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WORLD PIPELINES

Volume 16 Number 2 - February 2016


FEBRUARY 2016

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Contents
WORLD PIPELINES | VOLUME 16 | NUMBER 2 | FEBRUARY 2016

03. Editor's comment PIPELINE INTEGRITY MANAGEMENT: VIBRATION


Update on Nigeria.
47. I'm pickin' up bad vibrations
05. Pipeline news Neil Parkinson, AVT Reliability, UK.
Numerous TransCanada pipeline projects undergo debate; British Columbia
may oppose Kinder Morgan's Trans Mountain pipeline expansion; Enbridge has 51. Free span threats
boosted its security after pipeline sabotage; and multiple subsea contracts Graham Wilson, Jee Ltd, UK.
have been awarded.
SUBSEA OPERATIONS
REGIONAL REVIEW 56. Providing problematic pipeline protection
Jason Tieman, Oceaneering Maritime Operations, PortVision, USA.
12. The battle for Central Asia
Central Asia’s strategic value grows amid escalating geopolitical conflicts, 63. Components to a comprehensive subsea PIMS
explains Ng Weng Hoong. Tara Podnar McMahan and Jorge Suarez PhD, DNV GL, North America.

for Central Asia FLOW MANAGEMENT


69. Maintaining reliable meters
Bart Winters and Seshasai Yesantharao, Honeywell Process Solutions.
75. Flow management starts with pumps
Central Asia’s strategic value grows
amid escalating geopolitical conflicts,
explains Ng Weng Hoong.

The battle Wally Baker, Emerson Process Management, Rosemount, USA.


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
81. Maintaining flow around the globe
Alan Robinson, Arc Energy Resources, UK.
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

PIG LOCATION & TRACKING


85. Fibre optic is here
Dr. Chris Minto and Dr. Alastair Godfrey, OptaSense, UK.
PAGE
12 13
12 PIGGING
91. Is your pipeline piggable?
Paul Westwood, Penspen.

PLANNING AND CONSTRUCTION


COATING TECHNOLOGIES
95. Advising on HSE integration
20. Shedding light on dual powder systems Alan Fowler (Singapore) and Adelya Pavlenko (UK), Ramboll Environ.
Charles Zhou and Meghan Hodge, Axalta Coating Systems, Powder
Coatings, USA. PIPELINE EQUIPMENT
PIPELINE CORROSION 99. Up to the challenge
Derrick Butterfield, Volvo Construction Equipment, Germany.
25. Evolving CP practices
Len J. Krissa, Enbridge Pipelines Inc., Canada and Christophe Baeté,
Elsyca n.v., Belgium.
32. Not just a walk along the ROW
Ted Huck, MATCOR Inc., USA.

PIPELINE INTEGRITY MANAGEMENT


37. ILI data at the click of a button
Igor Mahkin and Andy Glover, Associated Technology Pipeline Ltd, UK.
42. Trending drones
Jack Behar, Samollet, USA.
WORLD PIPELINES

Volume 16 Number 2 - February 2016


FEBRUARY 2016

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Copyright© Palladian Publications Ltd 2016. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form
or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this
journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in
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Comment
UPDATE ON NIGERIA

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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World News
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BP spends millions to upgrade Baku-Supsa TransCanada to make headway after Keystone XL


pipeline denial
British oil company BP intends to spend US$150 million in Despite the rejection of TransCanada’s Keystone XL pipeline
order to upgrade certain parts of the Baku-Supsa oil expansion project by US President Barack Obama, the company is
pipeline, which runs from Azerbaijan to Georgia, reports now attempting to make headway in the oil refinery complex, in
from the Georgian government stated. America’s Gulf Coast.
The issue was discussed during the Georgian Prime TransCanada’s Houston Lateral pipeline and tank terminal is
Minister’s meeting with BP’s CEO Bob Dudley at the World intended to be available by 2Q16. It will connect the existing Keystone
Economic Forum in Davos, the Georgian government’s press pipeline system to the company’s Houston refineries.
service said in a statement. Paul Miller from TransCanada stated: “Today, we probably move
“BP will spend US$150 million on modernisation of some over 300 000 bpd of crude oil from Canada to the US Gulf Coast, and
stretches of the pipeline and improvement of ecological we represent about a third of that. As we see the connection of our
standards,” the Davos press service said. system going to these additional markets in the US Gulf Coast, we
Azerbaijan exports oil via the Baku-Supsa pipeline from would look to increase both our share as well as the absolute
the Chirag oilfield, which is operated by BP. volume.”
Exports through the Baku-Supsa pipeline rose to In order to strengthen the relationship between its Houston
3.9 million t in January - November 2015 from 3.8 million t in Lateral pipeline and terminal and the Gulf Coast energy markets, the
the same period a year earlier. company – along with Magellan Midstream Partners LP – has decided
In related news, BP CEO Dudley is reported to have said to construct a US$50 million pipeline, which will transport
that despite the volatility of oil prices at the world market, 200 000 bpd from TransCanada’s terminal in Houston to Magellan’s
the South Caucasus gas pipeline project is being East Houston terminal.
implemented according to schedule and will be completed Miller explained: “It’s small from a dollar perspective, but it’s
by 2018. hugely significant from a connectivity perspective, providing
connectivity to both the Houston and the Texas City refineries.
[Additionally,] Louisiana is another attractive market for TransCanada,
North Dakota approves Dakota Access considering the existing footprint we have down to the US Gulf
Coast.”
Pipeline
However, despite numerous smaller pipeline projects being
North Dakota regulators have approved a proposal to build undertaken by TransCanada, the Houston Lateral pipeline and terminal
the largest capacity pipeline to date. The 1130 mile long will not be able to replace the benefits or success the Keystone XL
pipeline will transport approximately 600 000 bbls of pipeline project could have brought.
crude oil from the Bakken oilfields through 50 counties Yet, TransCanada is not deterred from the Keystone XL’s rejection.
across four states. In early January 2016, the company announced that it had filed a
On 19 January, the North Dakota Public Service Notice of Intent to initiate a claim under Chapter 11 of the North
Commission approved permits for the pipeline, which American Free Trade Agreement (NAFTA) in response to the US
would transport crude oil through the Dakotas, Illinois, and Administration’s decision to deny a Presidential Permit for the
Iowa. Keystone XL pipeline on the basis that the denial was arbitrary and
The project is expected to cost US$3.8 billion, with the unjustified. TransCanada also filed a lawsuit in the US Federal Court in
North Dakota leg alone costing US$1.4 billion. Houston, Texas, asserting that the President’s decision to deny
Dallas-based Energy Transfer Partners claims to have construction of Keystone XL exceeded his power under the US
easement agreements on 85% of the land the pipeline Constitution.
crosses. TransCanada CEO Russ Girling said the Keystone XL pipeline was
The pipeline’s capacity is about half of North Dakota’s still possible, continuing to state: “It’s pretty clear we have been
current production. The North Dakota portion is the longest harmed in an arbitrary and discriminatory way. I don’t think there’s
leg of the pipeline. The company says regulators in South anybody that would say this isn’t an egregious abuse of authority and
Dakota and Illinois already have approved permits for the that we weren’t treated fairly or equitably to whatever standards you
project. choose – cross-border pipelines, domestic pipelines, or imports from
The Iowa Utilities Board announced it has scheduled other countries.”
four days of public meetings in February for deliberations Similarly, BMO Capital Markets Analysist Ben Pham argued that
about an Iowa permit. the company could have a “credible case.” However, he continued to
The pipeline is to be built by Dakota Access LLC, a explain that “having said that, the odds appear to be against
partner of Energy Transfer Partners. TransCanada, as no company has been successful with a NAFTA
Tentative plans are to begin pipeline construction in the challenge so far with the US, and the process could take years to
spring and have the line in service by late this year. resolve unless early settlement.”

FEBRUARY 2016 / World Pipelines 5


IN BRIEF
World News
FOR MORE NEWS VISIT HTTP://WWW.ENERGYGLOBAL.COM/PIPELINES/

Mountain Valley Pipeline to transport natural gas throughout northeast


Nigeria US
Nigerian National Petroleum Corporation
(NNPC) has shut two refineries in the Mountain Valley Pipeline, LLC and its gas customers’ needs. The MVP and
southern city of Port Harcourt and Kaduna Consolidated Edison, Inc. have announced Equitrans capacity agreements allow
in the north, after crude oil pipelines were their intent to deliver natural gas to customers to achieve significant savings,”
sabotaged. industrial and consumer end-use markets said Ivan Kimball, Vice President of Energy
located in the growing demand areas of Management, Con Edison.
Russia the northeast US, through a 20 year With the rapid development and vast
Gazprom and Shell have been discussing transportation agreement with supply of natural gas in the Appalachian
issues related to their strategic Consolidated Edison Company of New region, the strategic design of the MVP will
co-operation and upcoming oil and gas York, Inc. (Con Edison) for 250 000 dkth/d extend from the Equitrans transmission
projects. of firm capacity on the Mountain Valley system in Wetzel County, West Virginia, to
Pipeline (MVP). Transcontinental Gas Pipeline Company’s
Poland Con Edison also agreed to a 20 year (Transco) Zone 5 compressor station 165 in
Polish President Andrzej Duda opposes firm transportation agreement for Pittsylvania County, Virginia.
the Nord Stream II pipeline project, 250 000 dkth/d on the Equitrans system, The MVP is expected to provide
claiming it is dictated by politics rather located in northern West Virginia and 2 million dkth/d of firm transmission
than economics. southwestern Pennsylvania, providing capacity and has secured commitments at
Equatorial Guinea more direct access to supply resources 20 year terms for this amount, which will
upstream of MVP. Equitrans is owned and support communities along the route, as
The Government of Equatorial Guinea –
operated by EQT Midstream Partners. well as the growing demand markets of
represented by the Ministry of Mines,
“Con Edison is responsible for the Mid-Atlantic and southeast regions of
Industry and Energy – has signed a
obtaining low-cost, reliable supply to meet the US.
memorandum of understanding (MoU)
with the Oil and Natural Gas Corp. Ltd
(ONGC Videsh) for sweeping energy Tough times for Energy East pipeline
co-operation.
The Mayor of Montreal, Denis Coderre, Premier Rachel Notley, and her plans to
USA has slammed TransCanada’s Energy East connect the province to new markets by
With the decreasing price of crude oil, pipeline project. Montreal – and 81 building pipelines.
Tenaris has had to layoff approximately neighbouring communities – is united Trudeau stated that provinces need to
100 of its workers at its welding pipe mill against the pipeline project, citing work together to ensure energy
in Blytheville, Arkansas. environmental and economic concerns. development and environment protection.
TransCanada’s proposed 4600 km, “I am solidly in one camp on this one,” he
Singapore CAN$15.7 billion pipeline is set to said. “I am very much in the camp of both
Harding has been awarded contracts for transport 1.1 million bpd of oil from the premiers, [Ontario’s Kathleen] Wynne and
nine FF1200 freefall lifeboat systems, Alberta oilsands and Saskatchewan, to the Notley, who demonstrated that Canada
complete with davits on Heerema east coast of Canada. can and should work together on
Offshore Services BV’s Semi Submersible Coderre explained that the potential economic issues for all of us.”
Crane Vessel Sleipnir. environmental damages outweigh the Additionally, Ontario’s Premier
economic benefits of the pipeline project, Kathleen Wynne praised Notley for the
Canada stating: “TransCanada’s project includes NDP government’s climate change plan
Pengrowth Energy Corporation has been important risks for our environment and and gave at least tentative backing to the
fined CAN$250 000 after a 48 day oil spill too few benefits for our economy.” CAN$15.7 billion Energy East pipeline.
of 537 000 l in Alberta, Canada. Tim Duboyce, a TransCanada The Liberal Premier said Alberta’s
USA spokesman, stated that the company has effort “makes the national conversation
already filed 700 amendments to the about climate targets and pipelines
The Federal Energy Regulatory pipeline project, in order to deal with the easier.”
Commission (FERC) announced that it will concerns raised. Calgary-based “We appreciate that there is a need for
be investigating four interstate natural gas TransCanada is anticipating hearings in 2016 a way to get Canadian oil, that is allowed
pipelines, to determine if the companies and the National Energy Board’s (NEB) final under Alberta’s new emission cap, to
may be substantially over-recovering their report to be published in 2017. However, no overseas markets. And the people of
costs, resulting in unjust and unreasonable official deadline or date has been decided Ontario care a great deal about the
rates. upon. national economy and the potential jobs
Yet, despite countering concerns from that this proposed pipeline project could
Coderre, Canadian Prime Minister Justin create in our province and across the
Trudeau has voiced his support of Alberta country,” said Wynne.

6 World Pipelines / FEBRUARY 2016


Events DIARY
World News
FOR FURTHER INFORMATION ON EVENTS VISIT WWW.ENERGYGLOBAL.COM/EVENTS

NED pipeline: defective? BC will oppose the Trans Mountain


A leading nonprofit organisation has filed a pipeline expansion
18 - 20 February 2016
10th Annual Midstream Summit
formal protest with the Federal Energy First Nations and environmentalists have
Regulatory Commission (FERC), charging called on Canadian Prime Minister Justin
Houston, USA
that the Tennessee Gas Pipeline (TGP) Trudeau to stop a National Energy Board
http://www.infocastinc.com/
Company’s application for the proposed (NEB) review of the Trans Mountain pipeline
Northeast Energy Direct (NED) pipeline expansion project.
24 - 26 February 2016
project is incomplete and riddled with The hearings will last for 10 days in British
AOG inaccuracies. Columbia (BC) and will finish in Calgary. Local
Perth, Australia The 14 page protest document filed by municipalities, environmental groups, First
http://aogexpo.com.au/ Northeast Energy Solutions (NEES) requests Nations and residents who live along the
that FERC reject the TGP application as it is pipeline are set to deliver final arguments.
6 - 10 March 2016 “not minimally commensurate with the The NEB streamlined the review process
NACE Corrosion complexity of the proposal and its potential to meet time limits set by the previous
Vancouver, Canada for environmental impact.” Conservative government. Interveners are not
http://nacecorrosion.org/ The document lists over 50 specific allowed to cross-examine Kinder Morgan
deficiencies in the application for the representatives and instead had to send in
20 - 24 March 2016 proposed pipeline. written questions. The company answered a
2016 No-Dig Show Vincent DeVito, a partner with Bowditch portion of those questions.
Dallas, USA
& Dewey, the legal counsel for NEES, said: The BC government previously said it
http://nodigshow.com/
“The industry has never witnessed a would not support the proposed expansion. It
proposal for a project seeking government could not support the project because of
4 - 8 April 2016
approvals that’s as patently defective as the concerns about spill response and aboriginal
one submitted by TGP.” support, while the Alberta government issued
Tube Düsseldorf 2016
The protest document requests that its support because of the economic benefits.
Düsseldorf, Germany FERC consider holding an evidentiary Hearings were suspended last summer to
http://www.tube.de/ hearing on the TGP application so NEES avoid a perceived conflict of interest after a
because of the numerous issues in the Kinder Morgan consultant took a job with the
25 - 29 April 2016 application that are of ‘jurisdictional import’ NEB.
Hannover Messe to the commission.
Hannover, Germany
http://www.hannovermesse.de/
Enbridge boosts security
2 - 5 May 2016
Offshore Technology Conference
Calgary-based company Enbridge Inc.
has boosted its security after a number News Highlights
Houston, USA of its pipelines were shut down due to
http://2016.otcnet.org/
protestors.
Enbridge’s Line 9 was under sabotage
23 - 25 May 2016
by protestors in December 2015. The line
was offline for approximately 90 mins as
Pipeline Technology Conference
the protestors were removed from the
Berlin, Germany
site. Similarly, on 3 January, another
http://www.pipeline-conference.com/
sabotage occured, which caused the
company’s Line 7 in Ontario, Canada, to
29 May - 2 June 2016 shut down.
Pipe Line Contractors Associaton Enbridge Spokesman, Graham White,
of Canada stated: “Enbridge sites are locked, ➤➤ SeaTrepid buys AUV systems
Charlottetown, Canada secured and monitored for the safety of
➤➤ Ongoing Kinder Morgan
http://www.pipeline.ca/ people and the environment. As with
pipeline projects
any vital infrastructure or service, they
7 - 9 June 2016 can be made dangerous if tampered ➤➤ World’s first hydraulic pipe
Global Petroleum Show with or sabotaged. We are assessing and recovery tool unveiled in
Calgary, Canada employing various additional, permanent Middle East
http://globalpetroleumshow.com/ measures to enhance our security and
➤➤ World crude steel output
safety at these sites to help prevent
decreased by 2.8% in 2015
these types of tampering activities in the
future.”

8 World Pipelines / FEBRUARY 2016 To read more about the articles go to


www.worldpipelines.com
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Nord Stream II tenders cancelled Forum Subsea Rentals to rent Aquatec’s


Gazprom has cancelled several tenders for construction of LEAKlog
over 400 km of a gas trunk pipeline needed for the planned Forum Subsea Rentals, a subsidiary of Forum Energy
Nord Stream II project, according to documents posted on a Technologies, Inc., and Aquatec Group Ltd. are pleased to
government procurement website. announce the signing of a global agreement for the rental of
Nord Stream II, led by Gazprom, aims to increase Russian Aquatec’s proven LEAKlogTM leak detection and inspection
natural gas exports to Europe by doubling the amount of gas suite.
Russia sends to Germany under the Baltic Sea. The Aquatec LEAKlog leak detection sensors are utilised for
The expansion project has met with criticism from some routine inspection and surveillance of a variety of subsea
European Union member states, who oppose the bypassing of installations as well as for permanent leak monitoring
Ukraine and other Baltic nations. applications. The suite incorporates a data acquisition system
Reports say that Gazprom cancelled one tender for building and interchangeable sensors.
a section of the Ukhta-Torzhok 2 trunk pipeline on 30 December Aquatec Group has been manufacturing innovative
2015 and cancelled three more on 11 January 2016. instruments for measuring, monitoring and communicating in
In November, a source at a pipe supplier to Gazprom told water since 1990, and offer a proven range of subsea leak
Reuters the Nord Stream II pipeline consortium had delayed the detection sensors, including long range fluorometers,
results of a pipe tender due to changes in the shareholding directional acoustic sensor and differential temperature
structure of the consortium. detectors. This full equipment range will be available through
Ukhta-Torzhok 2 is designed to be around 970 km long when Forum Subsea Rental’s global locations supported by their
completed and will feed the Nord Stream pipeline system. experienced technical teams coupled with the expertise of the
Aquatec’s engineering group.
Ramboll assesses integrity of ZADCO subsea Nicki Nicholls, Global Business Director, Forum Subsea
pipelines Rentals said: “This agreement gives FSR direct access to
Aquatec’s technology-leading LEAKlog range of products and
The international engineering and design consultancy Ramboll development team so we can offer not only the off the shelf
Oil & Gas has been awarded an important contract by Zakum packages, but also provide our customers bespoke
Development Company (ZADCO), Abu Dhabi. instrumentation solutions. We look forward to be working
The project, which entails an integrity study of 15 subsea closely with Aquatec, where the addition of this technology to
pipelines, will enable ZADCO to plan maintenance and our extensive range of rental assets gives our customers a cost-
potential replacement of equipment and thereby extend the effective and reliable leak detecting option for completing
remnant life of its existing pipelines. their inspection campaigns.”
The 15 pipelines are part of an oil pipeline network in The Managing Director of Aquatec Group, Andy Smerdon
ZAKUM field offshore UAE, which is one of the largest offshore commented: “Aquatec has been designing and providing subsea
oilfield in the world. Production on the ZAKUM field started in leak detection systems for over 15 years, and Forum’s team has
1983 and the project is performed in order to extend the design considerable experience in mobilising and deploying these
and service life of selected pipelines in the field by an sensors. We welcome this opportunity to work closely with
additional 20 years. them to provide first class service and informed technical
The scope of work includes review of available pipeline support directly to the users of our instrumentation.”
data, assessment of current and future pipeline integrity as well
as calculation and prediction of corrosion growth rate.
ROV support provided by Geo Oceans
Ramboll will perform the Remnant Life Assessment (RLA)
on the 15 subsea pipelines and assess their condition for future Geo Oceans has successfully completed a contract providing six
operations and life extension. weeks of continuous 24 hr/d ROV support for subsea pipeline
“ZADCO is an important client for Ramboll and we have decommissioning operations for Vale in New Caledonia.
been working closely with ZADCO for several years. With this The project involved operating ROVs from a construction
contract, we hope to bring our collaboration to the next level barge providing day and night ROV visual guidance for crane
and further showcase our expertise within the field of lifetime operators to remove 3.6 km of subsea pipeline in 40 - 60 m of
extension,” says Director, Abu Dhabi Branch, Ramboll Oil & Gas water.
Middle East, Jesper Thomsen. The ROV teams also provided visual guidance and
According to Thomsen, the current market conditions touchdown monitoring for an additional scope to lay
foster a focus on extending the lifetime of existing equipment approximately 300 concrete stabilisation blocks on an existing
and assets. He continues: “This project falls very much in line pipeline.
with our strategy to pursue asset integrity specialist services, Geo Oceans had two ROV teams in the field managing
starting with jackets and pipelines, where we have some very and operating the Seabotix vLBV ROVs around the clock. The
capable resources.” campaign was executed successfully within budget and on
The study will be finalised early 2016. time.

10 World Pipelines / FEBRUARY 2016


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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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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.

16 World Pipelines / FEBRUARY 2016


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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.

18 World Pipelines / FEBRUARY 2016


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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.

Why is UV protection needed for FBE


coated line pipe?
FBE coatings are made of several types of raw
material, including epoxy resins, curing agents
(hardeners), catalysts, pigments and fillers. The
epoxy resins most frequently used in FBE coatings
are aromatic, which – when exposed to UV light
– begin to degrade and form a residue on the
coating’s surface. The degradation and formation

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).

)) Profile: grit blast to angular profile 50 - 112 μm.

)) Application:

yy Preheat the pipe to 232 - 253˚C (450 - 488˚F).

yy Apply the single layer FBE or dual powder system using


electrostatic spray or flocking application.
yy Apply the Sol-Gard using electrostatic spray or flocking
application immediately after the FBE or dual powder
system. The basecoat must be at or above 218°C (425°F).
A separate reclaim system is required to eliminate
contamination of the FBE powder.
Figure 1. Gloss and colour change after Florida weathering yy Water quench the pipe after allowing sufficient time
exposure. for proper cure.

22 World Pipelines / FEBRUARY 2016


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Results and discussion preheated to 239˚C (463˚F). The first layer applied was FBE
corrosion coating at 355.6 ±50.8μ (14 ±2 mm), followed by
Weathering Sol-Gard powder coating at 76.2 - 101.6μ (3 - 4 mm). With
Because polyester is the main binder system in the top coat, a CSA gel time of 28 ±6 secs for the top coat, the dual
various UV protection formulation adjustments were made powder system was fully cured in 90 secs (quench time).
to improve Sol-Gard reactivity and ensure it meets the DSC cure data indicated the Delta Tg was less than 0.5˚C,
coating application and pipeline installation requirements. which was well below the requirement of less than 5˚C
A two year weathering test in Florida (USA) was completed (Table 1).
to study the changes when Sol-Gard coating was exposed Figure 2 shows the 24 hr/75˚C water soak adhesion and
to the local weather conditions (Figure 1). To complete this 24 hr/65˚C/3.5V cathodic disbondment test results for the
test, coating coupons were sent to a testing lab where gloss trialled ring samples. Water soak adhesion for both tested
(60˚) and colour were studied every three months for the first coupons were rated as 1 after the 24 hr/75˚C test and
12 months. This testing was then repeated every six months the cathodic disbondment results were 3 mm and 3.2 mm,
afterwards for up to two years. which are within the specification of 6.5 mm.
The results showed no gloss change for the first 12 months. The coupons were also tested for impact and flexibility
In fact, initial gloss was approximately 85 and results indicated requirements. The test’s outcome on the dual powder
that the gloss rate was still over 80 after the 12 months had system showed a passing rate of 3.0J on impact and 2.5˚/
passed. After two years of exposure, the gloss level dropped PDL flexibility requirement, both at -30˚C.
to over 40 while the overall coating integrity remained strong. Impact results are depicted in the top two coupons
A minor visible colour change did occur as indicated by the of Figure 3 and flexibility findings are found in the bottom
colour change index Delta E that was still well below 1.0. two coupons. Coating porosity, surface contamination
and degree of cure were also evaluated with satisfactory
Application trial results. Table 1 summarises all test results.
The FBE and polyester dual powder systems were applied at
a customer’s coating line without any issues. The pipe was Summary
The key to successful UV protection for coated line pipe
is a combination of an FBE single layer or dual layer FBE
system followed by a polyester powder top coat. Dual
powder systems using Sol-Gard are generally very easily
applied in the current pipe coating line without any issues
and produce excellent interlayer adhesion. Testing has
confirmed that Sol-Gard meets the desired flexibility and
field bend requirements and is recommended for use
whenever UV radiation is a concern.

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.

Figure 2. Water soak and cathodic disbondment of the dual


powder system. Table 1. Dual powder system test results
Acceptance
Test Results
criteria
Cathodic
disbondment ≤6.5 mm 3.0 mm 3.2 mm Pass
(24 hr/3.5V/65˚C)
Adhesion
1 - 3 rating 1 1 Pass
(24 hr/75˚C)
2.5˚ flexibility at
No cracking or tear Pass Pass Pass
-30˚C
3.0J impact at -30˚C No holidays Pass Pass Pass
Interface porosity 1 - 4 rating 2 2 Pass
Cross-section
1 - 4 rating 2 1 Pass
porosity
DCS cure ΔTg <5˚C 0.4˚C 0.2˚C Pass
Surface
Figure 3. Impact and flexibility of the dual powder system. ≤35% 10% 15% Pass
contamination

24 World Pipelines / FEBRUARY 2016


EVOLVING
CP practices
A view from Len J. Krissa,
Enbridge Pipelines Inc., Canada
and Christophe Baeté, Elsyca n.v.,
Belgium, on CP and corrosion
management of multiple pipeline
right-of-ways.

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

Figure 1. Example of multiple pipeline ROW extension.

25
)) Measurements may be influenced by
significant IR-drop because of residual
currents flowing between the pipelines.

Additionally, high-voltage power lines


may enter the ROW and cause alternating
current (AC) induced corrosion. It has been
established that control of AC corrosion
must be done in conjunction with
appropriate CP settings.
Enbridge operates the world’s longest
and most complex crude oil and liquid
hydrocarbon transportation system having
close to 25 000 km (15 500 miles) of pipeline
throughout North America. Areas of the
mainline corridor contain up to seven
parallel pipelines within the same ROW. The
common practice with facility expansion
has been to connect new pipelines into a
CP system common with the existing lines.
Upgrades are consequently made, which
include installation of auxiliary systems to
satisfy the increased current demand.
Presently, the ROW includes an
assortment of pipeline vintages
Figure 2. Holistic approach for CP managing of multiple pipeline corridors. (1949 - 2008) with various diameters
(12 - 48 in.) and coating types (coal tar,
PE-taped, FBE and HPCC/HPPC), which has
CP. A more holistic and sophisticated approach is necessary consequently resulted in unbalanced CP levels. Variations
to achieve efficient CP management of a multiple pipeline in soil properties along the corridor, and the occurrence of
corridor. inadvertent electrical shorting with grounding at motorised
valve stations, have contributed to the complexity of the
Challenging unbalanced CP systems problem.
CP of pipelines has demonstrated its value since the late
1940s. The effectiveness of the corrosion protection method The holistic approach
is relatively well understood and straightforward for simple Consecutive inline inspection runs (MFL and US) have
configurations, such as single pipelines or storage tanks. detected features with corrosion growth on both the
Newer grades of steel with less carbon and development legacy and expansion project pipelines within a mutual
of higher performance coating materials have generally corridor. Consequently, Enbridge has adopted a more
improved the overall quality of the infrastructure, resulting holistic approach for identifying the root cause of the
in better resistance to external corrosion. However, the risk corrosion attack and strategically implementing counter
for external corrosion can increase when a pipeline network measures for stabilising the CP system.
expansion is planned within an existing corridor. Each time Proper CP control requires knowledge on the coating
a new pipeline is introduced within the corridor, significant condition, the soil properties and the current distribution
changes in the electrical properties of the new network along the pipeline, and the polarisation behaviour of the
can occur and a shift in CP current distribution between steel surface at coating defects. Conventional CP surveys
lines is not unusual. This can create imbalance within the CP do not reliably provide this information for such complex
system, where back feeding of current can occur at rectifiers. pipeline systems. Therefore, the following state-of-the-art
Identifying the critical areas that cause the instability of the technologies were applied:
CP system is sometimes difficult to achieve with conventional )) CP coupons with stationary reference cells and data
CP evaluation techniques. The information collected on the loggers/RMUs.
pipelines are usually not discrete measurements that lead to
inconsistent or unreliable results because: )) Soil resistivity surveys and soil maps.
)) Measured ON potentials are rather mixed values. )) Remote monitoring of rectifier outputs.
)) Cathodic/anodic current exchange may not stabilise )) Inline cathodic current mapping inspection.
within typical OFF cycle due to capacitive differences
between the coatings. )) Advanced computational modelling.

26 World Pipelines / FEBRUARY 2016


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The CP coupons provide native and ON/OFF potentials between the data, which is not an easy task for such a
of the individual pipelines minimising the measurement complex system.
error. They also provide information on the current For example, the ON potential is determined by
demand of bare steel to achieve the desired protection the coating resistance, soil resistivity and CP current
level in soil surrounding the pipe. The soil resistivity survey distribution. The axial current is a result of the CP current
and soil maps provide information on the type of soil and distribution on the pipe, but does not provide information
its corrosivity. on whether or not the minimum pipe-to-soil potential of
Predicting the corrosion and CP polarisation behaviour -850 mV or 100 mV polarisation shift is achieved at the
of the pipe is accomplished by combining the coupon pipe surface of a complex multiple pipeline corridor. An
data with soil information. The RMUs of the rectifiers intelligent analysis tool is required to automatically treat
monitor the total current output (current demand) of each the large set of data and unambiguously find correlations
individual pipeline in a specific region. between the pipeline and CP parameters to objectively
The inline cathodic current mapping inspection tool draw the correct conclusions.
(smart pig) measures the voltage drop caused by the axial The Elsyca CatPro software is a BEM/FEM based
CP current that flows in the pipeline wall. The data set computational tool that simulates the CP and corrosion
provides an appreciation of the coating condition, which is behaviour of e.g. multiple pipeline corridors. The software
used to localise and quantify the current exchanged with connects the dots by integrating all the field data and
other structures of influence (e.g. bonding between pipes, system properties in a 3D physical model of the pipelines
shorts to ground). and CP components. All relevant parameters such as
The field data, pipeline properties and the the exact pipeline routing based on GPS co-ordinates,
characteristics of the CP system are consolidated in location/geometry of anode beds, cabling to rectifiers,
a computational model that enables calculating true bonds between pipelines, drains to groundings etc. are
protection levels of the individual pipelines. assimilated. Such a model calculates the CP current
distribution in the soil, and determines the polarisation
Connecting the dots level as a function of the coating resistance of the entire
Advances in electronics and portable power capacity pipeline corridor.
over the past 20 years have now enabled unprecedented Firstly, the coating resistance is estimated based on the
access to immense volumes of information that can be coating type, pipeline vintage and local soil resistivity. The
transmitted almost instantaneously from remote locations monitored current output of the rectifiers is applied in the
very economically. The ‘big data’ needs to be stored, model and an initial simulation is obtained that provides
visualised and, most importantly, analysed and evaluated results on:
in a practical and cost-efficient manner. Moreover, the )) Pipe-to-soil ON potential at grade level or at any depth.
abovementioned field data provides valuable information
on individual parameters, but a correlation must be made )) IR-free potential at pipeline surface.

)) Current density leaving/


entering the pipeline.

)) Axial current through the


pipe wall.

)) Rectifier voltage and


current output.

)) Current through bonds


and drains.

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

28 World Pipelines / FEBRUARY 2016


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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.

30 World Pipelines / FEBRUARY 2016


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© 2016 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.
© 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.

NOT JUST A WALK ALONG THE

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

34 World Pipelines / FEBRUARY 2016


CARE!
DARE TO
being collected is properly tagged to a specific location.
With today’s sub-metre (and even sub-centimetre) GPS
technology, almost all CIPS survey data is now tagged
with a specific GPS location for every data point to
facilitate data alignment.

CIPS data analysis and reporting


Close interval survey data and reports typically include
regular daily or weekly field progress reports during
the survey and complete data and final reports upon
completion of the survey. Often the raw data collected
needs to be processed by a data analyst to align the
Figure 3. CIPS alignment sheet data presentation. data sets and the GPS data and to eliminate spurious
readings.
cathodic protection system is critical. Has the system Final reports typically include the raw data set, the
been upgraded, have rectifiers been replaced or ground processed data, graphs/plots of the data, operating
beds or bonds added? Complete information greatly details of the CP system at the time the data was
assists the CIPS crew in planning and implementing close collected, ROW conditions, and any external effects on
interval survey work. the pipeline by other sources. Good CIS data fits right
into the pipeline GIS and compliance systems utilised
Select the CIPS type by most operators. Final CIS reports may also include an
CIPS surveys come in a variety of forms, including native engineering report that details the current status of the
potential, depolarised, on potential and instant off, or pipeline and any potential issues that may arise from
on-off interrupted potential that can be summarised into the survey findings.
two basic groups:
)) On potential and on-off interrupted potential surveys Other considerations
are used to determine if the -850 MV criteria is being In some cases, CIPS surveys may be especially
achieved. These are the most common surveys and challenging or conditions may make it infeasible to
are often preferred because they typically require collect data. This would include:
only a single pass over the ROW. )) Piping that is located especially deep where potential
readings may not be accurate.
)) Native potential and depolarised surveys establish a
baseline for using the -100 MV shift criteria. This criteria )) Pipelines installed in rock bores or with casings
requires survey data on the potential of the structure where potential readings cannot be attained.
without CP applied and then survey data once the
current is applied so that it is possible to confirm that a )) Areas of coating disbondment that can provide false
minimum shift of -100 MV has been achieved. Since the readings.
-100 MV shift criteria requires two data sets to measure
the shift in potential they are often used only when the )) Frozen soils, paved roadways and very dry, rocky soils
-850 MV criteria is not easily achieved. that may not allow for accurate potential readings.

)) Areas under the influence of telluric earth currents or


Collect the CIPS data
DC transit interference.
Once the close interval survey method is determined, CIS
crews gather data in the field with specialised equipment )) Congested plant environments with significant plant
by walking the length of the pipeline being surveyed. A earthing or grounding networks.
typical crew can effectively average about five miles per
day in moderate terrain, although a variety of factors can These should be identified during the planning phase
affect the data collection rate. and alternative integrity assessment methods or tools
For all CIPS surveys it is very important to identify may be required.
all of the potential current sources that might impact CIPS surveys are an effective and proven tool in the
the pipeline in the survey area. This would include the pipeline operator’s integrity programme that can be used
pipeline’s CP systems and those CP sources that are in to assess the effectiveness of the pipeline’s CP systems
the same area and could potentially have an influence and to identify areas of corrosion risk. When performed
on the pipeline. There are a variety of other factors on a regular basis they can be used to evaluate coating
that can impact the quality and integrity of the data degradation and provide information on areas requiring
being collected. It is also quite important that the data additional supplemental CP.

36 World Pipelines / FEBRUARY 2016


Igor Mahkin and Andy
Glover, Associated
Technology Pipeline
Ltd, UK, explore the
management of pipeline
integrity data and
programmes.

ILI data at the


click of a button
O
ne of the most important objectives of any pipeline operator is the preservation and licence to
operate a safe and reliable pipeline system. Without the right information or tools to process
information, a company cannot make sound strategic decisions on the state of any part of their
pipeline network.
Whether it comes down to designing maintenance schemes and inspection strategies, or demonstrating
the integrity of the grid, IT systems form a vital part of the overall management of the network to provide
auditable results.
This article looks at how engineers can use a pipeline integrity management software tool, such as
software offered by Associated Technology Pipeline Ltd – called PiMSlider, and in particular the inline

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.

38 World Pipelines / FEBRUARY 2016


Coating Inspector
Program (CIP)

NACE’s Coating Inspector Program is the world’s most recognized coating


inspector certification program. CIP trains coating professionals to
properly inspect the surface preparation and application of a protective
coating system on a variety of structures in any industry.

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
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§ CIP One-Day Bridge
§ Marine Coating Technology

To register or for more information, visit nace.org/wp2

* All certifications are administered by the NACE International


Institute, an independent affiliate of NACE International.

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.

40 World Pipelines / FEBRUARY 2016


Having analysed the ILI and
non-destructive testing data, the
integrity engineer can use the
software to assign a repair by
selecting the type from the set of
available repair types used in their
organisation. The software allows
the user to further expand and
enhance the list of repair types,
providing further configurability.
The ILI Expert module can
also automatically assign repairs
to a set of selected defects
according to company policy.
The defect selection criteria and Figure 4. Part of a dig sheet containing all the information required for an excavation.
repair assignment algorithms are
fully customisable and can be
created or enhanced by integrity
experts, without the involvement of IT personnel or software Conclusion
developers. Being able to analyse reports generated from ILI – integrated
A detailed set of documents for excavations and repairs are with other key pipeline data required for PiMS, in order to
automatically generated at the same time as repair assignment. make key decisions regarding the safe upkeep of a pipeline
After the repair is assigned, information about the repair network – is becoming an increasingly important part of the
can be sent to the company’s enterprise resource planning (ERP) pipeline integrity process.
system (such as SAP, MAXIMO) or any other system used to The best integrity software should provide integrity
organise the business processes involved with physically repairing engineers with the right tools to work quickly with high
the pipeline in the field. The ILI Expert allows the user to track volumes of data, and to be able to make the right decisions
the progress of the repair implementation and its current status. regarding the ongoing maintenance of the pipeline.

Making the world a cleaner place...


One pipeline at a time.™

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

44 World Pipelines / FEBRUARY 2016


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It can all be found here at the world’s most important exhibition —
the meeting point for international experts, specialists and global
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Figure 2. Pipeline monitoring at Thyssengas Erdgaslogistik.

commercial applications for drones. According to a


company executive, the company “decided to focus on
oil and gas because the barriers to entry are very high, but
there are real problems to be solved and the economics
were better, despite the very low oil price.”
On 23 June 2015, it was announced that the Nigeria
Security and Civil Defence Corps (NSCDC) will deploy
500 drones and aircraft to monitor pipelines and other
oil installations in a bid to protect the country’s oil and
gas infrastructure from attacks by militant groups. This
decision was followed by tests being conducted since
2003, as the company’s Aerostar Tactical UAVs with
12 hours of flight endurance have been patrolling offshore
oilfields on a regular basis. At night, the Aerostar’s Forward
Looking Infra Red (FLIR) camera reveals the presence of International Tube and Pipe Trade Fair
thieves and potential kidnappers, who often try to reach Internationale Rohr-Fachmesse
the rigs using small boats. Oil leaks and slicks also show up
clearly in infrared, and by detecting them early, Aerostar
has saved oil companies millions in fines, which are
imposed automatically for such leaks.
The French company GRTgaz announced the hiring of
Air Marine, to conduct monthly inspections on many miles
of natural gas pipeline. According to the company press
release, the first pilot inspections took place over the past
few months in southwestern France and ‘confirmed the
worth of this innovative solution’. The company – which
owns and operates pipelines – hopes to use the drones
to complement its current monitoring system of ground- Plant and Pipe and Tube Bending and Tube
Machinery Processing Forming Manufacturing
based inspectors along with piloted flyovers. Machinery Technology and Trading

The estimated 300 000 miles of natural gas pipelines


that crisscross the US would equal to circumnavigating the
planet 12 times, and could be a great appeal to persuade
companies that there is a lot of money to be saved by
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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.

Any item subject to ODS analysis has an almost infinite


number of DOFs that could be measured, but in practice
the number of these that are sampled during testing will
vary according to the size of the structure, the applications
and context involved. For pipework vibration assessments,
typically, vibration measurements would be taken at the
following positions: pipe bends, mid points of long spans, all

Figure 1. Visco-elastic damper installed to prevent vibration Figure 2. ODS Plot showing baseline model of relief valve
after ODS analysis. pipework.

48 World Pipelines / FEBRUARY 2016


support points, small bore connections, valves, and finally, Causes of the consequent excessive vibration vary, but
supporting structure. may include: forces generated by the item itself, inadequate
In some ways ODS analysis resembles modal analysis, support systems, unbalances, and external loads.
which is concerned with the natural frequencies and In ODS analysis, the degree of vibration in an item is
mode shapes of multiple DOF systems, however, the main measured and clearly visualised using specialist software,
differences with ODS are as follows: making the decisions connected with maintenance, adjustment
)) Modal analysis will identify all modal responses of the and optimisation much better informed and more likely to
system that could ‘potentially’ be excited. succeed than may otherwise have been the case.

)) 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.

)) A means of capturing a complex vibration baseline for


comparison against future surveys.

)) Increased equipment longevity (for example, by reducing


the damage caused by fatigue).

)) Increased productivity (mainly through reductions in


equipment failure, increased equipment efficiency, less
downtime for unplanned maintenance).

)) Assured compliance with environmental, legal and


regulatory requirements.
Figure 3. ODS Plot showing measurement locations of the
‘zoomed in’ section.
)) Detailed information about equipment performance
and status, which allows managers to make appropriate
decisions about equipment lifecycles, repair and
investments.

The unplanned maintenance of equipment and related


structures, such as piping and support systems, is often
responsible for significant disruption and thus production
losses, so it makes sense for manufacturers to turn to a
specialist partner to complete ODS analysis, such as AVT
Reliability.
Such partnerships give manufacturers and others not only
access to expertise in ODS analysis, but also to the company’s
ability to generate, present, model, and enact appropriate
solutions. AVT Reliability uses ODS analysis to identify areas
of concern and to provide comprehensive guidance regarding
possible changes and their outcomes. That way, ODS analysis
can be used to solve the problems caused by excessive
vibration before they cause major – even catastrophic –
issues, and helps the client to make fully informed, pragmatic
decisions about investment, modifications and the lifecycles
Figure 4. Showing ODS results. of their equipment.

50 World Pipelines / FEBRUARY 2016


FREE
SPAN
THREATS
There has been a strong drive to extend the operating lives of subsea
pipelines. Pipeline free spans are a potential source of fatigue damage, as
Graham Wilson, Jee Ltd, UK, explains while discussing numerous free
span assessment projects.

ipeline free spans are a common threat to induced vibrations (VIV). These vibrations are caused by

P pipeline integrity in certain parts of the world,


and can occur at any time during the pipeline’s
life, particularly when the seabed is mobile or the
local water particle velocities are high. As the length
of a free span increases, so does the susceptibility
the shedding of vortices in the wake behind the pipe
as the water flows past, resulting in the pipe oscillating
at the natural frequency of the spanning section when
the combination of current and wave-induced water
particle velocities is appropriate.
of the pipeline to buckling (under the application of The challenge for the industry is to determine
operational and environmental loading) and accelerated whether such free spans could lead to pipeline failure
fatigue damage due to direct wave loading and vortex- during the original or extended operating life of the

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

52 World Pipelines / FEBRUARY 2016


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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.

Summary of span services


Jee’s engineers have conducted thousands of
Figure 3. Jee’s span monitoring system. free span assessments using a combination of
calculations and numerical methods, such as FE
analysis and computational fluid dynamics (CFD)
to investigate, predict and solve potential and
existing spanning issues. This experience covers the
assessment of free spans in single pipe and more
complex solutions, such as pipe-in-pipe systems and
bundles.
In addition to its analysis based approach,
Jee has developed a unique free span monitoring
system in order to bridge the gap between the
assessments performed in accordance with
the available recommended practices for span
assessment and the ‘real world’ behaviour of the
span. This has allowed it to justify the continued
operation of pipelines with significant free spans
without the need for costly remediation and
the associated future integrity concerns that
Figure 4. Free span identified during survey. remediation may bring.

54 World Pipelines / FEBRUARY 2016


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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.

Latest USCG rules add new


asset protection opportunities
The US Coast Guard recently completed
the expansion of its Notice of Arrival (NOA)
regulatory requirements. The goal is to help
address threats to maritime transportation
safety and security by improving navigation
safety, enhancing the ability to identify
and track vessels, and heightening overall
maritime domain awareness (MDA). Among
other changes, the Final Rule (80 Fed. Reg.
5281), passed on 30 January 2015, expands
the applicability of both NOA and AIS
Figure 2. An example of a PortVision report of real time alerts of pipeline
requirements to include more commercial
encroachments from AIS transmitting vessels.
vessels.

58 World Pipelines / FEBRUARY 2016


pipeline infrastructure or other fixed asset. They
simply go through an application process with the
USCG. Once approved, the ATON can be used to
trigger automated safety messages to specifically
addressed vessels, giving them an extra layer of
awareness about pipelines and other assets.

Creating new opportunities


In addition to pipeline protection, oil companies
are extending the use of AIS-based tools to
include monitoring and preventing encroachment
and damage to a broader range of infrastructure
including unmanned platforms, subsea cables and
other sensitive infrastructure. Additionally, AIS is
being combined with radar and other data sources
to enable the owners of remotely operated fixed
structures to establish a virtual ‘watch team’ over
multiple remote assets anywhere in the world.
The addition of radar to the system ensures
Figure 3. Oceaneering’s PortVision 360 provides access to additional information that even vessels that are not transmitting AIS
with vessel intelligence, making pipeline monitoring more effective. signals can be monitored. Although these vessels
cannot be alerted in the same way that vessels are
alerted by ATONs, they can at least be seen and
In addition to meeting the Coast Guard’s safety and security included in a more complete picture of prevailing traffic patterns.
objectives, these changes will also make it easier to realise It is also common for fixed infrastructures, such as oil rigs to be
the many additional benefits of AIS data for providing instant, equipped with radar – this data can be ingested into AIS-based
continuous access to critical information about vessel activities vessel tracking tools that can, in turn, filter for relevant data about
at sea, and in ports and at busy marine terminals. One new key any encroachment that represents a threat to the asset and trigger
element is the ability to install AIS on offshore fixed structures the necessary alert.
to create an AIS aid to navigation (ATON) system – essentially a
‘virtual ATON’ as opposed to a traditional physical element such Adding vessel intelligence
as a lighthouse, buoy or beacon. ATONs enable an authority to Each of the aforementioned monitoring and alerting scenarios
use AIS for transmitting navigation information where no physical can be enhanced with the availability of more information. As
ATON exists. This is possible because AIS provides the ability to part of the USCG’s expanded NOA regulatory requirements, five
send messages to the unique MMSID assigned to the vessel’s AIS new data fields were added to provide more information about
transponder, bringing it right to the vessel’s wheelhouse. vessel size and voyage details. Even with these additions, however,
With the ATON alerting capability, there is an ongoing ATON information available with AIS data, alone, is limited to a set of
transmission approximately every three minutes to all vessels unique vessel identifiers with minimal, and usually inaccurate,
with the appropriate electronic charting or radar equipment vessel dimensions.
for receiving and displaying. When a vessel interacts with the To provide access to additional information that makes
ATON in a designated corridor, it triggers the transmission of an pipeline and asset monitoring and alerting programmes more
alert message only to the wheelhouse of the encroaching vessel, effective, the latest AIS vessel tracking services provide greater
warning its captain and crew the pipeline below. intelligence about encroaching vessels. One example is text, email,
As described earlier, CAMO was the first to use ATONs in phone and other contact information to improve alerting. Today’s
this way, for pipeline safety alerting. ATONs are also used to services also provide other vessel information for a variety of
broadcast weather and sea state information, and notify mariners valuable purposes. This can include information to identify vessels
regarding area whale migration activity. In these and other with specific features, locate nearby vessels for operational or
applications, AIS safety-related messages can also be broadcasted incident-response purposes, or build custom fleets based on these
to all vessels that are within range of the broadcasting base unique attributes so they can quickly identify not only the best
station. Previously, these ATON systems were prohibited on vessel for the job, but what vessel can be there first.
certain fixed structures, such as bridges. The USCG now allows this Pipeline safety is increasingly critical for oil companies who
practice, reaffirming that the primary benefit of AIS is to provide have hundreds of vessels crossing their pipeline infrastructure
near real time dynamic information. Fixed and charted structures each day. Protection programmes can now be augmented with
do not move, however some are used by vessels as navigational AIS-based vessel tracking tools that provide real time visibility in
aids, based on their position and proximity to shipping lanes. This all areas where encroachment could lead to a pipeline strike, an
Final Rule recognises that reality. automated alerting system to pre-empt imminent strikes, and a
One of the biggest advantages of the new USCG rule collaborative platform for assessing risk and moving forward with
expansion is that any organisation can create an ATON for their the best solution.

60 World Pipelines / FEBRUARY 2016


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Components of a
comprehensive subsea

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.

)) Detailed planning and performance of internal


and external inspection, monitoring, and testing
activities.

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.

)) A strategy that is prepared for handling any integrity issues


Risk assessment and IM planning
that require improvement through mitigation,
Risk assessments are fundamental to
intervention and repair.
understanding the risks and threats posed to
Table 1. Available assessment
the pipeline system. This process allows the codes for most common danage
operator to focus on activities that prevent or anomolies that impact subsea Inspection, monitoring and testing
and mitigate loss of containment. This also pipeline integrity IM programmes that are in accordance with
helps to ensure that the safety level premised Damage/anomaly Code/guideline
assessment of risk form the basis for detailed
in the design phase is maintained throughout planning of integrity control activities (i.e.
the life of the pipeline system. Metal loss DNV-RP-101 inspection, monitoring and testing).
Prior to calculating risk (which is the ASME B31G Inspection and monitoring are both
product of the probability of an event and Pipeline defect considered condition monitoring activities. C

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

64 World Pipelines / FEBRUARY 2016


)) Inline inspection (ILI) is an intelligent pigging of
the pipeline utilising various non-destructive
testing (NDT) methods. This measures continuous
end-to-end wall thickness loss and pipeline
anomalies.

)) Monitoring evaluates the pipeline using


corrosion probes, impressed current system,
process parameters, fluid composition, chemical
injections, and monitoring of loads, stresses,
strains, displacements, or vibrations.

)) Testing looks at the system or function testing of


equipment or control system.

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.

)) Mechanical assessments covering fatigue in free spans, fatigue


in buckles, displacement that causes damage, displacement
that causes overstress, or third party damage causing extreme
strains. The effects of environment on cracking should also be
considered.

An IM programme typically specifies applicable assessment


codes for various types of damage or abnormality. Table 1
Figure 2. Submarine pipeline under free span. provides an overview of available assessment codes for the
most common damage or anomalies that impact the integrity of
subsea pipelines.
different capabilities and areas of application. Below are the most
common tools and tool carriers used to inspect subsea pipelines: Mitigation, intervention and repair
)) General visual inspection (GVI) is the visual inspection carried The main activities related to mitigation, intervention, and repair
out by remotely operated vehicles (ROVs) or divers. GVI generally include detailed planning of the operation, technology
does not include any cleaning but will reveal most external qualification, and (if necessary) the mobilisation, execution of the
condition threats to the pipeline. operation, and documentation. Mitigating activities are, for the
most part, measures related to the internal pipeline condition.
)) Extended visual pipeline survey is a form of inspection that Typical means of mitigating activities are:
uses a pipeline work class ROV. Normally this includes 3-view
)) A restriction in operational parameters such as maximum
digital video digital camera, seabed transverse profiles, CP,
allowable operating pressure, inlet temperature, flowrate,
and a depth of pipe tracker. This type of survey reveals the
and number of given amplitudes of these. Such restrictions
same types of anomalies as GVI with the addition of detailed
may have an impact on the set-point value for the pressure
span profiles and depth of burial.
protection system or the pressure regulating system.
)) Close visual inspection is a detailed inspection of a specific
)) Use of chemicals to inhibit corrosion, improve flow,
area using either a diver or a work class ROV.
reduce scaling, or avoid hydrate formation.
)) High precision survey is a highly accurate positional survey
)) Maintenance pigging with the objective of removing scale,
that determines the absolute position and relative year-to-
deposits, liquid accumulation in sag bends. This could
year lateral movement of the pipeline on the seabed.

66 World Pipelines / FEBRUARY 2016


include temporary increased flowrate to flush out some Below is a list of commonly used repair methods for subsea
of the locally accumulated liquid or particles.
pipelines:
Pipeline intervention activities are typically actions related )) The damaged portion of the pipe is cut out and a new
to the external pipeline seabed interaction and support pipe spool is installed either by welding or by a mechanical
conditions. Pipeline intervention is used to control thermal connector.
axial expansion causing lateral or upheaval buckling, on-bottom
stability, protection against third party damage, to provide )) Local repair by installation of a repair clamp externally on the
thermal insulation, and/or to reduce free span length and gaps. pipeline.
Typical means of intervention include: )) Leaking flanges and couplings may be sealed by installing:
)) Rock dumping.
yy A seal clamp covering the leaking flange.
)) Pipeline protections against third parties (mattresses, grout
bags, protection structures, gravel cover). yy Installing a new coupling.

yy Increasing the bolt pre-load.


)) Trenching.
yy Replacing gaskets and seals.
Pipeline repair is typically actions with the objective to
restore compliance with requirements related to functionality,
structural integrity, and/or pressure containment of the Conclusion
pipeline system. The most suitable repair is dependent on While continuous operation of strategically critical subsea pipeline
the extent and mechanism of the damage, pipe material, pipe assets is paramount, unplanned release and downtime can also
dimension, location of the damage, load conditions, pressure, introduce adverse consequences related to the environment, public
and temperature. The purpose of the repair is to restore the safety, legal liability, regulatory scrutiny, and public relations.
pipeline safety level by reinforcing or replacing the damaged A well-planned, dynamic and comprehensive IM plan is
section. A repair may be either temporary or permanent, proven to be a critical tool for the subsea operator to ensure safe,
depending on the extent of the damage and method employed. continuous and extended operation of the asset.

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MAINTAINING
RELIABLE
METERS
Bart Winters and Seshasai
Yesantharao, Honeywell Process
Solutions, explain how an advanced
solution optimises pipeline meter
proving compliance and tracking.

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

Figure 1. Around the world,


there is a growing demand
for affordable energy.

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.

For pipeline businesses of all sizes, manual data collection,


consolidation and reporting efforts are costly and time-
consuming. Manual audit report generation and data entry
frequently results in labour inefficiencies, as well as data quality
and transcription errors, missed scheduled provings, overlooked
prover anomalies, and lost or missed records. These problems
contribute to a lack of regulatory compliance, which can lead to
fines, lawsuits and shutdowns.
Pipeline operators require a robust solution to consolidate
Figure 2. Pipeline metering systems must provide a single, information to respond to audits in a timely manner and meet
accurate number representing a fiscal measurement. various contractual obligations. They also need tools to centralise

70 World Pipelines / FEBRUARY 2016


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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.

)) Schedule provings based on defined


criteria.

)) Automate storage of all proving data in


a single standardised format.

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.

)) Summarise the status of all meters, provers,


transmitters, and test equipment for a selected node.

)) Generate and publish measurement reports as


defined by the business.

)) Prepare bad actor reports by selected assets to


identify issues for continuous improvement.

)) Utilise real time trends and charts to troubleshoot


problems and analyse meter health.

)) Access proving data for search and analysis by


measurement specialists, analysts and management.

)) Leverage information in a central repository to


Figure 4. Honeywell’s Uniformance Asset Sentinel accesses a real time, respond quickly to audits requests.
historical data repository of information from a variety of plant systems.
)) Integrate applications from multiple metering
vendors, applications and hardware.
proving information so measurement and asset management
specialists can provide reports, perform analytics, undertake )) Review and report on historical production performance.
predictive maintenance on meters and transmitters, and decrease
)) Online asynchronous collaboration between various roles
pipeline downtime. This includes the ability to access information (specialists and field operators).
electronically without adding equipment or placing greater burden
on field operators. )) Ability to track and maintain witness documents for third
party provings.
Improved pipeline metering solution
In order to optimise their calibration, test and certification )) Ability to perform optical character recognition for data entry
processes, and at the same time, reduce the cost of failed audits where the flow computers are not connected to the SCADA.
and compliance tracking, oil and gas companies are employing
a new breed of pipeline metering solution. This technology This advanced solution for meter proving compliance and
automates manual processes and tracks all of the required data to tracking enables operations staff to work smarter – not harder.
meet regulatory requirements. In addition, it uses advanced logic For example, improved proving schedule management and
to determine meter proving schedules based on API guidelines. tracking allows the schedule for proving runs to be stored,
An open, standardised pipeline measurement and meter updated and adjusted based on actual meter factors. It also
data management solution using Honeywell’s Uniformance® provides a standard proving data record for various compliance
Asset Sentinel helps measurement teams proactively keep records that need to be managed. Data from various sources
meters current with their provings, provers current with their can be converted into a standard format for greater ease of
certifications, transmitters current with their verification and use.
calibrations, and test equipment current with their certifications. By capturing this data into an asset-centric monitoring and
Honeywell’s robust application enables pipeline personnel calculation environment, users can benefit from a single source
to take control of proving schedule management/tracking, of the truth or system of record for important meter and proving
recordkeeping, data input, calculations and reporting, alerts and information.

72 World Pipelines / FEBRUARY 2016


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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.

)) Protection of company image and reputation.

Experience in the field has shown that an improved


pipeline metering solution can significantly reduce the costs
associated with proving data manipulation. It can also shorten
the time required for a typical proving, and as such, minimise
labour hours. Increased visibility into meter and pipeline
reliability prevents system downtime, and operators can better
detect prover anomalies and poor measurement performance.
Overall, enhanced pipeline metering and measurement
technology is the answer to lowering the cost of audit findings,
avoiding penalties for failed audits, and reducing the potential for
Figure 5. Improved technology for alerts and notifications legal action stemming from inaccurate custody transfer.
makes problems immediately visible so appropriate actions can
be taken. Conclusion
Automation suppliers have developed
powerful, scalable applications to help oil
and gas companies overcome the challenge
of accessing data from multiple sources and
turning it into actionable information. Aside
from improvements in pipeline meter proving
compliance and tracking, these solutions can
address many aspects of equipment health
monitoring and asset management. They provide
an integrated environment where users can
view and assess different types and classes
of assets across the enterprise – calculating
Figure 6. Proving schedule management and tracking capabilities allows the and monitoring equipment efficiency and
schedule for proving runs to be stored, updated and adjusted based on actual reliability, and ensuring a low cost-of-ownership
meter factors.
throughout the asset lifecycle.

74 World Pipelines / FEBRUARY 2016


Flow management
starts with pumps
T
Controlling flow in he pipelines used to transport oil and other liquid
hydrocarbons are powered by pump stations, with these
liquid hydrocarbon facilities providing the impetus to move product from
pipelines depends on one point to another (Figure 1). For a variety of reasons,
reliable and optimal the key components in these stations are the pumps.
Pumps in general consume large amounts of electricity, so it is
operation of pumping
important that they run at the required speed and no faster. They
systems, explains are prone to failure if not monitored and maintained correctly,
Wally Baker, Emerson with issues ranging from leaks to downtime. Numerous regulations
Process Management, govern their operation, chief among them API Standard 682, which
has recently been revised to require more stringent monitoring of
Rosemount, USA. pump seal systems in hydrocarbon applications.

Figure 1. Pump stations provide the


impetus required to transport liquid
hydrocarbons through miles of pipelines.

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.

Benefits of pump monitoring


Outputs from these wired or wireless sensors are connected to
control systems, either at the pump station or in a central control
room. The sensors and control systems combine to provide a
number of benefits:
Figure 2. Pump monitoring diagram. A wide variety of )) Reduces maintenance costs.
parameters are typically measured on pumps used in pipelines,
some of which are depicted in this diagram.
)) Enables proactive maintenance.

76 World Pipelines / FEBRUARY 2016


)) Facilitates regulatory compliance. Maintenance costs are cut because it is no longer necessary to
overhaul or perform maintenance on pumps on a periodic basis, or
)) Decreases environmental incidents.
in response to a problem. Instead, pumps can be maintained only
)) Improves safety. as needed, and with proactive rather than reactive scheduling.
API Standard 682 requires monitoring of pump seal systems,
)) Reduces need for visits to the pump station. and other regulations also require varying types and levels of
monitoring, all of which can be done more efficiently with
)) Provides troubleshooting information.
instrumentation and control systems as opposed to manual
)) Increases uptime. methods.
Environmental incidents can be decreased because pumps
)) Optimises operation. and related systems can be continuously monitored for leaks,
over pressure conditions and high temperatures. Some of these
conditions, such as leaks, represent an immediate environmental
issue – while others can indicate conditions leading to possible
incidents.
Reducing incidents improves safety, and safety is also
improved because fewer site visits are required to check
conditions, which also cuts costs. Remote monitoring also
provides information to aid troubleshooting, so that when site
visits are required, technicians can arrive with the tools and parts
in hand to perform required repairs.
All of the information gathered by sensors can be sent to a
control system, where operators and engineers can use this data
to increase uptime and optimise operation, particularly with
respect to pump operation and flow measurement.

Figure 3. Ultrasonic instruments transmit and receive pulses Flow measurement


diagonally across pipes to measure fluid flow. Flow sensors close the loop on pump systems, as information
from these devices is used to regulate the speed at which pumps
run, and/or to modulate flow control valves. These sensors are
installed at various points in the pipeline system starting at pump
output, and continuing downstream to ensure proper flow is
maintained throughout the pipeline. The most common type of
flow sensors in pipeline systems are ultrasonic and coriolis.
Ultrasonic flowmeters use the transit times of high frequency
sound pulses between a pair of transducers to determine fluid
velocity. A transducer pair is positioned within a meter tube body
to enable the pulses to be transmitted diagonal to the direction of
the fluid flow (Figure 3). Each transducer alternates as a transmitter
and a receiver, resulting in pulses being transmitted against and
with the flowing fluid.
A pulse travelling with the flow traverses the pipe faster than
the alternate pulse travelling against the flow, with the resulting
time difference proportional to the velocity of the fluid. Relating
this velocity to the known diameter of the meter tube results in a
continuous inferred volume measurement.
Multi-path meters for pipeline custody transfer and pump
efficiency tend to be more accurate since they collect velocity
information in several points of the flow profile. Ultrasonic meters
are typically considered because they are non-obstructive, have
no moving parts, accommodate high volume applications, and are
self-diagnosing.
Coriolis flowmeters are unique because they can measure
either mass or volume flow, or both simultaneously (Figure 4).
Figure 4. The gray U-tube design of each of these two micro
Coriolis meters are well known for accurate and long-term
motion coriolis meters are clearly visible at this pipeline measurement stability under varying process conditions. They
receiving station for a major storage terminal in Cushing, are able to measure different fluids including both liquids and
Oklahoma. gases without the need for recalibration. Coriolis meters are not

78 World Pipelines / FEBRUARY 2016


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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
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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.

Visit our website for complete details or call for a brochure.


Maintaining
flow around
the globe

Alan Robinson, Arc Energy Resources, UK,


discusses anti-corrosion coatings to extend
the service life of globe valves.

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.

Applying anti-corrosion coatings


In order to provide corrosion or erosion protection to the
internal surfaces of the valve, the designer has the options
of either manufacturing the valve out of solid corrosion
resistant alloy (CRA) or by specifying the application of
Figure 1. Globe valve being positioned to commence cladding. a weld overlay clad layer onto the wetted surfaces. The
former option can become very expensive,
especially when considering the larger (12 in.
NB plus) and higher pressure rating valves. In
these cases it is generally considered more
cost effective to produce the valve bodies
and bonnets from carbon manganese or low
alloy steel and clad the wetted surfaces with
a CRA, which is best suited for the medium
and service to which the valve will be put.
As globe valves are castings, and
therefore able to be made into any shape
the customer wants, designers generally
try to keep the inlets and outlets at a
constant cross sectional area so that the
flow is uniform. This means valve inlets are
circular to match incoming pipework, before
changing to an elliptical or square section of
the same cross-sectional area, which keeps
the valve dimensions compact. When a globe
valve is cast, the internal shapes do not need
to conform to any axis, thereby causing
major challenges to the application of weld
overlay cladding to the internal surfaces.
Indeed the application of cladding needs
to deposited on surfaces which cannot be
directly viewed and in all welding positions
including overhead.
Whilst it can be difficult to apply
anti-corrosion coatings to the internal
surfaces of castings, a leading weld overlay
cladding specialist Arc Energy Resources has
successfully applied its specialised coatings
to globe valves for a number of different
companies and has, more recently, developed
special techniques with the co-operation
of globe valve manufacturers to apply
the coatings more cost effectively. These
techniques are also dramatically improving
the protection performance of the valves.
Commenting for Arc Energy Resources,
Managing Director Alan Robinson says: “We
have been applying corrosion-resistant
Figure 2. Rotary head in operation.
coatings to equipment in the oil and gas

82 World Pipelines / FEBRUARY 2016


industry throughout the world and have been aware of In terms of the design changes needed to enable the
the difficulties with globe valves for some time. However, coating operation to succeed, Arc Energy briefed the
following an investment in some specialist machines that customer’s engineering teams on the specific design changes
we bought especially to handle the difficulties mentioned, involved, and followed that with further discussions and
we have already coated globe valves from 12 - 24 in. Since demonstrations at its Eastington facilities covering every
installation, these machines played an important part in the aspect of the project. The customer accepted that the new
initial planning for globe valve contracts and have applied approach was a combination of knowledge based on years
anti-corrosive coatings to the first batch of globe valve in the of engineering experience in the oil and gas industry, with
current contract.” experience of how globe valves work and their functionality.
Whilst also showing that the changes would not reduce the
Dedicated welding equipment performance flow of the globe valves, the engineers who
The machines extend the size and scope of corrosion resistant design, produce and sell the actual products, were impressed
coating contracts that Arc Energy can handle. The automated that lasting material flowrates could be accurately maintained.
machines manipulate the welding
torch around a fixed component,
accurately positioning it to apply
the overlay to large and/or complex
components using MIG or HW TIG.
Having worked with the
machines for five years, Arc Energy
has gained valuable experience
of their strengths, one of which
is its versatility. This has enabled
Arc Energy’s experienced welding
engineering team – which have The FUTURE of
many years of experience between
them – to develop a technique surface preparation
that enables the company to
dramatically improve access to the in corrosion
internal surfaces and vastly improve
the coverage and consistency of prevention is
the coatings that can be applied
to difficult internal and external here TODAY
surfaces. Significantly, this technique
has proved extremely valuable in
the application of coatings for globe
valves.
In order to supplement the
existing equipment, Arc Energy
has also invested in new state
of the art bicathode equipment
from Polysoude. The new process
significantly increases the deposition
rate whilst maintain top quality weld Eliminate soluble salts and prevent flash rust for 24+ hours
metal.
Provide the best achievable surface for coating adhesion
Designing a successful
coating operation
Robinson states: “To achieve the
improvements we now work with Recommended by Leading Coating Suppliers
valve manufacturers to develop
certain aspects at the design stage,
which enable us to apply coatings Use with: Dry Grit Blasting, Wet Abrasive Blasting,
more efficiently and cost effectively. UHP Water Jetting
The developers then analyse
our suggestions to confirm the On: Pipelines, Offshore Installations, O&G Terminals,
functionality of the globe valves is
still intact.”
Transport and Storage Facilities, and More

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

Figure 3. Seal face clading.


Fibre op
Fibre optic
is here
Dr. Chris Minto and Dr. Alastair Godfrey,
OptaSense, UK, discuss new developments
in pipeline integrity maintenance.

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.

)) Separation of shock waves by a time corresponding to the


Figure 2. Pipeline shock waves and interference noise from ~11 m pipeline segment length.
a passing cleaning pig – with distance horizontal and time
vertical, the pressure pulses can be observed travelling in both )) Speed of sound in oil propagation (~1200 m/sec.-1) of
directions.
shock wave down the pipe.

86 World Pipelines / FEBRUARY 2016


an artificial effect (optical not acoustic)
pertaining to different gain levels along the
fibre and is easily compensated for.

)) Areas of stronger signal – indicating


sections with a closer interference fit/
bends etc.

)) Evident departures from the straight


line ‘V’ signal – caused by departures
from linearity in the fibre/pipeline
relationship/moiré optical fringe
effects.
The behaviour of the signals
throughout is quite sufficient for spot
position monitoring, speed profiling
and overall average speed of transit.
Figure 3. Zooming to 4 hr, 30 km reveals some fading of the signal with distance (range The appearance does vary with pipeline
of interrogation) but still with sufficient strength to track over the equipment range. An pressure and product – for example in
interference signal from a block valve is evident around the 27 km mark.
a low pressure gas pipeline, only the
centre ‘rumble’ may be present where the
‘V’ structure may not develop – in these cases alternative
methods are available for tracking using the rumble itself.

Live position tracking and accuracy


Having raised the ability to detect the location of a device
transiting a pipeline to a ~10 m accuracy, an obvious
application is the monitoring of speed of transit – where
the operator may be seeking to be informed about slowing
conditions to prevent a stall, locating a stuck pig, monitoring
a stuck pig via pressure unbalancing or simply monitoring the
speed profile as an aid to plotting dynamic flow or pressure
distribution in a multiple take off line.
Although live tracking of the device is provided via the
Figure 4. Examples from a wet gas distribution pipeline
operation in India where the pig (travelling left to right) GIS (icon on map) the dynamic waterfall traces are illustrative
experiences speed changes from changing pressure profile. in terms of visualising the speed content – in this domain,
distance is horizontal, time is vertical and therefore unmoving
)) Varying intensity of ‘rumble’ signature – actually a acoustic elements appear as vertical continuous signals and
complex signal that can vary from rumble to a more the faster an item moves the more horizontal it appears. The
complex picture as the degree of interference fit changes. speed of the pig is therefore tracked, both from a detection
perspective at each point, but also easily visualised over a
)) Speed of transit of the cleaning device (maximum and longer time trace.
minimum alerts). By monitoring the speed of the device over an extended
)) Pressure pulse reflections from other pipeline furniture period, the overall speed of the transit can be plotted. In
(e.g. block valve in this case). variable flow or pressure conditions, speed variations are
largely conform to this flowrate variable, but in static flow
)) Lower intensity pulses caused by the stiction of the conditions, speed variations will indicate the severity of
normal transit in the pipe. obstructions in the pipeline (or the accumulation of wax for
example) and can be used to deliver feedback to additive
)) Varying intensity of the pulse signal.
injection operations or frequency of cleaning analysis. Such
By plotting these over an extended period, the transit of figures provide an important database for year-on-year
the pig across the complete pipeline can be observed and comparison.
plotted. In this situation, the centre line trend of the device
location is easily observed over a longer distance (~30km in Benefits of online pig tracking
this instance). Superimposed upon this are evident deviations There are many advantages to the use of an online tracking
in the pattern discussed: system and all can save considerable effort in time and
)) Systematic increase in perceived noise level as the device resources and in more austere locations improve personnel
comes closer to the fibre optic interrogator – this is safety.

88 World Pipelines / FEBRUARY 2016


It obviates the need for ‘time to trap’ reed switches listening equipment and human presence may be deployed
and/or mechanical position locators. These often fail from for active monitoring (e.g. during expensive instrumented
physical usage and are costly to repair, as it requires pipeline inspection runs), these costs can be eliminated, as the listening
intervention, possible shut down and is significant in field equipment is continually present.
activities. The use of OptaSense to track the position gives Instrumented inline inspection runs have a precise speed
immediate feedback from the waterfall display and map icon tolerance metric for the device to ensure quality control of
of the pig location. Clients using this technique, confirm that output, as well as device longevity. This is largely controlled
the use of OptaSense changes the dynamic of the operational by flowrate, and so a cautionary approach is taken. OptaSense
activities – rather than having to contend with having to can provide a dynamic feedback loop to the controller
visit hard to reach or insecure locations for maintenance and providing instantaneous speed display and warning of
consider costly replacement of devices – the use of DAS for limits being reached. In addition, the provision of historic
time to trap alerts is: information allows for forensic analysis in the event of issue.
)) Maintenance free. However, the biggest cost saving is in the case of a stuck
device. In traditional circumstances, there are a number
)) Often comes as a small add on as part of a wider package of costly actions that can be taken to try and remedy this
of right of way surveillance (leak prevention) or leak situation – and to find out where the device is stuck. In a gas
detection activities. line, an inspector can carry out a costly unbalancing operation
by underpressuring one side (venting) and over pressuring the
)) Can save hundreds of man-hours a year in terms of
reduced maintenance burden. other, in an attempt to unstick the device. OptaSense has
helped clients save hundreds of thousands of dollars of lost
)) Keeps maintenance staff working in safer locations on production time and wasted product in venting operations
frees them up to work on more strategic problems. by providing an immediate response when the stuck pig starts
moving again.
It can also move pigging from being a ‘fire and forget’ A second pig may be injected in an effort to free the first
activity, to being an informed actively monitored function. – or to track where it is reached (only applicable if there is
At all times, a glance to the screen gives comfort in knowing some residual flowrate). This would normally be an intensive
the precise pig location. In circumstances where field operation burdened with heavy manpower in an effort to

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bring as much information as possible on the transit of the identifying the location of the device to within a few tens
next device. OptaSense eliminates both the cost of the all of metres from the trace and then on the ground by simply
of the manpower associated, and in most cases, the effort walking up and down the controller can direct the field team
associated with the next pigging run – the information is to the precise last location of the pig – accurate to ~10 m.
already known. Finally, in the case of waxy deposits or condensate lines,
The worst case, however, is when a pig is accepted if there is a concern that a build-up of deposits or particular
as being stuck – but the information will only vaguely be geometry issues may lead to a potential stuck device, the
known – an inaccurate estimate may be provided from a mass speed profile of each run can be compared back to the
balance system for example. But this is often only accurate flow profile or pressure profile and locations where marked
to a few kilometres. The next and fairly serious step may be speed deviations are evident, and can be easily identified
to drill a hole in the pipe to try and establish whether you and marked for careful live observations during subsequent
are upstream or downstream of the pig – narrowing in on transits. Potentially avoiding more damaging incidents – or
the device. Finally, when it is close, a large section of land feeding into a control loop to ensure that speed is kept above
might be excavated until it is fully zoned in on and cut out. a minimum. Note that without live feedback, speed profiling is
OptaSense can reduce these costs to a bare minimum by only ever achieved during the infrequent statutory inspections
– every run between that is carried out
largely blind.

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.

90 World Pipelines / FEBRUARY 2016


IS YOUR PIPELINE
PIGGABLE?
Paul Westwood of Penspen asks
questions on the piggability of pipelines
and emphasises how pipeline integrity still
needs to be maintained even after the recent
decline in oil prices.

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?

)) Bridle pipework – can the pressure be equalised either


side of the pig?

)) Pig signalling devices – intrusive type, when were they last


serviced?

)) Types of reducer – concentric or eccentric?

)) Valve configurations – are they set up for pigging?

)) Door mechanism type – when was it last serviced?

)) 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.?

)) Overbore diameter and length – wall thickness is an


important measurement as a heavy wall thickness will
reduce the overbore internal diameter making pig loading
difficult. Is its length sufficient to contain the pig?

)) Nominal pipe length – the requirements differ for launch


and receive traps.

)) Tees – do they have pig bars fitted?

)) Height and angle of the pig trap – offshore the pig traps
are often vertical to save space.

)) Is sufficient space available in front and to the side of the


pig trap for access?

)) Is sufficient space available above the pig trap? Are there


any overhead obstructions like electrical cables (often
found if the pig trap is in a busy city location) or steelwork
Figure 2. Back-to-back tees. on offshore facilities?

)) Pipeline pressure – low pressure gas pipelines can cause


pigging records, and pig trap designs to name but a few. Once severe velocity excursions during pigging, which may
all this information has been collated, it will provide a good impact data integrity.
understanding of the pipeline configuration and hopefully give
)) Flowrate – is there sufficient flow to propel the pig? Is the
you that warm fuzzy feeling that the pipeline can be pigged by
velocity so high a bypass system is required on the pigs?
conventional free-swimming pigs.
If areas of this data are missing – which can sometimes be Once all of this information has been gathered, it is good
the case in countries affected by war, terrorism or simply by practice to photograph the site area, walk around the pig trap
bad management of data – the second part of the planning and take photographs from all sides, highlighting any pipework
process (the site visit) can help identify any missing pieces. or obstacles located in its vicinity.

Site visit Logistics


Now, I have lost count of the number of times I’ve been on Once you are confident with the information collected you
a pigging compound in my career, however the site visit is will need to envisage how the inline inspection (ILI) tool and
a critical step in the process of assuring the line is or is not relevant associated support equipment will arrive in front of
piggable. Visiting the site is applicable not only for maintenance the pig trap. Consider, for example, a 48 in. inspection pig that
pigging but also for inspection purposes, both of which can could weigh upwards of 6 t, something which will require a
have a different set of requirements. During the site visit the substantial crane along with transport to locate it in a suitable
engineer will need to check the pig trap dimensions, assuming position for loading in to the pipeline. This assumes your pig
launch and receive traps are fitted with measurements and trap is accessible by road.
notes recorded in relation to the following items: For an offshore location you may need a dedicated
)) Offtakes – especially back-to-back offtakes that could support vessel. How will you lift the pig from the boat to the
stall a pig. platform – will the same crane be utilised for lifting it to the

92 World Pipelines / FEBRUARY 2016


trap? A slight swell on the sea can cause severe movement on )) Food and shelter – is there a hotel close by or will
a crane jib perched 30 m above sea level when lifting on to personnel be staying on a camp environment or at a
unmanned platforms with no fixed crane. If you are working in cramped offshore installation with eight people sharing a
swampy areas, flat-bottom barges may be required to mobilise room and a communal shower block?
the equipment.
The logistics involved in navigating a large slow moving Piggability report
barge through a shallow waterway requires a degree of skill The piggability report will collate all of the information
and local knowledge. Later, you will also need to mobilise gathered from the site visit and the document review and
the crew along with all other associated personnel to site, confirm if the pipeline is piggable, or not. If the pipeline is
which may take place one week after the barge departed. not piggable recommendations will be made on modifications
Have you considered standby charges for the equipment required or alternative methods to be employed, e.g.
and technicians? The week long journey to the site has now bi-directional inspection technologies, crawler pigs etc.
cost you seven days of equipment rental plus potentially 14 Potential threats for individual pipeline segments will be
man days of technician time. Averaging those costs across investigated to ensure each inspection is tailor made. Does
three different vendors on a recent inspection project I was the pipeline run through areas, which suffer from ground
managing would place them at around £49 000 (US$75 000) movement? If so, an inspection tool fitted with an inertial
and that is prior to the pig even seeing the pig trap! mapping unit may be recommended to measure bending
strain. The type of product the tool is running in needs to be
Power and shelter considered, you cannot run an ultrasonic tool in a gas pipeline
without a liquid couplant for example.
Power Depending on your requirements an independent review
Will your chosen inspection company require an electricity of inspection vendors may be performed with budget prices
supply on site to power up laptops and electrical equipment and availability of the inspection tools included.
to commission the inspection tool? If so what voltage and
frequency is required, and is it available at the work site?

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?

Personnel Figure 3. Offshore ILI loading.


Will they require Visa paperwork? Does your pipeline pass
through different countries? Will you have to prepare letters
of invitation for an embassy? Armed security may be required
if working in hostile environments. Transportation in remote
areas may require the use of a helicopter to deploy Above
Ground Markers for example.
)) Training – do you have specific training courses that
personnel are required to attend? Offshore survival,
off-road driving, altitude awareness, hydrogen sulphide
awareness, may be required, to name but a few.

)) Consideration must also be given to the health of


personnel – inoculations maybe required. Malarone or
similar malaria tablets may be necessary, or in one of the
strangest cases I’ve come across, I had to keep medication
with me in case of contracting Bubonic plague, as there
was an outbreak during the time I travelled to Kazakhstan
back in the early 2000s. Figure 4. Pipeline debris.

FEBRUARY 2016 / World Pipelines 93


Documentation and execution )) Contact lists.
Once the line is confirmed piggable the execution phase
)) Post run decontamination procedure (NORMS, mercury,
requires a comprehensive range of documents, which could
benzene etc. can all contaminate pipeline pigs).
include:
)) Health, Safety and Environment (HSE) policies. Prior to mobilisation, a factory acceptance test (FAT)
should be performed with the ILI vendor to identify any
)) HAZID review documents. issues prior to incurring costly mobilisation charges. On
a recent FAT visit I captured the inspection tool vendor
)) Material safety data sheets.
preparing to mobilise a lower specification tool than that
)) Project, inspection vendor and waste disposal method specified, something an inexperienced operator might have
statements. missed.
So now you have got your people in-country, all the
)) Site pigging procedures. required training is complete, the inspection tool is at the pig
trap and the technician informs you there is an issue with the
)) Lifting plans.
tool and it cannot therefore be run.
)) Pig run contingency planning. OK, this may be an exceptional circumstance, but it
does happen. Reasons could include flat batteries, faulty
)) Inspection vendor equipment lists. electronics, damage which occurred during transportation
and a host of other things. Sometimes these issues can be
)) Reference drawings.
resolved onsite, but what if the length of time to fix the
)) Project plans and relevant project documents. problem means you have missed the batch of product that
you were going to use to propel the tool?
Now assuming the pig has been run, then everyone
will be eager to know the outcome of the inspection with
the onsite technician under pressure to ‘tell me where
there’s a defect?’ from the often expectant client. Now,
the most you can expect from the field technicians onsite
is confirmation that the tool has or has not functioned
correctly, and whether it has or has not collected a full
data set.
Issues with incomplete data can be attributed to:
)) Debris in the pipeline – who was responsible for cleaning
the pipeline?

)) Damage to the inspection tool – a partially closed valve,


velocity excursions, wear and tear, etc. could all be
contributors.
Figure 6. Pyrophoric dust on fire inside the pig trap.
)) Product issues, flow, velocity, pressure, temperature etc.

)) Onboard electronics issues.

)) Sensor issues causing data loss.

This list goes on. As inspection tools are in high demand,


some negotiation will often take place with the inspection
tool vendor, trying to persuade you to accept the degraded
inspection data. The implications of any decision to accept
data of a degraded quality need to be fully understood
along with the impact this will have on any future integrity
assessments planned.
With a large percentage of the world’s pipelines still
considered unpiggable for current inspection technologies,
a well-executed piggability study along with a well planned
and executed inspection programme will help fill in the
Figure 5. The end goal, a clean pipeline and a successful blanks for you and may just keep you one step ahead of the
inspection. regulator.

94 World Pipelines / FEBRUARY 2016


Alan Fowler
(Singapore) and
Adelya Pavlenko
(UK), Ramboll
Environ, highlight
how to overcome
the health, safety
and environment
challenges of new
international pipeline
projects.

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.

96 World Pipelines / FEBRUARY 2016


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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.

98 World Pipelines / FEBRUARY 2016


Derrick Butterfield, Volvo Construction
Equipment, Germany, highlights the
advantages of a rotating pipelayer concept for
lowering-in operations and steep slope work.

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

Figure 1. Boom uphill and


the upper structure locked,
for perfect stability and safe
operation when the slopes
get steep.

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.

Precise load management


A further safety enhancing feature is the machine’s unique,
onboard LMS, which alerts the operator of the need to engage
the machine’s heavy-duty, hydro-mechanical slew lock on slopes
above 10˚ and is calibrated to work on all slopes up to 30˚.
Using sensors mounted on the boom and on the machine’s
upper structure, the LMS permanently monitors the slope
inclinations – fore/aft and lateral – boom angle, orientation and
load. Information is fed continuously to the operator, via both

Figure 2. State-of-the-art, onboard LMS.

Figure 4. Lowering-in alongside both sidebooms and crawler


Figure 3. Cameras enhance site safety. cranes on the Bunde-Etzel 48 in. pipeline in northern Germany.

100 World Pipelines / FEBRUARY 2016


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Figure 5. Lowering-in alongside crawler cranes in soft, sandy Figure 7. Lowering-in alongside sidebooms on a project close
conditions: L’artère des Flandres in northern France. to Parma, Italy.

On the Greek project, pipelayer


operator Panagiotis Sotiropoulos was
quick to see the benefit. “The LMS
is a fantastic help in the lowering-in
application. As an operator you can
see the work loads of all the other
machines, thanks to a system of lights
mounted on both sides of the boom
and if one machine is overloaded you
can see that and help. This makes the
whole work process much safer and
easier for the lowering-in foreman and
the operators.”
A choice of single, double or triple
grouser shoes is available depending on
underfoot conditions, although when
it gets really tough, single grousers
provide just the right grip and traction
to keep them moving.

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.

102 World Pipelines / FEBRUARY 2016


The latest PL4809D, nonetheless, can travel faster on flat He went on: “operator visibility is outstanding making
ground as a result of its significantly improved tractive effort. it safer for both the operator and the on-the-ground crew.
When lowering-in, Volvo’s single, straight travel pedal feature It has superior reach and the onboard load management
leaves the operator’s hands free to control the boom and winch. system is fantastic. And the cab ... who wouldn’t like it ...
Volvo’s operator-friendly design even allows the operator to air conditioning, heating and a stereo. This is a first class
choose the preferred joystick to operate the winch, by simply machine.”
selecting left or right via a pattern change control valve. Given the importance of machine stability, the lower centre
When terrain conditions or obstacles call for the pipeline of gravity of Volvo pipelayers is a major contributor, in addition
to move from one side of the ROW to the other, the only to improving the ability to manage heavy loads. This is achieved
adjustment for a Volvo pipelayer is to simply swing the upper due to the boom being mounted inside the track frame of what
structure to position the boom on the other side. The same is already a wide and stable platform; the centre of gravity
applies should any pipes need repositioning as this 360˚ swing is further lowered with the addition of hook-on, track frame
capability enables it to position pipe anywhere around the counterweights on the PL4608 and latest PL4809D models. The
machine. counterweight design facilitates cleaning in addition to the ease
of hooking them off to reduce machine weight for transportation
When the going gets tough where strict weight limits may apply.
Canadian contractor Surerus operates PL3005D, PL4608 and On the PL4608/PL4809D a hydraulically variable
PL4611 pipelayers. Veteran operator Rick Gould was very pleased undercarriage allows the track width to be increased by
with the performance of the Volvo pipelayers. “After years of 500 mm for additional site stability and simply retracted for
operating a traditional side boom machine, these took a little bit transportation. Should at any point, due to ground conditions,
of getting used to. They were, simply put … different, but now I the machines may need to sit back from the trench, the flick
love them. They are versatile, you can literally offload the pipe of a switch can raise the hydraulically elevating cab to provide
and swing it 180˚ to the trench and you can’t do that with a side excellent visibility into the trench as well as over the work site
boom.” and, especially, to any personnel on the ground. The latest Volvo

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Schoenbeck GmbH & Co. KG • Germany
www.schoenbeck-maschinen.de • info@schoenbeck-maschinen.de
p l a n t a n d m a c h i n e t e c h n i q u e s Tel. +49 5721 99 44 39-26 • Fax +49 5721 99 44 39-23
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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.
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