Pipelines are often constructed in hazardous conditions, including extreme hot and cold temperatures, through mountainous and rocky terrain, and in wet areas. As such, pipelayer machinery needs to be engineered for a long life in extreme conditions.
PipeLine Machinery International (PLM) distributes Caterpillar pipelayers such as the large 587T and 583T models, which mirror the Caterpillar D8 tractor body with a heavy, strong and durable mainframe. Full box sections, steel castings and continuous rolled rails provide durable support to the undercarriage, elevated final drives and other integral frame components. The elevated sprocket undercarriage effectively isolates the drive train components from ground-induced impacts. The undercarriage is designed for optimised machine balance, performance and component life. The ACERT engine technology used in all new Caterpillar purpose-built pipelayer models ensures optimum engine performance and fuel-efficiency while meeting EPA Tier 3 and EU Stage IIIA engine exhaust emission regulations.
Working in extreme conditions
Gearing up for extreme cold conditions represents a number of challenges. Lessons learned in the 1970s during the construction of the Alyeska Pipeline have gone into the engineered design of Arctic solutions for all Caterpillar pipelayers.
All models can be equipped with Arctic fluids, engine oil, coolant, transmission, final drive, drawworks and undercarriage components. Quick evac solutions are also available on all Caterpillar pipelayers for added environmental safety. Special Arctic solution items include idlers, final drives, track roller cold weather seals and lubricants along with heavy-duty cold weather batteries, in addition to insulated cabs with thermo-pane glass. Component heaters using fuel-fired coolant circulation and 110 volt/240 volt electric water jacket heaters can be added for longer component life and additional cab heat for extreme cold conditions. The tractors are also equipped with solid engine enclosures, under hood air intake and reversible fans for added heat retention. Enhanced lighting solutions for operation in decreased daylight operations are available for added safety.
The quality of steels used in the mainframe, booms and counterweights helps to avoid the common ‘brittle steel’ problem associated with working at temperatures around -45 degree Celsius. The 583T, 587T and PL61 are all available with enclosed cabs. The cabs are designed for operator comfort and productivity in any climate, and are fully insulated with a heater (or can be equipped with air conditioning). Caterpillar cabs are designed with a maximum glass area (the dual pane option is available for cold weather) for excellent visibility. A skylight window is placed for viewing the boom and upper block, and side windows are screened to allow for ground communication and better ventilation.
Lifting capacity
The 587T has a lifting capacity of 91,625 kg and is powered by the Cat C15 ACERT engine performing at full-rated net power of 366 horse power (hp) at 1,800 rpm. The 583T has a lifting capacity of 63,504 kg and uses the same engine performing at a full-rated net power of 310 hp at 1,850 rpm. The large displacement and high-torque rise provides the 587T and the 583T with the power needed for the safe handling and consistent multi-functional operation required for poor ground conditions, while managing the less flexible characteristics of cold pipe.
As the pipe size and tractors required increases, the smooth operation of the hydraulic drawworks allows for precise and co-ordinated handling of 30 inch diameter and above pipe in all wall thicknesses in adverse conditions.
With a lifting capacity of 18,145 kg, the PL61 is well-suited to lifting smaller size pipe – generally below 16 inch in diameter. This unit has been designed to be ideal for gathering systems or for urban installations where transportation to the site and onsite clearances require a more compact machine. With counterweight and boom removed, the PL61 is a mere 2.9 m in width with a shipping weight of 16,070 kg.
Mountainous conditions
Stability during the lowering-in process in sloping conditions is a challenge requiring strict attention to safety, machine tolerances and operator capability. Numerous factors impact lifting capacity on slopes, including the length of the boom, the load, the load overhang, the load swing, ground conditions, operator experience and track tension. The higher the load, the less capability the machine has in sloping conditions. In order to mitigate this, the number of pipelayers used or the size of pipelayers should be increased so that the relative load per pipelayer is reduced.
The length of the sideboom used also has an effect on pipeline installation in mountainous terrain: the shorter the sideboom, the better the slope performance of the pipelayer. For example, a 7.3 m sideboom will outperform an 8.5 m sideboom by approximately 3 degrees, and a 6 m boom will outperform an 8.5 m sideboom by approximately 6 degrees. Increasing the load overhang has a positive impact on fore-aft slope capability. Keeping the boom further extended on a 20 degree slope will result in the load line location being closer to the rear of the pipelayer. The key is to always carry the load as far out as possible without impacting the side tipping point.
Load monitoring
Experienced pipelayer operators can ‘read’ a pipe load very effectively. However a reliable and precise pipelayer system is important when ground conditions change, when less experienced operators are at the controls or when tracks shift on loose rock. Distributed exclusively by PLM, the Pipelayer System by Cranesmart eliminates guesswork, and is designed to provide operators with the precise load-management information required for a safe and efficient job. All information regarding the load, slope, overhang, lift capacity and two-block alarm are integrated through Cranesmart’s wireless technology into a large, easy-to-read operator display panel. Operators have the information required to help prevent tip-overs, roll-overs and equipment damage due to overloading and extreme slope operations.
Pipeline training
Pipeline projects are often located away from large training facilities. The contractor’s equipment fleet is a diverse mix of types, makes and models, making operator training ‘hit and miss’. A construction contractors’ safety programmes needs to be disseminated to a large temporary workforce, often in a multi-language format, and owning companies and regulators have specific requirements for training.
PLM has teamed with ek pass to provide solutions to the training challenge. The training company is PLM’s exclusive provider of pipeline operator training and related consulting services around the globe. ek pass provides training services on equipment from over one hundred manufacturers. Training is focused on improved operator and right-of-way safety, productivity and reduced maintenance costs. Operator training is usually provided on a pipeline spread using the equipment that the trainees will be operating, saving time and increasing the relevancy of the training. The professional consultants with ek pass have been delivering award-winning, customised instructor-led training on client sites worldwide.
