Upgrade to current technology, minimize hardware cost, customize control system for application needs.

1. Pipe Laying Barge DrivePipe Laying Barge Drive
ApplicationApplication
• We were recently asked to retrofit a Pipe laying bargeWe were recently asked to retrofit a Pipe laying barge
with enhanced drive system controls to improve thewith enhanced drive system controls to improve the
performance and reliability of the system. The changesperformance 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 thisWe chose the Eurotherm Link System to implement this
change. Fiber optic networking provides noise immunitychange. Fiber optic networking provides noise immunity
and minimizes electrical wiring.and minimizes electrical wiring.
• We engineered the changes, sold the controls, andWe 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 desiredStandard Link Function blocks provide the desired
control for each section. Special application needs werecontrol 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 overallWe then proceeded to start-up and fine-tune the overall
system.system.

2. Main Crane for Pipe BargeMain Crane for Pipe Barge
• The large crane in centerThe large crane in center
aft is permanentlyaft is permanently
mounted and can handlemounted and can handle
any requirement forany requirement for
loading or offloadingloading or offloading
equipment from theequipment from the
Barge.Barge.
• It is not part of the systemIt is not part of the system
we worked on, but iswe worked on, but is
used to install all theused to install all the
heavy equipment on-heavy equipment on-
board.board.

3. System Components:System Components:
Forward & Aft Tensioners,Forward & Aft Tensioners,
Straightener-Aligner, & ReelStraightener-Aligner, & Reel

4. System integrationSystem integration
• The computerized Drive system selects the masterThe computerized Drive system selects the master
Tensioner by the first drive turned on, and for the reel byTensioner by the first drive turned on, and for the reel by
the first reel drive turned on.the first reel drive turned on.
• The Slave Tensioner Drives look at the Master’s current,The Slave Tensioner Drives look at the Master’s current,
and produce an output to assist the Master in controllingand produce an output to assist the Master in controlling
the Pipe movement and Tension on the Pipe.the Pipe movement and Tension on the Pipe.
• The Reel Motors all produce a torque based on theThe Reel Motors all produce a torque based on the
operator set-point, to pull the pipe and bend it for windingoperator set-point, to pull the pipe and bend it for winding
on the Reel. (Or holdback torque when paying out, toon the Reel. (Or holdback torque when paying out, to
straighten the pipe.) The system runs with 2, 3 or 4straighten the pipe.) The system runs with 2, 3 or 4
motors active on the reel. The torque set-point, staticmotors active on the reel. The torque set-point, static
and dynamic compensation, and trim feedback are alland dynamic compensation, and trim feedback are all
scaled automatically depending on the number of motorsscaled automatically depending on the number of motors
active.active.
• The system can be run in 2 modes; Conventional speedThe system can be run in 2 modes; Conventional speed
mode or Tension mode. Reel runs in speed mode, ormode or Tension mode. Reel runs in speed mode, or
pipe can be stacked on board and welded as it pays out,pipe can be stacked on board and welded as it pays out,
(Tension mode).(Tension mode).

5. Tensioner ControlTensioner Control
• There are Two Tensioners,There are Two Tensioners,
one fore and one aft unit.one fore and one aft unit.
• Each Tensioner consists ofEach Tensioner consists of
two tracks, (similar to Tanktwo tracks, (similar to Tank
tracks), which have rubbertracks), which have rubber
pads mounted on them. Thesepads mounted on them. These
tracks close on the pipe to griptracks close on the pipe to grip
it securely.it securely.
• Each track has two 500HP DCEach track has two 500HP DC
motors geared to the track.motors geared to the track.
• There is one motor designatedThere is one motor designated
as the master, and all otheras the master, and all other
motors on the two Tensionersmotors on the two Tensioners
are slaved to the master unit.are slaved to the master unit.

6. Motor & Gearboxes for PipeMotor & Gearboxes for Pipe
Winding ReelWinding Reel
• Workers guiding MotorWorkers guiding Motor
assembly into place on-boardassembly into place on-board
the barge, to Power the Reelthe barge, to Power the Reel
for winding pipe. The reel canfor winding pipe. The reel can
wind up 80 miles of 4”wind up 80 miles of 4”
diameter, or 34 miles of 9”diameter, or 34 miles of 9”
diameter Steel Pipe prior todiameter Steel Pipe prior to
embarking.embarking.
• The mission of the Barge is toThe mission of the Barge is to
lay Pipelines for commerciallay Pipelines for commercial
customers.customers.
• The pipe on the reel is 9”The pipe on the reel is 9”
diameter.diameter.

7. Motor Controls for systemMotor Controls for system
• One of 12 500HP DCOne of 12 500HP DC
Motor Controls in theMotor Controls in the
Drive housing.Drive housing.
• Four enclosures eachFour enclosures each
house 3 of these Drivehouse 3 of these Drive
units.units.
• All 12 Drives and variousAll 12 Drives and various
analogue and digital I/Oanalogue and digital I/O
are networked to provideare networked to provide
the system integration.the system integration.
• A PLC is integrated intoA PLC is integrated into
the system by anotherthe system by another
contractor.contractor.

8. Reel in OperationReel in Operation
• After commissioning theAfter commissioning the
system, the operators aresystem, the operators are
winding Pipe for a new job.winding Pipe for a new job.
• The Pipe exits a straightener-The Pipe exits a straightener-
aligner section before windingaligner section before winding
on the reel. This section andon the reel. This section and
both Tensioners move up andboth Tensioners move up and
down with the wraps on thedown with the wraps on the
reel.reel.
• Tension of the Pipe is criticalTension of the Pipe is critical
to prevent damage.to prevent damage.
• The Pipe is straightened againThe Pipe is straightened again
when paying out into thewhen paying out into the
water.water.

9. Winding PipeWinding Pipe
• As the jobAs the job
progresses, theprogresses, the
system must maintainsystem must maintain
proper tension on theproper tension on the
pipe to keep frompipe to keep from
“dropping wraps”.“dropping wraps”.
• Pipe windingPipe winding
completed for this job,completed for this job,
just prior tojust prior to
embarking for job.embarking for job.

10. Stinger to Guide Pipe-LayingStinger to Guide Pipe-Laying
• This assembly is attachedThis assembly is attached
to the barge after the aftto the barge after the aft
Tensioner to guide theTensioner to guide the
pipe for proper Lay down.pipe for proper Lay down.
When we arrive atWhen we arrive at
location, it is loweredlocation, it is lowered
below the water line.below the water line.
• Another boat follows theAnother boat follows the
barge to monitor thebarge to monitor the
actual touchdown of theactual touchdown of the
pipe with sonar monitor.pipe with sonar monitor.

11. Arrive at the job locationArrive at the job location
• The job location is aThe job location is a
drilling rig in the Gulf.drilling rig in the Gulf.
We are attaching toWe are attaching to
the well head andthe well head and
running 16 miles of 10running 16 miles of 10
inch pipe.inch pipe.

12. News Media arrivalNews Media arrival
• We were able to layWe were able to lay
the pipe at speeds upthe pipe at speeds up
to 101.6 fpm, which isto 101.6 fpm, which is
a world record.a world record.
• News mediaNews media
documented the jobdocumented the job
for publication andfor publication and
company use.company use.

13. Job CompleteJob Complete
• We completed the jobWe completed the job
in just over 3 ½ days,in just over 3 ½ days,
which was within thewhich was within the
scheduled time.scheduled time.
• This was in spite of aThis was in spite of a
number of unusualnumber of unusual
delays during thedelays during the
process.process.

14. Computer Access and MonitoringComputer Access and Monitoring
• The upper right window isThe upper right window is
access to all modules inaccess to all modules in
the system.the system.
• The left hand window isThe left hand window is
one of the module’sone of the module’s
configurations opened forconfigurations opened for
making changes tomaking changes to
parameters while theparameters while the
drives are running.drives are running.
• The lower right window isThe lower right window is
a list of parameters beinga list of parameters being
continuously monitored incontinuously monitored in
real-time.real-time.

15. Job ResultsJob Results
• New Speed record for laying pipe fromNew Speed record for laying pipe from
reel. Design spec is 90 fpm max reelreel. Design spec is 90 fpm max reel
speed, we ran at 101.6 fpm.speed, we ran at 101.6 fpm.
• We met or exceeded all the requirementsWe met or exceeded all the requirements
for the system.for the system.
• Drive controls worked with no changesDrive controls worked with no changes
required to the system during Pipe-layrequired to the system during Pipe-lay
operation.operation.