100 HP ROV SUPER SCORPIO
TYPE
(1000m Depth Rated)
GENERAL INFORMATION
1. Introduction
This Remote Operated Vehicle (ROV) is a heavy-duty underwater
vehicle designed to carry out a wide vvariety of recovery,
observation and manipulator tasks to a water depth of 1000
metres.
The ROV is equipped with Sonar, TV camera’s, lights,
manipulators and other specialised underwater survey equipment.
The ROV will also provide electrical and hydraulic interfacing
for general purpose and support tooling.
It is capable of free swimming or operating from a heavy-duty
underwater garage (TMS) via a 150m buoyant tether umbilical.
2. System Description
The system comprises of the Power Distribution Package, the
Control and Display Console, the winch assembly, the umbilical
and the ROV itself.
The equipment requires a stable power supply of 380 –
480v, 3-phase, 60Hz at 180kva.
2.1 System Performance
The ROV can be operated from a fixed installation up to a
sea state 4 whilst free swimming and up to a sea state 6 while
being TMS operated. During support vessel operation the limits
are, sea state 4 free swimming and sea state 6 for TMS operation.
The system can be operated in tropical or cold climate conditions.
The vehicle is powered by 2 axial, 2 vertical and 2 lateral
15 HP thrusters. It is capable of operating in currents of
2 knots to a depth of 1000 metres.
The modular buoyancy provides a vehicle payload of 100kg
and the safe working load of the lift frame is 2500 kg.
2.2 Surface Equipment
The surface equipment comprises a control cabin and a deployment
system and an electro hydraulic winch.
2.3 Control Cabin
The ROV control cabin is a 20’ x 8’ steel container
which houses all the ROV control equipment. The cabin is divided
into two areas, the operators control console section and
the power distribution section.
2.4 Operators Control Console
The major items of equipment in the console section are:
- Power Supply control panels
- Operators Control Console
- Multiplexer Control and DC power supply drawer
- Patch Drawer
- Attitude display processor
- Manipulator controllers
- Video Monitors
- Computer Generated Graphics Display unit
2.5 Surface Electronics System
The surface electronics system consists of the operators
control console and other specialised equipment which is fitted
into standard 19” racking situated either side of the
pilots seat. The operators control console provides the interface
for control of vehicle motion and the onboard support equipment.
The drawer system contains:
- Attitude display processor
- Surface electronics signal patch drawer
- Surface electronics MUX and control
- DC power supply
The principle elements of the system are the surface electronics
control and patch drawers. These house the surface multiplexer,
surface interface board and cross connect area that links
individual components to form the control and signal interfaces.
The upper right hand drawer contains the power supply units,
the multiplexer chassis and control components. The multiplexer
chassis is connected by ribbon cables via the patch drawer
to the operator control unit. This arrangement connects the
analogue, control and miscellaneous commands from the operator
via the following input devices:
- Joysticks
- Trim Controllers
- Lighting Potentiometers
- Sonar Deployment Control
- Digital input switch matrix
- Manipulator control switches
Analogue command inputs are routed to the patch drawer where
some of the signals are diverted for conditioning or interface
with the attitude display processor.
Vehicle motion control signals, joystick commands and trim
voltages are routed to an interface board that is a 37 way
module located in the patch drawer. This set up allows the
signals to be summated and calibrated for offset or gain prior
to transmission to the vehicle control system via the data
multiplexer.
Analogue output channels from the multiplexer are routed
within the surface electronics unit, then transferred to the
computer for processing and display on the attitude and status
indicators.
2.6 Surface Multiplexer
The surface telemetry control subsystem is built into the
electronics unit. The subsystem comprises a multiplexer chassis
that consists of a set of printed circuit boards housed inside
the surface electronic unit.
The set of PCB’s comprises:
- 1 x Mother Board
- 1 x Programme Board
- 1 x Mux Top Board
- 2 x Input/Output Boards
The surface multiplexer subsystem is designed to operate
as the master controller of the overall system, thus all system
timing is originated by the surface end of the datalink.
2.7 Umbilical Winch
The umbilical winch is an electro hydrauliclly driven unit,
which is spooled with 1200 metres of umbilical. The winch
assembly comprises:
- The electro hydraulic power unit
- The drum with auto level wind mechanism
- Hydraulic control lever
- Optical/Electric slipring unit.
2.8 Winch Connections
ROV power and control signals together with the winch power
supply are routed from the control cabin and power distribution
unit via separate deck cables. The ROV control signal cable
is connected to the winch static junction box and the winch
power supply is connected to the winch junction box.
The slipring unit is mounted on the winch drum axis. Internal
leads from the sliprings are linked to the rotating junction
box to which the ROV umbilical is connected.
3. ROV Umbilical
There are two types of ROV umbilical cable available to suit
specific operational requirements. One type is steel wire
wound whilst the other is Kevlar braided.
Both types of umbilical transmit the power, data, and video
signals to and from the ROV.
4. Deployment System
Deployment and recovery of the ROV is by means of a Latch
– Lock system that also acts as a guide for the umbilical.
The latch – Lock dogs are hydraulically operated by
means of an Enerpac hand pump.
Depending on the configuration of the support vessel either
an “A” frame or an articulated crane may be used
to deploy the ROV.
5. Remote Operated Vehicle
The ROV is a heavy-duty underwater vehicle designed to complete
a wide variety of tasks to a depth of 1000m.
5.1 ROV Main Frame
The ROV frame is an open frame design, constructed from HE30
aluminium I beam and channel that give good strength to weight
ratio. The frame is fitted on the base and outer surfaces
with HDPE rubbing strips to protect it from damage during
deployment and recovery. HDPE is a buoyant material when in
water therefore adding no weight to the vehicle when sub sea.
5.2 Buoyancy
The vehicle is held in a vertical attitude by means of six
contoured blocks of elastomer coated syntatic foam. There
are three on each side of the top frame.
5.3 Electronics
The operating system has been designed around hardware driven
Time Division Multiplex (TMD) telemetry datalink. The system
is half duplex and provides a reliable communications link
between the surface control equipment and the vehicle control
/ sensors system.
The vehicle primary electronic control and interfacing components
are mounted inside two electronic pods. Connections to the
external equipment are made through 24 pin Burton sub sea
connectors.
Penetrators are placed radially on the pod end dome and each
has a connector re mounted on the forward face. Each connector
receptacle mates to a matching cable plug on the cable assembly.
The port pod contains the following:
1. Multiplexer Chassis – PCB’s which for the
vehicle multiplexer sub system.
2. Sensor Chassis – interfacing PCB’s for propulsion
control and vehicle sensors subsystem.
3. Power Distribution System – DC power supply units
producing supply voltages fir the sensor systems and extra
fitted equipment.
4. A directional Gyro System comprising a Humphreys Gyro and
Flux gate unit which relays the vehicle heading to the pilot.
5. Lamp controllers – for single channel variable output
lighting.
6. Relay Panel.
7. Water intrusion leak detector.
The Starboard electronics pod contains the following:
1. Power Distribution System – DC power supply units
producing supply voltages for camera’s, lamp, Controllers,
solid-state relays, cathodic protection, Fibre optic, multiplexer
and cooling fan.
2. Solid State relays – provide switched power for bathymetric
profiler, pipetracker, tools and CP Interfaces.
3. FO Multiplexer – four channel fibre optic transmitter
to cameras.
4. Water intrusion leak detector.
5. Fan – for internal cooling
6. Stills charging circuit for camera
7. Robertson Servo Gyro
5.4 Vehicle Multiplexer
The vehicle datalink system is housed inside the port electronic
pod. It comprises a multiplexer chassis and a set of PCB’s
as follows:
- 1 x Programme Board
- 1 x Mother Board
- 1 x Mux Top Board
- 2 x Input/output boards
The vehicle multiplexer system is designed to operate as
a slave controller of the system, thus all system timing is
received from the surface end of the data link.
5.5 Sensors Interface Subsystem
The multiplexer analogue output and input boards are interconnected
with the sensor chassis set of PCB’s. These boards quantify
the control commands from the multiplexer to ensure the correct
operation of output devices, such as thrusters, and sensor
inputs (for use within onboard feedback control circuits and
transmission to the surface).
The sensor chassis set of PCB’s is as follows:
- Mother Board
- Pitch/Leak/Pan /Tilt
- Focus Control (8 Channel)
- Servo/Valve Driver x 2
- Vertical Control Board
- Auto Heading Control x 2
- Heading Interface
- Temperature/Pressure Interface
- Altimeter
5.6 Hydraulics
Hydraulic Power for the vehicle system is provided by an
electric motor driven Hydraulic Power Unit (HPU). It has an
operating pressure of 3000psi, and a flow of 110 liters per
minute.
This unit supplies motive power for the vehicle, the manipulators,
the pan & Tilt movement and tooling. The system is protected
from contamination by a high-pressure flow filter and low-pressure
return filter.
5.7 Propulsion System
The vehicle is propelled by two vertical, two axial and two
lateral thrusters. These thrusters are hydraulically driven
with proportional control provided by servo valves located
in the Thruster Control Unit.
The thrusters operate at full system pressure. The six electrically
controlled servo valves are mounted on a manifold inside the
thruster control unit where they are connected via cabling
to the main junction box.
5.8 8-Way Hydraulic Control Units
The two 8 way Hydraulic Control Units consist of auxiliary
valve packs of eight solenoid operated two-way valves. The
hydraulic control units are supplied from the high-pressure
manifold via a 1000psi pressure-reducing valve.
HCU No. 1 operates – Pan & Tilt units & 5 Function
manipulator or tooling.
HCU No. 2 operates – 7 Function manipulator or Tooling.
5.9 Manipulators
A seven-function manipulator is situated on the port side
of the front of the lower frame and a seven function similarly
mounted on the starboard side, both are powered by the HCU
located behind each manipulator.
5.10 Electronic Pods and Cabling
The umbilical is connected to the vehicle via the Survey
Junction Box located in the center of the frame; all power
and signals are distributed from the junction box to the Electronic
Pods and other functions.
5.11 Compensation Systems
There are compensation systems built into the ROV distribution
system.
Hydraulic:
There are five compensators fitted, two are fitted to the
Dual HPU reservoirs the other three are mounted between the
front frame legs and supply the main system, HPU Motor and
Termination Junction Box.
5.12 Underwater camera’s
There is provision for up to eight camera’s which may
be required if the vehicle is used in survey mode.
5.13 Underwater Lighting
There are six variable intensity lights fitted to the ROV
these are individually controlled. They provide an output
voltage up to 120v that is proportional to a 0v to +5v DC
control signal from the vehicle multiplexer system. The DC
signal is used for phase angle control of a Triac on the AC
supply.
5.14 Sonar System
The scanning sonar system comprises a display processing
unit and an underwater scanner, which is centrally mounted
at the front of the vehicle.
These units are directly connected, via the umbilical, by
a pair of shielded conductors that form the telemetry link.
The sonar interface is suitable for a Sea King Sonar system
or similar, the DC power is switchable via a solid-state relay
mounted in the starboard electronic pod.
6. System Specifications
6.1 Vehicle Dimensions
Length 3000 mm Excluding Front Bump Bar
Width 1450 mm including side protection
Height 1700 mm
Weight in air 2250 kg
Payload 100 kg
Depth Capability 1000 metres
6.2 Structure
Frame Aluminium Alloy HE30 Grade
Instrument Pods Aluminium Alloy HE30 Hard Anodised
Buoyancy Blocks Six Blocks Syntatic Foam
Buoyancy rating 689 kg
Reservoir and Comp Brackets HDPE
Pod Saddles HDPE
6.3 Vehicle Hydraulic Power Unit
Electric Motor Sub Atlantic 100HP 3000v 4P / 300v 60 Hz
Hydraulic Pump Rexroth 140cc Pump
Pressure Output 3000 psi (working)
Flow Rate 110 litres per min
HP Filter 3 micron
LP Filter 100 mesh strainer
6.4 HPU Status Sensors
Depth Kulite KPM 780/AR/SPL 0 to 1000 psi.
Hydraulic Pressure Kulite KPM 780/AR/SPL 0 to 5000 psi.
Leak Detection Terminal Type
6.5 Status Sensors
Temperature Platinum Film Resistor
6.6 Operating Fluids
Vehicle Hydraulics Shell Tellus 22 or equivalent
Electric Motor Housing Shell Tellus 22 or equivalent
Compensation system Shell Tellus 22 or equivalent
6.7 Thruster Control Units
Servo Valve Moog Type E077 Model 685
6.8 Thrusters
Motors Innerspace Type 4200S – 15
6.9 2 X 8 Way Hydraulic Control Units
Control Unit Manufactured by Perry Tritech
6.10 Fluid Compensation Units
Electric Compensation 1 x 1.3 litres capacity
HPU Motor 2 x 1.3 litres capacity
Hydraulics 2 x 1.3 litres capacity
6.11 Manipulators
Port Manipulator 5 Function
Starboard Manipulator 7 Function
6.12 Pan & Tilt Unit
Hydraulic Pan & Tilt Tritech Model PT 3636 c
Pan angle 360 deg adjustable
Tilt Angle 360 deg adjustable
Torque 56nm @ 200 bar
Payload 8 kg
6.13 Underwater Camera’s
Low Light Monochrome Camera Tritech Tornado
Colour Zoom Camera Tritech Typhoon
6.14 Vehicle Main Sensor Equipment
Scanning Sonar Tritech Super Sea King DFP
Gyro Compass Humphyres Directional Gyro
Depth Transducer Kulite KPM 780AR/SPL 0 to 1000 psi
Pressure Transducer Kulite KPM 780AR/SPL 0 to 5000 psi
6.15 ROV Control Cabin
Container Ferguson Seacabs 20 Ft x 8 Ft x 8 Ft
Fully lined with a/c fitted
Power Distribution Unit MCI Electronics
Power Transformer 130 Kva 360-380-400-420-440-460-480v-delta
Secondary voltage 3000v star +N, 3phase d Yn11,
50/60 Hz. HV coupler for GFI & HV fuses.
Power Transformer MCI Electronics
7 Kva 360-380-400-420-440-460-480v-delta
Secondary voltage 110v star+N, 3phase dY11,50/60 Hz
Remote Monitoring Panel 19” rack fitted with metering,
pushbuttons and indicators.
Control Console 3 x 19” Racks fitted with Operators
Control Unit and
Video Monitoring System.
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