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Contents
WORLD PIPELINES | VOLUME 16 | NUMBER 2 | FEBRUARY 2016
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ISSN 1472-7390
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A
EDITOR
Elizabeth Corner s I write, two out of four Nigerian Commentators have suggested that the
elizabeth.corner@worldpipelines.com
National Petroleum Corporation attacks on pipelines were retaliation against
(NNPC) refineries in Nigeria have this call for arrest and a warning against further
MANAGING EDITOR
James Little been shut down, following action that would disenfranchise ex-militants.
james.little@worldpipelines.com bombing attacks on pipelines in mid January. The now-apparent vulnerability of the pipeline
EDITORIAL ASSISTANT
The pipeline sabotage happened in the Niger assets might suggest to the new President that
Stephanie Roker Delta, in the south of the country, and is
it is better to work with ex-militants than
stephanie.roker@worldpipelines.com costing US$2.4 million/d in lost gas and
electricity. The refineries, situated in the against them.
ADVERTISEMENT DIRECTOR
Rod Hardy southern city of Port Harcourt and the MEND has denied carrying out the attacks.
rod.hardy@worldpipelines.com northern city of Kaduna, have been forced to In related news, the Nigeria Extractive
ADVERTISEMENT MANAGER close due to lack of crude supply. Pipeline Industries Transparency Initiative (NEITI) has
Chris Lethbridge attacks are nothing new in Nigeria, but these announced that it is intensifying efforts to
chris.lethbridge@worldpipelines.com latest attacks mark a massive shift in security push for accurate metering facilities at
ADVERTISEMENT SALES EXECUTIVE of supply. production and
Will Pownall
will.pownall@worldpipelines.com
A 2009 amnesty
dramatically reduced a
BUHAIR HAS export terminals in
Nigeria. The
PRODUCTION
Stephen North
long spate of attacks on ORDERED THAT organisation claims
stephen.north@worldpipelines.com
oil infrastructure in the
Delta (not to mention THE MILITARY that the royalties
paid to IOCs are
SUBSCRIPTIONS
Laura White
kidnappings). Brokered
by President Umaru
TAKE OVER based on inaccurate
flow computations
PROTECTION
laura.white@worldpipelines.com
OFFICE ADMINISTRATOR Yar’Adua, the terms of and that their
Jo Repton
jo.repton@palladian-publications.com
the amnesty granted
some 30 000 OF OIL moves to increase
transparency in the
WEBSITE MANAGER
Tom Fullerton
ex-militants monthly
subsidies of 65 000 naira
PIPELINES process have been
met with resistance
tom.fullerton@worldpipelines.com
(US$326) and offered job employment and from the purchasing oil companies.
WEBSITE EDITOR
Callum O’Reilly
training opportunities. Acting Secretary of NEITI Ogbonnaya Orji
callum.oreilly@worldpipelines.com Nigeria has a new President, Muhammadu is keen to erase irregularities in the way crude
DIGITAL EDITORIAL ASSISTANT Buhair, who came to power in March 2015, is measured at payment point and states that
Angharad Lock beating incumbent President Goodluck the country has until the end of February to
angharad.lock@worldpipelines.com Jonathan. The new President has been quoted submit a completed NEITI audit report.
PUBLISHER as saying he will end the amnesty programme Elsewhere, Royal Dutch Shell has been
Nigel Hardy (although it will run for at least another year, criticised for taking advantage of a huge tax
as planned). His stance on militants is much break in Nigeria, after details emerged that it
Palladian Publications Ltd,
15 South Street, Farnham, Surrey,
tougher than the previous administration. received billions of dollars in concessions
GU9 7QU, ENGLAND Since appointing himself Minister of between 2004 and 2012. This was on top of
Tel: +44 (0) 1252 718 999 Petroleum last November, Buhair has ordered the standard five year tax advantage that all
Fax: +44 (0) 1252 718 992
Website: www.energyglobal.com
that the military take over protection of oil companies enjoy when they commence
Email: enquiries@energyglobal.com pipelines in the nation, which has had the trading in Nigeria.
effect of taking security contracts from An ActionAid report claims that a
Annual subscription £60 UK including postage/£75/
e105 overseas (postage airmail)/US$120 USA/Canada
ex-militants. The Director of Defence consortium comprising Shell, Total and Eni
(postage airmail). Special two year discounted rate: Information has promised that the military will received total benefits of US$3.3 billion, with
£96 UK including postage/£120/e168 overseas
(postage airmail)/US$192 USA/Canada (postage be deploying high-tech security networks to Shell pocketing a US$1.7 billion share of the tax
airmail). Claims for non receipt of issues must be
made within three months of publication of the issue
protect pipeline assets from vandals. break. Shell and the Nigeria NLG consortium
or they will not be honoured without charge. The pipeline attacks came after the broke no laws, but many have suggested that
Applicable only to USA & Canada: Nigerian court issued an arrest warrant for the taxes could have been used to fund critical
World Pipelines (ISSN No: 1472-7390,
USPS No: 020-988) is published monthly by Government Ekpemupolo (know locally as services in Nigeria.
Palladian Publications Ltd, GBR and distributed in
the USA by Asendia USA, 17B S Middlesex Ave,
Tompolo), who once played a prominent part There is a silver lining for Nigeria at the
Monroe NJ 08831. Periodicals postage paid New in the Movement for the Emancipation of the moment. The country is benefiting from the
Brunswick, NJ and additional mailing offices.
POSTMASTER: send address changes to World Niger Delta (MEND). The court charges him decline in oil prices: the low price of crude
Pipelines, 701C Ashland Ave, Folcroft PA 19032 with theft and money laundering totalling means that petrol subsidies are no longer in
hundreds of millions of dollars. place, meaning a saving of US$5 billion.
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Central Asia’s strategic value grows
amid escalating geopolitical conflicts,
explains Ng Weng Hoong.
The battle
for Central Asia
O
nce courted for their fast-growing markets and huge energy
resources, Central Asia and the Caucasus (CAC) have become
a major prize in a new complex mix of geopolitical struggles.
Ironically, the region’s deteriorating economic and security
conditions have enhanced rather than diminished its appeal for those
sucked into an increasingly confusing battleground that includes a
revived Cold War, the US-led War on Terror and the Islamic State’s (ISIS)
campaign for a global caliphate.
The US, China, Russia, India and Japan are stepping up diplomatic,
military and economic efforts to court the region’s eight troubled
countries that include Kazakhstan, Turkmenistan, Azerbaijan and
Uzbekistan that have oil and gas reserves, and Armenia, Georgia,
Kyrgyzstan and Tajikistan that do not. ISIS is recruiting Central Asians to
12
13
extend its terror into the region and beyond, most notably terror attacks in Paris that sparked an increase in French and
into China. The US and Japan are loosely allied against China Russian bombing raids in Syria, and Turkey’s shoot-down of a
and Russia, while India has a foot in each camp, and they are Russian military jet plane. US, Russian and Chinese intelligence
all sworn to fight ISIS. The US – backed by its European allies have warned of ISIS’s escalating activities. The conflicts in
– and Russia are fighting a new Cold War, but may have to Syria and Iraq are threatening to spill over into the CAC
set aside their differences to stop the greater threat posed by region.
ISIS. The West covets greater economic ties with China, yet
wants to check Beijing’s global rise, which has Russia’s support. Region’s oil importers not benefitting from low
In Central Asia, Russia has roped in Kazakhstan and prices, says IMF
Kyrgyzstan – along with Belarus and Armenia – to form the The IMF stated that the CAC region will continue to reel from
Eurasian Economic Union (EEU), which will support China’s plan the impact of weak oil prices through 2016, with little hope of
to revive the old Silk Route under its ambitious ‘One Belt One their economies recovering to the levels before the collapse
Route’ strategy to connect the markets of Asia, the Middle of the energy markets in mid 2014.
East, North Africa and Europe. “A wave of external shocks – primarily falling commodity
China is deepening its reach into Central Asia with plans prices, spillovers from Russia, and movements in major
for more infrastructure investments, focused particularly exchange rates – continue to weaken growth prospects and
on the region’s two most hydrocarbon-rich countries – heighten financial vulnerabilities in the region,” the IMF said
Turkmenistan and Kazakhstan – to aid its push into the Middle in its External Shocks Dim Growth Prospects for Caucasus,
East and Europe. Laggards Japan and India are making up for Central Asia survey.
lost time with the Prime Ministers of both countries leading Growth will barely recover in 2016 despite improving trade
business and political delegations for the first time to meet with Russia and the Eurozone, as well as the short term impact
the region’s leaders in recent months. In early November, of the wave of currency depreciations recently undertaken by
the US despatched State Secretary John Kerry to Kyrgyzstan, the region’s beleaguered governments.
Uzbekistan, Kazakhstan, Tajikistan and Turkmenistan to push Despite weak energy prices, the CAC’s four oil importers
back against growing Chinese and Russian influence, and a will suffer more as they remain largely dependent on worker
rapidly expanding ISIS. remittances and trade with its four oil exporters and Russia,
The world’s rush into Central Asia has gained urgency said the IMF. Armenia, Georgia, the Kyrgyzstan and Tajikistan
in recent months amid mounting evidence of the region’s will feel the dual impact of Russia’s recession and the rouble’s
alarming economic decline that began when oil and gas prices collapse.
started crashing in mid 2014. In a grim update in October The IMF expects the economies of Georgia and Kyrgyzstan
2015, the International Monetary Fund (IMF) warned that the to each grow by 2% in 2015, down sharply from 4.8% and 3.6%
CAC’s economies are still reeling from “a wave of external respectively in 2014. Armenia’s economic growth will fall to
shocks” caused by falling commodity prices, sharp declines 2.5% from 2014’s 3.4%, while Tajikistan’s will plunge by more
in the value of their currencies, the contagion effects of than half from 6.7% to 3%.
Russia’s recession and political fallout with the West, and Despite the weak outlook on energy prices, Azerbaijan,
China’s slowing economy. The region’s economic problems will Kazakhstan, Turkmenistan and Uzbekistan can still rely on
accentuate threats to its political stability as rising inflation revenue from oil and gas exports, and their hoard of past
and unemployment are adding to domestic discontent savings.
resulting from slowing growth. “The region’s oil exporters have been able to draw on
The IMF’s assessment was issued before geopolitical savings built up when oil prices were higher. In the short term,
threats to the region intensified in November following ISIS’s this has helped them tackle their immediate fiscal challenges,
but more needs to be done,” said the IMF. In the medium
term, the fund recommends that they consolidate their fiscal
Table 1. CAC population and GDP in 2014. Source: World Bank
position, implement structural reforms and intensify efforts to
Population GDP Average GDP US$
diversify away from oil.
(million) (US$ billion) per capita
The IMF expects the region’s star economy, Turkmenistan,
Armenia 3.0 10.9 3627
to maintain its turbo-charged performance by growing 8.5%
Azerbaijan 9.5 75.2 7916 in 2015 and 8.9% in 2016, down slightly from 2014’s 10.3%.
Georgia 4.5 16.5 3670 Uzbekistan’s economy will also put in a world-beating
Kazakhstan 17.2 212.2 12 337 performance to expand by 6.8% in 2015 and 7% in 2016, to
Kyrgyzstan 5.8 7.4 1275 follow on 2014’s 8.1%.
Tajikistan 8.4 9.2 1095 The region’s largest economy, Kazakhstan, will be its worst
Turkmenistan 5.3 47.9 9038
performer with growth expected to collapse to just 1.5% in
2015 and 2.4% in 2016. Azerbaijan’s economy will expand by 4%
Uzbekistan 30.7 62.6 2039
in 2015, making it the only one in the region to show year-on-
TOTAL 84.4 441.9 5236
year improvement compared with 2.8% in 2014.
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Canada | Germany | Ireland | Malaysia | Mexico | Russia | Spain | UAE | USA
Japan hopes to rival China and Russia with Central Asia’s largest economy is also paying the price
promise of major investments for its heavy economic dependence on sanctions-hit Russia
Central Asia’s beleaguered economies may have found and slowing China, an ironclad formula that produced annual
another white knight in Japanese Prime Minister Shinzo Abe double-digit growth most of this century when those two
whose high-profile visit in late October ended with a promise countries were super performers themselves. All of Central
of fresh investment injections worth a total of more than Asia is hurting from Russia’s sharply devalued currency and
¥3 trillion (US$1 = ¥120). recessed economy hit by Western sanctions over Moscow’s
In his historic visit to Kazakhstan, Uzbekistan, Turkmenistan, conflict in Ukraine.
Tajikistan and Kyrgyzstan to shore up Japan’s political In response, Kazakhstan devalued its tenge by 19% against
influence, Abe’s delegation included representatives of 50 the US dollar in 2014 and allowed it to sink another 26% in
firms to help develop infrastructure and industrial projects. 2015. But that won’t be enough to stop the current account
With an eye on checking China’s international expansion, turning from a surplus of nearly US$6 billion in 2014 into a
Abe promised to help build the region’s infrastructure and deficit of US$5 billion in 2015 with inflation to surge past the
human resources. Japan is a late entrant to the ‘great game’ official target of 8%.
in Central Asia that once was the exclusive stronghold of the According to the World Bank, Kazakhstan’s dire condition
former Soviet Union states even after their independence reflects the combination of “falling oil prices, recession in
from Moscow in 1991. Russia, declining confidence, and lower capital inflows.”
Abe scored his biggest success in Turkmenistan with the Kazakhstan relies on crude oil for about 70% of its export
conclusion of 10 agreements, mostly related to energy and revenues, and sales of various commodities to Russia for
power, worth more than ¥2 trillion or nearly US$18 billion. around 7% of annual export earnings.
His meeting with President Gurbanguly Berdymukhamedov Thanks largely to Beijing’s financial and political support,
will further open up Central Asia’s richest country to Japanese Kazakhstan, Turkmenistan and Uzbekistan were able to
involvement in developing gas-fired power plants and gas- develop the foundation of Central Asia’s new pipeline
based chemicals production. network and infrastructure to export oil and gas to China. On
Japan is also angling for a role in the construction of the 12 December 2009, President Nursultan Nazarbayev and other
proposed US$10 billion Turkmenistan-Afghanistan-Pakistan- Central Asian leaders together with China’s then president
India (TAPI) pipeline to deliver natural gas from Central Asia to Hu Jintao jointly inaugurated the Kazakh section that started
South Asia. Most of that gas will be supplied by Turkmenistan, up the 1833 km Central Asia-China gas pipeline network.
which owns the world’s fourth largest natural gas reserves. Two days later, the Chinese leader was in Turkmenistan to
Another big beneficiary was Uzbekistan which concluded complete the launch of the new pipeline network that has
agreements worth a total of ¥1 trillion to boost its energy, played a major role in Central Asia’s economic take-off this
transportation and communications infrastructure. Japan decade.
has agreed to a ¥12 billion package in soft loans to help From just over US$6.8 billion in 2005, Sino-Kazakhstan
Uzbekistan pay for a gas-fired cogeneration power plant. Abe trade rose to US$20 billion in 2010 and US$28 billion in 2013
also agreed to provide aid to Kyrgyzstan and Tajikistan. as China’s gas demand surged. But reflecting the slowdown in
In his last stop in Central Asia’s largest economy, the both economies and the decline in oil and gas prices, bilateral
Japanese leader and Kazakhstan’s President Nursultan trade value plunged by over 21% in 2014. The two sides have
Nazarbayev agreed to jointly tap the region’s uranium scaled back their plans and are aiming to achieve bilateral
resources to produce nuclear energy for electricity. trade of US$40 billion by 2020 instead of 2016.
Abe undertook his six day visit to Central Asia, which In a series of intense meetings between May and
was previously not on Japan’s foreign policy radar, to counter September 2015, Nazarbayev and Chinese President Xi
China’s fast-growing influence in the region. Since launching Jinping agreed to strengthen ties and increase co-operation
China’s Silk Route strategy in Kazakhstan in 2013, President Xi in trade, and joint investments in energy, infrastructure
Jinping has been focusing much of Beijing’s political capital and high technology projects. The two leaders have signed
and investment efforts on linking up Central Asia’s economies several agreements to implement 25 energy, industrial and
with his country. infrastructure projects worth a total of US$23 billion.
The Kazakh leader – who has been in power since his
Kazakhstan again looks to China country’s independence from the former Soviet Union in
Kazakhstan is hoping for China to come to the rescue again in 1991 – has endeared himself to Xi with his pledge to support
a repeat of 2008 - 2009 when its economy last encountered a Beijing’s most important projects, the Asian Infrastructure
major downturn. Investment Bank (AIIB) and the revived expanded Silk Road.
According to the IMF, Kazakhstan will have the region’s Having already invested more than US$17 billion in
worst performing economy in 2015, as its growth will slow Kazakhstan, China expects to face renewed competition from
to just 1.5% from nearly a third of the previous year’s 4.3% the US, which says its companies have poured in a total of
rate. A toxic combination of low oil prices, weak domestic US$21 billion into the country. Chinese firms will implement rail
demand and decline in external trade will likely turn the and road projects through Kazakhstan as part of Beijing’s plan
country’s years of fiscal and current account surpluses into to link up the continents of Asia and Europe under its Silk Road
deficits in 2015. strategy.
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Tel.: +31 (0)547 26 00 00 • Fax: +31 (0)547-26 10 00 • info@maats.com • www.maats.com
For its contribution to the Kazakh economy, China may Berdimuhamedow together with Afghanistan’s President
yet land the most coveted prize: approval for state-owned Ashraf Ghani, Pakistan’s Prime Minister Nawaz Sharif and
China National Petroleum Corporation (CNPC) to buy into India’s Vice President Hamid Ansari jointly launched the
the giant northwestern Karachaganak gas condensate field to construction of the TAPI project in the eastern Turkmen
add to its 8.33% stake in the Kashagan oilfield. province of Mary.
Karachaganak is controlled by Karachaganak Petroleum At the ceremony, Berdymukhamedov said the pipeline
Operating (KPO) according to UK’s BG Group, which owns a will start-up by December 2019, with an annual capacity to
29.25% stake in the company. KPO’s other shareholders are deliver 33 billion m3 of natural gas. Despite his confident
Italy’s ENI (29.25%), US major Chevron (18%), Russia’s LukOil prediction, the project is shrouded in doubt owing to a
(13.5%) and Kazakhstan’s state-owned KazMunaiGas (10%). myriad of financial, political and security problems that have
Karachaganak accounts for around 45% of the country’s repeatedly delayed its implementation the last two decades.
total gas production and approximately 16% of total liquids Oil and gas prices are hovering near seven year lows
production. It holds around 9 billion bbls of condensate and and likely to go lower, threatening the viability of the
48 trillion ft3 of of gas, according to BG. proposed pipeline that will criss-cross some of the
In September 2013, CNPC paid US$5 billion for a stake in region’s most difficult terrain that are also vulnerable to
the Kashagan oil project in the Caspian Sea. terror attacks. The project aims to tap Turkmenistan’s
giant Galkynysh field which holds estimated reserves of
World Bank comments on Azerbaijan and 16 trillion ft3 of natural gas to feed the region’s growing
Uzbekistan energy demand. Boosted by Galkynysh’s start-up in
Azerbaijan’s growth accelerated to 5.7% in 1H15, driven by September 2013, Turkmenistan has raised its annual natural
public investment and a boom in the agricultural and non-oil gas production to around 70 billion m3.
manufacturing sectors. However, these gains were offset According to the US Energy Information Administration
by the decline in oil export earnings, causing the current- (EIA), Turkmenistan, owner of the world’s fourth largest
account surplus to fall sharply and pushing the budget gas reserves, exported 42.4 billion m3 of the fuel through a
balance into deficit. The Azerbaijani manat has stabilised network of pipelines in 2014. More than half of that went
against the US dollar following a 34% plunge in value in to China with the rest delivered mostly to Russia and Iran.
February 2015 that has stoked inflationary forces. In the race for Central Asia’s oil and gas reserves, China has
The bank expects Azerbaijan’s economy to grow at an locked up Turkmenistan’s rising gas output by signing a series
average annual rate of 2.4% between 2015 and 2017. Declining of long-term contracts for a total of more than 65 trillion m3
oil production and export revenues will reduce the country’s by 2020.
current account surplus to 5.2% of GDP. Russia’s economic China’s launch of the Central Asia-China Gas Pipeline in
slowdown will remain a downside risk as it accounts for 2009 has given it a huge first-mover advantage on tapping
one-third of Azerbaijan’s non-oil exports. the region’s oil and gas reserves.
The bank expects investment in the hydrocarbons sector Worried that they will be left out of Central Asia’s
to significantly increase in 2016 - 2017 with the construction ‘gas rush’, Afghanistan, Pakistan and India along with
of major gas pipelines. Nepal and Bangladesh are hoping to hurry up the
After growing by 8.1% in 2014, the Uzbek economy development of TAPI with the Asian Development Bank
will expand at a slower rate of 7% in 2015. Growth will be as project adviser.
dragged down by weaker external conditions including According to the ADB, the state gas companies of the
further declining world prices of key commodities and four countries established a joint venture last year to build,
Uzbekistan’s reliance on the economies of Russia and China. own and operate the pipeline to export up to 33 billion m3/y
While the government will continue to boost spending of natural gas from Turkmenistan to Afghanistan, Pakistan,
and lending to bolster economic growth, returning migrants and India for 30 years. The TAPI gas pipeline network will
will create pressures for new jobs. Workers’ remittances, which be equally owned by state-owned Turkmengas, Afghan Gas
accounted for about 9% of GDP in 2014, plunged by 48% in 1H15. Enterprise, Pakistan’s Inter State Gas Systems (Private) Limited,
The economy has also been hurt by the fall in prices and GAIL (India) Limited.
of Uzbekistan’s key export commodities, natural gas, Turkmengas and another state-owned firm,
copper, cotton, and gold. As a result, its export earnings are Turkmennebitgazgurlushyk, have been tasked to design and
expected to fall by 6.7% in 2015. build the country’s section of TAPI and the main project’s
support infrastructure.
Doubts persist over proposed TAPI gas Of growing concern is that Turkmenistan, TAPI’s lead
pipeline developer, and the other consortium members have been
Turkmenistan, the region’s strongest economy, is looking to unable to attract the participation of international investors.
the construction of Asia’s most ambitious pipeline project Malaysia’s Petronas and France’s Total have been mentioned
to provide the next leg of its economic development with as likely participants, while US majors ExxonMobil and
a plan to supply natural gas to Afghanistan, Pakistan and Chevron have pulled out after their request for equity stakes
India. On 13 December, Turkmenistan’s President Gurbanguly in Turkmenistan’s gas fields were rejected.
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Shedding light
ON DUAL
POWDER
SYSTEMS
UV resistant line pipe protection using dual powder
systems is necessary during pipeline construction,
explain Charles Zhou and Meghan Hodge from
Axalta Coating Systems, Powder Coatings, USA.
20
F
usion bonded epoxy (FBE) is considered
to be one of the most commonly used
corrosion coatings in the world for new
pipeline construction. However, corrosion
coatings alone may not provide adequate
protection that is necessary during the storage,
transportation, installation and operation of a
pipeline. To ensure the highest level of defence
possible, additional coating layers are often
applied to the FBE corrosion coating to provide
enhanced durability. An example of this added
layer of protection is an abrasion resistant outer
coat (ARO) that works to provide a more damage-
resistant coating system. Similarly, powder coating
can be applied over the existing FBE corrosion
coating to provide ultraviolet (UV) resistance for
use in above ground applications or during storage
of coated pipe.
21
of loose powdery residue on the coating’s surface is known A simple and effective manner of building UV resistance
as chalking. The extent of chalking depends on the extent in coatings is using a dual layer powder coating consisting
of the direct exposure to UV radiation, the intensity and the of an FBE corrosion coat and a UV resistant top coat. The
duration of the UV radiation, and the availability of water on UV resistant top coat can be applied directly after the
the coating surface.1 application of the FBE powder coating allowing for easy and
The two main FBE properties affected by chalking are clean applications, as well as good interlayer adhesion. Nap-
thickness and flexibility. When chalking occurs, the coating Gard® Sol-Gard (PCW601S9) manufactured by Axalta Coating
itself is actually degrading, which leads to a loss in overall Systems is a UV resistant top coat suitable for protection
coating thickness over time. Historical observation suggests over Nap-Gard single layer FBE or dual layer FBE systems.
that this thickness loss typically begins within 9 - 18 months This fast curing, thermosetting polyester coating is capable of
after chalking commences.2 The typical rate of thickness loss protecting FBE coatings from UV deterioration in both above
due to chalking is 10 - 40 mm/y. ground applications or during storage.
Sections of pipe stockpiled in Alberta (Canada) and North
Dakota (USA) were analysed for thickness and flexibility after Design of Sol-Gard
16 - 21 months of exposure. Results showed a 25 - 50 mm For approximately two decades, dual powder FBE systems for
thickness loss and a significant decrease in flexibility that pipe coatings have been used in corrosion protection. Because
failed the 2.5˚ pipe diameter flexibility requirements outlined the epoxy resins used in most standard FBE coatings are
in CSA Z245.20-98. No significant differences were observed Bisphenol A (BisA) based, resin suppliers have limited choices
regarding cathodic disbondment, adhesion or impact in the tailoring of resin structure and properties, especially
properties. From this study it was determined that FBE for UV resistance. But unlike BisA based epoxies, there are a
coatings should be protected in some manner if exposure to variety of monomer choices for polyester resins that provide
UV radiation for periods over one year is anticipated. the optimal reactivity and other useful properties needed,
such as hardness, flexibility, weatherability and gloss.
UV protection options for FBE coated line pipe FBE coating applications require certain speeds in order
Many different practices are used in the coatings industry to be productive, which includes a quench time of usually
to help reduce the effects of chalking on FBE coatings. One less than 3 mins. To meet these requirements, the polyester
popular option consists of shielding the FBE coating with a powder top coat must meet the following criteria:
physical cover or tarp. This option provides good protection )) High reactivity to meet application speed.
but can prove to be expensive and storing covers when not
in use can be inconvenient. Tarps can be difficult to utilise )) Excellent exterior durability.
over long stretches of pipe or in environments consistently
)) Good flexibility for field bend during pipe installation.
exposed to high wind.
Whitewashing the FBE coated pipe with a liquid UV )) Good adhesion to corrosion protection layer.
resistant coating is a less expensive option, however the
process must be completed offline of the FBE powder Application Procedure
application process and can prove to be very messy. In Polyester powder top coats are not designed to be corrosion
addition, this process requires a long drying time before protection coatings, and therefore should only be used in
the pipe can be marked for identification. If the FBE coated conjunction with single-layer FBE coatings. As with dual FBE
pipe is stored for a great deal of time or used in above powder systems, it is critical to follow the proper procedures
ground application, whitewashing often has to be repeated. for application in order to achieve the desired coating
Compatibility concerns also exist between whitewashing and performance.
FBE coatings. )) Cleanliness: grit blast to NACE Near-White specifications
(Swedish Standard Sa 2.5).
)) Application:
Our sealing solutions protect pipelines from dangerous leaks and spills and ensure the safe flow of fluids in
pipeline transmissions, distribution and process piping systems under the most rigorous sealing requirements.
Pigging Products . Flange Isolation & Sealing . Pig Detection & Tracking
Bibliography
1. KEHR A.J., Fusion Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion
Protection, NACE International, 2003.
2. CENTINER, M., Singh, P., and ABES, J., Stockpiled FBE - Coated Line Pipe Can
Be Subject to UV Degradatio,. 2001.
E
xternal corrosion control becomes extremely
challenging for multiple pipeline corridors that
have been expanded over time with additional
facilities. Effective cathodic protection (CP)
management relies on the correct analysis of accurate field data
retrieved from each of the individual pipelines within the right-of-
way (ROW). Conventional CP survey techniques often will not provide
a sufficient level of distinction required to ascertain the adequacy of
25
)) Measurements may be influenced by
significant IR-drop because of residual
currents flowing between the pipelines.
years of
continuous sales
expansion
Parameters such as
ON potential and current
flow (axial current through
the pipeline wall, rectifier
output and current exchange
through bonds and drains)
are used to calibrate
the model for the as-is
condition. The simulation
results are again compared
Figure 3. 3D computational model of pipeline corridor with CP system (red line) and electrical with the measured field
shortings (green line). data and if a discrepancy is
External blasting Internal blasting & lining Offshore pipe handling Spool base equipment
External coating Concrete weight coating Field joint blast & coat Pipeline rehabilitation
www.selmers.com
identified further adjustments and refinement to the model previous step, the amount of current entering the pipe
is made. through the soil is now known. Through the polarisation
Secondly, smaller pipeline sections are defined and curve, the current can then be converted to true or IR-free
the coating resistance of each section of the individual potential of the pipeline. Polarisation levels can be further
pipelines is adjusted until the simulation results are aligned refined by characterising the size and amount of coating
with accurately measured field data. Persistent deviations defects. Segments that do not receive sufficient CP current
are often explained by incorrect or missing field data and or experience an anodic stress due to the other pipelines
undocumented changes to the system. Typical examples present in the same ROW become apparent. As an example,
are accidental drains, failed equipment or non-reported Figure 4 shows an area with a transition of soil type near
bonds or electrical shorting. Once clarified a baseline a waterway that resulted in some sections on two recent
model with the correct distribution of the CP current is pipelines tending to have (slightly) positive or anodic
obtained. Multiple iterations and a continual integration current density.
of field data are required to obtain a realistic model of
such a complex system. Some special algorithms are under Treat the disease, not the symptoms
development to automate this process. Once the model is in place, strategic counter measure
Finally, the model allows a quantitative analysis of the scenarios can be reviewed at the design stages of
CP effectiveness, where the OFF potential and coupon expansion projects for a relatively low cost. Ad hoc actions
current demand are used to define the polarisation curve in the field such as adding anode beds to bring potentials
of steel in the local soil. Since the CP current distribution to more negative values can sometimes worsen the
has been calculated for each pipeline section in the situation in unexpected remote locations. Equipotential
bonds should be installed at the
appropriate locations to avoid CP
currents from flowing in undesirable
directions.
Alternatively, the model has
revealed that it is crucial for shunt
resistors to be installed for each
rectifier negative cable connecting
the individual pipelines. The value of
the resistor is calculated by dividing
the average IR-free potential by the
axial current occurring in the sections
with the most electropositive
potentials. The resistor should be
installed in the line with the most
electronegative potentials. Through
iteration the resistor value for each
Figure 4. Simulated current densities indicating areas with anodic behaviour. line is optimised.
Proposed solutions are verified
up-front by introducing them in the
model and calculating their global
impact on the CP performance. As
such, logical control and optimisation
of the CP system becomes feasible,
eliminating costly excavations and
substantially reducing the risk of
failure.
Continuous surveillance of the
CP status becomes cost-effective
by keeping the model apprised with
incoming remote monitoring data
and field measurements. Changes in
the protection behaviour of each
individual pipeline are visualised in
a geographic information system
and new simulations are easily
Figure 5. Example of corrosion attack caused by interference between pipelines.
updated.
Delivering
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© 2015 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow,” 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.
Figure 1. CIPS survey.
32
Ted Huck, MATCOR Inc., USA, highlights the importance of close interval potential surveys as a
means of ensuring pipeline cathodic protection systems are operating to specified standards.
P
erhaps you have seen a safety vest-wearing consequences of pipeline failures. One of the primary
survey crew walking down a pipeline right-of-way threats to metallic pipelines is corrosion, indeed the
(ROW) – a lead person walking in front with a United States’ Department of Transportation’s ‘Pipeline
pipe locator, and a second person following with Incident 20 Year Trends’ reports corrosion as the second
a pair of poles and a backpack containing a spool that is leading cause of all reported incidents behind material/
trailing a long thin copper wire – and wondered what they weld/equipment failures, and ahead of mechanical
were doing. Well, they are enjoying a nice walk along the damage from third parties (call before you dig). So, any
pipeline ROW; collecting valuable information that is used discussion of assuring pipeline integrity has to address
to ensure the integrity of the pipeline they are walking. corrosion as a significant threat.
This article is a primer on close interval potential Current best practices to prevent metallic pipeline
surveys (CIPS). For those in the US, the ‘P’ is dropped and corrosion include a combination of coatings and cathodic
is referred to as CIS. Either way, this survey methodology protection (CP). Coatings provide the primary defence
is an invaluable assessment tool that is frequently against corrosion by isolating the pipeline from the
mandated by pipeline regulatory authorities. This article environment while CP provides a secondary level of
describes the process of collecting the information corrosion prevention through the application of direct
and how that information is used as a tool to ensure a current (DC) current along the length of the pipeline.
pipeline’s integrity. This CP current is intended to flow through the earth
Any discussion of CIPS surveys should start with a seeking out exposed metal defects, also known as voids
basic understanding of what pipeline integrity means. or holidays, in the pipeline coating along the length of
Pipeline integrity represents the efforts by the pipeline the pipeline. As current flows onto the exposed metal,
owner to maintain their pipeline assets, and to ensure the electrical potential of the metal shifts, becoming
that the public is protected from the very serious more negative as a result of the current application. This
33
potential shift changes the environment around the metal CP. The second is to demonstrate that there is at least a
and inhibits the corrosion reaction as the steel structure is -100 MV shift of the polarised structure from its native
polarised. With sufficient polarisation, the corrosion rate or depolarised potential. The data collected in the
for the metallic pipeline is reduced to virtually zero and CIPS survey allows the pipeline operator to assess the
the corrosion risk is eliminated. polarised potential of the pipeline to ensure that it meets
Though the vast majority of pipelines are carbon criteria and that the CP system is working effectively in
steel and the technology is applicable for other metallic conjunction with the coating system to prevent corrosion.
pipelines, for the purpose of this article, metallic and The CIPS survey can be conducted on buried or
carbon steel are used interchangeably. Since pipeline submerged pipelines. At regular intervals along the
operators utilise coatings and CP to prevent their carbon pipeline – typically every 2.5 ft (76 cm) – measurements
steel pipeline from corrosion damage that can adversely are taken of the potential or voltage difference between
affect the integrity of their assets, they should be very the pipeline, and a reference electrode in contact with
interested in assessing the condition of the coating and the soil or water. That is a technician with the two poles.
the effectiveness of the CP system. One of the most Every step along the ROW one of the poles makes contact
effective tools to assess the effectiveness of a pipeline’s with the ground, and the technician pushes a button that
CP system and the condition of the pipeline’s coating submits data collected by the data logger in a backpack.
system is the CIPS survey. The data collected during a close interval survey can be
used to establish a baseline for CP on a new pipeline,
What does a CIPS survey do? or assess the performance and operation of existing
The goal of any CIPS survey is to measure the electrical underground pipeline CP systems. CIPS can also identify
potential of the steel pipeline along the length of the areas with insufficient CP and may detect large coating
pipeline area being surveyed. As noted earlier, the goal of defects or holidays, however small defects may not be
CP is to polarise those exposed areas along the pipeline detected.
that are not fully isolated from the environment by the
coating system. If the coating system for a 10 km long, Keys to a successful CIPS survey
12 in. dia. pipeline were 99% effective and only had 1% of
holidays, there would be almost 96 m2 of exposed steel Selecting a qualified survey crew
along the length of pipeline. Each of these coating defects Whether the CIPS survey is being performed by the
or holidays along the pipeline are potential corrosion pipeline operator’s personnel or by a supplier that
sites unless the CP system is properly polarising the specialises in these surveys, the qualifications and
pipeline along its entire length. experience of the survey crew are critical to collecting
While there are a variety of accepted criteria for what accurate data. When contracting the CIPS survey work
constitutes proper polarisation, the two most widely key considerations should include: safety record, makeup
accepted are those detailed in NACE specifications – of crew, whether crew members are full time employees
the criteria descriptions are simplified and apply to the or subcontractors, the type of equipment they have,
majority of buried and submerged pipelines in typical engineering and IT support for data analysis and reporting,
ambient temperature environments, where the criteria may and turnaround time for reporting.
need to be adjusted for elevated operating temperatures Many operators have started to specify that at
and especially corrosive chemical environments. least the crew leader must have NACE certification,
The first is the -850 MV polarised potential criteria. that the crews must be full time employees and not
NACE deems any pipeline that has a negative polarised subcontractors, and that a NACE CP or corrosion
potential of -850 MV to meet the criteria for effective specialist must review and stamp the final report. One
additional note on contracting CIPS surveys – some
survey companies compensate the field crew based on
miles per day. This model has led to data being collected
quickly, but often not correctly as the crew rushes down
the ROW. Many operators prefer to pay a fixed crew day
rate to avoid the danger of pay-per-mile incentives.
Advanced planning
Before any survey, it is important to properly plan.
Typical information required in advance of starting a CIPS
survey includes historical survey data, rectifier output
information, maps and alignment sheets detailing the
pipeline, surrounding terrain and structures. Also helpful
is information about any remediation done in the area,
such as construction activity, additional pipelines or
Figure 2. CIPS crew gathers potential data along pipeline ROW. new power lines. Noting any changes or upgrades to the
37
inspection (ILI) Expert module – to interpret and manage vast The database stores pipeline stationing (construction) data
amounts of data in order to manage the everyday activities (depending when and how the client has organised this linear
related to pipeline integrity. data). During the ILI data upload process, the log distance of
For key decisions to be made effectively, the gathering features (logged during the ILI process) is uploaded into the
and interpreting of large amounts of correct data becomes database.
an important task. The best way to resolve this problem is to The challenge is then to align the uploaded log
transfer client data to a single uniform relational database. distances from the new ILI report, with the existing pipeline
Storing and analysing pipeline data in a single source can stationing data. The ILI Expert provides the appropriate tools
be achieved by connecting different sources of data into a (automated, manual or a combination of both) to align these
consistent and clearly defined format. points – resulting in the ILI features being connected to the
With this information available, the operator can analyse correct, or very close, points along the pipeline. Additionally,
the relationship between the different data, and make the software can automatically calculate the co-ordinates of
appropriate decisions when proposing pipeline inspections, all defects even if they were not provided in the report.
repair plans and further preventative measures. The result of this data linking process is that the
anomalies/cracks/dents found as part of the ILI can now be
Inspection management physically located at the correct point along the pipeline.
Today, ILI vendors provide inspections in a report that contains
a list of all ‘features’, which have been encountered in the Feature analysis
course of the ILI tool ‘run’. Another major feature of the ILI Expert module is to be able
One of the main features of the PiMSlider ILI Expert to analyse inspections in some considerable detail. With
module is the ability to upload these reports (commonly each reported defect, the user can determine whether the
known as a pipe tally report) into the PiMSlider database. defect is dangerous on its own, how close the defect is to
As ILI vendors can provide the data in different file formats, other defects, how the proximity of the defect can affect the
the ILI Expert module is equipped with a flexible mechanism integrity of the pipe at that location, and how far girth and
for describing different templates allowing engineers or longitudinal welds are from the defect. All of these (and many
integrity specialists to upload almost any spread sheet of any other) issues will be extremely important for the integrity
structure – whether the report is in CSV, MS Excel or even engineer.
MS Access format. To ensure the data can be used correctly By using the ‘browse anomalies’ function of the ILI Expert
in the software (and features utilised to their full potential), module, integrity engineers can conveniently visualise and
it is advisable to keep to a certain classification of features, analyse every aspect related to the defects, their danger,
such as ‘anomaly’, ‘corrosion’, and ‘dent’. For example, one of as well as calculating safe and burst pressures and different
the ILI Expert CSV upload formats/templates conforms to the methods of repairs.
Pipeline Operator Forum 3.2 data format; a standard commonly Along with visualising defects, it is possible to show any
used for ILI. Although not mandatory, it is desirable that all repairs that are either already completed or planned, as well
inspections in a particular system use the same specification. as casings and other parts of the pipeline system found by the
Using templates allows an expert to easily upload any ILI ILI tool and which may be of interest during defect analysis.
report from any vendor into the PiMSlider database without The ILI Expert module also allows the user to calculate a
the help of the software designer or IT specialist. variety of strength characteristics for pipelines with defects.
Additionally, the user can
create calculation algorithms
and embed them into the
software. The ILI Expert module
is delivered with pre-configured
algorithms for corrosion defects
based on industry standards,
such as B31G, B31G Modified,
DNV Recommended Practice
(RP) F101b.
Once the integrity engineer
has finished analysing ILI
defects, there may be a need to
perform certain actions, such
as repairs or further research.
The engineer can automatically
create a set of documents in
order to carry out, for example,
Figure 1. PiMSlider – ILI Expert module.
excavations.
Courses include:
§ CIP Level 1 For information on
§ CIP Level 2
earning your CIP
§ CIP Level 3 Peer Review
§ Nuclear Power Plant Training for
Certification, visit
Coating Inspectors naceinstitute.org
§ CIP One-Day Bridge
§ Marine Coating Technology
MORE Money Opportunities GET MORE Did you know? The majority of survey respondents, nearly 25%, said the one job aspect they would
with NACE Recognition Education Opportunities change is more opportunities for advancement. NACE Training and Certification can
give you just that. Source: 2015 NACE International Annual Corrosion Career Survey
Despite its apparent
simplicity, the task of
comparing pig runs is not
entirely straightforward.
When we know the
parameters of the defect
now and the parameters
five years ago, it is not
difficult to calculate
how much it may have
‘grown’. The challenge
is to be able to identify
the anomalies found in
the previous run and the
anomalies found in the
Figure 2. PiMSlider – ILI run comparison feature.
latest run are actually
describing the same
defect.
Considering that the number of anomalies
found in a pig run report can reach into the
millions for both runs, the task of ‘run comparison’
becomes close to impossible by manual analysis.
Integrity experts can still undertake this kind of
analysis with the help of readily available tools
(such as MS Excel) but the quality and results of
the work could raise some doubts.
The PiMSlider ILI Expert module provides a
comprehensive set of ILI run comparison features.
What would normally be weeks of manual labour
comparing runs can now be replaced by the touch
of a button, as the software will automatically
find all the matching (and non-matching) defects
between the two pig runs.
It is then possible to automatically generate
reports, which include compared and non-
compared defects, a list of the omitted or
newly discovered joints, and the statistical
Figure 3. Defect growth comparison screenshot.
corrosion rate over the entire length of the
pipeline with the calculation of average values
These documents contain all the information required for and the mean distribution.
the field engineers performing the excavation, including the
co-ordinates of the defect, its exact clock position on the Repair planning
pipe, the distance to the downstream and upstream markers Whilst the PiMSlider ILI Expert module is a great tool for
and valves, and the angular position of the longitudinal welds analysing and documenting the results of ILIs, the next logical
for targeted and neighbouring joints. This allows engineers to step is to generate a detailed action plan, in order to address
find the exact location of excavation and be able to identify the threats to the integrity of the pipeline based on the
the defects to be repaired. results of ILI data analysis. A generated plan can include two
kinds of repair:
Run comparison
)) An urgent repair.
Pipelines can be inspected by ILI methods at different times
during the life of the pipeline. This means that for the same )) The need for an additional examination of the defect
pipeline, it is likely that multiple sets of defects are detected at (including non-destructive inspection methods – such as
different times, possibly by different inspection companies. It NDT).
is also likely that the inspections carried out at different times
by different companies describe the same defects. It therefore The ILI Expert module includes a complete set of tools
becomes very interesting for the integrity engineer to be able for assigning, storing, reporting and analysing NDT data. The
to track the development of these defects over time. module also allows you to compare NDT data with ILI data.
Tel:281-351-2749
Fax:281-351-4658 distributors
Toll Free:800-578-7436 wanted
Email:Sales@pigsunlimited.com
TRENDING
DRONES
Jack Behar, Samollet, USA, discusses drones for the oil and gas pipeline industry.
O
il and gas pipelines installations
positioned across widespread areas that
are difficult to monitor and guard are
exceptionally valuable and important
assets. Attacks, damage or leaks to such installations
can lead to massive environmental and ecological
damages including, but not limited to, massive
lawsuits and revenue losses.
In the past, many methods of monitoring,
surveying, detecting, and locating leaks or damages
in the oil and gas pipelines have been quite costly,
ineffective and unproductive to perform and
accomplish with any great accurate results, causing
lengthy repair activities including shutdowns.
43
Recently, with the falling oil and gas prices, companies it allowed ConocoPhillips Co. to use drones in the Chukchi
have been examining new methods and technologies Sea in Alaska to survey ice and marine life.
that encompass accurate and effective detection tools at
reduced costs. The Houston Chronicle reported on Funding through a crude slump
19 May 2014, that energy companies are considering using Oil and gas companies are currently on the hunt for new
drones to inspect offshore platforms, pipelines and flare ways to save funds in the midst of a global crude slump
stacks at oil refineries. that is drying up revenue and are increasingly turning to
the tech industry for non-traditional ideas that could help
Pipeline inspections them operate faster and better than their competitors.
The oil and gas giant BP has already tested a drone for With the growing drone’s usage, no longer do
pipeline inspections, and the Houston-based Apache Corp companies have to send workers to remote regions to
has used them in the UK to monitor flare stacks at a gas conduct routine inspections instead they are sending their
plant. In Alaska, BP is using the Puma Unmanned Aerial drones to do the same risky and expensive jobs that pose
Vehicle (UAV) to monitor its extensive pipeline network to potential dangers to employees.
check for damage while also staying on top of weather- UAS offers the industry new methods and capabilities
related disruptions, such as icy conditions and floods. that decrease costs – including operational hazard – while
Currently, Royal Dutch Shell is also getting into the mix also improving effectiveness. UAVs and UASs can be used
and the Oregon based VDOS Global LLC has won approval to measure and quantify oil spills, determine how the oil
from the Federal Aviation Administration (FAA) in 2014 to is moving in water and provide information and imagery,
use drones to inspect Shell’s flare stacks in the Gulf of increase safety and the ability to make better decisions
Mexico. VDOS says that it anticipates ‘significant demand’ in the repairs and clean-up efforts, and additionally,
for its services as a result of more than 3500 potential specialised sensors are also used to detect emissions of
inspection sites in the Gulf alone. Key advantage of drones gas leaks.
for these inspections: they can detect corrosion or other Drones have become the most economical type of
problems with equipment without interrupting operations. platform for the inspection of the thousands of miles
Commercial drone use is currently mostly prohibited of pipelines transporting oil and gas around the world.
in the USA while the FAA is writing and updating the rules These infrastructures must constantly be monitored to
for them. In 2007, the FAA imposed what amounted to reduce the potential for undetected leaks, which in the
a nationwide no-fly zone on commercial drones in the past have caused life threatening fires and explosions.
USA while it wrote rules regulating their operations. But The temperature differences between fluid and soil mean
in March, a judge for the National Transportation Safety that oil and gas leaks show up well in thermal imaging.
Board (NTSB) said it expected to issue newly updated Operators can fly drones and hover at low altitudes less
regulations for the commercial regulations of drones. than 400 ft over the pipelines with special cameras and
In February 2015, the FAA proposed a new set of sensors, sending information to the assessor showing the
regulations for the Unmanned Aircraft Systems (UAS) pipe’s condition.
and the US Congress passed the FAA Modernisation Fitted with advanced seismic sensors, drones are now
and Reform Act of 2012, instructing the FAA to develop also capable to replace exploration teams by recording
standards for the commercial and public use of drones. and registering subterranean data from hundreds of feet
The FAA realised that UAVs and UAS are proving to be in the air. These capabilities entail a big shake-up for
beneficial in the energy sector. As part of FAA’s research, one of the world’s most entrenched industries, with less
strip mining, fewer accidents, and cheaper fuel for the
consumers.
Innovative solutions
While trying to improve pipeline monitoring and
associated costs, BP began researching the use of
unmanned aircraft in 2006. Royal Dutch Shell Plc began
a year earlier, while in Canada, the two biggest pipeline
operators – Enbridge Inc. and TransCanada Corp. – still
prefer the costly traditional methods for inspecting its US
pipeline routes. In the US, ConocoPhillips is still examining
and evaluating the effectiveness of UAV monitoring.
Sky Futures – headquartered in London – is a drone
inspection company specialising in the oil and gas industry
and counts BP, Shell, Apache, BG Group and Statoil
among its clients. It is one of a handful of companies,
Figure 1. Oil pipeline in Alberta, Canada bursts.
including Cyberhawk, PrecisionHawk and SenseFly that find
join the best — welcome to the world’s leading trade fair for the
tube industry! Those who wish to find comprehensive informa-
tion about the latest innovations in tubes and pipes, manufacturing,
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It can all be found here at the world’s most important exhibition —
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A special area is reserved for them, because the question of ma-
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www.messe-duesseldorf.de
Connections
you can rely on
A small commercial unmanned vehicle fitted with a heat-sensing
Böhmer ball valves have been connecting industries
camera costs about US$85 000, while it costs about US$3000
and markets for 60 years. Our product solutions per flight hour to send a helicopter to monitor an oil pipeline,
ensure safe pipeline operation anywhere, anytime. according to Dave Kroetsch, CEO of the drone manufacturer
Aeryon Labs Inc. The drone, therefore, would pay for itself within
29 hours.
According to Reuters, Alaska UAVs are used to inspect oil and
gas pipelines at a fraction of the current traditional cost (fixed
wing aircrafts or helicopters. The 20 min. test flight, conducted by
BP Plc, was just a glimpse of a future where oil and gas companies
in the Arctic can rely on unmanned aircraft to detect pipeline
faults, at a fraction of the cost of piloted helicopter flights.
A new trend
One area of interest for the oil and gas industry and regulators
alike is methane detection and location around unconventional
gas and oilfield production sites. Current methods for surveying,
detecting, and locating leaks, are at times too inefficient and costly
to conduct, potentially leaving many leaks unrepaired. These initial
applications spur continued development and miniaturisation of
high-definition imaging sensors. The use of drones is still relatively
new but there appears to be real demand for drone use in the
energy sector both in the US and internationally.
Using drones is proving to be a new trend in the oil and gas
Ball Valves industry particularly when large companies like Google, Boeing,
from 1/8” to 56” Northrop Grumman, AeroVironment, Inc., General Atomics, and
Israel Aerospace Industries, which according to a major study by
for numerous environments,
the Frost & Sullivan, was recently anointed as the world’s largest
applications, liquids and
exporter of the small surveillance drones.
gasses The impact of remote and self-piloted drones comes in the
form of speed and major savings. By monitoring job sites 24 hr/d
in very high resolution, oil and gas companies get an up-to-the-
minute view of how their resources are deployed, especially when
the weather conditions are too dangerous for manned flights.
Instead of planning fleet movement’s way in advance, decisions can
now become instant, hence cutting costs and making management
more responsive and effective
All the above companies have significant drone businesses, and
each of these firms will benefit. Drones are becoming more widely
used, not just in the energy sector, as more and more businesses
around the world are discovering the benefits and challenges
of integrating UAV systems into their operations. Accurate and
reliable data acquisition – though important – is the first part of
the future for effectively monitoring oil and gas pipelines, as the
unmanned aircraft and the data they can collect provide great
opportunities for the oil and gas industry to realise new gains in
efficiencies, increase safety, and decrease costs.
Bibliography
http://www.energyfuse.org/drones-could-become-commonplace-in-the-oil-industry/
http://thehill.com/policy/energy-environment/206524-energy-companies-eye-drones-
for-pipelines-offshore-platforms
http://www.dohenydrones.com/commercial-drones-for-oil-and-gas
http://www.bloomberg.com/news/articles/2015-08-21/flying-robots-replace-oil-
roughnecks
http://www.barnardmicrosystems.com/UAV/pipeline_monitoring/pipeline_
monitoring.html
http://aeryon.com/in-the-news/alaska-oilfield-drones
http://www.rawstory.com/2013/06/alaska-uses-drones-to-inspect-oil-and-gas-pipelines-
at-a-fraction-of-the-cost/
www.boehmer.de
Neil Parkinson, AVT Reliability,
UK, relays the use and benefits of
operating deflection shape analysis.
I’m pickin’ up
bad vibrations
bad vibrations
S
ustained, excessive vibration in many key structures, including machinery, tools, pipes and support systems,
can have catastrophic results. If left uncorrected, such vibration can cause failure of the unit and, as a direct
result, huge losses in terms of productivity/downtime and unplanned maintenance or replacement costs.
Even before the unit fails, excessive vibration can greatly reduce the reliability of machinery and generate
environmental hazards – it may also render the machinery (and thus the company or organisation that operates it) non-
compliant with legal and regulatory requirements, for example by causing a hazard to employees’ health and safety.
For complex systems with many degrees of freedom and with potentially multiple mode shapes and frequencies, it
can often be very difficult for the structural vibration analyst to fully understand the nature of the vibration, making it
very difficult to determine the optimum corrective actions.
To assist in the interpretation of such complex vibration problems, one of the most powerful tools available to the
specialist is a measurement-based technique, which enables the actual in-service vibration modes to be individually
visualised and animated. The technique is known as operating deflection shape (ODS) analysis.
47
ODS analysis clearly identifies the vibration patterns component of vibration separately, it is much easier for the
occurring under real life conditions, and so machinery and specialist to understand very complex data. The data is useful
structural supports can be adjusted and optimised in light of for identifying a number of key factors:
those findings. When used as part of a proactive maintenance )) Which excitation frequency produces the greatest
schedule, particularly when this is done in partnership with an amplitude of vibration?
experienced and recognised specialist in asset integrity and
performance, ODS analysis can help organisations to avoid )) Which positions of the structure show the largest
the threats posed by vibration-induced machinery problems, displacement amplitudes?
and to make more efficient decisions around investment and )) Are there any positions of looseness of fixings or any
product lifecycles. structural supports that appear to be too flexible?
What is ODS? )) Where would be the best positions to try to re-inforce the
ODS analysis is a means of visualising the vibration pattern structure to resist the observed directions and amplitudes
occurring in a structure. That vibration may result from the of vibration?
structures own operating forces, or from forces external to it.
In ODS analysis, vibration is measured at various points and in The analysis
various directions within the structure – these are referred to There are four main types of ODS analysis:
as degrees of freedom (DOFs). )) Time ODS – used to investigate vibration as a function
Specialised software is used to convert the measurements of time, this method can visualise deflection shapes
into appropriate formats, in particular, as animated graphic generated by both transient and stationary signals.
representations of the structure being analysed. These
animations clearly show how and where the vibration is )) Running orders ODS – used to evaluate vibration patterns
at specific orders as a function of rotational speed or
causing problems, and to what degree. Typically, the structural
frequency.
responses will be greatest at a number of specific natural or
forced frequencies where, at each frequency, the structural )) Running modes ODS – evaluate vibration at given
deflection forms a particular mode shape (illustrated by frequencies as a function of rotational speed or frequency.
relative amplitudes and phases at each position on the
structure). In reality, all structural modes are happening at the )) Frequency/spectral ODS – used to examine vibration
same time, however, by animating each different frequency patterns at specified frequencies in stationary conditions.
Figure 1. Visco-elastic damper installed to prevent vibration Figure 2. ODS Plot showing baseline model of relief valve
after ODS analysis. pipework.
)) ODS will identify only those modal frequencies, which are Who needs ODS analysis, and why?
being excited at that time. A powerful tool that permits the clear and detailed
visualisation of vibration, ODS can be used to pinpoint
)) ODS will also identify any other vibration mode shapes
caused by forced excitation i.e. not occurring at a problems in a range of machinery, tools and structures,
structural natural frequency. particularly those involving periodic excitation, and in a
number of industrial and engineering settings. What is more,
ODS analysis can be carried out while the plant is in operation,
so there is no downtime – this is often a particular advantage
in manufacturing environments.
The key advantages of timely ODS analysis include, but are
not limited to:
)) A powerful tool for vibration trouble-shooting.
ipeline free spans are a common threat to induced vibrations (VIV). These vibrations are caused by
51
asset. Industry codes and standards are available to guide need for remediation and the associated timeframe such
engineers in the span assessment process, but they can be that fitness-for-service is not compromised.
overly conservative. For more complex problems, such as the assessment of
free spans in pipe-in-pipe systems or bundles, the company
Span assessment adopts a finite element approach in accordance with DNV-
Jee’s engineering team has applied their expertise of RP-F105, ensuring that the differences in structural response,
pipeline free spans to problems from all over the world. damping and fatigue properties from a single rigid pipeline
The team uses their in-depth understanding of the are accounted for.
industry codes and standards and their wealth of integrity
management experience to remove undue conservatism in Span monitoring
free span assessments. The balance between compliance with the recommended
Coupled with regular pipeline inspection to monitor practices for free span assessment and the observed, ‘real
span development, the company is often able to help life’ span behaviour is a consideration that Jee not only has
its clients avoid the need for costly remediation whilst experience of, but encourages the industry to adopt.
ensuring the continued safe operation of their assets. It has developed a free span monitoring system enabling
Free span remediation generally takes the form of rock simultaneous real time recording of pipeline movement
placement and, considering remediation can in itself lead along a free span, along with the associated water particle
to additional issues such as the formation of long free velocities at the span location. The data is used to identify
spans either side of the rock berm, its avoidance can greatly if pipeline vibration is occurring at the flow velocities
simplify future integrity management and remediation predicted to cause excitation by the assessments performed.
requirements. If vibration does not occur when anticipated, the data
In order to assess free span acceptability, Jee typically collected can be used to identify the areas of conservatism
adopts the approach specified in DNV-RP-F105, using a in the analysis, which can then be updated accordingly.
combination of code compliant calculations and finite The system comprises a number of accelerometers, a
element (FE) analyses as appropriate. The company’s remote power source, a data logger and current meters to
experience of delivering these free span assessments has measure the local water particle velocity. This equipment
enabled them to build up a suite of validated calculation is housed in a streamlined module, which is strapped to
templates and base models, which are reviewed and updated the spanning pipeline. The weight and positioning of the
as the standards are revised. This allows the team to turn system (at least two modules are used for each assessment)
around free span assessments quickly, giving clients the is designed so that it minimises interference with the
required information to make informed decisions on the pipeline response whilst enabling the acceleration of the
free span and therefore mode
of response to be identified
through comparison of the results.
Pipeline response data is logged
for an agreed period of time, after
which the data is retrieved and
downloaded for processing.
This monitoring system has
been deployed in numerous
locations worldwide and has helped
arrive at a number of interesting
conclusions. For example, the
company has found that free spans
Figure 1. Loads experienced by a freespanning pipeline.
of a significant length (over 100 m)
that industry codes had predicted
to fail imminently, were not actually
experiencing VIV. These findings had
a significant impact on the strategy
the client adopted for managing
free spans in the region.
Case study
The problem
Jee secured a contract with a major
Figure 2. FEA mode of spanning pipeline. oil and gas operator to perform a
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Phone +39 0521 671288 • Fax +39 0521 673295
Email: info@scaip-srl.it • www.scaip-srl.it
pipeline free span monitoring study in the Gulf of Thailand. the data needed to assess the acceptability of any future
The deployment period lasted six months, and involved free spans identified. Future free span lengths can be
monitoring a number of potentially high-risk pipeline free compared to the calculated maximum allowable length
spans, which were longer than the code, defined allowable for each section of pipeline. Without this in situ data,
limits. the free span would have been marked for remediation.
Equipped with this knowledge, the operator was able to
The solution focus on the free spans that presented a risk and avoid
The free span monitoring kit was deployed on a selection unnecessary and costly remedial works on the other
of spans across a range of pipeline diameters. The data pipeline sections.
recovered showed that the pipeline free spans were
not experiencing VIV, despite the local environmental Span assessments in lifetime extension
conditions being in the range predicted by the analysis As well as forming a fundamental part of pipeline design
to excite the span. Using the data collected and further and integrity management, free span assessments are also
analysis taking account of the identified conservatisms, the a staple feature of pipeline lifetime extension studies. Free
span anomaly limits were modified accordingly. spans are normally identified as a threat to a pipeline’s
extended life during the risk assessment stage. Fatigue
The benefits damage has often accumulated throughout the pipeline’s
The project confirmed that the pipeline free spans were 20 - 25 year life, and the pipeline strength may have been
not a threat in their current state and gave the operator compromised during the period of operation to date –
the wall thickness of the pipeline may have been
reduced due to corrosion for example.
Jee draws upon its expertise in pipeline design
and integrity management to compliment the free
span assessments performed as part of the lifetime
extension process. The company understands how
the design codes have changed over the decades
of pipeline operation, and know where extra
conservatism has been added or removed. They also
have an appreciation of the code’s limitations, so
its engineers are able to effectively challenge them
without adversely affecting safety, maximising the
allowable extension to pipeline operating life. As
part of this process, free span anomaly limits may
be updated based on the results of the analysis
performed.
A global industry
requires a global
publication
CRC-Evans.com
O
il and gas companies are now augmenting their marine
pipeline protection programmes with automatic
identification system (AIS) based vessel position data
and analytical tools that enable them to proactively
monitor and respond to vessels that appear to be threatening their
remote assets, pre-empting problems before they occur. There is
growing enforcement and expansion of AIS carriage requirements,
allowing for greater monitoring of potential pipeline threats as well
as an unprecedented ability to run analytical reports of vessel traffic
to better understand the threat of vessel impacts and how to better
target outreach and pipeline integrity funding.
Proven benefits
The benefits of using of AIS-based vessel tracking and asset
monitoring tools to prevent pipeline strikes have been
demonstrated by the Coastal and Marine Operators (CAMO) group,
which launched a pipeline monitoring and protection programme
Providing problematic
PIPELINE
PROTECTION
Jason Tieman, Oceaneering Maritime
Operations, PortVision, USA, highlights how
using AIS-based vessel tracking data can
protect pipelines and remote assets.
56
during August 2015 in partnership with the Greater LaFourche Port
Commission and Oceaneering.
Port entrances and other waterways are often in close proximity to
dense networks of marine natural gas and liquid pipelines. These fixed
underwater assets can be damaged by vessel anchors, spud barges and
direct vessel impacts, especially in shallow water where the pipelines
are most densely distributed. To keep this from happening, CAMO is
using Oceaneering’s® PortVision® AIS-based vessel monitoring service
to monitor and alert vessels that might be slowing or anchoring in two
charted pipeline corridors north and south of Port Fourchon that pass
under its main navigable channel.
The process is simple: when the PortVision service shows that a
vessel is operating at a speed less than 0.5 knots for three minutes or
more within one of these corridors, an addressed, one-time AIS safety
related message (also known as ‘message 12’) is immediately transmitted
directly to the vessel’s wheelhouse that says, ‘PIPELINE BELOW’.
Depending on the equipment installed on the receiving vessel and its
57
equipment configuration, there may be visual and/or audible Kinetica’s programme focuses on assets in approximately 50
variations in how the AIS safety alert is received. locations where water is less than 15 ft deep and there is a greater
“Pipeline protection is increasingly important, with the typical risk of exposed pipeline or navigation hazards. Roughly 90% of
incident costing an average of at least US$1 million to repair, these locations are in remote areas that are typically inspected
not counting the incalculable costs of injury or death,” said Ed via helicopter. These fly-overs cost an average US$3000 each,
Landgraf with Shell, and Director of CAMO. “This AIS-based safety yet provide only a snapshot in time – not adequate for assessing
broadcasting system makes it easier for mariners to know where long-term vessel traffic patterns and associated risk. Budget was
and when to take protective measures as they transit or operate wasted on fly-overs where there were low traffic volumes, and
near submerged pipelines, and we look forward to a successful Kinetica was also concerned it was not focusing enough attention
roll-out here and in other ports nationwide.” on higher risk locations.
With access to AIS vessel-tracking data, Kinetica now has both
Other ways to protect assets with AIS data real time and historical information to inform resource-allocation
AIS-based vessel tracking tools are also being used by numerous decisions. The integration of AIS and other data has revealed
oil companies, as a means of improving their pipeline and asset that, in some cases, certain threat risk levels are acceptable, giving
protection programmes. One example is Kinetica Partners LLC, Kinetica the confidence to reduce inspection frequency and vessel
which operates approximately 1600 miles of pipe serving products notification parameters and re-direct resources.
in and near the Gulf of Mexico. The company is using these tools Kinetica also takes advantage of historical AIS data to analyse
to optimise planning and implementation decisions. It also has and optimise notification parameters for the most effective
incorporated AIS data into its risk-based inspection activities. pipeline threat monitoring and management. There is the future
opportunity to also receive alerts when pipeline segments hit
traffic thresholds, triggering a look at inspection and notification
policy changes. Another use for historical data is to provide insight
into specific vessels and fleets that appear to regularly operate
near assets – this too can influence awareness and prevention
efforts.
Analytics based on historical data can also be used to
influence decisions about permitting and whether to seek
an emergency coastal zone permit for a location with high
vessel traffic. The data can also be used to analyse notification
procedures, and determine whether the standard USCG ‘notice
to mariners’ is adequate or if there should be a different mode
of stakeholder communication. AIS analytics can also influence
regulatory compliance, training, and where to install new pipelines
based on historical vessel traffic patterns.
Additionally, historical AIS data is often one of the first
sources of information to corroborate that an incident has
occurred in the absence of eyewitnesses. An example is when an
operator’s pipeline flow monitoring system reports a pressure
Figure 1. A wheelhouse receiving the AIS safety alert message drop in a remote area – this could be a major rupture. AIS data
that they are in a pipeline area.
can be used to confirm the event, identify
the responsible vessel, help understand traffic
patterns, and both plan and launch optimal
response activities.
PIMS S
Tara Podnar McMahan and Jorge
Suarez PhD, DNV GL, North America,
ubsea pipelines are critical for deepwater
field developments. Loss of containment
typically results in significant consequences
to those experiencing the release, as
well as other stakeholders who are impacted
by safety, environmental, property, and business
consequences.
A well-planned and dynamic integrity
management (IM) system is considered the most
valuable tool available to operators. This ensures
discuss aspects of subsea pipeline that subsea pipelines are able to perform as
integrity and the role of an overall designed. An effective IM system normally includes
integrity management plan. the following steps:
)) Risk assessment and IM planning; including
threat identification and assessments with both
short and long-term perspectives.
63
)) Detailed planning and performance of integrity assessments The results of a risk assessment will drive decision-making
based on inspection and monitoring results and other and long-term IM programmes. The programme justifies
relevant historical information. which activities are performed, including why, how and when.
Minimum required integrity control activities are specified for the
)) Detailed planning and performance of necessary mitigation,
different pipeline sections; this includes strategies for integrity
intervention, and repair activities.
improvement activities. Simply put, the objective of an IM
DNV GL’s recommended practice DNV GL’s recommended programme is to provide:
practice can be referenced (DNV-RP-F116), and provides )) A long-term plan (through inspection, monitoring, testing, and
recommendations for managing the integrity of submarine integrity assessment activities) that verifies the behaviour of
pipeline systems throughout their lifecycle. As the basis for the pipeline is in accordance with expected development
this article, the DNV GL’s recommended practice should be when compared to the predications established during
referenced. Reviewing these recommended practices will provide the design phase and/or previous assessments during the
the additional detail needed for each of the IM system steps. operational phase.
its consequence) an operator must first assessment These are executed to collect operational M
manual
understand the potential threats to a subsea data and condition indicators of a component. Y
pipeline and identify those that may impact Dent DNV-OS-F101 Operational data can be physical data such as
CM
their pipeline system. Data and information DNV-RP-F113 temperature, pressure, flow, injection volume of
should be gathered and reviewed in order to DNV-RP-C203 chemicals, or the number of operating cycles. MY
identify threats. A number of common threats European For submarine pipelines, the inspection CY
are considered for subsea pipelines; each of Pipeline and monitoring programme normally covers CMY
them is categorised into the following six Research Group maintenance activities. Maintenance activities
(EPRG) K
groups: can include cleaning (scraper pigs or chemical
)) Design, fabrication, and installation. Crack DNV-OS-F101 treatment) or removal of external debris from
DNV-RP-F113 anodes prior to cathodic protection (CP)
)) Corrosion or erosion. BS-7910 measurements, as necessary. Generally, an
Pipeline defect inspection monitors the physical state of a
)) Third party.
assessment component (for example wall thickness, damage
)) Structural. manual to the pipeline, coating defect, and pipeline
Gouge Pipeline defect displacement), while monitoring is the collection
)) Natural hazards. assessment of relevant process parameters, which can
manual
deliver indirect information about the condition
)) Incorrect operation. Free span DNV-RP-F105 of a component.
Different approaches are used to DNV-RP-C203 In the context of IM of subsea pipeline
assess pipeline risk. This can be evaluated Local buckle DNV-OS-F101 systems, testing typically includes system
qualitatively and/or quantitatively (as is most DNV-RP-F113 pressure testing, testing of safety equipment,
feasible). It is anticipated that additional Global buckle DNV-RP-F110
pressure control equipment, over-pressure
inspections and other kinds of data collection protection equipment, emergency shutdown
Germanischer
(e.g. data gathered from monitoring) will Lloyd Rules systems, automatic shutdown valves, and safety
drive the subsea pipeline community towards Exposure DNV-RP-F107
equipment in connecting piping systems. System
quantitative risk approaches and away from pressure testing is not normally applied as a
Displacement DNV-OS-F101
qualitative and relative risk approaches. Still, regular integrity control activity, however, in
DNV-RP-F109
it is important to note that no matter which some cases this may be considered.
approach is used, a documented procedure DNV-RP-F110 Inspection, monitoring, and testing of
must be followed and any deviations from the Coating damage DNV-RP-F1-2 pipeline systems can be carried out with
procedure must be documented and justified. Anode damage DNV-RP-F103 different tools, or combinations of tools, having
Integrity assessment
IM programmes determine the need for planned
integrity assessments. That said, potentially
Figure 1. IM system. unacceptable damage or an abnormality may be
observed or detected, and an integrity assessment is
required to evaluate the damage, or abnormality,
and the possible impact on integrity.
Integrity assessments, planned or unplanned, are most
commonly categorised as follows:
)) Corrosion assessments covering internal and external
corrosion.
I
are
nomy, pipeline operations
n today’s energy-driven eco duc ts to bo th con sumers
eum pro
critical to delivering petrol
ustry. For oil and gas firms, pipeline meters are
and ind ship
there is a transfer of owner
situated at any point where iste r’ of the ir
y represent the ‘cash reg
of a product. As such, the ure acc ura cy of the
rds are in place to ens
business. Rigorous standa ent s of liqu id and gas ,
nsfer measurem
meters used for custody tra wever, ma ny
h industry regulations. Ho
as well as compliance wit ses and spread sheets to
nual proces
companies still rely on ma
l functions.
manage and track these vita
es an advanced meter and
The following article describ ng and
ution for scheduling, tracki
measurement reporting sol
69
reporting on meter proving, prover certification, transmitter petroleum liquids in the supply chain, and is obtained by dividing
verification, and test equipment certification in accordance with the actual volume of liquid passed through the meter during
American Petroleum Institute (API) guidelines. proving by the volume registered by the proving device.
Meter proving is only part of the compliance puzzle. Prover
Importance of accurate measurements certification, transmitter verification and calibration, and test
When it comes to moving oil and gas though pipelines, the equipment certification are also required. Through the verification
accuracy of flow measurement devices is a top priority – and auditing of metering systems at every stage of their use, it is
particularly in the custody transfer (sometimes called ‘fiscal possible to guard against potential meter, instrument or system
metering’) process. Ensuring and maintaining precise measurements problems, while guaranteeing trustworthy data reporting and
is essential for efficient and profitable operations, as well as fair full traceability. This trust or lack thereof impacts the image
transactions. and reputation of the operating company and can influence the
Custody transfer applications involving oil and gas are financial bottom line.
influenced by:
)) Industry regulations. Need to manage proving data
Petroleum producers manipulate vast quantities of meter proving,
)) National metrology standards. transmitter and test equipment calibration, certification and
test data, and many companies rely on manual systems without
)) Contractual agreements between custody transfer parties.
automation to support these critical regulatory and business
)) Government regulation and taxation. functions. In many cases, due to a company’s growth through
acquisition there are a variety of work processes and systems
Pipeline metering systems must provide a single, accurate involved. Typical challenges include:
number representing a fiscal measurement. It is important that )) Variety of data input mechanisms – meter factors and proving
this single version of the ‘truth’ is accurately captured, recorded, records can be obtained electronically from a supervisory
and made visible throughout the organisation and among all control and data acquisition (SCADA) system or third party via
the vendors. Due to the high level of precision required in these PDF document or a scanned, hand-written document.
applications, metering technologies are subject to approval by
industry organisations, such as the API. )) Variety of record formats – due to the variety of data sources,
For custody transfer of oil and liquid products, physical no standard record format or system of record is used.
Therefore, information is not readily accessible and useful
proof testing to assure meter accuracy is essential. Measurement
across the organisation.
performance is monitored through the regular inline proving
of meters under actual field conditions, and meters must be )) Information stored in different locations – information is also
adjusted to accommodate changing process parameters, such as stored on individual employees PCs, on webservers and on file
temperature, flowrate, pressure, density and viscosity. A variety of servers, making it difficult to find and access the required data.
proving systems can be used for this task, including ball provers,
small volume provers, bi-directional provers, master meters, tank/ )) Formal scheduling and tracking process – most companies rely
weigh systems, and portable/stationary proving systems. on manual scheduling and tracking and do not have a formal
According to the API Manual of Petroleum Measurement system to track when tests and calibrations were performed.
Standards (MPMS), the purpose of meter proving is to determine Proving test schedules are also dynamic based on the change
of products and percent change in meter factors, which also
the meter factor. The meter factor is an essential element in
complicates the scheduling process.
calculating the net standard volume of a receipt or delivery of
)) Detecting system anomalies and potential failures – without
a central repository, and historical records there is no
mechanism to monitor performance data. Without these, it is
impossible to detect degrading meters, transmitters and other
potential equipment problems.
Vietz GmbH
Vietz GmbH
Fraenkische Straße 30–32 +49 (0)511 949 97-0 info@vietz.de
Fraenkische Straße 30–32 +49 (0)511 949 97-0 info@vietz.de
30455 Hannover (Germany) +49 (0)511 49 51 42 www.vietz.de
30455 Hannover (Germany) +49 (0)511 49 51 42 www.vietz.de
notifications, and enterprise access. With
this solution, utilising an interactive, real
time dashboard, they have the ability to:
)) Implement a single point for enterprise
visibility and near real time monitoring
of data from meters.
Figure 3. Petroleum producers are required to manipulate vast quantities of meter )) Summarise and report on proving,
proving information. certification and verification in the
current month.
Self-Energisation
Valve Maintenance
Leak-Tight Seals
Zero-Energy Zone
Double Block &
Bleed Isolation
www.statsgroup.com
With enhanced calculation and reporting capabilities, it is The specific benefits to end-users include:
possible to perform necessary calculations, view the proving )) Effective information management made possible by a single
schedule, and trend and display meter factors. These solutions source of the truth, combined with improved data quality,
also automate the proving reporting process, with information integrity, availability and security.
automatically pulled into appropriate databases so there is no
lag time from when proving is done and field operators pass off )) Enhanced operational efficiencies through increased uptime
reports for use by specialists. and reliability; improved proving schedule visibility; faster
Improved technology for alerts and notifications makes detection of equipment problems; and increased visibility of
the frequency of commodity change, volume and flowrate.
problems immediately visible so appropriate actions can be taken.
Personnel gain insights into both successful and failed proving )) Prevention of unplanned shutdowns resulting from meter
runs, and can accurately predict asset maintenance requirements proving issues and failures.
to prevent pipeline shutdowns. Alerts notify users when a proving
is complete and there is a shift in meter factor. )) Greater employee productivity (up to 10% reduction in meter
Lastly, proving compliance and tracking information can proving activities) due to an infrastructure that supports
now be provided in an integrated system with enterprise access improved work processes, reduces the time required for
available to a variety of users – from management, to the meter proving activities, expands data access, automates trend
measurement team, field technicians, and engineering department. analysis, and minimises reporting effort.
This enables diverse stakeholders to access critical data to )) Improved safety and regulatory compliance enabled by real
improve their performance. Security and permission is based on time visibility of meter/pipeline reliability, as well as pipe
the user’s role so they only view information relevant to their job volumes and materials for incident management.
function.
)) Effective tracking of audit records to demonstrate compliance.
Benefits to end users
)) Reduction in the time needed to meet audit requirements.
Thanks to ongoing innovations in meter data management
technology, pipeline operators are able to effectively manage the )) Reduction in fines, which could represent thousands of dollars
maintenance and calibration of pipe provers and meter proving per incident.
across commodities by performing robust trend analysis and
analytics on proving data. )) Avoidance of lawsuits potentially costing millions.
75
This article will first examine the role of pump monitoring )) Pump seal system reservoir level (LT-101) – indicates buffer
sensors and systems in liquid hydrocarbon pipelines, and then fluid level, recommended by API-682 instead of level switch.
will touch upon measurement technologies, which work hand in
)) Pump seal system vapour vent pressure (PT-104) – indicates
hand with control systems to manage liquid hydrocarbon flows in
high pressure, normally a result of process liquids leaking into
pipelines.
the buffer system and flashing to the vapour phase in the
seal reservoir. Recommended by API-682 instead of pressure
Pump monitoring measurements switch.
Pumps in pipeline systems are monitored with a wide variety of
sensor types, some of which are depicted in Figure 2 as wireless As noted above, pump seal systems often require level and
sensors. Main monitoring points include: pressure measurements. API Standard 682 Fourth Edition describes
)) Pressure at pump intake, PT-101 – ensures the pump has changes in instrumentation used to monitor pump seal systems.
appropriate pressure. If there is not enough intake pressure, This new edition now indicates a preference for continuous
the pump can run dry, a particular hazard for centrifugal measurements using level and pressure transmitters versus the
pumps. prior practice of using simple on-off switches.
In some applications, a pump may have a filter or a strainer.
)) Level at pump intake – detects when the liquid level drops, Installing a differential pressure sensor across the filter/
can be used to protect against dry running. strainer will indicate when maintenance is required. Instead of
)) Pressure at pump discharge, PT-102 – used to infer the pump’s just manually checking pressure periodically, this signal can be
level of output, and to ensure the pump is operating. monitored to show when the filter/strainer should be flushed
or cleaned out, which will reduce excess strain on the pump by
)) Flow at pump discharge – indicates proper pump operation, removing the flow restriction.
and can be used to close the loop for pump control, as On larger pumps, there may be a lube system. If this is a
explained more fully later in this article. pressurised lube system, a transmitter can be installed to ensure
proper lube pressure is maintained. This is important so that
)) Differential pressure between pump intake and discharge,
process fluids in the pipeline do not contaminate the lube system.
PT-103 – detects cavitation.
Lube level is another important measurement, and can be made
)) Pump motor temperature – indicates when a pump motor is with a level switch or transmitter.
running hot.
Wireless sensors save
)) Pump bearing temperature – indicates when a bearing is Wireless sensors are increasingly used in pump monitoring systems
exceeding safe temperature. because they are easier to install, simpler to maintain, and much
)) Pump vibration, VT-101 – this measurement is a good less costly to connect to control systems.
indication of pump health, particularly when tracked over With traditional wired instruments, it’s necessary to run either
time and compared to a baseline. Increases in vibration signal wiring for a loop-powered 2-wire instrument, or power and
indicate conditions such as bearing wear or pump imbalance, signal wiring for a 4-wire instrument. This new wiring is very costly
which can lead to failures. to install, and many existing wiring drawings need to be updated.
The signal wiring needs to be connected back to the control
system, which can be very expensive, particularly if no spare I/O
points are available.
By utilising wireless technologies, measurement points
can be quickly deployed. No signal wiring is needed because
measurement information is transmitted via a wireless mesh
network, and no power wiring is needed because each wireless
sensor includes its own power module.
Wireless sensors have advantages, but wired sensors are often
used instead, particularly in real time control applications, and in
pump installations with easy access to wiring infrastructure such
as cable trays and wiring cabinets.
which to choose
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Making P igs Squeal
Since 1984
Our transmitters emit the strongest affected by flow profile, so no flow conditioning or straight
runs are required. They have advanced diagnostic capabilities
signal in the industry, so it is easier to to verify meter accuracy in situ without interrupting normal
locate your pig or determine the time operations.
For these and other reasons, coriolis meters are
of its passing. commonly chosen as custody transfer meters, and they
are also often used in leak detection systems to avoid the
risk of false alarms. Coriolis meters also measure density, a
With a full range of transmitter diameter sizes and parameter often used for pipeline batch interface detection
mounting options for any type pig that accompany to optimise the control of divert valves and minimise the loss
numerous signal receiver options, Pipeline of good product to the slop tanks.
Inspection Company should be your first stop for
Flow management
successful pigging operations. The output from flow sensors is sent to control systems,
with modern smart sensors employing high-speed two-
APPLICATIONS way digital data links such as FOUNDATIONTM Fieldbus or
WirelessHART®. These links allow the control system to
• Mainline Transmission
remotely calibrate the sensors, detect problems before
• Gathering Lines they occur, and provide diagnostic information to aid in
• Subsea Lines troubleshooting.
• Municipal Gas Smart sensors are particularly critical given the remote
• Water and Wastewater location of many pump stations and correspondingly
infrequent maintenance visits. If a technician does need to
• Refining and the Process Industries visit the site, the diagnostic information provided by smart
sensors to the control system will allow him or her to bring
the needed tools and parts to complete a repair in one trip.
The control system uses the process variable information
received from flow sensors to optimise pump operation.
For example, a flow sensor installed near the output of a
pump is typically used as the process variable input to a PID
Pipeline Inspection Company
Phone : (713) 681-5837 controller. The PID controller compares this input value to
Email : sales@picltd.com the desired setpoint, and adjusts pump speed or control valve
www.picltd.com position accordingly to maintain the flowrate at or near the
setpoint.
Flow sensors installed downstream of pumping stations
provide critical data to the control system, which is processed
internally to yield actionable information to operators and
engineers. For example, comparing flows at various points in
the pipeline can show if a major leak has occurred. Flow data
from downstream sensors can also be used to optimise pump
operation, as it is often found that pump speed setpoints can
be lowered while still maintaining sufficient flow – saving
energy, reducing maintenance and increasing pump life.
Conclusion
Flow management of pipelines transporting liquid
hydrocarbon products starts at the pumps, and continues
throughout the pipeline system. Accurate and reliable
measurement of various process parameters is required
throughout the pumping and pipeline system. These
measurements have traditionally been made using wired
instruments, but wireless sensors are finding favour for
monitoring key parameters, while wired solutions are still
preferred for real time control applications.
G
lobe valves, which are used for regulating flow in pipelines,
consist of a movable disk-type element and a stationary ring
seat in a generally spherical body. They are named for their
spherical body shape, with the two halves of the body separated
by an internal baffle.
Globe valves are linear motion valves and are commonly used as on/
off valves and for throttling systems for both gas and liquid systems. The
gradual change in spacing between the disk and seat ring gives the globe
valve good throttling ability, as long as the pressure and temperature limits
81
are not exceeded, and the process does not require special
materials to combat corrosion.
However, it is generally acknowledged that globe
valves contain inherent cavities that can easily promote
contamination and allow slurry material to become entrapped
in the body of the valve, disabling the valve operation. This
often prevents globe valves being specified for high purity or
slurry systems.
holdtight.com
“The business approach was actually quite intriguing. The client spoke to a
major cladding competitor, who recommended us. We received emails saying
they had a number of globe valves they were having real trouble with, and could
we help them? This was quite interesting because it confirmed that there are
companies having problems with globe valves, and that it is recognised that we
are one of few companies in the world capable of solving the problem,” Robinson
expresses.
Such is the growth at Arc Energy Resources, the company is investing in a
new workshop and equipment which, when complete in April 2016, will double
the workshop capacity. The existing machines are already fully scheduled to
the middle of 2016, which is good news for the business. So, with another 30 in.
contract anticipated, the company is confident the pattern of growth is set to
continue. The new welding equipment is now to be supplemented by state of the
art bicathode equipment which will enhance the productivity significantly
II 2G c IIA T4 X
P
ipeline cleaning and inspection
operations are an essential component
of any pipeline maintenance regime.
However, until recently, the process
has been completely opaque to any live
analysis. Instead, the detritus – weighed by
passive devices – is checked after each run
and trended. Any detailed information on
the status is set aside until (the less frequent)
intelligent inspection devices have been run.
This way the information can be compared
over much longer timescales, including the
specific location of defects or highlighted areas
of concern.
Although providing immensely detailed
output, such operations are not without their
issues – device positions are estimated on
dead reckoning principles with no external
input, and constrained to operate within a
mandated speed regime that is only possible to
assess after the event.
85
Any conventional tracking is either done by failure-prone static flow conditions). This article explores the methods of
mechanical reed switches or direct listening in the field – monitoring internal pipeline operations from an external fibre
creating an additional maintenance burden and cost – and in optic sensor, and illustrates from real world examples the
the case of working in a hazardous security environment, a benefits that can accrue.
simple inspection action may become significantly burdened
by personnel protection costs and logistics. Recent advances Principles of operation
in external pipeline sensing with fibre optics (distributed The passage of a cleaning pig or inspection device produces
acoustic sensing: DAS) have revolutionised pipeline security two distinct acoustic signals that are readily identified:
and theft prevention activities, and are poised to bring )) A low frequency rumble produced by the continuous
similar benefits to leak detection activities. They can also contact of the pig with the pipe.
bring significant cost savings to conventional maintenance
operations. )) A series of regular broadband pressure waves (transient
Such systems act as highly sensitive, highly distributed and impulses) caused by the impact of the pig seals with the
highly accurate microphonic sensors virtualised across the butt welds.
whole pipeline length, and can bring massive operational gains
to the conduct of pipeline scraping or inspection activities: This latter trace gives the passage of a pig a distinct
bringing a real time perspective on operations and absolute heartbeat, which is at the heart of DAS pig tracking
position measurement at any time. capabilities. The pressure wave extends far down the pipe in
The value of this is not limited to speed tracking of pigs or either direction as a shock wave travelling at the speed of
inspection devices, but includes a stuck pig location (to within sound in the product, typically ~1200 m/sec. in oil and
±10 m) and immediate awareness of re-movement, distributed 400 - 900 m/sec. in gas: dependent on pressure and
flow profiling, slack line monitoring, highly accurate time to temperature.
trap alerts, gas pressure profiling, slug monitoring, multiple A process analogous to a water hammer effect produces
pigs headway monitoring, and speed trace monitoring (in the shock wave, whereby the laminar flow of the product
is suddenly brought to a momentary stop by the pig skirt
interfering with the weld on the two pipeline segments. This is
sufficient to produce a significant low frequency shock wave
that can extend many kilometres in both directions in the
pipeline fluid (liquid or high pressure gas).
These signals are easily detected by a close fibre optic
cable (to a few metres distant), which is connected to a
Figure 1. Schematic of a cleaning pig passing a butt weld and DAS interrogator. The DAS system converts the standard
the generation of the pressure pulse. telecoms fibre into a series of continuous, distributed
virtual microphones – typically 10 m in length – many
thousand across the complete length of pipeline. Each
virtual microphone corresponds to a specific 10 m section of
pipeline – whose position is easily calibrated. By continually
observing the signals at a sufficiently high frequency (typically
2500 Hz) the microphone output from each microphone can
be recorded over time. By performing these calculations in
parallel over every channel in real time, the acoustic profile
of the pipeline valid for that instant in time can be derived.
By observing this over an extended period, the behaviour of
static and dynamic artefacts can be continually monitored.
Automatically detecting, classifying, and locating the trace
via online detectors easily track devices, such as pigs tracked
along the pipeline with a positional resolution close to the
channel size – down to 10 m. This means that the passage
of the pig can be observed and listened to from a central
remote location. In Figure 1, there are a number of features
characteristic of the passage of a cleaning pig:
)) Double shock wave from the front and back skirts of the
scraper.
Conclusion
Pigging is one of few activities that
are carried out on pipelines that are
of significant importance, have major
cost implications and yet are so poorly
monitored: other than during instrumented
inline inspection – where the data can only
be reviewed after the event. There is a need
to provide feedback to pigging operations –
to keep the man out of the field, to provide
dynamic control and to provide knowledge
over the status of the pipeline. Rather than
aggregating that information to a summary
of what was extracted from two remote
points or how long the transit took, there is
a need for a better solution.
Live pigging observation from DAS can
provide this mechanism by placing ears
Figure 5. Example from a North African installation where a change in flow every 10 m along the pipeline – giving the
conditions in a first charge on a gas pipeline results in an abrupt change in speed. controller immediate feedback on the status
of their operations. This has the
potential to deliver significant cost
savings and safety enhancements
by allowing staff to monitor pigging
activities safely from the control
centre and can vastly decrease the
costs of dealing with devices stuck
in pipes.
The benefits of using DAS for
pigging operations have been rapidly
realised by those customers who
have invested in DAS for pipeline
leak detection or pipeline leak
prevention operations: there is
significant benefit in either using
DAS as a service during pigging or
inline inspection operations – or as
part of a permanent fit. All that is
Figure 6. An example of a cleaning pig in a gas pipeline experience momentary stops in required is a fibre optic cable in the
transit due to a combination of pressure and fit.
vicinity of the pipeline.
D
ue to the recent collapse of the price of oil, many pipeline could have to be depressurised to allow the lodged
operators are looking to sell off their assets and pig to be cut out.
reduce their head count in the ever-changing world So if you have just purchased an ageing asset, and your
of oil and gas. The recent slump has seen job cuts experienced staff members have all been dispatched to the
take hold, with mature staff too often bearing the brunt. Yet, trench awaiting final backfill, what are your options when
it’s these operational employees who have all the experience: the regulator is breathing down your neck questioning the
they know the company’s procedures like the lines on their integrity of your pipeline? You know you need to inspect, but
experienced faces. where do you start?
Now although the dilution of jobs and disposal of assets As with any engineering project, a pipeline inspection
continues, the integrity of your pipeline still needs to be project needs careful planning. Starting with the basics, a
maintained. Your pipeline inspection still needs to happen as piggability assessment should be carried out, as this will give
a matter of regulatory cause and the regulator will not accept you confidence that the pipeline can be pigged and it will
the fact that you’ve delayed your integrity programme due to help identify the technical challenges to be faced. It will also
the low price of oil. consider the often overlooked logistical side of the inspection
The US Department of Transport, Pipeline and Hazardous operations. A structured approach is therefore required to
Material Safety Administration (PHMSA) spent 44% of ensure you get it right first time.
its working time in 2014 inspecting pipeline facilities for
compliance with PHMSA operation, maintenance and Document review
emergency response safety regulations. So rest assured the Regardless of the age of your pipeline, the expectation is that
knock on the door will come! you will possess some documentation, although it is not the
Pipeline pigging is one of the most hazardous operations end of the world if you do not.
to take place during the operation of your pipeline, therefore A typical document review will investigate the
it needs to be taken seriously. A stuck pig could reduce supply construction records, wall thickness transitions, valve
or completely block it and, in the worst case scenario, the specifications, pipe bend radii, pre- and post commissioning
91
)) Kicker lines – used to launch the pig, are they sufficient in
diameter?
)) Does the pig trap have any internal fittings – slip trays to
aid pig loading, receive baskets for foam pigs, retractable
Figure 1. Hazardous products. pins for sphere loading etc.?
)) Height and angle of the pig trap – offshore the pig traps
are often vertical to save space.
Shelter
What are the typical weather conditions for the region, wet,
cold, hot and humid? I have had the opportunity to work in
the extremes from 50˚C in the Saudi Arabian desert to -40˚C
in the Vasyugan swamp, the largest swamp in the northern
hemisphere and I have experienced issues with the sensitive
inspection tool electronics in both extremes.
How will you protect these tools to ensure they function
correctly when they arrive on site and are prepared for use? You
may have conducted your site survey in the summer and the
inspection may not happen until the winter, or indeed vice versa.
Have you taken the seasonal variations into consideration?
HSE
ADVISING ON
integration
W
ith greater strain on the energy
sector and its transportation
systems due to growing cleaner
energy demands, pipelines – which
remain the safest way to transport both oil and
natural gas – continue to be built.
Health, safety and environmental (HSE) risks
are inherent to pipeline development, with the
construction phase posing the most significant
challenge to projects worldwide.
Risks during construction are influenced by
the use of materials and equipment that are
often unique to this sector and are extremely
large in size and weight. They involve significant
numbers of contractors performing simultaneous
high-risk activities within tight timeframes
and often in extreme climates, rough seas and
challenging terrains – all of which increase
the risks of accidents and serious impact on
individuals, businesses and the environment in
which they operate.
The project planning process should reduce
these risks at the outset, with pipeline routing
and site selection being an important factor. But while subcontractors’ performance is often overlooked as
every business aims for minimal environmental impacts construction companies are expected to take the lead
and zero-accident projects, in reality very few large in this field. However, with environmental incidents and
international projects are completed with this success health and safety accidents resulting from contractors’
rate. This is the area where greatest improvements can activity remaining the most frequent category in this
be made and there is always scope to further reduce risks sector, HSE needs a high priority throughout the supply
and mitigate potential damage. This article outlines the chain and effective leadership is required at every level.
most important areas to focus on. Pre-contract audits are time-consuming, costly and
can result in having to go back to the market if the first
Senior management commitment to HSE carefully selected contractor does not pass the HSE audit.
One of the most common causes of substandard But making prior HSE performance a critical selection
HSE performance is not affording health, safety and criterion at contractor selection phase is a management-
environment the same level of importance as schedule level responsibility, and it is the job of the HSE lead to
or cost. Management teams may question the time and get this message across.
funding put into HSE planning, training, certification, Project procurement and HSE teams should work
inspections and audits but this investment is vital to a together on developing and incorporating HSE-related
high standard of HSE performance. No reported incidents clauses into the contract, making sure suppliers and
means that this investment is working and needs to contractors know that they are bound by these terms.
continue – using it as a reason to reduce costs or HSE Monitoring contractor performance by establishing
activity will quickly undo any progress in this area and measurable indicators and collecting statistics, conducting
expose your business and employees to greater risk. frequent monitoring and inspections and analysing the
information received is critical to getting all contractors
Competency to work to the standard of the industry’s best operators
Personnel involved in pipeline construction projects and ensuring individual projects are not compromised.
have all been selected for their skills and are all
qualified. But, when every pipeline is unique, personnel Management systems
will not necessarily have been trained to identify and The importance of a systematic approach on fast-paced
address the project-specific risks they are likely to face. large-scale projects should not be underestimated.
Environmental and social specialists cannot be fully Investing resources into a robust HSE management system
familiar with every pipeline project location; engineers before construction commences is a highly effective way
are not necessarily good at risk identification and near to identify, assess and manage risks, thereby avoiding
miss reporting; mechanics do not necessarily know how or minimising adverse HSE impacts. Ideally, the system
to work safely at heights; and electrical personnel may should meet the requirements of recognised international
not know how to enter a confined space safely solely standards, such as ISO 14001 (environmental) OHSAS 18001
because they have 20 years of experience. (occupational health and safety) and IFC Performance
If your project is offshore, are all team members Standard 1 (environmental and social management) and be
involved familiar enough with maritime industry-specific tailored to manage project-specific risks.
health and safety hazards? Do they know enough Then, the way that HSE information is fed into
about risks and the environmental commitments of the the wider decision making process by the HSE team is
project, and can they ensure those commitments are crucial. Setting and regularly reviewing key performance
implemented? indicators at both company and contractor level is
Project developers should work on the basis that one way to help ensure that everyone retains focus on
training is required in all project phases, particularly in this area throughout the project. More broadly, non-
respect of construction. Projects vary greatly and people’s confidential, transparent HSE reporting is a useful way to
work experiences are unique (and hard to objectively analyse and learn from mistakes before they escalate and
verify). Set a bar, allocate a budget, and train. Then seriously damage the project’s HSE standing.
refresh.
Risk assessment
Contractor risks Risk management processes on large-scale construction
Finding a contractor that can undertake the project projects often boil down to just making sure the risk
to specification on both a tight schedule and a tight assessments are done, while they should, in fact, be much
budget, is already a major challenge, and compatibility more comprehensive.
of the operator’s and contractor’s attitudes to HSE can The management framework should address effective
sometimes be overlooked in the selection process. communication of risks up and down the management
While major world operators and construction chain. It should involve means of identifying inappropriate
companies in this heavily regulated industry are held and unsafe behaviours early, before they become
up to its highest HSE standards, their contractors’ and environmental incidents or result in accidents and injuries.
th
Anniversary
Unique Networking HSE Promotion & 1966 - 2016 Construction Industry-specific
Opportunities Awards Innovation & Awards Workshops
www.opus-srl.it
This will start happening as soon as the company’s near- accidental and emergency situations associated with
miss process – another essential – starts to work and the the project in a manner appropriate to prevent and
analytical data starts coming in. mitigate any harm to people and/or the environment.
After that, the formal risk assessment process is
)) Simple and concise assessments, narrowed down to
required. A common error can be to focus on large,
the most likely potential scenarios.
catastrophic, often environmental, process-related or
political risks, while ignoring those resulting from social )) Clear criteria for emergency team member
impacts. This can affect both local communities and the qualification and training.
project workforce. It can also be a result from regular
construction activity, such as daily transportation to )) Clear criteria for rapid and accurate assessment of an
site or hygiene levels in construction camps that could emergency, identification of escalation potential and
potentially generate major losses. involvement of third parties.
Establishing a risk tolerance might be required, as )) Specific instructions for every member of the
some risks might be too insignificant to be brought to emergency response team for the main identified
the attention of the top management. But no risk is too scenarios. A defined chain of notification and
small to be ignored during the assessment itself. command.
When implemented with the right level of detail and
commitment, these processes – if nothing else – help )) Clear means of assistance to casualties, notification
focus people’s attention on the risks associated with of next-of-kin notification and ensuring project
the project. They are also more likely to plan better and continuity.
concentrate on the HSE aspects of their work, lowering )) The emergency preparedness and response activities
the level of uncertainty that they themselves experience. will need to be periodically reviewed and revised, as
Another common flaw can be to think that risks are necessary, to reflect changing conditions.
something that should be dealt with by the HSE/risk
people exclusively. Risk ownership should be spread across Once the emergency response plan is written, there
the project developer and contractor teams, to ensure are two further steps required to successfully put it
everyone is equally involved. Identify a team of experts and into effect: training and drills. These elements are often
ask them to come up with a shortlist of the most significant overlooked but are the key to effective implementation.
risks in various disciplines. Establish risk likelihood and the Not all people are naturally prepared when facing
severity of the potential impact. Add to the company’s a crisis, particularly a major environmental incident
tolerability threshold by establishing which risks it cannot or an industrial accident with potentially multiple
afford to take. Identify controls and watch the/a incident, casualties. A manager needs to be able to rely on their
near miss, equipment failure and damage statistics in the emergency response team to successfully lead a project
coming months – do these controls prove effective? out of a range of situations – and they need to be well
Prepare for things to go wrong, and plan accordingly. prepared.
Consider getting specialists to conduct this training.
Robust emergency response plans Companies that focus on this type of training can
Emergency response planning in the fluid environment identify gaps in a company’s system and may bring
of a pipeline construction project is every HSE first-hand experience that the team can draw on. Once
manager’s greatest challenge. Emergency preparedness everyone is trained, regular drills will complete the all-
and response is a fundamental requirement of the round defence of the project and ensure that the many
international environmental and social standards for HSE risks faced have been considered, prepared for and
international pipeline projects. In addition, multiple minimised.
contractors, inaccessibility of high standard medical
assistance, remote locations, and the distances travelled In summary
by staff on a daily basis, combined with the weight A typical international pipeline construction project has
of responsibility over a human life, make emergency a complex set of HSE risks, some of which are unique to
response planning in respect of health and safety one of the project. Avoidance of adverse HSE impacts must be
the most important and demanding tasks a manager will recognised as a fundamental project goal which should
have to complete over the project’s lifespan. be achieved via a systematic methodology for the
The most important elements of successful identification, assessment, management and monitoring
emergency response planning are: of risks. A truly integrated approach to HSE management
)) Establishing and maintaining an emergency in which developers and contractors co-operate is the
preparedness and response system to respond to most effective way to meet this objective.
to the challenge
‘O
ne of the most challenging projects in Europe’ is
how the Megalopolis project for the expansion
of the Greek natural gas transmission system was
described; complicated due to mountain terrain,
steep slopes and rocky conditions. It is also the largest and most
expensive high-pressure gas pipeline ever built in the country.
This project, owned by DESFA – the gas transmission system
operator in Greece – entailed a 143 km section using 24 in. pipe
and a 15.5 km stretch using 30 in. pipe and was completed in 2013.
In this mountainous region of the Peloponnese, altitudes may
not be very high, but there are always ups and downs, with the
99
contractor J&P-AVAX regularly having to encounter steep slopes 360˚ upper structure swing capability, the boom can simply be
of sometimes 30 - 35˚ inclination. positioned uphill, thereby allowing the load to be kept ahead of
Working safely in this tough environment was the most the machine, ensuring better stability and operational safety in
important consideration for this contractor and why, on this these demanding conditions. Boom pads fitted to the underside
project, the company elected to rely only on Volvo CE’s rotating of the boom will protect the pipes from damage, although it is
pipelayer technology for all pipe handling duties. The company’s not uncommon for a contractor to apply additional padding to
fleet comprised 16 units – 10 PL3005D (51 t tipping capacity), help hold the pipe more steady and prevent swinging, thereby
five PL4608 (80 t tipping capacity) and one PL4809D (90 t minimising unnecessary concern for the operator who can then
tipping capacity, and up to 102 t with the optional, additional focus on the task in hand.
counterweight). The additional counterweight is ideal when The tendency for pipe to swing downhill on a slope naturally
working with a boom extension for tie-in operations or pipe puts extra strain onto machine components. To overcome this
unloading and stacking. The smaller PL3005D features an extra problem Volvo pipelayers feature a heavy duty, hydro-mechanical
heavy, standard counterweight for added stability. slew lock. This lock can be engaged at every 10˚ interval around
John Joannou, responsible for machine procurement at J&P- the slew ring, enabling the operator to lock the upper structure
AVAX, said at the time: “I was impressed by the machines’ excellent at the most appropriate angle to combat pipe backswing while
stability. The 360˚ swing capability, cab comfort and the load at the same time resisting additional strain and wear on the
management system (LMS) is much appreciated on this hilly project.” machine’s components. The steeper the slope, the more the
boom can be positioned towards the front of the machine. When
Unrivalled safety working on tie-ins, this slew lock feature enables the pipe to be
Safety is at the forefront of Volvo’s rotating pipelayer design. held steady during the start of the welding process.
Lowering-in pipe on steep slopes, or even travel on steep Carlos Aiello, a pipelayer operator with French contractor
slopes, is not without its hazards. Gravity takes over, allowing SPAC, appreciated the slew lock for other reasons, commenting:
the pipe to swing downhill and increase weight to the rear, “It is a very delicate operation doing tie-ins and this machine
which can be potentially dangerous. With Volvo’s unique, is extremely stable and precise. I also like the machine’s upper
structure swing lock feature for pulling pipes under crossings.”
Improving further still its slope performance, the latest model
PL4809D brings a 70% improvement in tractive force enabling it
to climb a 30˚ slope with ease with a heavy load in the hook, in
addition to its ability to move with ease over rough terrain.
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the latest
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All-round safety
To assure safety for personnel on the
ground – whether pedestrian or in any
Figure 6. Rough terrain, rocks and slopes; when the going gets tough, the tough PL4608s
get going.
vehicles moving along the right-of-way
(ROW) – both rear and side-mounted
cameras are fitted.
visual and audible signals, ensuring that he/she is aware at all On the large, in-cab monitor, the operator can select to view
times of the state of the load and what can be safely lifted. The the camera images either separately or, with a split screen, both
system provides an accurate calculation and display of the ‘safe images simultaneously. This additional reassurance only serves to
working load’, which is calculated as 85% of the machine’s rated underline the importance of site safety.
tipping load (ISO8813), thereby providing an additional margin of As travel speed is not an issue in lowering-in, Volvo
safety. It also displays the actual load on the hook. pipelayers can and do work equally well alongside conventional
The LMS monitor graphically displays all information required sidebooms or most likely in soft, sandy conditions, crawler
by the operator on the state of his load and also utilises a series cranes, or sometimes both. This was the case with Italian pipeline
of lights moving from green to red, when the safe working load contractor Ghizzoni working on the Bunde-Etzel 48 in. gas
is reached. These lights are mirrored on the external boom- pipeline in northern Germany. The green lights of the LMS on the
mounted light bars, which communicate to other operators on Volvo pipelayers are clearly visibile, showing their ease with the
the line, but especially to the lowering-in foreman. load.
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Schoenbeck GmbH & Co. KG • Germany
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pipelayers feature a four bar cab riser system, which – with the cab
in the elevated position – retains a feeling of cab rigidity, ensuring
Directory
operator comfort and confidence.
In the unlikely event of tipping, roll over protection (ROPS)
is now a standard feature, with all new Volvo pipelayers being
ROPS certified. The requirement for ROPS is a factor increasingly
Advertiser Page in demand to ensure operator safety and even a legal requirement
Böhmer GmbH 46 now in some markets where machines will not be granted site
Canusa-CPS 9 access unless they are ROPS compliant.
Corrpro and Aegion Coating Services 59
Tougher climbs ahead
CRC-Evans 4, 55
Under way since autumn 2014, the 32 in. Southern Peru Gas Pipeline
Darby 7 project (Gasoducto Sur Peruano – GSP), will be the second pipeline
DeFelsko 67 to carry natural gas from the abundant Camisea fields in the jungle
Denso North America, Inc. 49 region. Given Peru’s geographical diversity, this 1000 km (620 miles)
Enduro Pipeline Services, Inc 61 pipeline will need to traverse both rainforest and, at the other
extreme, the high Andes to reach its Pacific coast destination where
ERCIYAS 77
it will provide natural gas to the future Quillabamba thermal station.
Girard Industries 89
More than 80% of this pipeline will be constructed at altitudes
Holdtight Solutions, Inc. 83 of more than 3000 m above sea level, and even up to 4400 m.
IPLOCA 97 Some challenging slope work will certainly present itself and
Laurini 87 five Volvo PL3005D pipelayers are supporting this project, so yet
Maats Pipeline Equipment 17
another opportunity for these unique machines to demonstrate
again their agility and flexibility in what will be extremely difficult
Magnatech International IBC
and challenging conditions.
Messe Düsseldorf 45 Even moving equipment on rough roads is a challenge, but the
Midwestern 2 Volvo pipelayers can be transported with ease, as there is no need
MONTI – Werkzeuge GmbH 84 to dismantle the boom. The larger PL4611 is the one exception,
NACE International 39 where, using a system of hydraulic jacks, it raises itself from the
ground, dismantles the track frames using the pipelayer boom and
NACE International – CORROSION 2016 62
a truck can then slide under the raised machine onto which it is
NDT Global 15
then lowered. The boom remains on the machine and the entire
NRI OFC, 68 disassembly process takes less than one hour.
OPUS s.r.l 97
Pigs Unlimited International, Inc. 41 More slopes to tackle
Pipeline Inspection Company Ltd 80
In Mexico, contractor SICIM is using Volvo PL4611’s on the Ramones
Phase II South pipeline, a segment of the Ramones natural gas
PipeLine Machinery International 31
pipeline system, which is one of the largest energy infrastructure
Pipetech 23 projects in Mexico’s history, extending from the Texas border to
Polyguard Products 27 central Mexico. Spanning 291 km (180 miles) the Ramones II South
Rosen IFC pipeline will have the capacity to deliver 1.4 billion ft3/d of natural
Scaip s.r.l 53 gas. Here too, with sections over 2500 m altitude, some tough
slopes and rocky underfoot conditions present their respective
Schoenbeck GmbH & Co. KG 103
challenges.
Seal for Life Industries 35
With a track length of 5.37 m (17 ft, 8 in.) and a maximum
Selmers 29 machine width of 6.58 m (21 ft, 7 in.) on 900 mm (36 in.) track shoes,
SERCO: World Leading Portable 79
the PL4611s footprint is huge and provides outstanding stability to
Machining Solutions tackle whatever conditions it faces.
STATS Group 73 Meanwhile, in Argentina, six PL3005Ds will soon be fully
T.D. Williamson 11 operational, with three more on the way. Two units were shipped
by contractor EVSDA to support a project in the ‘fire land’, in the
Tekfen Construction and Installation 65
Co., Inc most southern part of the country.
Vacuworx Global OBC Whatever challenges may ultimately await them, these
machines have already been used for unloading pipes from trucks
Vermeer 19
and have carried out a lot of different jobs on this pipeline project.
VIETZ GmbH 71
Sold with the additional digging equipment, enabling pipelayer
World Pipelines 55, 101, 103 to excavator conversion, in addition to their other capabilities,
Worldwide Machinery 79 the PL3005Ds provide the typical ‘all-rounders’ that any pipeline
construction site needs.
PIPELINER II
AUTOMATIC
PIPE WELDING
SOLUTIONS
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