
Jun 11, 2015 |
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62174368 |
Jun 11, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 17/01 20130101;
E21B 19/006 20130101; E21B 19/22 20130101; E21B 19/02 20130101;
E21B 19/008 20130101; G01P 13/02 20130101; F16D 65/092 20130101;
G05B 15/02 20130101; F16D 7/02 20130101 |
International
Class: |
E21B 19/00 20060101
E21B019/00; E21B 19/02 20060101 E21B019/02; E21B 17/01 20060101
E21B017/01 |
Claims
1. A reel assembly for an offshore umbilical comprising: a frame
having an axle; a spool having flanges and a drum wherein said
spool is mounted on said axle and adapted to hold said offshore
umbilical; a motor in communication with said spool and adapted to
rotate said spool; a tensioning device adapted to automatically
maintain a relatively constant tension and a relatively constant
slippage load on said umbilical when deployed from said spool; and
a processing computer in communication with said tensioning device
and said motor wherein said processing computer is adapted to
compute said relative constant tension and said relative constant
slippage and control said motor.
2. The reel assembly of claim 1 wherein said tensioning device
includes at least one slip clutch attached to said frame, adapted
to engage said spool, and in communication with said processing
computer.
3. The reel assembly of claim 1 wherein said tensioning device
includes at least two proximity sensors attached to said spool,
adapted to detect rotational direction of said spool, and in
communication with said processing computer.
4. The reel assembly of claim 1 wherein said tensioning device
includes at least two accelerometers attached to said spool,
adapted to detect rotational direction of said spool; and in
communication with said processing computer.
5. The reel assembly of claim 1 further including a computer module
in wireless communication with said processing computer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed from U.S. Provisional Application Ser.
Nos. 62/174,348, 62/174,363, and 62/174,368 all filed on Jun. 11,
2015, and incorporated by reference herein.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] In general, the present invention relates to an apparatus,
system and method for a self-adjusting computer controlled reel
assembly. More particularly, the present invention provides a new
and improved reel assembly that may maintain a constant tension and
constant slippage setting on the umbilical of an offshore reel as
the radius to the umbilical varies and the deployment direction is
reversed.
[0004] 2. Description of the Prior Art
[0005] When subsea blowout preventer stacks are lowered to the
seafloor to facilitate the drilling of oil and gas wells, they are
lowered on a drilling riser, which has a long conduit with an inner
diameter typically about nineteen inches, which acts as the main
conduit for the drilling operations. On the outside of this conduit
will be flotation material to make it lighter in water, high
pressure circulation lines called choke and kill lines, and control
umbilicals. The control umbilicals can be hydraulic, electrical,
fiber optic, or a combination of these.
[0006] The umbilicals are clamped to the high pressure lines on the
riser such that the drilling riser carries the weight of the
deployed lines. The umbilicals are handled at the surface by reels,
which must payout the umbilical when the drilling riser is lowered
and rewind the umbilical when the drilling riser is retrieved.
Umbilicals may be hoses, wire rope, cable, hoses, fiber optics,
electrical, or combinations of these.
[0007] A first level of control of these reels was to have a valve
controlling a motor on the reels and simply keep up with the
movement of the drilling riser. This was made practical with a
"service loop" which sent the umbilicals over a first sheave, down
a loose loop, back up over a second sheave, and then clamped to the
riser.
[0008] A next level of control was to simply use an air throttle
and put the umbilical in tension at all times. When the drilling
riser is lowered, it pulls the motor against the pneumatic supply
and pumps air back into the air system, somewhat like regeneration,
or dumped the generated air across a relief valve. Dumping the
generated air is more workable as the pneumatic supply is likely of
too high a pressure to pump back into. As the radius to the
umbilical being deployed from a full spool to an empty spool can
vary by as much as 3/1, an umbilical tension of 1,000 lbs. at the
outer wrap will translate into 3,000 lbs. at the inner wrap. This
means that you must have personnel monitoring the reel to keep the
tension down with a reasonable range. Furthermore, you have a slip
clutch to prevent high tension if a drilling riser is lowered when
the brakes are set on the reel; a slip clutch setting of 1,500 lbs.
at the outer wrap becomes a slip clutch setting of 4,500 lbs. at
the inner wrap.
[0009] What this means is that in all these cases, personnel must
be committed to monitor and control the umbilical tension at all
times during the running operations. This added head count in a
space constrained expensive offshore rig is required at the
critical time when the blowout preventer stack and drilling riser
is run and personnel commitment is at the maximum.
[0010] Even with the added personnel commitment to monitor and
control the umbilical tension, no solution has been available for
this high safety slippage setting when the umbilical is being paid
off from the inner wraps. With the long studies of trying to reduce
personnel requirements on these offshore rigs, there has been no
solution offered for these problems.
[0011] Prior art attempts at improvements to this problem have
obviously not provided the desired solutions. Thus, there is a need
for an apparatus, process and or system that provides a
self-adjusting intelligent reel assembly for reels. The above
discussed limitations in the prior art is not exhaustive. The
current invention provides an inexpensive, time saving, more
reliable apparatus, method and system for reels where the prior art
fails.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing disadvantages inherent in the known
types of reels utilized with offshore applications now present in
the prior art, the present invention provides a new and improved
reel apparatus, system and method of using same. As such, the
general purpose of the present invention, which will be described
subsequently in greater detail, is to provide a new and improved
reel, which has all the advantages of the prior art devices and
none and or fewer of the disadvantages.
[0013] It is, therefore, contemplated that the present invention is
an apparatus, system and method of automatically maintaining a
relatively constant tension and a relatively constant slippage load
on an umbilical which is deployed from a spool on a reel by being
clamped to a subsea drilling riser comprising a frame having an
axle; a spool having flanges and a drum wherein said spool is
mounted on said axle and adapted to hold said offshore umbilical; a
motor in communication with said spool and adapted to rotate said
spool; a tensioning device adapted to automatically maintain a
relatively constant tension and a relatively constant slippage load
on said umbilical when deployed from said spool; and a processing
computer in communication with said tensioning device and said
motor wherein said processing computer is adapted to compute said
relative constant tension and said relative constant slippage and
control said motor.
[0014] There has thus been outlined, rather broadly, the more
important features of the invention in order that the detailed
description thereof that follows may be better understood and in
order that the present contribution to the art may be better
appreciated. There are, of course, additional features of the
invention that will be described hereinafter and which will form
the subject matter of the claims appended hereto.
[0015] In this respect, before explaining at least one embodiment
of the invention in detail, it is to be understood that the
invention is not limited in this application to the details of
construction and to the arrangements of the components set forth in
the following description or illustrated in the drawings. The
invention is capable of other embodiments and of being practiced
and carried out in various ways. Also, it is to be understood that
the phraseology and terminology employed herein are for the purpose
of description and should not be regarded as limiting. As such,
those skilled in the art will appreciate that the conception upon
which this disclosure is based may readily be utilized as a basis
for the designing of other structures, methods and systems for
carrying out the several purposes of the present invention. It is
important, therefore, that the claims be regarded as including such
equivalent constructions insofar as they do not depart from the
spirit and scope of the present invention.
[0016] Further, the purpose of the foregoing abstract is to enable
the U.S. Patent and Trademark Office and the public generally, and
especially the engineers and practitioners in the art who are not
familiar with patent or legal terms or phraseology, to determine
quickly from a cursory inspection the nature and essence of the
technical disclosure of the application. The abstract is neither
intended to define the invention of the application, which is
measured by the claims, nor is it intended to be limiting as to the
scope of the invention in any way.
[0017] Therefore, it is an object of the present invention to
provide a new and improved reel apparatus, system and method of
utilizing same that may provide an automatically controlling of the
tension of a deepwater umbilical as a blowout preventer stack is
lowered on a drilling riser and the radius to the umbilical
changes.
[0018] Furthermore, an object of the present invention is to
provide a new and improved reel apparatus, system and method of
utilizing same to provide an automatically controlling of the spool
slippage setting of a deepwater umbilical as a blowout preventer
stack is lowered on a drilling riser and the radius to the
umbilical changes.
[0019] Another object of the present invention is to provide a new
and improved reel apparatus, system, and method of utilizing same
to provide a method of intrinsically safely automatically
controlling the tension of a deepwater umbilical as a blowout
preventer stack is lowered on a drilling riser and the radius to
the umbilical changes.
[0020] Yet another object of the present invention is to provide a
new and improved reel apparatus, system and method of utilizing
same to provide a method of intrinsically safely automatically
controlling the spool slippage setting of a deepwater umbilical as
a blowout preventer stack is lowered on a drilling riser and the
radius to the umbilical changes.
[0021] Still another object of the present invention is to provide
a new and improved reel apparatus, system and method of utilizing
same that may intrinsically safely determine the direction of
rotation of the spool.
[0022] Yet another object of the present invention is to provide a
new and improved reel apparatus, system and method of utilizing
same that may provide air to increase slippage.
[0023] It is a further object of the present invention to provide a
new and improved reel apparatus, system and method of utilizing
same, which is of a durable and reliable construction and may be
utilized in numerous types of reel and or winch applications.
[0024] An even further object of the present invention is to
provide a new and improved reel apparatus, system and method of
utilizing same, which is susceptible to a low cost of manufacture,
installation and labor, which accordingly is then susceptible to
low prices of sale to the consuming industry, thereby making such a
system economically available to those in the field.
[0025] Still another object of the present invention is to provide
a new and improved reel apparatus, system and method of utilizing
same, which provides all of the advantages of the prior art while
simultaneously overcoming some of the disadvantages normally
associated therewith.
[0026] These, together with other objects of the invention, along
with the various features of novelty, which characterize the
invention, are pointed out with particularity in the claims annexed
to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages, and the
specific objects attained by its uses, reference should be had to
the accompanying drawings and descriptive matter in which there are
illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE PICTORIAL ILLUSTRATIONS, GRAPHS, DRAWINGS,
AND APPENDICES
[0027] The invention will be better understood and objects other
than those set forth above will become apparent when consideration
is given to the following detailed description thereof. Such
description makes reference to the annexed pictorial illustrations,
graphs, drawings and appendices.
[0028] FIG. 1 is a general illustration of a preferred embodiment
in accordance with the invention depicting a system of subsea
equipment utilizing a reel with the characteristics of this
invention.
[0029] FIG. 2 is a general illustration of a preferred embodiment
in accordance with the invention depicting a perspective view of a
reel utilizing the features of this invention.
[0030] FIG. 3 is a general illustration of a preferred embodiment
in accordance with the invention depicting a front view of the reel
of FIG. 2.
[0031] FIG. 4 is a general illustration of a preferred embodiment
in accordance with the invention depicting an end view of the reel
of FIG. 2.
[0032] FIG. 5 is a general illustration of a preferred embodiment
in accordance with the invention depicting a perspective view of a
slip clutch which is utilized in this invention.
[0033] FIG. 6 is a general illustration of a preferred embodiment
in accordance with the invention depicting a side view of the slip
clutch of FIG. 5 taken generally along section lines "6-6".
[0034] FIG. 7 is a half section of the cylinder portion of the slip
clutch taken generally along section lines "7-7".
[0035] FIG. 8 is a general illustration of a preferred embodiment
in accordance with the invention depicting a schematic of the
implementation of the present invention utilizing a single computer
module.
[0036] FIG. 9 is a general illustration of a preferred embodiment
in accordance with the invention depicting a schematic of the
implementation of the present invention utilizing a stationary
computer module on the frame and a rotating computer module in the
spool.
[0037] FIG. 10 is a general illustration of a preferred embodiment
in accordance with the invention depicting an independent module
utilized to update the modules of the schematics in FIGS. 8 and
9.
[0038] FIG. 11 is a general illustration of a preferred embodiment
in accordance with the invention depicting a schematic of the
implementation of the present invention.
DETAILED DESCRIPTION OF INVENTION
[0039] Referring to the illustrations, drawings and pictures,
reference character 10 generally designates a new and improved reel
apparatus, system and method of using same that may generally
maintain constant tension on a reel umbilical. Invention 10 is
generally used with reels and or winches with offshore applications
but is to be understood that invention 10 may be utilized for
non-offshore applications and may be utilized in other operations
with reels and or winches in general. For purposes of convenience,
the reference numeral 10 may generally be utilized for the
indication of the invention, portion of the invention, preferred
embodiments of the invention and so forth.
[0040] Referring now to FIG. 1, a view of a complete system for
drilling subsea wells 20 is shown in order to illustrate the
utility of the present invention. The drilling riser 22 is shown
with a central pipe 24, outside fluid lines 26, and umbilical,
cable or hose 28.
[0041] Below the drilling riser 22 is a flex joint 30, lower marine
riser package 32, lower blowout preventer stack 34 and wellhead or
wellhead system 36 landed on the seafloor 38.
[0042] Below the wellhead 36, it can be seen that a hole was
drilled for a first casing string 40, that first casing string 40
was landed and cemented in place, a hole drilled through the first
casing string 40 for a second casing string 42, the second casing
string 42 cemented in place, and a hole is being drilled for a
third casing string by drill bit 44 on drill string 46.
[0043] The lower blowout preventer stack 34 generally comprises a
lower hydraulic connector for connecting to the subsea wellhead
system 36, usually 4 or 5 ram style blowout preventers, an annular
preventer, and an upper mandrel for connection by the connector on
the lower marine riser package 32, which are not individually shown
but are well known in the art.
[0044] Below outside fluid line 26 is a choke and kill (C&K)
connector 50 and a pipe 52, which is generally illustrative of a
choke or kill line. Pipe 52 goes down to valves 54 and 56, which
provide flow to or from the central bore of the blowout preventer
stack as may be appropriate from time to time. Typically, a kill
line will enter the bore of the blowout preventers below the lowest
ram and has the general function of pumping heavy fluid to the well
to overburden the pressure in the bore or to "kill" the pressure.
The general implication of this is that the heavier mud cannot be
circulated into the well bore, but rather must be forced into the
formations. A choke line will typically enter the well bore above
the lowest ram and is generally intended to allow circulation in
order to circulate heavier mud into the well to regain pressure
control of the well. Normal circulation is down the drill string
46, through the drill bit 44.
[0045] In normal drilling circulation, mud pumps 60 take drilling
mud 62 from mud tank 64. The drilling mud 60 will be pumped up a
standpipe 66 and down upper end 68 of the drill string 46. It will
be pumped down the drill string 46, out the drill bit 44, and
return up the annular area 70 between the outside of the drill
string 46 and the bore of the hole being drilled, up the bore of
the second casing string 42, through the subsea wellhead system 36,
the lower blowout preventer stack 34, the lower marine riser
package 32, up the drilling riser 22, out a bell nipple 72 and back
into the mud tank 64.
[0046] During situations in which an abnormally high pressure from
the formation has entered the well bore, the thin walled central
pipe 24 is typically not able to withstand the pressures involved.
Rather than making the wall thickness of the relatively large bore
drilling riser thick enough to withstand the pressure, the flow is
diverted to a choke line or outside fluid line 26. It is more
economical to have a relatively thick wall in a small pipe to
withstand the higher pressures than to have the proportionately
thick wall in the larger riser pipe.
[0047] When higher pressures are to be contained, one of the
annular or ram blowout preventers are closed around the drill pipe
and the flow coming up the annular area 70 around the drill pipe is
diverted out through choke valve 54 into the pipe 52. The flow
passes up through C&K connector 50, up outside fluid lines 26,
which is attached to the outer diameter of the central pipe 24,
through choking means illustrated at 74, and back into the mud tank
64.
[0048] On the opposite side of the drilling riser 22 is shown cable
or hose 28 coming across a sheave 80 from a reel 82 on vessel 84.
The cable or hose 28 is shown characteristically entering the top
90 of the lower marine riser package 32. These cables 28 typically
carry hydraulic, electrical, multiplex electrical, or fiber optic
signals. Typically, there are at least two of these cable 28
systems for redundancy, which are characteristically painted yellow
and blue. As the umbilicals 28 enter top 90 of the lower marine
riser package 32, they typically enter a control pod 92 to deliver
their supply or signals. Hydraulic supply is delivered to one or
more dual hydraulic accumulators 94 located on the lower marine
riser package 32 or the lower blowout preventer stack 34 to store
hydraulic fluid under pressure until needed.
[0049] Referring now to FIG. 2, the reel 82 is shown in greater
detail. Reel 82 has frame 100, lifting padeyes 102, 104, 106 and
108, spool 110 having flanges 111 and drum 112 mounted on axle 113
and bearing 114, slip clutches 116, motor 118, swivel 120,
levelwind assembly 122 mounted on banana shaped mounting 124,
control box 126, and gear or sprocket 128. Swivel 120 can be
hydraulic, electrical, fiber optic, or a combination of any of
these. Gear or sprocket 128 is mounted on slip clutches 116 which
are fixed to spool 110.
[0050] Also shown on reel 82 are frame control module 130 and spool
control module 132 which is shown inside spool 110.
[0051] Referring now to FIG. 3, the relationship of slip clutches
116 and the frame control module 130 is shown such that as spool
110 rotates, each of the slip clutches 116 pass near frame control
module 130. As will be discussed later, each time a slip clutch 116
passes the frame control module 130, they will be detected and
counted to determine both the number of rotations of the spool 110
and the direction of rotation of the spool 110. In an alternate
embodiment, accelerometers on or within spool 110 will provide this
capability.
[0052] Referring now to FIG. 4, slip clutches 116A, 116B and 116C
are seen, with the fourth slip clutch 116D being hidden behind
control box or panel 126. This means that for each rotation of the
spool 110, spool control module 132 will see four indications, so
will divide the number by 4 to get the actual number of rotations.
Access covers 134 and 136 are shown on the end of spool 110. These
give access to the inside of the spool 110 to install and service
spool control module 132.
[0053] Referring now to FIG. 5, a perspective view of one of slip
clutches 116 is seen, showing mounting bolts 150 to fix it to the
side of spool 110, brake pads 152 and 154 to engage the gear or
sprocket 128 and provide a frictional gripping force, and cylinder
156, which provides controlled loading to regulate the frictional
slipping load.
[0054] Referring now to FIG. 6, a view of slip clutch 116 is shown
according to the view "6-6" taken from FIG. 5. Gap 158 is shown
between brake pads 152 and 154 for slidable receipt of gear or
sprocket 128.
[0055] Referring now to FIG. 7, a half section of cylinder 156 is
shown taken from section "7-7" of FIG. 6. Spring washers 170
provide a force against piston 172, which in turn loads brake pad
152 through end 174. Regulated air pressure through port 176 on
piston area 178 provides a force to offset the force of spring
washers 170, regulating the force on end 174, and therefore, brake
pad 152 to adjust the force required to cause gear or sprocket 128
to slip. Regulated air pressure through port 180 and porting 182 in
piston 172 act on piston area 184 of piston 172 to be additive to
the force of spring washers 170 when greater frictional force is
desired. Piston cap 186 is rotated on threads 188 to provide an
initial mechanical adjustment to the magnitude of force from spring
washers 170.
[0056] Referring now to FIG. 8, box 200 generally encompasses the
mechanical components of reel 82, box 202 generally encompasses the
components of the local control panel 126, box 204 generally
encompasses the components of the frame control module 130, and box
206 generally encompasses the components of the driller's control
panel.
[0057] Box 200 includes spool 110, axle 113, slip clutches 116A to
116D, air swivel 210, air supply 212, air shutoff valve 214, air
motor 216 with gear or sprocket 218 mounted, driven gear or
sprocket 220, and levelwind drive motor 222. Driven gear or
sprocket 220 is shown aligned with gear or sprocket 218 and is also
shown with a face view having four protrusions 224 at 90 degrees.
The protrusions 224 are likely a portion of the slip clutches 116
but they can be other quantities and other components. Brakes 226
are shown and will be operated by control box 126.
[0058] Box 202 includes the components of a pneumatic control box
which would provide constant torque control of a reel, and some
components which change it to having constant tension operation, as
will be described as follows.
[0059] Box 204 is the control box which includes the components
which convert the reel to constant tension operation. Proximity
sensor(s) or sensing component(s) 230 and 232 can be acoustic,
laser, microwave, or other means to detect when the protrusions 224
pass by. Further they are positioned such that both will sense
protrusion 224 one after the other, but the second to sense
protrusion 224 will also sense before the first stops sensing.
Sensing component 230 is the primary sensing component and sensing
component 232 is the secondary sensing component. When sensing
component 230 first senses one of the protrusions 224, sensing
component 232 will be checked to see if it is sensing at the same
time. If sensing component 232 is sensing when sensing component
230 starts sensing protrusion 224, it will mean that the reel is
rotating in the take-up direction. If sensing component 232 is not
sensing when sensing component 230 starts sensing protrusion 224,
it will mean that the reel is rotating in the payout direction.
[0060] Processing computer 240 is initially set up with inputs on
the spool drum diameter, spool width, spool flange diameter,
umbilical diameter, the starting dimension from the outer diameter
of the spool flange, and the distance from the side of the spool
flange to the current umbilical position. The processing computer
240 receives the indications from sensing components 230 and 232,
calculates the current wrap of the umbilical on the spool, and
determines the appropriate motor air pressure to provide the
appropriate torque and the appropriate slip clutch air pressure for
port 176 of FIG. 7 to set the appropriate slippage setting. The
general goal of these calculations is to end up with a constant
tension pull on the umbilical, e.g. 1000 lbs., and an appropriate
slippage setting on the spool, e.g. 1,500 lbs. umbilical tension.
This umbilical tension setting and slippage setting is to remain
relatively constant from a full spool starting the lowering of the
blowout preventer stack to its landing on the seafloor and back up
to the surface. This not only involves the fact that the motor
torque and slippage settings must change each time the umbilical
starts on new wrap level, but also that simply reversing the reel
has frictional hysteresis assisting you in one direction and
working against you in the other direction.
[0061] The computed appropriate motor air pressure is sent to the
motor along line 250 to selector valve 252, to large bore pressure
regulator 254, through large bore selector valve 256, and then to
air motor 216. The method of generating the appropriate air motor
pressure signals is to measure the pressure in line 250 using
pressure transmitter 260 and sending the information back to the
processing computer 240 along wire 262. If the air pressure in line
250 is low, processing computer 240 sends a signal through wire 264
to valve 266 to temporarily open the valve and let the higher
supply pressure in supply line 268 vent into line 250. If the air
pressure in line 250 is low, processing computer 240 sends a signal
through wire 270 to valve 272 to temporarily open the valve and
vent the pressure in line 250 to reduce the pressure. Processing
computer 240 is programmed in a repetitive loop, so it will
repeatedly check the pressure in line 250 through pressure
transmitter 260, continually making sure the pressure in line 250
is within the required pressure band.
[0062] When deploying the umbilical and all the umbilical is
deployed for a wrap and the reel starts to deploy from the next
lower wrap, the radius is reduced so the spool/motor torque
requirement is reduced. At that time the computer 240 computes the
lower pressure required for line 250 and begins pulsing valve 272
until the pressure is in the proper range. Alternately, when
recovering the umbilical as the blowout preventer stack returns to
the surface and the umbilical begins wrapping on the next higher
layer, the computer 240 begins pulsing valve 266 to increase the
pressure in line 250 to the required computed level.
[0063] Similarly a signal is calculated by processing computer 240
and built in line 280 for slip clutches 116A, 116B, 116C and 116D
using pressure transmitter 282, valve 284 to increase the pressure,
and valve 286 to reduce the pressure. In this case the signal in
line 280 is communicated to the slip clutches 116A, 116B, 116C and
116D through air swivel 210. Air swivel 210 can be made integrally
with the axle 113 or can be a slip on air swivel 210 as is
illustrated in FIG. 8.
[0064] Box 206 shows a single valve 290, which is mounted in a
remote location such as the driller's control house. Valve 290 is a
two position detented valve and in the present position, the
pressure in line 292 is simply vented. This means that the air
signal in line 250 will be communicated through valve 252 to
regulator 254 and sets the pressure on the motor as determined by
the processing computer 240. Similarly, the air signal in line 280
will be communicated through valve 298 to the slip clutches 116A,
116B, 116C and 116D as determined by the processing computer 240.
When valve 290 is moved to the alternated detent position, higher
pressure air supply from line 294 is introduced into line 292
shifting valve 252 to allow the pressure from the manual throttle
296 to control the motor pressure and shifting valve 298 to vent
the air pressure from the slip clutches 116A, 116B, 116C and 116D.
This returns the reel to what is known as constant torque control,
or a reel which simply maintains the present spool torque until the
throttle is changed and has no adjustment on the slip clutch
settings. Valve 300 is the brake control valve.
[0065] Infrared port 302 is used to refresh the computer program in
process computer 240 through line 304 when an upload module as will
be described later is engaged with profile 306 for proper
alignment.
[0066] Referring now to FIG. 9, a schematic similar to FIG. 8 is
illustrated, with boxes 202 and 204 being identical. Reel box 200
is replaced with reel box 310 and box 204 is replaced with box 312
and box 314.
[0067] Box 314 is also shown to be located inside spool 110 as
shown in box 310 rather than on the frame as box 312 and box 204
are. Whereas box 204 provided a single processing computer 240 to
control both the motor pressure and the slip clutch pressure, in
this configuration box 312 controls the motor pressure and box 314
controls the slip clutch pressure. One effect of this is that the
signal is going through the swivel in the opposite direction, and
another is that you no longer need a swivel if you make battery
pack 315 within box 314 large enough to run several trips to the
seafloor or sufficient air supply can be supplied in air tank 316
through connector 317 or air swivel 210 to power air motor 318,
which drives generator 319 to keep the battery pack 315
charged.
[0068] Box 310 shows that the air supply line 268 is taken by air
line 320, through valve 322, line 324 and exits from the air swivel
210 as air line 326, which goes to power the box 314. Whenever the
valve 290 in box 206 is actuated and applies pressure to line 292,
valve 322 is shifted and the pressure in lines 324 and 326 is
dumped returning the slip clutches to the default constant torque
(non-adjustable) mode.
[0069] Box 312 includes all the components of box 204 of FIG. 8
except the components 280, 282, 284 and 286, which were used to
control the setting on slip clutches 116A, 116B, 116C and 116D,
which are included in box 314.
[0070] Infrared port 325 is used to refresh the computer program in
process computer 327 through line 328 when an upload module as will
be described later in engaged with profile 330 for proper
alignment.
[0071] Box 314 is located within the spool 110 (as shown in box
310), it does not have the reference information which box 204
provided. Accelerometers 350 and 352 are provided to detect
rotations and rotational direction as will be described later. As
was done in FIG. 8, this will be used to determine whether the
umbilical is going to the next outer or the next inner wrap when it
reaches either of the side flanges on the spool.
[0072] The computation of the needed slip clutch pressure is done
in process computer 354 and sent to the slip clutches 116A, 116B,
116C and 116D along lines 356 and 358. Valve 359 is provided
between lines 356 and 358 and is opened by pressure from the supply
air line 326 along line 360 to allow the computed signal to pass.
If the supply pressure is reduced to zero, the supply signal in
line 360 is vented and the reel returns to constant torque
operation.
[0073] A signal is calculated by processing computer 354 and built
in line 356 for slip clutches 116A, 116B, 116C and 116D using
pressure transmitter 362, valve 364 to increase the pressure, and
valve 366 to reduce the pressure, similarly as pressure transmitter
282, valve 284, and valve 286 were used in FIG. 8.
[0074] Infrared port 370 is used to refresh the computer program in
process computer 354 through line 372 when an upload module as will
be described later is engaged with profile 374 for proper
alignment.
[0075] Referring now to FIG. 10, in one full rotation of spool 110,
the accelerometers will see plus one g's and minus one g's and can
count the g cycles as rotations. When primary accelerometer 331 is
at one-g displaced as shown, secondary accelerometer 332 can be
positioned at 45 degrees as shown towards the payout direction 361.
This angle is an example, the actual angle can be any angle other
than 0 degrees, 90 degrees, 180 degrees, or 270 degrees. When the
primary accelerometer 331 is at zero-g's, whether the secondary
accelerometer 332 is reading plus one or minus one-g's will tell
the direction of rotation. In this case, if the g-readings are
declining it will mean that the spool 110 is rotating in the payout
direction. If the g-readings are increasing it will mean that the
spool 110 is rotating in the take-up direction. This information
can be fed back into the process computer 354 to determine when the
umbilical comes to the end of a wrapping a layer whether to add to
the radius to the umbilical or to subtract from it.
[0076] Referring now to FIG. 11, an upload module 380 which as a
profile 382 for convenient engagement and alignment with profiles
306, 330, and 374 when process computers 240, 327, or 354 need to
be initially programmed or refreshed. Infrared transmitter 384
engages infrared port 302, 325, or 370 for initially programming or
refreshing the appropriate process computers. Process computer 388
is uploaded from a standard computer through a USB or other port
390 which is made explosion proof by an appropriate cap protector
392. Lines 394 connect the port 390 to process computer 388 and
line 396 in turn connects process computer 388 to the infrared port
384.
[0077] When upload module 380 is taken to refresh a process
computer on the reel, it will often be in the hazardous explosion
prone area of an offshore drilling rig. For this reason all modules
used need to be explosion proof. In this case the switches required
to operate the upload models are magnetic switches buried in solid
potting material 397. The other modules described before will
likely be of the same construction. Magnet 400 is used to operate
the switches with functions such as off and on 402, enter, upload
in upload mode 404 or download in download mode 406, increase
reading 408, and decrease reading 410. Readout 412 will display the
readings of the current mode being adjusted. Likely only the off
and on, upload, and download buttons will be used and most
programming will simply be input through port 390.
[0078] Invention 10, therefore, contemplates a reel assembly for an
offshore umbilical comprising a frame having an axle; a spool
having flanges and a drum wherein said spool is mounted on said
axle and adapted to hold said offshore umbilical; a motor in
communication with said spool and adapted to rotate said spool; a
tensioning device adapted to automatically maintain a relatively
constant tension and a relatively constant slippage load on said
umbilical when deployed from said spool; and a processing computer
in communication with said tensioning device and said motor wherein
said processing computer is adapted to compute said relative
constant tension and said relative constant slippage and control
said motor.
[0079] Invention 10 also therefore contemplates a reel assembly for
an offshore umbilical wherein said tensioning device includes at
least one slip clutch attached to said frame, adapted to engage
said spool, and in communication with said processing computer;
wherein said tensioning device includes at least two proximity
sensors attached to said spool, adapted to detect rotational
direction of said spool, and in communication with said processing
computer; wherein said tensioning device includes at least two
accelerometers attached to said spool, adapted to detect rotational
direction of said spool; and in communication with said processing
computer; and may further include a computer upload module in
wireless communication with said processing computer.
[0080] The particular embodiments disclosed above are illustrative
only, as the invention may be modified and practiced in different
but equivalent manners apparent to those skilled in the art having
the benefit of the teachings herein. Furthermore, no limitations
are intended to the details of construction or design herein shown,
other than as described in the claims below. It is therefore
evident that the particular embodiments disclosed above may be
altered or modified and all such variations are considered within
the scope and spirit of the invention. Accordingly, the protection
sought herein is as set forth in the claims below.
[0081] Changes may be made in the combinations, operations, and
arrangements of the various parts and elements described herein
without departing from the spirit and scope of the invention.
Furthermore, names, titles, headings and general division of the
aforementioned are provided for convenience and therefore, should
not be considered limiting.
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