Pipe Laying Barge Drive Pipe Laying Barge Drive ApplicationApplication• We were recently asked to retrofit a Pipe laying barge We were recently asked to retrofit a Pipe laying barge

with enhanced drive system controls to improve the with enhanced drive system controls to improve the performance and reliability of the system. The changes performance and reliability of the system. The changes improved operating speed from 30 fpm to 100 fpm.improved operating speed from 30 fpm to 100 fpm.

• We chose the Eurotherm Link System to implement this We chose the Eurotherm Link System to implement this change. Fiber optic networking provides noise immunity change. Fiber optic networking provides noise immunity and minimizes electrical wiring.and minimizes electrical wiring.

• We engineered the changes, sold the controls, and We engineered the changes, sold the controls, and configured the drive system to meet requirements. configured the drive system to meet requirements. Standard Link Function blocks provide the desired Standard Link Function blocks provide the desired control for each section. Special application needs were control for each section. Special application needs were met by integration of other function blocks as needed. met by integration of other function blocks as needed.

• We then proceeded to start-up and fine-tune the overall We then proceeded to start-up and fine-tune the overall system.system.

Main Crane for Pipe BargeMain Crane for Pipe Barge• The large crane in The large crane in

center aft is center aft is permanently mounted permanently mounted and can handle any and can handle any requirement for loading requirement for loading or offloading equipment or offloading equipment from the Barge.from the Barge.

• It is not part of the It is not part of the system we worked on, system we worked on, but is used to install all but is used to install all the heavy equipment the heavy equipment on-board. on-board.

System Components:System Components:Forward & Aft Tensioners,Forward & Aft Tensioners,

Straightener-Aligner, & ReelStraightener-Aligner, & Reel

System integrationSystem integration• The computerized Drive system selects the master Tensioner The computerized Drive system selects the master Tensioner

by the first drive turned on, and for the reel by the first reel by the first drive turned on, and for the reel by the first reel drive turned on.drive turned on.

• The Slave Tensioner Drives look at the Master’s current, and The Slave Tensioner Drives look at the Master’s current, and produce an output to assist the Master in controlling the Pipe produce an output to assist the Master in controlling the Pipe movement and Tension on the Pipe.movement and Tension on the Pipe.

• The Reel Motors all produce a torque based on the operator The Reel Motors all produce a torque based on the operator set-point, to pull the pipe and bend it for winding on the Reel. set-point, to pull the pipe and bend it for winding on the Reel. (Or holdback torque when paying out, to straighten the pipe.) (Or holdback torque when paying out, to straighten the pipe.) The system runs with 2, 3 or 4 motors active on the reel. The The system runs with 2, 3 or 4 motors active on the reel. The torque set-point, static and dynamic compensation, and trim torque set-point, static and dynamic compensation, and trim feedback are all scaled automatically depending on the feedback are all scaled automatically depending on the number of motors active. number of motors active.

• The system can be run in 2 modes; Conventional speed mode The system can be run in 2 modes; Conventional speed mode or Tension mode. Reel runs in speed mode, or pipe can be or Tension mode. Reel runs in speed mode, or pipe can be stacked on board and welded as it pays out, (Tension mode).stacked on board and welded as it pays out, (Tension mode).

Tensioner Control Tensioner Control • There are Two Tensioners, There are Two Tensioners,

one fore and one aft unit.one fore and one aft unit.• Each Tensioner consists of Each Tensioner consists of

two tracks, (similar to Tank two tracks, (similar to Tank tracks), which have rubber tracks), which have rubber pads mounted on them. pads mounted on them. These tracks close on the These tracks close on the pipe to grip it securely.pipe to grip it securely.

• Each track has two 500HP Each track has two 500HP DC motors geared to the DC motors geared to the track.track.

• There is one motor There is one motor designated as the master, designated as the master, and all other motors on the and all other motors on the two Tensioners are slaved two Tensioners are slaved to the master unit.to the master unit.

Motor & Gearboxes for Pipe Motor & Gearboxes for Pipe Winding Reel Winding Reel • Workers guiding Motor Workers guiding Motor

assembly into place on-assembly into place on-board the barge, to Power board the barge, to Power the Reel for winding pipe. the Reel for winding pipe. The reel can wind up 80 The reel can wind up 80 miles of 4” diameter, or 34 miles of 4” diameter, or 34 miles of 9” diameter Steel miles of 9” diameter Steel Pipe prior to embarking. Pipe prior to embarking.

• The mission of the Barge is The mission of the Barge is to lay Pipelines for to lay Pipelines for commercial customers.commercial customers.

• The pipe on the reel is 9” The pipe on the reel is 9” diameter.diameter.

Motor Controls for systemMotor Controls for system• One of 12 500HP DC One of 12 500HP DC

Motor Controls in the Motor Controls in the Drive housing. Drive housing.

• Four enclosures each Four enclosures each house 3 of these Drive house 3 of these Drive units.units.

• All 12 Drives and All 12 Drives and various analogue and various analogue and digital I/O are networked digital I/O are networked to provide the system to provide the system integration.integration.

• A PLC is integrated into A PLC is integrated into the system by another the system by another contractor.contractor.

Reel in OperationReel in Operation• After commissioning the After commissioning the

system, the operators are system, the operators are winding Pipe for a new job.winding Pipe for a new job.

• The Pipe exits a The Pipe exits a straightener-aligner straightener-aligner section before winding on section before winding on the reel. This section and the reel. This section and both Tensioners move up both Tensioners move up and down with the wraps and down with the wraps on the reel.on the reel.

• Tension of the Pipe is Tension of the Pipe is critical to prevent damage.critical to prevent damage.

• The Pipe is straightened The Pipe is straightened again when paying out into again when paying out into the water. the water.

Winding PipeWinding Pipe• As the job As the job

progresses, the progresses, the system must system must maintain proper maintain proper tension on the pipe tension on the pipe to keep from to keep from “dropping wraps”.“dropping wraps”.

• Pipe winding Pipe winding completed for this completed for this job, just prior to job, just prior to embarking for job.embarking for job.

Stinger to Guide Pipe-LayingStinger to Guide Pipe-Laying• This assembly is This assembly is

attached to the barge attached to the barge after the aft Tensioner after the aft Tensioner to guide the pipe for to guide the pipe for proper Lay down. When proper Lay down. When we arrive at location, it we arrive at location, it is lowered below the is lowered below the water line.water line.

• Another boat follows the Another boat follows the barge to monitor the barge to monitor the actual touchdown of the actual touchdown of the pipe with sonar monitor.pipe with sonar monitor.

Arrive at the job locationArrive at the job location• The job location is The job location is

a drilling rig in the a drilling rig in the Gulf. We are Gulf. We are attaching to the attaching to the well head and well head and running 16 miles of running 16 miles of 10 inch pipe.10 inch pipe.

News Media arrivalNews Media arrival• We were able to We were able to

lay the pipe at lay the pipe at speeds up to 101.6 speeds up to 101.6 fpm, which is a fpm, which is a world record. world record.

• News media News media documented the documented the job for publication job for publication and company use.and company use.

Job CompleteJob Complete• We completed the We completed the

job in just over 3 ½ job in just over 3 ½ days, which was days, which was within the within the scheduled time. scheduled time.

• This was in spite of This was in spite of a number of a number of unusual delays unusual delays during the process. during the process.

Computer Access and Computer Access and MonitoringMonitoring• The upper right The upper right

window is access to all window is access to all modules in the system.modules in the system.

• The left hand window The left hand window is one of the module’s is one of the module’s configurations opened configurations opened for making changes to for making changes to parameters while the parameters while the drives are running.drives are running.

• The lower right window The lower right window is a list of parameters is a list of parameters being continuously being continuously monitored in real-time.monitored in real-time.

Job ResultsJob Results• New Speed record for laying pipe New Speed record for laying pipe

from reel. Design spec is 90 fpm max from reel. Design spec is 90 fpm max reel speed, we ran at 101.6 fpm.reel speed, we ran at 101.6 fpm.

• We met or exceeded all the We met or exceeded all the requirements for the system.requirements for the system.

• Drive controls worked with no Drive controls worked with no changes required to the system changes required to the system during Pipe-lay operation.during Pipe-lay operation.