Challenge
Our client, Proserv, required two custom designed Umbilical Reelers to support their Intervention Work Over Control System (IWOCS). Both Reelers where designed to store, deploy and recover an umbilical capable of operating the Subsea Christmas Tree. Safety and functionality were at the forefront of all decisions during the design phase – for this reason the Reelers had automatic over load protection systems, integrated davits to prevent manual handling of heavy stab plates, remote and local controls to ensure the operator is always situated in the safe location during operation.
Our client required its operator to control the reeler from a remote or local location, in a quick and easy manner without needing to disconnect the hoses or reposition a control stand. The unit also required an automatic level wind system, allowing controlled, pneumatically-driven unspool of the umbilical synchronised with the drum layers.
Solution
We manufactured pneumatically-driven IWOCS umbilical reelers with the frames and the drum sizes, designed to store 81mm diameter and up to 320m of umbilical, and the second reeler, 125mm diameter and up to 320m length of umbilical.
The reelers had two control stations (a remote type and a local integrated type within the reeler frame).
As a safety feature, both controls could not be operated simultaneously. The synchronisation of the drum with the level wind was achieved using a pneumatic motor coupled with the gearbox fixed to the frame, and pinion gear meshed with the large ring gear fixed to the drum. We also included an override function allowing fine adjustment in case of umbilical misalignment. Maximum line pull of the unit was set to 90% of the umbilical SWL, and a failsafe brake was set to slip at 90% of the umbilical safe working, which provided protection.
