Automated Winch Package for Pipeline Tool Testing

RPME’s Automated Winch Package is a fully integrated, programmable pulling system engineered for controlled, repeatable pipeline tool testing operations.

Designed for indoor installation, this frame-mounted winch system pulls testing tools through horizontally laid pipe strings with precision tension control, programmable speed profiles, and comprehensive data capture. The system is ideal for validation testing, tool qualification, and performance verification applications.

Complete Testing System Integration

The pipes are arranged horizontally, with a centerline spread of up to 12 feet from the first to the last pipe. RPME’s traversing winch frame allows the main pulling winch to automatically align with each pipe position.

The winch assembly travels horizontally on linear ways mounted to a structural frame/skid. A cable chain system manages power and control routing during movement, ensuring safe and reliable operation across the full travel range.

To support full-cycle testing efficiency, the package includes:

• Rail-mounted auxiliary tow-line winch for pulling the rope back through the pipe
• Shuttle cart with rails to return testing tools to the pipe inlet side
• Vertical centerline rope guide system for precise alignment

This integrated configuration minimizes manual handling, reduces reset time, and improves overall testing throughput.

Main Winch Performance Specifications

• Pulling Capacity: 8,000 lbs
• Maximum Pulling Speed: 8 mph
• Drive System: 200 HP Variable Frequency Drive (VFD) electric winch
• Rope Capacity: 400 ft of ½” synthetic rope
• Single-Layer Drum Build-Up for consistent tension and repeatable performance

The single-layer drum design eliminates multi-layer tension variability, improving data accuracy and protecting rope integrity during repeated test cycles.

Zero-Fleet Angle Levelwind System

A programmable, servo-driven levelwind system automatically traverses the drum to maintain a zero (0) fleet angle during winding.

This ensures:

• Uniform rope spooling
• Reduced rope wear
• Consistent tension measurement
• Increased rope service life

The winch itself traverses horizontally to align with each pipe string, providing both pipe-to-pipe positioning and precision rope management in a single integrated assembly.

Advanced Controls & Data Acquisition

The system is equipped with PC-based controls utilizing Wonderware software, delivering programmable test control and full data visibility.

Programmable & Display Functions:

• Acceleration and deceleration profiles
• Line speed control
• Constant-velocity run distance
• Maximum allowable tension

Data Logging Capabilities:

• Pull Force vs. Distance

Speed vs. Distance

CSV data outputs for pull, distance, and speed

A tension meter/load cell provides direct, closed-loop rope tension feedback, ensuring accurate, real-time control throughout the testing sequence.

Local operator controls include:

• Emergency Stop (E-Stop)
• Start / Stop
• Forward / Reverse
• Adjustable jog speed

The control system also enables coordinated rope payout to the auxiliary winch for streamlined test reset operations.

Engineered for Repeatable, High-Integrity Testing

RPME’s Automated Winch and Track Package transforms pipeline tool testing into a controlled, data-driven process. By combining programmable motion control, precision tension management, and integrated material handling, the system reduces variability, increases throughput, and delivers reliable performance data for engineering validation.