cover story: read about saudi aramco's plans for the future. saudi

ISSUE 27 | MARCH 2016

The history of the first HDD rig designs Page 46

Douglas-Westwood: pipeline industry forecast to 2019 0

Cover story: Read about Saudi Aramco’s plans for the future. Saudi Aramco General Manager Pipelines Mohammed Sultan Al-Qahtani exclusivePage 30

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CONTENTS

Issue 27 | March 2016

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The history of the first HDD rig designs

6

Douglas-Westwood: pipeline industry forecast to 2019Page 10


REGULARS

From the editor 4World wrap 6News in brief 8Events 60Advertisers’ index 64

INDUSTRY NEWS

Stuck in the pipeline: project delays hit industry outlook 10Instilling a leak-detection culture: API releases RP 1175 16The changing pipeline industry 20Real-time demand for a gas pipeline design: dealing with modern challenges – Part 2 24Prepare your inventory: how to limit downtime on your construction site 28

REGION REVIEW: MIDDLE EAST

Interview with Saudi Aramco’s Mohammed Sultan Al-Qahtani 30How to enhance your company’s presence in the Middle East 34Conference programme 36Interview with McConnell Dowell’s Mark Burrows 40Qatar pipeline isolation: fast-track delivery meets demand 44

HDD AND MICROTUNNELLING

Designing the first HDD rigs 46

PIGGING

Reliability engineering: a target-driven approach to integrity management 50All about pigging: providing solutions to pipeline integrity 54

RISK MANAGEMENT

Damage vs failure: a risk assessment needs to know the difference 58

UPCOMING EVENTS

EITEP’s pipeline conference and exhibition now to include a focus on supply networks 60Pipeline training in Colombia 62

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FROM THE EDITOR

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Page 46

Douglas-Westwood: pipeline industry forecast to 2019

Page 10


Construction of Saudi Aramco’s 217 km Shaybah – Abqaiq Oil Pipeline, which was completed in 2010, and is an integral piece of infrastructure in Saudi Arabia.

Editor-in-Chief John Tiratsoo

Managing Editor Lyndsie Clark

Sales Director Julie McConachy

Senior Account Manager David Marsh

Sales Representative Megan Lehn

Design Managers Bianca Botter Katrina Rolfe

Events Manager Luke Rowohlt

Data Manager/Analyst Gareth Weaver

Publisher Zelda Tupicoff

As this issue of Pipelines International went to press, the 28th Pipeline Pigging and Integrity Management Conference and

Exhibition was about to begin in Houston. Again organised by Clarion Technical Conferences and Great Southern Press’ Tiratsoo Technical division, the event (see page 54) was considerably larger than even in 2015 (which set the record for exhibitors and visitors attending), to the considerable surprise of the organising team when considering the straightened times being faced by many areas of the hydrocarbons’ industry. The truism that, despite the oil price, pipelines are needed more than ever (and to be maintained as cost-effectively as possible, and with maximum integrity and safety), is being borne out in practice. The expanded technical programme of the conference with 38 papers, and the sold-out exhibition of 108 companies (and there’s a waiting list), testifies that the pipeline industry has a huge and continuing significance for the communities which it serves.

The potentially rosy image presented by these exhibitors with their tremendous achievements with innovative products and services, and the authors of the technical papers with their presentations on many cutting-edge technologies and solutions, misses out a detail that is becoming more-and-more significant to the industry: that of the competency of its engineers. [This is by no means a criticism: rather, as will be seen, it’s a comment about how standards are to be maintained and improved into the future.]

In the past, it may have been adequate for those responsible for pipeline design, construction, and operations, having obtained an appropriate engineering education, to be trained ‘on-the-job’, taking the benefit of the experience of their seniors and mentors who may well have been among what can be described as the first generation of pipeline engineers. The loss of senior staff through age, lay-offs, or company amalgamations and realignments, means that this route can no longer be assured for the engineers who will have to be responsible for the networks in the future. This combines with the need for ‘competency’ to be more clearly defined, and even codified, a concept with which the industry’s regulating authorities are becoming increasingly engaged. In recognition of this issue, the first paper of the conference was not about engineering or technical issues, but rather on ‘competency in engineering’, presented by Michelle Unger of the Rosen Group and Dr Phil Hopkins of Phil Hopkins Ltd, both of whom are

UK-based. A brief overview of their important remarks will introduce the subject here: their full paper will be published in the March edition of the Journal of Pipeline Engineering.

In their paper’s abstract, Ms Unger and Dr Hopkins introduce an American psychologist, David McClelland who, in the 1960s, showed that traditional IQ tests and personality assessments being used by companies to hire new staff were poor predictors of competency. He proposed that these hiring decisions are better based on ‘demonstrable competencies’ relating specifically to the position being filled. The authors then define ‘competence’ as ‘the ability to do something well’, in particular, the ability to undertake responsibilities, and to perform activities to a recognised standard. This has, of course, long been a requirement in the engineering industries, and the pipeline industry is clear about the need for competency: for example, the American Society of Mechanical Engineers’ pipeline standard states: “... the Code is not a design handbook; it does not eliminate the need for the designer or for competent engineering judgment”; and the International Standard for pipelines (ISO 13623) states: “... the design, construction, testing, operation, maintenance and abandonment of the pipeline system shall be carried out by suitably qualified and competent persons”. Consequently, pipeline regulatory bodies can justifiably ask operators to demonstrate the competency of any or all of their staff, particularly after a pipeline failure. This may be an awkward request.

As Ms Unger and Dr Hopkins conclude, “Competency is now a hot topic in the pipeline business, and demonstrating competency is essential in pipeline engineering.” Their paper explains the meaning of competence, stressed its importance, and summarises competency frameworks and management systems. It will hopefully provide food for thought for those who have not fully considered these issues, and guidance for those for whom the definitions of competency and confidence are synonymous which, as will be seen, they clearly are not.

John TiratsooEditor-in-Chief

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WORLD WRAPWORLD WRAP

To stay updated with opportunities on the Northern Gas Pipeline, visit www.gateway.icn.org.au/project/3767/northern-gas-pipeline-construction

58 km deepwater Gulf of Mexico pipeline brought into serviceEnbridge’s 20 inch diameter, 58 km Heidelberg Oil Pipeline has been brought into service three months ahead of schedule. The Heidelberg Oil Pipeline is located in the Gulf of Mexico, approximately 322 km southwest of New Orleans, Louisiana, and transports crude oil from Anadarko Petroleum Corporation’s Heidelberg development to an existing third-party pipeline system. The pipeline was laid in water depths of up to 1,600 m, and is designed to transport up to 120,000 bbl/d of oil.

Punj Lloyd–Limak JV wins TANAP pipeline contractA joint venture (JV) between Punj Lloyd and Limak has been awarded a contract to construct a 459 km section of the 48 inch diameter TANAP Gas Pipeline in Turkey. The 1,841 km Trans Anatolian Natural Gas Pipeline Project (TANAP) is designed to transport natural gas produced in the Shah Deniz 2 field and other fields in Azerbaijan and its neighbours, through to Turkey and Europe.

TAP awards two EPC pipeline contractsTrans Adriatic Pipeline AG (TAP) has awarded an engineering, procurement and construction (EPC) contract for a pipeline receiving terminal (PRT) to Renco S.p.a. A joint venture comprised of Enereco S.p.a. and Max Streicher S.p.a. has been awarded the EPC contract for a 36 inch diameter, 8 km section of onshore pipeline in Italy, which will connect the project offshore section at the landfall with the PRT. TAP will transport natural gas from the Shah Deniz II field in Azerbaijan to Europe. The approximately 878 km long pipeline will connect with the Trans-Anatolian Pipeline (TANAP) at the Turkish-Greek border at Kipoi, cross Greece, Albania, and the Adriatic Sea, before coming ashore in Southern Italy.

TANAP awards control infrastructure contractABB has been awarded a contract to deliver the control infrastructure for the 1,850 km Trans-Anatolian Natural Gas Pipeline (TANAP). ABB will deliver the infrastructure to contribute to safe, secure and reliable operation of the pipeline throughout its lifetime. The US$11 billion pipeline will bring Azerbaijan’s natural gas directly to Europe and will interconnect with two others: the South Caucasus at Turkey’s border with Georgia, and the Trans Adriatic at its border with Greece.

McConnell Dowell seeking EOIs for Northern Gas PipelineConstruction contractor for Australia’s 623 km Northern Gas Pipeline, McConnell Dowell, is seeking expressions of interest for supplier and subcontractor opportunities that may arise for the pipeline. McConnell Dowell has been engaged by Jemena to construct the pipeline, which will connect the gas fields in the Northern Territory with customers in the eastern gas market, running between Tennant Creek in the NT and Mt Isa in Queensland. The construction scope includes the 623 km high-pressure gas pipeline, two compressor stations and mid-line facilities. Construction is expected to commence in early 2017 and be completed by 2018. Procurement packages associated with the construction works will begin to be listed in the second half of 2016.

Gazprom cancels pipeline tender for Nord Stream II expansionRussia’s Gazprom has cancelled a major tender worth US$50 million for a domestic gas pipeline that is part of the expansion of Nord Stream. This recent cancellation means Gazprom has now cancelled tenders for the construction of the Ukhta-Torzhok 2 pipeline, worth a total of around 16.8 billion roubles (US$220.2 million). Ukhta-Torzhok 2 was to allow more Russian gas to be fed into Nord Stream’s extension, which is designed to carry Russian gas to Germany.

Operation begins on Shell Corrib Gas PipelineShell’s Corrib Gas Pipeline has officially commenced operations, following approval from Ireland’s Minister for Communications, Energy and Natural Resources. The 20 inch diameter Corrib Gas Pipeline transports gas from the offshore Corrib Gas Field to a gas terminal at Ballenaboy Bridge, County Mayo, Ireland. Approximately 83 km of the pipeline is offshore, linking the wells at the Corrib field to the landfall at Glengad. A 9 km onshore pipeline links the landfall to the Ballenaboy Bridge terminal. Gas is processed at the terminal to meet the requirements to flow into Ireland’s Bord Gáis Eireann pipeline network.


NEWS IN BRIEFNEWS IN BRIEF

NDT Global appoints new COOUltrasonic pipeline inspection and integrity services provider NDT Global has appointed a new Chief Operating Officer with 24 years’ experience in the in-line inspection (ILI) industry.

Andy Bain served in the British Royal Navy for 10 years before starting his 24 year career in the ILI industry with British Gas. He has worked in the ILI service industry from field operations through project management and operations management, progressing to lead new product development.

Over the last four years, Mr Bain has been an ILI consultant on behalf of oil and gas majors, delivering Inspection solutions for deep subsea systems. He has a global perspective, having had the experience of operating in six of the seven continents.

NDT Global has embarked on a steady growth path with significant investments in inspection tools, data analysis and customer service teams. Mr Bain will oversee and be responsible for the group’s global business operations.

“We are delighted that Andy Bain has joined the executive management team at NDT,” said NDT Global Chairman Mario Lemme. “He brings a long industry track record and unique insights into operator needs that will help us reach our goal of 100 per cent first run success.”

Serimax and Technip form strategic partnership for pipeline weldingWelding solutions provider and Vallourec subsidiary Serimax has signed an agreement in principle with Technip in order to achieve a strategic partnership for pipeline welding.

Technip, a long-lasting customer of Serimax, would acquire a minority stake in Serimax.

Technip and Serimax will combine their expertise and will deploy the Serimax welding technology at Technip’s spoolbases and S-lay vessels. A spoolbase is primarily used for the fabrication and spooling of rigid pipe onto vessels with reel-lay capability. Technip owns and operates four rigid pipe spoolbase facilities located close to clients’ deepwater developments.

This strategic partnership, which at the time of writing, was subject to regulatory approvals, will include exclusive arrangements in the Reel-lay welding pipeline segment as well as research and development (R&D) related programmes.

The partnership will allow both partners to invest in joint R&D programmes and innovative reel-lay welding solutions to meet the growing technical challenges of projects.

Serimax will remain an independent service and technology provider, and will continue to serve its clients in the offshore, onshore pipeline and fabrication markets.

Petronas awards US$150 million pipeline rehabilitation contractsPetronas has awarded two multi-year contracts for the production and installation of pipeline rehabilitation technology worth in excess of US$150 million. The contracts for the rehabilitation of various 6 inch, 8 inch and 10 inch subsea crude oil gathering and high-pressure gas and condensate lines, varying in lengths from 700 m to 3.5 km, were awarded to APS Malaysia (APS).

The contracts will involve the use of InField Liner®, a flexible Kevlar reinforced liner installed in existing subsea pipelines. Once installed the liner then acts as a corrosion barrier, providing protection against aggressive service conditions and extending the use of the pipeline beyond its original design life.

The liner system has been independently tested by a third party to meet oil and gas industry standards API 17J (2008), 15S 2006; DVGW G

469-2010; DIN 53536 (1992) and ASTM F1545-97, D4060, D1599-99. It can extend the lifetime of existing pipelines by up to 30 years.

InField Liner® was successfully piloted at Petronas Carigali Sdn Bhd’s (PCSB) Samarang field offshore Malaysia in September 2013 and a commercial trial deployed at West Lutong field in the Baram Delta offshore Sarawak in November 2014.

On the back of the recent successful internal application of this technology and the subsequent large contracts awarded to APS, Petronas has further granted APS a global 20-year exclusive licence to apply the technology for other oil and gas operators.

Through this exclusive licensing agreement, APS will manufacture and market worldwide the InField Liner®, Petronas’ proprietary subsea pipeline rehabilitation system with internal liners.

PIN reader surveyPipelines International recently sent out a survey to our readers to better understand how our magazine and website is used within the industry. The information and feedback we received was really interesting, and we wanted to share this with you.

67% of readers have purchased products and services after seeing their advertisement in Pipelines International

94% of readers either make or influence purchasing decisions within their company

79% of readers rely on Pipelines International magazine and website for their pipeline industry information

52% of readers come from companies that make US$5 million plus a year.

New export pipeline critical to boost East African oil production: analyst Uganda and Kenya need to develop a new export pipeline to successfully commercialise oil reserves and boost upstream development in the region, says research and consulting firm GlobalData.

Recoverable oil reserve estimates in Uganda sit at approximately 750 MMbbl of oil, while Kenya’s oil reserves are approximately 600 MMbbl.

Provided an export pipeline is developed, GlobalData says that overall oil production in Uganda could peak at about 200,000 bbl/d by 2023, while Kenya’s production could reach approximately 85,000 bbl/d by 2027.

GlobalData Upstream Oil and Gas Analyst Jonathan Markham says that, while a range of possible pipeline routes to ports in Lamu, Mombasa or Tanga have been proposed, upstream development in the region has stalled due to a lack of progress in developing an export route for these inland discoveries.

Mr Markham adds that the development of an export pipeline would also be a driver for upstream exploration in the region. Some blocks have already been licensed by governments in central and eastern Africa, but the remote locations have dampened interest from major oil companies.

New hydrostatic testing manual available for pre-order A new manual entitled Hydrostatic testing of pipelines: Zen and the art of the squeeze is available for pre-order from the Pipelines International shop.

This manual is a comprehensive reference tool in the field of hydrostatic testing of pipelines, primarily those transporting liquid and gas hydrocarbons, but also the general principles applying to water and other types of pipelines.

Author Lynndon Harnell is based in Australia, and has over 30 years of pipeline hydrostatic testing experience. He has performed numerous hydrostatic tests as a signatory for Australia’s National Association of Testing Authority (NATA) for four NATA laboratories, and is currently a member of the ME 38.5 Standards Sub-Committee for hydrostatic testing of pipelines.

For more information, visit www.pipelinesinternational.com/shop

New safety leadership course developed for pipelinersA new safety leadership programme made specifically for pipeliners has been developed, with a focus on personal accountability for safety and incident prevention. The new programme has been developed by Caterpillar, in collaboration with PipeLine Machinery International, Inc. (PLM) and a group of industry leading companies.

The five-module programme is designed to foster safe work environments by helping leaders at all levels understand and leverage the power of culture on safety performance. Emphasising engagement, effective communication and positive recognition as the building blocks of safety culture excellence, the course reveals the impact each leader has on employee attitudes, behaviours and beliefs.

The programme includes video produced on actual job sites and featuring interviews with real pipeliners, and the content is tailored to reflect the specific challenges and risks inherent in pipeline industry work. Proven methods for building a culture of safety are explained through scenarios, imagery and testimonials drawn from the environments in which participants work every day. The educational content is derived from decades of Caterpillar research and development of effective safety management strategies.

The complete program package includes a binder with facilitator and train-the-trainer instructions and a USB Flash drive with videos, presentation materials and handouts. For more information visit PLM’s website www.plmcat.com

ABOVE: Andy Bain.


The substantial fall in oil prices since July 2014 has weakened the onshore pipeline market, causing project delays

and a focus on reducing costs for pipeline owners. Despite this, the delays observed to date have a different complexion to other oilfield sectors – deepwater capital projects or drilling programmes, for example – and have been limited in large part to the North America region. In general, the onshore pipeline market itself is well-cushioned from short-term commodity-price fluctuations with projects typically responsive to long-term demand and supply trends, both within and between regions. Other geopolitical factors tend to be of greater relative importance than for other sectors, which has played its part in limiting the impact of the downturn, so far.

Douglas-Westwood expects onshore pipeline capital expenditure (CAPEX) to grow modestly, totalling US$220 billion over 2015–2019, an increase of 14 per cent compared with US$193 billion over the preceding five-year period. The major expenditure categories of construction and linepipe procurement have steady growth throughout the forecast. In contrast, CAPEX relating to stations (pumping, compressor, and pigging) is expected to plateau or decline slightly year-on-year, as gas lines gain market share over liquids, and station efficiency gains are realised internationally.

Installation activity in most regions is expected to increase, supported by continued product demand growth in both new and existing

population centres, new and increasing hydrocarbon supply, and a shift in energy demand preferences toward gas.

DEMAND SHIFTING TO NON-OECD REGIONS

Population growth and overall energy demand continue to rise in non-OECD economies, particularly in the Asia-Pacific region. This is driving additional infrastructure requirements of which transportation of fuel and products is an important element.

A continuation of robust growth in non-OECD markets saw Asia overtake North America as the largest regional market by CAPEX in 2015, although the volume of pipeline installations will remain higher in North America throughout the forecast period.

North America will suffer the greatest impact as a result of the decline in commodity prices. Regardless, pipe installation demand is set to increase steadily in this region from 2016 onward. In contrast, Western Europe CAPEX is in decline, a trend expected to continue over the next five years.

Pipeline activity in the Middle East is currently growing at a faster rate than in any other region, a trend expected to remain over the next five years. Iraq, Saudi Arabia, and the UAE in particular have followed a strategy of increasing production in recent months with a positive impact in the near-term on pipe installations. The lack of political stability and security in many

While the fall in oil prices continues to impact the pipeline industry, particularly in North America, the latest World Onshore Pipelines Market Forecast from Douglas-Westwood states that the five-year outlook for the global pipeline industry is positive, with onshore pipeline expenditure forecast to grow by 14 per cent between 2015 and 2019.

LEFT: Matt Loffman, Douglas-Westwood, Faversham, UK

By Matt Loffman, Douglas-Westwood, Faversham, UK

Stuck in the pipeline: project delays hit industry outlook

INDUSTRY NEWS

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areas is still a key threat to pipeline projects, however. As the level of uncertainty increases, there is potential for further project disruptions.

KEY TRENDS IMPACTING THE NATURE OF PIPELINE CONSTRUCTION

With an anticipated 35 per cent increase in global energy demand between 2010 and 2040, natural gas is expected to significantly increase its share of the energy mix – growing by 65 per cent over the same period. Investment in new infrastructure to support LNG and unconventional gas developments will be a major factor shaping future demand for pipelines. Outside the major oil province of the Middle East, gas pipelines accounted for 62 per cent of the total pipeline length installed over the past five years, with this figure expected to increase to 66 per cent for the 2015–2019 period. The reduction in the oil price since mid-2014 has tempered the rise of gas demand to an extent, however, reducing investment in natural gas transport technologies. Nevertheless, this constraining impact is anticipated to be short-term, with industry fundamentals suggesting an increasing proportion of gas pipeline construction in the coming years.

While gas pipelines will increase in volume, installation of liquid lines contracted by 15 per cent in 2015, primarily as a result of a reduction in US demand associated with additional unconventional liquid production.

The specifications of the pipelines themselves have trended toward large-diameter lines over the past three years and this trend is expected to continue to 2016. In 2017 and beyond, smaller-diameter pipelines are expected to gain relative market share driven in part by maturing networks within population centres of non-OECD countries and a return of US onshore production growth.

We have seen lower steel prices and greater manufacturing capacity become available. Lower levels of near-term activity among tubular-goods providers have released manufacturing capacity for linepipes.

GEOPOLITICS AND ENVIRONMENTAL CONCERNS

Geopolitics continues to challenge a wide range of projects around the world. Due to the lack of an overarching authority or jurisdiction for transnational pipelines, geopolitical complication

INDUSTRY NEWS

FIGURE 2: Global CAPEX by region 2015–2019. Source: Douglas-Westwood’s World Onshore Pipelines Market Forecast 2015–2019 report.

2010G

lob

al C

apex

($b

n)

Global Onshore Pipeline Expenditure 2010 – 2019

0

5

10

15

20

25

30

35

40

45

50

2011 2012 2013 2014 2015 2016 2017 2018 2019

Global Capex by Region 2015 – 2019

Africa

Australasia

Latin America

North America

Asia

Eastern Europe & FSU

Western Europe

Middle East

3%

8%

22%

3%16%11%

15%

22%

FIGURE 1: Global onshore pipeline expenditure 2010–2019. Source: Douglas-Westwood’s World Onshore Pipelines Market Forecast 2015–2019 report.

is arguably the most difficult challenge to overcome, threatening the execution of ambitious inter-regional projects such as the Turkmenistan – Afghanistan – Pakistan – India (TAPI) Pipeline aiming to bring Turkmenistan gas to Pakistan and India via Afghanistan, and others. As a result, commercial interest must be the overriding driver for large transnational projects to be executed successfully as opposed to softer geopolitical interests.

Environmental concerns remain a vital challenge for major pipeline projects with public opposition causing significant delays in the

approval process. This trend is most often observed in highly regulated regions such as North America with the well-publicised example of Keystone XL Pipeline in the US, which was ultimately cancelled.

RELATIVE STABILITY, DESPITE PROJECT DELAYS

While lower commodity prices threaten pipeline-construction projects, particularly in the US and Canadian markets, global expenditure will continue to climb in 2016 as sanctioned projects are delivered and international growth

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INDUSTRY NEWS

Interested in reading the full report? This fifth edition of the World Onshore Pipelines Market Forecast presents a comprehensive view of the historic market from 2010–2014 and the forecast period from 2015–2019. A detailed database of projects, combined with an involved, bottom-up modeling and forecasting process, result in a unique view of the market in terms of length and value.

For more information, and to purchase the report, visit www.douglas-westwood.com/report/energy/world-onshore-pipelines-market-forecast-2015-2019/

Established in 1990, Douglas-Westwood is a leading provider of market research and consulting services within the engineering, OEM, and field-services sectors of the energy industry. Douglas-Westwood is an independent organisation supported by proprietary data, insight, and knowledge, with one of the largest sector-focused teams located in its offices in the Americas, Europe, and Asia. To date Douglas-Westwood has completed more than 1,100 projects for clients in more than 70 countries. www.douglas-westwood.com

About the authorMatt Loffman has led a range of commercial due diligence and market intelligence studies focusing on international drilling, pipeline services, and downstream facility sectors. His previous experience includes a post as a consultant to the United Nations. In the past year, Mr Loffman has headed-up global market studies relating to in-line inspection services, cryogenic pumps, linepipe manufacturing, and heat-tracing equipment, amongst others. Mr Loffman is a graduate of the London School of Economics, a fluent Arabic speaker, and a member of the Society of Petroleum Engineers and of the Society for Underwater Technology.

outweighs the contraction in North America. Douglas-Westwood expects almost 309,000 km of linepipe to be installed between 2015 and 2019, an increase of 11 per cent compared to the previous five-year period. The consistency of annual expenditure in the global pipeline market (relative to other sectors of the upstream and midstream oil and gas industry), and high volume, will facilitate opportunities for the supply chain around the world as the infrastructure network continues to grow.

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TECHNOLOGY IN LINE


A critical element of a pipeline operation is the leak-detection system, and a great deal of focus goes into ensuring equipment and controllers are able to identify releases or determine the difference

between an actual event and a false alarm. There are actually several industry documents published by the API that provide best-practice guidance on leak-detection elements, such as alarm management and computational pipeline monitoring (CPM), but recent incidents have brought emphasis to ensuring industry is putting the appropriate resources to mitigating leaks. In fact, the US Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (DOT PHMSA) asked API to provide guidance to the industry on leak-detection-programme management.

API willingly engaged its members who operate pipelines to draft API Recommended Practice (RP) 1175, Leak detection program management, with the goal of establishing a structure for leak-detection-programme management for hazardous-liquid pipelines. While there is industry guidance and learnings on particular leak-detection systems, this RP provides a holistic framework that encompasses these best practices and provides operators with details to develop, implement, and manage a sustainable and risk-based leak-detection programme to minimise the size and consequences of leak events. Also, since API developed the document, it was subjected to API’s ANSI-accredited process, meaning several stakeholders from operating companies, the government, and the public, had to approve, which confirmed that a beneficial RP was published.

One valuable aspect of API RP 1175 is that it not only challenges operators to evaluate their programme, but also to ensure an appropriate leak-detection culture is established. This culture should be defined and enhanced by ongoing management direction and support, and it needs to urge employees to go from “thinking to knowing”, meaning take necessary steps to realise if a leak event is occurring versus just assuming. By instilling an effective leak-detection culture within a company, the cultural discipline of “doing every task, the right way, every time,” is institutionalised.

The American Petroleum Institute (API) has produced new guidelines for leak detection that provide operators with the details to develop, implement, and manage a sustainable and risk-based pipeline leak-detection programme to minimise the size and consequences of a leak event.

By Stuart Saulters, American Petroleum Institute (API), Washington, DC, USA

Instilling a leak-detection culture: API releases RP 1175

INDUSTRY NEWS

This RP provides a holistic framework that encompasses these best practices and provides operators with details to develop, implement, and manage a sustainable and risk-based leak-detection programme to minimise the size and consequences of leak events.

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ARIN-007 - LNG18 Full Page 01_v26_215.9x276.23.indd 1 9/02/2016 4:47 PM


Another constructive element provided in the new document is detail on selecting and establishing performance measures. Four leak-detection metrics are suggested:

1. Reliability – can you depend on the alarms?2. Sensitivity – how small a leak can you detect?3. Accuracy – how good are the size/location estimates?4. Robustness – will it work in a less than perfect environment?Operators must set targets to achieve the desired level of these. If the

targets are not accomplished and gaps are identified, then changes must be made to address them.

The goal of establishing metrics and ensuring goals are obtained is to guarantee continual improvement, which will help the industry achieve appropriate leak-detection performance.

The discussion on selecting the necessary leak-detection systems to obtain an effective leak-detection programme is another positive aspect of API RP 1175. There is great detail included, intended to help operators evaluate and select various leak-detection principles, methods, and techniques to include in their leak-detection programme. Also, instruction is provided on how to select new applications and add them, or re-examine existing systems.

This whole process in selecting leak-detection systems to achieve a substantive programme should be a multi-step, multi-faceted, and iterative process requiring adequate documentation of each facet or step, and API RP 1175 provides great detail for this. There is a great amount of information on leak detection currently available, and the guidance provided in the new RP will help any operator, large or small, filter through it to achieve a successful leak-detection programme.

The overall goal of any leak-detection programme should be to detect leaks quickly and with certainty, thus facilitating quicker shutdown, and therefore minimising negative consequences. Operators must understand vulnerabilities and risks when developing a programme, and the new RP 1175 provides guidance on how to use a risk-based approach to establish an adequate leak-detection programme.

INDUSTRY NEWS

More information about the document and how to obtain a copy can be found at www.api.org/pubs

For further details on pipelines, visit www.nergyinfrastructure.org and www.pipeline101.com

API is the only national trade association representing all facets of the oil and natural gas industry, which supports 9.8 million USA jobs and 8 per cent of the US economy. API’s over 625 members include large integrated companies, as well as exploration and production, refining, marketing, pipeline, and marine businesses, and service and supply firms. They provide most of the US’ energy, and are backed by a growing grassroots movement of more than 25 million Americans.

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“There’s a lot of confidence in the industry again,” says Jon Heinen, Senior Pipeline Manager at

Vermeer. “A lot of contracts have been awarded already for upcoming work, and permits are pending. Contractors are gearing up. The vibe is positive.”

In recent years, the midstream business drove the pipeline construction market. But it’s slowing down. Now, the focus is on installing transmission pipelines, and that’s where much of the activity will be in 2016 and 2017.

These new transmission pipelines are larger in diameter at 36, 42 and 48 inches compared with the 20 and 24 inch pipelines of the past. This upsizes the equipment needed for pipeline jobs including horizontal directional drilling (HDD) rigs with pullback forces of 2,224.1 kN (500,000 lb) and greater.

This is only one of the trends Vermeer sees as it meets with executives of energy and pipeline construction companies. Vermeer – a leading manufacturer of HDD drills for the pipeline installation market – has the opportunity to meet

with pipeline contractors all over the world and understand industry needs from a big-picture perspective.

Vermeer pipeline experts are in constant communication with industry colleagues around the globe regarding pipeline trends, new applications and installation methods, and the general state of the industry. Having global offices on four continents allows Vermeer to stay connected.

What other trends does Vermeer see impacting the pipeline installation industry? The pace of business, the use of technology, and the importance of safety and regulations.

The pipeline industry is no longer a seasonal business where a contractor works for only six months a year. Today the industry moves at a much faster pace all year round. Pipeline project owners are also expecting more from contractors – and in turn contractors are expecting more from their suppliers. Contractors need answers or solutions now, not in 24 hours. Vermeer addresses those needs by having hundreds of touchpoints, from the factory and the dealer to the jobsite.

Global pipeline construction in the oil and gas industry is going strong. The reason is that when times are tough, companies try to be more efficient. And pipelines help energy companies meet that goal.

The changing pipeline industryBy Greg Ehm, Public Relations Director, Two Rivers Marketing, Des Moines, IA, USA

INDUSTRY NEWS

ABOVE: Contractors need personalised support from OEMs. Vermeer is heavily invested in the pipeline industry to help contractors by successful.

FP Ad 7Vermeer

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AS SENIOR PIPELINE MANAGER AT VERMEER, JON HEINEN’S DAY IS MORE THAN SELLING EQUIPMENT.He’s busy looking for global pipeline industry trends, new techniques and solutions to existing challenges. Then he shares his insight, including new ideas that contractors like you can use to help make a real impact on your productivity and profi tability. As a former owner and operator, Jon understands contractors’ day-to-day issues and can help you face your most complex challenges. Learn more about Jon at bit.ly/JustAskJon.

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“At Vermeer, we feel we need to be close to our customers to provide assistance, and our global dealer network can help set us apart from other suppliers in this respect,” says Mr Heinen.

Pipeline contractors are looking at technology to help manage the maintenance needs of their equipment fleet, and new tools to enhance the operator experience and help make them more productive. Contractors are also looking for ways to provide confirmation of performance on the

jobsite that can be easily shared with a project owner. Telematics, project planning, jobsite tools and digital reporting are examples of the types of technology that are already used and will become more common in the coming years.

“There is going to be a huge demand for data,” Mr Heinen says. “For job performance data, for operator-specific data, for ground conditions data, for tooling data, for the mud pump, everything you can imagine. With the

introduction of Vermeer Productivity Tools, Vermeer is leading the way in bringing this technology to the pipeline industry.”

Safety is a top concern among pipeline contractors around the globe. If a contracting company does not have a clean jobsite safety record, it may not get awarded the next project. This ties to safe working practices, but also to the design of the equipment it is using. Vermeer follows a design philosophy based on national and international safety standards – safety is definitely a priority for Vermeer.

In addition, government regulation can be a significant challenge to the pipeline industry, especially in the North American market. Regulations can seem like such a moving target that it’s hard to plan a business project around them.

Falling under the regulations umbrella is drilling fluid. Although drilling fluid is basically just water and a special clay, it may be treated in some jurisdictions as a hazardous material. This can hit contractors hard when it comes to management and disposal, as drilling fluid management, in such cases, could amount to up to half a contractor’s total expenses for a project.

Pipeline contractors are turning to reclaimers and large vacuum excavators to help meet their fluid management needs. In addition, industry associations, equipment manufacturers and institutions are studying the issue to bring more science and data to regulation that can sometimes seem more like a matter of public relations and conjecture. Other alternatives may include exploring alternative uses for drilling fluid.

As complex as the pipeline business is, it is pretty simple. Contractors want to be productive and they want to be successful. Vermeer is heavily invested in the pipeline industry to help contractors be successful. Contractors need personalised support from OEMs, and that is what Vermeer provides.

“If we as an industry and company can provide contractors the insights, information and the tools to be productive, which their customers are demanding, then in turn, we aid them to be able to be successful and to reinvest in their business,” says Mr Heinen. “We are business partners to our customers; we are not just an equipment supplier. If they are successful, then we can be successful.”

INDUSTRY NEWS

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INDUSTRY NEWS

The availability to study the compression system and the optimum capacity ramp-up of a transmission system are the new

functionalities of the application, and are of key importance in the process of designing a feasible gas pipeline project.

INNOVATIVE TECHNOLOGYFollowing the approach presented in the

previous article, At Work Rio has implemented new features in the GasPipelineExpansion application, which are described here through a case study that highlights the application’s capabilities.

The application has been designed to: » Perform cost estimates for new gas

pipeline projects or capacity expansions of existing projects;

» Allows the addition of compressor stations to an existing project, undertake capacity ramp-up and availability studies; and,

» Work with GIS information (latitude, longitude, and elevation profile) for the pipeline route.

NEW PROJECT OR CAPACITY EXPANSION

Where transmission or distribution companies see an opportunity to increase the system’s

capacity, GasPipelineDesign and GasPipelineExpansion can be used together to provide the best feasible solution for the expansion project, be it construction of a loop pipeline, compressor station(s), or a pipeline interconnection.

CAPACITY RAMP-UP New gas pipeline projects generally do not start

operation with full capacity and it is necessary to determine the best configuration for compressor stations and compressor units to cope with the capacity ramp-up through the first years of operation, along with the schedule for installation of compressor stations and compressor units. The GasPipelineExpansion approach optimises CAPEX cash flow and makes the project more competitive.

AVAILABILITY STUDY GasPipelineExpansion incorporates a powerful

and flexible module for an availability study that performs Monte Carlo simulations. Compressor unit failures, their frequency and scenarios, are identified and each scenario is thermos-hydraulically simulated and its capacity under failure is quantified. The frequency of failures versus capacity under failure will allow the evaluation of the compressor-system availability, and also support decisions on the provision of an

Following-on the previous article on this subject published in the December 2015 issue of Pipelines International, this article presents new functionalities of the GasPipelineDesign and GasPipelineExpansion mobile applications as part of the innovative mobile technology that has been developed to support gas pipeline design through the web.

By Sidney Santos, At Work Rio Solutions Ltda, Rio de Janeiro, Brazil

Real-time demand for a gas pipeline design: dealing with modern challenges – Part 2

INDUSTRY NEWS

Reliability (%) Availability (%)

Electric motor + centrifugal 99.4 98.9

Gas turbine + centrifugal 98.2 97.1

Gas motor + reciprocating 97.1 94.3

TABLE 1: The reliability and availability values of different compressor station arrangements as surveyed by the Electric Power Research Institute.

adequate level of redundancy (stand-by units) for gas pipelines. The simulation process can be as follows:

1. Simulate the compression system without any stand-by units and obtain the availability.

2. Select target compressor stations to have stand-by units, and re-run the simulation to obtain an improved availability for the system.

3. Continue testing other arrangements of stand-by units until the availability satisfies the project’s needs.

4. Alternatively, simulate using a stand-by unit for all the compressor stations and compare the outcomes.

Electric Power Research Institute (EPRI) [1] has surveyed many compressor stations with different arrangements of compressor (centrifugal or reciprocating) and driver (electric motor, gas turbine, or gas motor) and identified reliability and availability values in Table 1.

The simulation runs 100,000 iterations and compiles groups of failure results with their respective gas-transmission capacity and frequency. The application can handle different sizes and types of compressor units at any compressor station, with each unit having its own availability figures. An availability study using a Monte Carlo simulation is of key importance for a feasible gas pipeline project. Transmission

companies must mitigate their operational risk to comply with their transportation agreements with local distribution companies or end users with regard to firm-capacity clauses and related penalties for non-compliance. In the event of a compressor unit’s failure impacting the pipeline capacity, the transmission company would face penalties and loss of revenue, dramatically impacting its economic result [2-5].

ABOVE: The graphical result of a GasPipelineExpansion thermohydraulic simulation (left) showing a availability analysis without a stand-by compressor units, and the results of a capacity ramp-up study (right) with one compressor station (year 1), three compressor stations (year 2), and seven compressor stations (years 3 to 30).

Compressor unit failures, their frequency and scenarios, are identified and each scenario is thermos-hydraulically simulated and its capacity under failure is quantified.


INDUSTRY NEWS

CASE STUDY: GASBOL PIPELINEThe case study used to illustrate this article is

based on the GASBOL pipeline project if it was being designed now. Based on the prevailing market condition and technical and economic assumptions at the time it was designed – around 1995 – the main section of the project has a nominal diameter of 32 inches and 14 compressor stations. The transmission capacity is 1,059 MMcf/d.

With the same technical requirements and today’s economic assumptions, and by using At Work Rio’s innovative technology, the best alternative for the project is as follows:

(a) Technical assumptions:Capacity: 1,059 MMcf/d Length: 1,068 miles (straight route) Length: 1,118 miles (geographic route)MAOP: 1,420 psi Pipe material: API 5L X-80Gas specific gravity: 0.6000 Inlet pressure: 1,410 psig Delivery pressure: 1,000 psig Compression ratio: 1.4000 Gas deliveries, MMcf/d:

D1, at milepost 363.4 miles: 1.7657 D2, at milepost 589.3 miles: 47.6748 D3, at milepost 781.6 miles: 68.8636 D4, at milepost 877.1 miles: 2.8252 D5, at milepost 1025.1 miles: 14.1259 D6, at milepost 1092.5 miles: 40.2587 D7, at milepost 1104.3 miles: 5.6503

(b) Economic assumptions:Pipe material cost: US$2,500/ton Fuel gas cost: US$5/MMBTU Pipeline operation and maintenance cost: 1.5 per cent of pipeline CAPEX per year Compressor station operation and maintenance cost: 5 per cent of compressor station CAPEX per year Project economic life: 30 years Discount rate: 12% per year Construction time: 4 years Pipeline CAPEX schedule: 15% year 1, 30% year 2, 30% year 3, 25% year 4 Compressor station CAPEX schedule: 0 % year 1, 10% year 2, 40% year 3, 50% year 4

Results for the selected gas pipeline configuration:(a) Technical:

Nominal diameter: 36 inchesTotal length: 1,118 milesTransmission capacity: 1,100.76 MMcf/dNumber of compressor stations: 7Number of operating units per compressor station: 2Number of stand-by units per compressor station: 1Total required power: 125,144 hpTotal installed power: 298,812 hpTotal required fuel gas per year: 9,517.08 MMcfCompressor system availability: without stand-by units: 0.9811with one stand-by unit at CS# 4: 0.9836with stand-by units at CS# 2, 4, and 6: 0.9925with stand-by units at all CS: 0.9997

Capacity ramp-up: with one compressor station (CS# 4): 565.21 MMcf/dwith three compressor stations (CS# 2,4,6): 775.83 MMcf/dwith seven compressor stations (CS# 1,2,3,4,5,6,7): 1,100.76 MMcf/d

(b) Economic (in MM US$):Pipeline total cost: 3,528.48Pipeline total cost present value: 2,630.48Compressor station total cost: 800.55Compressor station total cost present value: 546.13Pipeline operation and maintenance present value: 270.95Compressor station operation and maintenance present value: 204.91

Total fuel gas present value: 237.26Inventory (line pack) gas present value: 11.01Total CAPEX: 3,176.61Total OPEX: 724.13Total Project PV: 3,900.73

CONCLUSIONAt Work Rio’s innovative technology covers all

the important aspects related to the design process for a gas pipeline, including thermos-hydraulics, failure analysis with Monte Carlo simulation, capacity ramp-up, cost assessment, and economics. This state-of-the-art, innovative mobile technology improves productivity for gas pipeline conceptual design with simple, practical, accurate, reliable, and speedy solutions.

REFERENCES1. Electric Power Research Institute, 1999.

Report No. RP 4CH2983.2. S.P.Santos, 2009. Monte Carlo simulation

– a key for a feasible gas pipeline design. Pipeline Simulation Interest Group, Galveston, TX, USA.

3. S.P.Santos, 2008. Availability and risk analysis effects on gas pipeline tariff making. International Pipeline Conference, 2008, Calgary, Canada.

4. S.P.Santos, M.A.S.Bittencourt, and L.D.Vasconcellos, 2006. Compressor station availability – managing its effects on gas pipeline operation. International Pipeline Conference, Calgary, Canada.

5. S.P.Santos and E.Saliby, 2003. Compression service contracts – when is it worth it? Pipeline Simulation Interest Group, Bern, Switzerland.

About the developerThese mobile technology applications have been developed by the author Sidney Santos, who retired from Petrobras in 2012 after working for more than 25 years as a Senior Consultant and a gas-pipeline design engineer. Using his knowledge of pipeline design technology, as well as programming using spreadsheets Visual Basic and C#, Mr Santos has recently worked with qualified software developers to perfect his applications. His most recent projects at Petrobras, prior to retiring, were the design of the Bolivia – Brazil Gas Pipeline (GASBOL), and the expansion project for the gas pipeline network in Brazil. He had a role in many prospective projects such as the Venezuela – Brazil Gas Pipeline (GASVEN) and the Integration Gas Pipeline (GASIN); he also provided consulting assistance to KazTransGas and Intergas Central Asia for the Kazakhstan section of the Trans Asia Gas Pipeline.

Contra 4PTC

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Europe‘s biggest onshore & offshore pipeline conference & exhibition:www.pipeline-conference.com

in parallel to “PIPE AND SEWER CONFERENCE” and exhibition


Over time, trenching machines have evolved due to the requirements of the industry. Equipment manufacturer

Tesmec states that, by using a trencher on pipeline construction sites, it is possible to achieve higher digging speeds than when using other pipeline installation methods.

A Tesmec spokesperson says “The trencher is a mature machine. We can say that the machines have reached very high levels of reliability. But projects and construction teams are now asking for the machines to do even more. Construction teams are now requesting machines to dig in very hard conditions, including through rock, and abrasive conditions. And, because market competition is increasing, construction companies are requesting high-performances and low-cost solutions.

“Low cost means ‘no stop’.“Because of this, when considering how a

trencher might perform on a pipeline project, construction companies need to look not only at the machine, but also at the manufacturer’s services that are provided to guarantee the machine’s performance until the end of the project.”

Tesmec provides the following services when its trenchers are used:

» Training for operators and mechanics; » Presence on the jobsite of any special

tools required for the machine; » Use of advanced systems for digging

control and machine diagnostics; and, » The supply of strategic parts or materials

to ensure no downtime on site.

THE STRATEGIC SUPPLY OF PARTS Tesmec provides ‘corrective supply’ and

‘preventive supply’ services for its machines. The corrective supply service is provided when

a machine needs parts that are not available on site. Tesmec explains, “Generally in this case the machine is forced to stay idle for several days, and a lot of stress is generated by those on site.”

The preventive supply service is activated before there is a need for any extra parts, reducing any downtime for the machine or workforce.

“The idea of corrective and preventive supply doesn’t mean that we recommend starting a project with a stock of extra parts. Instead, we are encouraging our clients to plan their supplies, and regularly monitor their use, and make requests for further parts in advance. A good project manager can put a value of 0 as a KPI for corrective supply,” Tesmec continues.

HOW TO MANAGE A WELL-ORGANISED SPARE PARTS’ INVENTORY

Tesmec recommends that job-site warehouses are well organised with anti-rollover shelves and dividers for different supplies that can be easily and safely moved.

Tesmec uses an interactive spare parts system called Inter-Parts as its official channel for fulfilling spare parts’ orders for its clients. Inter-Parts is an online system, also available in a downloadable offline version, which allows clients easily to identify the spare parts that are needed, and to send supply requests directly from the

Trenching machines are now considered as standard equipment for pipeline construction sites, capable of digging trenches in almost all operative conditions. Manufacturer Tesmec outlines how construction companies can make the most of its equipment, and ensure no downtime while on site.

INDUSTRY NEWS

Prepare your inventory: how to limit downtime on your construction site

INDUSTRY NEWS

jobsite. It is a user-friendly tool that simplifies jobsite management, helps to avoid mistakes, and provides useful inventory information for the construction team and the equipment provider.

PREVENTIVE SUPPLY USED IN THE ATACAMA DESERT

A consortium between Bechtel and Techint used Techint’s preventive supply system while constructing the Escondida Water Supply (EWS) project in Chile.

The consortium used four TRS1675 machines to construct two parallel 183 km pipelines in the Atacama Desert.

The logistic department installed at the construction camp in Antofagasta was designed for the needs of the machines, and a good maintenance service provided the correct information for the supply of new parts in an appropriate time frame for the project requirements.

“The implementation of the preventive supply system enabled the consortium to complete construction of the pipelines within schedule,” says Tesmec.

ALL MACHINES HAVE NEEDS Tesmec explains “Our machinery is very

reliable, but all machines have needs, and not preparing appropriate supplies of key parts can compromise the outcome of a project.

“It is very important that construction companies consider what spare parts may be needed before starting a project. We deal with forwarders and local customs daily, and we understand the difficulties that projects can face around timing. Like Mum continuously repeating “Don’t walk where I’ve just cleaned”, we repeat “Don’t forget the additional parts: they will take time to arrive!”.

A

B

C

A: Tesmec service providers will come to site for any special tools required for the machines.

B: Tesmec provides training for machine operators and mechanics.

C: A Tesmec trencher being delivered to site.

www.pipelinesinternational.com March 2016 | Pipelines International | 31

REGION REVIEW: MIDDLE EASTREGION REVIEW: MIDDLE EAST

How long have you been working in the pipeline industry, and what did you do prior to joining the pipeline industry in Saudi Aramco?

I started my career with Saudi Aramco 30 years ago. I started as an operator in the field. That exposure provided me invaluable insight into the practicality of operating our pipelines and site realities within a vast country like Saudi Arabia. Upon completion of a mechanical engineering degree in the US, I gained hands-on work experience as an engineer, further enhancing my understanding about pipeline design; replacement; maintenance and inspection; robustness; reliability, etc. This multidisciplinary approach further developed my abilities to work across the organisation, and built my interpersonal and management skills. As a leader,

I soon realised that our main asset is our people. To lead, you have to inspire people through fairness, and provide training and development. To maintain morale, I insist that the key enabling values – progress and recognition – are recognised at every opportunity, to make a positive difference within our organisation.

What has been the best – or most challenging/rewarding – pipeline project that you have been involved with?

Although I have been involved in several capital projects during my career with Saudi Aramco, I consider the Hawiyah Gas Plant downstream pipelines project as the most challenging. It definitely broadened my knowledge of business case development.

Saudi Aramco Pipelines Department General Manager Mohammed Sultan Al-Qahtani spoke with Pipelines International Editor-in-Chief John Tiratsoo about future projects and pipeline management plans, and how he came to lead the Saudi Aramco Pipelines Department.

Interview with Saudi Aramco’s Mohammed Sultan Al-Qahtani

“As a leader, I soon realised that our main asset is our people. To lead, you have to inspire people through fairness, and provide training and development.”

RIGHT: Saudi Aramco Pipelines Department General Manager Mohammed Sultan Al-Qahtani.

OPPOSITE: Construction of Saudi Aramco’s 217 km Shaybah – Abqaiq Oil Pipeline, which was completed in 2010, and is an integral piece of infrastructure in Saudi Arabia.

What is your favourite aspect of working in the pipeline industry?

The extent of the varied engineering and operational challenges that are offered on a day-to-day basis, when combined with the need to be strategic in vision, while following best practices in everything that we do. We are transitioning from a time-based approach of pipeline operations management, toward a risk-based approached, following our Enterprise Risk Management policy. These fundamental changes require a change in mindset to achieve a successful outcome without undermining existing practices. The ability, to lead and inspire positive changes, to provide value in everything that we do – individually and collectively – motivates me as a leader.

How have Saudi Aramco’s pipeline operations changed over the last 10 years?

Our pipeline network has expanded, and the only sustainable way to manage pipeline technical integrity – for a network of this size – is to follow

scientific methods, and implement the latest technology, deployed and operated by highly trained engineers.

What is the next area of growth for Saudi Aramco’s Pipelines Department?

The next area of growth is maintaining the integrity of our entire pipeline systems by using a risk-based approach and deploying the latest technologies, once they are proven, to support the requirements.

What innovations have the Pipelines Department made, to aid pipeline operations and integrity management?

To date, the Pipelines Department has been successful in obtaining five granted patents by the US Patent and Trademark Office (USPTO) for pipeline-related innovative solutions. We are also working with industry experts on several innovations – one example is a joint development with a valve maker for a new large-capacity control valve, intended for erosive service applications.

Where does Saudi Aramco see major gains in safety can be made, in terms of pipeline operation?

Our pipeline operation and expansion work is underpinned by our corporate culture, which stipulates that safety always comes first. We perceive safety as a reliability and efficiency enabler, and we never consider it as a barrier to success. In my opinion, fostering a corporate culture and positive employee behaviour toward safety is the most influential gain for any responsible pipeline operator.

What techniques does Saudi Aramco use to maintain its pipeline system, and why is it important to complete such maintenance?

To maintain our pipelines’ integrity, we have been transitioning from a reactive case-by-case approach to a more holistic, proactive, and knowledge-based approach. Our maintenance and integrity management practices are centred on the concept of Total Quality Management (TQM).



We have developed an integrity planning process – for our existing pipelines – that is comprehensive and risk based. It goes beyond simply responding to in-line inspection reported defects, to aligning our data collection and processing, to better understand the predominant threats identified for our pipelines, and how we can mitigate these threats through root-cause analysis.

As an organisation, we steer our efforts toward continuous improvement. We monitor developments in many knowledge areas in the industry, and conduct benchmarking studies and engage in collaboration with international pipeline operators. We embrace the responsibilities and trust placed in us by the company.

A new 115 km oil pipeline is set to be constructed from Saudi Aramco’s Abqaiq plant to Bahrain. What are the benefits of this project to the region? This project speaks for the strategic partnership that ties the Kingdom of Saudi Aramco and the Kingdom of Bahrain as Gulf Co-operation Council (GCC) members and close neighbours. The new pipeline will enhance the overall crude supply reliability from Abqaiq to Bahrain for many years to come, and satisfy the new refinery upgrade requirements for the Kingdom of Bahrain. This will contribute to the prosperity and wellbeing of our region as a whole.

What other transmission pipeline projects does Saudi Aramco have planned over the next 24 months?

Saudi Aramco continues to expand the transmission pipelines network to satisfy the demand for hydrocarbons across the Kingdom, and there are two grassroots projects that will expand the sales-gas pipeline network. The utilisation of our enormous gas reserves provides a strategic foundation for further economic growth and diversification within the Kingdom.

What advice could you give to contractors who would like to secure work in the Gulf region?

Safety and project execution efficiency are the two key attributes that contribute to our business-performance strategy. I would advise contractors to staff projects with a competent workforce to ensure compliance with the safety regulations and guidelines set by Saudi Aramco and the local authorities.

Can you outline Saudi Aramco’s continuing and future plans for research into the transmission pipeline industry?

As part of its Accelerated Transformation Program, Saudi Aramco has rolled out a plan to increase research activities. In addition to our in-house network, we have a wide range of collaborative relationships with leading Saudi and international research universities and institutions,

to support our strategic technology objectives. The Pipelines Department, just like other Saudi Aramco organisations, strives to engage more in research activities and exploit all available resources, to excel in this side of the business.

Do you have any advice for those just beginning their careers in the pipeline industry?

The pipeline industry is a professionally exciting and rewarding industry. Pipelines encompass a variety of multidisciplinary roles and can provide a sustainable career. For young engineers who would like to pursue careers in the pipeline industry, I would strongly encourage them to get exposure in the field, in the areas of operations and maintenance, to broaden their basic understanding of system and core functions. This knowledge transfer is very effective when young engineers work with operators and maintenance foremen. Subsequently, young engineers need to have their mentors create developmental plans in the areas of simulation, corrosion, valves, reliability, and, more importantly, integrity management, with a risk-based approach. Finally, I would like say that hard and focused work during the first five years is critical for young engineers to become specialists and subject-matter experts.


ABOVE: Construction of Saudi Aramco’s 217 km Shaybah – Abqaiq Oil Pipeline.

GSP FP 1

11-14 APRIL 2016 GULF CONVENTION CENTRE MANAMA, BAHRAIN

PLATINUM ELITE SPONSOR SILVER SPONSORS

Held under the Patronage of His Excellency Dr. Abdul Hussain bin Ali Mirza, Minister of Energy, Kingdom of Bahrain

CONFERENCETechnical streams presented by industry leaders covering a wide range of subjects will run over the two and a half day event.

Some of the subjects to be discussed;

EXHIBITIONA comprehensive exhibition will be part of the event, allowing companies from around the world to showcase their products and services. Visit our website to book your space.

NETWORKINGThroughout the event there will be ample opportunities to network with participants to further your business relationships. Meet with industry leaders from around the world.

Register now at: www.pipelineconf.com

Track A - CorrosionTrack C – DesignTrack D – ILITrack E – Operations’Track F – ManagementTrack G – Cracks and SCC

Track H – IntegrityTrack I – OffshoreTrack J – MaterialsTrack K – CoatingsTrack L – Leak DetectionTrack M – Maintenance

www.pipelinesinternational.com March 2016 | Pipelines International | 35 34 | Pipelines International | March 2016 www.pipelinesinternational.com

An effective way for companies to quickly learn about and network with key contacts in the Middle East is to attend

regional industry events. Pipelines International looks at three key ways in which industry events can help you to establish your presence and relationships in the region.

1. ATTEND TARGETED, ESTABLISHED AND REPUTABLE INDUSTRY EVENTS

There are a number of oil and gas events held in the region, but few focus solely on pipelines. The Pipeline Operations and Management Middle East Conference and Exhibition (POMME) is being held in Bahrain from 11 – 14 April 2016, and is structured in such a way to provide attendees with the most relevant regional pipeline industry knowledge necessary to do business in the Middle East.

The third in a series of international technical events for the pipeline industry, the three-and-a-half day POMME Conference and Exhibition is the Gulf region’s definitive essential congress on pipeline technology and management. The event has drawn more than 1,100 industry professionals from 33 countries.

The event is organised by Tiratsoo Technical (a division of Great Southern Press) and Clarion Technical Conferences, in association with Global Webb Energy Consultants. Between them the event organisers have over 35 years’ experience organising international, include 20 years of organising events in the Gulf region.

The POMME event is supported by Platinum Elite sponsor Saudi Aramco, and held under the patronage of His Excellency Dr Abdul Hussain bin Ali Mirza, Bahrain’s Minister of Energy.

2. BRUSH UP ON YOUR KNOWLEDGE OF REGIONAL ISSUES, PROJECTS AND LATEST DEVELOPMENTS

In business, knowledge is power, and one of the most efficient ways to get up-to-date with the latest industry issues, projects and developments is to attend a carefully structured conference programme.

The multi-track POMME conference programme features 75 papers from 17 countries, bringing together experts from within and outside the region to discuss the latest technologies and concepts for maintaining and operating oil and gas pipelines in the most efficient, cost-effective, and professional manner, while taking account of environmental and other concerns of the communities through which they pass. Turn to page 36 for more information.

The programme has been collated and peer reviewed by a Technical Committee of 30 industry experts from leading pipeline companies such as Saudi Aramco, Bapco, Petroleum Development Oman, and Petronas, and organisations including King Fahd, University of Petroleum and Minerals Saudi Arabia, Penspen, EPRG, PRCI, and DNV.

Saudi Aramco Pipelines Department’s General Manager Mohammad Sultan Al-Qahtani says the event provides “a great opportunity for pipeliners to gather and share knowledge. There are many challenges we ought to overcome and it will help a great deal if we can solve them collaboratively.”

Six topical workshops will be held on 11 April 2016, for those that are interested in more detailed information than available on the conference programme. Workshops are being held on black powder, microbiological corrosion,

offshore pipelines, in-line inspection, direct assessment, and pipeline integrity management plans.

3. MAKE USE OF ANY OPPORTUNITY TO NETWORK AND FORM BUSINESS RELATIONSHIPS

Exhibitions are a quick and easy way to learn about the latest industry technology and developments, and meet key contacts that can provide the products and services necessary for you to fulfil your business orders.

At POMME, an associated technical exhibition will be conveniently situated close to where the technical papers are presented. The exhibition will feature the leading providers of solutions for best practices in pipeline operations and management, including companies such as Silver Sponsors ROSEN Group, Clock Spring, Bapco, and Al-Qaryan Group.

All exhibitors will showcase the latest in pipeline technology, equipment and services, and the event schedule allows delegates appropriate time to network with some of the industry’s most recognisable brands.

Industry analysts have predicted that the fastest growth for the onshore pipeline industry between 2015 and 2019 is expected to occur in the Middle East. So it is important that companies active in the industry consider how to make the most of the opportunities in the region.


How to enhance your company’s presence

in the Middle East

To view the full conference programme and abstracts, the topical workshops, or the Technical Committee, visit www.pipelineconf.com

For a full list of exhibitors, visit www.pipelineconf.com



Tuesday 12 April Tuesday 12 April

8:45 VIPs arrive

9:00 Opening plenary session

10:00 Exhibition opening ceremony

10:30 Coffee

Track A: Corrosion topics Track C: Design topics Track D: ILI topics Track E: Operations’ topics

11:00 [A01] Defect matching of successive IP runs in corroding steel pipelines, by Paul Herwig, r+k Consulting Engineers, Netherlands

[C01] Best practice of piping daylighting flyover design, by Mosaed Al-Ghamdi, Terminal Operations Dept, Saudi Aramco, Dhahran, Saudi Arabia

[D01] ILI for pipeline integrity: case histories, by Dr Abdelmounam Sherik (1), Thibault Villette (1), MohsenAl-Nasser (2), and Joe Short (3) 1 Saudi Aramco, Saudi Arabia; 2 Rosen Group, Saudi Arabia; 3 MACAW Engineering, UK

[E01] Hydrotesting and ILI: now and the future, by Jerry Rau, RCP Inc., USA and Dr Mike Kirkwood, T.D. Williamson Inc., Abu Dhabi, UAE

11:30 [A02] Internal-corrosion monitoring program, by Rami M Moaikel, Alaa Khairy, and Abdulrahman S Qahtani, Saudi Aramco, Saudi Arabia

[C02] Joint trench for pipelines and fibre-optic cables design optimisation, by Abdullah Al-Nufaii, Khalid Al-Usail, and Dr Husain Al-Muslim, Saudi Aramco, Saudi Arabia

[D02) EVO Series 1.0: the latest generation of UT crack and corrosion tools for high-speed pipeline inspection, by Dr Thomas Hennig, NDT Global GmbH & Co, Ireland, and Girish Lokwani, NDT Global FZE, UAE

[E02] A smart approach for operational pigging, by Steve Mayo, Pipelines 2 Data, UK

12:00 [A03] Power water injection pipelines assessment and corrosion control, by Bander Abdulaziz Otaibi, Saudi Aramco, Saudi Arabia

[C03] Calculation of tsunami force acting on surface gas pipeline facilities and countermeasures, by Toshiya Tanaka, Toshiro Mayumi, and Yoshimi Ono, JFE Engineering, Japan

[D03] Verification of ILI inspection results with the use of auto-UT data, by Nishant Sasi Philip, Derek Balmer, Steven Farnie, Ian Murray, and Holly Plummer, PII Pipeline Solutions, UK and Qatar

[E03] Cybersecurity framework for industrial control systems: plan, implement, and respond, by Khalid Al-Ghamdi, Saudi Aramco, Saudi Arabia

12:30 Lunch

13:30 [C04] Standards for pipeline pigs, urethane, and cleaning, by Doug Batzel, Batzel Consulting Inc, USA, and Beate Altmann, Consultant, Norway

[D04] Guided wave examination of pipelines, by Raymond Carswell, Saudi Aramco, Saudi Arabia

[E04] Analysis of failure of pull-back operation of a 28 inch OD, 538 m, pipe string from a 42 inch tunnel made by HDD technology, by Nitu Maurya, IOCL, India

14:00 [A05] Caustic corrosion cracking of MP hot water system challenges at Hawiyah NGL plant, by Mohammed Al-Hashem, Saudi Aramco, Saudi Arabia

[C05] Pipeline trenchless laying technologies: Saudi Aramco case study, by Abdulaziz A. Ajaji and Abdulaziz N. Ababtain, Saudi Aramco, Saudi Arabia

[D05] Achieving critical assessments of pipelines through accurate and reliable inspection information, by Tony Andraos, Andrew Caley, Martin Bluck, Jane Dawson, and Jeff Sutherland, PII Pipeline Solutions, Qatar

[E05] Pipeline operations: innovative approaches to preserve pipelines during low demand, by Ali S Ibrahim, Saudi Aramco, Saudi Arabia

14:30 [A06] Challenges in installation of cathodic protection systems for existing above ground crude oil storage tanks - experience sharing of Indian Oil pipelines, by Jitendra Sinha and Anand Terawi, Indian Oil Corporation Ltd Pipelines Division, India

[C06] Pipeline risk assessment methodology and practice for upstream pipelines, by Mohammed Al- Hamaqi, Saudi Aramco, Saudi Arabia

[D06] Inspection of loading lines and flow lines equipped with three-way valves, by Frank J Mueller and Mohammed Jaarah, Rosen Group, UAE

[E06] Communicating precise locations is key for the efficient management of pipelines operations, by Chris Sheldrick, What3Words, UK

15:00 Coffee

15:45 [C07] Existing buried pipeline crossings using geogrids, by Diego D’Alberto, Agostino Napolitano, Salvatore Morgante, and Gilberto Latini, Saipem SpA, Italy

[D07] Inspection of CRA clad pipelines: challenges and solutions, Johannes Keuter and Mohammed Jaarah, Rosen Group, Germany

[E07] An offshore pipeline gas leak investigation and repair, by Mahmood Al-Ridy, Saudi Aramco, Saudi Arabia

16:15 [C08] Strain-based design of buried horizontal cold-formed bends under high-temperature loading, by Matthew Laing, Dr Andy Young, and Timothy Turner, Penspen,UK

[D08] Large stand-off magnetometry for pipeline integrity assessments: an industry-independent evaluation, by John O’Brien, Chevron Corporation, USA

[E08] Fibre-optic sensing: comprehensive pipeline-integrity monitoring, by Marco Rettig, OptaSense, UK

16:45 End of day

Wednesday 13 April Wednesday 13 April

9:00 Track F: Management topics Track H: Integrity topics

[F01] Mechanical completion punchlisting challenges: practical project management solutions, by Michael McGraw, Saudi Aramco, Saudi Arabia

[C09] Armenia’s export gas transmission pipeline, by Maaryam Karkehabadi, Hamoon Gostar Sanat, Tehran, Iran

[H01] Pipeline integrity management system, by Rajesh Uprety, Oil Industry Safety Directorate, India

9:30 [F02] Pipeline management system, by Badr Al-Hussain, Saudi Aramco, Saudi Arabia

[C10] A case study on achieving efficiencies in the pipeline services industry in a low-cost market environment, by Chris Cloyde, Global Continuous Improvement HT&P Operations, T.D. Williamson, Inc., USA

[H02] Asset integrity management and life extension of gas transmission pipeline network and off-take stations, by Dr Abe Nezamian, WorleyParsons Advisian, and Peter Cox, WorleyParsons, Australia

10:00 Coffee

Conference ProgrammeResigter nowRegistration is open for the Pipeline Operations and Management Conference and Exhibition.

To register online, or view the full conference programme including abstracts, visit www.pipelineconf.com



Thursday 14 April Thursday 14 April

Track L: Leak topics

9:00 [K03] Polyethylene pipeline coating: failure and rehabilitation, Dr Mahmoud A. Dweib, Naim M. Dakwar, Yahya T. Janabi, Ahmad H. Malki, and Abduljalil. H. Al-Rasheed, Saudi Aramco, Saudi Arabia

[L01] Automated airborne oil leak detection for pipelines, by Eric Bergeron, FlyScan Systems Inc./ National Optics Institute, Canada

[J05] Composite solutions: 2016 and beyond, by Donald Chapman and Stuart Mckay, IMG Composites, UK

[M03] Maintenance pig design optimisation for cleaning a multiphase flow line, by Doug Batzel (1), Heider Suarez (2), and Sergey Makarov (2) 1 Batzel Engineering, Inc., USA 2 Exxon Neftegas Ltd, Russia

9:30 [K04] Reliable pipe protection in thrust boring and in challenging Sabkha environments: high-performance polyurea coatings, by C. Wolken, H. Rosenbleck-Schmidt, M. Magerstädt, M. Jaarah, K. Ross, and R. Altmeppen, Rosen Group, Switzerland, and Naim Dakwar and Mana Mansour, Saudi Aramco, Saudi Arabia

[L02] Wireless plug-in framework for legacy sensor systems in oil and gas pipelines, by Ahmed Al-Maghaslah, Saudi Aramco, Saudi Arabia

[J06] Considerations for repairing live piping using engineered composite repair systems, by Murali Kurup, Neptune Research Inc., UAE

[M04] A novel approach to the rehabilitation of subsea hydrocarbon pipelines using high-performance Solef PVDF flexible Kevlar-reinforced liners, by Jim Dymock, Anticorrosion Protective Systems LLC, UAE, and Dr Roger King, International Corrosion Services Ltd, UK

10:00 [K05] FBE-coated pipe storage and handling: a review of risks, standards, and integrity, by Oscar Salazar, Saudi Aramco, Saudi Arabia

[L03] The new revolution in leak detection, by Timothy G. Brown, Heath Consultants Incorporated, USA

[J07] A plastic plate to protect buried pipelines from third-party interference, by Yannick Joubeaux and Alain Turion, Overpipe, France

[M05] The future – monitoring and condition-based maintenance, by Saleh Elkadiki, Saudi Arabian Development Co Ltd, Saudi Arabia

10:30 Coffee

11:00 Closing plenary session

12:00 Lunch

14:00 Depart

10:45 Track G: Cracks and SCC Track C: Design topics continued Track H: Integrity topics continued Track I: Offshore topics

[G01] Corrosion and cracking in steels: advanced inspection applications for pipelines, by Mark Rosa, Saudi Aramco, Saudi Arabia

[C11] The susceptibility of vertical imperfections to upheaval buckling in high-temperature pipeline design, by David Simpson, Timothy Turner, and Dr Andy Young, Penspen, UK

[H03] PIMSyS - pipeline integrity management from space, by Jan Ridder, Orbital Eye BV, Netherlands

[I01] Transportation fatigue assessment of double- jointed pipe, by Abdulkarim Rinawi (1), Richard Keith (1), Walter Cimbali (2), Luigi Vitali (2), Christian D’Angelo (2), Ala Sharif (1), Khaleel Hussain (1), and Husain Muslim (1)1 Saudi Aramco, Saudi Arabia; 2 Saipem, Italy

11:15 [G02] Piping crack failure investigation and repair procedure at crude unit product line, Ras Tanura Refinery, by Ameer Al-Zawad, Saudi Aramco, Saudi Arabia

[C12] Opportunities and challenges for optimisation of internal company pipeline standards: a case study for design factor for liquid pipelines, by Dr Husain Al-Muslim, Saudi Aramco, Saudi Arabia

[H04] Advantages of smart pig XYZ mapping on pipeline assessments, by Tod Barker, T.D. Williamson, Inc., USA

[I02] Integrity evaluation of a 70-year-old veteran subsea pipeline, by Mushaid Nauman, Dr Roger King, and Ali Alani, Penspen Integrity, UAE, and Naim Dakwar, Saudi Aramco, Saudi Arabia

11:45 [G03] Prediction models and condition monitoring technologies to manage hydrogen-induced cracking growth, by Dr Abderrazak Traidia and Dr Abdelmounam Sherik, Saudi Aramco, Saudi Arabia

[C13] PIM software – a risk-based planning approach, by Lene Synnestvedt, DNV GL, Oslo, Norway, and Dr Mustafa Dameh, DNV GL, Abu Dhabi,UAE

[H05] S-S curve controlled high-strain line pipes are effective to ensure pipeline integrity in harsh environments, by Dr Nobuhisa Suzuki and Takekazu Arekawa, JFE Steel Corporation, Tokyo, Japan, and Andrei Arabey, Gazprom, Moscow, Russia

[I03] External corrosion management of offshore pipelines – new IRM strategies and case histories, by Jim Britton, Deepwater Corrosion Services, Inc., USA

12:15 Lunch

13:30 [G04] Susceptibility of stress-corrosion cracking in liquid and gas pipelines: Saudi Aramco study using a statistical approach, by Abdulaziz N. Ababtain, Nauman Tehsin, Dr Hussain Al-Muslim, and Nader A. Al-Otaibi, Saudi Aramco, Saudi Arabia, and Dr Tom Bubenik, DNV GL-Oil & Gas, USA

[C14] Method and tool used to predict the service life of a pipeline, by Dr Pawel Raczynski and Marceli Lewandowski, CDRiA Pipeline Services Ltd, Warsaw, Poland

[I04] Risk-based strategy for the development of an emergency pipeline repair system, by Ali Alani, Penspen, UAE

Track J: Materials topics

14:00 [G05] Probabilistic assessment of EMAT and UTCD ILI effectiveness for managing stress-corrosion cracking on buried pipelines, by Nauman Tehsin, Abdulaziz Al-Saif, Nader A. Al-Otaibi, and Abdulaziz N. Ababtain, Saudi Aramco, Saudi Arabia, and Dr Tom Bubenik, DNV GL Oil & Gas, USA

[C15] Practical root cause analysis, by Taimore Afzal, Saudi Aramco, Saudi Arabia

[J01] Material cost savings from pipeline wall thickness optimisation design case, by Ahmad Saif, Saudi Aramco, Saudi Arabia

[I05] Mechanical systems for offshore pipeline repair in Saudi Aramco: a case study, by Riyadh Alshiban and Shadid Al-Nutaifat, Saudi Aramco, Saudi Arabia

14:30 [G06] Stress-corrosion cracking (SCC) integrity management plan for onshore liquid and gas pipelines: Saudi Aramco comprehensive study, by Nauman Tehsin, Nader A. Al-Otaibi, and Abdulaziz N. Ababtain, Saudi Aramco, and Dr Tom Bubenik, DNV GL-Oil & Gas, USA

[J02] Study of temperature effect on toughness changes across thickness of the line pipe steel by CVN and DWT tests, by Syed Jainulaudeen, Dr Hamid Bayati, and Yousuf Al-Ghandeer, SABIC Technology Centre, Saudi Arabia

[I06] Acoustic determination of remote subsea valve status, by David Russell, Karl Dawson, Lucy Lingard, Pipeline Engineering, UK, and Barry Lennox and Kassandra Papadopoulou, University of Manchester, UK

15:00 Coffee

15:45 Track K: Coatings Track M: Maintenance topics

[K01] The weathering effect on pipeline coating performance in the Gulf area, by Nayf Rasheedi, Sultan Mutairi, Anas Rushaid, Turki Khaldi, and Abdullatif Abdulhadi, Saudi Aramco, Saudi Arabia

[J03] The significance of material model on upheaval buckling analyses, by David Simpson, Andy Young, and Timothy Turner, Penspen,UK

[M01] Enhancing pipeline safety through proper preventative maintenance of valves, by Mohanned Tarabzouni, Saudi Aramco, Saudi Arabia

16:15 [K02] A one-layer, non-shielding coating system: simple and fast to apply, by Nathan Muncaster, Polyguard Products, Ennis, TX, USA

[J04] Advanced NDT techniques utilised on pipelines, by Raymond Carswell, Saudi Aramco, Saudi Arabia

[M02] Case study: premature failures of new trap isolation valves, by Mohanned Tarabzouni, Saudi Aramco, Saudi Arabia

16:45 End of day


What has been the most challenging/rewarding pipeline project that you have been involved with in the region? And overall?

Within the Middle East I was involved in an advisory role for the major Baku – Tbilisi – Ceyhan (BTC) Pipeline and South Caucasus Pipeline (SCP) projects constructed by our Middle East team for BP in Azerbaijan. My overall favourite project was the Australia Pacific LNG Pipeline completed in 2014 – this was a world scale pipeline project successfully delivered in an integrated team environment.

Does McConnell Dowell have companies that it partners with in the Middle East to fulfil projects? If so, how has this relationship/s developed?

McConnell Dowell in the Middle East is a joint-venture company with Dutco established in 1977. Dutco is a large and diverse Dubai-based company with a number of construction and other business interests. We also have an established partnership with CCC having delivered a number of major projects in joint venture with CCC over the past 15 years in the Middle East, Africa and the Asia-Pacific region. Our approach to partnering is made on a project-by-project basis and is subject to a number of factors.

Please describe your current role and the McConnell Dowell presence in the Middle East

In my role of Managing Director for Dutco McConnell Dowell I oversee all aspects of the business. Our Middle East operation, based out of our regional office in Dubai, is fully staffed with QHSE, engineering, estimating, finance and admin/HR. We also have access to specialist support from McConnell Dowell that we can call on as required. In Dubai we have a large fabrication facility for pipe spooling and structural steel fabrication, as well as specialist CNC machining and welding capabilities, for example for duplex and stainless steel. To support the business we have satellite offices established in Qatar, Saudi Arabia, Abu Dhabi, and the Oman. Our main focus in the region is pipelines, tunnelling, and mechanical fabrication and installation.

How long have you been working in the pipeline industry, and in what regions have you worked?

I have worked in the pipeline industry since graduating as a Civil Engineer in New Zealand in 1982. Over the past 33 years I have worked on pipeline projects in New Zealand, Australia, PNG, Indonesia, Bangladesh, Myanmar, the United Kingdom and now the Middle East.

At which company did you commence your career in the industry, and at what others have you worked at? How has this influenced the way that you view the industry today?

I initially commenced work in New Zealand with a company called Perry Dines and I have also worked for A.Hak in the UK in the early 1990s. The

majority of my career has been spent with McConnell Dowell which has allowed me both to develop professionally and also be involved with

many major and challenging pipeline projects around the world.

What are the main challenges of working in the Middle East, and how does McConnell Dowell

overcome these? You need to be competitive and you need to deliver on your commitments with relationships with your

clients being paramount.

Construction company McConnell Dowell has established offices in the Middle East to better service the region. Pipelines International caught up with Dutco McConnell Dowell Managing Director Mark Barrows to discuss the company’s plans for the region, previous experience, and future projects.


Interview with McConnell Dowell’s Mark Barrows

“Do not over commit to work, and do not over staff your operation with expatriates – make use of local skills and expertise. Look at strategic local partners to assist your transition into the region.”


ABOVE: Speaking with the McConnell Dowell team on the APLNG Project.

RIGHT: An aerial view of the APLNG Project gas hub.



Where do you see the main growth areas in the pipeline industry in the Middle East over the next five years?

In the near term we see ongoing opportunities in the gas, water, power and transportation sectors to support a growing regional population, as well as ongoing work in the oil sector to maintain or improve production.

What initiatives does McConnell Dowell provide for the skills and training of its workforce in the Middle East?

The Middle East operation benefits from the global McConnell Dowell management systems, including training, with policies and documents being translated into a number of languages.

What three pieces of advice could you give to companies who would like to secure work in the Gulf region?

Tread carefully and be prepared to learn as with any new market there are challenges. Do not over commit to work, and do not over staff your operation with expatriates – make use of local skills and expertise. Look at strategic local partners to assist your transition into the region.

What future challenges or trends do you see for the pipeline industry?

In the short term the influence of a low oil price on projects. In the longer term retaining the skills and ‘can do’ attitude of pipeliners.

Why is knowledge sharing and industry training so important for the continued success of the global pipeline industry?

The industry is going through generational change so we need to ensure the new managers, engineers and superintendents are prepared to take over and benefit from the lessons of the past.

What is your favourite aspect of working in the pipeline industry?

People and challenges – over my career I have met so many great people who thrive on meeting the many and varied challenges that pipeline projects bring especially in remote areas bring.

Do you have any advice from those just beginning their careers in the pipeline industry?

Embrace the opportunities and be prepared to travel which brings learning and cultural rewards.

“You need to be competitive and you need to deliver on your commitments with relationships with your clients being paramount.”

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Page 46


Page 10

Cover story:Saudi Aramco General Manager Pipelines Mohammed Sultan Al-Qahtani exclusivePage 30

FLORIDA

LOUISIANA

MISSISSIPPI

GEORGIAALABAMA

SOUTH CAROLINA

ARKANSAS

TEXAS

NORTH CAROLINA

TENNESSEENEW MEXICOOKLAHOMA

ARIZONA

KENTUCKY VIRGINIA

MARYLAND

DELAWARE

KANSAS

MISSOURI

WEST VIRGINIA

COLORADO

NEW JERSEY

INDIANA

OHIO

NEVADA UTAH

CALIFORNIA

RHODE ISLAND

CONNECTICUT

PENNSYLVANIA

ILLINOIS

MASSACHUSETTS

NEBRASKA

IOWA

WYOMING

NEW YORK

VERMONT

NEW HAMPSHIRE

MICHIGAN

SOUTH DAKOTA

OREGON

WISCONSIN

MAINE

NORTH DAKOTA

IDAHO

MONTANA

WASHINGTON

MINNESOTA

BRITISH COLUMBIA

ALBERTASASKATCHEWAN

MANITOBAQUEBEC

NEWBRUNSWICK

ONTARIO

BAJACALIFORNIA

SONORA

CHIHUAHUA

COAHUILA

NUEVOLEÓN

TAMAULIPAS

DURANGO

SINALOABAJA

CALIFORNIASUR

San Antonio Houston

El Paso

Jacksonville

Dallas

San Diego

Memphis

Los AngelesCharlotte

San Jose

San FranciscoBaltimore

Chicago

Philadelphia

Detroit

Milwaukee

New York

Portland

Seattle

Austin

Tallahassee

Jackson

Montgomery

Phoenix Atlanta

Little Rock

Oklahoma City

Columbia

Santa FeNashville

Raleigh

Jefferson City

Topeka

Frankfort

Denver

CharlestonRichmond

Springfield Indianapolis

SacramentoLincolnCarson City

Cheyenne

Columbus

Salt Lake City

Annapolis

Des MoinesHarrisburg

Trenton

Madison

Lansing

Pierre

Boise

Hartford

Saint Paul

Albany Boston

Concord

Bismarck

HelenaSalem

Montpelier

Augusta

Olympia

Washington D.C.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18*

19

20*

21*

22

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24

25

26*

27

28*

29

30

31*

32

33

34

35

36

37

39*

40*

0

0 500 km250 km125 km

500 miles250 miles125 miles

CANADAALASKA

38

0

0 500 km

500 miles

KEYNAME OWNER PRODUCT CAPACITY

LENGTH (miles)

1 El Paso Natural Gas Pipeline System Kinder Morgan Gas 6,182 MMcf/d 10,200

2 Algonquin Gas Transmission Spectra Energy Partners Gas 3,347 MMcf/d 1,129

3 Texas Eastern Transmission Spectra Energy Partners Gas 7,332 MMcf/d 9,022

4 Tennessee Gas Pipeline Kinder Morgan Gas 6,686 MMcf/d 13,900

5 Panhandle Eastern Pipeline Panhandle Energy Gas 2,840 MMcf/d 6,445

6 Northern Natural Gas Pipeline Northern Natural Gas Gas 7,442 MMcf/d 14,700

7 ANR Pipeline ANR Pipeline Company Gas 7,129 MMcf/d 10,600

8 Transcontinental Gas Pipeline Williams Gas 8,466 MMcf/d 10,500

9 Gulf South Pipeline Gulf South Pipeline Company Gas 6,260 MMcf/d 6,886

10 Natural Gas Pipeline Co of America Kinder Morgan Gas 4,848 MMcf/d 9,200

11 Florida Gas Transmission Pipeline Florida Gas Transmission Company Gas 2,217 MMcf/d 4,889

12 Kern River Gas Transmission Pipeline Kern River Gas Transmission Company Gas 1,833 MMcf/d 1,680

13 Trunkline Pipeline Panhandle Energy Gas 3,025 MMcf/d 4,202

14 Texas Gas Transmission Boardwalk Pipelines Gas 4,065 MMcf/d 5,671


LENGTH (miles)

15 Southern Star Central Pipeline Southern Star Gas 2,801 MMcf/d 5,803

16 Dominion Pipeline Dominion Resources Gas 6,655 MMcf/d 3,505

17 Colorado Interstate Gas Pipeline Kinder Morgan Gas 4,099 MMcf/d 4,300

18 Alliance Pipeline System* Alliance Pipeline Gas 2,053 MMcf/d 2,311

19 Columbia Gulf Transmission Columbia Pipeline Group Gas 2,386 MMcf/d 4,124

20 Northern Border Pipeline* TC PipeLines; ONEOK Partners Gas 2,400 MMcf/d 1,408

21 Great Lakes Gas Transmission Pipeline* Great Lakes Gas Transmission Company Gas 2,958 MMcf/d 2,115

22 Transwestern Interstate Pipeline Energy Transfer Gas 2,439 MMcf/d 2,560

23 Questar Pipeline Questar Pipeline Gas 3,192 MMcf/d 1,858

24 Wyoming Interstate Pipeline Kinder Morgan Gas 2,736 MMcf/d 800

25 Centerpoint Energy Gas Transmission CenterPoint Energy Gas 5,385 MMcf/d 6,374

26 Northwest Pipeline* Williams Gas 4,950 MMcf/d 3,880

27 Southern Natural Gas Company System Kinder Morgan Gas 3,967 MMcf/d 7,635

28 Gas Transmission Northwest* TransCanada Gas 2,636 MMcf/d 1,356


LENGTH (miles)

29 Columbia Gas Transmission NiSource Gas Transmission & Storage Gas 9,350 MMcf/d 10,365

30 National Fuel Gas Supply Corporation System National Fuel Gas 2,312 MMcf/d 2,300

31 Keystone Pipeline* TransCanada Crude oil - 2,639

32 Seaway Pipeline Enterprise Products Partners; Enbridge Crude oil 850,000 bbl/d 500

33 Gulf Coast Project TransCanada Crude oil 700,000 bbl/d 485

34 Longhorn Pipeline Magellan Midstream Partners Crude oil - 700

35 Double H Pipeline Hiland Partners Crude oil 84,000 bbl/d 485

36 Pony Express Pipeline Tallgrass Energy Crude oil 230,000 bbl/d 690

37 Olympic Pipeline BP Crude oil 315,000 bbl/d 400

38 Trans-Alaska Pipeline System Alyeska Pipeline Service Company Crude oil - 800

39 US Mainline (Lakehead System)* Enbridge Crude oil 2,600,000 bbl/d 1,900

40 Alberta Clipper* Enbridge Crude oil 800,000 bbl/d 1,000

MAJOR PIPELINE SYSTEMS OF THE USA

Compiled and published by Great Southern Press Pty Ltd. Tel: +61 3 9248 5100

Product information and graphic design © Great Southern Press, 2016. Source map courtesy Map Resources.

www.mapresources.com.au

For additional copies of this poster and for advertising enquiries, email [email protected]

This map is intended as a general source of information only.

NOTE: This is a schematic representation and shows approximate routes of major US pipelines. It does not show exact pipeline routes. Route, length, and capacity information is approximate and intended as a guide only, and is correct as at May 2015.

A detailed overview of select existing major pipeline systems in the USA.

Pipelines marked with * indicate a pipeline route that begins in Canada.

www.pipelinesinternational.com

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300 miles150 miles

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YUKON TERRITORY

NORTHWEST TERRITORIES

NUNAVUT

BRITISH COLUMBIA

ALBERTA

SASKATCHEWAN

MANITOBA

ONTARIO

QUEBEC

NEWFOUNDLAND&

LABRADOR

NEW BRUNSWICK

NOVASCOTIA

PRINCEEDWARDISLAND

Kamloops

Lethbridge

Red Deer

Kingston

Moncton

DrummondvilleTrois-Rivieres

Brandon

Moose Jaw

Saint John

Richmond

Thunder Bay

Saskatoon

Brampton

VancouverCalgary

London

Montreal

Hamilton

Edmonton

Toronto

HalifaxQuebec

Winnipeg

Regina

Victoria

St. John's

Fredericton

Yellowknife

Whitehorse

Charlottetown

Iqaluit

Ottawa

KEYNAME OWNER PRODUCT LENGTH DIAMETER

1 Alberta Clipper (Line 67) * Enbridge Inc. Crude oil 1,069 km 36 inches

2 Alliance Pipeline * Enbridge Inc. (50%); Versan (50%) Natural gas 1,560 km 36–42 inches

3 Brunswick Pipeline Emera Brunswick Pipeline Company Natural gas 143 km 30 inch

4 Canadian Mainline TransCanada Pipelines Natural gas 14,114 km 36 inch

5 Cochin Pipeline System Kinder Morgan Propane and ethane-propane 995 km 12 inches

6 Deep Panuke Pipeline Encana Corporation Natural gas 175 km

7 Enbridge Pipelines (NW) Inc. System Enbridge Inc. Crude oil 855 km

8 Enbridge Mainline * Enbridge Inc. Crude oil 2,306 km 30–36 inches

9 Enbridge Westspur Pipeline Enbridge Inc. Crude oil 175 km 12 inches

10 Enbridge Southern Lights (Line 13) * Enbridge Inc. Crude oil 1,241 km 20 inches

11 Express-Platte Pipeline System * Spectra Energy Crude oil 434 km 24 inch

12 Foothills Pipeline System TransCanada Pipelines Natural gas 1,241 km 36–42 inches

13 Keystone Pipeline * TransCanada Pipelines Crude oil 1,227 km 30–36 inches

14 Maritimes and Northeast Pipeline Spectra Energy (77.53%); Emera (12.92%); ExxonMobil Corporation (9.55%) Natural gas 575 km 30 inch

15 Nova Gas Transmission Pipeline System (NGTL) TransCanada Pipelines Natural gas 24,373 km 16–42 inches

16 Ontario–Quebec Pipeline TransNorthern Pipeline Inc. Refi ned fuel products 850 km

17 PTC Pipeline Spectra Energy Natural gas liquids 930 km

18 Trans Mountain Pipeline System Kinder Morgan Crude oil and refi ned products 1,142 km 24–36 inches

19 TransQuebec and Maritimes Pipeline Mainline TransCanada Pipelines (50%), Gaz Metro (50%) Natural gas 572 km

20 Westcoast Pipeline System (B.C Pipeline) Spectra Energy Natural gas 2,900 km 24–42 inches

21 Dawn to Parkway Trunkline Union Gas Natural gas 257 km

* Pipeline continues into United States of America.

The Major Pipeline Systems of Canada map provides an overview of existing major pipeline systems in Canada that are over 100 km in length. The map includes the name, owner, product, approximate length and diameter of the pipeline.

Information used to collate this map was directly provided by companies, the National Energy Board (NEB) and the Canadian Energy Pipeline Association (CEPA).

Information on this map is intended as a general source of information only. Compiled and published by Great Southern Press Pty Ltd. Tel: +61 3 9248 5100




With the support of:


MAJOR PIPELINE SYSTEMS OF CANADAA detailed overview of select existing major pipeline systems in Canada.

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Plug was confirmed as providing double block isolation, allowing the valve maintenance to commence. The Remote Tecno Plug remained in place to isolate the pipeline for three days while the valve was replaced.

With maintenance work successfully completed, the Tecno Plug was used as a test boundary to perform a reinstatement pressure test. “This was achieved by raising the pipeline pressure from the launcher side while the Tecno Plug remained in a fully ‘set’ condition. The reverse pressure test operation created a test boundary to confirm the newly installed valve. Finally the plug was unset and reverse-pigged back to the launcher for demobilisation,” says Mr Shangari.

“The successful delivery of the project demonstrates STATS’ ability to provide safety critical isolation services that enable urgent maintenance activity to be completed, within schedule and with minimal production outage.”

With a verified double block and bleed isolation in place, valve replacement and maintenance work was then

successfully carried out on a 16 inch production tee connected to the pipeline.

In line with the client’s standard maintenance and safety procedures, a verified double block-and-bleed isolation is compulsory prior to valve replacement on a live system. “Conventional repairs of this type would typically require the entire pipeline to be completely hydrocarbon free and nitrogen purged to enable a safe intervention. This approach adds extensive operational and procedural requirements which have significant time, environmental and cost implications,” says STATS Group Business Development Manager – Middle East, Vikas Shangari.

After a detailed site survey and piggability assessment, STATS proposed the use of a Remote Tecno Plug™. In order to verify functionality for the offshore operations, all equipment was subject to a Factory Acceptance Testing programme at STATS Group headquarters in Kintore, Aberdeenshire, Scotland, prior to delivery to Qatar. “This fast-track project was engineered, risk assessed, assembled and mobilised within a two-week window,” says Mr Shangari.

Once onsite, the Remote Tecno Plug was pigged with nitrogen from the launcher through two valves, passed the production tee and through three 90 degree bends to the set location.

Mr Shangari says “Once at location and hydraulically set, the Tecno Plug provides fail-safe and fully tested double block isolation against pipeline pressure and contents, ensuring a safe and reliable barrier prior to breaking containment.”

During pigging operations the Remote Tecno Plug was tracked and accurately positioned using through-wall communication. An extremely low-frequency (ELF) radio control system sets and monitors the plug throughout the isolation. The remote control system provides a high degree of flexibility and eliminates the need for tethers or modified pig-trap doors.

Independent testing of each seal with full pipeline pressure confirmed leak-tight isolation and the pipeline was bled down to ambient from the platform launcher to the rear of the Tecno Plug. The annulus between the Tecno Plug seals was vented to ambient to create a zero-energy zone.

After a 12-hour isolation stability hold period, an ‘Isolation Certificate’ was issued and the Tecno

STATS Group were recently retained by a major oil producer in Qatar to provide fast-track delivery of a high-pressure isolation tool to facilitate the safe and reliable isolation of a 24 inch pressurised gas pipeline.


Qatar pipeline isolation: fast-track delivery meets demand


A B C

A: The 16 inch valve to be changed out.

B: STATS field technicians with the Remote Tecno Plug™ following successful valve change-out.

C: The 24 inch Remote Tecno Plug™ recovered from the launcher.

“This fast-track project was engineered, risk assessed, assembled and mobilised within a two-week window.”

STATS Group Business Development Manager – Middle East, Vikas Shangari.

QPH 1Power Associates


manufacture drills. The second is Vermeer implementing and practicing ‘lean manufacturing’ in order to be able to produce the ever-increasing volume of drills.

Reflecting on that initial predication of 10 units, Mr Rankin said “Wow! Kind of hit that ball out of the ball park!”

LOOKING TO THE FUTUREImproving and innovating with equipment, for

Vermeer, is core to the company’s philosophy. “If Henry Ford would have viewed his first car

as ‘this is it’, we wouldn’t be riding around in the luxurious vehicles we enjoy today!” says Mr Rankin.

“Gary Vermeer, the founder of Vermeer said ‘find a better way and build the best’. I truly believe when I pull the boots on every day that there is a better way things can be done. That doesn’t mean I’ll find that way, but if you put your mind to it you can improve on everything.

“You always hope and want to believe that history and experience helps an engineer make new advances. Part of the challenge is being able to transfer that history and experience in going forward,” says Mr Rankin.

Vermeer is a company that keeps innovating, and one area that is becoming a focus for the drilling industry is environmentally conscious technology. The company has been making innovative developments with its fluid reclaimers, an area in which Mr Rankin has been heavily involved in recent years.

“This is an area that has big opportunities at

many different levels and for many different reasons. The biggest reason, like directional drilling itself, is that it is ‘green technology’ and that is important to me.”

DITCH WITCH

Dr Kelvin Self, Research & Development Project Manager

The road to developing Ditch Witch’s first HDD rig began with the company’s first commercial service-line trencher, which was created in 1949 by trenchless industry pioneer and Ditch Witch founder Ed Malzahn. While the trencher represented a major advancement for the installation of small pipe and cable in urban environments, it still faced one major jobsite challenge: like all open-cut excavations, the technology required major construction work to cross obstacles.

Dr Self says “There were many situations where the open-cut method was too difficult, too expensive, or too disruptive to be a sufficient solution for all underground applications. Case in point: prior to HDD technology, a simple road crossing often resulted in road closure, tearing up the concrete to excavate, and then fully rebuilding the road – taking several days to complete.

“For even a small river crossing, the flow would be diverted by building a cofferdam and excavating in the muck and mud; repeating the same process for the next area of the river, taking many days or sometimes weeks to cross.”

Because of this inconvenience, the industry moved to innovate, with many working on different

types of technologies to help solve the problem.“As with most technical innovations, various

types of separate technologies needed piecing together to develop an effective solution. Early contractors – including Martin Cherrington and later Flow Mole, among others – created functional machines to combat these challenges; however, the machines generally lacked key elements of modern HDD rigs, which stunted their effectiveness.”

Many at Ditch Witch were also conducting research to find effective trenchless solutions to HDD challenges. Dr Gerald Stangl and Roger Layne, who have now both retired, were key personalities to this early research and development.

Around the mid-to-late 1980s, Dr Stangl and Dr Layne learned of another contractor-inventor who possibly held another piece of the HDD technology puzzle. The two men travelled to meet with Richard Dunn, a gentleman who had invented a small boring machine with a crucial piece of technology.

“After watching the machine run, the Ditch Witch organisation eventually purchased the intellectual property for what is now known as the slant-faced method of boring,” Dr Self says.

VERMEERJim Rankin, Application Engineer

Jim Rankin is one of the most well-known individuals in the HDD industry. His career within Vermeer spans an impressive 38 years, and one of Jim’s many accolades includes being instrumental in the development of Vermeer’s directional drills, including the company’s first commercially marketed drilling equipment.

Mr Rankin says “In the very beginning, I remember being pulled into my manager’s office and asked if I knew or had ever heard of a term or technology called ‘directional drilling’, which I hadn’t.

“He said, ‘Well, I don’t know a lot about it either, but I want you to book a ticket to Charlotte, North Carolina, meet up with the local Vermeer Dealer, and watch a unit in operation that’s been manufactured by a company that’s just starting to make a move into this industry’.”

PROTECTING HOSPITAL POWERMr Rankin recounts that the trip was right

after hurricane Hugo had hit the Charlotte area and the storm had taken down several overhead powerlines at a nearby hospital. The directional

drilling project involved moving powerlines underground to reduce any future loss of power to the facility. This required the installation of a 42 m power conduit underneath the hospital’s emergency entrance bay.

As one would imagine, shutting down the driveway to break up the concrete, dig a trench, bury the conduit, compact the soil back, and replace the concrete wasn’t a viable option; the time for the concrete to set before reopening the drive would be days, and emergency vehicles would have to be rerouted to another hospital entrance point, or even another hospital, adding more time to a possible life-and-death situation.

“At that time,” said Mr Rankin, “It took the better part of two days to do this 42 m bore. Compared to today’s standards, we would have been sacked and sent back to running a shovel. But the flow of traffic to the emergency entrance wasn’t interfered with.

“Back then we didn’t have the luxuries there are today like a seat, rod loaders, cabins, and self-propelled machines. Drill racks were manually manoeuvred into place, every drill stem was manually carried to the rack, and you can’t forget laying down the earthing matts and driving the stakes down with a sledge hammer!

“There are a lot of operators out there now that don’t realise the work that was involved in the whole operation back then.”

UNCERTAIN BEGINNINGSMr Rankin says he came back from that project

not totally convinced of the technology, and wondering if he wanted to take the lead on a project to commercialise the technology.

At the time, Vermeer had very modest plans for the success of the new technology.

“Well into the project, I remember asking my manager how many units he thought Vermeer would sell per year so we could leverage price breaks,” says Mr Rankin.

“He said if we built and sold 10 complete units a year he would be thrilled and amazed. He believed Vermeer was a company building trenchers nobody was going to shut down their trencher and follow.”

In present day, the original factory floor at Pella, Iowa, where these first units were developed, has seen two big changes during Mr Rankin’s tenure. One is the early prediction of 10 units per year being quickly surpassed, resulting in an urgent need for more floor space to

Horizontal directional drilling (HDD) rigs are widely used on transmission pipeline projects efficiently and economically to complete river and road crossings, and traverse environmentally sensitive areas with the lowest impact. But how did the technology develop? Pipelines International speaks to representatives from Vermeer, American Augers and Ditch Witch to learn more about how each company developed its first HDD rig.

Designing the first HDD rigs

HDD AND MICROTUNNELLINGHDD AND MICROTUNNELLING

A B C

A: While they were considerable breakthroughs at the time, the first Navigator-series HDD rigs were a far cry from the rigs of today. Image supplied by Vermeer.

B: Sales team training for the new (at the time) Vermeer Navigator rig. Image supplied by Vermeer.

C: Technical drawings from the 1990 patent application for a slant-face HDD rig. Image supplied by Ditch Witch.


After successful applications in the oil and gas industry, American Augers’ drilling units were quickly adopted for the placement of fibre optic cables. Once the technology was proven on a variety of installation types, the rate of applications grew rapidly.

“Frank Vestfall, Biyue Li, and Jim Firmin were all key to the development of American Augers’ first drilling rigs. They each worked directly with prospective customers to develop the early specifications and new design concepts to meet the needs of individual projects,” says Mr Levings.

OHIO MANUFACTURING GOES GLOBAL

American Augers’ first rigs were manufactured near Wooster, Ohio. They were often built to meet individual project specifications before being sold directly to contractors. It wasn’t long before American Augers became a worldwide manufacturer of maxi-HDD systems and set up processes to service its units across the globe.

Today American Augers has evolved into a world-class provider of pipeline construction

equipment. The company still has a manufacturing site located just outside of West Salem, Ohio, and utilises the latest manufacturing equipment and techniques to produce maxi-HDD rigs.

As a global company, American Augers has been able to observe differences in project specifications and requirements across the world.

Mr Levings says “Some of the major differences we’ve seen include package size, configuration and price differences; and, variations in environmental regulations and standards, and health and safety requirements.

“These country-to-country differences present many challenges to the American Augers’ product line, and require the company to be consistently flexible with its manufacturing processes.”

THE TIMES, THEY ARE A-CHANGIN’Since it was initially developed, American

Augers has seen significant advancements in HDD techniques and technology. This includes improvements in hydraulics and electronics, which have helped to improve performance, as well as the addition of operator interfaces,

wrenching devices, rotary systems, and track-mounted carriers to HDD rigs. Despite these changes, the form of units is still very similar to the original designs.

These days, the company manufacturers a range of different HDD rigs. The development of these rigs can vary from a few months to more than a year.

The speed of the development process is mostly driven by the needs of the end user and the process of translating those needs into useful design solutions.

American Augers continues to innovate and push HDD technology forward. With new environmental pressures being placed on end users across the world, the company is being driven to work very closely with the trenchless industry to meet ever-changing equipment requirements and project outcomes.

“As a company, American Augers will continue to seek unique solutions to meet these challenges head on,” says Mr Levings.

A NEW SLANT ON HDDSlant-face technology was first used to install

small-scale pipes and cables using a fluid-assisted boring unit. The technology breakthrough was patented by Mr Dunn and recognised as US patent 4953638 in 1988. The technology was a breakthrough for the industry; a significant improvement on the techniques that preceded it. However, there was still one major problem with the slant-faced boring machine: it wasn’t trackable.

“Ditch Witch married the slant-face technology with the locating sonde technology that was already being used in other Ditch Witch trenchless products,” says Dr Self.

“This was the birth of the first Jet Trac, a utility class HDD rig manufactured in Perry, Oklahoma, at the Ditch Witch facility. The unit was sold worldwide through Ditch Witch dealerships from 1990 onwards. Though crude by today’s standards, in many ways the newly designed drill unit functioned similarly to HDD boring systems that are still being used today.”

WHERE TO FROM HERE?The first HDD units were designed to install

pipe and cable in areas where trenching was difficult or impossible. In good soil conditions, the first HDD units were capable of installing small pipe and cable up to a few hundred metres.

“The early HDD units were difficult to use

successfully and very labour intensive,” says Dr Self. “They often failed to complete the bore the first time. So when first introduced, many thought the machines would only be a small niche in the industry.”

However, over the years HDD units have grown in size and capabilities. Today they are commonly used to quickly and efficiently install underground product ranging from a small cable TV across a backyard to a 36 inch pipeline over a kilometre in length or more. Modern-day units are commonly used to bore through all kinds of soil, from soft topsoil to extremely hard rock and cobble.

Overall, it took nearly four decades after Mr Malzahn’s invention of the service-line trencher before the creation of an efficient trenchless boring machine with all the key elements of a modern HDD unit.

TRACKING COMPANY GROWTHDitch Witch has a long history as a global

company; even though the manufacturing plant has always been based in Oklahoma, the dealership network was spread across the globe long before the advent of HDD.

Ditch Witch has seen significant growth and changes since the introduction of HDD in the late 1980s. The manufacturing site has grown substantially, allowing for the production of HDD rigs, followed by drill pipe, downhole tools, fluid systems, and vacuum excavation systems.

In addition to this, since 1991, Ditch Witch has put significant energy into developing electronics to support HDD tracking applications and downhole tooling to support Ditch Witch products. This business is now known as Subsite Electronics, a stand-alone company supporting underground construction with a suite of electronics products. Ditch Witch has also continued to expand its training facility and courses, with many thousands of HDD operators and service personnel trained at the site since the first Jet Trac.

AMERICAN AUGERS

Richard Levings, Director of Product Development

“American Augers’ first commercially marketed drilling equipment was developed in 1998 for several large customers, some of which are the world’s largest HDD contractors today,” says Mr Levings.

The machine in question was a trailer-mounted, rack-and-pinion drive drilling unit that had approximately 176 tonnes of pullback power. The rig was developed for the installation of oil and gas pipelines under rivers and interstate highways in the United States. One of the first projects on which the unit was used was the installation of a 36 inch gas pipeline under the Mississippi River in Louisiana.

HDD AND MICROTUNNELLINGHDD AND MICROTUNNELLING

This article first appeared in Pipelines International’s sister publication Trenchless International. For more information on trenchless news and projects, or the Trenchless International magazine, visit www.trenchlessinternational.com

D E F

D: The first Navigator HDD rigs lacked seats, rod loads, cabins, and self-propulsion. Additionally, prior to operation, earthing matts had to be laid down. Image supplied by Vermeer.

E: The slant-face HDD rig at work. Image supplied by Ditch Witch.

F: American Directional Drilling’s HDD rig in 1993. Image supplied by American Augers.


DEVELOPMENT OF INTEGRITY TARGETS

The PoF represents a statistical way to express the chance of a lagging event. By using this approach, every element that contributes to overall uncertainty can be examined individually. This enables better understanding of systems, and allows focused improvements to operational processes in order to improve reliability.

Figure 3 illustrates examples of how PoF can be altered using:

1. Data/technology focused methods (for example, reducing distribution spreads), or

2. Traditional methods (for example, moving distributions away from each other).

A significant aspect of developing a reliability-based integrity-management model is the definition of an acceptable level of safety in numerical terms. Numerous industries refer to the term ‘as low as reasonably practicable’ (ALARP) to reflect the goal of achieving the lowest possible PoF that is realistically obtainable. To help determine an appropriate order of magnitude, Enbridge retroactively applied probabilistic modelling to data from historical incidents. It was found that each line had a PoF of 10-2 or worse prior to failure. By calibrating against previous data, a minimum safety target of 10-5 was set, and the PoF of Enbridge’s entire system has now been improved to this level or safer.

Figure 4 provides context of Enbridge-derived PoFs relative to other industries. It also highlights the improvement in reliability since 2010, when Enbridge had retroactively calculated PoFs in the range of 10-1. By today’s 10-5 minimum standard, the condition of every pipeline that has failed historically would have been deemed unacceptable and required intervention prior to failure.

The significant reduction in PoF since 2010 is largely due to the fact that, in the past, outliers and inaccuracies were not sufficiently considered and accumulated, whereas the full ‘practicable’ range of variability is now factored into PoF modelling. Today, the majority of Enbridge’s lines have been improved to have PoFs beyond the 10-9 range (Figure 5).

DATA-DRIVEN DECISION MAKINGAPI 1173 highlights the Plan-Do-Check-Act

methodology as a valuable model for SMS definition. Enbridge’s ‘Core Process’ framework for pipeline-integrity management follows this cycle, as outlined in Figure 6. By implementing reliability targets within this framework,

This methodology allows pipeline conditions to be objectively assessed in terms of the level of remaining

uncertainty by using probability statistics which are benchmarked against historical incident data. The effectiveness of additional measures such as hydrostatic testing can be quantified, allowing operators to determine actions within an overall integrity-management programme decision framework in order to meet required thresholds of safety.

THE NEED FOR OBJECTIVE MEASUREMENT

API 1173, a recommended practice released in 2014 which outlines ‘Pipeline Safety Management System Requirements’, follows in the footsteps of numerous other industries which have embraced the use of safety-management systems (SMS). Developed through contributions from operators, regulators, academia, and public stakeholders, it emphasises the need for companies to have objective measures of performance.

In an era where both regulators and the public are demanding clear and tangible proof of pipeline safety, it is imperative that operators establish consistent, data-driven methods for demonstrating system reliability. Incident metrics are not statistically effective as a measure of safety due to their low frequency. What is needed is a quantitative, leading metric approach that will enable the development of industry-wide thresholds representing a consensus response to the question of ‘how safe is safe enough?’.

For a range of other industries and regulatory bodies worldwide, the concept of establishing an ‘acceptable level of safety’ is not new. For decades,

industries such as aerospace and nuclear-power generation have embraced data-driven analysis and reliability engineering to establish ‘safety targets’ – numerical measures employed by both regulators and operators that clearly define the levels of safety required.

USE OF RELIABILITY ENGINEERING PRINCIPLES IN INTEGRITY MANAGEMENT

Traditionally, the pipeline industry has taken a ‘deterministic’ approach to safety. This method defines exact values for input parameters based on empirical data, and is suited to well-understood variables in predictable systems. However, when those parameters contain uncertainty, as is the case with many aspects of pipeline-integrity management, this approach is not necessarily satisfactory.

A ‘probabilistic’ approach, on the other hand, incorporates uncertainty by considering statistical distributions of input variables. For example, Figure 1 illustrates the differences in

representation of pipe strength using deterministic and probabilistic approaches.

Whereas a deterministic approach uses a safety factor to ensure there is sufficient buffer between defined values for pipe strength and the strength required for operation, probabilistic analysis defines the variability of each, and assesses their interaction. Any overlap between the two distributions represents a potential threat to safety, and the extent of overlap is quantified as a number – the probability of failure (PoF). This is illustrated in Figure 2.

The generation of probabilistic models considers a wide range of inputs such as pipe properties, diagnostic accuracy, modelling accuracy, and operating conditions. However, robust outputs are dependent on a statistically relevant quantity of input data, and without an integrity-management model founded in data-driven processes, the approach is not feasible. The use of technology such as ILI, coupled with extensive field validation, greatly aids the effective implementation of this method.

In the past several years, Enbridge has gathered an extensive amount of data from in-line inspections (ILI), investigative excavations, pipe replacements, and hydrostatic tests. This collation of evidence, and the analytics that have followed, have resulted in a ‘data-driven’ model using principles of reliability engineering to advance pipeline safety.

By John Munro, Enbridge Pipelines Inc., Edmonton, AB, Canada

Reliability engineering: a target-driven approach to integrity management

PIGGINGPIGGING

FIGURE 2: Safety factor (SF) vs probability of failure (PoF).

FIGURE 3: Improving PoF.

FIGURE 4: PoFs of numerous industries.FIGURE 1: Representing pipe strength – deterministic vs probabilistic methods.


scrutiny. In parallel, however, is an unprecedented potential for operators to maintain the safety of their systems, given modern advancements in technology and analytics.

The tools are available to raise the bar on pipeline-integrity management. The first article in this series demonstrated the highly successful results being achieved by modern ILI tools. However, reliance on ILI alone is not sufficient to ensure safety. Validation of ILI data through statistically relevant quantities of field results is necessary for effective threat management. The second article in this series provided a case study of how insufficient analysis of available ILI data can lead to failures. It highlighted, however, that ILI works when implemented as part of a comprehensive programme.

Effective integrity management is not just about having multiple barriers of defence. The effectiveness of those barriers also needs to be assessed in an objective, quantitative fashion. This article closes the series by demonstrating how reliability engineering principles can be utilised to consider the many different elements at play, and

ensure that the safety barriers in place are adequately robust.

Using these measures to establish reliability targets allows clear assurance of pipeline safety. However, there is yet to be consensus agreement within industry on what constitutes an acceptable level of safety. It is imperative that operators share learnings in a collaborative manner to further integrity science and develop consensus approaches. This is the surest way to facilitate an accelerated journey toward the goal of zero incidents.

DISCLAIMERAny information or data pertaining to Enbridge

Employee Services Canada Inc., or its affiliates, contained in this article was provided to the authors with the express permission of Enbridge Employee Services Canada Inc., or its affiliates. Enbridge Employee Services Canada Inc. and its affiliates and their respective employees, officers, director, and agents shall not be liable for any claims for loss, damage, or costs, of any kind whatsoever, arising from any errors, inaccuracies, or incompleteness of the information and data contained in this article or for any loss, damage, or costs that may arise from the use or interpretation of this article.

a systematic approach to decision making can be established.

Although ILI serves as the primary data source, the framework provides a ‘Check’ phase regarding ILI reliability. If ILI is deemed insufficiently reliable, additional mitigation is implemented (the ‘Act’ phase). With the uncertainty of a given line established in numerical terms, the effectiveness of additional mitigants such as hydrostatic testing can be quantified, and the potential benefits better understood.

The entire Core Process involves the collection of vast amounts of data, which are constantly assessed to validate the methods being employed. For example, ILI reliability assessment is largely

based on comparisons with field measurements, obtained using non-destructive examination (NDE). Although NDE is a globally accepted practice, there may still be inaccuracies present, and this can impact the ILI reliability assessment. As such, it is critical to have a robust NDE quality management programme in place to ensure accuracy and understanding of overall uncertainty.

THE REGULATORY FRAMEWORK FOR INTEGRITY MANAGEMENT

The use of a reliability-centered, data-driven approach encapsulates all elements of PHMSA’s new Hazardous Liquid Integrity Verification Plan (HL IVP). In the plan, PHMSA outlines

numerous options for establishing maximum operating pressure:

1. Pipe replacement2. De-rate pipeline3. Engineering critical assessment (ECA)4. Hydrostatic testing5. Alternative technology. Some within the industry have questioned the

adequacy of ECAs as a form of safety assurance. However, ECAs can be made extremely robust if backed by a comprehensive integrity-management programme. They align with the ‘safety case’ methodology of other industries that operate under performance-based regulatory regimes, which require evidence-based arguments to justify that systems are acceptably safe. This is a contrasting approach to the traditional assumption that adhering to a prescribed process will generate the required level of safety. There is no single mitigative tool that presents a total solution to pipeline integrity.

Enbridge’s integrity programmes are based on a foundation of ILI technology, with reliability assessments being carried out on an ongoing basis as part of the Plan-Do-Check-Act cycle. Additional mitigants are employed as necessary, with pipe replacement, pressure restrictions, and hydrostatic testing all considered as options where appropriate. This is beyond the scope of regulatory requirements, but it is Enbridge’s position that such a comprehensive approach is crucial to maintaining pipeline safety.

CONCLUSIONThe pipeline industry currently faces an

unprecedented level of public and regulatory

PIGGINGPIGGING

FIGURE 5: Current system PoFs.

FIGURE 6: Enbridge PI Core Process.

There is yet to be consensus agreement within industry on what constitutes an acceptable level of safety. It is imperative that operators share learnings in a collaborative manner to further integrity science and develop consensus approaches.

This article is the third in a series of three to be published in Pipelines International detailing Enbridge’s experience with best-in-class inspection technology and associated analytical approaches. The first two articles can be read on the Pipelines International website www.pipelinesinternational.com

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Effective implementation of a crack in-line inspection programme

Successful management of the pipeline cracking threat using an ultrasonic in-line inspection tool – a case study

PIGGING

HPH 2Girard Pipeline Pigs


February’s Pipeline Pigging and Integrity Management (PPIM) Conference and Exhibition – the 28th in the annual series

organised in Houston by Clarion Technical Conferences and Tiratsoo Technical – saw the confluence of 38 conference papers, 108 exhibitors, and over 2,000 visitors at the Marriot Westchase Hotel. With delegate and visitor numbers approaching the record-breaking totals achieved in 2015, the organising team was delighted to find that the problems being faced elsewhere in the hydrocarbons’ industry seem to have a minimal impact on pipelines and maintaining their integrity. It’s fair to say, too, that the low oil price has had little effect on natural gas. As many at the event were keen to point out, summarised by co-organiser BJ Lowe of Clarion in his opening remarks, “pipelines will always be needed” despite the changing value of what they transport, and this event has clearly become a significant and recognised opportunity for meeting, learning, and networking for this industry.

As in previous years, the four days of the meeting were structured around two days of training courses (there were 11), a two-day conference, and the exhibition which included two early-evening receptions at which the many visitors were able to take advantage of the hospitality provided by sponsors Rosen Group and Precision Pigging. There was also a half-day briefing on pipeline pigging and integrity in ‘non-technical language’ which proved popular

and helpful to those new to the industry, and a special conference session on in-ditch NDE technologies for detecting and sizing cracks and seam-weld anomalies, which included an opportunity for those attending to get some hands-on experience of the latest technologies that are available in this area. A final component of these hectic few days was an evening ‘happy hour’ organised by the Young Pipelines Professional of the USA, and sponsored by a number of industry companies. The YPP is a fast-growing group, and the reception – though ‘party’ is probably a better word – brought members of the association and guests together for an entertaining hour or two. Attendees were briefly but eloquently welcomed by vice-chair Molly Laughlin.

For the first time in this event’s history the number of papers offered broke all records. The programme advisory committee (composed of six senior representatives from pipeline operators and three independent consultants) had a hard task in whittling down this number to fit the number of presentation slots available, and the result was a two-track programme on the first afternoon and a three-track programme on the second morning, with plenary sessions at the beginning and the end. This required careful planning, particularly as the main meeting room had to be split into two during the first lunch break, and the two halves then had to be combined during the second lunch break. All went smoothly with these processes, however, due to the clever design of the

Pipelines International’s Editor-in-Chief John Tiratsoo reports from the Pipeline Pigging and Integrity Management Conference and Exhibition that was held in February.

All about pigging: providing solutions to pipeline integrity

PIGGINGPIGGING

A: Attendees collecting their passes.

B: Attendees arriving for the Young Pipeline Professionals reception.

C: Attendees visiting the exhibition.

D: Aaron Lockey of Penspen, addresses the conference.

E: The Q-INLINE team.

F: The Rosen Reception kicked the event off in style.

G: Members of the Rosen group.

H: The Precision Pigging Team.

I: BJ Lowe officially opens the conference program.

J: Delegates hear from Michelle Unger of Rosen.

A

F H

I

D

J


“Competency is now a hot topic in the pipeline business, and demonstrating competency is essential in pipeline engineering.”

– Michelle Unger of Rosen Group and co-author Dr Phil Hopkins of PHL in the UK.

B

C

E G


audio-visual display by meeting planner Ayers Meetings & Events and GVP, the contractor, as well as skilful help from the hotel staff.

The main track of the conference was, unsurprisingly, pipeline pigging in its many facets, with secondary tracks considering offshore topics, crack topics, data topics, and materials’ topics. The programme began, however, with a discussion of competency in engineering presented by Michelle Unger of Rosen Group on behalf of herself and co-author Dr Phil Hopkins of PHL in the UK. As they conclude, “competency is now a hot topic in the pipeline business, and demonstrating competency is essential in pipeline engineering.” This comment was combined with the caveat that confidence does not predicate competence. The programme moved on to look at various aspects of hydrotesting, including posing questions about its

necessity for proving integrity, with contributions from Dr Mike Kirkwood and Dr Abdel Zellou of TD Williamson, Mike Rosenfeld and Dr Jing Ma of Kiefner & Assocs, and Dr Ted Anderson of Team Industrial Services.

There is, regrettably, not enough space to discuss each of the papers, the abstracts of which remain online at www.clarion.org. However – and totally subjectively – one or two highlights deserve mentioning, although their choice has been difficult. Aaron Lockey of Penspen in the UK gave a clear and precise analysis of a validated assessment method for dent fatigue, based on his work for UKOPA, and this was followed by an overview of risk as a ‘competitive advantage’ presented by Matt Byrne on behalf of him and his co-author Matt Hastings of Williams. In terms of new technologies, Steve Banks from i2i Pipelines in the UK described his company’s work in

PIGGINGPIGGING

developing data sensors that can be installed in the simplest of pigs in his paper titled ‘Sensors on everything’, and Dr Stephen Bellemare of Massachusetts Materials Technology introduced his company’s portable NDT device for evaluation a pipeline’s mechanical properties during integrity digs. Later in the programme, Rick Desaulniers of Lake Superior Consulting combined these themes with his paper on ‘Comparing apples to apples: correlating ILI with direct examination’ which gave useful guidance on this fraught subject.

As mentioned above, there was also a special afternoon conference session on cracks, co-ordinated by Sergio Limon of Limon Pipeline Analytics. Six presentations were given, and delegates were able to us the actual equipment involved at the end of the session. Of particular interest was Athena Industrial Services’ Echo 3-D, which has been under development by the

company in Calgary for a number of years. Along with the other technologies discussed from Zetec, Riccardelli Consulting Services, SGS, and Eddyfi, it’s clear that NDE for detecting and sizing cracks and seam-weld anomalies is no longer a hit-or-miss affair.

The success of the exhibition is such that there is a growing waiting list of companies eager to join in (a happy thought for the event’s organisers!), and so it was announced that next year’s event (on 27 February – 2 March) will be held at the much larger George R Brown Convention Centre and the next-door Marriott Marquis Hotel (currently under construction), in downtown Houston. The 2017 conference and its preceding training courses will be held in the hotel, while the exhibition and its social events will be held in the GRB, to which the hotel will be connected by a high-level walkway. The organisers say that there are many advantages to

this move, not least of which will be that more space will be available in the exhibition as well as for the conference, so that space for further growth can be sustained.

In signing-off from last month’s event, co-organisers BJ Lowe and this author congratulated all the authors and speakers who took part, commended the sponsors and exhibitors for their support, and thanked all who visited. It is heartening that this fascinating and important industry continues to provide solutions to almost every imaginable pipeline-integrity assessment problem, although there are still challenges to be met. PPIM is where you’ll find the answers!

It is heartening that this fascinating and important industry continues to provide solutions to almost every imaginable pipeline-integrity assessment problem, although there are still challenges to be met. For more information about future

PPIM events visit www.clarion.org

HPH 4Enduro Pipeline

HPH 3Pigs Unlimited


is reduced, implications for component strength include:

» Less capacity for pressure containment » Faster time-to-failure (TTF) for

degradation mechanisms » Higher D/t leading to reduced buckling

capacity » Lowered resistance to external forces

including localised (such as puncture) and uniform (for example, subsea hydrostatic pressure) loadings.

Therefore, weaknesses can be efficiently modelled in terms of equivalent reduction in wall thickness. More reduction in effective pipe-wall thickness is the same as forecasting increasing failure rates under assumed loading scenarios. As a modelling convenience, we ‘translate’ each weakness type – metal loss, dent, girth weld defect, axial seam crack, etc. – into an equivalent loss of wall thickness.

Whether a more robust or more modest assessment is desired, it must take into account the probabilities of various weaknesses coinciding with various loading scenarios. The general process calls for an estimate of potential loads, stresses, and strains which is overlaid with

estimates of known and suspected weaknesses due to previous damage or questionable manufacturing/construction processes (see also our previous column on Threat interaction: a case of confusing terminology).

Resistance is especially highlighted in regulatory Integrity Management Plans. Inspections and integrity assessments are essentially measurements of resistance. They may imply aspects exposure and mitigation, but they are predominantly telling us about system strength. Recall our previous example illustrating this point:

External metal loss on a typical pipeline, usually detected by inspection such as in-line inspection, actually tells us several things about every location where it is found: » Some damage has occurred. We should now

know remaining wall thickness and, hence, available strength against future loads. Even if the metal loss is not actionable, some incremental strength, perhaps inconsequential, has nonetheless been lost.

» Both of the typical mitigation measures, coating and cathodic protection, have failed.

» At least some exposure, usually soil corrosivity, exists.

The most compelling and certain of these is the first – the measure of resistance. Some knowledge of exposure and mitigation is also now available and should be included in the risk assessment, but it carries more uncertainty. For instance, when did corrosion begin? When was each of the mitigation measures lost? Was the exposure level (the soil corrosivity) constant?

Understanding that resistance prevents failure, but does so in a different way from how mitigation prevents failure, provides enormous insights into failure potential and opportunities to reduce risk.

Even though we may have few opportunities to significantly change resistance for an existing pipeline, this understanding is critical. In the design phase of a pipeline, we have the opportunity to choose the balance between mitigation and resistance levels for the changing exposure levels along the route.

This is an exercise in risk management. When done well, it ensures the safest design at the lowest cost.

RISK MANAGEMENTRISK MANAGEMENT

Recall that proper probability of failure (PoF) estimation requires independent measurement of three components:

exposure, mitigation, resistance. Without the independent measurement of each of these, we cannot fully understand PoF. When threatened by failure mechanisms (as all pipelines are) a pipeline survives by either:

1. Defending against or blocking the attacking mechanism, or

2. Absorbing or resisting the threatening force.

Let’s discuss the last of these: resistance.Resistance is the amount of damage a

component can withstand without failure. Resistance measurements tell us the difference between damage potential and failure potential.

To measure resistance in a way most useful to a risk assessment, we must estimate the possible presence of weaknesses, the rate of emergence of future weaknesses, and the role of each weakness in strength reduction. As to the last issue – the role of each weakness type – the central question to be answered is: what has been lost due to the presence of this feature? For instance, how many overpressure events, longitudinal stress loadings, fatigue cycles, vehicle impacts, etc., can now no

longer be resisted, due to the presence of this weakness? How much shorter is the time to failure from cracking or material degradation?

Varying levels of rigour are available to the risk assessment designer. The underlying engineering, physics, and material-science concepts can be complex. However, approximations often provide sufficient accuracy and will be appropriate for many types of risk assessment.

When more precision in resistance estimation is desired, pairings of specific weaknesses with specific potential loadings can be analysed using solutions up to robust finite-element analyses. For example, issues related to longitudinal-seam susceptibilities or girth-weld imperfections have dramatically different weakness implications for various loadings such as internal pressure, external forces, or cyclic fatigue.

For more approximate assessments, resistance can be efficiently captured by modelling a pressure-containing component’s effective wall thickness. Wall thickness is a very strong determinant of strength and therefore is a useful surrogate for all other strength-influencing factors.

Increasing forces or defect severities will each reduce effective wall thickness and, hence, the ability to resist additional forces. As wall thickness

Since several of our recent columns have dealt with management-of-risk issues, let’s go back now to the technical side. That is, let’s take a deeper look into an aspect of the mechanics of good risk assessment – the measuring of risk.

By W. Kent Muhlbauer, WKM Consulting, Austin, TX, USA

Damage vs failure: a risk assessment needs to know the difference

W. Kent Muhlbauer is a regular columnist for Pipelines International, author of Pipeline Risk Assessment: the Definitive Approach and its Role in Risk Management, and presenter of the Advanced Pipeline Risk Management course run internationally with Clarion Technical Conferences and Tiratsoo Technical.

For more information, visit www.pipelinerisk.net

To measure resistance in a way most useful to a risk assessment, we must estimate the possible presence of weaknesses, the rate of emergence of future weaknesses, and the role of each weakness in strength reduction.

QPH 2BMT Fleet


UPCOMING EVENTS

The international event brings together more than 500 delegates from 50 different countries in Berlin.

Participants come from all the relevant technology and service providers, and a wide range of international pipeline operators. More than 100 delegates from 50 different pipeline operators attended ptc in 2015 in order to talk about their specific requirements.

In 2016, the ptc will take place in parallel to the new Pipe and Sewer Conference (PASC). Both events will share the same exhibition hall. All delegates are free to move between 15 technical sessions and a scientific advances poster

session, with more than 100 different presentations in total. The unique gathering of pipeline, pipe and sewer professionals from all over the world will create a multitude of synergies, and furthers the exchange of experience across borders and transported media.

The upcoming 11th ptc together with the 1st Pipe and Sewer Conference will take place from 23–25 May 2016 at the Estrel Convention Center in Berlin, Germany. Following the conference and exhibition, several company workshops and technical seminars will take place directly after the event.

For more than 10 years, the international pipeline community has met annually at EITEP’s Pipeline Technology Conference (ptc).

EITEP’s pipeline conference and exhibition now to include a focus on supply networks

For more information visit www.pipeline-conference.com or www.pipeandsewer.com

ABOVE: Dr Thomas Hüwener, Managing Director Technical Services of Open Grid Europe and Vice President Gas of DVGW, delivers the keynote speech at ptc 2015.

GSP Ad 3Online Training Courses

What if you could have the acclaimed Pipeline Engineering courses from Clarion Technical Conferences and Tiratsoo Technical

right on your desktop?

NOW YOU CAN!In partnership with Penspen Integrity, Clarion and Tiratsoo Technical are pleased to announce the immediate availability of the following popular courses via online distance-learning, each of which is structured as a self-paced learning and reference resource:

> Unit 1 – Defect assessment in pipelines (17 classes) > Unit 2 – Onshore pipeline engineering (24 classes) > Unit 3 – Materials and corrosion (10 classes) > Unit 4 – Risk management of pipelines (8 classes) > Unit 5 – Geohazards (8 classes)

Purchase an entire course or targeted groups of modules of most interest. All complete course purchases receive a 20% discount.

COURSE ALUMNI: If you attended any of the public editions of these courses offered by Clarion and Tiratsoo Technical, you are eligible for a 10% discount on any of the groups of modules available, or 25% off the complete course.

For more information and to purchase the online courses, visit www.clarion.org

Online_Learning_Courses_2015_FP_Letter.indd 1 21/07/2015 10:42 am

www.pipelinesinternational.com March 2016 | Pipelines International | 63 62 | Pipelines International | March 2016 www.pipelinesinternational.com

EVENTS

The programme for the courses and workshop is:Defect assessment in pipelines, 8:00 on 2 May to 12:00 on

4 May, presented by Dr Phil Hopkins, Phil Hopkins Ltd, UKPipeline risk management, 8:00 on 2 May to 17:00 on 3 May,

presented by Kent Muhlbauer, WKM, USAPipeline in-line inspection, 8:00 on 2 May to 17:00 on 3 May,

presented by Dr Michael Beller, ROSEN Group, GermanyPipeline defect assessment workshop, 13:00 on 4 May to 12:00 on

5 May, led by Marco Pardo, ROSEN Group, Colombia.Full details in English and Spanish are at www.tiratsootechnical.com

El programa de los cursos y el taller se presenta a continuación:Evaluación de defectos en ductos, de 8:00 el 2 de Mayo a

12:00 el 4 de Mayo, presentado por el Doctor Phil Hopkins, Phil Hopkins Ltd, Reino Unido.

Gestión de riesgos en ductos, de 8:00 el 2 de Mayo a 17:00 el 3 de Mayo, presentado por Kent Muhlbauer, WKM, USA.

Inspección interna en ductos, de 8:00 el 2 de Mayo a 17:00 el 3 de Mayo, presentado por el Doctor Michael Beller, Grupo ROSEN, Alemania.

Taller de evaluación de defectos en ductos, de 13:00 el 4 de Mayo a 12:00 el 5 de Mayo, presentado por Marco Pardo, Grupo ROSEN, Colombia.

Para mayor información en inglés y español, relacionada con el evento, visite www.tiratsootecnical.com

Tiratsoo Technical and Clarion Technical Conferences, supported by the ROSEN Group, are organising three pipeline-industry training courses and a new training workshop in Bogota, Colombia, on 2–5 May 2016. Although the courses and workshop will be presented in English, simultaneous translation will be provided into Spanish throughout the event.

Tiratsoo Technical y Clarion Technical, con el apoyo del Grupo ROSEN, presentan tres cursos de capacitación en la industria de ductos e introducen un nuevo taller en evaluación de defectos en ductos en Bogotá, Colombia, del 2 al 5 de Mayo 2016. Los cursos serán representados en inglés, con traducción simultánea al español durante todo el evento.

Pipeline training in Colombia

Capacitación en Ductos en Colombia

UPCOMING EVENTS

®

®

Don’t forget these events for 2016:

PIPELINE OPERATIONS & MANAGEMENT MIDDLE EAST 2016 11–14 APRIL 2016

Manama, Bahrainwww.clarion.org

LNG 18 CONFERENCE & EXHIBITION 11–15 APRIL 2016

Perth, WA, Australiawww.lng18.org

GLOBAL PETROLEUM SHOW 2016 7–9 JUNE 2016

Calgary, AB, Canadawww.globalpetroleumshow.comNACE ITALIA 29–31 MAY 2016

Genoa, Italywww.naceitalia.it/genoa2016 SOUTH TEXAS OIL FIELD EXPO 27–28 JULY 2016

San Antonio, Texas, USAwww.southtexasoilfieldexpo.com OKC OIL FIELD EXPO 17–18 AUGUST 2016

Oklahoma City, Oklahoma, USAwww.okcoilfieldexpo.com

INTERNATIONAL PIPELINE CONFERENCE AND EXPOSITION 26–30 SEPTEMBER 2016

Calgary, AB, Canadawww.ipcyyc.com

Exhibition space availablewww.pipelineconf.com

What if you could have the acclaimed Pipeline Engineering courses from Clarion Technical Conferences and Tiratsoo Technical

right on your desktop?

For more information and to purchase the online courses, visit www.tiratsootechnical.com

Technical Training Courseswww.tiratsootechnical.com

© Jess Kraft / Shutterstock

GSP QPHPIN Wallcharts

FLORIDA

LOUISIANA

MISSISSIPPI

GEORGIAALABAMA

SOUTH CAROLINA

ARKANSAS

TEXAS

NORTH CAROLINA

TENNESSEENEW MEXICOOKLAHOMA

ARIZONA

KENTUCKY VIRGINIA

MARYLAND

DELAWARE

KANSAS

MISSOURI

WEST VIRGINIA

COLORADO

NEW JERSEY

INDIANA

OHIO

NEVADA UTAH

CALIFORNIA

RHODE ISLAND

CONNECTICUT

PENNSYLVANIA

ILLINOIS

MASSACHUSETTS

NEBRASKA

IOWA

WYOMING

NEW YORK

VERMONT

NEW HAMPSHIRE

MICHIGAN

SOUTH DAKOTA

OREGON

WISCONSIN

MAINE

NORTH DAKOTA

IDAHO

MONTANA

WASHINGTON

MINNESOTA

BRITISH COLUMBIA

ALBERTASASKATCHEWAN

MANITOBAQUEBEC

NEWBRUNSWICK

ONTARIO

BAJACALIFORNIA

SONORA

CHIHUAHUA

COAHUILA

NUEVOLEÓN

TAMAULIPAS

DURANGO

SINALOABAJA

CALIFORNIASUR

San Antonio Houston

El Paso

Jacksonville

Dallas

San Diego

Memphis

Los AngelesCharlotte

San Jose

San FranciscoBaltimore

Chicago

Philadelphia

Detroit

Milwaukee

New York

Portland

Seattle

Austin

Tallahassee

Jackson

Montgomery

Phoenix Atlanta

Little Rock

Oklahoma City

Columbia

Santa FeNashville

Raleigh

Jefferson City

Topeka

Frankfort

Denver

CharlestonRichmond


SacramentoLincolnCarson City

Cheyenne

Columbus

Salt Lake City

Annapolis

Des MoinesHarrisburg

Trenton

Madison

Lansing

Pierre

Boise

Hartford

Saint Paul

Albany Boston

Concord

Bismarck

HelenaSalem

Montpelier

Augusta

Olympia

Washington D.C.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

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18*

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20*

21*

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26*

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28*

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31*

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34

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36

37

39*

40*

0

0 500 km250 km125 km


CANADAALASKA

38

0

0 500 km

500 miles


LENGTH (miles)

1 El Paso Natural Gas Pipeline System Kinder Morgan Gas 6,182 MMcf/d 10,200

2 Algonquin Gas Transmission Spectra Energy Partners Gas 3,347 MMcf/d 1,129

3 Texas Eastern Transmission Spectra Energy Partners Gas 7,332 MMcf/d 9,022

4 Tennessee Gas Pipeline Kinder Morgan Gas 6,686 MMcf/d 13,900

5 Panhandle Eastern Pipeline Panhandle Energy Gas 2,840 MMcf/d 6,445

6 Northern Natural Gas Pipeline Northern Natural Gas Gas 7,442 MMcf/d 14,700

7 ANR Pipeline ANR Pipeline Company Gas 7,129 MMcf/d 10,600

8 Transcontinental Gas Pipeline Williams Gas 8,466 MMcf/d 10,500

9 Gulf South Pipeline Gulf South Pipeline Company Gas 6,260 MMcf/d 6,886

10 Natural Gas Pipeline Co of America Kinder Morgan Gas 4,848 MMcf/d 9,200

11 Florida Gas Transmission Pipeline Florida Gas Transmission Company Gas 2,217 MMcf/d 4,889

12 Kern River Gas Transmission Pipeline Kern River Gas Transmission Company Gas 1,833 MMcf/d 1,680

13 Trunkline Pipeline Panhandle Energy Gas 3,025 MMcf/d 4,202

14 Texas Gas Transmission Boardwalk Pipelines Gas 4,065 MMcf/d 5,671


LENGTH (miles)

15 Southern Star Central Pipeline Southern Star Gas 2,801 MMcf/d 5,803

16 Dominion Pipeline Dominion Resources Gas 6,655 MMcf/d 3,505

17 Colorado Interstate Gas Pipeline Kinder Morgan Gas 4,099 MMcf/d 4,300

18 Alliance Pipeline System* Alliance Pipeline Gas 2,053 MMcf/d 2,311

19 Columbia Gulf Transmission Columbia Pipeline Group Gas 2,386 MMcf/d 4,124

20 Northern Border Pipeline* TC PipeLines; ONEOK Partners Gas 2,400 MMcf/d 1,408

21 Great Lakes Gas Transmission Pipeline* Great Lakes Gas Transmission Company Gas 2,958 MMcf/d 2,115

22 Transwestern Interstate Pipeline Energy Transfer Gas 2,439 MMcf/d 2,560

23 Questar Pipeline Questar Pipeline Gas 3,192 MMcf/d 1,858

24 Wyoming Interstate Pipeline Kinder Morgan Gas 2,736 MMcf/d 800

25 Centerpoint Energy Gas Transmission CenterPoint Energy Gas 5,385 MMcf/d 6,374

26 Northwest Pipeline* Williams Gas 4,950 MMcf/d 3,880

27 Southern Natural Gas Company System Kinder Morgan Gas 3,967 MMcf/d 7,635

28 Gas Transmission Northwest* TransCanada Gas 2,636 MMcf/d 1,356


LENGTH (miles)

29 Columbia Gas Transmission NiSource Gas Transmission & Storage Gas 9,350 MMcf/d 10,365

30 National Fuel Gas Supply Corporation System National Fuel Gas 2,312 MMcf/d 2,300

31 Keystone Pipeline* TransCanada Crude oil - 2,639

32 Seaway Pipeline Enterprise Products Partners; Enbridge Crude oil 850,000 bbl/d 500

33 Gulf Coast Project TransCanada Crude oil 700,000 bbl/d 485

34 Longhorn Pipeline Magellan Midstream Partners Crude oil - 700

35 Double H Pipeline Hiland Partners Crude oil 84,000 bbl/d 485

36 Pony Express Pipeline Tallgrass Energy Crude oil 230,000 bbl/d 690

37 Olympic Pipeline BP Crude oil 315,000 bbl/d 400

38 Trans-Alaska Pipeline System Alyeska Pipeline Service Company Crude oil - 800

39 US Mainline (Lakehead System)* Enbridge Crude oil 2,600,000 bbl/d 1,900

40 Alberta Clipper* Enbridge Crude oil 800,000 bbl/d 1,000

MAJOR PIPELINE SYSTEMS OF THE USA










0

0 300 km150 km

300 miles150 miles

123

45

6

7

8

9

10

1112 13 14

15

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1718

19

20

21

22

YUKON TERRITORY

NORTHWEST TERRITORIES

NUNAVUT

BRITISH COLUMBIA

ALBERTA

SASKATCHEWAN

MANITOBA

ONTARIO

QUEBEC

NEWFOUNDLAND&

LABRADOR

NEW BRUNSWICK

NOVASCOTIA

PRINCEEDWARDISLAND

Kamloops

Lethbridge

Red Deer

Kingston

Moncton

DrummondvilleTrois-Rivieres

Brandon

Moose Jaw

Saint John

Richmond

Thunder Bay

Saskatoon

Brampton

VancouverCalgary

London

Montreal

Hamilton

Edmonton

Toronto

HalifaxQuebec

Winnipeg

Regina

Victoria

St. John's

Fredericton

Yellowknife

Whitehorse

Charlottetown

Iqaluit

Ottawa

KEYNAME OWNER PRODUCT LENGTH DIAMETER

1 Alberta Clipper (Line 67) * Enbridge Inc. Crude oil 1,069 km 36 inches

2 Alliance Pipeline * Enbridge Inc. (50%); Versan (50%) Natural gas 1,560 km 36–42 inches

3 Brunswick Pipeline Emera Brunswick Pipeline Company Natural gas 143 km 30 inch

4 Canadian Mainline TransCanada Pipelines Natural gas 14,114 km 36 inch

5 Cochin Pipeline System Kinder Morgan Propane and ethane-propane 995 km 12 inches

6 Deep Panuke Pipeline Encana Corporation Natural gas 175 km

7 Enbridge Pipelines (NW) Inc. System Enbridge Inc. Crude oil 855 km

8 Enbridge Mainline * Enbridge Inc. Crude oil 2,306 km 30–36 inches

9 Enbridge Westspur Pipeline Enbridge Inc. Crude oil 175 km 12 inches

10 Enbridge Southern Lights (Line 13) * Enbridge Inc. Crude oil 1,241 km 20 inches

11 Express-Platte Pipeline System * Spectra Energy Crude oil 434 km 24 inch

12 Foothills Pipeline System TransCanada Pipelines Natural gas 1,241 km 36–42 inches

13 Keystone Pipeline * TransCanada Pipelines Crude oil 1,227 km 30–36 inches

14 Maritimes and Northeast Pipeline Spectra Energy (77.53%); Emera (12.92%); ExxonMobil Corporation (9.55%) Natural gas 575 km 30 inch

15 Nova Gas Transmission Pipeline System (NGTL) TransCanada Pipelines Natural gas 24,373 km 16–42 inches

16 Ontario–Quebec Pipeline TransNorthern Pipeline Inc. Refi ned fuel products 850 km

17 PTC Pipeline Spectra Energy Natural gas liquids 930 km

18 Trans Mountain Pipeline System Kinder Morgan Crude oil and refi ned products 1,142 km 24–36 inches

19 TransQuebec and Maritimes Pipeline Mainline TransCanada Pipelines (50%), Gaz Metro (50%) Natural gas 572 km

20 Westcoast Pipeline System (B.C Pipeline) Spectra Energy Natural gas 2,900 km 24–42 inches

21 Dawn to Parkway Trunkline Union Gas Natural gas 257 km

* Pipeline continues into United States of America.

The Major Pipeline Systems of Canada map provides an overview of existing major pipeline systems in Canada that are over 100 km in length. The map includes the name, owner, product, approximate length and diameter of the pipeline.

Information used to collate this map was directly provided by companies, the National Energy Board (NEB) and the Canadian Energy Pipeline Association (CEPA).

Information on this map is intended as a general source of information only. Compiled and published by Great Southern Press Pty Ltd. Tel: +61 3 9248 5100




With the support of:


MAJOR PIPELINE SYSTEMS OF CANADAA detailed overview of select existing major pipeline systems in Canada.

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Upcoming wallcharts include the Major Pipeline Systems of the United States.

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ADVERTISERS’ INDEX

Allu Finland 18

American Augers OBC

Anticorrosion Protective Systems L.L.C. 14

BMT Fleet Technology Ltd 59

Canusa CPS 13

E-Z Line Pipe Support company, Inc. 42

Enduro Pipeline Services 57

Girard Pipeline Pigs 53

International Pipeline Conference and Exposition 2016 19

LNG 18 17

NACE Milano Italia Section 23

NDT Global IFC

Pigs Unlimited International 56

Power Associates International Inc 45

Quest Integrity Group 1

Romstar Group 3

Rosen Technology & Research Center GmbH 5

STATS Group 15

TESMEC S.p.A. 11

Vermeer 21

In the next edition of

Flexible pipelines, featuring a case study from Technip

ALSO FEATURED

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Operational piggingA frontline tool to control internal corrosion of pipelines

India region reviewIncluding an exclusive from GAIL

Robotic ILICase study of a Transco pipeline in an urban area



Page 46


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Creating an effective crack management programme

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ISSUE 26 | DECEMBER 2015

Investigating pipeline airborne leak detection

Page 14

Cover story:Record pipelaying in the Norwegian SeaPage 42

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Major Pipeline Systems of the USAThis wallchart displays route and pipeline information for select major US pipelines.

FLORIDA

LOUISIANA

MISSISSIPPI

GEORGIAALABAMA

SOUTH CAROLINA

ARKANSAS

TEXAS

NORTH CAROLINA

TENNESSEE

NEW MEXICO

OKLAHOMA

ARIZONA

KENTUCKY VIRGINIA

MARYLAND

DELAWARE

KANSAS

MISSOURI

WEST VIRGINIA

COLORADO

NEW JERSEY

INDIANA

OHIO

NEVADA UTAH

CALIFORNIA

RHODE ISLAND

CONNECTICUT

PENNSYLVANIA

ILLINOIS

MASSACHUSETTS

NEBRASKA

IOWA

WYOMING NEW YORK

VERMONT

NEW HAMPSHIRE

MICHIGAN

SOUTH DAKOTA

OREGON

WISCONSIN

MAINENORTH DAKOTAIDAHO

MONTANA

WASHINGTON

MINNESOTA

BRITISH COLUMBIA

ALBERTASASKATCHEWAN

MANITOBA

QUEBEC

NEWBRUNSWICK

ONTARIO

BAJACALIFORNIA

SONORA

CHIHUAHUA

COAHUILA

NUEVOLEÓN

TAMAULIPAS

DURANGO

SINALOABAJA

CALIFORNIASUR

San Antonio Houston

El Paso

Jacksonville

Dallas

San Diego Memphis

Los Angeles

Charlotte

San Jose

San Francisco

Baltimore

Chicago

Philadelphia

Detroit

Milwaukee

New York

Portland

Seattle

AustinTallahassee

Jackson

Montgomery

Phoenix

Atlanta

Little Rock

Oklahoma City

Columbia

Santa FeNashville

Raleigh

Jefferson City

Topeka

Frankfort

Denver

Charleston

Richmond


SacramentoLincoln

Carson CityCheyenne

Columbus

Salt Lake City

Annapolis

Des Moines

HarrisburgTrenton

Madison

Lansing

Pierre

Boise

Hartford

Saint Paul

Albany Boston

Concord

Bismarck

HelenaSalem

Montpelier

Augusta

Olympia

Washington D.C.

1

2

3

4

5

6

7

8

9

10

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1213

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20*

21*

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40*

0

0500 km250 km125 km


CANADAALASKA

38

0

0 500 km

500 miles

KEYNAME

OWNER PRODUCT CAPACITY LENGTH (miles)

1 El Paso Natural Gas Pipeline System Kinder Morgan Gas 6,182 MMcf/d 10,2002 Algonquin Gas Transmission Spectra Energy Partners Gas 3,347 MMcf/d 1,1293 Texas Eastern Transmission Spectra Energy Partners Gas 7,332 MMcf/d 9,0224 Tennessee Gas Pipeline Kinder Morgan Gas 6,686 MMcf/d 13,9005 Panhandle Eastern Pipeline Panhandle Energy Gas 2,840 MMcf/d 6,4456 Northern Natural Gas Pipeline Northern Natural Gas Gas 7,442 MMcf/d 14,7007 ANR PipelineANR Pipeline Company Gas 7,129 MMcf/d 10,6008 Transcontinental Gas Pipeline Williams

Gas 8,466 MMcf/d 10,5009 Gulf South Pipeline Gulf South Pipeline Company Gas 6,260 MMcf/d 6,88610 Natural Gas Pipeline Co of America Kinder Morgan Gas 4,848 MMcf/d 9,20011 Florida Gas Transmission Pipeline Florida Gas Transmission Company Gas 2,217 MMcf/d 4,88912 Kern River Gas Transmission Pipeline Kern River Gas Transmission Company Gas 1,833 MMcf/d 1,68013 Trunkline Pipeline Panhandle Energy Gas 3,025 MMcf/d 4,20214 Texas Gas Transmission Boardwalk Pipelines Gas 4,065 MMcf/d 5,671

KEYNAME


15 Southern Star Central Pipeline Southern Star Gas 2,801 MMcf/d 5,80316 Dominion Pipeline Dominion Resources Gas 6,655 MMcf/d 3,50517 Colorado Interstate Gas Pipeline Kinder Morgan Gas 4,099 MMcf/d 4,30018 Alliance Pipeline System* Alliance Pipeline Gas 2,053 MMcf/d 2,31119 Columbia Gulf Transmission Columbia Pipeline Group Gas 2,386 MMcf/d 4,12420 Northern Border Pipeline* TC PipeLines; ONEOK Partners Gas 2,400 MMcf/d 1,40821 Great Lakes Gas Transmission Pipeline* Great Lakes Gas Transmission Company Gas 2,958 MMcf/d 2,11522 Transwestern Interstate Pipeline Energy Transfer Gas 2,439 MMcf/d 2,56023 Questar Pipeline Questar Pipeline Gas 3,192 MMcf/d 1,85824 Wyoming Interstate Pipeline Kinder Morgan Gas 2,736 MMcf/d 80025 Centerpoint Energy Gas Transmission CenterPoint Energy Gas 5,385 MMcf/d 6,37426 Northwest Pipeline* WilliamsGas 4,950 MMcf/d 3,88027 Southern Natural Gas Company System Kinder Morgan Gas 3,967 MMcf/d 7,63528 Gas Transmission Northwest* TransCanada Gas 2,636 MMcf/d 1,356

KEYNAME


29 Columbia Gas Transmission NiSource Gas Transmission & Storage Gas 9,350 MMcf/d 10,36530 National Fuel Gas Supply Corporation System National Fuel Gas 2,312 MMcf/d 2,30031 Keystone Pipeline* TransCanada Crude oil - 2,63932 Seaway Pipeline Enterprise Products Partners; Enbridge Crude oil 850,000 bbl/d 50033 Gulf Coast Project TransCanada Crude oil 700,000 bbl/d 48534 Longhorn Pipeline Magellan Midstream Partners Crude oil - 70035 Double H Pipeline Hiland Partners Crude oil 84,000 bbl/d 48536 Pony Express Pipeline Tallgrass Energy Crude oil 230,000 bbl/d 69037 Olympic Pipeline BPCrude oil 315,000 bbl/d 40038 Trans-Alaska Pipeline System Alyeska Pipeline Service Company Crude oil - 80039 US Mainline (Lakehead System)* Enbridge Crude oil 2,600,000 bbl/d 1,90040 Alberta Clipper* Enbridge Crude oil 800,000 bbl/d 1,000

MAJOR PIPELINE SYSTEMS OF THE USACompiled and published by Great Southern Press Pty Ltd. Tel: +61 3 9248 5100

Product information and graphic design © Great Southern Press, 2016. Source map courtesy Map Resources.www.mapresources.com.au







Pipelines International (four issues)

PIPELINECONSTRUCTION

The Construction Spread Poster provides a visual representation of the major stages involved in the construction of an onshore pipeline, as well as a description of the main equipment and machinery used at each stage.

This poster is a schematic representation of some of the machinery and equipment used in pipeline construction, and shows generic depictions of these. It does not show specific brands of machinery.


Product information and graphic design © Great Southern Press, 2015.


9248 5100

1 CLEARING AND GRADINGThe pipeline right-of-way is cleared and graded to prepare for construction. Where possible, the larger trees will remain and special care is taken to ensure areas of heritage or environmental significance are not disturbed.

2 STRINGING AND BENDINGSections of pipe are placed along the right-of-way in preparation for welding. Some of these pipes may require bending depending on the pipeline alignment.

4 WELDINGPipe is welded together above ground on timber skids to form long strings of pipe. The welders are highly-skilled tradesmen who perform to stringent quality procedures. After the pipe has been welded, a grinder is used to smooth the weld seam.

7 LOWERING INThe pipeline is lowered into the trench. The pipe is ‘jeeped’ to ensure that any pipe coating imperfections (holidays) in the parent or field joint coating are identified and repaired prior to its placement in the trench.

8 PADDING AND BACKFILLINGFine soil is placed around the pipeline in the trench to protect it from its surroundings. Padding beneath a pipeline is referred to as ‘bedding’ while padding covering a pipeline is known as ‘shading’. After shading, the remaining excavated material is placed to fill the balance of the trench in a process known as backfilling. As an alternative to bedding, sometimes the pipeline is placed on foam pipe pillows inside the trench and, in this case, only shading is required.

9 HYDROSTATIC TESTINGA final integrity check of the pipeline is undertaken where water is pumped into the pipeline and held to a predetermined pressure higher than the maximum allowable operating pressure. It is generally held for four hours for a strength test, and then for 24 hours for a leak test. The pressure is monitored during this time and any pressure losses are accounted for to ensure that the pipeline can be safely commissioned. Prior to testing the pipeline, a pig is run through the pipeline to check the roundness of the pipe, then another pig is run through it to clean it of debris. After hydrostatic testing, the pipeline is typically dried to a dewpoint of -20° Celsius.

Excavators, graders and dozers undertake bulk earthworks to ensure that a level working platform is achieved to safely undertake subsequent activities.

Graders scrape the seed stock and topsoil to be safely placed in stockpiles along the right-of-way extremities until reinstatement.

A series of pipelayers with roller cradles attached lower the pipe into the trench.

A padding machine sifts out larger material such as rock and gravel from the excavated material, leaving smaller fine material (padding) to support and protect the pipeline.

Bulldozers clear the scrub and foliage.

A fleet of bucket wheel and saw trenching machines are deployed to excavate a trench to the required design, into which the pipeline is laid. In hard rock conditions, excavators with hydraulic drill attachments or drill and blast techniques can be used as alternatives to mechanical trenching machines.

5 NON-DESTRUCTIVE TESTINGNon-destructive testing is performed prior to the coating and lowering in of the pipeline to ensure the integrity of each weld is maintained. A number of methods can be used, including X-ray, ultrasonic and visual.

6 FIELD JOINT COATINGAfter the pipe has been welded and cleared with non-destructive testing, the pipeline is grit-blasted to a profile that facilitates maximum adherence between the field joint coating system and the steel pipe. Field joint coating is an external coating system applied to the welded joint to protect the metallic surface from corrosion and mechanical impacts.

10 REINSTATEMENTThe right-of-way is returned to its original state prior to construction in a process that is crucial to reducing the pipeline’s long-term environmental impact.

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An excavator with a vacuum pipelifter attachment is often used to lift pipe and place it continuously alongside the right-of-way, ready for welding, in a process called stringing.

Prime movers with 18 m extendible trailers are used to transport pipe from the pipe manufacture or pipe storage facilities directly to the right-of-way.

Hydraulic bending machines are used to cold-bend lengths of steel pipe to the contour and radius of the designed trench prior to welding. For tighter bends, induction or ‘hot’ bends are used, and these are fabricated offsite with purpose-built machines that heat the pipe to soften the steel and make it pliable.

Occasionally, a protective wrap can be applied after field joint coating for additional pipeline protection. The wrap shields the pipeline coating from damaging backfill, and acts as an additional line of defence against corrosion.

Coating systems can vary from the application of tape or a heat shrink sleeve to a liquid or powder-spray epoxy, which is applied over the weld.

In Australia, pipe diameters are generally of a smaller diameter, over long distances. The high-speed nature of cross-country pipelines lends the welding method to a manual vertical-down cellulous welding procedure.

For larger diameters, an automated welding system is used, with automatically controlled machines (bugs) manipulating welding conditions such as arc length and travel speeds while the process is monitored by a welding machine operator.

An optional further integrity check involves running a calliper or intelligent pig. A calliper pig operation is usually undertaken as part of the commissioning process, or as a periodic integrity check during operations.

3 TRENCHINGA trench is dug, into which the pipeline is laid.



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Page 10

Cover story:Saudi Aramco General Manager Pipelines Mohammed Sultan Al-Qahtani exclusivePage 30

Creating an effective crack management programme

Page 34

ISSUE 26 | DECEMBER 2015

Investigating pipeline airborne leak detection

Page 14

Cover story:Record pipelaying in the Norwegian SeaPage 42

cover story: read about saudi aramco's plans for the future. saudi

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