REQUEST FOR PROPOSAL WOODS HOLE OCEANOGRAPHIC INSTITUTION HIGH MODULUS ROPE HANDLING SYSTEM FOR WHOI LONG CORE PROGRAM 18 APRIL 2005

Transcription

1 REQUEST FOR PROPOSAL WOODS HOLE OCEANOGRAPHIC INSTITUTION HIGH MODULUS ROPE HANDLING SYSTEM FOR WHOI LONG CORE PROGRAM 18 APRIL 2005

2 INTRODUCTION After a comprehensive survey of potential high performance rope candidates and an extensive 2-week regime of laboratory testing at Tension Member Technology, the Woods Hole Oceanographic Institution has purchased a hybrid product manufactured by Puget Sound Ropes in Anacortes, Washington for use in a new long coring system. The 2 diameter high modulus rope has a 12 X 12 braided construction and has a minimum breaking strength of 355,000 pounds. The 7000 meter length of rope currently under construction has a 5500 meter midsection of pure PLASMA [Appendix A.] and 750 meters of B. O. B. [Appendix B.] blended on either end. The Vectran/Plasma mix [B. O. B.] has been added on the ends to enhance durability of the rope where repetitive rigging procedures will occur. It has been blended to either end with the intent of swapping ends of the rope in the future to extend the life of the product. With this RFP the Woods Hole Oceanographic Institution is seeking proposals from vendors for a purpose built system to serve as the primary handling device for this large diameter high performance rope. This rope handling system must be portable and initially will be installed on the R/V Knorr [AGOR 15], operated by Woods Hole Oceanographic Institution. By their nature, fiber ropes are more susceptible to surface wear, inter-strand abrasion and elevated levels of frictional heat than similarly sized wire ropes. The entire rope handling system must be designed to avoid damaging frictional [slip] and abrasive contact between rope and winch components and protect the fiber rope from excessive wear and accidental operational failure. It is important that potential vendors work directly with Puget Sound Ropes to guarantee that their design optimizes handling of the hybrid high modulus rope The focus of the rope handling system design should be to develop a machine which not only meets the performance specifications in this document, but also maximizes rope service life and minimizes [abrasive, frictional] rope wear, while maintaining effective winch operation and rope control. Proposals must be specific in defining how these objectives will be met. THE CORING ENVIRONMENT The purpose built rope handling system that WHOI requires for the new long coring project must be optimized for the specific work environment defined by the projected long coring operational sequence. The goal of the underway project is to create an integrated yet portable system capable of recovering deep sea sediment cores up to 50 meters long in full ocean depths. [See Figure 1] The mass of the corehead is adjustable according to the total deployed core barrel length and the known physical properties of the targeted sea floor sediment. It s expected that the total weight of the head and barrel assembly will fall in the range of 15,000-25,000 pounds. In addition, a shaped mass [3,000-5,000 #, the ballast or drag plate] will be located just above the corehead at the termination of the synthetic rope. 1

3 A typical coring station might consist of the following conditions: Core system weight 25,000 # [can be modified], water depth = 5400 meters. The corer would be rigged on deck, lowered to the seabed, released for penetration, extracted from the seafloor [pullout] then returned to the sea surface and eventually the deck of the vessel. Because of the low specific gravity of the Plasma [.98] and B.O.B. [1.18] negligible weight is added to the over-boarding sheave during the lowering sequence. We feel it safe to conclude that the line load will be nearly constant [at the core system weight] about 99% of the time that the rope handling system is in operation. The exceptions to this are in the initial and final phases of the rigging process where only the weight of the release module [3-4,000 pounds] is in play, and during pullout where we ve modeled that line pulls of up to 75,000 pounds may be required to extract the corer from the seabed with its sample after release and penetration. EVENT Rope tension [lbs.] Duration COMMENTS Rig corer release module 4, min On deck ops Lowering of corer to sea floor 20,000-35,000 Modem release of Corer 4,000-5,000 10,000- Core Penetration 20, min. The line tension represents corer and release module weights. Tension shown is the range of variable system weights. Should not fluctuate significantly during a discreet lowering..25 sec. Corer free falls before penetration sec. Core extraction [Pullout] 60,000-75,000 Peak 5-10 sec. Retrieval of the corer to the ship 25, ,000 min. Corer captured by shipboard 4, equipment min. Residual weight is release module. Piston suction gradually retensions rope during sample recovery. Highest [dynamic] tension of the entire process. Retrieval of corer to the surface Release module handling after separation from corehead Table 1: Projected loads and load durations during a long coring station. TMT TESTING AND RESULTS A test program evaluating selected candidates and completed at Tension Member Technology for the Woods Hole Oceanographic Institution was specially designed to simulate modern fiber rope/ handling system interaction. [Appendix C.] We investigated conditions and materials that we felt would be useful to potential vendors in the design of a purpose-built system winch. Throughout the test effort, the coefficients of friction of the rope candidates were measured under a wide variety of conditions and selected sheave groove materials while abrasion and wear of the fiber rope was monitored. Precision data on elongation at a range of tensions is also included in the 2

4 attached document and tables. See [Appendix D.] for additional data on Plasma elongation. The entire test report is included in this document so that the data generated by our testing is available to vendors at the design proposal phase. Further distribution of the test results should occur only with the permission of WHOI.. ROPE CONSTRUCTION DETAILS The individual braids of PSR s 12 X 12 rope construction consist of lightly twisted strands of parent fiber that have been woven into a 12 strand primary rope. A proprietary Urethane coating is applied at the primary stage to insure more effective coverage on the final rope. Penetration of the coating is more thorough at this small diameter phase. The urethane adds coherence to the braids, provides inner fiber to fiber lubrication and increases the Coefficient of Friction of the final unjacketed product. Twelve of these primary ropes are then braided into the full size rope. This rope made with rope fabrication process was designed specifically for high modulus, high strength fibers like UHMWPE [Plasma] and Vectran, and is patented by Puget Sound Ropes. This process results in a strong, durable, torque balanced [rotation-free] rope that has a soft hand which makes it easy to inspect, and a rope that can be terminated [ tuck eyespliced] in the field. In addition, as a result of being made of smaller strands with a lower twist angle [also unique to this construction] individual fibers all share the load more evenly which reduces peak loads on any fiber and thus, long term damage due to [tension] fatigue. Specification of the 2 diameter rope [MBL = 355,000 #] for the WHOI long coring program was based on the following considerations: 1. Maintenance of a high factor of safety during all phases of the coring operation. Target safety factors: to 1 during system deployment and recovery; 5-6 to 1 at maximum dynamic loading [core pullout]. 2. By keeping the weight of system/rope strength ratio extremely high, pre-release elongation and subsequent rebound after core triggering will be minimized. This enhances our ability to control/dampen the elastic recoil at core system release and adjust system parameters to avoid sample disturbance. In addition, as a result of our testing and dialog with other end users and application consultants, we concluded that a larger rope would simply last longer. ROPE HANDLING SYSTEM DESIGN FACTORS [Applicable to traditional traction winch arrangements] While WHOI maintains that the final winch design is entirely the responsibility of the vendor we ve identified a number of factors which we feel will significantly influence rope service life and effective transfer of the coring rope tension onto the winch. These include: a) The shape of the rope groove. b) The size of the groove relative to the rope diameter. 3

5 c) The groove surface smoothness and hardness. d) The actual sheave/groove material. e) The static coefficient of friction of a wet capstan groove surface with a wet rope. f) The optimized number of rope grooves. g) The ratio of sheave diameter to rope diameter. h) The sheave base diameter changes along the rope path. i) The angular position of the aft versus forward capstan axes to eliminate rotating forcing of the rope running over the winch. As described in the Introduction, proposals should clearly define how rope wear and service life will be optimized by specifically identifying materials and critical dimensions and how they will interact to achieve project performance requirements. WINCH PERFORMANCE SPECIFICATIONS ADDITIONAL CONDITIONS PROPOSAL REQUIREMENTS Proposals MUST address an arrangement that includes 1. A Rope Handling System and 2. An independent rope storage Drum. ROPE HANDLING SYSTEM: Line Pull: 100,000 pounds at a maximum of 20 meters per minute Line Pull: 40,000 pounds at a maximum of 75 meters per minute Line speed should be continuously variable for zero to 75 meters per minute in increments of approximately 2 meters per minute. D:d ratio: Minimum of 30:1 in high tension traction zone. 15/20: 1 in low tension fairleads, level wind mechanism, and storage drum. Dimensioned Groove Profile [if applicable] should be specified. Traction sheave material [if applicable] should be specified. Corrosion resistance in this portion of the system is HIGHLY desirable. The rope handling system shall be designed for continuous operation in a severe marine environment, and built to marine standards. The rope handling system will operate up to 12 hours at a time in temperatures from 0 o to 120 o Fahrenheit. Characteristics of the main drive components of the rope handling system should be specified. Vendors are encouraged to propose a fully electric solution to the main drive. Line Voltage / Amperage available on the Main deck of the R/V Knorr: 480 VAC / 800 A. Hydraulic systems will also be considered. Proposals should include prime mover details, ratings, HP and working RPM ranges. Proposals should quantify the frictional capacity of the rope handling system. The frictional capacity of the system must have sufficient margins to accept variations of the Coefficient of Friction of the rope due to factors such as rope wear; and wet or dry conditions. 4

6 Slip or spin of the high modulus rope shall not occur on the rope handling system throughout the entire performance range of the system. Proposals must explain how this is accommodated by their design. Brake capacity of the handling system should be quantified. An emergency stop capability must be part of the proposed system. The rope handling system shall be so arranged to allow for easy installation of the long coring rope on the system with the tuck-eye splice termination in place. Details of the termination can be obtained from the manufacturer. [Appendix E.] The winch foundation [deck interface] must be specifically designed to match the R/V Knorr Superdeck and corresponding Superdeck socket arrangements. [See Superdeck.dwg] In order to conform to pre-existing layouts [centerline position of fixed overboarding stern sheave, and superdeck sockets] two conditions must be met in the design and orientation of the rope handling system. First, the Plasma rope must leave the rope handling system under-wrapped ; that is, the high tensioned segment must come off the bottom of the machine. Second, the exiting rope must be on the centerline of the vessel [also centered between the Superdeck sockets] in order to align with other portions of the core handling system and the overboarding stern sheave. That is, the machinery must be oriented on the foundation [See Glosten.dwg] is such a manner as to insure that the last wrap corresponds with the stern sheaves amidships position. Line tension, payout speed and rope length deployed will be measured at another component of the coring system [the over-boarding stern sheave] but integration of these data is likely to be necessary into the rope handling systems control module. The vendor must be willing to coordinate with the sheave vendor to accomplish the necessary interfaces. ROPE STORAGE DRUM The rope storage drum must have a minimum capacity of 7000 meters of 2 Diameter [48mm] 12 X 12 Plasma manufactured by Puget Sound Ropes. Vendors are encouraged to submit an arrangement for the storage drum that is optimized for the allowable deck space but also for Shipping and Handling. [Figure 2] shows an overview of the fantail. Note that the areas available are only estimated and may change with the actual footprint of the rope handling system. WHOI feels that a system based on an 8 X 8 X 20 CONEX shipping container is the ideal configuration. A container with portable sides or an entire removable cap is envisioned. A separate level wind subassembly deployable upon installation onboard the vessel is acceptable. If this design concept proves difficult or impossible to achieve, alternative arrangements will be considered as long as they conform to the space available and are portable to the degree that transportation according to standard U. S over the road regulations is possible. As a rule widths greater than 10 feet require special permitting, escorts and can be subject to travel-time restrictions. Innovative solutions to storage of the rope are welcome, including the possibility of elevating the drum. 5

7 An efficient and reliable level winding arrangement is required on the storage drum. Consideration should be given to fitting the drum core with a Lebus shell or equivalent to insure a tight array of wraps at the start of winding on the storage drum. Back tension at the drum must be addressed in proposals. If applicable, vendors should specify any perceived range required to meet performance specifications, and clarify how this back tension will be controlled at the storage drum in order to maintain optimal traction conditions from zero to full load. GENERAL Proposals should include: An arrangement drawing of the rope handling system showing all components in the general configuration and Superdeck interface plan, including dimensions, weights and centers of gravity of the major components. 46 cfr/per Glosten. Overhaul intervals and expected lifetimes of rope handling system components. Estimated hours and costs for labor and parts necessary for various maintenance and overhaul items. Price and delivery date, from receipt of order, with attached bid schedule completed. Price is to include delivery to Woods Hole, Massachusetts. In addition the price should include four sets of detailed technical manuals listing all manufacturer's part numbers plus maintenance and operation techniques, as well as detailed drawings in AUTOCAD, with a bill of materials. Manuals shall also contain detailed drawings and documentation of the main drive [electric/hydraulic] systems. Warranty information. A priced list of manufacturer's recommended spares, and authorized manufacturer s representative locations. Example copy[s] of complete documentation package[s] from similar rope handling system project[s] undertaken by the vendor including all drawings, installation details, auxiliary systems diagrams, maintenance procedures, plus any additional information appropriate to the evaluation of the vendors documentation, installation planning and user support system. List of previously installed winches or similar customized rope handling systems which have API, ABS and USCG certification, and confirmation that vendor holds API certification capability. This system will not be API certified. 6

8 INSTALLATION AND TESTING The completed rope handling system shall be factory tested in accordance with a Factory Test Plan submitted by the selected vendor 90 days after the award of the contract. The owner will witness the manufacturer's factory testing. The Woods Hole Oceanographic Institution will supply a test length of 2 Plasma for testing at the builder s facility. The Owner shall be notified at least 30 days in advance of the factory test. The rope handling system will be installed by the Owner with assistance from the manufacturer's representatives. The selected vendor shall provide technical services at Woods Hole, Massachusetts, for installation and final testing in accordance with a Shipboard Test Plan submitted by the manufacturer. Daily rate, travel, and expenses shall be included in the basic price of the system. The daily rate shall also be listed on the bid schedule attached. The rope handling system shall be load tested on the vessel after installation and witnessed by an ABS Surveyor. 7

9 P L A S M A 1 2 S T R A N D 1012 SECOND STREET ANACORTES, WA USA TEL: FAX: sales@psrope.com T3/T33 REV April 2003 Plasma 12 strand is the highest strength synthetic rope available. Plasma 12 strand is manufactured from Honeywell Spectra Fiber that has been enhanced by Puget Sound Rope's patented recrystallization process. This process is especially effective in medium to large diameter ropes where strengths are over 50% higher and creep is significantly less than that of standard Spectra 12 strand. Plasma 12 strand comes standard with a polyurethane finish and is easily spliced using a simple lockstitch type splice, or Tuck splice. Its soft, torque free braided construction provides easy handling. Highest strength Lowest stretch Low creep Soft hand Torque free Easy splicing Floats 12 STRAND 12 STRAND 12 X 12 STRAND % Elongation Nominal Diameter Inch MM /8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 13/16 7/ /8 1-1/4 1-5/16 1-1/2 1-5/8 1-3/ /8 2-1/4 2-1/2 2-5/8 2-3/ /8 3-1/4 3-5/ Elongation (%) Load (% of average strength) Size Number (circ) 1-1/4 1-1/2 1-3/ /4 2-1/2 2-3/ /2 3-3/ / / / / / / Approximate Weight Lbs/100ft Kg/100m , / , / , / , / , / ,500 ABS AND DNV TYPE APPROVED SIZES Minimum Tensile Strength Pounds kn 21,000 31,300 37,900 51,400 68,500 74,000 92, , , , , , , , , , , , , , , , ,000 1,250,000 1,520, Tensile Strengths are determined in accordance with Cordage Institute 1500, Test Methods for Fiber Rope. Weights are calculated at linear density under standard preload (200d 2 ) plus 4%. See reverse side for application and safety information. Specific gravity 0.98* Melting point 284 F (140 C)* Critical temp. 150 F (65 C)* Coefficient of friction * Elongation at break 4%-5% Fiber water absorption 0% UV resistance moderate Wet abrasion superior Dry abrasion superior * - value based on data supplied by the fiber manufacturer for new, dry fiber Plasma is Trademark of Puget Sound Rope Corp Spectra is a Trademark of Honeywell

10 Psrope.com - PUGET SOUND ROPE - Synthetic ropes for Heavy marine, Off...ploration, and Industrial Applications. Where Do You Want To Take Us? TO GET A QUOTE OR FOR MORE INFORMATION click here sales@psrope.com file:///c /CDH/winchRFP/bob.asp.htm (1 of 3)1/5/2005 7:33:20 AM

11 Psrope.com - PUGET SOUND ROPE - Synthetic ropes for Heavy marine, Off...ploration, and Industrial Applications. Where Do You Want To Take Us? TO GET A QUOTE OR FOR MORE INFORMATION click here sales@psrope.com file:///c /CDH/winchRFP/bob.asp.htm (2 of 3)1/5/2005 7:33:20 AM

12 Psrope.com - PUGET SOUND ROPE - Synthetic ropes for Heavy marine, Off...ploration, and Industrial Applications. Where Do You Want To Take Us? TO GET A QUOTE OR FOR MORE INFORMATION click here sales@psrope.com file:///c /CDH/winchRFP/bob.asp.htm (3 of 3)1/5/2005 7:33:20 AM

13 1012 Second Street Anacortes, WA USA Telephone: Fax: Elongation Characteristics of 22mm Plasma 12-Strand Rope [N.B. These measurements were done on Rope 22mm. This rope is approximately 45 % the diameter and has 25% of the MBL of the WHOI long coring rope. ] A length of 22mm Plasma 12-strand rope was cycled between 4 tonnes and 14 tonnes to determine the elastic elongation and the change in the rope diameter at the different load levels. The test procedure involved splicing up a test sample and first loading it to the standard reference load for 22mm rope (~70 kg.). A gage length was then measured out on the rope while under the reference tension. A gage length was used to eliminate the effect of the splices on the overall elongation of the rope. The diameter of the rope at the reference load was also measured. The rope was then loaded to the 4-tonne load level and the gage length and diameter were remeasured. The rope was then loaded to the 14- tonne level and measured again. After these initial measurements, the rope was cycled 20 times between the 4-tonne and the 14-tonne load level. The purpose of this procedure was to stabilize the rope construction. Brand new rope that has not been subjected to any appreciable load will exhibit some constructional stretch or compaction. This stretch is not equivalent to elastic elongation. However, after approximately 20 cycles the rope structure is basically stabilized, meaning that the elongation characteristics exhibited by the rope are no longer being influenced by the compaction of the rope structure. Consequently, the measured stretch is now a representative indication of the elasticity of the rope and fiber. After cycling, the gage length was measured for the final time at both the 4-tonne and 14-tonne load level. The stabilized elastic elongation of the rope between these two load levels was calculated at %. The following tables contain the measurements made during the procedure described above: Initial Load Measurements Load Diameter Gage Length Initial reference load mm mm Initial load to 4 tonnes 21.6 mm mm Initial load to 14 tonnes 20.8 mm mm 1. The total stretch going from the initial gage length to 4 tonnes was 2.87% 2. The total stretch from the initial reference load to 14 tonnes was 4.25% 3. The net stretch between 4 tonnes and 14 tonnes was 1.35% Note: These numbers are not representative of the elastic elongation in the rope. A Subsidiary of The Cortland Companies Cortland Cable Company Cortland Fibron BX Puget Sound Rope

14 Stabilized Load Measurements Load Diameter Gage Length 4 tonnes 20.8 mm 1505 mm 14 tonnes 20.8 mm 1511 mm 1. The elastic elongation between 4 tonnes and 14 tonnes is %. 2. The diameter is stabilized at 20.8 mm. As a point of comparison, the total stretch (constructional and elastic) exhibited by the rope in going from the initial reference load to the final stabilized loads of either 4 tonnes or 14 tonnes can be determined by comparing the gage length measurements. As an example, the total stretch from the initial load to the stabilized 4-tonne load is 1505 mm/ mm = 4.18%. Most of this is attributable to the constructional compaction of the rope structure. This is also obvious in the diameter reduction of the new rope compared to the stabilized construction. A Subsidiary of The Cortland Companies Cortland Cable Company Cortland Fibron BX Puget Sound Rope

15 CONTACTS PUGET SOUND ROPES Randy Longerich 1012 Second Street Anacortes, WA USA Telephone: Fax: Alt: Dick Kilburn WOODS HOLE OCEANOGRAPHIC INSTITUTION James E Broda Woods Hole Oceanographic Institution Mclean Laboratory Woods Hole, MA USA Telephone: Fax: jbroda@whoi.edu Alt: Al Suchy Telephone: Fax: asuchy@whoi.edu TENSION MEMBER TECHNOLOGY Philip T. Gibson TMT Laboratories Tension Member Technology 5721 Research Drive Huntington Beach, CA Telephone: Fax: Gibsontmt@aol.com

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