Technical Specification for Pipelay Equipment
Scope of Supply
1.0 Linear Pipe Tensioner / A&R Winch System
1.1 2 units 70-ton Linear Pipe Tensioner
1.2 1 unit 150-ton Abandonment & Recovery Winch
1.3 1 unit Instrument Sheave
1.4 2 units 4 X 270-Hp Hydraulic Power Unit
1.5 1 unit Remote Operator Console
2.0 Pipe Handling System
2.1 2 units Longitudinal Idle Roller, Elevating
2.2 4 units Longitudinal Driven Roller, Elevating
2.3 4 units Longitudinal Driven Roller, Fixed
2.4 1 system Transverse Chain Conveyor
2.5 2 units Transfer Vehicle
2.6 2 units Line-up Module
2.7 4 units Fixed Roller Support Units
2.8 1 unit Elevating Stern Roller Support Units
2.9 2 units 2 x 75-hp Hydraulic Power Units
2.10 1 unit Front End Control Console
2.11 2 units Local Control Panel
2.12 5 units Stinger Roller Units
Technical Specifications
1.1 70-ton Linear Pipe Tensioner
Type : 2-track Vertical
Nominal Tension : 70 tons @ 25 m/min
Drive : Hydraulic
Minimum Pipe Diameter : 6”
Maximum Pipe Diameter : 60” OD (including weight coating)
Design Coefficient of Friction: 0.45
Bottom of Pipe (BOP) : 1.85m
Track Assemblies : - Two units vertical. Each track assembly comprises twosprocket-driven trackchains fitted with track
shoes that contactthe pipe surface.
- Lower track assembly fixed, Upper track assembly moveable toprovide uniform grip.
- Upper track assembly actuated by hydraulic cylinder ormechanically-synchronized jack screws located at four columns
Control : - Local / Remote Master
- Local control for set-up in Manual mode only
Operation Modes : Manual / Auto / Standby
Manual Mode : Joystick for step-less variable speed control for pay-in / pay-out
Stand-by Mode : Fail-safe disc brakes on tracks drives come on in the event of :
- Power failure
- Loss of hydraulic pressure, preventing loss of pipe string
- Failure of both control loops
Features : - Two moulded polyurethane track pads bolted onto each v-shapedcross-tie grip pipeline
- Adjustable track pad bolting position for pipe diameters varyingfrom 6” to 60”
- Four columns guide moveable upper track assembly
- Upper Track can open up to 2.5 meters to allow subsea valvesetc to pass through tensioner
- Pipe diameter variations and irregularities are absorbed by apneumatic suspension system
- Fail-safe disc brakes on hydraulic drives for tracks
- Tension, speed and displacement monitoring
- Load cells mounted between skid and foundation on the downstreamend of the tensioner unit transmits signals back to
controllers for tension monitor and control
- Air pressure transducer transmits signals to remote operatorconsole for pneumatic pressuremonitoring
Dimensions LBH : Approximately 8.2 X 4.5 X 6.6 meters
Weight : Approximately 85 tons (reference)
1.2 150-ton (Full-drum) Abandonment & Recovery Winch
Layer Line Pull (ton) Line Speed (m/min) Wire Rope on Drum (m)
1 203 25 111
2 181 27 235
3 164 30 372
4 150 33 522
Type : Single Drum with Spur Gear driven by piston hydraulic motors
Wire Rope Capacity : 500 m X 77 mm wire rope (MBL 343 ton EIPS)
No. of Wraps per Layer : 27
Drum Dimensions : Ø 1250 mm X 2180 mm wide X Ø 2500 mm flange
Drive : Hydraulic (Rexroth / Sauer or equivalent)
Brake : Fail-safe Hydraulic-release Disc Brake on Motors
Winch Control : Local and Remote
Operating Modes : Manual / Auto Tension / Stand-by
Features : Diamond lead screw Spooling Device with horizontal and vertical rollers
Dimensions LBH : Approx. 4.2 X 4.3 X 3.1 meters (Reference)
Approximately Weight : 28 ton (Reference)
1.3 Instrument Sheave
Wire Rope Diameter : 77 mm
Orientation : Horizontal
Contact : 90 degrees
Load Pin Rating : 150 tons
Monitor : - Line Tension
- Line Speed
- Line Displacement
Dimensions LBH : Approximately 1.8 x 1.8 x 0.4 meter (reference)
Weight : Approximately 6.6 tons (reference)
1.4 4 x 270-hp Hydraulic Power Unit
Drive : Electric – 4 X 270 hp / 480V / 3ph / 60Hz / 4-pole / IP 56
Hydraulic Pump : Variable-displacement Axial Piston Closed Loop (Sauer or equivalent)
Features : - Built-in resilience with multiple pump sets
(tension is maintained atthe expense of speed in the event onepump set is down)
- Heavy-duty Open Skid
- Star Delta Start
- Reservoir Accessories
- drain, breather cap
- level sight gauge with thermometer
- oil level shutdown
- oil temperature high alarm
- suction strainer
- access manhole cover
- Relief Valve
- Pressure Gauge
- Sea-Water Cooler
- Return Filter with Clog Indicator and Bypass / Clog Switch
Dimensions LBH : Approx. 5.0 X 2.8 X 2.5 meters (reference)
Approximately Weight : 15 tons (dry) (reference)
1.5 Remote Operator Console
Controls : - Allen-Bradley or equivalent
- Full redundancy with dual PLC’s
- Failsafe monitor automatically transfers control to back-up controllerin the event active controller fails
- If both controllers fail, system goes into standby mode and brakesbecome set
Operator Interface : High-resolution Touch-Screen (100% Redundant)
Mode select : - Manual
- Automatic (constant tension)
- Stand-by
Automatic Mode : - In Auto mode, operator sets desired pipe tension (15% to 100% ofthe rated tension) which is then
maintained by the system
- Constant tension mode
- Deadband setting of up to 25% of tension set-point
- Gain adjustment
- Critical faults activates emergency stop and setting of brake
Manual mode : - operator pays in / out using a joystick on either the local ormaster console
Standby mode : - pipe string is held motionless by tensioner brakes when :
- loss of electrical power supply
- failure of both Controllers A & B
- loss of track drive power
- Brakes are automatically set under failsafe conditions
Tension Control : - Two load pins, located on the downstream end of the tensioner unit.
The signals are algebraically summed at the controller to obtain thepipe tension
- Setting the tension on the active controller also sets the sametension on the stand-by controller.
The standby controller is hencealways ready to take over command when the active controllerfails.
Squeeze Pressure : Squeeze pressure transducers measures air pressure applied to thetracks and ultimately the pipe. Squeeze pressures are displayed onboth controllers.
Tension Transfer : Automatic from Tensioner to A&R Winch during abandonment and visa-versaduring recovery
Power Unit Status : Charge and system pressures on the closed loop pump sets aremonitored for pressure loss. Indicators and alarms are located on bothcontrollers.
Alarms : Loss of charge pressure in the hydraulic circuit, motor temperature high,failsafe conditions sets off the visual &
audible alarm
Chart Recorder : Digital 3-channel recording of tensioner and A&R winch tensions, andpipeline displacement
2.1 Longitudinal Idle Roller Unit, Elevating
No. of Rollers : 2
Roller Arrangement : Vee In-Line
Roller Material : Vulcanized Polyurethane
Roller Drive : Idle
Bottom of Pipe (BOP) : 1.85m
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Pipe Joint Length : 12 m ± 1 m
Rated Pipe Joint Weight : 32 tons
Rated Conveying Speed : Not Applicable
Elevation Adjustment : Hydraulic Cylinder
Dimensions LBH : Approx. 1.2 m x 1.8 m x 1.8 m
Weight : Approximately 3 ton
2.2 Longitudinal Driven Roller Unit, Elevating
No. of Rollers : 2
Roller Arrangement : Vee In-Line
Roller Material : Vulcanized Polyurethane
Roller Drive : Hydraulic
Bottom of Pipe (BOP) : 1.85m
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Pipe Joint Length : 12 m ± 1 m
Rated Pipe Joint Weight : 32 tons
Rated Conveying Speed : 15 m/min
Elevation Adjustment : Hydraulic Cylinders
Dimensions LBH : Approximately 1.2 m x 2.0 m x 1.8 m
Weight : Approximately 3 ton
2.3 Longitudinal Driven Roller Unit, Fixed
No. of Rollers : 2
Roller Arrangement : Vee In-Line
Roller Material : Vulcanized Polyurethane
Roller Drive : Hydraulic
Bottom of Pipe (BOP) : 1.85m
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Pipe Joint Length : 12 m ± 1 m
Rated Pipe Joint Weight : 32 tons
Rated Conveying Speed : 15 m/min
Elevation Adjustment : Fixed
Dimensions LBH : Approximately 1.2 m x 2.0 m x 2.3 m
Weight : Approximately 3 ton
2.4 Transverse Chain Conveyor
Pipe Rack : Wood-lined Transverse Steel Frame
Pipe Conveyor : 2 x Transverse Roller Chain with push-roller chain attachmentssliding on Pipe Rack
Conveyor Drive : Hydraulic
Bottom of Pipe (BOP) : 1.85m
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Pipe Joint Length : 12 m ± 1 m
Rated Pipe Joint Weight : 32 tons
Rated Conveying Speed : 7.62 m/min
Features : Adjustable push-roller chain attachments
Dimensions LBH : 7.8 X 7.8 X 2.0 meter
Weight : Approximately 20 tons (excluding pipe joints on rack)
2.5 Transfer Vehicle
No. of Rollers : 2 Spin
Roller Drive : Hydraulic
Transverse Speed : 7.62m/min
Bottom of Pipe (BOP) : 1.8m (to be confirmed)
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Pipe Joint Length : 12m ± 1m
Rated Pipe Joint Weight : 32 tons
Track Length : Approximately. 8 meters
Features : - Track mounted
- Dual frame construction
- Inner frame elevated by 2 hydraulic cylinders
- hydraulic drive
- Safety bumper
Dimensions LBH : Approximately 3.2 m x 1.6 m x 2.3 m
Weight : Approximately 5 tons
2.6 Line-Up Module
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Pipe Joint Length : 12 m ± 1 m
Rated Pipe Joint Weight : 32 tons
Rated Conveying Speed : 25 m/min
Bottom of Pipe (BOP) : 1.85m
Degrees of Freedom : - 4 (X-, Y-, Z-, and pivot)
- X-Axis Longitudinal forward and backward along firing Line byendo rollers
- Y-Axis ±12 inch Horizontal Transverse by hydraulic cylinders
- Z-Axis ± 10 inch Vertical from BOP by hydraulic cylinders
- Pivot
Per Module
Number of Rollers : 2 pairs
Roller Material : Vulcanized Polyurethane
Roller Drive : Hydraulic
Features : - Proportional control
- Constant abutment force on pipe joint against stand pipe
Dimensions LBH : Approximately 3.8 m x 2.2 m x 1.8 m
Weight : Approximately 8 tons
2.7 Fixed Roller Support Units
No. of Rollers : 4 pairs in vee-formation
Roller Arrangement : Each pair arranged Vee In-Line on pivoted beam carrier
Roller Material : Vulcanized Polyurethane
Roller Drive : Idle
Bottom of Pipe (BOP) : 1.85m
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Load Capacity : 45 tons
Dimensions LBH : Approximately 2.2 m x 1.8 m x 2.2 m
Weight : Approximately 5 tons
2.8 Elevating Stern Roller Support Units
No. of Rollers : 6 pairs in vee-formation
Roller Arrangement : Each pair arranged Vee In-Line on pivoted beam carrier
Roller Material : Vulcanized Polyurethane
Roller Drive : Idle
Minimum Pipe Diameter : 6”OD
Maximum Pipe Diameter : 60”OD
Rated Loading Capacity : 75 tons
Elevation Adjustment : Hydraulic
BOP Range : 1400-1900mm (min adjustment pitch 20mm)
Features : - Hour-glass Steel Rollers on both ends of unit for A&R winchwire rope
- Corrosion protection for operation in splash zone of barge
Dimensions LBH : Approximately. 2.9 m x 2.4 m x 2.5 m
Weight: Approximately 20 tons
2.9 Hydraulic Power Unit
Drive : Electric Total 2 x 150-hip / 480V / 3ph / 60Hz / 4-pole / IP 56
Hydraulic Pump : Variable-displacement Axial Piston, Open Loop
Make : Sauer / Parker or equivalent
Displacement Control : pressure-compensated
Features : - Heavy-duty Open Skid
- Star Delta start
- Return filter with clog indicator and by-pass
- Reservoir accessories
- drain, breather cap
- level sight gauge with thermometer
- oil level low alarm / shutdown
- oil temperature high alarm
- relief valve
- pressure gauge
- air-to-oil cooler
Dimensions LBH : Approximately 3.5 m x 2.2 m x 2.3 m
Weight : Approximately 5.0 tons
2.10 Front End Control Console
Controls : - Electronic Joysticks for control of:-
- Line-up Table Motion
- Line-up Rollers
- Spin Rollers
- Spin Rollers Up / Down
- Chain Conveyors / Transfer Vehicle
- Remote Power Pack Controls
Indicators : - Digital for oil pressure
- HPU status
Dimensions LBH : Approximately 1.5 m x 0.5 m x 1.2 m
Weight : 300 kg
2.11 Local Control Panel
Controls : - Electric Joysticks / Push Buttons
- Emergency stop
Indicators : Pump on / off
Panel Rating : IP56
Dimension : Approx. 400 x 400 x 210 cm
2.12 Stinger Roller Support Units
No. of Rollers : 4 pairs in vee-formation
Roller Arrangement : Each pair arranged Vee In-Line on pivoted beam carrier
Roller Drive : Idle
Minimum Pipe Diameter : 8”OD
Maximum Pipe Diameter : 60”OD
Elevation Adjustment : Manual
Vertical Load Rating : 60 tons
Dimensions LBH : Approximately 3.0 m x 2.2 m x 2.7 m
Weight : Approximately 2.5 tons
General
Surface Preparation / Coating : Abrasive-blasted to Swedish Standard SA2½
Zinc-rich epoxy primer
Epoxy intermediate coat
Polyurethane top coat
Degree of Protection : All electrical enclosures are splash-proof