By Tim Schneebeck

Operating in some of Earth’s most unforgiving environments, offshore oil and gas operations represent the front line of maritime resource development, where equipment reliability isn’t just preferred; it’s critical. If a single component fails, the consequences can quickly spiral, halting production, driving up costs, and putting both workers and the environment at risk.

One important yet often overlooked component is cable management for the top drive systems, which provide the torque that drives the drill string into the seabed. Until recently, service loops have been the go-to, yet imperfect solution for cable routing in these systems, prone to snagging on equipment in windy conditions, as well as strain-related damage.

Their design also creates a vulnerability. These assemblies, which comprise cables and hoses bundled within a large outer hose, are secured by potting with epoxy at both ends. If an individual cable fails or catches on equipment, the entire service loop assembly must be replaced, driving costly downtime and maintenance efforts.

The igus e-loop technology represents a game-changing response to these challenges. This modular energy chain system reimagines cable management for suspended applications in harsh environments, including the top drive systems in many offshore drill rigs. For operators pursuing sustainable and efficient ocean resource development, this technology transforms a chronic point of failure into a source of operational confidence.

e-loop

Addressing the limitations of service loops, the igus e-loop is a modular energy chain system that combines the flexibility of a polymer energy chain with the strength of a high-performance composite rope. This rope, which is 15 times stronger than steel, lies at the core of the e-loop design. It absorbs the tensile forces exerted on the cables, relieving them from strain and significantly extending their service life. The rope is also made of a synthetic plastic fiber, creating a shatter-proof, weather-resistant, flexible and corrosion-free solution.

The e-loop incorporates chain links made from high-performance plastic that are designed to be replaceable at any time, including during operation. This feature ensures the system can be easily maintained and adapted to changing requirements without the need for a complete overhaul. In addition, durable polyurethane foam bumpers, located on the outside of the e-loop, absorb impacts and further protect the system from damage caused by swinging or bumping into equipment. Like the other components in the system, these bumpers are replaceable, ensuring any damage can be quickly repaired without much downtime.

Thanks to this innovative design, the e-loop offers offshore operators many benefits. The e-loop’s modular construction and defined bend radius enhance operational reliability by reducing cable fatigue and minimizing maintenance requirements. These features improve system durability and reduce unexpected downtime.

The system’s robust design protects cables from impacts and vibrations, and its weather-resistant materials ensure reliable performance in extreme conditions. Its ability to reduce maintenance downtime and life cycle costs further supports sustainable practices by minimizing resource consumption and environmental impact.

The e-loop offers significant cost savings by reducing maintenance needs and extending service life. Its modular design allows for easy integration into existing systems, enabling seamless upgrades and minimizing installation time. These features contribute to overall cost efficiency, making the e-loop an attractive solution for industries operating in ocean and coastal environments.

 

 

Seadrill’s West Polaris Drillship

In a recent offshore use case, Seadrill, a major offshore drilling company, was faced with the challenges of the traditional service loops installed on its top drive systems. These loops were prone to snagging and strain-related damage, leading to costly replacements of entire assemblies.

The e-loop technology successfully addressed these issues once installed on Seadrill’s West Polaris drillship. From system design to on-site installation, igus provided Seadrill with support throughout the implementation process on the ship and delivered the e-loop as a ready-to-install solution.

Consisting of igus chainflex flexible cables, the system combined multiple power, signal and hydraulic loops into a single loop design that not only reduced the overall footprint, but also extended the system’s durability. Compared to standard industrial cables used in traditional service loops, chainflex cables are designed for continuous flexing and harsh environments, offering resistance to abrasion, oil, chemicals, and temperature extremes.

With less cable failures and maintenance, Seadrill has seen substantial cost savings. The system proved so successful that Seadrill installed it on a second vessel, the West Capella.

 

 

Pertamina Drilling Services, Indonesia

The top drive system from the Indonesian company Pertamina Drilling Services, delivers critical clockwise torque to drill strings on oil rigs. This equipment is much larger than a typical hand drill and essential to operations—any downtime is unacceptable. Between 2022 and 2023, service loop failures prevented top drive operation, causing losses of several hundreds of millions of dollars.

In response, Pertamina modernized its cable management system by implementing the e-loop systems with chainflex cables. The results have been transformative: not only does the system operate with significantly greater reliability, technicians also report increased confidence in the solution. Installation and maintenance have become more efficient, with cable installation time reduced from 12 to just 6 hr.—cutting maintenance downtime by 50 percent.

Akita Drilling in Canada

Akita Drilling, a Canadian company operating about 20 drilling rigs, implemented the e-loop to solve its cable management challenges. Operating in Saskatchewan’s harsh weather conditions, the company needed a robust solution to safely supply energy and signals to the top drive mechanism that moves drill pipes up and down.

The modular e-loop system replaced the previous service loop with a design featuring an internal tension cable that protects all power and signal cables from the forces encountered during operation. Its weather-resistant construction absorbs vibrations and impacts—even successfully withstanding severe snowstorm testing without issues.

 

 

Other Applications

In addition to the offshore oil and gas sector, the e-loop system offers reliability, flexibility, and versatility across multiple industries where robust cable management is essential.

In the wind energy sector, the e-loop addresses challenges such as cable fatigue due to undefined bend radii and vulnerability to extreme weather conditions. By providing a defined bend radius and weather-resistant materials, it improves system durability and reduces maintenance downtime, enhancing operational efficiency.

In shore power supply, to ensure reliable energy transmission in coastal areas, the e-loop’s modular design supports individual component replacement without dismantling the entire system. This feature is particularly beneficial for coastal zone management efforts, where minimizing environmental impact and operational disruptions is crucial.

In coastal construction projects, the e-loop provides a reliable cable management solution for heavy machinery. Its robust outer protection against impacts and vibrations ensures operational safety and reliability, even in harsh coastal environments. One use case involves the bucket wheel excavators used by Holcim for cement production. This implementation has enhanced the machines’ reliability by safely guiding cables with large cross-sections and heavy weights, preventing tangling and reducing maintenance.

Conclusion

The igus e-loop technology represents an advancement in cable management systems, offering significant benefits for maritime operations. Its robust design, enhanced operational reliability and cost efficiency make it an ideal solution for industries operating in challenging environments where component failure is not an option.

Tim Schneebeck is the industry manager for offshore oil and gas at igus.