March 2003

Pipelay Equipment

Design and manufacturing of special projects

CONTENTS
1 INTRODUCTION
1.1. GENERAL INFORMATION

1.2 CONCEPT DESIGN

1.3 WORLDWIDE SERVICE

1.4 RELIABLE EQUIPMENT

1.5 RELIABLE DELIVERIES

1.6 SHORT DELIVERY TIMES

1.7 RELATED EQUIPMENT

2 ENGINEERING
3 DIFFERENT TYPES OF PIPELAY SYSTEMS

2.1 S-LAY - RIGID PIPE

2.2 J-LAY - RIGID PIPE

2.3 REEL-LAY - RIGID AND FLEXIBLE PIPE

2.4 CAROUSEL-LAY - RIGID AND FLEXIBLE PIPE

2.5 VERTICAL-LAY - FLEXIBLE PIPE / UMBILICALS

2.6 ???-LAY

4 PIPELAY COMPONENTS

5 REEL-LAY SYSTEM - DEEP BLUE

6 J-LAY SYSTEM - BALDER
7 REFERENCE LIST

8 CONTACT INFO

WWW.HUISMAN-ITREC.COM

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1 INTRODUCTION
1.1 GENERAL INFORMATION
Huisman Special Lifting equipment b.v. designs and builds
equipment for the offshore construction industry. Pipelay is one of
the sectors of the construction industry in which Huisman is acti-
ve. Huisman has gained extensive experience with various pipel-
ay methods, especially with pipelay in deep water.
Huisman designs and builds pipelay equipment which is com-
pletely customized. The design is generally made, based solely on
conceptual ideas of the client, functional requirements and infor-
mation on the vessel to be outfitted with a pipelay spread.
1.2 CONCEPT DESIGN TO STARTUP OF OPERATIONS
TURN KEY DELIVERY
Huisman delivers pipelay equipment tailored to the needs of the
client. All engineering is done in our main facility in Schiedam,
The Netherlands. Fabrication is done in our workshops in The
Netherlands as well as in the Czech Republic. Final assembly
takes place in The Netherlands again. Our facility in Schiedam is
located at a deep water berth. This means that installation of the
equipment on board can be done at the Huisman quay.
is necessary to maintain total control over all aspects of the pro-
ject. This is achieved by combining engineering and fabrication
and by having in-house expertise related to every aspect of the
project. Because we do both engineering and fabrication, both
activities can be done concurrently. This eliminates interface pro-
blems and allows considerable reduction of delivery time.
Huisman is one of the very few companies that do not
have to rely on 3rd parties for engineering or delivery of
key elements of a project, nor for operating, maintaining or
servicing the equipment after delivery.
1.6 SHORT DELIVERY TIMES
The experience gained with previous projects, as well as the fact
that engineering and fabrication are completely integrated and
take place concurrently where possible, make it possible to deli-
- ver in very short time.
1.7 RELATED EQUIPMENT
Huisman provides other equipment besides pipelay related
equipment, such as for instance various types of cranes, handling
equipment for pipe, templates, ROV launch systems etc. This
allows Huisman to consider other aspects of the pipelay process
as well. This may for instance be pipe transfer from pipe carriers
or pipe handling on board.

All equipment is tested during harbor and seatrials, prior to A complete systems approach is possible which may result in
handover to the client. Our engineers may remain on board optimization of the entire spread on board.
during the first commercial operation of the system, for assistan-
ce, trouble shooting and training of clients personnel.
In other words, you may expect Turn Key delivery of an entire
pipelay system on board of your vessel.

1.3 WORLDWIDE SERVICE

Huisman provides worldwide service for installations delivered.
Our service bases are in Holland and in the Gulf of Mexico area.
Besides regular service, we also do upgrades and various modifi-
cations as required, anywhere in the world.

1.4 RELIABLE EQUIPMENT

The equipment delivered by Huisman usually is the core equip-
ment on board the offshore construction vessel. Equipment failu-
res in that case immediately cause the vessel to be idle. Equipment
reliability is therefore of prime importance.

All equipment is thoroughly tested in the workshop, prior to

installation on board. The time the vessel is required for commis-
sioning the equipment is minimal that way. The shoptesting pro-
gram is aimed at keeping the start up period of a new system as
short as possible. The pipelay installations delivered by Huisman
so far have demonstrated to work with very little or no downtime
due to equipment failures.

1.5 RELIABLE DELIVERIES

Huisman has a long track record of delivering large scale and 800t Mast Crane for
complex projects in time. Delivery against Lump Sum prices avoids Pipelay Barge Jascon 5,
costly budget overruns. In order to assure this deliver reliability, it CPL 2003

3
 2 ENGINEERING 3 DIFFERENT TYPES OF PIPELAY SYSTEMS

Huisman will take complete responsibility for all aspects of a
project. In order to be able to do that, we have in house experti-
se of all disciplines involved. This allows us to maintain control
over every part and phase of a project which is necessary to meet,
both a short delivery time and a properly functioning installation.
Huisman may provide the following engineering services in rela-
tion to pipelay systems:
- concept development
- basic and detailed engineering
- mechanical / hydraulic / electrical engineering
- pipe bending and straightening analysis
- control systems design, including 3rd party equipment
- evaluating motion behavior of the vessel
- workability analysis
- vessel engineering related to integration of the equipment on
the vessel
- FMEA analysis
As pipelay moved into deeper water, vertically oriented integra-
ted pipelay systems where introduced. This was a radical change
of the face of the pipelay industry. The majority of these deepwa-
ter pipelay systems were delivered by Huisman.
In this chapter the different basic types of pipelay systems are
shown. Most pipelay systems are according to any of these lay-
outs. Also combinations are possible however. Especially combi-
nations of J-lay and flex-lay, or reel-lay and J-lay have been made.
Also other combinations are conceivable.
Typical layouts of J-lay and reel lay systems, indicating the main
system components, are shown on page 10 and 12.
3.1 S-LAY - RIGID PIPE
Pipe joints are welded in a horizontal position. The pipe is gui-
ded to the seabed over a stinger with large bending radius, which
maintains pipe bending in the elastic range. The pipe is lowered
using tensioners.

S-lay

MAIN ADVANTAGES:
- high production rate because wel-
ding is done at multiple stations simultaneously
- no plastic bending of pipe
- allows laying of concrete coated pipe

MAIN DISADVANTAGES:
- very long stinger required when laying in deep water
- large vessel thrust required in deep water
The development of the 3.2 J-LAY - RIGID PIPE
Saipem J-lay tower: from
Pipe joints are welded in an inclined position, corresponding to
design, by atist impression
the top angle of the pipe catenery to the seabed. The pipe is lowe-
to ‘the real thing’
red with a traveling block engaging with collars on the pipe.

MAIN ADVANTAGES:
- no or smaller stinger required
- no plastic bending of pipe

MAIN DISADVANTAGES:
- low production rate due to single station welding and coating
- collars on pipes required (costs)

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 The disadvantages can be mitigated with a 2 workstation lay-
out. This increases the layrate and it allows pipelowering with 3.4 CAROUSEL-LAY - RIGID AND FLEXIBLE PIPE
tensioners. A much larger height of the tower is required howe- Large lengths of pipe are welded onshore and spooled on hori-
ver. Lay speed can also be increased by using longer pipe stalks. zontal reels on board the lay vessel. During pipelay the pipe is
This also increases the required tower height. unspooled from the carousel. Straightening of the pipe is required
before it is over boarded.
J-lay
Carousel-lay

MAIN ADVANTAGES:
- very high production rate
- pipe welding onshore under con-
trolled circumstances

MAIN DISADVANTAGES:
- dedicated spoolbase required for pipe preparation
- pipe is bend plastically
3.3 REEL-LAY - RIGID AND FLEXIBLE PIPE - tensioners need to move vertically to match the pipe elevation
Large lengths of pipe are welded onshore and spooled on ver- - very long stinger required when laying in deep water
tical reels on board the lay vessel. During pipelay the pipe is uns-
pooled from the reel. Straightening of the pipe is required before 3.5 VERTICAL-LAY - FLEXIBLE PIPE / UMBILICALS
it is over boarded. Flexible pipe is stored on reels, carousels or baskets. During
pipelay the pipe is unspooled over a tower. A vertically mounted
Reel-lay tensioner lowers the pipe to the seabed.

Vertical-lay - flexible pipe

MAIN ADVANTAGES:
- very high production rate
- pipe welding onshore under controlled circumstances MAIN ADVANTAGES:
- pipe is not bend under tension
MAIN DISADVANTAGES: - equipment is portable
- dedicated spool base required for pipe preparation - location on stern, side or at moonpool
- pipe is bend plastically
- laying of concrete coated pipe impossible MAIN DISADVANTAGES:
- not suitable for rigid pipe

5
 pressure. In general tensioner configurations for different applica-
3.6 ???-LAY tions are as indicated below.
- RIGID PIPE / FLEXIBLE PIPE / PIPE IN PIPE / ‘??? PIPE’

al
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New concepts developed by our clients may be realized.

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Huisman will use the expertise gained with previous projects to

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Type of pipe

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ty
assist with the development of any new concept.
rigid pipe - concrete coating H 2 PU on springs low
rigid pipe - no concr. coating H/V 2/4 PU fixed moderate
‘???-lay’ flexible pipe
umbilicals
V
H
4
2
Cast Iron
PU
fixed
fixed
high
low

4 track tensioners with high squeeze load capacity are very

compact. 2 track tensioners for low squeeze loads are very large
machines, in relation to their tension capacity.

Huisman has delivered the following tensioners so far:

2 tracks: 20 / 37t
4 tracks: 60 / 75 / 160 / 275t

A total of 24 tensioners have been delivered over the last 5

years
275t tensioner

4 PIPELAY COMPONENTS

Huisman has delivered complete pipelay systems as well as indi-

vidual system components. Typical components for pipelay sys-
tems, delivered are:

- Pipe tensioners
- A&R winches
- Hang off clamps
- Pipe straighteners
- Line up systems Our tensioners are of a modular design. This means that confi-
- Pipe storage reels guration changes between 4 and 2 tracks are possible. The ten-
- Carousels sioners further are extremely compact.
- Pipe handling equipment, lifts, conveyors etc.
- Pipe transfer cranes LINEAR TENSIONERS
- Stinger handling systems Linear tensioners have been proposed for applications where a
very high tension is required. These tensioners work according to
4.1 PIPE TENSIONERS the moving clamp principle. Specific to this type of tensioners is
Tensioners are the central element of most pipelay systems. that they operate with a very high squeeze pressure. A disadvan-
Their function is to hold the weight of the pipe hanging off the ves- tage of the moving clamp principle is that it reduces the produc-
sel to the seabed, while paying it out at controlled speed. The type tion speed.
of tensioner required, depends on the type of pipe to be laid as
well as the configuration of the lay system. Tensioners may be divi- Huisman has delivered and tested a 400 ton moving clamp
ded in track type and linear tensioners. Both types of tensioners which would be part of a 1600t tensioner, based on a compact
are patented. multiple clamp principle.

TRACK TYPE TENSIONERS

Track type tensioners for different applications are categorized
by number of tracks, type of pads that grip the pipe and squeeze

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 4.2 A & R WINCHES 4.3 HANG OFF CLAMPS
With increasing water depth, the required top tensions increase. Hang off modules are used in vertically oriented pipelay sys-
The required capacity for Abandon & Recovery winches increases tems, to hold the pipe during welding of a new pipesection. The
together wit the tensioner capacity. Apart form that, the increased capacity has to be sufficient to hold the weight of the pipe, also in
water depth calls for larger cable lengths to be handled by the case of flooding of the pipeline. Hang off clamps may be made
winch. The typical length of A&R wires for current water depths is skiddeable to move the pipeline in relation to the vessel. The
3000 m (10.000 ft). clamp may support the pipeline using collars on the pipeline, or
alternatively hold the pipe on friction.
120t A&R winch for Toisa
Perseus, Subsea 7, being tes-
ted at the Huisman quay

4.4 PIPE STRAIGHTENERS

Pipe straighteners are required in case the pipe is reeled. They
remove the curvature of the pipe which remains after plastic ben-
ding of the pipe on the reel. Straighteners work on the principle of
3 point counterbending of the pipe.

Huisman has developed a traction winch system for this appli-

cation. The winch is of a unique design, aimed at minimizing wear
of the wire. The
design is further 300t traction winch
extremely com-
pact in relation
to its capacity.
A&R winch sys-
tems have been
designed up to
650t pulling
capacity. This
corresponds to
the maximum
size of wire, cur-
rently available
at 3000 m
length.
Traction winch
systems up to
300t have been
delivered.

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 4.5 LINE UP SYSTEMS
To weld in a J-lay configuration the pipes to each other, line up
systems are being developed and built by Huisman-Itrec.

4.6 PIPE STORAGE REELS

Large driving systems keep the tension in the pipe while reeled.
Storage capacity of the reels can be up to 2500t.

Two carousels below deck

4.8 PIPE HANDLING EQUIPMENT, LIFTS, CONVEYORS ETC.

Huisman-Itrec has developed for several clients handling
equipment: a 16t Pedestal Mounted Offshore Crane for pipe
transfer, a welding street for (the new) p.l.v. Midnight Express and
several pipe rackers. Storage, transport and handling of pipes can
also be done in standard (patented) 40ft sea containers.

4.7 CAROUSELS
Flexible pipelaying is mostly done from horizontal reels. These
carousels can be stored eighter on or below deck.

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 Stinger Handling System being
4.9 PIPE TRANSFER CRANES tested in the Huisman workshop
For the further handling of the pipes Huisman-Itrec developed a
large variety of pedestal cranes of special designed pipe handling
cranes

16t pedestal crane

5 CSO DEEP BLUE PIPE LAY SYSTEMS

AN EXAMPLE OF A MULTIPLE PIPE LAY SYSTEM; J-LAY, REE-

LED-LAY AND FLEX-LAY ON ONE VESSEL.

REEL LAY (RIGID PIPES)

pipe diameters 100 - 600 [mm] = 4-24 [inch]
tension capacity 550 [t] = 1212 [kips]
speed 33 [m/min] = 108 [ft/min]
storage capacity reels 2 * 2500[t] = 2* 5500 [kips]

FLEX LAY
pipe diameters 100 - 600 [mm] = 4-24 [inch]
tension capacity 550 [t] = 1212 [kips]
speed 33 [m/min] = 108 [ft/min]

J-LAY
lengths of pipe 48 [m] = 160 [ft]
tension capacity 550 [t] = 1212 [kips]

total height of structure 65 [m] = 213 [ft]

4.10 STINGER HANDLING SYSTEMS tower angle adjustment 30 - 90 [degr]

For S-lay system a stinger is needed to guide the pipe while
lowering it to the sea bed. Huisman-Itrec developed a stinger See next page for more info about the components of
handling system to control the angle and position of the stinger. CSO Deep Blue.

9
 10 ton service

crane

aligner -

20 m diameter

straightener
tower angle adjuster

pipe centralizer
2 pc main pipe reels 2500t cap.

275t tensioner
reel drive unit

pipe centralizer
150 ton A&R winch

275t tensioner
40 ton tensioners

for pipe spooling

pipe deflector

Hang Off Clamp

300 ton A&R

winch

(traction type)

WWW.HUISMAN-ITREC.COM

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Reeled, flex and J-lay systems on
Deep Blue, CSO, 2001

11
6 J-LAY SYSTEM BALDER

WWW.HUISMAN-ITREC.COM

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13
7 REFERENCE LIST

m
yste
r
mete

ng s
to
e dia

ap.

able

weri
ion c
p any

rade
. pip
em

lo
el
Vess

Type

Tens
Com
Year

Syst

Pipe
Up g
Max
1997 1997 1996

Stolt Offshore Seaway Falcon rigid pipe horizontal firing line 12" 75t 300t tensioner
adjustable ramp
Halliburton Subsea misc. flexible pipe reel drive system 16" 10t 40t direct from reel

Halliburton Subsea Toisa Perseus flexible pipe Vertical lay system 16" 120t -- tensioners

Halliburton Subsea Toisa Perseus flexible pipe carousels 16" 20t -- --

2001 1999 1999 1999 1998 1997

DSND Lochnaghar flexible pipe bundle lay 16" 110t -- tensioners

Stolt Offshore Seaway Eagle flexible pipe Vertical lay system 16" 60t -- tensioners
rigid pipe 5"
DSND Kommander 3000 flexible pipe bundle lay 16" 110t -- tensioners

Saipem S7000 rigid pipe J-Lay System 32" 525t 2000t tensioners

Coflexip Stena Offshore CSO "Deep Blue" rigid pipe Reel Lay 16" 550t -- tensioners
rigid pipe J-lay 26" 550t 880t winch system
flexible pipe 16" 550t -- tensioners
2003 2002

Heerema Balder rigid pipe J-lay - quad joints 30" 1050t -- winch system
rigid pipe J-lay - hex joints 30" 525t 800t winch system
Torch Midnight Express rigid pipe Reel Lay 16" 160t -- tensioners

Seaway Falcon Toisa Perseus

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 Midnight Express
Seaway Eagle

Saipem 7000

15
 Overview of the Huisman office and quay, with the
loadout of the J-lay tower for Balder, Heerema 2002

Huisman-Itrec
P.O.Box 150 - 3115 HH Schiedam
Admiraal Trompstraat 2 - 3115 HH Schiedam
Harbourno. 561 The Netherlands
Telephone: +31(0)10-245 22 22
Fax: +31(0)10-245 22 20
E-Mail: mail@huisman-itrec.com
Internet:http:\\www.huisman-itrec.com

Huisman US Inc.
801 Travis suite 2100
Houston 77002 TX USA
Tel: + 1 (0) 281 586 7676
Fax: + 1 (0) 281 586 7878
E-mail: adegroot@huisman-us.com
March 2003 Huisman Special Lifting Equipment B.V including its subsidiaries and/or affiliates.
This leaflet is distributed by Huisman Special Lifting Equipment B.V. (Huisman) and may not be copied, reproduced, distributed or disclosed to or by any other without the express prior writ-
ten authority of Huisman’s Management. This leaflet shall not be deemed to make any representation or warranty as to the accuracy or completeness of the information reflected therein and
may not be used for any other purpose than to invite Huisman’s sales department in writing to provide additional information. On the products as described in this leaflet, patents are pend-
ing, three dimensional marks can be reserved by Law as well.

Design and manufacturing of special projects