pipeline journal 12.2009

DECEMBER 2009ISSUE 002

PiggingPipelayersGASTAU Pipeline

United StatesREVIEW

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2 PiPelines international | DeCeMBer 2009

issue 002 | DeCeMBer 2009

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ers. The publishers do not accept responsibility for any claims

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reGULArs4 From the Editor15 Pipes & People61 Media Kit64 Advertisers’ Index Subscriptionform Comingin future issues

AroUND the WorLD6 TransCanada supersizes

Keystone project7 IP Pipeline moves forward

after much discussion8 Technological breakthrough crucial for

Second West – East Gas Pipeline9 South Stream: providing more

gas to Europe10 Peru to complete Camisea pipeline

expansion ahead of schedule11 Egyptian pipeline complete12 World Wrap14 Project briefs

meet the compANy16 Enagás: expanding pipelines

in Europe

reGioN reVieW: UsA18 Pipeline development in

the land of the free23 REX appeal: pipeline construction

in the Rockies

terrAiN reVieW24 Protecting pipelines in mountain areas

poLicy AND opiNioN26 Canadian perspective: a goal-oriented

approach to regulating pipelines

techNicAL28 Environmental navigation of German

landfall and modelling pull-back operations

projects30 GDK: innovative pipeline construction

on GASTAU33 Pipeline link constructed

in central Australia

pipLiNe eQUipmeNt35 Pipelayers and sidebooms: the

essential pipeline machinery38 Pipelaying with the PL61

piGGiNG40 Optimal identification: getting up close

with ID anomalies43 GE’s MagneScan inspects

Normandy pipeline 44 Prickly pigging: PipeWay’s Porcupine

reaches the international market45 PPSA: providing squeaky clean pigging

advice46 Ensuring pipeline integrity:

talking pigging in Houston

VALVes48 5 simple steps to

total valve integrity

tech tALK50 A place for science in pipeline design

iNDUstry NeWs52 CTDUT: a model for sharing facilities

and costs in research and development

history54 Trans-Mediterranean Pipeline

proDUcts AND serVices56 Learn to weld with Lincoln Electric’s

virtual welding system56 Production begins on world’s largest

three-screw crude oil pipeline pump56 Latest edition of WinDOT – the

Pipeline Safety Encyclopedia56 Cure pipes with Curapipe

eVeNts57 Pipeline carnivale in Rio!58 Evaluating different

rehabilitation approaches59 Pipeline Technology Conference:

a scientific update from Ostend60 APCE: pipeline success in

South East Asia60 Australian industry gathers

in northern Australia

24 26 54

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It seems a paradox: 10–15 years ago, as intelligent inspection was developing and the science was coming into its

own, a major point of discussion was to do with the technology itself. The big question was “high resolution or low resolution?”, relating to the capacity of the equipment to detect pipewall features. Putting this another way, did the operator want a ‘quick-and-dirty’ (and therefore cheap) inspection, or was the ‘Full Monty’ required? The issue revolved around the capacity of the intelligent inspection tools to inspect, and the cleanliness of the pipeline that the tool was to inspect was sometimes considered of less significance.

Now, however, intelligent inspection tools are of an unimaginably greater sophistication, and the general question being asked is no longer to do with their capacity to accurately and precisely detect features, but to do with how clean the pipeline is. A pipeline’s internal cleanliness has, quite properly, become a question of great significance. Nevertheless, there are no published standards of cleanliness and although there are many ways in which deposits can be removed from a pipe wall, ensuring a pipeline is clean enough for an inspection to be carried out remains a subjective process.

It has often been said that the best cleaning tool is a magnetic-flux leakage intelligent pig, and this remains true. While it is clear that each pipeline and its operating regime are different, it seems surprising that it has not been found possible to establish some basic guidelines for achieving cleanliness. Under normal operating conditions, minimisation of pipewall deposits will improve flow conditions as well as a pipeline’s overall efficiency and cost-effectiveness, to say nothing of the effect on reducing the potential for corrosion. When it’s time for an inspection, deposits and other debris must be removed, both to ensure that the tool’s sensors can have unimpeded access to the pipewall, and to remove the possibility of debris clogging-up the tool, and even causing it to become stuck.

The question of ‘how clean is clean?’ is not unfamiliar and, in fairness, is being asked more frequently. One of the most detrimental cleaning problems for gas pipelines is the formation and accumulation of so-called ‘black powder’.

This material – which is as fine as flour, although far more dangerous because it is both abrasive and pyrophoric – is one of the least understood but most prominent contamination problems in gas pipelines. Black powder is the name given to the mixture of iron oxides, carbonates, and sulphides found in gas lines. Its sources include millscale, corrosion products, salts and scales from gas wells and wet gas gathering systems, and atmospheric corrosion. The variability of its composition is illustrated by reports of the powder ranging from being completely iron sulphide to completely iron oxide.

Black powder can cause product quality problems and excessive wear and erosion on internal pipewalls and many other pipeline components, including compressors, turbines, and valves. The accumulated solids can plug small orifices and consequently affect measurement equipment and, as the particles settle out of the gas stream, they can fill-in surface pits and other internal pipewall anomalies, preventing accurate inspection. In sag bends, these build-ups can harbour corrosive bacteria.

Although difficult to deal with, the problems caused by accumulations of this material can be overcome – as can most pipeline problems – by careful planning and attention to detail. However, removal of the black powder from the pipeline is not the end of the affair. As the material is hazardous, necessary arrangements for its disposal must be made, and obviously these should be in place before any pigging operations begin.

A special session on this problem is being organised at the Pipeline Pigging and Integrity Management (PPIM) Conference being held in Houston on 17–18 February (see page 46), and other papers at the event will also address the issue.

The more the subject of ‘how clean is clean?’ can be discussed, the more likely it is that shared experiences can lead to a shared solution; at the very least, ‘clean’ needs to be kept in the spotlight of pipeline integrity management and operations.

John TiratsooEditor-in-Chief

froM the eDitor

DECEMBER 2009ISSUE 002

PiggingPipelayersGASTAU Pipeline

United StatesREVIEW

Cover shows workers finalising pipe stringing on a portion of Enbridge’s Alberta Clipper Pipeline project, a 36 inch, 450,000 barrels per day crude oil pipeline from Hardisty, Alberta, Canada, to Superior, Wisconsin, USA.

Editor-in-Chief: John TiratsooAssociateEditor: Lyndsie MewettProductManager: Scott PearceJournalists: Stephanie Clancy Julia CookeSalesManager: Tim ThompsonSnrAccountManager: David MarshSalesRepresentative: Brett ThompsonDesignManager: Michelle BottgerDesigners: Sandra Noke Stephanie Rose Venysia KurniawanPublisher: Chris Bland

ISSN: 1837-1167

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February 15-16 Pipeline Risk Management (Houston)

February 15-16 Performing Pipeline Rehabilitation (Houston)

February 15-16 DOT Pipeline Safety Regulations - Overview and Guidelines for Compliance (Houston)

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April 12-16 Practical Pigging Training (Rio de Janeiro)

April 20-23 Engineering for Arctic Environments (Houston)

April 26-27 Microbiological Corrosion in Pipelines (Houston)

April 26-30 Subsea Pipeline Engineering Course (Houston)

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PiPelines international | DeCeMBer 2009 7

TransCanada is seeking regulatory approvals in Canada and the United States to construct and operate a 3,200 km expansion of its 3,456 km Keystone Pipeline, which would make it one of the largest oil delivery systems in North America.

In September 2009, Canada’s National Energy Board held a hearing to review the application for the Canadian

portion of the Keystone Gulf Coast expansion – dubbed Keystone XL – with a decision expected in early 2010. Permits for the US portion of the expansion are expected by mid-2010. Construction of the Keystone expansion is expected to begin once TransCanada receives the necessary regulatory approvals.

The proposed Keystone XL Pipeline would increase the capacity of the original pipeline system from Western Canada to the US Gulf Coast by 500,000 barrels of oil per day. Once completed, the pipeline system would have the capacity to deliver 1.1 million barrels of oil per day.

The extension is proposed to originate in Alberta, Canada, and extend south to serve markets on the Gulf Coast, Texas.

The 36 inch diameter pipeline would begin in Hardisty, Alberta, and travel 527 km to Monchy, Saskatchewan, and then 1,360 km from Morgan, Montana, to Steele City, Nebraska, where it would link

into the original 477 km Keystone Pipeline extension to Cushing, Oklahoma, scheduled for construction in 2010. From Cushing, Keystone XL will run to Houston and Port Arthur, Texas.

The total cost of the Keystone and Keystone XL project is expected to be approximately $US12 billion.

Meanwhile, the initial phase of TransCanada’s Keystone Pipeline is nearing completion with the pipelay works set to reach Patoka, Illinois, by the first quarter 2010.

At the time of writing, the first phase of the project was 90 per cent complete, with TransCanada on schedule to begin oil deliveries in the first quarter of 2010.

The Keystone Pipeline originates in Alberta, Canada, and extends 3,456 km to oil refineries in Wood River and a tank farm in Patoka, Illinois.

The first phase involves the construction of 2,592 km of pipe and the conversion of 864 km of natural gas pipeline to oil service. Converting the existing facilities in Canada began in 2008.

TransCanada supersizes Keystone project


arounD the worlD arounD the worlDarounD the worlD

Iran has completed a major portion of the construction work on the Iran – Pakistan (IP) Pipeline project with the gas pipeline to reach the Iran – Pakistan border within the next few months, according to the Iranian Consul General based in Pakistan, Masoud Mohammad Zamani.

Iranian Foreign Minister Manouchehr Mottaki has said that over 100 km of the 1,935 km pipeline project has been

constructed in Iran. Pakistan has also started construction on the project, added Mr Mottaki.

With an anticipated gas capacity of 26,485 cubic feet per annum, the 42 inch diameter gas pipeline will run from the Assaluyen Gas Field in southern Iran to Pakistan.

Formerly called the Iran – Pakistan – India Pipeline, the project has been under discussion for almost two decades and initially intended to include India. However, when Iran and Pakistan signed a gas sales purchase agreement for the pipeline project in May this year, India refrained from

partaking in signing the agreement due to security concerns about the pipeline.

In July 2009, the Iranian Ministry of Petroleum and Natural Resources announced that supply of gas from Iran has been scheduled for October 2013.

The Pakistani Economic Co-ordination Committee (ECC) approved the $US3.2 billion Iran – Pakistan gas pipeline the following month. A sub-committee of the ECC decided that the route of the pipeline would mainly run through the state of Balochistan, in Pakistan.

Pakistan Federal Minister for Petroleum and Natural Resources told local media that only local companies would be involved in the project.

In September, the Pakistani ambassador to Iran Muhammad Bux Abassi claimed

that India had definitely quit the pipeline, however Iranian officials are said to have denied these comments. Officials from Iran and Pakistan said that the option remains open for India to join the project at a later stage, but Iran said that it would not wait indefinitely for India to commit to the project.

Shortly after, the Iranian Ambassador to India Seyed Mehdi Nabizedeh told local news sources that China was interested in the project, but no formal agreements have since been made.

The original Iran – Pakistan – India Pipeline was proposed to be 2,670 km long, running from the Assaluyen gas field in southern Iran to the Gas Authority of India Limited’s Hazira – Vijaipur – Jagdishpur Pipeline in Gujarat.

IP Pipeline moves forward after much discussion

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Europe’s energy demand continues to grow, with an additional 205 billion cubic metres of natural gas estimated to be required by 2030. Gazprom’s South Stream Pipeline will make an important contribution to improving Europe’s energy security.

South Stream: providing more gas to Europe

arounD the worlD arounD the worlDarounD the worlD

The South Stream Pipeline will deliver gas from the Russian Unified Gas System, which sources its gas from Russian

domestic gas sources and Central Asian gas suppliers, to Europe via the Black Sea.

The pipeline involves the construction of three sections of pipeline: an onshore Russian section, an offshore section, and an onshore south and central European section.

Onshore route selectionThe Russian onshore section of the

pipeline will run from the Pochinki Compressor Station to the Black Sea coast. A feasibility study is currently underway to select the route for this section of pipeline.

Several possible routes for the onshore south and central Europe sections are currently being considered. Gazprom has negotiated inter-governmental agreements with Greece, Serbia and Bulgaria, which

contemplate the creation of joint venture enterprises between Gazprom and local companies to develop and operate the South Stream Pipeline on their territories. Gazprom is currently in the process of starting those joint ventures with its partners.

Offshore challengesThe offshore section of South Stream

will extend 900 km across the Black Sea at depths of up to 2 km and connect the Russian and Bulgarian coasts. Italian company Eni will partner Gazprom in the offshore construction of the project.

Gazprom and Eni have gained experience in the course of construction and operation of the Blue Stream Pipeline across the Black Sea. Gazprom says that Blue Stream has demonstrated that the construction of subsea projects has only a temporary and local effect on the marine environment,

and the risk of potential pollution can be effectively minimised.

Currently, Gazprom and Eni are carrying out a detailed feasibility study of the project’s offshore section, which is scheduled to be completed in the beginning of 2010. At the conclusion of the study the pipeline route, technical requirements and capacity will be finalised.

Speaking about the progress of the pipeline, Gazprom Management Committee Chair Alexey Miller said “We have the technical know-how required to build South Stream in compliance with the latest environmental and technological requirements, and we are making significant progress on the pipeline. We are currently carrying out feasibility studies which will allow more accurate routeing.”

Pipeline construction works are scheduled to be completed by the end of 2015.


The 8,704 km pipeline consists of one trunk link and eight branches that will connect Horgos, located in Xinjian

Uygur Autonomous Region with the Hong Kong Special Administrative Region after traversing 14 provinces, autonomous regions and municipalities.

CNPC has successfully incorporated technological breakthroughs from six of its research projects to support the construction.

Seven new products have been developed and manufactured domestically on an industrial scale. These products include large diameter, high grade steel pipe materials, spiral submerged arc welded pipes, hot bending bends and hot-drawn T-joint pipe fittings.

The new X80 steel welding wire and flux increased welding speed by up to 1.7 m per minute, which is 30 per cent higher than the speed achieved on the first West – East Gas Pipeline.

Welders on the Second West – East pipeline received guidance on more than 100 techniques developed through the project including automatic welding, semi-automatic welding, joint-connecting welding and rework welding of the X80 steel pipes. Significant progress was also made in fracture control, anti-corrosion field coating, gas storage location, integrity management technologies, and safety pre-warning technologies, which have benefited the construction and safe operation of the pipeline.

Pipeline progress The project has been divided into

eastern and western sections with Zhongwei, located in Ningxia Hui Autonomous Region, designated as the pipeline’s midpoint. The western section, running 2,461 km

from Horgos to Zhongwei, commenced construction in February 2008 and the welding work on the principle parts of the trunk line is now complete.

The eastern section, running 2,477 km from Zhongwei to Guangzhou with designed pressure of 10 MPa, commenced construction in December 2008. The eastern section is expected to connect into the Turkmenistan – China Gas Pipeline, which is currently under construction, by the end of 2009 and is scheduled to be comissioned in 2011.

On November 16, the tunnelled crossing of the Changjiang River was successfully completed. The crossing was a key engineering project for the Second West – East Gas Pipeline. The crossing took place between Jiujiang City in Jiangxi Province and Wuxue City in Hubei Province, with a horizontal crossing span of 2,590 m. China Oil and Gas Pipeline Company was the engineering, procurement and construction contractor.

The next step is to lay a 48 inch diameter pipeline in the tunnel, which is expected to be completed in April 2010.

Once completed, the pipeline will transport natural gas imported from Central Asian countries, as well as gas produced domestically in the Tarim, Junggat, Tuha and Ordos basins, to the Pearl and Yangtze River delta areas and the central west part of China.

The pipeline is expected to increase the share of natural gas in China’s energy consumption by 1–2 per cent and play a significant role in boosting the country’s domestic natural gas demand, facilitate the improvement of China’s machinery manufacturing, improve the nation’s energy structure and promote economic and social development to the adjacent regions along the pipeline.

China National Petroleum Corporation’s (CNPC) intensive research and development programme has been integral in the construction of its Second West – East Gas Pipeline.

Technological breakthrough crucial for Second West – East Gas Pipeline

Construction progressed as planned on the first West-East Gas Pipeline.

10 PiPelines international | DeCeMBer 2009 PiPelines international | DeCeMBer 2009 1110 PiPelines international | DeCeMBer 2009

Pluspetrol was scheduled to begin the mobilisation of materials and equipment to expand its Malvinas

Gas Processing Plant, which extracts gas from the Camisea Gas Fields to feed into the Camisea Gas Pipeline, in November 2009.

The Camisea pipeline connects the Camisea Gas Field, located in the Ucayali Basin, 431 km east of Lima, to the Port of Pisco, Peru. The downstream project consists of two pipelines: a 714 km natural gas pipeline and a 540 km liquids pipeline.

The two pipelines run parallel to each other from the Camisea field passing through the Andes mountain range via the Malvinas gas processing plant to Pisco. From Pisco, the natural gas pipeline turns north along the coastline to the Lima city gate to supply gas for domestic use.

Transportadora de Gas Peruano (TGP) is a consortium led by Argentina’s Tecgas and includes Pluspetrol, Hunt Oil, SK Corporation, Sonatrach and Grana y Montero. TGP was awarded three different

33 year contracts by the Government of Peru as part of the Camisea downstream project in 2000 – a contract for the transportation of gas from Camisea to Lima, a second contract for the transportation of natural gas liquids from Camisea to the coast, and a third for the distribution of gas in Lima and Calleo.

Two major upgrades, both due for completion in the second half 2009, are under way: an increase of capacity at a compressor station in the Ayacucho region and the construction of a loop along Peru's coast. The upgrades will expand the pipeline from its current capacity of 115 billion cubic feet per annum (Bcf/a) to a capacity of 164 Bcf/a in an attempt to meet the demand for gas in Peru’s densely populated coastal regions. It was originally anticipated that the pipeline would reach 164 Bcf/a in 2015; however the spike in Peruvian gas consumption from 95 Bcf/a in 2007 to 120 Bcf/a in 2008 has led domestic pressure to be placed on the Peruvian Government to meet domestic natural gas supply needs.

TGP is on schedule to complete the pipeline expansion in December 2009 according to Mr Gamarra. “TGP has made considerable advances in this process of amplification and it’s likely to be ready by the end of the year,” he said.

The Camisea Gas Pipeline, commissioned in August 2004, will increase its capacity by 43 per cent by the end of 2009, according to the Peruvian Minister of Energy and Mines, Pedro Sanchez Gamarra.

Peru to complete Camisea pipeline expansion ahead of schedule

arounD the worlD

Nile Valley Gas Company (NVGC) was granted an exclusive franchise by the Egyptian General Petroleum

Corporation (EGPC) in April 1998 to develop a natural gas transmission and distribution pipeline system to provide natural gas to consumers in Upper Egypt.

NVGC was formed as a joint venture led by British Gas with a 37.5 per cent interest, Edison with a 37.5 per cent interest, Orascom with a 20 per cent interest and Middle East Gas Association holding the remaining 5 per cent. Edison has since sold most of its Egyptian assets to Petronas of Malaysia.

NVGC holds the right to develop a pipeline system across an area, which commences at El Wasta, a small town 80 km south of Cairo, and extends through the governorates of Beni Suef, El Minya, Asyut, Sohag, Qena, Luxor and Aswan, including the New Valley governorate and Toshka.

The completed pipeline extends 1,200 km and its ultimate marketing capacity is targeted to be as much as 6 billion cubic feet per day (Bcf/d).

The 1,200 km pipeline has been constructed in five stages. In the first phase of the project, NVGC took over a pipeline built by the Government from Cairo to the Kuraymat Power Station located near Beni Suef. Stage 2 involved the construction of 150 km of 32 inch diameter pipeline extending from Beni Suef to Abu Qurqas. Stage 3 saw 136 km of 32 inch diameter pipeline laid from the governorate of Minya to Assiut at a cost of $US75 million, while Stage 4 involved the laying of 100 km of 30 inch diameter pipeline from Assiut to Sohag.

The final stage involved the laying of 408 km of 30 inch diameter pipeline from Sohag to Aswan. The last section of the pipeline was brought online at the end of November and Egyptian Minister of Petroleum

Sameh Fahmi attended a ceremony in Aswan to celebrate the completion of the project.

The project also involved the design and construction of three compressor stations – two between Beni Sueg and Assiut and one near Cairo.

The 1,200 km pipeline was worth approximately $US9.3 billion in investment and forms part of a broader development programme. Mr Fahmi said that the delivery of natural gas to the provinces of North and South Sinai would accelerate the reconstruction and development of the area by providing energy to attract industrial projects.

The whole pipeline has a design capacity of 0.84 Bcf/d across a zone populated with massive agricultural and agro-industrial settlements.

“The pipeline will have a major role in reshaping the investment map of the entire southern Egypt,” said Mr Fahmi.

The Upper Egypt Gas Pipeline reached the governorates of Minya, Assiut and Sohag in August this year and the final stage was completed in November, bringing gas to Aswan homes and businesses for the first time.

Egyptian pipeline complete

arounD the worlD

The spike in Peruvian gas

consumption from 95 Bcf/a

in 2007 to 120 Bcf/a in

2008 has led domestic

pressure to be placed on

the Peruvian Government

to meet domestic natural

gas supply needs.

worlD wraP

Gas pipeline extends into Northwest LouisianaAcadian Gas plans to extend its 1,609 km Louisiana intrastate natural gas pipeline system into Northwest Louisiana to provide producers in the Haynesville shale play with access to multiple markets through connections with the pipeline system in South Louisiana, as well as nine major interstate pipelines. The 400 km extension will have a capacity of 1.4 Bcf/d of gas.


Pemex awards pipeline contracts to UPM Petróleos Mexicanos (Pemex) has awarded United Pipeline de Mexico (UPM) a $US12.4 million contract for the construction, replacement and rehabilitation of approximately 40 km of pipelines in Mexico’s Chicontepec oil region, as well as a $US13.9 million contract for the construction of connecting pipelines and associated infrastructure to tie-in the oil wells produced in the same region.

worlD wraP

Vietnam to build nation’s longest gas pipelinePetroVietnam will construct a 400 km pipeline running from Depot B on the southwestern continental shelf to the Mekong Delta to supply the O Mon Power Station. Military Zone 9 Command will provide services to protect the pipeline in areas under its management during the time of construction and after completion. The project will be Vietnam’s longest gas pipeline.

Construction commences on China – Myanmar PipelineChina National Petroleum Corporation (CNPC) has commenced construction on the 771 km China – Myanmar Pipeline and a crude oil port in Myanmar. The pipeline will have a capacity of 12 MMt/a and connect Myanmar’s port at Maday Island in the Indian Ocean via Mandalay in central Myanmar, to Ruili in China’s southwestern province of Yunnan.


Nord Stream granted Swedish and Finnish permitsThe Swedish and Finnish governments have granted permits to Nord Stream AG to construct the twin 1,220 km Nord Stream natural gas pipelines through their exclusive economic zones in the Baltic Sea. The approvals process for the pipeline is also continuing in Russia and Germany, with construction scheduled to begin in early 2010.

Austria and Slovakia sign-off on Bratislava-Schwechat PipelineA joint venture between Slovakian company Transpetrol and Austrian OMV AG will build the Bratislava-Schwechat Pipeline, a 62 km oil pipeline connecting Slovakia’s Friendship Pipeline, which brings crude oil to the country from Russia, with a refinery in Schwechat, Austria. Construction of the 5 MMt/a capacity pipeline is scheduled to begin in 2012.

Kenya, Uganda agree to reverse-engineer oil pipelineThe Eldoret – Kampala Oil Pipeline, located in East Africa, will be reverse engineered to allow oil to flow in both directions through the pipeline, as it is becoming increasingly likely that an oil refinery will be built in Western Uganda. The 320 km pipeline is being built under a public private partnership between the Kenyan and Ugandan governments as well as Libyan contractor Tamoil East Africa.

Saudi Aramco begins offshore pipeline construction Pipeline construction and associated works have commenced at Saudi Aramco’s offshore Karan Gas Field, in Saudi Arabia’s Khuff region, approximately 160 km north of Dhahran. The Karan onshore facility will have the capacity to process 1.8 Bcf/d of Karan Khuff gas, which will then be transported through a 110 km subsea pipeline from the field to onshore processing facilities at the Khursaniyah Gas Plant.

Fugro maps out Peruvian oil pipelineOil and gas exploration and development company Perenco has engaged Fugro to provide detailed topographic mapping of a proposed oil pipeline route in northern Peru. Perenco’s proposed pipeline system will transport oil production to the Bayovar export terminal, located 1,000 km from its Block 67 group of oil fields, located in the Maranon Basin on the Pacific coast.

To stay informed on all this news and more, subscribe to the Pipelines International Update ›› www.pipelinesinternational.com


Name change for StatoilhydroStAtoilHyDRoASAHASchanged its name to StatoilASA.

The company advised that ticker symbols will remain unchanged as STL on the Oslo Stock Exchange and STO on the New York Stock Exchange.

Statoil is an international energy company with operations in 40 countries. The company is based in Norway and has more than 35 years of experience from oil and gas production on the Norwegian continental shelf.

Statoil is technical service-provider for approximately 7,000 km of pipeline from the Norwegian continental shelf to Europe.

New Chair at PRCI tHEBoARDofDirectors of Pipeline Research Council International (PRCI) elected Vice President of TransCanada Pipelines Operations and Project Services Paul F. MacGregor as Chair at its Annual Meeting on 15 September 2009. He replaces Enbridge Pipelines Oil Sands Projects Senior Vice President Art Meyer.

Mr MacGregor has been a PRCI Board member for four years, serving most recently as Vice Chair, a member of the Executive Committee, and Chair of the Audit and Finance Committee.

He has held numerous key positions with TransCanada since joining the company in 1981, and is currently responsible for the company’s supply chain management, procurement activities, and performance standards.

Mr MacGregor said “This is an important time for research, and particularly collaborative research, in the energy pipeline industry. I am honoured that my colleagues in PRCI have entrusted me with this position, and I look forward to working with them and the PRCI team to continue to extend the success of PRCI’s collaborative model.”

New Vice President at PLMPiPElinEMACHinERyintERnAtionAl(PLM) President Mel Ternan, is pleased to announce that Anthony (Tony) J. Fernandez has taken on the position of Senior Vice President with PLM.

“With Tony taking responsibility for daily operational and sales issues, we will have more opportunity at the president level to concentrate on strategic and PLM expansion plans,” said Mr Ternan.

Mr Fernandez has been with PLM since its inception in May 2005. He previously worked with Ring Power Corporation for 17 years as International Accounts Manager and later Pipeline Division Manager. Tony participated in the early discussions that resulted in a four-dealer partnership to form PLM and provide Caterpillar’s global focus to the pipeline industry.

Additional PLM information is available on the PLM website at www.plmcat.com

Role changes at Rosen AftER12yEARSof direct involvement in the Australasian industry, Vice President and General Manager Operations of Rosen Asia Pacific Chris Yoxall has relocated within Rosen to Houston, United States, to take up the position of Vice President, Rosen USA. He has been succeeded by Neil Pain who has been appointed as General Manager, Rosen Australia. Mr Pain is well known, having been in the industry for more than a decade, and has been with Rosen for over six years. In this time, Mr Pain has undertaken a number of responsibilities including quality assurance, project management and business development.

As part of the restructured changes, Myles Youngs has assumed the role of General Manager, Operations in Australia. Mr Young has been with Rosen for three years in capacity of Operations Manager. He is now responsible for all operational aspects including the processors of data evaluation, operations and maintenance within the Australian organisation.

ProjeCt Briefs


Project briefsKasimovskoye UGS – Voskresensk CS Gas TrunklinePRoPonEnt: OAO Gazprom, 16 Nametkina Street, Moscow GSP-7, Russian Federation Tel: +7 495 719 3001 JointVEntUREPARtnERS: Gazprom Transgaz Moscow, Gazprom UGSPRoJECtSCoPE: The Kasimovskoye UGS – Voskresensk CS pipeline, which began construction in 2005, connects the Kasimovskoye underground gas storage (UGS) to the Voskresensk compressor station (CS). The pipeline includes two compressor stations located at Tuma and Voskresensk and one gas metering station at Kasimov. The project includes a total of 108 rivers, streams, railways and highway crossings during construction and the trunkline will provide highly reliable and uninterrupted gas supply to Moscow and its suburbs.PRoJECtUPDAtE:Commissioning occurred on the trunkline in October.PiPElinElEnGtH:204 kmPiPElinECAPACity: 95 Bcf/a of gas when fully operational.CoMPlEtionDAtE:The pipeline has been commissioned with a ceremony marking the occasion held in Voskresensk District, Moscow Oblast on 23 October, 2009.

Shandong Natural Gas Pipeline NetworkPRoPonEnt:China National Petroleum Corporation (CNPC), 9 Dongzhimen North Street, Dongcheng District, Beijing 100007, P.R. China. Tel: +86 10 6209 4114JointVEntUREPARtnER: Shandong Natural Gas Pipeline Network CompanyPRoJECtSCoPE:The network will enable CNPC to transport gas from central Shandong to cities including coastal Qingdao and Weihai in the east, and tie in to the Shaan – Jing Gas Pipeline and the Second West – East Gas Pipeline via the Ji – Ning Pipeline and Taian branch of the Shandong Pipeline.PRoJECtUPDAtE: Construction has commenced on the Taian – Weihai section of the pipeline network.PiPElinElEnGtH: 1,067 km of pipeline system, consisting of one trunk line and six branch lines. PiPElinECAPACity: 388 Bcf/a of gas when fully operational.EXPECtEDCoMPlEtionDAtE: Late 2010.

MEDGAZ PipelinePRoPonEnt:MEDGAZ, Muelle de Poniente, Puerto de Almería, 04002 Almería, Spain Tel: +34 950 182 900JointVEntUREPARtnERS:MEDGAZ is a consortium of five international companies: SONATRACH, CEPSA, IBERDROLA, ENDESA and GDF SUEZ.PRoJECtSCoPE: The Medgaz Pipeline is a subsea gas pipeline that runs under the Mediterranean Sea from Beni Saf on the Algerian coast up to landfall on the Spanish coast of Almería. The pipeline is a strategic project for Algeria, Spain, and the rest of Europe, supplying natural gas directly from Algeria, without requiring transit through third countries. Saipem was contracted to construct the subsea infrastructure.PRoJECtUPDAtE: Saipem has completed subsea pipelay operations, with the tie-in completed 1.6 km off the Algerian coast. Hydrostatic tests are expected to be completed on the pipeline in March 2010. PiPElinElEnGtH:210 kmPiPElinECAPACity: 282 Bcf/a of gas when fully operational.EXPECtEDCoMPlEtionDAtE: June 2010

PLM Senior Vice President Anthony J. Fernandez.

The new look Statoil.

PiPes anD PeoPle

Fayetteville Express PipelinePRoPonEnt: Fayetteville Express Pipeline L.L.C, 3250 Lacey Road, 7th Floor, Downers Grove, Illinois 60515, USA.Tel: +1 630 725 3070PARtnERS: Fayetteville Express Pipeline LLC is a joint venture between Kinder Morgan Energy Partners and Energy Transfer Partners.PRoJECtSCoPE:The pipeline will originate in Conway County, Arkansas, and continue eastward through White County, Arkansas, and terminate at an interconnect with Trunkline Gas Company in Panola County, Mississippi. The project will parallel existing pipeline or electric transmission right-of-ways where possible to minimise impact to the environment, communities and landowners.PRoJECtUPDAtE: An application has been lodged with the Federal Energy Regulation Commission and approval is expected by the end of 2009. Construction contracts are currently being negotiated and it is anticipated that construction will commence in March 2010.PiPElinElEnGtH: 298 kmPiPElinECAPACity: The pipeline will have an initial capacity of 2 Bcf/d of gas. EXPECtEDCoMPlEtionDAtE: Early 2011

Pipes & People

Rosen’s Myles Young, Chris Yoxall and Neil Pain.

16 PiPelines international | DeCeMBer 2009 PiPelines international | DeCeMBer 2009 17

Enagás has developed and operated natural gas transmission pipelines in Spain since 1972. In 2000, the

company was appointed technical manager of Spain’s gas system in accordance with the Royal Decree-Law 6/2000, and this year the company has been designated the operator of the transmission system for Spain’s high-pressure gas network under the Royal Decree-Law 6/2009.

Today, Enagás’ main activities include natural gas transportation, regasification and storage. The company transports gas through over 9,000 km of high-pressure gas pipeline and owns three regasification plants located at Barcelona, Cartagena and Huelva, as well as a 25 per cent interest in the Bahía de Bizkaia Gas Regasification Plant in Bilbao.

The company continues to develop its transmission pipeline network and natural gas assets in Spain, as well as promote the development of a pan-European pipeline network to ensure greater security of natural gas to Europe.

Recent pipeline projectsEnagás recently completed the

500 million euro ($US748 million) Peninsula – Baleares Pipeline project. The company says that the project is a “very complex and important” subsea pipeline system that connects the Iberian Peninsula with the Balearic Islands.

The project consists of three components: a 65 km pipeline between Montesa and Denia, the 267 km Denia – Ibiza – Mallorca subsea pipeline, and a compressor station located at Denia.

Enagás says that only eight pipelay vessels in the world specialise in this type of project, which included installing pipe at depths as deep as 997 m.

Operator of Spain’s natural gas pipeline system Enagás continues to develop its transmission pipeline network, recently completing the complex Peninsula – Baleares Pipeline project. Here, the company talks about the project and its plans for future pipeline expansions.

The company used the Castoro Sei vessel and an auxiliary fleet of six boats to complete the project. Approximately 22,500 pipes were used to construct the underwater section of the pipeline.

More than 500 people were employed to construct the pipeline, not including the 500 who worked on the Castoro Sei pipelay vessel.

"To date, this has been one of the most complex pipeline projects constructed as part of the Spanish Gas System," a company spokesperson says.

Work began on the project in December 2007 and was completed in September this year.

Enagás says that the pipeline system will bring important benefits to the Islands.

Besides transporting natural gas for distribution to residents, the project allows the supply of natural gas to power plants on the Islands, increasing the uptake of natural gas in the area.

“The pipeline gives Baleares energy security as it connects the Islands directly

with the Spanish Gas System,” an Enagás spokesperson said.

Enagás also recently completed construction on the 292 km Almería – Chinchilla Pipeline, which was built to connect the Spanish Gas System with the Medgaz Pipeline currently under construction. The Medgaz Pipeline is a strategic project for Algeria, Spain, and the rest of Europe, supplying natural gas directly from Algeria, without requiring transit through third countries.

The 300 million euro ($US448.7 million) project was constructed in two sections – a 42 inch diameter, 122 km pipeline between Almería and Lorca, and a 42 inch diameter, 170 km pipeline between Lorca and Chinchilla.

The importance of gas storage and regasification facilities

Enagás has been investing in storage and regasification facilities since the company first began. This year, the Barcelona Regasification Plant is celebrating its 40th

year of operations.

In September this year, Enagás signed a contract for the purchase of a 25 per cent interest in a regasification plant at Bilbao. The company also owns an underground natural gas storage facility at Serrablo.

The company is currently working on the construction of its fourth regasification plant at El Musel Port in Gijón in the north of Spain, and another underground gas storage at Yela, Guadalajara.

“Regasification plants give flexibility to the gas system...reinforcing the security of natural gas supply for Spain,” says a company spokesperson.

The company says that it will continue to construct regasification plants and underground storage facilities as necessary to increase storage capacity.

Future pipeline projects: international connections

Enagás says that construction of international pipeline connections is essential for a secure natural gas supply for Europe. Spain has one of the most diverse natural gas supply portfolios in the world, and last year received natural gas from ten different countries.

“International connections are strategic investments and essential to continue guaranteeing gas system security,” says an Enagás spokesperson.

There are currently two pipeline connections between France and Spain – the 2.7 billion cubic metre per annum (Bcm/a) Larrau Pipeline, and the 0.2 Bcm/a Irun Pipeline.

Enagás is part of the European Union organisation, the High Level Group of the South West Regional Energy Market. The working group aims to:• Double the current capacity of the

Larrau Pipeline from 2.7 Bcm/a to 5.2 Bcm/a via looping and additional compression. The project is expected to reach completion in 2013;

• Increase the capacity of the Euskadour Pipeline from 0.1–2 Bcm/a by 2013; and,

• Construct the 190 km MidCat Pipeline, which will run along the Mediterranean coast and have a capacity of 7.5 Bcm/a. The project is planned for completion in 2015. “Having a pan-European gas network

is essential to have a real European natural gas market. It is necessary to have a network connecting Europe from north to south, making it possible that in case of any supply crisis, natural gas can circulate through Europe in both directions,” an Enagás spokesperson said.

Meet the CoMPanyMeet the CoMPany

Enagás: expanding pipelines in Europe

The Peninsula pipeline during pipelay works.

Lowering-in the Peninsula pipeline. Enagás headquarters in Madrid.

Balearic Pipeline construction.


The United States of America boasts well established oil and natural gas pipeline systems, which are continuing to grow with the proposal and construction of more pipelines across the country. Pipelines International takes a look at some of the major projects in the pipeline.

Southeast regionKinder Morgan Energy Partners and

Energy Transfer Partners began service on the MidcontinentExpressPipeline(MEP) in August this year. The MEP consists of a single pipeline originating near the town of Bennington in Bryan County, Oklahoma, and terminating with an interconnection into the Transcontinental Gas Pipeline at Transco’s compressor station near the town of Butler in Choctaw County, Alabama.

The pipeline is comprised of approximately 48 km of 30 inch pipe, 442 km of 42 inch pipe and 317 km of 36 inch pipe. The MEP also has two compressor stations. One station is located near Paris in Lamar County, Texas, and the other near Perryville in Union Parish, Louisiana.

The original capacity of the pipeline is being expanded through the addition of incremental compression. When completed in 2010, MEP will have capacity of 1.8 Bcf/d in Zone 1 and 1.2 Bcf/d in Zone 2.

Florida Gas Transmission is proposing to expand its natural gas pipeline system to meet the growing energy needs of the Gulf Coast and Florida. The company operates an 8,046 km pipeline system, which has the capacity to deliver 2.3 Bcf/d of natural gas to the Florida peninsula.

The PhaseViiiExpansionProject will consist of approximately 777 km of multi-diameter pipeline in Alabama, Mississippi, and Florida, with approximately 587 km built parallel to existing pipelines. One new compressor station will be built in Highlands County, Florida. The project will provide an annual average of 798 million cubic feet per day (MMcf/d) of additional firm transportation capacity. The project is expected to be completed and in service in 2011.

In 2007, El Paso Corporation placed Phase 1 of its CypressPipeline project into service. The pipeline is an expansion of the SouthernnaturalGas(SnG)Pipeline, and provides an incremental 220 MMcf/d of takeaway capacity from the company’s LNG facility near Savannah, Georgia. The 268 km pipeline extends the SNG system to interconnect with the Florida Gas Transmission system near Jacksonville, Florida.

Phase 2 of the project was placed into service in 2008. During this phase. compression facilities were installed to add an additional 116 MMcf/d of capacity to the pipeline. Phase 3 of the project, which is scheduled to be in-service by 2010, will add an incremental 164 MMcf/d through additional compression.

ETC Tiger Pipeline Company is proposing

to construct an interstate natural gas pipeline to provide takeaway capacity from the East Texas Carthage Hub area and the Haynesville Shale play. The 289 km, 42 inch diameter tigerPipeline will begin near Carthage, Texas, and extend to the Perryville, Louisiana area.

The project will have a capacity of 2 Bcf/d and is expected to begin operation in the first half of 2011. Four compressor stations have been planned for the pipeline.

The majority of the pipeline is to be constructed within the right-of-way of the existing 276 km CenterPoint Carthage to Perryville Pipeline and Gulf South’s 389 km East Texas to Mississippi Pipeline.

Enbridge has conducted an open season for the proposed 523 km interstate laCrossePipeline, which would run from the Carthage Hub in Texas to an interconnection with the SNG Pipeline in Washington Parish, Louisiana. The pipeline will be designed to provide an outlet for increasing supplies coming out of the Haynesville shale region. The pipeline is scheduled for completion in 2013.

Midwest regionEnbridge has recently completed

construction on the AlbertaClipperPipeline to transport oil between Hardisty, Alberta, Canada, and Superior, Wisconsin. This 1,607 km , 36 inch diameter pipeline is expected to be in service by mid-2010, complementing the recently completed Southern Access Project as crude oil supplies

from Western Canada continue to increase. Initial capacity will be 450,000 barrels per day (bbl/d), with an ultimate capacity of up to 800,000 bbl/d.

Enbridge is expected to complete construction of itsSouthernlightsProject by the end of 2009. The project will transport oil from Canada to markets in the US Midwest. It involves the construction of new pipeline and the use of some segments of existing pipeline on which the flow direction has been reversed. The 20 inch diameter pipeline was constructed at the same time as and along the Alberta Clipper line.

Enbridge is progressing the SouthernAccessExtension project. The project extends the company’s lakeheadSystem from the Flanagan Terminal near Pontiac, Illinois, south to a petroleum transportation hub in Patoka, Illinois.

Stage 1 began operations in 2008 and included 516 km of new pipeline along the Lakehead System in Wisconsin and the construction of additional pump stations. Stage 2 involved the construction of approximately 214 km of pipeline from Enbridge’s Delavan pumping station near Whitewater, Wisconsin, to the Flanagan terminal. This stage began operation earlier this year.

Stage 3 will see the system extend from the Flanagan, Illinois, to Patoka, Illinois. The cities are approximately 400 km apart. The pipeline system will be constructed in

Northeast regionTennessee Gas Pipeline Company

(TGPC), a subsidiary of El Paso Corporation, plans to increase the capacity of its 300 Line to transport new natural gas supplies to serve the growing demand in the northeastern US.

The 300lineExpansionProject involves the installation of seven looping segments in Pennsylvania and New Jersey totalling approximately 205 km of 30 inch pipeline, the installation of two new compressor stations to be located in northwestern Pennsylvania, and upgrades at seven existing compressor stations.

Upon completion, TGPC expects that the project will increase natural gas delivery capacity in the region by approximately 3.4 billion cubic feet per day (Bcf/d). The project is planned to be in service by November 2011.

Spectra Energy has proposed the Hubline/EasttoWestExpansionProject, which will be an expansion of the company’s Algonquin Pipeline System. The 1,800 km AlgonquinnaturalGastransmissionSystem, located in New England, transports 2.2 Bcf/d of gas. The pipeline connects to the Texas Eastern Transmission System and the Maritimes & Northeast Pipeline.

The expansion project will involve a total of 74 km of multi-diameter pipeline and associated support facilities. Of this, 20 km of new pipeline will be located in Massachusetts with 53 km of upgrades to existing pipeline in Massachusetts and Connecticut. The project is expected to be completed in November 2010.

Dominion Transmission, Dominion Resources’ natural gas transmission and storage subsidiary, is proposing the AppalachianGatewayProject to meet

demand for natural gas in the mid-Atlantic and northeastern US.

The project includes the construction of approximately 177 km of pipeline between 20 and 30 inches in diameter to run between West Virginia and Pennsylvania, as well as four new gas compressor stations. Construction is expected to start in 2011, with transportation services to begin by September 2012.

The pipeline will deliver natural gas to Spectra Energy’s 14,000 km texasEasterntransmissionPipelineSystem at Dominion’s Oakford Station in Delmont, Pennsylvania. The Texas Eastern Transmission Pipeline connects Texas and the Gulf Coast with markets in the mid-Atlantic and northeastern US. The 6.7 Bcf/d capacity pipeline connects the Algonquin Gas Transmission Pipeline with Spectra Energy’s 430 km East Tennessee Natural Gas Pipeline.

region review

Pipeline development in the land of the freeBy BJ Lowe, Clarion, Houston, USA and Lyndsie Mewett, Associate Editor

region review

Continued on page 20 ››

Construction works at Denbury Resources' Green Pipeline.A map of the Florida Gas Transmission Pipeline.

PiPelines international | DeCeMBer 2009 2120 PiPelines international | DeCeMBer 2009

2010 and begin operation later that year or by early 2011.

The 5,600 km Lakehead System was constructed in 1949 and is the world’s largest crude oil and liquids pipeline system, bringing crude oil from Western Canada to the US.

Vector Pipeline and Vector Pipeline Partnerships have launched a binding open season to secure shipper interest in a third expansion of the 550 km VectorPipelinesSystem, which transports natural gas between Joliet, Illinois, and the storage complex at Dawn, Ontario, Canada.

The additional expansion proposes to add long-haul capacity of up to 115 MMcf/d by adding two new compressors and upgrades to the US portion of the system. The expansion could also include incremental short-haul capacity by adding a loop to the US and/or Canadian portion of the pipeline system. The project is expected to be complete by November 2011.

The Vector Pipeline System, constructed in 2000, has already undergone two expansion projects. The first involved the installation of compressor stations at Joliet, Illinois, and Washington, Michigan. The second expansion was completed in October 2009 and involved the construction of a compressor station at Athens, Michigan, increasing the nominal capacity of the pipeline from 1.2 Bcf/d to approximately 1.3 Bcf/d.

Southwest regionKinder Morgan Energy Partners

and Energy Transfer Partners’ 298 km fayettevilleExpressPipeline has been proposed to run from Conway County Arkansas, via White County, to an interconnect on the 5,632 km Trunkline Pipeline, located in Panola County, Mississippi.

Willbros Group has been awarded a contract to construct spreads three and four of the pipeline, which includes laying 193 km of 42 inch diameter pipeline to parallel existing utility corridors in the region, beginning near Bald Knob, Arkansas, and ending at the Trunkline Gas Company interconnection. Spreads one and two of the pipeline are yet to be awarded.

Construction of the pipeline is expected to commence in March 2010 with the pipeline to be in service by January 2011.

In addition, Kinder Morgan and Copano Energy have entered into a letter of intent to construct, as a first phase, an approximately 35 km, 24 inch natural gas gathering pipeline. The natural gas pipeline will originate in LaSalle County and terminate in Duval County, Texas, and will have an initial capacity of 350 MMcf/d. The pipeline is expected to be completed in mid-2010.

Enterprise Products Partners and Duncan Energy Partners are planning to increase the capacity of the recently announced HaynesvilleExtensionProject from 1.4–2.1 Bcf/d. As a result, Enterprise and Duncan Energy placed an order increasing the size of the 249 km pipeline extension of their jointly-owned Acadian Gas intrastate pipeline into Northwest Louisiana to 42 inches in diameter.

The project is expected to be complete by September 2011. The Haynesville Extension will intersect with nine interstate pipeline systems.

Central regionThe RockiesExpressPipeline (REX)

runs from the Meeker Hub in Rio Blanco County, Colorado, to Audrain County, Missouri, and Warren County, Ohio. The 531 km section from Meeker to the Cheyenne Hub was placed in service in February 2007. The completion of REX-West in May 2008, added 1,147 km of 42 inch diameter pipeline, which runs from the Cheyenne Hub in Weld County, Colorado, to Audrain County, Missouri.

The 1,027 km REX-East Pipeline section completed commissioning in November this year. REX-East is the final segment of the REX Pipeline, and runs from Audrain County, Missouri, to the Lebanon Hub in Warren County, Ohio.

Following the completion of REX-East, the pipeline has a capacity of 1.8 Bcf/d of gas.

The pipeline is a joint venture between Kinder Morgan Partners, Sempra Pipelines and Storage, and ConocoPhillips.

TransCanada is currently constructing the 3,456 km KeystonePipelineproject, which combines both the new construction of pipeline and the conversion of an existing

pipeline from natural gas to oil service.Approximately 2,219 km of new

pipeline is to be constructed in the US. The Canadian portion of the project includes the construction of approximately 373 km of new pipeline and the conversion of approximately 864 km of existing TransCanada pipeline from natural gas to crude oil transmission. It is expected that the project will be complete by 2012.

In addition, the Federal Energy Regulatory Commission (FERC) has prepared a draft environmental impact statement for TransCanada’s proposed BisonPipeline.

The project includes approximately 486 km of 30 inch diameter natural gas transmission pipeline extending northeast from Wyoming through Montana to North Dakota. TransCanada has also proposed one compressor station at Hettinger County, North Dakota.

The pipeline is designed to have a capacity of approximately 477 MMcf/d of gas, but will be expandable to 1 Bcf/d. TransCanada has said that future development plans for the pipeline include the expansion and extension of the Bison Pipeline into the Rockies Basin.

Construction is expected to begin on the pipeline in 2010, with the pipeline to be operational in November of that year.

Colorado Interstate Gas Company (CIG), a subsidiary of El Paso, is building the RatonExpansionProject to serve increasing demands for Rocky Mountain natural gas supplies. The Raton Expansion Project involves the installation of approximately 188 km of 16 inch pipeline in Las Animas, Huerfano, Pueblo and El Paso counties, Colorado.

The Raton 2010 Expansion Project will start in southern Las Animas County and

will terminate in southern El Paso County at an interconnection with CIG’s pipeline system. This expansion will enable gas to be transported to CIG’s mainline for ultimate delivery to the Cheyenne Hub in northern Colorado for delivery to major national markets.

CIG had hoped to receive FERC authorisation for the project by October 2009, with a proposed in-service date in May 2010. The authorisation is still pending.

Enbridge has proposed the northDakotaSystemExpansionPhase6project to bring its northDakotaSystem expansion to 161,000 bbl/d of oil by early 2010. The expansion will involve upgrades to existing pump station sites.

The North Dakota System consists of 531 km of crude oil gathering and 998 km of interstate transmission pipeline. It delivers oil from North Dakota and Motana to Minnesota, where it connects with the Lakehead System and the third party MinnesotaPipeline.

Alliance Pipeline and Questar Overthrust Pipeline Company have jointly proposed the 1,738 km, 42 inch diameter RockiesAlliancePipeline (RAP) to connect the Rocky Mountain Region to the Chicago market hub.

The project will take advantage of existing Overthrust and Alliance infrastructure. The companies are currently undergoing a second open season to evaluate the potential gas capacity expansion of the pipeline.

The pipeline will originate from Wamsutter, Wyoming, where Questar’s overthrustPipeline will be expanded from the Opal and Meeker receipt hubs to meet the need for additional capacity. During an open season, Questar Overthrust Pipeline received interest for approximately 1 Bcf/d of new pipeline capacity for delivery into RAP.

Upon in-service of the proposed project, RAP will initially provide 1.3 Bcf/d of transportation capacity. The pipeline is expected to be commence construction in 2012 and completed by 2013.

Questar’s overthrustPipeline is a270 km, 36 inch diameter pipeline, located in southwestern Wyoming. The 141 km pipeline section from Whitney Canyon to Kanda comprises the western-most segment of the 701 km trailbalzerPipeline system. The 128 km section from Kanda to Wamsutter, completed in 2007, makes up the western segment of the REXPipeline.

The Questar Overthrust Pipeline expansion would run west from a compressor station near Rock Springs to Black Fork, Wyoming, and parallel an existing Questar pipeline that runs from Wamsutter to Blacks Fork and on to Opal.

The 69 km, 36 inch diameter pipeline would cost approximately $US94.3 million to construct and have a capacity of 800 MMcf/d of gas. The pipeline is expected to tie into El Paso Corporation’s proposed RubyPipeline.

The Ruby Pipeline will connect natural gas reserves in the Rocky Mountain region with markets the western US. The project will involve approximately 1,086 km of 42 inch diameter pipeline beginning at the Opal Hub in Wyoming and terminating at interconnects near Malin, Oregon.

The project will have an initial design capacity of up to 1.5 Bcf/d of gas and four compressor stations will be constructed: one near the Opal Hub in southwestern Wyoming; one south of Curlew Junction, Utah; one at the mid-point of the project, north of Elko, Nevada; and, one in northwestern Nevada.

region reviewregion review

cArboN DioxiDe pipeLiNesDenbury Resources recently began a feasibility study into constructing an 804 km and 1,126 km long carbon dioxide pipeline project connecting proposed gasification plants in the Midwest to existing pipeline infrastructure in Mississippi and Louisiana. Denbury has said that it expects the pipelines to take four to five years to complete. The study comes as two proposed Midwestern gasification plants, with which Denbury has carbon dioxide purchase contracts, have been granted approval to the term sheet negotiation phase under the US Department of Energy loan guarantee programme.A third proposed gasification plant has also been selected by the loan guarantee programme to be built along the Gulf Coast of Mississippi. Denbury plans to commission a study for a 177 km pipeline that could connect the plant to the existing Free State Pipeline.

‹‹ Continued FRoM page 19


Enbridge is expected to complete construction of its

Southern Lights Project by the end of 2009. The project

will transport oil from Canada to markets in the US

Midwest. It involves the construction of new pipeline and

the use of some segments of existing pipeline on which

the flow direction has been reversed.

Welded pipe during the construction of Alberta Clipper.

Pipe stacking in preparation for the Vector

Pipeline System construction.

The Rockies Express Pipeline, or REX, crosses eight states and travels approximately 2,735 km. Beginning in Colorado and ending in eastern Ohio, the REX project is one of the largest natural gas pipelines constructed in North America over the last 25 years.

Kinder Morgan Energy Partners; Sempra Pipelines & Storage, a unit of Sempra Energy; and, ConocoPhillips

jointly developed the Rockies Express (REX) Pipeline project. The pipeline was constructed in three phases:• The 528 km REX-Entrega section across

Colorado; • REX-West, which runs 1,147 km from

Colorado to eastern Missouri; and, • The recently completed REX-East portion,

which stretches from eastern Missouri to eastern Ohio. The REX-West section was completed in

early 2008, after receiving Federal Energy Regulatory Commission authorisation in April 2007. REX-East finalised construction and was placed into service on 12 November 2009. Following the completion of REX-East, the pipeline has the capability to transport up to 1.8 billion cubic feet (Bcf) of natural gas per day.

Each region along the 2,735 km pipeline route offered unique challenges for the construction of the pipeline. The majority of the route passed through mountainous terrain – starting in the Rocky Mountains and extending to the Appalachian Region – which brought with it significant technical challenges.

The REX-Entrega and REX-West pipeline routes cross the Rocky Mountains and much of the REX-East route also covers mountainous terrain, which presented the project’s crews with a variety of construction issues. However, the crew successfully managed to move the project forward without delay.

Most of the REX Pipeline was constructed along existing pipeline corridors. Much of the terrain was already level and ready for the pipe stringing and trenching in preparation for pipelaying, Mr Fore said, however construction crews faced a variety of landscape and geographical challenges as the pipeline construction progressed eastward along the route into the Appalachian Region on the REX-East Pipeline route.

Welding to scheduleNew technology was employed to

ensure that pipeline construction proceeded smoothly.

REX was designed with a construction schedule that favoured automatic field welding. The automatic welding equipment – provided by CRC Evans of Houston, Texas, and RMS Welding Systems of Nisku, Alberta – was a large part of how the construction proceeded in such an efficient fashion.

The automatic welding systems enabled a very high level of productivity that exceeded 100 welds per day for the mainline pipelay. Additional project pace was gained by the establishment of ‘mini pipe gangs’, which were capable of laying up to 20 joints of pipe per day. The mini gangs were ideal to lay pipe in the rough terrain encountered on the project.

The welding work was completed using cutting edge components.

Tie-in welds were made with Hobart welding wire, Trimark Flux Core and Fab Shield X80, which is a special wire produced to weld the high strength X80 pipe used. Once the welding was completed, each joint was checked carefully by the onsite scanning technology. Weld integrity was ensured by using ultrasonic weld inspection systems

to scan 100 per cent of the field welds for defects.

The system used was an analog to digital conversion unit, but an innovative ‘phased array’ weld inspection system, provided by UT Quality of Texas, was also used on the pipeline. The totally digital system was first qualified in the US for the REX-West project. By allowing the system to be less complex and highly accurate in weld interpretation, REX saw more robust results.

REX Director of Community Relations Allen Fore said “The REX Pipeline was constructed using the latest technology in all aspects of the construction process, but the biggest asset was the skilled and experienced workers employed on the project.

“The pipeline construction process is often compared to a sort of moving assembly line and during peak construction efforts, there were thousands of construction workers on the pipeline spread.

“The innovative technology employed ensured that the pipeline was built in the safest and most efficient way possible – and will maintain the integrity of the pipeline in the future,” said Mr Fore.

REX appeal: pipeline construction in the Rockies

region review

Western regionWilliams’ subsidiary Northwest Pipeline

has proposed to construct the 30 inch diameter, 192 km BlueBridgePipeline project.

The project involves six pipeline loops running parallel to Northwest’s existing 26 inch mainline along the Columbia River Gorge, Washington. Construction is set to begin in the first half of 2012, and commercial service to launch in the second half of 2012.

The proposed PalomarGastransmissionPipelineis a new interstate natural gas pipeline that will provide additional energy infrastructure to serve Oregon, the Pacific Northwest, and other western states. Palomar is a joint venture between TransCanada and NW Natural.

The 36 inch diameter pipeline will be approximately 354 km long. The proposed Palomar project is seeking a certificate from the FERC for permission to construct and operate the pipeline.

Subsidiaries of Williams, PG&E Corporation and Fort Chicago Energy Partners, have agreed to jointly pursue construction of a LNG import terminal (Jordan Cove LNG), to be located in Coos Country, Oregon, and a interstate natural gas transmission system (Pacific Connector). This project will increase the supply of natural gas for the Pacific Northwest, northern California and northern Nevada.

The PacificConnectorPipeline project

is a 370 km, 36 inch diameter pipeline designed to transport up to 1 Bcf/d of natural gas from the proposed Jordan Cove LNG terminal to markets in the region. The Pacific Connector project includes interconnects to Williams’ 6,276 km Northwest Pipeline, the 386 km Tuscarora Gas Transmission system, and Gas Transmission Northwest’s system, all located in Oregon.

Alaskan proposalsThere are currently two competing large

diameter pipeline projects proposed that would link Alaska’s North Slope gas reserves to markets in Canada and the US.

The proposed DenaliPipeline project consists of a gas treatment plant on the North

Slope, an approximately 3,219 km long pipeline to Alberta, Canada, and if required, a 2,414 km long pipeline from Alberta to Chicago at a current estimated cost of $US30 billion.

The proposed TransCanada AlaskaPipelineproject would include a gas treatment plant to be built at Prudhoe Bay, a 2,736 km long pipeline from North Slope Alaska through Yukon and northeastern British Columbia to the British Columbia/Alberta border near Boundary Lake, and would include new and existing infrastructure in Alberta.

The pipeline projects require a certificate of public convenience and necessity to be granted by the FERC in order to commence construction and operation activities.


region review


The REX Pipeline before lowering in.

Above: Overland Pass Natural Gas Pipeline map. Construction works on the Texas Eastern Transmission Pipeline System.


Steel transmission pipelines going through mountain areas often face significant risks during their construction and service life. One of the biggest challenges is to protect the pipe and its external coatings against mechanical damage from impact and penetration.

When installing and operating transmission pipelines in mountain regions, one has to

account for specific risks in order to mitigate potential lost time, increased costs, and accidents with human and economic costs.

Climate is an important consideration during both pipeline construction and operation in mountain areas. Some seasons can be harsh, with heavy snowfall or rain, and extreme temperatures and winds, restricting the access to the right-of-way (RoW) during construction. In addition, weather patterns are usually rapidly changing – quick temperature changes and flash rains – which can delay the construction of the pipelines. During pipeline operation, pipelines in permafrost regions face stability issues.

Geography is another significant risk factor with two sub-categories – topography and geology. Mountain areas can have a challenging topography such as steep slopes, river and lake crossings. Geology can also raise issues during both construction and operation, with companies faced with hard rock, wet or frozen ground conditions, earthquake and fault zones, erosion and landslides, karst and sinkholes.

Mountains often include environmentally sensitive and protected areas, such as national parks. Pipeline projects have to be designed, installed and operated with a minimum footprint on flora and fauna, usually translated in reduced RoW and temporary workspace. Minimising any risk of accidental harmful discharge or contamination is also important.

Supplying some of the required materials such as sand for padding, and safely disposing of surplus materials can be difficult during the construction phase of a mountain pipeline.

Finally, building and operating pipelines in mountain regions can be dangerous for the people involved. Clear safety standards and operating procedures have to be in place to avoid accidents.

In order to address the above-mentioned risk factors, the pipeline industry is dedicating a lot of effort to prepare and standardise the construction and operation of pipelines in mountain regions.

The International Pipeline and Offshore Contractors Association (IPLOCA) presents ten different pipeline construction environments in its recently released recommended construction practices for

onshore pipelines, Onshore Pipelines: The Road to Success. Three of these environments directly describe mountain areas – the side slope, ridge and rock RoW scenarios. Another two refer to arctic conditions and the environmentally sensitive area often encountered in mountain terrain. In all the scenarios, one of the most efficient ways of mitigating the pipeline construction and operating risks is to protect the steel pipe against mechanical damage from impact and penetration.

The need for supplementary mechanical protection

Mechanical damage to the pipe can occur during all phases of the pipeline construction and operation, for example during transportation, handling (loading in and out), storage, lowering-in, backfilling, and during pipeline’s service life. Impacts and penetration damage can be caused by many factors:• Other pipes or pipe handling equipment; • Lowering-in; and, • Rocks in the trench bottom or impact

from the backfill material.Steel pipe is impact resistant by itself and

some of the external coatings applied on steel

increase this basic mechanical protection. However, in order to ensure an incident-free service life for the pipeline, the steel pipe and the anti-corrosion coating have to be intact during construction and operation. This cannot be guaranteed by the basic mechanical protection of the steel and anti-corrosion coatings. Therefore, the industry has developed supplementary mechanical protection systems that are aimed at reducing or eliminating the risk of mechanical damage.

As the industry uses a wide range of supplementary mechanical protection systems, this article will focus on the systems that protect the entire diameter and length of the pipe, and which are the most efficient in protecting the pipe and its coating against impact and penetration. Today, most pipeline projects use the following supplementary mechanical protection system: concrete coatings, sand padding and select backfill (mechanical padding), as well as non-woven geotextiles and rockshield materials.

Mechanical protection systemsConcrete coatings for mechanical

protection have been developed during the last 25–30 years in North America, Australia and Europe, and are usually applied in specialised coating facilities.

Steel wire mesh reinforced concrete coatings that are usually 20–25 mm thick and fibre-reinforced concrete coatings (8–10 mm thick) are the two types of mechanical protection concrete coatings. Wire-mesh concrete coatings are applied using a side-wrap process, while the fibre-reinforced concrete coatings are applied using a spraying process, without any damage to the pipe and the pipe coating during application.

The concrete coatings offer excellent damage resistance – minimum impact resistance of 150 J for the fibre-reinforced concrete coatings and 450 J for the wire-reinforced concrete coatings. The mechanical protection concrete coatings are fully bendable according to the industry standards; do not need additional equipment or manpower for installation; and, do not have any usage limitations in terms of terrain configuration, ground conditions or climate. Concrete coatings are currently the only supplementary mechanical protection systems that protect steel pipe through all the construction and service life phases – from transportation, handling and storage to lowering-in, backfilling and long-term service life.

Sand bedding and padding is still

the most frequently used supplementary mechanical protection system. Sand is usually supplied to the RoW, where it is used in the trench to protect the pipe against impact and penetration from rocky outcrops in the trench bottom or impacts from rocks in the excavated trench material. The sand layer usually has a thickness of 20–30 cm around the pipe and has a minimum impact resistance of 300–450 J. Sand padding needs additional equipment such as sand trucks, padding machines, temporary work and storage space at the RoW, as well as additional manpower and materials. Additional costs are usually incurred for the transportation and disposal of the original trench material that becomes surplus material after the use of sand. This system protects the pipe during the pipeline backfilling and operation phases, and industry experience shows that potential sand washouts can reduce long-term protection.

Sand padding also has limitations in terms of terrain configurations, such as steep slopes, climate, and wet or frozen sand. More recently, select backfilling (or mechanical padding) has been used as a sand padding technique. This requires special equipment that can screen the material excavated from the trench and install the finer grades around the pipe, while using the coarser material for closing up the trench. This system has terrain configuration, soil type (clay, silt) and climate limitations that are similar to sand padding, but has the advantage of re-using the trench material and thus avoiding most surplus material disposal costs.

Non-woven geotextile materials are polypropylene fibre-based rolls, and rockshield materials are polyethylene or PVC-based solid sheets or open-cell rolls that are installed around the steel pipe in the field, usually before the lowering-in phase. These materials are available in different styles and thicknesses, with the usual thickness per

layer at 4–14 mm for non-woven geotextiles and 6–11 mm for rockshield materials.

These materials also have a wide range of technical performance. As an example, their minimum impact resistance is in the 25–35 J range. These materials protect the pipe during lowering-in, backfilling and the pipeline service life. The installation of these materials is very slow, taking approximately 15 minutes for a team of three people to protect just one pipe joint, and the quality of the protection is highly dependent on the skills of the field installation team.

The impact resistance of these materials is limited. When rocks more than 10 cm in size are present in the backfill material, other protection systems such as sand padding have to be added, which further increases the total protection cost. Industry sources, such as a recent Interstate Natural Gas Association of America (INGAA) report entitled Emerging Bedding, Padding, and Related Pipeline Construction Practices, also mention concerns regarding the negative impacts of some of these materials – the solid sheet type – on the active anti-corrosion protection of the pipeline.

ConclusionBuilding and operating pipelines in

mountain areas is a challenging endeavor that can be facilitated by properly protecting the steel pipe and its anti-corrosion coating with supplementary mechanical protection systems.

The optimum supplementary mechanical protection system will be selected based on a well defined series of technical performance, design and constructability, environmental impact and economical criteria. The pipeline industry is using its field experience to improve the existing systems and to develop new ones. The above-mentioned INGAA study has identified two main areas as the focus for future innovations in mechanical protection systems – coatings that are resistant to damage, and new crushing/padding equipment.

Protecting pipelines in mountain areasBy Vlad Popovici, Bredero Shaw, Toronto, Canada

terrain reviewterrain review

FBE coating

3LPE coating

Rockshield material

Concrete coating

Sand/select

backfill

Standard protective layer thickness

0.4 mm 3.5 mm 11 mm 25 mm 300 mm

Diameter of backfill material that will damage the anti-corrosion coating

10–20 mm 50–60 mm 100–120 mm 300+ mm 300+ mm

Table 1 – Impact resistance of different protection systems.

A pipeline right-of-way in a mountain area. A pipeline protected by a bendable concrete coating.


Companies are advised that they have been selected for an audit via letter and are generally given several months to prepare. They are issued with a detailed set of audit protocols describing the conduct and focus of the audit.

An NEB audit follows the ISO management system process fairly closely and it audits against the Onshore Pipeline Regulations, which are for the most part written in goal-oriented language.

Dr Murray says that the company is expected to designate individuals at different levels, and at various locations, within the company as interviewees. The objective of the audit is to establish the adequacy and effectiveness of a company’s programmes.

“It has been our experience that management of change or internal communications is a common area of either ‘non conformance’ or ‘needs improvement’. Close out meetings are held at the end of each day of the audit and any findings shared with the company representatives, who may dispute them or provide clarification.”

The initial audit report is sent to the company for its comments and upon consideration of these, a final report is written and a date set for the filing of a corrective action plan.

“Conducting an audit is quite demanding of both NEB staff time and for a company in preparing for it, so a five to seven-year frequency seems about right for a full audit. Sometimes that would be pre-empted if, for example, the company were to undergo a change of ownership. Focused audits are less likely to be repetitive,” says Dr Murray.

Replacing the hydrotestThe NEB is currently addressing

applications to eliminate the hydrotesting of pipelines on the basis that the quality of pipeline fabrication, construction and

inspection techniques has improved to the point where the strength aspect of the hydrotest is redundant.

Dr Murray explains that in its place proponents have developed a fairly sophisticated quality management system referred to as ‘alternative integrity validation’ (AIV).

Several pilot projects have been successfully conducted under provincial jurisdiction and one under the NEB.

“It is important to note though, that in considering waiving the need to test two adjacent sections of pipe, to which the AIV methodology had been applied, the Board indicated that one of the sections had been hydrotested. Further it regarded the procedure as experimental with a comparatively low risk of failure as the hoop stress at the intended operating pressure was of the order of 56 per cent specified minimum yield strength (SMYS).”

A flame ionisation leak test was also conducted before placing the section into service.

“Unquestionably there are environmental and economic benefits associated with eliminating the hydrotest. Obtaining and disposing of large quantities of water can be a problem while, as a rule of thumb, for a large diameter pipe, hydrotesting costs could be as much as 5 per cent of the entire project cost,” Dr Murray points out.

Regulating US/Canada pipelinesPipelines crossing the border of Canada

and the US are regulated by separate regimes, with different requirements and philosophical approaches.

The NEB, regulating the Canadian sections of the international pipelines, has Memorandum of Understandings with the financial regulator responsible for approving interstates pipelines in the US – the Federal

Energy Regulatory Commission – and with the Pipelines and Hazardous Materials and Safety Administration (PHMSA), who is responsible for the safety and integrity of those facilities.

Dr Murray says that the organisations meet regularly to share information.

“Since we are separate jurisdictions, companies that operate cross border pipelines have to comply with the requirements of both systems and that can’t be easy!” he says.

Differences in pipeline regulation include physical differences, such as valve spacings, burial depths and some welding procedures. For example, the US stipulates a 72 per cent SMYS for pipelines, whereas Canada specifies an 80 per cent SMYS. This means that the wall thickness of international pipelines increases upon entry into the US.

The two countries also have differing approaches concerning Integrity Management Programmes (IMPs).

“Whereas re-inspection or hydrotesting intervals are prescribed in the US, in Canada as part of the goal oriented philosophy, we come to an agreement with the company as to what constitutes a reasonable interval, supported of course by a sound rationale.

“I think it is fair to say that it is uneconomic for a company to maintain two separate IMPs so it may choose to use the one deemed more onerous,” says Dr Murray.

He notes that a company may also apply to PHMSA for a waiver, for example to operate at 80 per cent SMYS in Canada, with several companies having recently done so successfully.

“There is a will between Canadian and US regulators to push toward harmonisation and we have undertaken joint studies to see where this would be most effective,” Dr Murray concludes.

The National Energy Board (NEB) of Canada is an independent federal agency that regulates oil, gas and

electric utility industries, including the pipeline industry. The Board promotes safety and security, environmental protection and efficient energy infrastructure and markets.

Here, NEBs Professional Leader – Engineering Dr Alan Murray outlines some of the issues currently facing the regulation of Canadian pipelines.

The role of the NEBThe NEB regulates pipelines that cross

provincial or international boundaries, while pipelines located within a Canadian province are the jurisdiction of that province.

Both the provinces and the NEB adopt the same national pipeline standard, CSA Z662. The standard covers oil and gas pipeline systems and is a consensus document reflecting the viewpoints of operators, regulators, contractors and consultants.

Dr Murray says that the standard inevitably sets out minimum requirements in quite prescriptive terms, which in turn has meant that the original regulations developed were similarly prescriptive.

In 1999 the NEB decided that the onus for ensuring safety and protection of the environment should fall on the pipeline operators since they have a direct influence over the condition and operation of their pipelines.

“By adopting a goal-oriented approach to regulation, the NEB can be assured that the prescriptive elements of Z662 are being met, while enabling companies to make use of the latest technologies and knowledge of their own system, to develop best practice procedures,” Dr Murray says.

The audit processDr Murray says that the NEB “uses a life

cycle approach to compliance in a goal-oriented world”.

Pipeline construction is subject to frequent inspections, while the assessment of a company’s ongoing operations is made as a result of regular integrity meetings with Board staff and in depth audits.

The NEB conducts two types of audit – a full audit or a focused audit.

“The determination to conduct an audit is made based upon our assessment of the risk a particular company poses using its operating history (what we know about

them) and to some extent its geographic location,” Dr Murray continued.

“For example we regulate a pipeline company whose system delivers liquid products to three major Canadian cities and two of our largest airports. Leaving to one side the probability of failure, the consequence of a line break are such that the company will always be deemed a high risk and hence will have a full audit, usually on a five-year cycle.”

Dr Murray says that if a company experiences many incidents involving safety, or the environment, then it would be appropriate to conduct a focused audit of that function.

“Conversely, if a company exhibits exemplary behaviour throughout its activities, the level of scrutiny during the application stage of a new project could be less onerous, since it has been demonstrating programme adequacy and effectiveness.

“The challenge for the Board staff lies in conducting audits since the check list approach, in a prescriptive regime, has to give away in some areas to one of professional judgement and that takes a lot of experience,” he says.

Encouraging a goal-oriented approach, eliminating hydrotesting and moving toward a more streamlined approach to regulating Canada/United States cross border pipelines are some of the issues currently being addressed by the National Energy Board of Canada. Pipelines International recently caught up with Professional Leader – Engineering Dr Alan Murray to talk about the issues currently facing Canada’s pipeline regulator.

Canadian perspective: a goal- oriented approach to regulating pipelines

PoliCy anD oPinionPoliCy anD oPinion

Alan Murray.


Pipeline installation by HDD: pull-back governs success

Soil reaction force at the head of the pipeline during the pull-back operation of horizontal directional drilling, by J P Pruiksma, H J Brink, H M G Kruse, and J Spiekhout.

Horizontal directional drilling (HDD) for installing pipelines under obstacles such as river or canal crossings, and road and railway embankments, is widely used for pipes up to 20 inches in diameter and above. The method is particularly suited to soils such as clays through which it is easy to drill. Considerable lengths of pipe can be installed in this way: the process involves drilling an oversized pilot hole along the planned trajectory, filling it with drilling ‘mud’ such as Bentonite, and then ‘pulling-back’ the actual pipeline through the drilled hole.

There are few standards that actually provide guidance for this operation, the most critical aspect of which is the pull-back operation. The cost of damaged pipes if things go wrong, and the cost of additional measures during and after the pull-back, can be considerable. Recently, in the Netherlands, problems occurred during pull-back operations at a number of locations where relatively large diameter pipelines are being installed. The problems varied from high pulling forces to abandoned pull-back operations due to a jammed pipeline. The pipeline–soil interaction during the pull-back operation has been identified as the cause of these pull-back operations.

The current Dutch method for calculating the pull-back force on the pipe is based on the soil-pipeline interaction, developed over 10 years ago. The method considers the distribution of the normal forces between

the pipeline and the wall of the pre-reamed borehole. For general design purposes, this is a quick and relatively simple method for the calculation of the distribution of normal forces between the pipeline and the borehole wall, and gives a reasonable estimate of the maximum pull-back force. The reason for pulling problems, however, cannot be explained with this method, and recent research has shown that the behaviour of the head of the pipeline is of major importance in the pull-back operation.

The joint paper from the Netherlands-based National Institute Geo-Engineering Unit in Delft and NV Nederlandse Gasunie reports on research undertaken into the behaviour of the head of the pipeline at its connection with the pull-back equipment in the curved sections of an HDD trajectory. The authors describe the model they have developed for the pull-back operation, and simulations they performed to study the behaviour of a pipeline in the borehole during the pull-back operation of an HDD project. The model describes the complex set of interactions between the pipeline, the drilling pipe, the drilling fluid, and the soil in the borehole.

From the simulations and analytical solutions, the authors show that the soil-reaction forces are much higher when the head of the pipeline is located in the bend compared to when the head of the pipeline has passed through the bend. Depending on the ground conditions and the bending radius, these high soil reaction stresses in the curved section may cause damage to the pipeline coating, and may lead to penetration of the borehole wall, which in turn leads to high pulling forces and may lead to a stuck pipeline or to damaged pull-back equipment.

Nord Stream Pipeline series: considering environmental impacts

The Nord Stream Pipeline’s German landfall: the challenges ahead, by Nigel S Kirk and Dipl-Ing Björn Dobberstein.

The current issue of the Journal of Pipeline Engineering includes the first of three articles on one of the world’s biggest current pipeline projects – the Nord Stream Pipeline. The series will review various aspects of the project, with specific attention paid to the pipeline landfall in Germany. The German landfall crosses an area that requires a high degree of environmental protection. The first article describes the project and its general technical details, together with a description of the German landfall, including the environmental and authorisation issues, anticipated construction techniques, and the expected installation schedule.

The second article, which will be published during the construction period for the Nord Stream Pipeline next year, will provide a general update of the project and describe the installation design together with the actual construction activities and the challenges encountered. The final article, planned for 2011, will review the project on completion of the first pipeline and assess the positive and

negative aspects of the German landfall’s construction.

As described in the last issue of Pipelines International, the Nord Stream Pipeline project consists of two 1,223 km long parallel 48 inch diameter offshore pipelines laid across the Baltic Sea, connecting the pig launchers close to the compressor station at Portovaya Bay, Russia, and the pig receivers adjacent to the Greifswald receiving terminal in Germany. At the Russian end, the pipelines cross the coastline southbound at Vyborg, northwest of St Petersburg. The route runs westward through the Gulf of Finland for approximately 440 km, and then turns southward and east of the Swedish island of Gotland. Following this the route turns southwest to skirt the Danish island of Bornholm, continuing in a south-southwest direction and eventually landfalling close to Lubmin, east of Greifswald in Germany. The project is very significant for Europe as, once fully operational, it will transport energy sufficient for 13–14 million people, and supply approximately 25 per cent of Europe’s imported gas requirements.

The pipeline’s route is highly sensitive from many viewpoints, not the least of which is its environmental aspects, and Nord Stream AG has gone to great lengths to ensure that the environmental impact of the pipeline is kept to an absolute

minimum along its complete length. The pipeline profile in the German landfall area has been designed to satisfy a variety of criteria in respect of the burial depth: the cover to the pipeline varies from 1–4.5 m depending on pipeline stability, pipeline protection, coastal erosion, and local shipping authority requirements. The pipeline’s route crosses a sandbar known as the Boddenrandschwelle, an area where the water depth is relatively shallow, varying between 2.5 m and 4.5 m deep, and through which the pipe trench has to be widened over a length of about 1,100 m to ensure a minimum trench width of approximately 50 m to allow access for the laybarge.

After installation of the pipelines, the dredged material contained within the offshore storage area will be re-dredged and backfilled into the trench. Selected coarse-grained material will be placed directly around the pipeline to ensure that liquefaction of the material does not occur and induce buoyancy, and cohesive soil will be placed above the coarse material, with topsoil finishing off the layered backfill. The backfilled trench will be accepted on completion of a detailed bathymetric survey, after which the offshore and pull-in sections of the landfall will be hydrostatically tested in combination with the remainder of the Nord Stream Pipeline.

Environmental considerations for pipeline construction are discussed in the latest edition of Pipelines International’s sister publication The Journal of Pipeline Engineering (JPE). Here, Editor-in-Chief John Tiratsoo outlines articles discussing the Nord Stream Pipeline project and horizontal directional drilling construction methods.

Environmental navigation of German landfall and modelling pull-back operations

teChniCalteChniCal

This article highlight some of the papers published in the current issue of the Journal of Pipeline Engineering. Abstracts of the complete contents and subscription information can be found at www.j-pipe-eng.com


Surveying underway on the Nord Stream Pipeline route.


simultaneously with the final completion date of the whole project scheduled for December 2010.

Brazilian pipeline construction company GDK S.A is responsible for two contracts for the GASTAU Project.

GDK was awarded a 32 km section of the API 5L X70 pipeline running between São José dos Campos Refinery and Taubaté station. The scope of work involves the design, engineering, construction, pigging and testing, drying, commissioning and start-up support for the pipeline.

The second contract involves the execution of seven special crossings of major rivers, dams and highways that are crossed by the gas pipeline. Petrobras tendered the special crossings contract separately due to the complexity of works involved and high level of execution difficulty.

The two contracts are managed and performed by two independent GDK teams, and both involve unique challenges.

ChallengesThe 32 km section of pipeline runs

through a highly developed region, with industrial plants, big cities of more than 2 million inhabitants, large farms and an impressive highway network built within the

vicinity of the project. Some sections of the pipeline cross housing development areas, which are densely populated, and require 12 road crossings over a distance of less than 1 km. A total of 35 road and highway crossings are being performed with large boring machines.

In addition, the GASTAU Pipeline is parallel to and located on the same right-of-way as three operating trunklines. This requires special construction procedures to ensure safe conditions are maintained to those existing lines.

GDK says that each kilometre of the pipeline has varying environmental conditions. Route terrain profile and soil conditions are varied, ranging from swamps to hills, side slope sections, rock incidence and farm lands.

GDK says that a detailed study and survey was required to select the most appropriate method for the particular characteristic of each of the crossings required for the project.

In addition to the technical execution requirements, GDK has also defined an environmental plan, as a major part of the two contracts is located inside a Federal Permanent Environmental Preservation

Area, with strict environment restrictions. Safety was also a primary concern.

The GASTAU Project requires development within a tight contract schedule. GDK took this into consideration, as well as heavy rains experienced in the region from September to February, when conducting technical studies to select the final pipeline construction methods to be used.

To comply with all these requirements, GDK´s team is using innovative methods and special equipment – some of which have never before been used for onshore pipeline construction.

The special equipment includes: • CAT 320 hydraulic excavators on Kori

amphibious floating tracks to allow ditch opening at the steep rivers banks and in swampy areas; and,

• Extra-long Doosan 24 tonne hydraulic excavators, on special ‘H’ configurated floating pontoon sets, to open the ditch in the deeper river beds, reaching up to 15 m.

GDK is currently completing construction on Petrobras’ GASTAU Project, which includes a 28 inch diameter, 97 km natural gas pipeline extension running from the north coast of Brazil to 760 m elevated plains between the cities of São Paulo and Rio de Janeiro.

The GASTAU Project will run from the Caraguatatuba Gas Treatment Plant to Taubaté Custody Transfer Station and

São José dos Campos Refinery, in São Paulo State, Brazil.

The 97 km pipeline will transport natural gas produced from the Mexilhão field, located in the offshore Santos Basin. The first phase of the field’s development is expected to produce 15 million cubic metres per day (MMcm/d) of gas. The project is of strategic importance to Brazil, aiming at increasing natural gas supply to feed industrial, automobile fuel and domestic consumption in São Paulo and Rio de Janeiro cities.

The offshore platform and facilities, offshore and onshore pipeline and compressor stations are under construction

ProjeCtsProjeCts

GDK: innovative pipeline construction on GASTAU

Crossing Method Width Features

Carvalho Pinto Expressway I HDD 180 m 6 lanes

Carvalho Pinto Expressway II HDD 140 m 6 lanes

Tamoios Highway Boring machine 130 m

Paraíba River Lay and post-trenching

420 m 25 m depth

Santa Branca Dam Pre-trenching and lay 230 m Rock

Capivari River Pre-trenching and lay 280 m 15 m depth/rock

Lourenço Velho I River Pre-trenching and lay 300 m Swampy area

Lourenço Velho II River Pre-trenching and lay 170 m Swampy area

Table 1: Summary of the features of the GASTAU Pipeline crossings.

GDK profiLeGDK is a Brazilian company, focused in oil and gas construction activities including onshore and offshore pipeline construction, offshore platforms and facilities, refineries, gas processing units and petrochemical plants.GDK has approximately 3,000 employees, and owns 90 per cent of the equipment used in its projects. This includes 1,500 pieces of heavy construction equipment: • 140 pipelayers• 120 22/24 tonne excavators• 20 pipe carrier• 65 dozers• Bending machines• Welding coupling machines• Road boring machines from

4–8 inch • Three HDD rigs with up to

1,000,000 pounds pulling force. The company is a member of the International Pipeline and Offshore Contractors Association (IPLOCA) as well as corporate member of the IPLOCA Novel Group, which focuses on the research and development of pipeline construction technology.

Route terrain profile and

soil conditions are varied,

ranging from swamps to

hills, side slope sections,

rock incidence and farm

lands.

Continued on page 32 ›› Crossing the Paraiba River.

Preparing the Lourenço Velho River crossing. Right: Lourenço River crossing preparation.


The QSN Link project connects the935 km South West Queensland Pipeline (SWQP) with Epic Energy’s

780 km Moomba to Adelaide Pipeline and the 1,367 km Moomba to Sydney Pipeline.

The SWQP receives coal seam gas at Wallumbilla in Queensland, and transports that gas to Ballera to service the Mt Isa market, before continuing into South Australia to Moomba. The SWQP also delivers gas into the Roma to Brisbane Pipeline and the Queensland Gas Pipeline, utilising the gas hub at Wallumbilla.

The project included the construction of the 180 km, 400 mm diameter QSN Link, and a midline compressor station on the SWQP near Charleville and compression at Epic’s Wallumbilla compound.

Co-operative constructionIn July 2007, Epic Energy set up an in-

house project team to manage the QSN Link project. Headed by Daniel Wallace, the team of up to 12 people included both long-term Epic employees seconded to the project for its duration and contractors employed specifically for the project.

During construction of the pipeline and compressor facilities, around 300 new jobs were created and Epic Energy employed additional staff to operate and maintain the new pipeline and facilities post commissioning.

BlueScope Steel supplied approximately 17,000 tonnes of high-strength PIPESTEEL, suitable for conversion into API 5L X70, to Orrcon's Pipe and Large Tube Division. The steel supplied was developed specifically to meet the stringent requirements of high-strength, high-pressure pipeline applications and has been used in over 20 other pipeline projects.

An early contractor involvement (ECI) process was adopted for the project, which enabled the construction contractor Nacap to become intimately involved in the planning and contract negotiation for the job prior to contract award. The ECI process also assisted the company to ‘hit the ground running’

once the contract was awarded. Onsite cultural heritage monitoring

continued while ground-breaking activities were underway in Queensland and onsite flora and fauna monitors were in place to ensure minimal impact on the natural habitat.

Construction of the compressor stations, at Scraper Station 4 near Charleville, and at Wallumbilla, commenced on 31 March 2008 and on 4 August 2008, respectively. All phases of construction being managed by Epic Energy were completed on time, for a mid-January 2009 first gas date.

Hot tapping the pipelinesThree hot taps were included on the

project – a Class 900 tap on the SWQP, the Moomba to Adelaide Pipeline and on the Moomba to Sydney Pipeline. Nacap subcontracted the hot tap works on all pipelines to experienced hot tap contractor Furmanite.

Tight time-frames and environmental awareness

The main concern with respect to engineering was the fast track nature of

the job. Again the co-operative nature of the project between Nacap, Epic Energy and engineering consultant WorleyParsons in Brisbane, meant that any issues identified during the process were resolved quickly and with minimal impact on the construction process.

There were literally hundreds of culturally significant sites identified by

Epic Energy recently completed construction of the QSN Link Pipeline, which for the first time directly links the sales gas systems in Queensland, Australia, to both New South Wales and South Australia.


Paraíba River crossingGDK says that one of the most

challenging jobs under the contract is the Paraíba River crossing.

The Paraíba River – the most important river in the region – is 420 m wide and 25 m deep with a deep ‘V’ channel and steep banks that do not allow conventional construction methods or directional drilling methods.

After an extensive technical study, GDK has decided to apply a combined onshore and offshore solution. This solution is to prepare a pipe length with a concrete jacket to run along the entire width of the river and bank and kept afloat using twin-buoys sets.

Following the correct positioning of the 420 m string at the crossing, the pipe will be lowered to the river bed by water-ballasting the buoys. After reaching its correct position in the river bed, a post-trenching machine – applied only in offshore pipelines – will excavate the ditch below the pipe, burying it 1 m into to river bed, and stabilising the pipe section.

GDK says that the application of this solution can be credited to the combination of the company’s expertise in both onshore and offshore pipeline construction. GDK has previously performed several offshore

pipeline construction contracts. While assembling large diameter pipelines in a sensitive area of the Guanabara Bay in Rio de Janeiro, GDK employed a similar method resulting in a very cost-effective solution to the client, as well as limiting the environmental impact of the project.

Construction continuing on schedule

Completion of all the seven major crossings is scheduled to be achieved in January 2010. By October 2009, five of the crossings were already complete and the overall work progress had reached above 70 per cent. The pipeline contract is expected to be complete by March 2010, in line with a special requirement stipulated by Petrobras.

Having to apply new techniques and equipment to perform the jobs, the GASTAU Project highlights the experience of GDK personnel and establishes a new benchmark in terms of pipeline construction performance.

Pipeline link constructed in central Australia

GAstAU project GDK mANAGiNG teAmDirector - Conrado SerodioProject Manager - José Guido de OliveiraContract Manager - Sérgio Menezes BorgesConstruction Manager - Sérgio LimaConstruction Supervisor - Edson de Souza



Trenching activities are completed on the QSN Link project.

Welders hard at work.

Left: Launching the Lourenço II river crossing.Paraiba River crossing preparation.

Road crossing boring machine.

ProjeCts ProjeCts


local indigenous groups during pre-construction surveys of the planned route. On mobilisation to site, Nacap immediately flagged these as ‘no-go’ areas for the duration of the project. The identification of these areas, as is usually the case, resulted in minor re-alignment of the pipeline route and reduced work space in areas where re-alignment was impractical.

The most environmentally significant sites on the project were identified early in the pre-construction surveys around the creek areas and, in particular, the Cooper Creek crossing near the Nappa Merrie bridge. Numerous planning

visits were undertaken to the proposed Cooper crossing site by personnel including Nacap, Epic and environmental consultant, RPS Ecos, to ensure that the optimum route was chosen with minimal environmental impact.

Further expansionWork continues on bringing the

previously announced proposed Stage 3 expansion of the SWQP to fruition. The Stage 3 expansion involves the construction of a new circa 935 km, 450 mm diameter pipeline adjacent to the SWQP. The expanded SWQP’s daily capacity would be increased from 168 TJ to approximately 380 TJ.

Pipelayers and sidebooms: the essential pipeline machinery

PiPeline equiPMent

When selecting a pipelayer or sideboom to construct a pipeline, many considerations must be

taken into account. A pipelayer will be selected based on the size and weight of the pipe to be installed and topography of the construction site. These considerations impact on the lifting capacity of the pipelayer, transportability and ease of service required for the project.

Volvo Construction Equipment's Derrick Butterfield says “The larger and heavier the pipe to be used – for example, concrete coated pipe for immersion in water – demands equipment with the lifting capability and stability to manage it safely.”

If limited access to the right-of-way is encountered, transporting the pipelayer to site can be an issue.

PipeLine Machinery International's (PLM) Sherry Gettis says “The contractor may need to consider using machines with lower lift capacity, but use more of them to lift a section of pipe. Ease of service can be a crucial consideration on remote access pipelines or projects with tight completion timelines.”

The contractor could also choose to purchase a large pipelay machine with the ability to self-disassemble, such as in Volvo’s large pipelayer range.

StabilityMr Butterfield says that machine

stability remains a known issue with pipelayer and sideboom machinery.

“Volvo’s excavator-based pipelayer solution dramatically increases stability thanks to a wide, almost square, operating platform on the two largest models – PL4611 and PL015. A hydraulic variable undercarriage is used on the latest model, PL4608.”

Dressta has developed a pipelayer with a boom prop to improve stability. The SB-60 BP aims to provide contractors with the ability to safely lift larger loads of pipe – up to 60,000 kg – by extending a prop to support a sideboom with an overhang of

2.2–6 m. The company’s pipelay machines are also fitted with hydraulically controlled counterweights for machine stability.

Maats/Liebherr has developed the RL 64 pipelayer with wide track pads on the load side in order to increase stability and maintain a low ground pressure to improve safety when working on porous ditch edges.

SafetySafety improvements are continually being

made within the pipelayer/sideboom industry. Within the last 12 months, Volvo has

developed a roll over protective structure (ROPS), load management systems, increased load capacity and better stability on its machines.

Pipelayers and sidebooms are an integral piece of machinery on any pipeline construction site. There are many machines currently available to choose from, and issues such as safety and the environment are driving further developments within the industry.

iNNoVAtioNsThe following innovations were employed by the project team: • The contract for the supply of linepipe with Orrcon included triple random lengths of up to 19.3 m in length. These long lengths

significantly increased pipeline construction rates with welding achieving approximately 5.5 km per day for the entire length of the pipeline.

• Automatic Ultrasonic Testing (AUT) was employed to test 100 per cent of the circumferential welds. The AUT process also meant high examination rates were achieved by AUT contractor, UT Quality. AUT enables quick examination of the weld and a fast return on assessment of testing, which is complete within one minute of the welding being scanned. AUT also enables easy electronic storage of all examination data in Epic Energy’s Geographical Information System (GIS).


Pipe stringing along the QSN Link route.

Construction works underway on the pipeline.

PipeLine Machinery International provides Caterpillar pipelayers.


ProjeCts


Maats/Liebherr has also recently developed a ROPS for the Komatsu D355C-3 machine, which complies with the EN 13510:2000 and ISO 3741:2006 standards.

Dressta has improved safety on its pipelayer machines through the incorporation of emergency free-fall on the load line, an automatic boom kick-out to prevent boom damage, an automatic overwind device and a load indicating device.

PLM’s Ms Gettis notes several features of the Caterpillar pipelayers that have been adapted with safety in mind. New cab designs maximise the operator’s view around the machine. Fingertip controls and quick release blocks are designed to keep operators out of trouble.”

Ms Gettis also notes that adequate training is imperative to ensure safety on the construction site, and this includes knowing how to properly operate pipelay and sideboom equipment.

“The most important safety aspect on the pipeline right-of-way is well-trained operators on well-maintained equipment.

Caterpillar and PLM are working closely with industry training facilities to ensure that new operators have the best equipment to learn on,” says Ms Gettis.

The environmentWithin the industry, there is a growing

concern about reducing the carbon footprint of pipeline construction projects. Companies that manufacture and distribute pipelayer and sideboom equipment are responding by developing pipelayers with engines that have lower emissions.

Caterpillar is continuing to develop Tier 4 rated engines and has recently launched the first electric drive tractor – the D7E.

Maats/Liebherr has installed its RL 64 pipelayer with a diesel engine with an output of 275 kW/374 horse power that complies with all common emission regulations.

Ms Gettis notes that there are issues that need to be addressed as manufacture is increased on lower emissions engines.

“Lower emissions requirements and alternative low-sulfur diesel fuels are

issues that will affect major northern hemisphere pipeline projects. Low ambient temperatures are a challenge for today’s low-emissions engines. Addressing this issue on projects to be built in -4.4 degrees Celsius temperatures is our challenge and one we have been working on with the industry for several years,” she says.

Future developmentsEach pipeline construction spread is

different, requiring contractors to think carefully about the machinery that would best suit the project. Pipelay and sideboom manufacturers offer many different options for pipeline projects, while taking key issues such as safety and the environment into consideration.

In addition, pipelay and sideboom machinery continues to be developed. The industry continues to improve the transportability of the equipment, develop accessories to improve operator comfort and efficiency, and continue to engineer machinery required for new trends in the pipeline industry.

PiPeline equiPMent

“The larger and heavier

the pipe to be used – for

example, concrete coated

pipe for immersion in water –

demands equipment with the

lifting capability and stability

to manage it safely.”

– VoLVo’S DERRICk BUTTERfIELD

Dressta pipelayers and sidebooms complete the job.

Volvo Construction Equipment pipelayers in action.



PiPeline equiPMent

The Caterpillar PL61 pipelayer provides 40,000 lb lift capacity and the capability to meet pipeline contractor requirements, with improved control, transportability, operator comfort, visibility and durability.

PipeLine Machinery International is supplying Caterpillar’s PL61 pipelayer – a new technically refined model at the

small end of the pipelayer product line – to the worldwide pipeline industry.

The Caterpillar pipelayer system includes a winch, 5.5 m lightweight boom, counterweight and frame. The boom is constructed of specialty strength steel and the counterweight is extended hydraulically for improved load balance and clearance. Counterweight segments are contoured to provide a low centre of gravity and an enhanced forward and right side viewing area necessary for job site safety.

The frame is engineered to last throughout the extended service life of the PL61. The one piece main frame is

designed to absorb high impact shock loads and twisting forces. The machine can be configured for both standard gauge and low ground pressure.

The PL61 features an electronically controlled hydrostatic drive system with independent power and control of each track for fast acceleration, variable speed control, and on-the-go direction changes.

The Caterpillar C6.6 Diesel Engine with ACERT Technology meets worldwide emissions requirements for EPA Tier 3, EU Stage IIIA and Japan Moc Step 3 engine exhaust emission regulations.

Caterpillar PL61 pipelayers can be ordered globally through PipeLine Machinery International or by contacting your local Caterpillar dealer.

Pipelaying with the PL61

For more information on Caterpillar’s pipelayer line available through PipeLine Machinery International visit www.plmcat.com

The Caterpillar C6.6

Diesel Engine with

ACERT Technology meets

worldwide emissions

requirements

ONE WORLD.ONE FOCUS.ONE NAME.

PipeLine Machinery International (PLM) supports the global needs of mainline pipeline construction customers with one-stop access to the most extensive pipeline machinery expertise in the business.

New and used PLM-supplied Caterpillar machines are now operating around the world delivering maximum productivity and reliability, together with industry-leading technology in the areas of environmental compliance, safety and ease of operation.

www.plmcat.com

© 2008 CaterpillarAll Rights Reserved

CAT, CATERPILLAR, ACERT, their respective logos, SystemOne, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.


The United States Department of Transportation (DOT) requires that mechanical pipeline defects such as dents must be reported. Operators often find it particularly challenging to effectively assess such ID anomalies.

Research programmes to enhance the assessment of this type of damage have led to a new approach in the detection

of inner diameter anomalies by means of the latest generation of high-resolution geometry inspection technology.

Based on experimental data obtained in the course of several research projects, this article presents the benefits of high-resolution geometry tools in conducting baseline surveys for the purpose of subsequent assessment of mechanical damage. The operating benefits gained thereby are explained in the context of other in-line inspection technologies.

The nature of ovalities and other ID anomalies

Being very complex in structure, ID anomalies can appear in a wide range of forms. The American Society of Mechanical Engineers (ASME) defines a dent as ‘a gross disturbance in the curvature of the pipe wall’.

The most important type of anomaly for the purposes of the present investigation are ovalities. Defined as ‘a deviation of the circular shape of the cross section of the pipeline’, an ovality affects the entire circumference of the pipeline cross section. Ovalities usually appear in combination with a dent making them part of a more complex ID anomaly.

A new approach to the detection of ID anomalies

To ensure full compliance with all requirements governing the wide variety of ID anomalies, a new approach consisting of two main features is now taken. Firstly, a new sensor has been developed which combines the proven mechanical caliper arm system with a ‘touchless’ eddy current device. Secondly, a new arrangement of these sensor devices with a second sensor ring, circumferentially offset from the first,

ensures complete coverage of the internal pipeline circumference. In combination, the new sensor systems and their innovative arrangement have significantly improved probability of detection. Figure 1 shows how this new approach is implemented in a single tool.

Since it is often impossible to give a full description of the depth, length and width of many ID anomalies including dents, an accurate assessment of the properties of such anomalies based on reliable high-resolution geometry data leads to more detailed knowledge and consequently more reliable analysis of the pipeline contour. In combination, pipeline curvature and dent shape provide an important parameter for the calculation of dent strain, also known as ‘local strain’: abrupt changes in pipeline curvature are more severe and result in a higher dent strain value than plain dents. The new RoGeo·Xt makes an invaluable contribution to local strain assessment.

In addition, if the RoGeo·Xt is equipped with an Inertial Measurement Unit (IMU); it can also measure regional strain resulting from the displacement of pipeline segments due to external forces such as landslides. Whereas the displacements are detected with the IMU, all subsequent bending strain assessment decisions are as a rule supplemented by data obtained during the same inspection run on the basis of internal pipeline contour sampling with ID mapping sensors.

Exceeding regulatory requirements

Adopting a modular inspection approach whereby the newly developed high-resolution geometry technology is combined with other ILI methods such as magnetic flux leakage (MFL), geometry mapping and, as in this case, an IMU to

form so-called ‘multi-purpose tools’, enables merging and mapping data sets to provide a more complete picture of the pipeline as well as a more thorough assessment of specific anomalies. Such multi-purpose tools incorporating a variety of ILI methods have been developed further to accommodate multi-diameter pipelines.

Difficult operating conditions in deep water, high-pressure or heavy wall pipes as well as challenging pipeline design features such as wyes have always placed great demands on the design of ILI tools and runs. The highly accurate data furnished by the enhanced geometric inspection system is therefore a great step forward in assessing

Optimal identification: getting up close with ID anomalies By Steffen Paeper, Daniel Molenda (PhD) and Johannes Palmer, Rosen Technology & Research Center, Germany

Pigging


Figure 1: 30 inch RoGeo·Xt featuring two inspection planes for 100 per cent coverage of the internal pipeline surface.

Figure 2: Pipeline long seam arrangement of an offshore pipeline as detected by the Rosen geometry inspection tool.

TREATMENT.As a leader in pipeline inspection, ROSEN not only supplies

a complete range of treatments for pipelines butalso keeps your engineering structures up and running.

www.roseninspection.net

EMPOWERED BY TECHNOLOGY

359_07_ros_090519_anz_block_A4_RZ.indd 1 19.5.2009 9:45:45 Uhr


Pigging

the condition even of assets posing great inspection challenges.

In addition to the codes and regulations governing pipeline inspections, pipeline manufacturers must meet specifications for the production of pipeline joints and bends, for example by documenting in detail the manufacture of submerged arc-welded longitudinal seam pipes and stating the rating of manufactured bends to ensure satisfactory fitting of pipeline joints. An accurate baseline survey firstly confirms that these various pipeline elements perfectly fit each other following installation, and secondly provides an ideal database for analysing the pipeline’s ability to resist buckling due to environmental loading.

These strict requirements have led to greater interest in ID anomalies. In line with this interest, tools with improved performance have been developed, and this has in turned resulted in a significant increase in the number of features reported to an average of 1.5 dents per kilometre. The DOT guidelines for dents without any stress riser use as a critical benchmark a dent depth of 2 per cent and above in outer diameter. The first Rosen statistics based on ID anomaly data gathered with the RoGeo·Xt show that more than 80 per cent of detected ID anomalies are shallower than 2 per cent, meaning that the tool not only meets but by far exceeds current regulatory requirements.

Measuring ovality and welded areas including long seams as part of baseline surveys

Regulators specify that ovality (or ‘out-of-roundness’) is an applicable value for assessing the quality of manufactured

pipeline joints. High-resolution geometry tools are a suitable instrument for assessing recent as-built pipelines in baseline surveys, which specify an ‘out-of-roundness’ value for all manufactured pipeline joints. ILI methods are then used to prove or disprove this value.

Figure 2 shows an example of a data set recorded during a geometric ILI of an offshore pipeline. The long seams (green appearance) around the 12 o’clock line (red) are very clear and distinctive; their position alternates between 2 o’clock and 10 o’clock with minimal scatters. This geometric inspection data allows a more comprehensive feature assessment, for example of dent curvature associated with seam welds.

Pipelines are usually welded with the long seams offset, typically at 10 and 2 o’clock. Such a pipeline layout scheme is shown in Figure 3.

A detailed comparison of the data sample and the actual pipeline layout highlights the sensitivity of the RoGeo·Xt ILI tool. This high sensitivity enormously benefits integrity management programmes, as the detection of welded areas including

long seams forms a vital source of information for several defect assessment methods.

The unprecedented sensitivity in the sub-millimetre range of geometric ILI tools such as the RoGeo·Xt extends their range of applications, since internal wall thickness loss can be treated as ID changes. This means that geometry tools can now be used to support wall thickness recordings obtained from metal loss mapping tools.

Internal corrosionThe RoGeo·Xt is highly sensitive to

features affecting the whole circumference of the pipeline. The sensitivity of geometric ILI tools to local features can be enhanced by combining high-resolution geometric technology with an ultrasonic (UT) device. As the distance between the UT sensor and pipe wall is known, UT not only measures wall thickness but also the stand-off signal. Since the two technologies use different measurement methods to supply the same type of information, their combination permits reliable feature assessment based on a comparison between UT stand-off and the lift-off measurement (eddy current sensor) of the RoGeo·Xt.

Due to the high sensitivity of the lift-off sensors, the RoGeo·Xt can even be used to search for shallow internal corrosion. This means that the extended tool can be used to detect and size shallow internal corrosion in exceptionally challenging conditions, for example where complete magnetisation of the pipe wall is extremely difficult or using UT is altogether impossible.

ConclusionRosen’s RoGeo·Xt has been proven in

field applications to fulfil the requirements of standard codes and regulations. Based on a new sensor combining a mechanical calliper arm with a ‘touchless’ eddy current device as well as a novel arrangement of these sensor devices with a second sensor ring to ensure 100 per cent internal coverage, the new approach to the detection of ID anomalies provides a more complete picture of the condition of pipelines. Due to the enhancement of the tools’ geometric inspection capabilities, even marginal ovalities can be detected and sized.

Pigging

This article is a condensed version. The full version of this article, including references can be found at the Pipelines International website www.pipelinesinternational.com

Figure 4: Correlating the azimuth angle of ovalities with the pipeline layout.

Figure 3: Schematic illustration of a typical pipeline joint layout with long seams offset at 10 and 2 o’clock (dashed red line indicates the 12 o’clock position).



Earlier this year, GRTgaz successfully completed its advanced magnetic flux leakage (MFL) inspection on a 6 inch

diameter, 39 km pipeline in Normandy, France. Built in 1965, the pipeline is located to the northwest of Paris and is part of GRTgaz’s 32,000 km gas pipeline system in France.

The MFL inspection was completed using the MagneScan in-line inspection system, which allows operators to map pipelines of diameters as small as 6 inches while also inspecting for metal loss and geometry features.

The new MagneScan system deployed by GRTgaz is the first able to inspect pipelines — of varying diameters and sharp bends — for multiple types of features in a single run. The system was developed by GE Oil & Gas’ PII Pipeline Solutions Centre of Excellence for Magnetics in Northumberland, United Kingdom. PII Pipeline Solutions was instrumental in developing the original MFL technology used for oil and gas pipeline inspection in the 1970s when it was under British Gas ownership.

The system records the position of the pipeline features and anomalies such as: • Dents, ovalities, and bends; • Internal and external pitting and

general corrosion on the pipe body; • Metal loss in the vicinity of welds; and, • Metal loss associated with dents and

under casings. The new MagneScan systems are

designed to locate and size areas of metal loss of five per cent wall thickness or greater, and — in practice — detect metal loss even smaller.

Technical features of the new MagneScan that are attractive to pipeline operators include its 216 low noise Hall effect sensors that record readings taken on axial, radial and transverse vectors every 2 mm. This new 3D configuration covers 100 per cent of the pipe circumference

and optimises defect-sizing accuracy for width, length and depth. The system simultaneously maps the pipeline and checks it for corrosion, using high resolution MFL sensors that deliver high quality data to identify and locate metal loss and is suitable for geographic information systems (GIS) analysis. Mapping data is integrated with inspection information during the run, reducing the amount of post-processing required.

The improved accuracy means less digs for the operators following inspection runs, which convert to significant savings and reduced environmental impact.

While GRTgaz and GE’s PII Pipeline Solutions had originally agreed that the project would consist of a maximum of five runs to gauge, clean, geometric survey, inspect and map the pipeline, GE instead completed the scope of supply in only four runs, running gauge, cleaner ‘profile’ and the new MagneScan.

“We were very pleased with the performance of the new MagneScan system. It allowed us to complete the inspection with a single pass after the initial gauging, cleaning and dummy tool runs had been completed,” said GRTgaz spokesperson Stéphane Ardiet.

“GE was also able to complete the project within our very tight window – between 19 and 30 January 2009 – to minimise the impact on production from our gas storage facility in St Illiers.”

In addition to the tool’s reliable performance allowing the operation to be carried out ahead of schedule, the project maintained strict compliance with the European Union’s ATEX safety requirements, for operations in potentially explosive atmospheres.

“We have delivered to our client the full inspection report within the eight-week timeframe that was agreed upon, and the results from the analysed data have amazed even the most experienced of our staff,”

said General Manager of GE Oil & Gas PII Pipe Solutions John Bucci.

“This technology enables pipeline operators to choose the level of analysis of data they wish to review upon completion of inspection, and allows them to come back to GE later with additional requirements for more in-depth analysis leading to remediation plans.”

To aid data analysts in improving characterisation of complex (interactive or axial) corrosion defects, the new technology presents visually powerful data derived from three magnetic fields – transverse, radial, and axial. These data sets are combined to achieve enhanced defect sizing specifications and improved probability of identification.

Since its introduction at the International Pipeline Conference in Calgary in September 2008, the new technology has completed more than 40 inspection runs, covering over 2,500 km of liquid and gas pipelines across three continents.

Establishing a technical benchmark in pipeline security and environmental protection, GDF Suez’s wholly-owned gas transmission system operator, GRTgaz, has completed its first project with the new MagneScan in-line inspection system.

GE’s MagneScan inspects Normandy pipeline By Martin Bluck, Product Line Leader, GE Oil & Gas, PII Pipeline Solutions

The MagneScan in-line inspection system.


PipeWay’s Porcupine ultra high resolution technology has been developed to solve some of the limitations of magnetic flux leakage and ultrasonic technology that affects detection and definition of internal defects on pipeline systems.

Winner of the 2007 Global Pipeline award presented by the American Society of Mechanical Engineers

International Pipeline Technology Institute, the Porcupine detects and defines longitudinal defects including channelling corrosion, erosion, preferential longitudinal weld line and general wall thinning, as well as typical pitting corrosion and small inner diameter (ID) corrosion.

The magnetic flux leakage (MFL) technique using longitudinal induced flux fields does not do well on the sizing definition of longitudinally oriented corrosion or on defects that create general wall thinning.

MFL technology is also limited by wall thickness especially above 19 mm. In MFL

pigs of 14 inches or below, the limitation of internal area for magnets intensifies the problems created by wall thickness. As production goes deeper, the wall thickness of pipelines generally increases so that the use of MFL in some systems has a limited application.

Ultrasonic (UT) technology requires a homogeneous liquid to fill the pipeline, reducing its application on most production pipelines and all gas pipelines. A second limitation of UT is that pipelines inspected by that method need to be very clean to avoid false or no signal return.

The Porcupine’s direct measurement of the internal surface and its discontinuities avoids these limitations. The sensor fingers measure axial movement in both directions from its calibrated set point at the nominal inner diameter (ID) of the system being inspected. The range of motion of the sensor is accurate to 0.004 inches. The sensor finger range also allows the accurate measurement of almost any wall thickness.

In comparisons to UT pig results and to external C-Scan UT inspection, the correlation has proved the tool’s performance and resolution to be similar in both normally formed corrosion and longitudinal channelling corrosion.

Porcupine’s direct measuring technique is also very tolerant of soft or movable debris in the pipeline allowing for inspections in lines that are resistant to cleaning such as those containing paraffin. Debris that is not movable such as scale or other hard deposits will be detected and measured as to the area covered and the thickness of the deposits. This information allows the evaluation of pipeline cleaning programs and their modification based on data from the Porcupine.

Scale deposits that may hide corrosion or corrosion colonies can also be defined as to thickness, area covered and location. Operators can then decide the best method

for eliminating the areas of scale, allowing chemical or mitigation treatments to reach the affected areas.

Another benefit of the Porcupine technology is the tool’s flexible design. The tool has been proven in dual diameter pipelines and in bend radius down to 1D in some sizes. This will allow some systems now considered unpiggable to be pigged with the technology.

The technology has now been used in pigs up to 42 inches and is now being adapted down to 3 inches. Proof of the technology in field applications and comparison of the technology to both MFL and UT techniques have proven this system is now ready to be applied to any pipeline system.

The high resolution response and the high degree of flexibility also make this technology applicable to other areas where the technology will answer integrity questions about high value assets. Some of these asset classes are heat exchangers, like steam generation systems and coker refinery units. PipeWay is currently developing the Porcupine technology for tube inspection for the applications.

The inspection of tubes in these heat exchanger systems will be able to detect and define defects such as small diameter corrosion, erosion, and general wall thinning and bulging. The detection and definition of the defects will be for both the straight pipe and the numerous elbows in the system.

An added benefit of this inspection is that it will be able to check for remaining scale, therefore determining whether the tubes are clean prior to putting the units back in service.

The Porcupine technology offers a unique, flexible and accurate method to inspect pipeline and tubed systems for required defect and cleanliness information to make integrity and asset management decisions.

Pigging

Prickly pigging: PipeWay’s Porcupine reaches the international market

Pigging

PipeWay’s Porcupine ultra high resolution technology.

The Pigging Products and Services Association plays a major role in promoting the knowledge of pipeline pigging and related products and services.

Following an initiative that developed from a series of pipeline pigging conferences, the Pigging Products

and Services Association (PPSA) was formed in 1990. The Association now has over 95 members, and represents the pigging industry throughout the world.

Providing pigging servicesWholly funded by members through

annual subscription fees, the PPSA plays a major role in providing information and sourcing equipment and services for pipeline operators and the industry generally. It has a newly refurbished website where visitors can source the products and services they need, and link to PPSA’s technical information service and other facilities. The Association runs an annual seminar in Aberdeen, occasional training courses on pigging, sponsors lectures and meetings about the subject, and supports relevant conferences.

The PPSA’s annual general meeting is usually held to coincide with the Houston Pipeline Pigging and Integrity Monitoring Conference and Exhibition, in which many PPSA members and their companies are involved. Next year’s will be held on 16 February, at the Marriott Westchase Hotel in Houston.

The Association publishes a regular newsletter Pigging Industry News, which contains news about members’ companies and brief articles of general pigging interest. A number of years ago the PPSA published An Introduction to Pipeline Pigging, a 104 page book which was written to give a comprehensive overview of the most important aspects of pipeline pigging. The book is now in its eighth edition, and continues to be an invaluable source of reference to the wider industry.

The Association also publishes an annual directory, containing contact details of all the members and a brief overview of their capabilities and activities. The directory

is free, and currently has a circulated to approximately 5,000 copies around the world.

Why is a pig called a pig?One of the PPSA's most popular general

questions is “How did a pig get its name?”.There are several possibilities. One story

says that two pipeliners were told to clean a pipeline and listen for the pipe cleaner to go by. This pipe cleaner consisted of a steel pipe or mandrel body with flanges welded on both ends. Discs made of leather sheets were stacked together to provide thickness, and attached to the flanges. As the pipe cleaner travelled down the line pushing out debris, it made a squealing, scraping, noise. As the cleaner went by, one pipeliner made a comment to the other about “hearing that pig squeal”.

A similar squealing is attributed to a very early type of pig that was made up from a bale of hay wrapped around by barbed wire, and stuck into the pipeline. A third account claims that an early sphere pig was in fact a pig’s bladder – like a football – that was inflated to the necessary oversize. These stories are generally accepted as possibly being true, although none can be verified.

Pigs through historyFor more than half a century pigs

consisted of steel bodies and rubber, leather, or urethane cups or discs. The tools were equipped with wire brushes, scrapers, knife

blades, and other devices for ploughing. Until 1960, most pipe cleaning was limited to the oil and gas industry. Then the foam bullet-shaped pig was developed – referred to as the ‘polly’ pig because it was made of polyurethane foam.

Although the oil and gas industry remains the largest user of foam pigs, many new industries such as the water and wastewater industry, as well as the chemical processing, petrochemical and mining industries are now using pigs in their pipelines, realising gains such as energy savings, increased flows, decreased pumping pressures, cleaner product, and salvaged product.

The lessons learned from standard pigging operations to clean, dewater, fill, and displace product from pipelines, and the pressures, speeds, and problems incurred, have contributed greatly to the development of instrumented pigs. These were introduced in the late 1960s, and development is continuing to the present day.

There are now literally hundreds of different types of pigs, some with specific or limited use. Apart from the main functions of sweeping, drying, wiping, cleaning, scraping, inspection, and integrity monitoring, ‘semi-intelligent’ pigs now perform additional functions such as alerting and initiating actions involving pumps and valves, making inputs in computerised operations, sometimes through pipe-wall communications, and pipe sealing to allow repairs or tie-ins.

PPSA: providing squeaky clean pigging advice PPSA aim

“To promote the knowledge of pigging and its related products and services by providing a channel of communication between the members themselves, and with users and other interested parties.”

For further information about the PPSA and its activities, or to receive a free copy of the Directory of members, please contact the Association via email [email protected], or visit www.ppsa-online.com


Houston, Texas, will be abuzz with pipeline pigging in February 2010, with the annual Pipeline Pigging & Integrity Management Conference and Exhibition gearing up to be a great success.

The 22nd Pipeline Pigging & Integrity Management Conference and Exhibition is once again set to take

the world by storm – taking place at the Marriott Westchase Hotel, Houston, Texas, from 15–18 February 2010.

The premier Conference and Exhibition provides a forum dedicated exclusively to pigging for maintenance and inspection, as well as pipeline integrity evaluation and repair. It enables delegates to come face to face with the industry’s top professionals and create important and lasting contacts.

The 2010 event is expected to draw more than 1,000 participants including engineering management and field operating personnel from both transmission and distribution companies concerned with improved operations and integrity management.

The two-day technical programme, starting on 17 February, will feature ‘unpiggable pipelines’, new pigging tools and techniques, regulation, inspection,

multi-diameter and bi-directional pigging, data interpretation and management, and much more.

The Exhibition will run from 16–18 February, and showcase more than 70 companies’ products and services – providing the world’s largest specialised exhibition of pipeline pigging and related products and services.

Delegates will be able to talk to product and service providers directly to find out about the latest innovative solutions available.

Seven training courses will also be available from 15–16 February. These courses will cover:• Pigging and in-line inspection• Pipeline risk management• Pipeline repair and in-service welding• Pipeline rehabilitation• Defect assessment in pipelines• Excavation inspection and applied non-

destructive evaluation• USA Department of Transportation

pipeline safety regulations.

Ensuring pipeline integrity: talking pigging in Houston

Make sure you don’t miss out on the latest pipeline pigging updates, products and services. To register for the Pipeline Pigging & Integrity Management Conference and Exhibition visit www.clarion.org

Pipeline professionals

around the world are

looking forward to this

event. Get in quick to

register.

Pigging


PIGGINGPIGGING

Courses

Conference

Exhibition

Now entering it 22nd year, the PPIM Conference is recognized as the foremost international forum for sharing and learning about best practices in lifetime maintenance and condition-monitoring technology for natural gas, crude oil and product pipelines.

More than 100 specialized providers of pipeline inspection and integrity services

850+ attendees

2 days of cutting-edge technicalpresentations

7 critically acclaimed training courses

Plan to be there: www.clarion.org or call us at +1 713 521 5929

The international gathering of the global pigging industry!

Houston, February 15-18, 2010

Pipeline Pigging and Integrity Management

Houston Marriott Westchase Hotel, Houston, Texas

Conference Organisers

Conference Supporters

PPIM_FP.indd 1 7/12/09 3:24 PM


Selecting the right valves

There are many valve manufacturers and valves for any type of production, temperature, pressure and service condition can be found. Of these makes and styles there is a wide range of feature options to choose from, such as full or reduced port, floating or trunion-mounted ball, rising or non-rising stem gate.

When selecting a crucial component like a mainline block valve, it is best to consider the service conditions. What is the likelihood of the valve seat seals being worn enough to cause significant leakage due to continued dry cycling or the presence of an abrasive like construction debris, black powder or sand? For instance, a metal-seated plug valve would suit a mainline block cross-over assembly application better than a soft-seal ball valve. Due to line purging and throttling, damage can easily occur on the soft-seat seals of a ball valve, whereas metal-seated plug valves are designed to resist seat wear in these conditions.

Many manufacturers claim to produce valves that do not require lubrication and, hence, do not include a seat sealant system to inject lubricant or emergency sealant. Every valve will eventually leak if not properly maintained and the operator’s ability to maintain production or to isolate a pipe section could depend greatly on sealing one leaking valve.

Storage and handling

Valve care is often neglected before initial installation. Often large diameter block valves are stored on a dusty construction site with no end covers or alternative protection from airborne contaminants. Rarely is the internal sealing integrity of the valve taken into consideration by construction crews whose number one concern is its timely installation.

Likewise, the improper transportation of the valve itself should be of paramount concern to project managers. Any rough handling of the valve could cause the ball or gate to ‘creep’ out of its seat, exposing the seat ring and body cavity to debris contamination. Any opportunity to prevent contamination of the valve assembly will increase the likelihood of achieving a positive seat seal test once installed.

Careful handling and storage of valves prior to installation, as well as following correct procedures during construction and commissioning, ensures a more efficient and safe pipeline, with less chance of lost production and failed isolations. This article outlines five steps to follow for a healthy valve.

simple steps to total valve integrityBy Jason Chisholm, Sealweld Corporation

valvesvalves

Upgrading

Once the valve design that best suits the operating conditions of the pipeline has been chosen, one of the most important steps is to outfit the valve with the proper internal check valves, sealant injection fittings, body vent/drain fittings, packing injectors, and riser lines (if required). The only chance at maintaining the sealing integrity of the valve depends on the ability to inject synthetic lubricants and sealants into the seat and stem areas of the valve. It only takes one cycle of a contaminated valve to completely destroy the highly sensitive soft seals inside the seating area.

Typically, these upgrades are overlooked during the design phase as future wear and tear is rarely taken into account. Specifying 3/8 inch riser lines, opposed to the more popular and slightly cheaper ¼ inch riser lines, enables service technicians a much greater chance of injecting a heavy sealant faster if leakage is occurring in the seat area and a seal must be achieved. Likewise for injection fittings, a threaded cage design is more likely to withstand the injection pressures of heavy emergency sealants than a crimped cage design, which can fail under as little as 3,000 psi (20,700 kPa). Studies have shown that threaded cage style fittings can withstand injection pressures of well over 50,000 psi (344,700 kPa).

Valve maintenance technicians rely on the ability to blow-down the valve body cavity to create pressure differentials across leak paths in order to ‘draw’ sealants into the required areas. Technicians are often faced with servicing valves of up to 60 inch inner diameter that are outfitted with ¼ inch body vent ports. This is hardly an ideal situation as the drain port will not be able to vent enough pressure to create the kind of differential that is required to deliver the sealant to the areas that need it the most. Many pipeline operators are beginning to specify full-port ball valves in place of body vent fittings on large diameter valves for this reason.

Inspecting and commissioning

Of any step taken toward ensuring that a pipeline runs efficiently and safely, valve commissioning is the most crucial. A case in point involves the resurrection of three brand new 36 inch buried mainline block valves due to the complete washout of seat seals during nitrogen purging. The cause: no lubricant in the seat sealant system or seat ring groove.

As a result of valve installation, construction debris becomes trapped inside the pipe where the butt ends are welded. Once installed, the purging process pushes the construction debris against the ball and into the gap between the seat ring and the sealing face. At this point during the aforementioned construction project, had any lubricant been injected into the valve, it would have pushed enough of the debris out and away from the sealing area and minimal damage would have occurred. Instead, the valve was dry cycled and so severely damaged to the point that it required replacement before the pipeline section could be brought online.

The engineers and managers of this pipeline project would go on to implement a strict valve commissioning and pipe inspection procedure. As a result; welding slag, dirt, rocks, and any other kind of debris was meticulously removed from pipe sections before valve installation. Every valve was purged of factory grease and replaced with a high quality synthetic lubricant and air tested to ensure that the seat seals maintained their integrity. Eight years later, every commissioned valve on this project retains perfect sealing integrity.

Routine maintenance

If the preceding four steps have been followed, the valve should be online with no problems concerning sealing capability. In order to maintain the valve properly, the operator will need to implement a scheduled routine of sealant system top-ups with synthetic lubricant. Typically, a new valve will require top-up more often than a valve that has been in operation for one year or more. It is this first critical year of operation that the valve seals sit tightest against the ball plug or gate slab and lubricant is required to reduce the breakout torque during operation.

It is advised to top up the lubricant every time a valve is operated for the first year in addition to a semi-annual full service schedule. It may seem excessive, but a small investment in time and preventative maintenance on the front end could potentially save hundreds of thousands, if not millions of dollars on the back end taking into account pipe section isolation during emergency shutdowns. Compared to the cost of an emergency valve body sealing job, a preventative maintenance routine will quickly pay for itself.

ConclusionMuch of this information is not new to

pipeline operators, yet thousands of valves in every sector of the petroleum industry are scheduled for replacement every year causing lost production. By taking a few simple steps like these ones above, one could almost completely eliminate having to replace valves before their service life expectancy. In combination with specialised sealants and pumping equipment, it is conceivable that any given valve could stay in service indefinitely and retain sealing integrity.


The advantages of X80 pipe, importance of drop-weight tear tests and new welding processes were topics high on the agenda at the Pipeline Technology Conference held in Ostend, Belgium, during October 2009.

A place for science in pipeline designBy John Tiratsoo, Editor-in-Chief

The Pipeline Technology Conference in Ostend (see our report on page 59) showcased 117 papers over three

days, making it difficult to listen to each presentation. This article discusses three papers presented at the Conference. Each paper presents different subjects, and while acknowledging that there could be as many equivalent selections made as there are reviewers available, the below papers are considered to be of particular interest.

X80 pipe X80 pipe is being used more and more

widely due to its higher strength and thinner wall thickness. A further advantage over thicker materials is that less longitudinal and girth welding is required.

Authors Dallam et al. examine the criteria

for X80 pipe welding, in terms of the weld performance in wide-plate tests. As they point out, considerable resources and efforts are expended in the design and fabrication of safe and economical pipelines. While differing design philosophies may be employed, the suitability for service and the risk of failure ultimately depend on the material’s behaviour in actual service conditions.

The trend in design, and consequently pipeline material development, is to use higher-strength materials to take advantage of either less material performing the same function, or the same amount of material supporting greater operating loads.

One approach involves ‘overmatching’ the weld metal yield strength, making the weld metal stronger than the host metal of the pipe. The motivation for this is to achieve

higher performance and safety at a lower total project cost.

With increased pipe strength, and the potential for thinner wall pipe, cost reductions can be made due to the decreased pipe weight; thinner pipe requiring less welding; and, the lower cost of transporting the pipe to the job site. For example, switching from X70 to X80 pipe could reduce wall thickness by 12 per cent because of the ratio of pipe strength, while the weld metal volume could be decreased by 25 per cent.

Testing at a small scale has evolved to prove the materials and the design. Tensile tests and Charpy V-notch impact tests are normally performed on small specimens, and consider the most extreme set of expected service conditions. On the other hand, large-scale tests more accurately

teCh talkteCh talk

The papers mentioned above can be obtained from Great Southern Press’ UK office. Email [email protected], or phone +44 1494 675139

simulate service conditions, and this is a recommendation where higher-strength materials and welding processes are being investigated. The authors point out, however, that as the required strength increases, the number of possible processes, procedures, and consumables that are suitable for welding decrease.

The drop-weight tear testDr Andrew Cosham and co-authors

continued the theme of testing in their paper on the drop-weight tear test (DWTT). For over 40 years, linepipe specifications have stipulated minimum requirements for the shear area in a DWTT to ensure the arrest of a long-running brittle fracture, and the test has been very successful in preventing such fractures. However, many current pipeline engineers do not understand the background or importance of the test – this can lead to problems, as the test is an essential requirement for many types of pipeline.

Pipelines that transport gaseous fluids, two-phase fluids, dense-phase fluids, or liquids with a high vapour pressure, are susceptible to propagating fractures. Once initiated, a fracture can spread for long distances in either the brittle or ductile mode. Toughness specifications for linepipe have been developed to ensure that any propagating fracture is arrested within an acceptable length. The DWTT shear area requirement ensures that such fractures will not occur. Tests show that fractures will not propagate if the shear area measured in the test is 85 per cent or higher at the minimum design temperature.

Following original research in the 1960s and subsequent testing in a variety of conditions, the DWTT requirement was incorporated into API 5L in 1969, and has proven to be very successful in preventing in-service long running brittle fractures. The introduction of the test also led to significant improvements in the manufacturing of linepipe steel, and for many years linepipe has met the shear area requirement without difficulty.

However, the background to the development of the DWTT is in danger of being lost in time, and there is now a risk of complacency. The authors of this paper point out that in a number of recent projects, the linepipe supplied does not meet the DWTT shear area requirement.

Additionally, there are inconsistent and arbitrary limits on DWTT – such as it only being required for welded pipe of 20 inch diameter or larger – which now need to be reviewed and revised.

The authors conclude that, even 40 years

after its introduction, the background to the development of the DWTT still needs to be recognised and fully understood, as the DWTT shear-area requirement is just as relevant to today’s pipeline designers as it was at its introduction.

New welding processIt is widely acknowledged that there will

be a great increase in pipeline construction in the coming years, and upwards of 280,000 km of new pipeline construction has been announced worldwide. We can reasonably assume that these new pipelines will require approximately 20 million welds to join the pipes – an unparalleled challenge on welding operations in terms of productivity, quality assurance, employee safety, and environmental impact.

Traditional manual or semi-automatic welding techniques have a number of limitations in relation to this challenge:• The higher strength steel grades that are

becoming more commonly used (X80 and above) are more difficult to weld with conventional technologies;

• Increasingly stringent quality requirements demand constant, reproducible, welding quality, which only automatic welding can guarantee to provide;

• Relatively slow joint completion rate due to the slow process of traditional welding and number of passes required, which also require higher energy consumption and give rise to increasingly unacceptable carbon dioxide emissions; and,

• The difficulty of finding skilled welders and to encouraging them to work in often remote and inhospitable areas.

In order to meet these challenges, several automatic welding processes have been developed by the industry. Friction welding is a forge welding process in which the heat is generated through the friction between two surfaces rubbing against each other under controlled axial pressure. However, conventional friction welding is not suitable for joining long components, such as pipes, since these cannot be rotated for obvious practical reasons.

To enable pipelines to be welded using the friction-welding process, an innovative variant of the conventional process has been created. Called the FRIEX process, this welding process was developed by Denys NV in co-operation with the Soete Laboratory of Ghent University and the Belgian Welding Institute, with the financial support of the Institute for the Promotion of Innovation by Science and Technology in Flanders.

The major difference between the FRIEX process and conventional friction welding is that a ‘filler material’ in the form of a solid ring is used. This ring is placed between the pipes and is rotated under an axial load that generates the required friction and associated heat (see Figure 1). After the two adjacent pipes are brought into contact with the rotating ring, the friction between the ring and the pipes increases the temperature in the contact area until the forge temperature is reached. At that moment, the rotation of the ring is rapidly stopped and the axial force is increased to the final forge force.

Forging is done using either a hydraulic or pneumatic force, and after welding, the remaining welding ring material and welding flashes are removed using automated turning and milling machines. As an example of the speed of this operation, two 20 inch diameter X65 grade steel pipes were completely welded together in around 12 seconds.

The developers of this process recognise that further testing is required, but the feasibility of their system has clearly been effectively demonstrated. Among its many advantages over other methods are its speed, reliable weld quality consistency, and a minimum requirement for highly-skilled labour, all of which will be welcome to contractors and pipeline owners alike. Figure 1: Schematic of the FRIEX process.


traditional research models, which may have their centres of excellence inside universities or other specialised institutions. It is not the intention of CTDUT to replace or supersede other already adopted solutions, but to complement what already works well, and act as a catalyst, providing evident advantages for both the ones who have, and the ones who need, specialised knowledge in the oil and gas pipeline industry. In such a model, other laboratories and specialists are not perceived as ‘competitors’, but as important partners in the initiatives with which CTDUT may be involved.

As an example of this network-based approach, which includes the main participants in the Brazilian pipeline sector, CTDUT has participated in drafting the proposed Safety rules for operation of pipelines, being prepared by ANP – the Brazilian National Agency of Oil, Natural Gas and Biofuels – a project that brought together a wide range of experts with differing backgrounds and interests.

Facilitating development Current facilities at CTDUT include a

14 inch diameter test loop, a pipeline pig pull-through and defect-characterisation facility and a laboratory for research into structural integrity, among others. The 14 inch, 100 m test loop is equipped with flanged spools that, among other applications, allow installation of spools with mapped defects so that the performance of intelligent tools can be assessed under controlled circumstances. The test loop also provides the option for training operators in the procedures involved for safely launching and receiving pigs, including the operation of control and lock valves, and opening and closing the pig trap closures. The loop can also be used for training for intervention operations in pipelines, and in maintenance procedures.

The pig pull-through rig is a testing assembly consisting of pipelines with diameters ranging from 6 inches to 16 inches, containing a variety of mapped defects. The rig is equipped with a variable speed winch, and has been designed to be suitable for tests that evaluate the detection efficiency and calibration of instrumented pigs and other equipment used for the detection of defects, such as long-range guided acoustic waves. Pipes of other diameters can also be incorporated, according to the test requirements.

The structural integrity laboratory offers an area for both destructive and non-destructive integrity tests on carbon

steel or composite material pipes of any diameter, as well as on ancillary equipment such as valves. The laboratory is equipped with a 10 tonne capacity crane, a hydrostatic pressurising pump of up to 1,000 bar, a safety bunker with high-impact protection, and monitoring cameras. The 4.1 m x 18.1 m underground test area is covered with heavy steels plates for maximum protection.

Among the research activities being currently developed are seven projects with the financial support of two government organisations (CTPETRO and FINEP) as well as Petrobras. The projects are looking into leak detection, transient flow in pipelines, drag reduction, and the development of techniques for internal lining of pipeline. Other partners include various Brazilian universities and research institutions.

Non-associated external organisations can also use the CTDUT facilities. An example includes the pigging training course developed by John Tiratsoo of Pipelines International and Houston-based Clarion in association with UK-based Penspen and pigging companies Rosen of Germany and PipeWay of Brazil. The five-day course is planned to run at half-yearly intervals, running in April and September this year. The syllabus, developed by Penspen, involves demonstrations of actual pigs being safely launched, run in real time, and retrieved, as well as classroom-based lectures and discussions. Pigs have been provided to the course by both Rosen and PipeWay, and include the whole range of tools from foam pigs through to caliper and magnetic flux leakage tools. The course is seen as an increasingly important part of CTDUT’s activities combining, as it does, a number of the institution’s facilities.

A further part of CTDUT’s infrastructure currently under construction is a 12 inch diameter, 2.5 km test pipeline, which can be operated with oil, and a 16 inch diameter, 2.5 km test pipeline in the same right-of-way that can be operated with gas. The oil and gas will come from the nearby Petrobras/Transpetro Duque de Caxias refinery. These new test pipelines will be used to support research and development of new equipment, tools, and systems for inspection and protection of pipelines, as well as flow tests under various actual operating conditions for validation and developed of simulation software. Other planned projects that will be appropriate to these pipelines will be testing and certification of control equipment and systems; protection, monitoring, inspection and maintenance of pipelines beyond the certification of processes and operating procedures; and, the training and qualification of operators and technicians. Both pipelines will eventually be used for the pigging training course as well.

The pipeline industry has particular difficulties in terms of testing and research due partly to the risks

associated with any testing programme and difficulties in simulating the extreme conditions in an operational pipeline. In addition, there are economic and practical disadvantages of stopping and starting an operating pipeline for the purposes of a testing or research programme.

It is also important to consider that the availability of well-trained researchers inside the company, in all areas of expertise can lead to the formation of a research and development structure but at considerable cost. Balanced against this, the growing technological challenges created by the need to exploit new fields often leads companies to undertake research and development activities as a means of remaining competitive and keeping pace with their market’s requirements.

Created with the objective of meeting such needs, and working as a shared research centre available for use by all companies in the sector regardless of their membership status, the Centro de Tecnologia em Dutos (CTDUT) – which translates as the Centre for Technology in Pipelines – offers such services to the pipeline community, seeking to act as an independent institution and discussion forum for the industry.

Created as a non-profit association, the model for CTDUT came from an audacious and original concept that is performing well and producing excellent results. Inaugurated on 10 May 2006 as an initiative of its three founding partners – Petrobras, Transpetro, and Pontifícia Universidade Católica do Rio de Janeiro (PUC-Rio) – CTDUT now has

45 members, including several prominent institutions in their respective fields of pipeline engineering and operations.

CTDUT’s facilities are dedicated to testing and training, and available for use by the whole pipeline community. The organisation also has specialised and trained operating personnel who are able meet all the demands likely to be required of such a facility. The institution’s management co-ordinates the research and development projects that are undertaken, although CTDUT does not have its own dedicated team of in-house researchers. The work undertaken at CTDUT is often part of wider research projects, which are carried out at the facility due to the organisation’s ability to provide the necessary hardware and expertise.

Working togetherThe research model on which CTDUT is

founded is that of a science and technology institution that does not house its researchers on its staff, but instead relies upon a network of researchers from other institutions, both public and private, which are invited to join a working group whenever a research project requires expertise in their respective areas of specialisation. This model of a Brazilian ‘network of competence in pipelines’ transects the traditional boundaries of research institutions, and encourages and focuses the collective work of teams from different research groups towards a common goal.

The management and those responsible for CTDUT are finding that this model is being increasingly accepted, demonstrating its feasibility as a solution and complementing

Any dedicated facility for pipeline industry testing has high costs of construction, operation, and maintenance, and few companies can afford this structure without imposing extensive costs on their customers. Centro Tecnologia em Dutos (CTDUT) has been formed to offer such a service to pipeline owners and operators.

CTDUT: a model for sharing facilities and costs in research and developmentBy Arthur Braga, Executive Director, CTDUT, Rio de Janeiro, Brazil

inDustry news inDustry news

Details of the pigging training course held at the CTDUT facility can be found at www.piggingtraining.com


Participants at CTDUT’s pigging course and pipe bursting test facility.

Pipelines International's Editor-in-Chief John Tiratsoo (second from right), who developed the pigging course held at CTDUT in association with Clarion, Penspen, Rosen and Pipeway, visits CTDUT's pigging course and pipe bursting test facility.


LNG from Algeria instead. This manoeuvre resulted in Tunisia accepting a 5.625 per cent transit fee of transported gas volumes, and the pipeline progressed.

Pipeline progressConstruction began with an official

ceremony in Algiers in June 1979 and by the end of 1980, the three pipelines spanning the Sicilian channel had been completed. Pricing disagreements arose once again, this time with the Algerian Government demanding an increase of $US2 per 1 million british thermal unit from the price set in the 1977 agreement. Construction halted when Eni refused to

comply with the new demands and the Algerian Government ordered a halt to all Italian industrial contracts and construction projects in Algeria. Construction of the Algerian onshore section of the pipeline did not recommence until a new pricing agreement was reached in 1982.

The first line of the Trans-Mediterranean was finally commissioned in June 1983, while the second phase was completed between 1991 and 1994, which saw the capacity of the pipeline double to 1 trillion cubic feet per annum. Slovenia secured access to the pipeline through the construction of a 35 km spurline, which connects into the Italian end.

Present dayIn 2005 Eni and Sonatrach reached

an agreement to expand the Trans-Tunisian Pipeline, a section of the Trans-Mediterranean Pipeline that runs through Tunisian territory. Saipem was contracted to carry out the engineering, procurement, construction and commissioning of two new gas compression stations and the upgrading of the existing compression facilities. Work was completed in October 2008 to increase the capacity by 113 Bcf/a and works are planned to increase capacity by a further 116 Bcf/a starting from 2012.

During the 1960s the Trans-Mediterranean Pipeline project was conceived as the most effective way

to monetise Algeria’s extensive gas reserves and to enable Italy to expand its natural gas consumption. A preliminary feasibility study was conducted in 1969 and the first route survey completed during 1970.

Italian stated-owned Eni pursued the construction of the subsea pipeline in favour of proposals to ship LNG across the Mediterranean and in 1973, signed a contract with the Algerian Government for the supply of 414 billion cubic feet of gas from the Hassi R’Mel Gas Field for a period of 25 years.

The agreement gave rise to the technical challenge of crossing the Mediterranean with a subsea pipeline at record-breaking depths.

Constructing in deep watersThe 2,340 km pipeline route begins at

the Hassi R’Mel field in Algeria and runs 550 km to the Tunisian border. From there it travels 370 km through Tunisia to El Haouaria, after which it crosses the 155 km wide Sicilian Channel.

In 1975 Sonatrach and Eni awarded Eni subsidiary Saipem a $US237 million contract to lay three 20 inch gas transmission pipelines across the Sicilian Channel in water depths of up to 610 m and a further four pipelines across the Straits of Messina from Sicily to the Italian mainland.

At the time, worldwide experience in design, construction and maintenance of offshore pipelines was limited to water depths of 150 m. The Trans-Mediterranean Pipeline project necessitated the research and development of new technologies to overcome the engineering and construction hurdles presented by the pipeline’s depth.

Saipem constructed Castoro Sei, a computer-controlled, semi-submersible pipelay vessel, to break the world record and lay pipes in depths up to 610 m. The Castoro Sei was equipped with three tensioners, which provided a maximum tension of 180 t in the pipes being laid. The laying system was comprised of three ramps – one fixed and one pivoting ramp, and a ‘stinger’, which was hinged to the internal pivoting ramp.

The severe unevenness of the seabed and steep slopes posed the main difficulties

for the project, limiting free spans in the pipeline construction. Saipem developed a model to monitor the stress status of the pipes on the sea floor both during and after laying to minimise the risk of buckling and avoid the associated long delays.

A 45.7 m wide corridor was required to be opened up through rock and coral in water depths of 503 m over a length of 4.8 km in the Sicilian Channel. After obstructing materials were successfully blasted through, a guide cable was laid along the wall of the trench to act as a reference line for surveying the position of the first pipeline, which was laid parallel to it.

The Tunisian crisis In 1977 Tunisia sought to take

advantage of rising oil prices, Eni’s growing commitment to the project, and the fact that the only feasible route for the Trans-Mediterranean Pipeline passed through its territory, to negotiate a transit fee of 12 per cent of the value of the gas that passed through its territory. The demand forced Eni to investigate the option of abandoning the pipeline project in favour of shipping

The 2,340 km Trans-Mediterranean Pipeline, which was constructed between 1978 and 1983 to bring natural gas from Algeria to Italy, involved the deepest subsea pipeline installation at the time. More than a quarter of a century on, Pipelines International reflects on the achievement.

historyhistory

Trans-Mediterranean Pipeline

The Algerian section of the pipeline is operated by Algerian state-owned company Sonatrach while the Tunisian section is owned by Sotugat (Société Tunisienne du Gazoduc Trans-Tunisien) and operated by Sergaz. The section across the Sicilian Channel is operated by TMPC, a joint venture of Eni and Sonatrach. The Italian section is operated by Eni's subsidiary Snam Rete Gas.

Castoro Sei, which is still in service, under repair at Keppel Verolme. Image courtesy of Keppel Verolme.

The Castoro Sei at work offshore Sciliy.


For more information visit www.VRTEX360.com

The biennial Rio Pipeline Conference and Exhibition, organised by the Instituto Brasileiro de Petroleo Gas e Biocombustiveis (IBP) in association with ASME, was held on 22–24 September 2009. Pipelines International Editor-in-Chief John Tiratsoo reports.

One of the Southern Hemisphere’s major oil and gas pipeline industry gatherings, the 2009 Rio Pipeline

Conference and Exhibition, was bigger than ever. With over 320 papers in multiple tracks (chosen from around 500 submissions), and 124 exhibiting companies, the three-day event provided plenty of opportunity for delegates and visitors to occupy their time to the full.

One of the benefits of events such as these is the networking opportunities they present, and the atmosphere of Rio was imbued with the spirit of making new contacts and refreshing old ones. This year’s event also provided the opportunity for the launch of Pipelines International, copies of which were widely distributed to delegates and visitors, attracting pleasing feedback.

A diverse programmeA diverse range of papers was

presented at the event, with many papers from Brazilian authors – Petrobras and its research institutions, along with universities such as PUC-Rio were well represented – as well as a considerable international contingent of authors, from over 35 countries, many from outside South America.

Topics covered inlcuded:• Automation and SCADA• Compressors and pumps• Corrosion• Environmental safety• GIS• Inspection• Integrity• Logistics • Rehabilitation• Reliability and risk• Slurry pipelines• Social responsibility• Subsea pipelines.

A major plenary session was held in which Petrobras’ Pre-Salt Executive Manager Jose Miranda Formigli gave an informative overview of the vast ‘Pre-Salt’ oil and associated gas reserves that have been discovered around 300 km offshore Brazil in around 2,200 m of water. This huge reservoir, with over 30 billion barrels of oil, underlies the Espiritu Santo, Campos, and Santos basins and, if predictions are correct, will provide a significant proportion of the world’s

energy supplies for many years to come. The Brazilian Government and

Petrobras are currently working out how best to exploit and export these reserves, and are considering what their impact will be internationally. Pipelines will obviously form a part of this exploitation, and Mr Formigli discussed some scenarios for the large-diameter, deepwater pipelines that may be required.

A number of panel sessions were also held, one of which discussed the future of the global pipeline industry. The clear message that came from this is that huge investment in pipelines, their materials, and their ancillary equipment, will be required in the foreseeable future in order to transport the great quantities of gas and oil required by the world’s energy consumers. Presentations by Enbridge International’s Operations Director in Canada Bill Trefanenko and Director of Sinopec International Petroleum Service of China’s Wang Zhonghong emphasised this point, reinforced by comments from Petrobras’ Pipelines and Terminal Director Claudio Campos.

As an observer of the industry, it is clear that what these speakers had to say is true. However, it is always encouraging to see industry leaders getting together and saying it in public.

Exhibiting pipeline styleThe exhibition attracted many visitors,

and there was a great range of equipment and services on show for them to see.

Pipelines International had a stand in the exhibition, at which much interest was raised by the business card prize draw, for which the winner would receive an iPod Nano. Such was the enthusiasm that on the day of the draw, several possible winners gathered at the stand and wouldn’t move until they had witnessed the drawing of the card. Congratulations go to Karina Vargas from Sinopec for winning the iPod Nano.

The Rio Pipeline Conference and Exhibition is increasingly gaining attention on the international stage as an important and useful forum. The next event, on 20–22 September 2011, will undoubtedly strengthen such international support, and will once again provide a great opportunity for an industry gathering.

Pipeline carnivale in Rio!

ProDuCts & serviCes events

Learn to weld with Lincoln Electric’s virtual welding system

Lincoln Electric has developed a new way to teach welding techniques through a virtual

welding system called VRTEX 360. The VRTEX 360 provides a virtual,

hands-on training experience, similar to a video game, which provides real-time welding technique feedback to both trainers and students.

The training system feeds computer-generated data with a virtual welding gun and helmet equipped with internal monitors. Students are able to practice welding in simulated environments, including a welding booth training environment and field-welding applications.

Instructors can set up the VRTEX 360 to accommodate various types of welding techniques, including push and drag GMAW techniques; stringer beads; and, weave techniques – straight, triangle and box weave.

The product allows welding to be taught without the use of shielding gas, welding electrodes or welding coupons and does not require weld fume removal.

Are you launching a new product or

service?

Contact us [email protected]

For more information visit www.curapipe.com

For more information visit www.viadata.com

For more information visit www.colfaxcorp.com

Production begins on world’s largest three-screw crude oil pipeline pump

Colfax Corporation has begun production of the world's largest rotary positive displacement three-screw crude oil pump.

The Imo 8L-912Y pump can be installed on pipelines up to 24 inches in diameter and can transport more than 85,000 barrels of oil per day at pressures up to 13.78 MPa.

Colfax’s 8L-912Y pump requires no external lube system and can be direct-coupled to a synchronous-speed driver, without the need for a gear reducer. This reduces the overall footprint of the equipment and simplifies the driver-to-pump alignment.

The performance of this pump series can be further controlled with the use of a variable-speed drive to dial in the required flow rate.

The Imo 8L Series of pumps is designed to ensure constant oil flow, even in the presence of varying system back pressures due to changes in viscosity; nonpulsating flow, without the need for pulsation dampeners, which reduces the risk of pipeline failure; and, low noise and vibration levels, minimising foundation requirements.

Latest edition of WinDOT – the Pipeline Safety Encyclopedia

The August 2009 edition of WinDOT includes the current United States federal pipeline

safety regulations 49 CFR 190-199 and Part 40, including amendments, interpretations, waivers and advisory bulletins. WinDOT incorporates the January 2009 edition of Gas Piping Technology Committee Guide, including the Distribution Integrity Management Program Guidance by linking code sections directly to the guide material. Users can search by word or phrase to find regulations, interpretations and guide material to assist them in compliance programs and research.

The latest release of WinDOT includes updates to pipeline regulations for 16 states and 15 new or updated pipeline standards. There are 55 standards available on the WinDOT CD, including 35 that are incorporated by reference.

Cure pipes with Curapipe

Curapipe has developed a leak curing solution for pinhole leaks and cracks that go undetected by

conventional detection methods.The Curapipe solution is a viable

pipeline repair solution launched remotely and applied internally. A pig train carrying Curapipe’s innovative curing substance is inserted upstream through a pig launcher. As the pig train passes through the pipeline, the curing substance penetrates, seals and fixes pinhole leaks and cracks.

Deployed as a preventive measure for the pipeline industry, Curapipe’s solution cures undetected leaks and cracks (below SCADA system thresholds) before they become larger and more problematic leaks that would require pipeline shutdown and excavation.

The Curapipe solution is intended to prevent spills and product loss; as well as costly downtime for repairing fully grown leaks; and, decreases the need for, and cost of, pipeline inspection, monitoring and maintenance.

The Rio Pipeline Exhibition.

Delegates enjoyed papers presented at the Conference.


Papers at the Evaluation and Rehabilitation Conference and Exhibition, held between 21 and

22 October 2009, described a wide variety of approaches and solutions. While replacement is sometimes the only option, and can provide an additional lifespan of 50+ years to a pipeline, rehabilitation is often the more cost effective solution. Many techniques have now been developed to assist pipeline owners with rehabilitation decision-making and implementation, and the rehabilitation industry is growing as a consequence.

The conference’s opening presentation focused on rehabilitating – and even, recycling – the pipes themselves after they have been lifted from the trench. Truboetal of Moscow and Incal Pipeline Rehabilitation of Houston described a plant that has been set up in Russia to refurbish 56 inch diameter pipes taken out of the ground by Gazprom. Upwards of 20,000 km of pipe per annum is currently being replaced in Russia by Gazprom and others, and the pipes can often be reused provided careful attention is taken to their refurbishment and subsequent inspection.

Bill Bruce of DNV Columbus gave a review of hot tap and sleeve welding. This process is fraught with issues that demand very careful attention to the details of the welding involved. The wrong temperature, or inattention, can lead to the perils of ‘burn-through’ and consequent leakage. Mr Bruce’s ‘rules of thumb’ to be considered for pipeline sleeving start with “Is the repair required at all?” – a question that surprisingly often can be answered in the negative.

Dr Chris Alexander from Stress Engineering of Houston gave a comprehensive overview of materials and techniques. Alan Morton of TD Williamson and Bart Davis of Neptune Research’s Syntho-Glass division spoke about various

projects their companies had undertaken in which composite wraps had been used with great success. There is now a considerable range of composite-wrap alternatives, and care needs to be taken in specifying the one that is to be used for any particular job as their properties vary quite widely.

Two other ‘wrapping’ techniques were presented. Smart Pipe has developed what presenter Richard Huriaux described as a ‘mobile factory’ that allows a pipe to be made onsite using a process in which a high density polyethylene (HDPE) core pipe is wrapped with high-strength fibre tapes and windings, cased in an HDPE outer wrap and laid in the ground. Diameters up to 24 inches are currently feasible, and there are many advantages of this process over ‘traditional’ pipelaying. In addition, Pipestream of Houston, a company set up to develop new technology for Shell Global Solutions, is now able to wrap a host pipe with a steel reinforcing strip in such a way that the resulting wrapped pipe is considerably stronger than the original. The paper given by Ray Burke illustrated this by showing a series of burst tests where the host pipe burst well away from the location of the repair.

A major refurbishment job was then described by Sid Taylor of Incal. The project involved recoating 60 km of the Caspian Pipeline Consortium Oil Pipeline in Kazakhstan – a 1,510 km, 42 inch diameter line running from the Tengiz Oil Field to Novorossiisk on Russia’s Black Sea coast.

The Russian contractor has developed an interesting and efficient coating removal, cleaning, and recoating system in the trench, which allows up to 150 m per day to be exposed, refurbished, and backfilled while in service.

Houston-based Dr John Smart of John Smart Consulting Engineers reviewed the problems associated with black powder in gas pipelines. Dr Smart pointed out that the problem is not only the physical aspects of the powder itself, but also its movement through a pipeline; it can be extremely damaging to both the internal pipe wall and rotating equipment, such as compressors, and management of the material demands considerable planning. One of the key research papers in this field was published in 1998 by Richard Baldwin of Southwest Research Institute in San Antonio on behalf of the Gas Research Council.

The final paper of the conference was from Doug Batzel of Galaxy Brushes in, Phoenix, Arizona, US. Mr Batzel gave an enthusiastic presentation on the importance of brush selection for cleaning pigs. Mr Batzel’s company has pioneered the development of so-called ‘pencil’ brushes, which are designed to deflect into pits and other internal pipeline features that stiffer wire brushes will pass over. This technology has already found favour with a number of pipeline operators in the Middle East who are reporting considerable success of their cleaning pig runs.

Over 60 per cent of the world’s major oil and gas transmission pipelines are now more than 40 years old – leaving some operators to face stark choices: to rehabilitate, or to replace? Held in Pittsburgh, Pennsylvania, United States, the Evaluation and Rehabilitation of Pipelines Conference and Exhibition addressed this difficult question.

The high-level programme at the Pipeline Technology Conference – this year, of 117 papers – is renowned worldwide as the foremost opportunity to learn about the latest developments and approaches being employed in high-pressure transmission pipeline design, materials and welding research.

events

The widely-respected Pipeline Technology Conference, organised by Professor Rudi Denys of the University

of Gent, Belgium, and the country’s Technological Institute-KVIV, based in Antwerp, is held every five years in Ostend, Belgium.

Held this year from 12–14 October, the delegate list of the event read like a ‘Yellow Pages’ of the industry’s cutting edge scientific researchers and technological developers. The ability for this forum to meet regularly provides an unmatched opportunity for discussions and networking of the highest calibre.

Topics covered at the 2009 Pipeline Technology Conference • Pipeline steels;• Pipeline design and construction; • Toughness and residual stresses;• Strain-based design;• ECA and validation testing;

• Sour service;• Ductile failure and crack arrest;• Pipeline welding; and,• Pipeline inspection.

The panel of authors represented nearly all of the major manufacturers and researchers involved in these areas, and came from countries as far afield as Argentina, Australia, Brazil, Canada, China, Iran, Japan, South Korea, as well as Russia, Europe, and the United States.

One of the traditions of the Pipeline Technology Conference is that social activities are arranged for the delegates, a welcome relief after a long day discussing strain-based design or fracture arrest. This year, a visit had been arranged to nearby Bruges with a canal trip and an opportunity to taste the products of the Halve Maan brewery. There was a conference dinner the following evening at one of Ostend’s grand casinos, and both events proved highly enjoyable.

Evaluating different rehabilitation approaches

Pipeline Technology Conference: a scientific update from Ostend

events

Next coNfereNce to be heLD iN berLiN 2010!The Evaluation and Rehabilitation of Pipelines Conference

and Exhibition was first held last year in Prague, Czech Republic. The organisers plan for the event to alternate between

North America and Europe. The next conference is planned for Berlin, Germany, on 20–21 October 2010.

Further details on papers presented at the conference can be found at www.piperehabconf.com For full details of the event and photos of social functions visit www.pipeline2009.com

Papers from the conference are available as PDF files on a searchable CD, which is presented with the A4-sized book of abstracts, and can be obtained from Great Southern Press’ UK office. Email [email protected], or phone +44 1494 675139.

Professor Rudi Denys presents one of his papers.Pipelaying at the Ostend conference – a superb model on the Denys stand.

Delegates enjoy a coffee break.

Dr Michael Beller, Professor Rudi Denys and

Pipelines International Editor-in-Chief

John Tiratsoo on the NDT stand.


The most prestigious Australian pipeline event of the year – the Australian Pipeline Industry

Association (APIA) Convention was held between 17–20 October in Cairns, Queensland, Australia.

An interesting two-day business program featured the most up-to-date information about projects, international issues, technical, environmental and economic challenges, as well as investigating new developments in the industry.

Keynote presentations included Cape York Partnerships Director Noel Pearson speaking about pipeline development on Aboriginal land, and Canada’s National

Energy Board Professional Leader – Engineering Alan Murray, who discussed the similarities and differences between the Australian and Canadian industries.

The Exhibition provided a great opportunity for delegates to discuss the latest products and services for the industry with approximately 60 suppliers.

Queensland was a fitting location for the APIA Convention and Exhibition as the state is developing as a natural gas and LNG export hub for Australia. Seven LNG projects have been proposed in the state, involving the construction of hundreds of kilometres of pipeline from the state’s coal seam gas fields to port sites.

event snaPshots


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BRINGING THE PIPELINE WORLD TOGETHER

1. PipelinesInternational is published by two of the longest standing names in the pipeline media.

2. Magazine advertising remains the most effective way to market your products and services.

3. Natural gas is set to play an ever increasing role in energy production and will need pipelines to reach markets.

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The event was held at the Sutera Harbour Resort, Sabah, and attracted approximately 150 participants.

The focus of this year’s Conference was ‘Optimising Pipeline Performance by Harnessing our Human Capital’ and a wide range of case studies was presented ranging from industry training, optimising asset performance, intelligent pigging, integrity management and flow assurance.

The highlight of the Conference was the opening by Datuk (Dr) Abdul Rahim Hj Hashim who gave his first regional address as the newly appointed President of the International Gas Union (IGU).

Datuk Rahim expanded on what the IGU

Presidency means for Malaysia and South East Asia generally. He observed that the gas industry should not take demand growth for its product for granted; indicating that the long lead times means there is a challenge to develop gas markets.

Professor Andrew Palmer from the Centre for Offshore Research and Engineering, University of Singapore, gave an enlightening presentation on the looming shortage of experienced personnel in the oil and gas industry. He highlighted the importance of recruiting students who want challenging, exciting work, stimulating colleagues, travel and reasonable monetary compensation.

APCE: pipeline success in South East Asia

From L-R: Dato' Margaret Fung-CEO Sabah Energy Corporation; Soh Mey Lee-Chairperson IGU Task Force 2; Dr Allen-Executive Director AGC; Datuk Rahim-President, Malaysian Gas Association and President, International Gas Union; Khairuddin-AGC Board Chairman; Prof Andrew C Palmer-National University of Singapore.

Australian industry gathers in northern Australia

DATE/VENUE EVENT CONTACT

15 – 18 February, 2010Houston, United States

22nd International Pipeline Pigging & Integrity Management Conference www.clarion.org

9 – 11 March 2010Brisbane, Australia

FutureGAS 2010 www.futuregas.com.au

31 March – 2 April 2010 Langfang, China

International Pipeline Exhibition www.pipechina.com.cn/en/

19 – 20 April 2010Hannover, Germany

Pipeline Technology Conference 2010 www.ptc2010.com

3 – 6 May 2010Houston, Texas, USA

Offshore Technology Conference 2010 www.otcnet.org/2010/

9 – 10 June 2010Jakarta, Indonesia

IndoPipe 2010 www.indopipe2010.iee-c.com

11 – 14 September 2010Darwin, Australia

2010 APIA Annual Convention www.apia.net.au

27 September – 1 October 2010Calgary, Canada

International Pipeline Conference 2010 and International Pipeline Exposition

www.internationalpipelineconference.com

27 September – 4 October 2010Venice, Italy

44th IPLOCA Convention www.iploca.com

The Australian Pipeline Industry Association Exhibition held in Cairns.


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PipelinesInternationalis the new magazine for the global pipeline industry. Published quarterly, the magazine will reflect the diversity of the pipeline industry across the continents.

The magazine will include region reviews; project reviews; and project, company and regulatory news, as well as features on important industry areas such as integrity management.

The magazine is directly mailed to over 10,000 decision-making pipeline industry members around the globe with a balance between regions and roles. The magazine is present at a wide number of industry events throughout the year.

The Pipelines International team

PipelinesInternational is being published by the merger of two long-standing pipeline media companies, Scientific Surveys and Great Southern Press. The new company will be known as Great Southern Press.

John Tiratsoo and Scientific Surveys are long-time publishers of information on pipelines – including information on companies, projects, the latest news and technical information. John is also the editor of the must-have book on pigging, Pipelinepiggingandintegritytechnology.

Great Southern Press has been publishing about pipelines since 1972. It publishes TheAustralianPipeliner – the flagship of the Australian pipeline industry – as well as a number of other industry titles including GasToday.

Current and former publications from the PipelinesInternational team include PipelineWorld, PipelineAsia, Pipes&PipelinesInternational, TheIndonesianPipeliner, Pipeline,Plant&Offshore, and the JournalofPipelineEngineering.

bringing the worldwide pipeline industry together

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regular

MARCH 2010 JUNE 2010 SEPTEMBER 2010 DECEMBER 2010

Region Review Middle East Southeast Asia Canada Western Europe

Feature Trenchless Technology Compressors Valves Pigging

Equipment

FeatureAutomatic Welding Padding Machines Trenchers Pipe Layers &

Side Booms

Terrain Review Offshore Desert ForestSwamps/marsh

DEADLINE 12March2010 14May2010 6August2010 29october2010

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