Offshore Reel Tension Control via Proximity Sensor Direction Detection
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Solution Overview
Problem
Current offshore reel systems require manual monitoring to maintain constant tension and slippage settings during the deployment and retrieval of umbilicals, which is labor-intensive and inefficient, especially when the radius of the umbilical changes, leading to varying torque requirements.
Innovation Solution
A self-adjusting reel system utilizing dual proximity sensors to determine the rotational direction of the spool, automatically maintaining constant tension and slippage by adjusting motor torque and slip clutch frictional load based on the umbilical's radius and position, with sensors detecting indicator pads to calculate appropriate settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual monitoring is used to maintain constant tension and slippage settings, then personnel can directly control and adjust settings, but labor intensity increases and efficiency decreases
Solution Approach 1:
The reel system automatically monitors and adjusts tension and slippage settings without requiring continuous manual intervention. Sensors detect umbilical position and radius changes, and the control system automatically adjusts motor torque and slip clutch settings, allowing the system to serve itself
Solution Approach 2:
Manual mechanical monitoring and adjustment operations are replaced with an automated electronic control system that uses sensors, processors, and actuators to maintain tension and slippage settings, eliminating the need for continuous manual operation
2Force
If tension is maintained at outer wrap radius, then adequate tension is provided, but at inner wrap radius the same tension setting creates excessive force
Solution Approach 1:
The tension control system dynamically adjusts the motor torque setting based on the real-time radius of the umbilical wrap. As the umbilical transitions from outer to inner wraps, the system automatically reduces the torque setting to maintain appropriate tension levels, making the control adaptable to changing conditions
Solution Approach 2:
The system uses sensors to continuously monitor the umbilical position and wrap radius, feeding this information back to the control system which then adjusts the motor torque and slip clutch settings accordingly, creating a closed-loop control system
3Reliability
If slip clutch setting is increased to prevent high tension at inner wrap, then safety is improved, but the setting becomes excessively high for outer wrap deployment
Solution Approach 1:
The slip clutch setting is dynamically adjusted based on the umbilical wrap radius. The system reduces the slip clutch setting as the umbilical moves to inner wraps and increases it for outer wraps, providing appropriate safety margins at each stage without excessive settings
4Extent of automation
If dual proximity sensors are added to detect rotational direction, then automation capability is improved, but device complexity increases
Solution Approach 1:
Mechanical direction detection methods are replaced with electronic proximity sensors that detect the rotation direction of the spool by monitoring the passage of indicator pads, providing automated detection with simpler mechanical components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Automates the maintenance of constant tension and slippage settings, reducing the need for manual monitoring and minimizing personnel requirements, while ensuring reliable operation across varying umbilical radii and directions of rotation.
Implementation Method 1
determining the direction of rotation of the spool by fixing the position of two or more proximity sensors in a predetermined relationship to one or more indicator pads such that when a first proximity sensor detects the one or more indicator pads, if a second proximity sensor is detecting the one or more indicator pads it will mean the spool is rotating in a first direction
Implementation Method 2
relatively constant tension is determined by a motor torque on a motor
Implementation Method 3
relatively constant slippage load is determined by a frictional load on one or more slip clutches
Data Source
AI summary
The present invention is a reel apparatus, system and method of using same that may utilize sensors and proximity sensors in determining the rotational direction of an offshore reel as a component of maintaining a constant tension and constant slippage setting on the umbilical of the offshore reel as the radius to the umbilical varies and the deployment direction is reversed.