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DECEMBER 2010
ALL WRAPPED UP
Europe
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DEEP CONNECTIONS
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REGULARS
From the Editor Pipes & people Advertisers Index Subscription form Coming in future issues Enbridge set to expand North Americas crude oil pipeline network Leighton awarded pipelay contract offshore Iraq Colombia moves toward construction of its longest oil pipeline OPAL Germanys pipeline gem GSPL to construct Indias two longest pipelines World Wrap Project briefs Energy security and pipeline politics in Europe A pipelayer for every season: choosing the right equipment for your next challenge Padding machines WorldWide Inside and out: benefits of pipeline coating Weld smarter: CRC-Evans new welding system with laser vision technology Getting the job done in swamp, marsh and wetland terrain Punj Lloyd: specialising in swamp pipeline construction Oando nearing completion on Nigerian pipeline
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technical
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Dealing with the technicalities of CO2 pipelines Cleaning pigs maintaining pipeline integrity Fitness-for-service assessment of unpiggable pipelines Kick start a successful business year at PPIM 2011 A snapshot of engineering contractors and their capabilities Committed to corrosion prevention: NACE International The Salaya Mathura Pipeline System HSE keeping UKs pipelines safe PLM and ek pass team-up to provide pipeline training Emerson launches Shafer SH Series gas-over-oil pipeline actuator Maats and Liebherr develop environmentally-friendly equipment Galaxy pencil brushes on trial in Gulf of Suez Industry converges on Calgary for IPC 2010 Pipeline convention down under Rehabilitation conference hits the target Get to the premier CO2 transportation event in June 2011 Solve the unpiggable pipeline puzzle in Houston this March Be the best in the business, meet the best in the business
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any were injured to various degrees and eight people died in the gas pipeline explosion at around 6:11 pm on 9 September in San Bruno, California. The Pacific Gas and Electric (PG&E) Line 132 Pipeline ruptured at a road intersection in the small town in the southern suburbs of San Francisco, releasing approximately 1.7 MMcm of gas, destroying 37 houses and damaging 18 more. The effect of events such as these has the potential to impact surrounding communities in increasingly devastating ways. The scenario is becoming every pipeline operators worst nightmare as owners and operators deal with issues of encroachment. In this case since 1956, but in many other cases around the world for varying lengths of time, communities have expanded to spread into areas that were open countryside at the time of the pipelines construction. The 30 inch diameter X42 steel pipeline with 0.375 inch wall-thickness was constructed in 1956, originally coated with hot-applied asphalt, and was cathodically protected. According to the operator, the pipelines specified maximum operating pressure (MOP) was 2,586 kPa and the maximum allowable operating pressure (MAOP) for the line was 2,759 kPa. According to the US National Transportation Safety Boards (NTSB) preliminary review of the incident, a short while prior to the accident PG&E was working on its uninterruptable power supply (UPS) system at its Milpitas Terminal, around 63 km southeast of the accident site. The report states: During the course of this work, the power supply from the UPS system to the SCADA system malfunctioned so that instead of supplying an output of 24 volts, the UPS system supplied 7 volts or less to the SCADA system. Because of this anomaly, the electronic signal to the regulating valve for Line 132 was lost, resulting in the valve moving from partially open to fully open, as it had been designed to do. The pipeline pressure then increased to 2,662 kPa. The over-protection valve, which was pneumatically activated and did not require electronic input, maintained the pressure at 2,662 kPa. At about 5:45 pm, the SCADA system indicated that the pressure at PG&Es Martin Station downstream of the rupture location exceeded 2,586 kPa. The SCADA system showed that the pressure at the station continued to rise until it reached 2,689 kPa at about 6:00 pm, and at 6:08 pm, the pressure dropped to 2,662 kPa; at 6:11 pm, the pressure at Martin Station decreased to 2,492 kPa; within one minute, the pressure dropped further to 1,999 kPa.
PG&E dispatched a crew at 6:45 pm to isolate the ruptured pipe section by closing the nearest mainline valves. The upstream valve was closed at about 7:20 pm, and the downstream valve (at Healy Station) was closed at about 7:40 pm. Once the ruptured section was isolated and the gas flow was stopped, the resulting fire from the damaged pipeline self-extinguished. Later that evening, PG&E isolated the gas distribution system serving residences in the area, and within a minute of stopping the gas flow at about 11:30 pm, fires from escaping natural gas at damaged houses went out. The NTSB reports that its initial investigation of the pipe segments involved have shown that there were longitudinal fractures in the first and second pup of the ruptured segment, and a partial circumferential fracture at the girth weld between these two pups. There was also a complete circumferential fracture at the girth weld between the fourth and fifth pups in the ruptured segment. The longitudinal fracture in the first pup continued into the pipe, ending in a circumferential fracture in the middle of the pipe. It will take some time for the NTSB investigation to establish the final cause of this incident. Meanwhile, PG&E has reacted fast and responsibly, and has rapidly set up considerable funding to help the residents of San Bruno. The company has also introduced its Pipeline 2020 programme, the five areas of which will strengthen the utilitys 67,425 km of gas distribution pipelines, and 10,300 km of gas transmission pipelines, through a combination of targeted investments, research and development, improved processes and procedures, and tighter co-ordination with public agencies according to a company statement. With relation to encroachment, it is certainly not unknown for developers to have no idea that they are constructing new homes across hazardous pipelines. Vigilant operators are well aware of this issue, and work hard to maintain safe distances and rights-of-way. Increased internal inspection, route walking and overflying are all carried out, but the problem of how to manage a pipeline that was in the country and is now in the town is becoming seriously significant. The issue of encroachment is certain to be a key industry issue now and in the future.
ISSUE 006
DECEMBER 2010
d up
ALL WRAPPED UP
Europe
ISSN: 1837-1167
Rio Pipeline
Conference & Exposition
2011
Athabasca River
SUNRISE ENERGY SITE
TWP-095
September 20-22
FORT MacKAY
ATHABASCA TERMINAL
TWP-092
Steepbank River
NOREALIS PIPELINE
Clearwater River
FORT McMURRAY
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ANZAC
Gregoire Lake
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TWP-086
CHEECHAM TERMINAL
TWP-083
QUIGLEY
PROPOSED NOREALIS PIPELINE WOODLAND PIPELINE-CONSTRUCTION TO BEGIN LATE 2010 WAUPISOO PIPELINE ATHABASCA PIPELINE
September 2010
TWP-080
Christina River
CHARD
881
Bohn Lake
CONKLIN
RGE-12W4 RGE-9W4
Christina Lake
RGE-06W4 RGE-03W4
TWP-077
Norealis Pipeline
Enbridge will construct a 112 km, 24 inch diameter pipeline from Hartley to the companys Cheecham Terminal as part of Huskys Sunrise Oil Sands Project, located in Alberta. Under the contract Enbridge will also construct a new originating terminal at Hartley, additional tankage at Cheecham, and provide additional pipeline transportation services on its existing Regional Oil Sands System for up to 90,000 bbl/d of diluted bitumen produced from Phase 1 of the Sunrise project. The estimated cost of the project is approximately $US475 million with an initial capacity of 90,000 bbl/d, expandable to 270,000 bbl/d. Subject to obtaining regulatory approval, RoW clearing is expected to begin in late 2011/early 2012. Pipeline construction is
(Line 26) by EEP, and the construction of two new pumping stations and enhancements of the pipeline north of Berthold. It is expected that the project will begin construction in mid-2011 and be operational by early 2013. The Canadian portion of the Portal Link (Line EX-02) will be extended with the construction of a new 121 km, 16 inch diameter pipeline from Steelman, Saskatchewan, to the Enbridge terminal at Cromer, Manitoba. Enbridge said that it is anticipated that the Canadian section of the project will begin construction mid-2012 and be completed and in-service in early 2013. Tenders for both the US and Canadian portions of the project are expected to be announced between the second quarter of 2011 and the first quarter of 2012.
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Fabrication and installation of a subsea valve manifold; and, Dredging works to achieve pipeline burial. The project will provide enhanced export facilities from the Fao Terminal near Al Basrah, and forms a major part of the South Oil Companys strategic redevelopment programme for Iraq. Leighton Offshore will use its vessels, Eclipse, Stealth and Mynx, to complete the project. The contract forms part of the Iraq Crude Oil Export Expansion Project which is developing offshore loading facilities to enable export capability of 4.5 MMbbl/d of oil.
JAN 2011
FEB 2011
Leighton Offshores Stealth vessel, which will be used to complete work for SOC in the Persian Gulf.
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January 2528 January 31 February 4 January 31 February 4 Subsea Production Systems Engineering (Aberdeen) Defect Assessment in Pipelines (Amsterdam) In-line Inspection of Pipelines (Amsterdam) February 1 February 3 Subsea Pipeline Engineering Course (Amsterdam) Defect Assessment in Pipelines (Houston) February 1415 February 1415 February 1415 February 1415 February 1415 February 1415 February 1415 February 1415 March 1718 March 2125 DOT Pipeline Safety Regulations Overview and Guidelines for Compliance (Houston) Pigging & Inline Inspection (Houston) Pipeline Repair Methods / InService Welding (Houston) Introduction to Excavation Inspection & Applied NDE for Pipeline Integrity Assessment (Houston) Performing Pipeline Rehabilitation (Houston) Stress Corrosion Cracking in Pipelines (Houston) Advanced Pipeline Risk Management (Houston) Microbiological Corrosion in Pipelines (Houston) Onshore Pipeline Engineering (Houston) April 2529 April 2529 Deepwater Riser Engineering Course (Houston) Subsea Pipeline Engineering Course (Houston)
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Colombia moves toward construction of its longest oil pipeline Maintaining Nigerias pipeline integrity
Nestoil has completed commissioning activities on Spread A of the 97 km Nembe Creek Oil Pipeline, which transports crude oil from the Bonny Export Terminal to Nigerias Atlantic coast as part of a programme to replace ageing pipelines in the Niger River delta. A new company has been incorporated in Colombia to construct and operate a new oil pipeline, which will run from the Casanare Department to the port of Coveas in order to facilitate oil exports from the Llanos region, considered one of the most prospective regions in Colombia.
he proposed Bicentennial Pipeline will be owned and operated by newly-formed company, Oleoducto Bicentenario de Colombia. The shareholders of the company are Ecopetrol (55 per cent), Pacific Rubiales (32.88 per cent), Petrominerales (9.65 per cent), Hocol (0.96 per cent), C&C Energa, Rancho Hermoso Canacol Energy Ltd and Vetra Exploracion & Produccion Colombia SAS (0.5 per cent each). The pipeline will consist of 42 inch and 36 inch diameter pipe, and have a capacity of 450,000 bbl/d of crude oil. The project will be constructed in three stages. The first stage includes the laying of 226 km of pipe from Araguaney to Banadia as well as infrastructure upgrades at the port of Coveas. Stage two of the project will see 387 km of pipe laid from Banada to Ayacuch, while the final stage will see construction of the 310 km section from Ayacucho to Coveas. The entire project is estimated to cost $US4.2 billion. An Ecopetrol spokesperson said that the bidding for the engineering, procurement and construction contact has closed and that the contract will be awarded soon. The pipeline is expected to be operational by 2012.
he existing Nembe Creek trunkline collects crude oil from 14 oil pumping stations across the Nembe Creek, Krakama, Awoba, Ekulama and San Bartholomew oil fields and transport it to the Cawthorne Channel field and Shell Petroleum Development Company (SPDC) of Nigerias Bonny Export Terminal for dehydration and export. The replacement pipeline has a greater capacity than the existing pipeline to accommodate a planned production increase, and security of the pipeline has been improved to stop crude oil theft. As a result of deterioration in the integrity of the existing trunkline due to the harsh Niger Delta environment, vandalism and agerelated deterioration, the replacement project was initiated to improve, modernise and restore the technical integrity of the facilities. The project involved the construction of three sections of pipeline including: 5 km of 12 inch diameter pipeline from the Nembe Creek III manifold to the Nembe Creek tie-in manifold; 44 km of 24 inch diameter pipeline from Nembe Creek to San Bartholomew; and, 46 km of 30 inch diameter pipeline from San Bartholomew to Cawthorne Channel. Spread A involved the construction of a 49 km pipeline, consisting of the 12 inch diameter, 5 km segment and the 24 inch diameter, 44 km segment. This section is located in the harsh mangrove swamp terrain of the Niger Delta region of Nigeria, and traverses five neighbourhoods consisting of approximately 100 communities in both the Bayelsa and Rivers states in the Niger Delta region.
The installation required six major river crossings, the longest being approximately 1.1 km. Another 44 river and creek crossings of various sizes required extensive dredging activities, and the fabrication and site installation of one main tie-in manifold, six block valve platforms, four pig traps and associated piping. The new line runs parallel to the existing Nembe Creek Pipeline, within an expanded right-of-way (RoW). The existing line is now to be decommissioned. The contract for Spread B of the pipeline 46 km of 30 inch diameter pipeline from San Bartholomew to Cawthorne Channel was awarded to Saipem in 2007.
River Niger
The location of Shell Petroleum Development Company of Nigerias Bonny Export Terminal.
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he 470 km OPAL project is being built by Wingas on behalf of OPAL NEL Transport GmbH and E.ON Ruhrgas AG. It will run from the German Baltic Sea coast through Mecklenburg-West Pomerania, Brandenburg and Saxony to the Czech Republic. With a 56 inch diameter and a capacity of 36 Bcm/a, the OPAL Pipeline is the largest natural gas pipeline to be laid in Europe. We are very satisfied with the progress of the construction work so far, said Managing Director of OPAL NEL Transport Bernd Vogel. Despite the long winter and difficult weather conditions at the start of the year, we are on schedule. We want to bring OPAL on stream in October 2011 together with the Nord Stream Pipeline, he said. A significant portion of the construction work in Mecklenburg-West Pomerania and
Saxony is expected to be completed toward the end of the year. There are currently 2,500 people working on the entire pipeline track between Greifswald and the Ore Mountains. The builders will have to cross 172 roads, four highways, 27 rail lines and 39 rivers and streams before completing the construction work.
The topsoil has been removed from more than 400 km of the pipeline track; over 400 km of pipe has been welded together, said Wingas Chief Construction Manager Michael Muth, detailing the progress of construction work. Mr Muth is confident that the pipeline will be completed on schedule. We have already begun recultivating the farmland in some areas.
Despite the long winter and difficult weather conditions at the start of the year, we are on schedule. We want to bring OPAL on stream in October 2011 together with the Nord Stream Pipeline.
opal net transport managing director bernd vogel
mix of domestic and imported gas. The consortium expects to commission both pipelines between 2013 and mid-2014. The pipelines are expected to cost $US1.3 billion each. GSPL holds a 52 per cent interest in the consortium, Indian Oil Corporation has a 26 per cent stake, and Hindustan Petroleum Corporation Limited and Bharat Petroleum Corporation Limited each hold interests of 11 per cent.
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Pipeline works underway on the OPAL Pipeline.
PIP_HPH.indd 1 22/11/10 5:38 PM
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world wrap
world wrap
Construction commences on South Stream Pipeline in Serbia Willbros to build export pipelines
CB&I has awarded Willbros Group an engineering, procurement and construction contract for 72 km of export pipelines associated with a new gas processing plant to be built in California, USA. The new gas plant, to be owned and operated by Occidental of Elk Hills Inc., will be constructed by CB&I. The project is scheduled for completion in the first half of 2012. Construction on the South Stream Pipeline has begun in the southeastern Serbian town of Nis. The 120 km Serbian section of the pipeline will transport gas 52 km from Nis to Leskovac, and then on to Vranje. The Nis to Leskovac section is expected to be completed by May 2011.
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project Briefs
Project briefs
Dabhol Bangalore Natural Gas Pipeline
PROMOTER: Gas Authority India Limited (GAIL), 16 Bhikaiji Cama Place, R.K. Puram, New Delhi 110066, India. PROJECT SCOPE: This 1,400 km long pipeline will run from Dabhol through Kinjalkarvadi, Kasari, Kharaklat, Tappalkatti Harva, Gadag, Gannaikanahalli, Gullur, Sarajapur, Palmaner, Chittoor, Kattivakkam to Chennai. All works associated with construction of the pipeline from Dabhol to Bangalore have been divided into ten spreads. Included in these are two spur lines, which will extend from Gokak in Belgaum District, Karnataka to Goa and from Sulivara in the South Bangalore District, Karnataka to Bangalore. PROJECT UPDATE: GAIL has awarded pipeline construction contracts for the natural gas pipeline. Punj Lloyd has been awarded the construction contracts for seven of the ten spreads, comprising 820 km of the pipeline. Two spreads have been awarded to KSS-KSSIIPL Consortium and the remaining spread has been awarded to Advance Stimul Consortium. PIPELINE LENGTH: 1,400 km PIPELINE CAPACITY: 16 MMcm/d of gas EXPECTED COMPLETION DATE: March 2012
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Region Review
for me to carry on the success of CNOOC, and deliver long-term return to shareholders. Ill do my best, said Mr Hua.
Gordie Tieberg.
John M. Katok named Willbros Upstream International Operations Senior Vice President
John M. Katok has been named Willbros Upstream International Operations Senior Vice President. In this role, Mr Katok will be responsible for the companys upstream international business development and operations outside the United States and Canada. Mr Katok joins Willbros after two years with Global Industries where he served as Worldwide Business Development Senior Vice President and earlier as Middle East Business Unit Vice President. Mr Katok also held the position of Technip US Commercial Operations Vice President for five years and spent 25 years with Kellogg, Brown & Root and its predecessor companies in a variety of roles.
at Caterpillar offices in Chile, Peru, France, Germany, Austria, and various US and Canadian locations. Cat Financial Territory Manager Anthony Zaccari will be taking over the pipeline financing business effective 1 November 2010.
Construction is underway on the 1,224 km Nord Stream Pipeline, which involves the construction of two offshore parallel 48 inch pipelines, each with a capacity of 27.5 Bcm/a. The pipeline will establish a direct link between Russias vast gas reserves, via Portovaya Bay in Russia, and the European gas transportation systems, and will deliver gas to Belgium, the United Kingdom, Germany, Denmark, the Netherlands, France, and the Czech Republic.
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Region Review
Region Review
Possible Nabucco IGI link German utility and Nabucco Pipeline stakeholder RWE has proposed to link the Nabucco Pipeline to the proposed Interconnector Greece Italy (IGI). RWE said that it would be possible to connect IGI to Nabucco at two points; either in Turkey via a short interconnector or in Bulgaria through the Bulgaria-Greece Interconnector. According to RWE the connection of the two pipelines would open Greece and Italy to the secure and stable transportation route of Nabucco.
Construction is underway on the OPAL Pipeline in Germany.
At the landfalls at Portovaya Bay, Vyborg, and at the German Landfall at Lubmin, near Greifswald in Germany, both strings of the pipeline have also already been constructed and pulled ashore. The Castoro Sei pipelay vessel has commenced pipelaying activities in Danish waters after picking up the pipeline in German waters where the flat-bottomed Castoro Dieci pipelay vessel had completed the difficult shallow-water section at and near the German landfall ahead of schedule. At the other end of the pipeline, the worlds largest pipelay vessel, Allseas Solitaire, has reached the Finnish Exclusive Economic Zone after completing a key section of the pipeline in Russian waters. The pipeline is on schedule to start transporting gas from Russia to customers in the EU in late 2011. Construction works are on schedule for the 470 km Ostsee Pipeline AnbindungsLeitung (OPAL) in Germany. The pipeline will run from the German Baltic Sea coast through Mecklenburg-West Pomerania, Brandenburg and Saxony to the Czech Republic, and is one of two pipeline projects proposed to connect the Nord Stream Pipeline to the existing pipeline grid in middle and Western Europe, the other one being the Norddeutsche Erdgas Leitung (NEL) Pipeline. The OPAL Pipeline is being built by Wingas on behalf of OPAL NEL Transport and E.ON Ruhrgas AG and is scheduled to come on stream in October 2011.
The NEL Pipeline is a planned 440 km natural gas pipeline in Germany, which will run from Greifswald to Rehden. It will connect the Nord Stream Pipeline with the existing Rehden Hamburg and MIDAL gas pipelines. Together with MIDAL, the NEL Pipeline will create a GreifswaldBunde connection. The majority of pipeline works are scheduled to be completed during 201112 and the pipeline is expected to come online in 2012. The invitations of tender for the construction work of the NEL Pipeline are currently underway. Serbia has commenced construction on a 120 km pipeline, which will transport gas from Nis to Leskovac and then on to Vranje. It is anticipated to connect with the proposed South Stream Pipeline. Gazproms proposed South Stream Pipeline will include a 900 km offshore section traversing the Black Sea from the Beregovaya compressor station on Russias southwest coast to the Bulgarian coast. From Bulgaria the pipeline will transport up to 63 Bcm/a of natural gas to south and central Europe. Two possible routes are under review for South Streams onshore section from Bulgaria one heading northwest and the other heading southwest. A feasibility study is scheduled to be completed in early 2011, and construction is expected to start in 2013, with a commissioning date anticipated for late 2015. Intergovernmental agreements have been signed with Bulgaria, Serbia, Hungary, Greece, Slovenia, Croatia and Austria in order to implement the projects onshore section beyond Russia.
Governments position, The Bulgarian Government hasnt made a final decision regarding the construction of the Burgos Alexandroupolis Oil Pipeline. Bulgaria is going to wait for the completion of the environmental assessment of the oil pipeline, and only then will it make a final decision. A spokesperson for Greeces Deputy Minister of Environment, Energy and Climate Change said that the final investment decision is expected to be taken during the second half of 2011 after the approval of the environmental studies. Depending on the timely approval of the environmental studies by the governments of Greece and Bulgaria, construction on the pipeline is scheduled to commence by November 2013 with a scheduled commissioning date of the second quarter of 2016.
Gazproms proposed South Stream Pipeline will include a 900 km offshore section traversing the Black Sea from the Beregovaya compressor station on Russias southwest coast to the Bulgarian coast.
supplying natural gas directly from Algeria, without requiring transit through third countries.
The Gja platform, located in the Norwegian North Sea. The Gja Pipeline is nearing completion to enable gas export from this platform. Image courtesy of Statoil.
The respective engineering works have been ordered for the two feeder lines. Depending on the exact routes of the proposed feeder lines, the total length of the pipeline project is estimated to increase to approximately 4,000 km. The pipeline promoters are understood to have decided against constructing a feeder line to the Turkish Iranian border, citing the current political situation in Iran. Project shareholders include OMV Gas&Power, MOL, Transgaz, Bulgarian Energy Holding, BOTAS and RWE. The final investment decision for the 800 km Interconnector Greece Italy (IGI) is expected to be made in December 2010. All environmental authorisations are in place for the project, which will consist of a new 210 km offshore pipeline that will connect the Greek and Italian natural gas transportation systems and a 590 km pipeline to be constructed onshore in Greece. The offshore section of the IGI, known as the Poseidon project, will complete the natural gas corridor through Turkey, Greece and Italy following the inauguration of the 296 km Turkey Greece Pipeline in 2007. The Interconnection Turkey Greece Italy (ITGI) will allow Italy and the rest of Europe to import natural gas from the Caspian Sea and the Middle East. The onshore section of the Turkey Greece Italy pipeline that remains to be implemented in Greece will be constructed by Greeces public gas corporation DEPAs subsidiary The Hellenic Gas Transmission System Operator (DESFA) and will run approximately 590 km from Komotini to the IGI Poseidon metering station in Thesprotia. The 42 inch diameter pipeline will have a capacity of 15 Bcm/a of gas and will includes the construction of two compressor stations, one at Komotini and one at Nea Mesimbria, Thessaloniki. DEPA and Edison have entered discussions with natural gas suppliers in the Caspian area, specifically Azerbaijan, for the supply that will be transmitted through the pipeline system. Front-end engineering and design work commenced in April 2010 and the service control verification and implementation study commenced in July 2010. The tender for pipe supply is progressing after completion of the pre-qualification stage, while the detailed marine survey tender is being finalised. Construction is scheduled to begin in 2012 and it is anticipated that the pipeline will be brought online in mid-2015.
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Region Review
Romania, Azerbaijan and Georgia have signed a Memorandum of Understanding for the Azerbaijan Georgia Romania Interconnection (AGRI) LNG Project, which would include the construction of a pipeline to transport gas from Azerbaijan to Georgias Black Sea coast. From here the gas would be liquefied and shipped to Romanias coast where it would be re-gasified and delivered into Romanias pipeline system and shipped to European markets. Proponents from both the AGRI LNG project and the Nabucco Pipeline will be seeking commitments from Azerbaijan to secure access to the countrys finite gas resources. Albanian Ministers and government officials have endorsed the revised route of the Trans Adriatic Pipeline (TAP) through Albania. Traversing a total distance of 520 km, the pipeline will originate near Thessaloniki, Greece, and cross Albania and the Adriatic Sea, before terminating near Brindisi, Italy. The pipeline will have an initial capacity of 10 Bcm/a of natural gas. TAPs construction schedule aligns with the development of the Shah Deniz gas field in Azerbaijan. The project is currently at the front-end engineering design stage, with preparations underway for the final investment decision and construction. TAP will transport gas from the Caspian Sea and Middle East regions to Italy, through Turkey, Greece and Albania. The pipeline will have a capacity of 10 Bcm/a. The proposed White Stream Gas Pipeline will provide a link between the South Caucasus Gas Pipeline in Georgia and Romania. The length of the pipeline is estimated to be 1,100 km, which includes a 700 km offshore section to be constructed across the Black Sea in water depths in excess of 2,000 m connecting Georgia to Crimea in the Ukraine. A spokesperson for the consortium said that the feasibility studies carried out have proven the technical, economic and legal feasibility of the project. Detailed routing studies are now moving forward, particularly for the Black Sea crossing, including a reconnaissance marine survey and environmental impact studies. The project is currently on schedule for a final investment decision towards the end of
Getting (inter)connected
Some of the pipeline projects proposed or underway to connect Europes gas transmission system: FGSZ declared the results of binding Open Season for the Slovakia Hungary Interconnector as unsuccessful for the Hungarian part of the planned interconnection. Despite the result the company will analyse further alternatives to have the Slovakia Hungary Interconnector project potentially financed and constructed in another way. The proposed Poland Lithuania gas pipeline would link the Baltic states of Estonia, Latvia and Lithuania to the Polish gas supply and transmission system. Polands gas transmission operator Gaz-System and Lithuanias Lietuvos Dujos will conduct a feasibility study to determine the possibility of constructing a gas pipeline between the two countries. Bulgarian Energy Holding, Greeces DEPA and Italys Edison International Holding have reached a development agreement regarding the construction of the Interconnection Pipeline Greece Bulgaria (IGB). The 160 km IGB, proposed to transport gas from Komotini, Greece, to Stara Zagora, Bulgaria will have a capacity to transport between 3 and 5 Bcm/a and is due to come into operation in 2013. Bulgarias Minister for Economy, Energy and Tourism Traycho Traykov, and Serbias Minister for Mining and Energy Petar Skundric have signed a joint statement paving the way for the proposed 180 km Bulgaria Serbia Gas Pipeline. The pipeline would have a capacity of 2 Bcm/a starting in Nis, Serbia and cross the border near Dimitrovgrad in Bulgaria and would be the first interconnector between the transmission systems of Bulgaria and Serbia. In Spain several gas interconnections are currently under construction: Tivissa Paterna Pipeline, Tivissa Castelnou Pipeline, Zarza Tajo Yela Pipeline, and Yela Villar Arnedo Pipeline. These four interconnections have a total length of 681 km and a capacity of 3.14 Bcm/a and are scheduled to enter into operation by the end of 2012.
A map o routes.
m and N
abucco p
ipeline
2013 with construction starting in 2015 and the first pipeline with 8 Bcm/a capacity becoming operational in 201718, shortly after the start-up of the Nabucco Pipeline. After the initial pipeline is bought online, construction on a further three pipelines of similar capacity will commence to meet expected export demand of both Azerbaijan and Turkmenistan. Transnafta has proposed a 1,320 km pipeline to transport crude oil from the Caspian and Black Sea region to the PanEuropean Oil Pipeline (PEOP). PEOP is a newer manifestation of a project formerly known as the Constanta Pancevo Omisalj Trieste Pipeline, and is designed to take Caspian and Russian oil from the Black Sea port of Constanta in Romania, through Serbia, Croatia and Slovenia, to Trieste in Italy. From there it would join with the existing Trans-Alpine Pipeline and the Italian pipeline network, with any excess oil to be shipped from Genoa in Italy.
North Sea fast facts 21 new petroleum fields were discovered in the North Sea in 2009 alone Approximately 155 MMcm of oil equivalent was produced in North Sea fields last year Norwegian gas is exported to markets through a network of pipelines approximately 7,800 km long
The pipeline would transport approximately 1.2 MMbbl/d of oil to supply Italy and central Europe, with around nine per cent of the oil to be supplied to Serbia and Croatia. The feasibility study for the project had originally estimated that the pipeline would commence operations in 2011, however no tender for construction works has been announced.
The second pipeline string is pulled ashore at the German Landfall for the Nord Stream Pipeline project.
As part of the gas roundabout project, a new pipeline being constructed is the 485 km, 48 inch diameter, North South Pipeline, which is in two sections. The longer one is in the east of the country and runs from Rysum in northern Germany and Oude Statenzijl in the north of the Netherlands, to Schinnen in the south. The shorter section runs from a new compressor station at Wijngaarden in the centre of the country to an export station at Zelzate in the southwest, on the Belgian border. Meanwhile, the Baltic Gas Interconnector proposed to connect the gas networks of southern Sweden, northern Germany and eastern Denmark is currently under review. Despite receiving authorisation for each of the three countries involved in the project, the possibility of the Nord Stream Pipeline being extended to the Swedish gas pipeline network combined with a change in Swedens energy priorities to promote renewable energy options, has led to a delay in the project, originally anticipated to enter into operation in 2010. The Baltic Pipe aimed at connecting the Danish and Polish gas systems to Norwegian gas resources has been delayed after the Skanled Pipeline project was suspended. The gas pipeline would be offshore with an approximate length of 3845 km, and would have an estimated capacity of 2.5 Bcm/a of gas.
The Skanled Pipeline aims at connecting the Danish and Swedish gas systems to Norwegian gas resources. The planned pipeline will go from Karsto, on the Norwegian West Coast, to the Norwegian East Coast, and on to Sweden and Denmark. The pipeline is expected to have a capacity of 8.3 Bcm/a and a total length of 1,130 km, including an 860 km offshore section, a 250 km Danish onshore section and a 16 km Swedish onshore section. Though feasibility studies have been performed, the project was suspended in April 2009 due to increased commercial risk combined with the global economic developments that have given an uncertain view on future gas demand. The project may be re-launched if commercial conditions become more favourable in the future.
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Pipeline equipment
All Caterpillar pipelayers can be equipped with components suitable for Arctic conditions, including engine oil, coolant, transmission, final drive, drawworks and undercarriage components.
A pipelayer for every season: choosing the right equipment for your next challenge
Pipelayers and sidebooms are integral to pipeline construction and often have to work in extreme or hazardous conditions. PipeLine Machinery International Vice President Product Support Lindley Imeson describes some of the features required for working in Arctic and mountainous conditions, explaining how efficient pipelaying can still be achieved with the right equipment and know-how.
ipelines are often constructed in hazardous conditions, including extreme hot and cold temperatures, through mountainous and rocky terrain, and in wet areas. As such, pipelayer machinery needs to be engineered for a long life in extreme conditions. PipeLine Machinery International (PLM) distributes Caterpillar pipelayers such as the large 587T and 583T models, which mirror the Caterpillar D8 tractor body with a heavy, strong and durable mainframe. Full box sections, steel castings and continuous rolled rails provide durable support to the undercarriage, elevated final drives and other integral frame components. The elevated sprocket undercarriage effectively isolates the drive train components from ground-induced impacts. The undercarriage is designed for optimised machine balance, performance and component life. The ACERT engine technology used in all new Caterpillar purpose-built pipelayer models ensures optimum engine
performance and fuel-efficiency while meeting EPA Tier 3 and EU Stage IIIA engine exhaust emission regulations.
electric water jacket heaters can be added for longer component life and additional cab heat for extreme cold conditions. The tractors are also equipped with solid engine enclosures, under hood air intake and reversible fans for added heat retention. Enhanced lighting solutions for operation in decreased daylight operations are available for added safety. The quality of steels used in the mainframe, booms and counterweights helps to avoid the common brittle steel problem associated with working at temperatures around -45 degree Celsius. The 583T, 587T and PL61 are all available with enclosed cabs. The cabs are designed for operator comfort and productivity in any climate, and are fully insulated with a heater (or can be equipped with air conditioning). Caterpillar cabs are designed with a maximum glass area (the dual pane option is available for cold weather) for excellent visibility.
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Pipeline equipment
Pipeline equipment
increases, the smooth operation of the hydraulic drawworks allows for precise and co-ordinated handling of 30 inch diameter and above pipe in all wall thicknesses in adverse conditions. With a lifting capacity of 18,145 kg, the PL61 is well-suited to lifting smaller size pipe generally below 16 inch in diameter. This unit has been designed to be ideal for gathering systems or for urban installations where transportation to the site and onsite clearances require a more compact machine. With counterweight and boom removed, the PL61 is a mere 2.9 m in width with a shipping weight of 16,070 kg.
Mountainous conditions
Stability during the lowering-in process in sloping conditions is a challenge requiring strict attention to safety, machine tolerances and operator capability. Numerous factors impact lifting capacity on slopes, including the length of the boom, the load, the load overhang, the load swing, ground conditions, operator experience and track tension. The higher the load, the less capability the machine has in sloping conditions. In order to mitigate this, the number of pipelayers used or the size of pipelayers should be increased so that the relative load per pipelayer is reduced. The length of the sideboom used also has an effect on pipeline installation in mountainous terrain: the shorter the sideboom, the better the slope performance of the pipelayer. For example, a 7.3 m sideboom will outperform an 8.5 m sideboom by approximately 3 degrees, and a 6 m boom will outperform an 8.5 m sideboom by approximately 6 degrees. Increasing the load overhang has a positive impact on fore-aft slope capability. Keeping the boom further extended on a 20 degree slope will result in the load line location being closer to the rear of the pipelayer. The key is to always carry the load as far out as possible without impacting the side tipping point.
A Caterpillar pipelayer working in desert conditions.
Caterpillar pipelayers are fitted with ACERT engine technology and meet EPA Tier 3 and EU Stage IIIA engine exhaust emission regulations.
The higher the load, the less capability the machine has in sloping conditions. In order to mitigate this, the number of pipelayers used or the size of pipelayers should be increased so that the relative load per pipelayer is reduced.
A skylight window is placed for viewing the boom and upper block, and side windows are screened to allow for ground communication and better ventilation.
Lifting capacity
The 587T has a lifting capacity of 91,625 kg and is powered by the Cat C15 ACERT engine performing at full-rated net power of 366 horse power (hp) at 1,800 rpm. The 583T has a lifting capacity of 63,504 kg and uses the same engine performing at a full-rated net power of 310 hp at 1,850 rpm. The large displacement and high-torque rise provides the 587T and the 583T with the power needed for the safe handling and consistent multi-functional operation required for poor ground conditions, while managing the less flexible characteristics of cold pipe. As the pipe size and tractors required
Load monitoring
Experienced pipelayer operators can read a pipe load very effectively. However a reliable and precise pipelayer system is important when ground conditions change, when less experienced operators are at the controls or when tracks shift on loose rock. Distributed exclusively by PLM, the Pipelayer System by Cranesmart eliminates guesswork, and is designed to provide operators with the precise load-management information required for a safe and efficient job. All information regarding the load,
slope, overhang, lift capacity and two-block alarm are integrated through Cranesmarts wireless technology into a large, easy-to-read operator display panel. Operators have the information required to help prevent tipovers, roll-overs and equipment damage due to overloading and extreme slope operations.
Pipeline training
Pipeline projects are often located away from large training facilities. The contractors equipment fleet is a diverse mix of types, makes and models, making operator training hit and miss. A construction contractors safety programmes needs to be disseminated to a large temporary workforce, often in a multi-language format, and owning companies and regulators have specific requirements for training.
PLM has teamed with ek pass to provide solutions to the training challenge. The training company is PLMs exclusive provider of pipeline operator training and related consulting services around the globe. ek pass provides training services on equipment from over one hundred manufacturers. Training is focused on improved operator and right-of-way safety, productivity and reduced maintenance costs. Operator training is usually provided on a pipeline spread using the equipment that the trainees will be operating, saving time and increasing the relevancy of the training. The professional consultants with ek pass have been delivering award-winning, customised instructor-led training on client sites worldwide.
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industry news
The companys machines are constantly being upgraded. Machines can be tailored to clients needs.
Safety features
WorldWides padding machine at work for Nacap Australia.
WorldWide Machinery recognises the importance of safety on a pipeline construction spread. The companys padding machines were the first padding machines to be fitted with roll-over protection structures. Recently, the company has added cameras to the back corners of each machine to reduce blind spots. Combined with the wide front screen, optimal vision is achieved. The operator can control the machine entirely from the cabin, which is fitted with a dust filter and air conditioning. The SPD-450 also has two operator platforms in the cabin so that the operator can work on both sides of the machine. This gives the operator a much better view of what is going on in the ditch, says Mr Hafemann.
WorldWide ensures that operators receive appropriate training before using the companys machines. Technicians are sent with delivery of the machine to help with assembly and train operators in proper usage and maintenance. The training takes approximately one week. The technicians take the new operators for a dry test run, then a test run together. The hardest part is getting used to driving with the machine on the backfill, and you stay on the backfill side when you have a big ditch. The backfill pile can be around 3 m high and the ditch can be around 2 m deep, so you can get quite a surprise if you look down at the ground, says Mr Hafemann. WorldWide Machinery also manufactures pipelayers, bending machines, earthmoving equipment, pipe bevelling and cold cutting machines and vacuum pipe lifting equipment.
SPD-450 features Engine model: Caterpillar C-13 ACERT Tier 4 Interim Stage III B Power: 328 kW Main pumps: Bosch Rexroth Transmission: hydrostatic Motors: hydromatic Gearbox and final drives: Bosch Rexroth Undercarriage: Berco Screening area: 8.4 sq m Fuel tank: 720 litres Hydraulic system circuit: 800 litres For more information visit www.worldwidemachinery.com
Padding machines can be built for pipeline projects from 6 to 60 inches in diameter.
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industry news
pipeline. These reduced energy costs can provide a financial payback within three to five years of service. It may also be possible to achieve further savings by reducing the number of compressor stations, or compressor size and capacity. The Zamoranos 2002 study concluded that fuel gas costs for the compressor stations situated along the 1,200 km length of the Atacama Gas Pipeline, were 26.9 per cent lower on the coated section of pipeline than on the uncoated section.
ver the past 40 to 50 years it has become standard industry practice to apply both internal and external pipeline coatings. The concept of internally lining gas pipelines known as internal flow coating was first developed in the 1950s to counter the adverse effects on pipeline capacity, operation and pumping costs caused by the rough internal surface of steel pipes and the build-up of deposits and corrosion products. Externally, fusion-bond epoxy (FBE) coating systems were introduced in the 1960s to form a barrier between the metal surface of the pipe and the surrounding environment. Since then, 3M has supplied more than 170,000 km of internal flow coating and more than 135,000 km of FBE for pipeline projects worldwide.
have also been conducted elsewhere, demonstrating a 1421 per cent increase in pipeline capacity for internally-coated pipelines. While these studies indicate a significant increase in flow capacity when internal flow coating is used, it is generally accepted that even a one per cent improvement in throughput provides the financial justification for internal coating.
Single-layer FBE has proven performance in both onshore underground and offshore subsea environments. The product is an effective corrosion-resistant barrier for line pipe, field joints, fittings and bends. Since its first use in New Mexico in 1960, FBE coating has remained the external pipe coating of choice in North America. Since their introduction in 1991, duallayer powder coatings have also gained popularity for use with pipelines operating at a high temperature. A relatively lowcost solution, dual-layer FBE offers the performance and installation characteristics of single-layer FBE, while also providing superior damage resistance with only a minimal reduction in flexibility. The 1980s saw the introduction of threelayer polyethylene or polypropylene coatings in Europe. These coatings comprise a FBE primary coating, a polyolefin-adhesive or tielayer and a polyolefin topcoat, and are based on earlier single-layer and two-layer systems. The thick layer of polyolefin, which provides a high level of damage resistance, is deemed to facilitate installation under conditions of harsh environments or inexperienced handling in the factory or onsite.
Corrosion protection
A major issue with uncoated pipelines is corrosion. When uncoated pipelines are flooded with seawater, the extent of corrosion can be considerable. A report completed in 2006 by John Grover of BJ Process & Pipeline Services noted that an estimated 157,000 kg of corrosion debris was removed from a 161 km section of 36 inch diameter pipe with a wall thickness of 14.3 mm, only three months after total immersion in tropical sea water. As increasingly stringent regulations governing the disposal of scale and corrosion debris into the environment are being applied, it has become industry practice to blast clean the pipe and apply an internal flow coating prior to the pipe being delivered to site. This prevents corrosion from reforming, eliminating the need for additional pre-commissioning work.
We have
3M Corrosion Protection Products, 3M United Kingdom plc, Northallerton, United Kingdom Telephone: +44 (0)1609 780170 Fax: +44 (0)1609 788707 Email: pipecoatings.cpp.uk@mmm.com www.3M.com/corrosion www.3M.co.uk/scotchkote
(12022)CPP_Oil&Gas 185x125_ad.indd 1
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industry news
Weld smarter: CRC-Evans new welding system with laser vision technology
CRC-Evans Automatic Welding has developed a new welding system that incorporates laser vision welding and inspection technology. Designed to reduce the duration of the pipeline welding process while increasing weld quality, the Vision System provides new levels of flexibility in the field.
omponents of CRC-Evans Vision System include the V Weld, an external welding machine with adaptive weld technology; the V Bevel for bevel inspection at the beveling station; the V Root for root inspection at the welding station; and, the V Purge a fully automatic purge control system to control and monitor the purge chamber parameters. All the equipment utilises laser vision technology. We engineered laser vision technology into our welding technology to enhance productivity in narrow groove pipe joints and increase weld quality through pre-weld and post-weld in-line inspection. It raises the bar for the whole industry, said New Product Development Vice President Shankar Rajagopalan.
Held under the Patronage of His Excellency Dr. Abdul Hussain bin Ali Mirza, Minister of Oil & Gas Affairs and Chairman of the National Oil & Gas Authority, Kingdom of Bahrain
PLATINUM SPONSOR
ORGANIZERS
Join leaders in the international pipeline industry as they converge for the Best Practice in Pipeline Operations and Integrity Management Conference and Exhibition in Bahrain.
CONFERENCE
Six technical streams covering a wide range of subjects will run over the two and a half day event (and presented by industry leaders). Planning, design, construction and materials Operations and maintenance Asset integrity management Inspection and cathodic protection Repair and rehabilitation Automation and control Leak detection Paper abstracts are now being accepted.
EXHIBITION
A comprehensive exhibition will be part of the event, allowing companies from around the world to showcase their products and services. Contact us today to book your space.
NETWORKING
Throughout the event there will be ample opportunities to network with participants to further your business relationships. Meet with industry leaders from around the world.
The V Bevel.
The Vision System will be used for the first time in the field as part of an Incalloyclad project in Norway. CRC-Evans provides pipeline construction equipment, automatic welding systems, managed subsea services, field joint coating and heat treatment, and non-destructive testing. Based in Houston, Texas, CRC-Evans has offices in North America, Europe, South Africa and the Middle East.
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www.pipelineconf.com
Terrain review
Terrain review
new line construction, vegetation control, auxiliary transport vehicle, and wildfire suppression. Sunland Construction has completed two major 42 inch pipeline spreads for Cheniere Pipeline's Creaole Trail Pipeline in Louisiana, totalling 68 km, with the help of Sunland-Kori amphibious undercarriages. Sunland Construction also used Sunland-Kori amphibious undercarriages while working on 27 km of 42 inch pipeline for the Golden Pass Pipeline in Texas. Sunland Construction Gulf Coast Division Manager Louis Ledet Jr says that during those projects amphibious equipment allowed excavators to manoeuvre in marsh and swamp areas without disturbing the terrain. This is an important characteristic as contractors today are responsible for complying with strict environmental standards. Being versatile is key when working in swampland, and amphibious equipment manufacturers offer a variety of boom-andstick options, buckets, and other attachments to meet the demands of any operation. Many upper attachments are interchangeable and mounting can be done in a few hours. Other accessories, such as tree cutters, are designed to be quickly switched with the bucket. In addition to excavators,
other heavy equipment can be mounted on amphibious undercarriages. Some examples of options include draglines, backhoes, geophysical drills, and personnel/cargo carriers, says Mr Ledet Jr.
within these hydrologically and ecologically sensitive areas. RoW clearance and operation RoW clearance and operation, temporary sediment control and trench dewatering should all be undertaken with the addition of special measures to protect wetlands and marsh areas and to minimise the impact to the environment. As outlined in Sakhalin Energys EIAA, constructors should limit construction equipment operating in wetland areas to that required for RoW clearing, trenching, installation of the pipeline, backfill of the trench and RoW reinstatement. Vegetation should be cut just above ground level so that the plants existing root systems are left in place. Any cut vegetation should then be removed from the wetland for disposal. It is also important that the pulling of tree stumps and grading activities are limited to the area directly over the trench line. When clearing the RoW, workers should not grade or remove stumps or root systems from the rest of the construction RoW, unless an environmental inspector has determined that safety-related construction constraints require grading or the removal of tree stumps from those areas. The EIAA also directs constructors to refrain from using rock or soil imported from outside the wetland, and from using tree stumps or brush riprap to support equipment on the construction RoW. According to Sakhalin Energy If standing water or saturated soils are present, or if construction equipment causes ruts or mixing of the topsoil and subsoil in wetlands, constructors should use low ground-weight construction equipment, or operate normal equipment on timber riprap, prefabricated equipment mats, or terra mats. Temporary sediment control Another consideration for contractors constructing pipelines through wetland, swamp or marsh environments is temporary sediment control. Sakhalin Energys EIAA recommends that sediment barriers are installed across the entire construction RoW at all wetland crossings, where necessary, to prevent sediment flow into the wetland. Removable sediment barriers can be removed during actual construction, but must be re-installed after construction has stopped for the day and/or when heavy precipitation is imminent.
Getting equipped
Choosing the right equipment is essential to avoid getting bogged down when installing pipelines in marsh, swamp and wetland terrain. Three manufacturers and distributors of amphibious equipment in North America explain the benefits of amphibious equipment.
Remote access vehicle manufacturer PFM Manufacturing supplies Land Tamer amphibious vehicles to pipeline construction companies in North America and around the world. PFMs Patrick Miller Jr says that the main advantage of using amphibious vehicles for marsh or swamp terrain is their low ground pressure design. They can cross over bogland, mud or swamp without leaving deep tracks and because of the low ground pressure, are much more environmentally friendly than other vehicles. Most amphibious equipment can float in water and this is the major advantage over non-amphibious vehicles. An amphibious vehicle needs to be able to make the transition from hard ground to swamp muskeg, to open water and get you back to your destination safely with minimal problems and minimal hassle, says Mr Miller Jr. US-based amphibious vehicle manufacturer Hydratreks Craig Simonton agrees that amphibious equipment has a range of benefits saying There are many applications and reason to use amphibious equipment in marshes, swamps, and wetland areas. First, the machines are made from
100 per cent aluminium, which provides added durability, ruggedness, and safety over conventional all-terrain vehicles. Second, most equipment is built standard with rubber overthe-tyre tracks that can be used for multiple terrains and surfaces. The tracks lower the ground pressure significantly and allow the vehicles to handle heavy mud, excessive vegetation and debris with relative ease. Due to the rubber track system, the environmental impact is reduced significantly. Most equipment that is used in the industry is very large and weighs several tonnes. Utilising tracks instead of tyres will reduce the ground pressure, keeping the equipment from uprooting the vegetation and allowing the area to recover more quickly. Also, the diesel engines are very clean burning and fuel efficient compared to gasoline engines, says Mr. Simonton. Several small and large companies such as Tennessee Valley Authority, Georgia Power, Texas Gas Transmission, Hydro One, Atco Electric and Xcel Energy are using Hydratrek amphibious equipment on a daily basis for utility and gas projects all across North America. Applications range from right-of-way (RoW) survey and management,
A Hydratrek amphibious vehicle has twin bronze propellers that allow the machine to cross bodies of water in wetland terrain.
Wilco Pipelines backhoe equipment trenches a ditch to accommodate pipe installation in marsh terrain.
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Terrain review
Where wetlands are adjacent to the construction RoW and the RoW slopes toward the wetland, install sediment barriers along the edge of the RoW as necessary to contain spoil and prevent sediment flow into the wetland. These sediment barriers should be removed during the RoW cleanup following pipeline installation. Trench dewatering Finally the EIAA suggest that contractors should dewater the trench (either on or off the construction RoW) in a manner that does not cause erosion and does not result in heavily silt-laden water flowing into any wetland. The Addendum states Remove the dewatering structures as soon as possible after the completion of dewatering activities.
involved a 6 km, 30 inch diameter steel pipeline near Hackberry. The second project was completed for Denbury Resources and involved a 24 inch diameter steel pipeline approximately 21 km in length in the Atchafalaya Basin near Lottie. Wilco Managing Member John Wilson Jr says When there is access from existing public roads a push site is established. Depending on the pipe diameter, the overall site size would be 18 to 30 m wide by 183 to 244 m long. Mats would be staged to provide firm foundation for the equipment and pipe racks. If land access is not available, then several barges would be used tethered together to provide similar area. Once the push site is established, rollers are strategically placed to accommodate random pipe lengths. Various stations are established to accommodate initial and final welding, quality control inspection, repairs, coating application and float placement, says Mr Wilson Jr. Mr Wilson Jr says that access is a major concern when water is encountered as conventional equipment typically would not be able to manoeuvre in the extreme
conditions encountered. Specialised equipment like the soft terrain vehicle or buggy exerts low ground pressure and is available for rent and purchase. Also depending on the overall size of the pontoons, the buggy can float in up to 2.4 m of water and still be able to excavate the pipe ditch. With modern coating systems and quality control, any potential for corrosion can be mitigated. Mr Wilson Jr says that original coating system and application is critical, while sacrificial anodes and rectifier systems can mitigate corrosive environments. Other than routine safety measures like eye and hearing protection, lifting devices, electrical shock and individual strains, additional safety procedures are implemented to identify plants and insects that may be prevalent in the region. Mr Wilson Jr also notes Employees are also cautioned concerning snakes, alligators and other wildlife in the region. Depending on the remoteness of the project, additional provisions may be implemented for use of helicopter equipment in the event that an individual requires emergency evacuation.
8. 9. 10.
Move in equipment and personnel to establish and prepare right-of-way for continuous access. Identify and mark sensitive areas. Determine logistics for pipe, material and personnel movement. Backhoe equipment trenches ditch with sufficient depth and width to accommodate pipe installation. Crews perform welding, coating and quality control functions and then install sufficient floats for buoyancy purposes. Equipment then guides different sections into final position before removing floats. Equipment and personnel are dispatched to remote locations to weld all sections in advance of backfilling. After substantial backfill and all welding is completed, entire line is subjected to hydrostatic testing to confirm suitability for intended use. After hydrotest, tie-ins are completed. Final cleanup, restoration and move out equipment and personnel. Pipelines International | December 2010
equipment, comprising purpose-built barges, amphibian equipment, shallow tugs and dredgers with a draft of one metre. The tie-in of the two strings was carried out in the onshore swamp trench. The pipe pull head was at kilometre point 1,350, which meant a total of 750 m of pipe section was pulled offshore. Four flexi-yoke barges with 32 t safe working load were deployed along with two swamp excavators to carry out this specialised tie-in onshore. The onshore activity was tide-dependent and the movement of flexi-yoke barges was possible only during the high tide. Tie-ins and other associated activities such as radiography and field joint coating were performed at low tides.
Continued on page 38
Cranes lift pipes into position on the Tambora Field Development project.
Pipelaying through swamp waters on the Tunu Field Development Phase 9 project.
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Projects
e.
In terms of environmental considerations, the discharges from the project activity had to be controlled to prevent water pollution which would adversely affect living organisms, materials, and even cause deterioration in the quality of water. Remoteness of the location was a major challenge for the project team, restricting mobilisation of personnel and machinery. The complexities of swamps and marshes were considered throughout the entire project from the selection of appropriate marine vessels to survey the right-of-way, to the logistics of trench excavation, pipelaying, welding and non-destructive testing (NDT), coating and tie-ins, river crossings, floatation of the string, pulling cable, tie-ins and riverbank re-instatement.
where the swamp was generally 2 m deep. Piles were driven in these sections and prefabricated structures were installed to support the pipes. At HDD locations, the strings were prefabricated. For this activity, lifting equipment such as cranes was required and swamp equipment was used extensively. Work was carried out by positioning the equipment and material throughout the alignment of the aerial section of the pipeline, while the traditional installation method of push-pull was undertaken from one location only. At HDD locations, the strings were prefabricated on these aerial sections. Temporary jetty and platforms were installed at all these locations for resources and material mobilisation and demobilisation and the HDD strings were pre-tested before pull back and were placed over rollers to facilitate smooth pull back. Dredging at river crossings used a clamshell barge and the prefabricated rivercrossing spools were installed by a rivercrossing work barge, which had been fitted with davits at the Sungaipurun yard. Punj Lloyd President Offshore V. P. Sharma has successfully executed projects in the swamp terrain for more than a decade. Speaking on the construction challenges in the swamp terrain he said The major challenge which we continuously face in the swamp terrain is working in an environmentally sensitive region so as to preserve the endangered ecosystem. All project-related work has to be executed keeping in mind the protection of the rare flora and fauna. Long years of working in the swamp region have taught me new methods of overcoming challenges. I have spent 11 years working in the Mahakam Delta where every project taught me new ways and methods to conquer hurdles.
Method of construction
24 inch diameter trunkline
Pipe bridge: 7 Sections 3,916 m HDD crossing: 4 Sections 5,494 m Open cut river crossing: 1 Section 64 m
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Projects
The 128 km pipeline project is being completed to supply natural gas to industrial areas in the southeast of Nigeria.
The pipeline route is characterised by undulating and rocky topography. The RoW also has swampy areas, and the seasonal and recurring flooding along the route also presents some civil engineering and logistical challenges.
We hope to reach all parts of the country with the gas grid in the coming years, said Mr Awobokun. We have built a network in Lagos. We are doing the same in the east of the country, and very soon we shall start work in the west. The company also aims to replicate the success of the Greater Lagos natural gas distribution scheme in other parts of Nigeria and West Africa by making significant investments in pipelines and related infrastructure to ensure a reliable supply of natural gas.
ando Gas & Powers 128 km pipeline project involves the construction of an 18 inch diameter pipeline from the existing Obigbo ALSCON Pipeline at Ukanafun, Akwa Ibom state, to Mfamosing, near Calabar in Cross River state. The pipeline is being constructed to supply natural gas to industrial areas in the southeast of Nigeria. In addition to the 100 km gas pipeline distribution network the company has constructed in Lagos, the project will service over 100 companies. The foundation customer is United Cement Company which is estimated initially to offtake 22 MMcf/d to fuel to its new cement plant at Calabar. Upon completion, expected in the first quarter of 2011, the transmission pipeline will deliver 100 MMcf/d of gas.
Pipeline construction
Zishan Engineering completed engineering and design work on the pipeline, and construction began on the pipeline in November 2008. Oilserv Nigeria Ltd is the primary construction contractor on the project. The scope of work under the contract includes right-of-way (RoW) survey; pipeline trench excavation; stringing and welding of the pipes; non-destructive testing of the welded joints; field-joint coating; flushing, hydrotesting and drying; and, execution of the associated civil works. East Horizon Gas Company (EHGC) also subcontracted major aspects of the project, including horizontal directional drilling (HDD) and swamp pipeline construction, to local contractors Enikkom and MJD Oil Services respectively. In addition, EHGC
engaged the services of NACE-certified Solewant/Kema Coating Nigeria Ltd to undertake corrosion coating of the field bends and their girth welds. Oando Gas & Power is committed to safety, quality, health and environment standards. The pipeline design and construction is compliant with the ASME B31.8 standard, and the pipeline is fitted with pressure relief valves set at 10 per cent below the pipeline maximum allowable operating pressure. The pipeline is built to the Nigerian standard of Class 2 Human Density. This category necessitates the installation of automatic line-break valves located at intervals prescribed by the applicable codes, and at the banks where the pipe crosses a waterway.
Challenges
The pipeline route is characterised by undulating and rocky topography. The RoW also has swampy areas, and the seasonal and recurring flooding along the route also presents some civil engineering and logistical challenges. Pipeline construction in swamp areas were executed using anchor blocks to create required negative buoyancy for the welded pipeline, and to avoid flotation of the line. The trench backfill was also increased from 1.2 m to 2 m in these areas. HDD was deployed at all the seven river crossings as opposed to the traditional opencut practice. This technique was chosen to mitigate the social and environmental impacts of the river crossing construction. Thrust boring was also used for pulling the welded spool under major roads without
affecting their integrity and structure. EHGC held a number of awareness sessions to educate host communities on the environmental, health and safety impact assessment of the project. Landowners whose farmland and trees were affected by the RoW clearing were duly compensated at levels determined by state government. In addition, community shrines and sacred areas were avoided, and cultural heritage sites along the pipeline RoW were also adequately compensated prior to relocation.
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Technical
Technical
Following the successful International Forum on the Transportation of CO2 by Pipeline held earlier this year, the December issue of the Journal of Pipeline Engineering is dedicated to this topic, including key learnings, a phased approach to developing a CO2 pipeline network, project design and operating issues.
he issue includes a number of papers written for the Forum, Held in July, the Forum was organised by Tiratsoo Technical, a division of Great Southern Press, Clarion Technical Conferences and the University of Newcastle, UK. As readers of Pipelines International may know, there is a dearth of published material on this specific aspect of the so-called carbon economy. Although the concept of carbon capture and storage (CCS) has been relatively well-known for a number of years, the subject of transportation from the material's capture site to its storage site seems only recently to have begun to be considered. Although many are quick to point out that over 7,000 km of CO2 pipelines have been operational in the US for a number of years, it is important to remember that these pipelines transport pure CO2 either from geologic reservoirs or from extraction plants, for the specific purpose of enhanced oil recovery. The gaseous material involved in CCS schemes often now known as anthropogenic CO2 is very different, being both at high temperatures and pressures, and containing considerable gaseous impurities. Anthropogenic CO2 does not behave like natural gas, and the science and engineering developed for the latter can therefore not necessarily be straightforwardly applied to the former. This article highlights several of the papers from the December issue of the Journal of Pipeline Engineering which, with an earlier issue, encompasses a broad overview of many aspects of the CO2 transport by pipeline. The issue is introduced by a guest editorial, written by Dr Julia Race of the University of Newcastle, which reviews progress in this field. The University is at the heart of much research into the area of CO2 transportation, and participates in a number of joint-industry projects and other initiatives on this subject.
How to select wall thickness, steel toughness, and operating pressure for long CO2 pipelines
By Graeme G King, Tensor Engineering Ltd, Calgary, Alberta, Canada; and, Satish Kumar, Masdar Carbon, Abu Dhabi, UAE Masdar Carbon is planning to capture CO2 from power plants, smelters, steel works, industrial facilities, and oil and gas processing plants in Abu Dhabi in a phased series of projects. Captured CO2 will be transported in a new national CO2 pipeline network with a nominal capacity of 20 MMt/a to oil reservoirs where it will be injected for reservoir management and sequestration. The design of the wall thickness, pipe toughness, and operating pressure of the network considered fundamental thermodynamic properties of CO2, code requirements, toughness needed to control long ductile fractures, and cost optimisation to resolve contention between the different technical requirements and arrive at a safe and economical pipeline design. The work selected a design pressure of 24.5 MPa, well above the critical point for CO2 and much higher than is normally seen in conventional oil and gas pipelines.
The Second International Forum of Transportation of CO2 by Pipeline will be held at the Newcastle-Gateshead Hilton Hotel on 2223 June 2011, and the organising committee is currently soliciting papers for the Forum. Chaired by Professor Martin Downie of the University of Newcastle, the committee is composed of Dr Julia Race of the University, John Tiratsoo of Tiratsoo Technical, and BJ Lowe of Clarion Technical Conferences, Houston. For more information email jtiratsoo@gs-press.com or bjlowe@clarion.org
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Pigging
Pigging
in the commissioning process. BJB says Solid urethane pigs have a longer wear life than foam pigs but have less flexibility. Polyurethane pigs are often used on internally-coated pipelines, as they are not equipped with cleaning devices that could damage or remove the coating. If a gas pipeline is free of internal coating, a cleaning pig with brushes can be used.
One of Inline Service s cleaning pigs after a run through a pipelin e.
Mandrel pigs, cups and discs Mandrel pigs have a metal body with seals, scraper cups or discs on the exterior. The pigs can be used to clean the line, for an ovality check or for gauging the internal diameter of the pipe, as a sealing pig, as a combination clean/sealing pig, or for batching, dewatering and drying after testing. According to Inline Services The majority of highly efficient cleaning pigs are mandrel pigs, using drive or cleaning cups and discs,
or aggressive brushes that are matched for the application and conditions. Rosen agrees, stating that guiding and sealing discs for mandrel pigs have the same hardness as a polyurethane pig, and can be refurbished for use on different pipeline projects. Extra discs, brushes or cups can be provided to attach to mandrel pigs to scrape extra debris: for example, crude oil lines can get a heavy wax build-up and sometimes require extra discs on the pig to clean the line. Cups are also used to push debris out of a pipeline. BJB explains that it provides cups of different shapes that vary in cleaning strength. A conical cup is our least aggressive cup profile and is generally used when the condition of the line is not well known or significant quantities of debris are expected. The scraper cup has a similar profile, but has a built-in scraper edge providing a more aggressive clean. Inline Services says that discs are used to either seal or scrape the pipe wall. Sealing discs are usually softer, while scraping or guide discs are sized close to the pipes internal diameter and made from harder materials.
Continued on page 46
turn determines the force of the pigs cleaning edge, with higher-speed pigs being able to remove tougher debris. According to Enduro Foam pigs are good to clean a dry pipeline once the bulk of the water or liquids have been removed. They are also good to use when starting a cleaning programme, when there may be a large amount of debris present in the system, causing partial blockage. For this, you would start with undersized pigs and work your way up to running metal-bodied pigs in different configurations, or running all-urethane pigs. BJB explains Medium and high-density foam pigs are often used as the first pigs in a cleaning operation because they are able to push significant quantities of loose debris in the line, and are flexible enough to pass through many restrictions. Light-density foam pigs are often used to soak-up liquids as their open-cell foam aids drying the pipeline after hydrostatic testing. Solid polyurethane pigs are also used as a first or second pig for a cleaning operation, and can be designed to be used in batching or displacement of fluids in petroleum, chemical or process industry pipelines. Batching refers to when a pig is used between batches of
product, such as between petrol and various other types of fuel. A displacement pig displaces one fluid with another and is used
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Pigging
Pigging
Advanced ultrasonic in-line inspection tools provide accurate, repeatable, 100 per cent coverage data that can be used to manage pipeline reliability.
ipeline operators have long been aware of the need to manage and maintain the integrity of their systems. Recent advances and proven deployment of compact, highly accurate ultrasonic inspection tools for unpiggable and difficult-to-inspect pipelines, in addition to engineering assessment, allow operators to analyse and make decisions that affect continuing reliability. Quest Integrity Group has developed a number of leading-edge solutions for the inspection and assessment of unpiggable pipelines. InVista is an ultrasonic, fully self-contained, free flowing in-line inspection tool. Unlike other systems, it provides direct measurement of anomaly characteristics for superior pipeline integrity assessment. The tool detects internal and external corrosion in addition to the dimensional change in difficult configurations, including 1D bends. The tool is easily launched and bi-directional, and is designed to provide high-resolution measurement data of axial position, geometry, and wall thickness.
A cleaning pi g available
Girard Industries adds A disc pig is generally considered more efficient at removing liquids than a cup pig. In addition, both metallic and nonmetallic brushes can be attached to mandrel pigs. Generally brushes are used when more aggressive cleaning is required to remove tough debris. Liquids pipelines are best cleaned with a pig equipped with cleaning devices attached, such as brushes, which can remove fine solids that may have settled in the pipeline. Enduro states Brushes can be manufactured from a number of different materials: round wire bristles, flat coarse bristles, pencil brushes and nylon bristles. Rosen also says that it supplies a large variety of accessories for cleaning pigs such as spring-loaded brushes, standard accessory flanges for installation of transmitters and data loggers, and Roplast Easy Clean for pre-commissioning and routine pigging operations in most pipelines.
Market developments
One of E nduros cleaning pigs.
BJB Services says that pig designs are becoming increasingly diversified to allow for greater flexibility when cleaning a line, with pig-tracking equipment becoming much more sensitive, and wireless applications beginning to appear on the scene.
In the United States, we are seeing that the majority of the cups we have sold over the past year are being run in lines that have never been pigged, or that have not had a pig run through them in over ten years. We have also seen an increase in the number of launcher and receiver installations over the past year. Hopefully, this is a sign that industry awareness of pigging is improving, the company says. Enduro states that it is working toward improving its pig designs for dual-diameter and multiple-diameter pipelines. We are working on custom-designing pigs for pipelines that have in the past been deemed non-piggable due to diameter changes or other non-piggable features. Inline Services has also observed a number of market developments. With the current demand for inspecting pipelines with in-line inspection tools, cleaning prior to inspection has increased dramatically. Although inspection tools are very robust, they require a clean pipeline to ensure that the environment they are operating in allows for collection of usable data. In addition to the use of pencil brushes to clean corrosion pits, there are several new innovative concepts being used. One is the use of cutter discs which incorporate a serrated outer edge that helps to scrape debris from the pipe wall. This is especially effective in wax, sludge, and black powder applications.
We provide highly accurate, technology-enabled inspection and assessment solutions that help companies in the process, pipeline and power industries increase profitability, reduce operational and safety risks and improve operational planning. Quest Integrity Group is built on a foundation of leading edge science and technology that has innovated and shaped industries for nearly forty years. As a dynamic business with a global presence, we are responsive to your needs and focused on empowering your operating and maintenance decisions. +1 281-557-2255 +1 253-893-7070 www.QuestIntegrity.com/pi Sales@QuestIntegrity.com
Fitness-for-service assessment
Fitness-for-service assessment is a multi-disciplinary approach to evaluate structural components to determine if they are fit for continued service. Pipelines may contain flaws or other damage, or may be subject to more severe operating conditions than the original design anticipated. Quest Integrity Groups LifeQuest pipeline assessment solution uses API 579-1/ASME FFS-1 fitness-for-service methodology to deliver an assessment of the pipeline for continued operation at defined maximum allowable operating pressure. An evaluation of remaining life and/or inspection intervals may also be part of such an assessment.
For additional information about Quest Integritys products and services visit www.questintegrity.com
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REGISTE R TODA Y Visit the Clarion website to register now www.cla rion.org
This event is supported by Platinum Sponsor Rosen and Silver Sponsor A. Hak Industrial Services 2011 PPIM Conference and Exhibition dates Training courses: 1415 February 2011 Conference programme: 1617 February 2011 Exhibition: 1517 February 2011
Now entering it 23rd year, the PPIM Conference is recognized as the foremost international forum for sharing and learning about best practices in lifetime maintenance and condition-monitoring technology for natural gas, crude oil and product pipelines.
The full list of speakers and abstracts of their papers can we found at www.clarion.org/ppim/ppim11/program
Conference Organizers
The Pipelines International team will be on hand to bring you all of the Conference news and looks forward to seeing you there!
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Areas served
Contact
Level 3, 220 St Georges Terrace, Perth, Western Australia 6000 Australia Tel: +61 8 9322 7922 Contact: Eric Jas www.atteris.com.au Pipeline Execution Centre 40 Eastbourne Terrace London W2 6LG UK Tel: +44 20 7053 3000 Contact: Harry Sheftali www.cbi.com
Company
Description
JP Kenny provides a range of engineering for onshore and offshore pipelines including: Conceptual studies Surveying and mapping FEED Detailed engineering Procurement services Project management and field services. JP Kenny can provide services for pipelines 456 inches in diameter as well as services for subsea systems, renewable energy, onshore oil and gas field development. Pipeline System Engineering (PSE) provides a range of engineering services for both onshore and offshore pipelines including: Conceptual studies Surveying and mapping FEED Detailed engineering Project management and field services. PSE works on pipelines of 656 inches in diameter as well as pump stations and terminals.
Areas served
Contact
Thames Plaza, 5 Pine Trees, Chertsey Lane, Staines, Middlesex, TW18 3DT UK Tel: +44 1784 417 200 Contact: Graham Freeth www.jpkenny.com
Atteris
JP Kenny
Africa Asia Pacific Europe Middle East North America South America
CB&I
GHD
199203 Charlotte Street Brisbane, Queensland 4000 Australia Tel: +61 7 3316 3000 Contact: Barbara Jinks www.ghd.com Gulf Plaza 16010 Barkers Point Lane, Suite 600, Houston, TX 77079-9000 USA Tel: +1 713 850 3400 Contact: Robert J. Sprick www.gie.com 840 7th Ave SW Suite 700 Calgary, AB T2P 3G2 Canada Tel: +1 403 269 9555 Calgary contact: Sean Weber Australian contact: Mark Coates Tel: +61 7 3166 7777 www.hatch.ca
Africa Asia Pacific Europe Middle East North America South America
26/28 Hammersmith Grove London W6 7BA UK Tel: +44 20 8834 1002 Contact: Roberto Pirani www.pseuk.com
Africa Asia Pacific Europe Middle East North America South America
The March edition of Pipelines International will feature companies providing offshore construction services for the pipeline industry. If your company specialises in offshore construction and is interested in being included in the March feature, email news@pipelinesinternational.com requesting a questionnaire.
The data in this feature have been provided by the companies themselves and all claims are their own.
Hatch Associates
Hatch Associates provides a range of engineering for onshore pipelines including: Conceptual studies Surveying and mapping via a known subcontractor FEED Detailed engineering Procurement services Project management. Hatch can provide services for pipelines 642 inches in diameter.
Africa Asia Pacific Europe Middle East North America South America
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NACE International
ACE International is a technical society committed to developing corrosion prevention and control standards. Established in 1943 by eleven corrosion engineers in the pipeline industry, NACE was originally known as the National Association of Corrosion Engineers. These founding members were involved in a regional cathodic protection (CP) group, which formed in the 1930s, when the study of CP was introduced. Built upon decades of knowledge and expertise from dedicated members around the world, NACE is now involved in every industry and area of corrosion prevention and control, from chemical processing and water systems, to transportation and infrastructure protection. NACE also serves as the forum for public policy makers to learn about corrosion prevention and its role in extending the life of infrastructure. Executive Director of NACE International Bob Chalker says Corrosion science has evolved to become its own legitimate engineering discipline with globallyimplemented advanced technologies to manage corrosion. NACEs membership includes scientists, engineers and technicians from a range of organisations, including infrastructure operators and suppliers of maintenance and life-extending technologies. The association aims to raise awareness of the need to invest in corrosion control personnel at all levels and strongly supports career development in this area. Mr Chalker adds NACE is not a trade association representing one group. It is an educational group connecting researchers, scientists, engineers, field technicians, and even industrial painters
"This is the sweet spot for NACE and its members: the development and deployment of cutting-edge technologies that extend the useful life of the worlds industrial infrastructure."
NACE International Executive Director Bob Chalker
Mr Chalker also says that members frequently collaborate via educational courses, conferences and programmes to discuss the most efficient ways to ensure the safe and efficient transport of oil, gas and water, and the longevity of pipelines, bridges and other assets that corrode over time.
replacement projects can be avoided. This is the sweet spot for NACE and its members: the development and deployment of cutting-edge technologies that extend the useful life of the worlds industrial infrastructure, according to Mr Chalker. With changing and aging infrastructure, more attention needs to be paid to corrosion expertise than ever before. NACE and its members regularly communicate with public policy makers and the corrosion industry to improve upon the maintenance standards that are already in place and to build pipelines that keep the flow of oil and natural
to establish standards and best practices for maintaining the infrastructure that preserves quality of life and keeps the economy competitive. NACE members are dedicated to improving and maintaining infrastructure, extending its useful life, to keep the public and the environment safe from corrosionrelated failures, and to protect the economy from the impact of failed assets. In a world in which corrosion continually challenges and threatens our industrial infrastructure, NACE and its members establish standards for technologies that control the effects of corrosion, which is the common denominator in all aging infrastructure issues, he says.
NACE is not a trade group representing one group. It is an educational group connecting researchers, scientists, engineers, field technicians, and even industrial painters to establish standards and best practices for maintaining the infrastructure that preserves quality of life and keeps the economy competitive.
bob chalker
gas steady while keeping citizens safe. The association also has a key focus on education. NACE has a global network of training and certification providers that have been dedicated to training corrosion personnel for more than 50 years. Today, high-quality training and certification for corrosion professionals are much more accessible. A new fouryear corrosion engineering degree from the University of Akron in Ohio, USA, demonstrates the importance of corrosion as a stand-alone educational discipline. NACE expects that the future will hold more of these four-year degrees and that the association will continue to grow, says Mr Chalker. In the future, NACE hopes that organisations will continue to be increasingly proactive in their maintenance activities to reduce the likelihood of corrosion and adopt a new perspective that considers the consequences of corrosion and prioritises maintenance activities on a risk basis. Mr Chalker concludes It is through these forward thinking practices that a higher standard of safety and maintenance will be developed throughout the pipeline industry.
NACE members participate in major conferences, such as the annual NACE CORROSION event, where more than 6,000 participants from more than 20 countries come together to share best practices in corrosion control and to learn new techniques from almost 400 exhibitors. Mark your calendar for NACE CORROSION 2011 to be held on 1317 March 2011 at the George R. Brown Convention Centre in Houston, Texas, USA.
Left and right: NACE International is committed to corrosion research for the improvement and maintenance of infrastructure such as pipelines.
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History
History
Passing through Indias of Gujarat, Rajasthan and Uttar Pradesh, Indian Oil Corporations Salaya Mathura Pipeline System was constructed in three sections, and covers a total distance of more than 1,200 km. Since the commissioning of the pipeline in 1978, numerous branch pipelines, spur lines, pump stations, tank farms and other facilities have been added to the system to meet Indias energy demands.
Construction continued through both winter and summer seasons, with temperatures rising to 50 degrees Celsius in summer in the states of Rajasthan and Gujarat, and heavy rains for a three to four month period in Uttar Pradesh.
ndian Oil Corporation (IOC) proposed the Salaya Mathura Pipeline System in the early 1970s. The system was planned to deliver imported and Bombay High crude oil from Indias west coast to the companys proposed refinery at Mathura in the state of Uttar Pradesh. In 1978, IOC had set up a single point mooring (SPM) system in the Gulf of Kutch to receive imported and Bombay High crude oil via tankers. The crude oil was delivered into storage tanks at Salaya, Vadinar, through a subsea pipeline system and twin onshore pipelines. From here, the crude was to be transported via the proposed Mathura Salaya Pipeline to the companys refinery in Mathura, and to IOCs Koyali Refinery via a branch line. In-house engineers at IOC prepared a detailed project report based on surveys, crude oil characteristics and the
and the quantity applied was required to make sure that optimum thickness was achieved. Cathodic protection (CP) was also installed on the pipeline system as protection against external corrosion. While the Salaya Mathura Pipeline system is ageing, a recent intelligent pig survey found that the pipeline is in good condition. This can be attributed to regular monitoring and maintenance of the mainline and CP system.
the construction period of this pipeline, horizontal direction drilling (HDD) technology was not common. Because of this all rivers, channels, streams, and canals along the route were crossed using the submerged crossings method.
Construction works underway on the Salaya Mathura Pipeline.
Rajasthan and Gujarat, and heavy rains for a three to four month period in Uttar Pradesh. Also, crossing bodies of water was made difficult by flooding. While working on many of the river crossings, flash flooding occurred, which increased risk when completing the open-cut submerged crossings.
hydraulic design of the system. The design was evaluated by consultant Pipe Line Technologists. A detailed project report for offshore facilities was prepared by an Indian consulting firm Engineers India Ltd with backup support from Fedric R. Harris of Holland.
Project details
well as two intermediate stations, located at Abu Road and Sendra, on the Viramgam Mathura section. Route selection was guided by a number of criteria. IOC wanted to achieve the shortest route possible while avoiding hilly areas, marshland, forest reserves, wildlife sanctuaries, highly populated areas, and mining areas when possible.
During the construction period of this pipeline, horizontal direction drilling technology was not common. As such, all rivers, channels, streams, and canals were crossed using the submerged crossings method.
The pipeline project comprised a 275 km, 28 inch diameter pipeline from Salaya to Viramgam, a 141 km, 18 inch diameter pipeline from Viramgam to Koyali and a 24 inch diameter pipeline, which extends 803 km from Viramgam to Mathura. The project also included the SPM system in the Gulf of Kutch along with an onshore terminal at Salaya. The initial transmission capacity of the Salaya Viramgam section was 10 MMt/a, with the option to increase to 12 MMt/a following an envisaged expansion of the Koyali Refinery. The capacity of the Viramgam Koyali section was initially planned to be 3 MMt/a and that of the Viramgam Mathura section was 7 MMt/a. The pipeline system included a station at Salaya, two pump stations at Viramgam, as
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Safety
he Health and Safety Executive (HSE) has a robust regulatory regime for ensuring pipeline safety. In the UK there are approximately 22,000 km of pipelines defined as major accident hazard pipelines (MAHPs) by the Pipelines Safety Regulations 1996. Approximately 20,000 km of these MAHPs transport natural gas at above 700 kilopascals. The remainder transport ethylene and other volatile fluids. Pipeline operators in Great Britain are required to comply with a number of different aspects of legislation and regulations to ensure the pipelines are properly designed, built, operated, maintained and decommissioned. The Gas and Pipelines Unit is responsible for the enforcement of health and safety law in relation to all pipelines in the UK, its territorial waters and the UKs Continental Shelf. In particular, it enforces health and safety laws for operators of pipelines classed as MAHPs.
valves, and wellhead pipework. The Units work includes the assessment of safety cases under the Gas Safety (Management) Regulations 1996 (GSMR); pipeline aspects of safety cases under the Offshore Safety Case Regulations 2005; safety reports under the Control of Major Accident Hazard Regulations 1999 (COMAH); and, pipeline notifications under the Pipelines Safety Regulations 1996 (PSR). HSEs specialist pipelines inspectors assess the way each operator manages the risk through examination of design, operation and maintenance regimes, backed up by inspection of the assets themselves. The inspector examines pipelines and above ground installations during the construction phase to make sure that the materials and techniques being used are in accordance with the design. In addition, the HSE develops intervention plans relating to each pipeline and operator to reflect risk and other parameters. HSE also inspects pipelines during the operation phase as part of its National Transmission System (NTS) intervention plan, which is the basis of HSEs inspections for all 6,800 km of the system.
Key issues include: Leadership from senior managers to ensure that pipeline safety is managed by all aspects of the business; Ensuring that operators develop and use key performance and safety performance indicators to ensure that they gather and evaluate the information they need to manage pipeline risks; and, The HSE consults with stakeholders and central government in the development of new pipeline safety regulations. Often these new developments are subsea and involve new pipelines, sometimes with difficult technical features such as high temperatures or deep water, which require specialised engineering solutions. As a result industry is considering options to extend operational parameters beyond previously accepted levels. Some installations are approaching the end of their design life and operators are looking for novel means of recovery of hydrocarbons from marginal fields. Head of Gas and Pipelines Unit Tony Hetherington said We must ensure that safety standards are maintained both by established operating companies under pressure to cut costs, and by the new players who now operate some fields. Well-established pipeline standards have been the cornerstone of delivering high standards of safety and we will continue to encourage their development.
ipeLine Machinery International (PLM) and ek pass have partnered for the provision of global training and consulting services for the pipeline industry. ek pass specialises in the development and delivery of heavy equipment and safety training, addressing a variety of areas ranging from clearing to clean-up. Training begins with classroom instruction where fundamentals including safety, basic maintenance, operating techniques and advanced skills are covered. The bulk of the training comprises hands-on learning, which is conducted by an ek pass expert and usually provided on an actual job site. By teaming with ek pass we connect our customers with world class, custom training delivered in classrooms, at job sites, through e-learning in whatever format the contractors or owning companies require, PLM Senior Vice President Tony Fernandez said.
For more information, visit the PLM website at www.plmcat.com or the ek pass website at www.ekpass.com
iebherr and Maats Pipeline Equipment have taken the next step in developing environmentallyfriendly pipeline equipment. The new Generation 4 Liebherr pipelayers are now compatible with environmentally-friendly fluids. Both models, the RL44, with 45.9 t load capacity, and the RL64, with 90.8 t load capacity, are now completely suitable for use with biodegradable fluids. This is significant because it means that approximately 126 litres of mineral oil on the RL44 or 215 litres for the RL64 can be conserved and replaced by an environmentally-friendly filling. Both machines can also be operated with biodiesel instead of standard diesel. Any variety of biodiesel fuel, which complies with either the DIN-EN 14214 or the ASTM D6751 specifications. Biodiesel is not only more environmentally friendly, but it is also much safer than standard diesel. With a flash point of approximately 130 degrees Celsius, biodiesel fuel is safer to store, handle and transport.
Key elements of the HSEs regulatory regime for ensuring pipeline safety can be found here: www.hse.gov.uk/pipelines
T
Galaxy's brushes mounted on a pig.
rials of Galaxy pencil brushes have been completed in several oil pipelines in the Gulf of Suez. The brushes were attached to the rear of standard bi-directional pigs and were used to remove mineral scales and wax, helping to control internal corrosion, reduce flow restrictions and prepare the lines for intelligent pigging. Galaxy pencil end brushes are used on magnetic flux leakage pipeline inspection applications. The brush size, bristle density, trim length and mounting plate geometry are customised to specific needs and tool characteristics. Virtually any brush pattern and brush angle could be achieved depending on the application.
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Event reviews
The technical papers and panelwere well-attended.
Event reviews
An unprecedented time in the pipeline industry, with unprecedented opportunities was one of Australian Pipeline Industry Association President Peter Coxs opening remarks in his welcoming address to the Associations recent Annual Convention held in Darwin.
The Intern ational Pip eline Exposition .
Featuring 350 technical papers from 40 countries, and a number of panels and tutorials, the 8th International Pipeline Conference and Exposition, was held in Calgary, Canada, from 27 September to 1 October 2010.
Conference
The Conference proceedings opened with a keynote presentation from the University of Albertas Department of Economics Professor Andre Plourde. Mr Plourde gave an animated speech about how pipeline owners and operators can manage their assets, while working both with government bodies and the community. He said that there is a need for a close relationship between the pipeline industry and policy makers, although a clear separation of the bodies different interests was also important to maintain. Following Mr Plourdes address, the technical papers began. Papers were organised into 14 streams covering issues such as integrity management, risk and liability, safety regulations, environmental concerns, material specifications, and construction techniques. The technical papers were of a highstandard, with 25 papers being nominated for the American Society of Mechanical Engineers Pipeline Systems Divisions (ASME PSDs) Rio Pipeline Award. The award is given to the best paper of the conference. This year, Kamal Botros and J. Geerligs won the award for their paper on Decompression wave speed in rich gas mixtures at high pressures (37 MPa) and implications on fracture control toughness requirements in pipeline design. The conference included various panel sessions, at which delegates discussed
Keynote presenter Professor Andre Plourde.
topics including issues involved with transporting anthropogenic CO2, improving the effectiveness of seam weld anomalies when completing in-line inspections, and the obligation of parties to proactively remediate pipeline operational problems. In addition to the technical and panel sessions, delegates heard from keynote speakers during the Conference lunches. On successing days the speakers were Common Ground Alliance (CGA) President Bob Kipp and Enhance Energy President Susan Cole. Mr Kipp spoke of the recent activities of the CGA, which is a 1,420-strong memberdriven Association made up of 16 key stakeholder groups such as engineering, gas
distributors, one-call centres, and insurance companies. The Association champions pipeline safety and damage prevention in North America. CGA was recently instrumental in streamlining the different locale one-call centre numbers for companies to dial before commencing excavation works. Ms Cole discussed the possibilities of CO2 use, with reference to Enhance Energys proposed project to construction a 240 km, 16 inch diameter CO2 pipeline in Alberta. Ms Cole said that once this pipeline was completed it is likely that further CO2 transportation infrastructure will develop for the purpose of enhanced oil recovery in the area.
resentations at the Convention outlined the challenges and opportunities for pipeline development in Australia and the surrounding region. These challenges included the increase in Australias population, projected to grow to 36 million by 2050, and the subsequent encroachment on pipeline easements. New developments were also noted as set to influence current and future pipeline infrastructure in the country, fluctuating loads, technology issues (increasing transportation of CO2 and slurries), and the fact that gas must remain affordable.
of gas in this category and the issues to do with their extraction. CSG developments will continue as a first priority, with further consideration of shale and tight gas projects. There will be many pipeline opportunities to connect [these reserves] to the existing mainlines, Mr Beukelman said.
include its Inverse Wave-field Extrapolation (IWEX) which produces a 3D seismic approach to girth-weld imagery. Herrenknechts Ren von Rautenkranz showed examples of the direct drill method of pipe installation, which is suitable for lengths up to 800 m and pipe diameters up to 56 inches. In addition to presentations on new technology, delegates could get hands-on with the latest products and services at the APIA Exhibition, held in conjunction with the Conference.
CSG development
The development of a burgeoning coal seam gas (CSG) industry has spurred the Australian Pipeline Industry Association (APIA) to establish a CSG Working Group to develop a CSG gathering system code of practice for polyethylene (PE) pipe. At the Convention, Working Group Chairman Hugh Luckhurst-Smith of Fyfe Pty Ltd, and Mark Heathcote of the Plastics Industry Pipe Association of Australia outlined that the Working Groups recommendations will include the retraining of skilled electrofusion personnel in large diameter pipelines; and, as there are no consistent pressure-testing methodologies currently available, the new code will recommend a minimum regime based on risk assessment for the use of this material. There are numerous CSG to LNG projects proposed for development in Australias northeast. These developments include significant pipeline components. AJ Lucas Ben Cooper highlighted the significant differences between the construction of these proposed larger diameter pipelines than those previously constructed in Australia. Other speakers attested to the fact that the industry will need to make considerable changes in its approach once these projects come to fruition. Other non-conventional gas opportunities were discussed, with Paul Beukelman of OSD Pipelines describing the various types
at the
Exposition
Over 150 companies were on show at the Exposition, which ran from Tuesday to Thursday. Delegates visited the many stands, which showcased products and services ranging from construction companies to pipeline pig providers, to machinery and pipeline security devices. The Exposition provided the perfect forum for delegates and service providers alike to make key contacts for further business.
New technology
Delegates heard a number of presentations on new technologies, including the replacement of an offshore valve, girt-weld inspection and direct drilling for pipe installation. TD Williamsons Rolf Lie described how his companys Smart Plug technology has been used to replace an emergency shutdown valve on Shells Malampaya Pipeline in the Philippines. The system allows a plug to be remotely installed and precisely controlled, at differential pressures up to 20,000 kPa. Jan van der Ent of Applus RTD provided a review of the present and future status of automated ultrasonic testing (AUT) of girth welds. The company is currently developing advanced AUT and future developments
The Exhibition showcased many local and international products and services.
The International Pipeline Conference is held every two years, and organised by the ASME PSD. Proceeds from the event are used to support education initiatives for the pipeline industry. The Conference will return in 2012. Keep 2428 September free to attend the event. Visit the event website for further updates: www.internationalpipelineconference.com Rio Pipeline 2011 The Rio Pipeline Conference is held in Rio de Janeiro every alternating year. The 2011 conference will be held from 2022 September 2011. For more information visit www.riopipeline.com.br
The 2011 APIA Convention and Exhibition will be held in Sydney, Australia, from 22 25 October 2011. For more information visit APIAs website www.apia.net.au
Australian Senator M athias Corm Executive ann, APIA Cheryl Cart Ch wright and Peter Cox. APIA Presid ief ent
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Event reviews
HT C EA
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ther subjects discussed at the conference, organised by Great Southern Press Tiratsoo Technical division in partnership with Clarion Technical Conferences, included fitness-forservice assessments; a French operators strategy for asset management; effective rehabilitation of a cathodic protection system in Tanzania; and, a record replacement of 32 20 inch diameter pipe lengths, on the Druzhba Pipeline in the Czech Republic in only 88 hours. Preceded by training courses on pipeline rehabilitation from Incal Pipeline Rehabilitations Sidney Taylor and pipeline in-service welding and repair from DNV Columbus Bill Bruce, the two-day conference brought together delegates from 24 countries, including Libya, Sudan, Nigeria, Israel and Saudi Arabia, as well as a contingent from Russia for whom simultaneous translation was provided. The keynote address was given by Heinz Watzka, Technical Director of Open Grid Europe, the newly formed transmission arm of E.ON Ruhrgas. He commented upon the regulatory environment in Germany that has seen some recent changes requiring pipeline operators to establish fundamental changes in planning, forecasting and implementation of technical projects. Thomas Salvan of Trapil in France discussed how the large quantity of data from an inspection should be dealt with. He took the pragmatic approach that, after an initial analysis and prioritisation review, a simple lowering of pipeline pressure can allow a defect to be rendered acceptable while repair or rehabilitation options are discussed. Dr Jochen Stratmann of Open Grid Europe followed, with an interesting review of gas pipeline inspection using ultrasonic tools. Dr Stratmann told the conference that his company had conducted successful
ultrasonic inspections by completely filling a gas pipeline with clean water before the inspection to ensure the necessary coupling was made for the tools ultrasonic wave transmitters and receivers. However, this is costly, presents environmental difficulties, and is not always possible. As an alternative, a short section (or batch) of liquid may be run through the pipe in order to avoid completely filling it, with pigs separating the liquid from the surrounding gas in the pipeline, and the inspection tool being kept within the liquidfilled section. However, batches may assume considerable velocities in the event of large slopes along the pipeline route, which can influence the tools detection capability and, give rise to pipeline damage if the velocities become too high. A team of three speakers from GRTgaz in France introduced the theme of asset management to the conference, using the companys 32,000 km pipeline network as an example. GRTgaz has developed a method of undertaking an objective technical and economic analysis allowing prioritisation of maintenance work according to the corrosivity of the soil and the pipelines environment which is now being used to inform decisions about the rehabilitation or replacement of ageing pipelines. The final operator paper at the conference was given by Botas Internationals Okan Sandalloiglu, the emergency pipeline repair supervisor for the 1,076 km Baku Tblisi Ceyhan Oil Pipeline. Mr Sandalloiglu gave a fascinating insight into the everyday problems of pipeline operations across long distances and through communities with whom contact with the operator is often tenuous. An overview of permanent repair activities for mechanically-damaged pipes
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was given, and a range of pipe-repair application scenarios were discussed, which included the use of the Clock Spring, composite sleeves, and epoxy coating applications. He went on to illustrate the difficulties and huge costs of an illegal fitting removal which, in a recent case, required a three-month hot tap and stopple operation with a temporary by-pass and reinforcing full-encirclement sleeve at a point on the Turkish section. Markus Brors of Rosen Integrity solutions presented a case study on the implementation of a pipeline integrity management system at a major state-run pipeline operator. This was followed by a joint paper from Dr Gregory Brown and Dr Ted Anderson of Quest Integrity Group on the subject of evaluation of pipeline dents using in line inspection data, and Paul Clayton of PII Pipeline Solutions and Mark Kelso of BP on the challenges faced in order to clean and inspect the UK North Seas 36 inch diameter, 412 km long CATS gas pipeline. Unfortunately space does not permit an account of other papers on the conference programme. However, a selection of papers presented at the conference will be published in Pipelines Internationals sister publications The Journal of Pipeline Engineering and Pipelines International Digest.
Great value packages offering exposure on websites & e-news Huge discounts on offer for multiple bookings Fully audited readership and performance figures for advertisers
The next Evaluation, Rehabilitation and Repair of Pipelines conferences will be in Houston on 31 October to 3 November 2011, and in Berlin from 1922 March 2012. Calls for papers will be distributed in due course, but offers of papers are welcome at any time, and should be sent either to John Tiratsoo, email: jtiratsoo@gs-press.com, or BJ Lowe, email: bjlowe@clarion.org
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Contact David Entringer dentringer@gs-press.com
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Event previews
Event previews
uilding on the success of the First International Forum on the Transportation of CO2, held in July 2010, the 2011 Forum will examine the opportunities and challenges faced by regulators, engineers and operators of pipelines used for CO2 transportation. The International Forum on the Transportation of CO2 is the only dedicated
event organised each year to update the industry on the issues of transporting anthropogenic CO2. The Forum is being organised by Tiratsoo Technical, a division of Great Southern Press, Houston-based Clarion Technical Conferences, and the University of Newcastle, UK. The event is supported by the UK-based Carbon Capture and Storage Association.
Didnt make it to the 2010 Forum and want to know what it was all about before registering for the 2011 event? Pipelines Internationals sister publication, The Journal of Pipeline Engineering, will publish a selection of papers from the Forum and elsewhere on this subject in its December issue. Visit www.j-pipe-eng.com to read paper abstracts free-of-charge, or subscribe to the Journal to keep informed about technical advances across a range of pipeline engineering subjects.
Keep informed with the latest news on the Second International Forum on the Transportation of CO2 visit www.clarion.org
rom 1517 May 2011, Bahrains prestigious Gulf Convention Centre will host the Middle Easts premier pipeline Conference and Exhibition bringing together industry members already active in the region and those looking to break into this lucrative market. The event is held under the patronage of His Excellency Dr Abdul Hussain bin Ali Mirza, Minister for Oil and Gas Affairs and Chairman of the National Oil & Gas Authority, Kingdom of Bahrain. The Conference and Exhibition, proudly supported by Platinum Sponsor Saudi Aramco, will attract representatives from the industrys most successful companies
looking to update their skills and continue to build their business networks. The two and a half day conference will be inaugurated by the Minister, and accompanied by a major exhibition showcasing the latest in products and services from companies around the world. The simultaneous tracks for the technical programme of the event will include: Design, construction, and materials Inspection of piggable and unpiggable pipelines Risk and integrity assessment and planning Operations and maintenance Leak detection
Repair and rehabilitation Trenchless and other construction methods System and data management and control. A Technical Committee has been set up under the chairmanship of John Tiratsoo of Tiratsoo Technical to establish the programme and to ensure the highest quality of presentations, and offers of papers are now being solicited.
DATE/VENUE
EVENT
CONTACT
31 January 4 February 2011 Amsterdam, The Netherlands 1417 February 2011 Houston, Texas, USA 2226 February 2011 Kapalua, Maui, USA 16 March 2011 Fajardo, Puerto Rico 1317 March 2011 Houston, Texas, USA 3031 March 2011 Houston, Texas, USA 45 April 2011 Hannover, Germany 1417 May 2011 Gulf Convention Centre, Bahrain 2223 June 2011 Newcastle, UK 2022 September 2011 Rio de Janeiro, Brazil
Pipeline training courses including: pipeline defect assessment; subsea pipeline engineering; in-line inspection of pipelines PPIM Pipeline Pigging & Integrity Management Conference and Exhibition Pipe Line Contractors Association Conference (USA) DCA Annual Conference NACE Corrosion 2011 Unpiggable Pipelines Solution Forum Sixth Pipeline Technology Conference The first international conference and exhibition on Best Practices in Pipeline Operations and Integrity Management The Second International Forum on Transportation of CO2 by Pipeline Rio Pipeline
npiggable pipelines are an increasing industry focus. For this reason, Clarion and Tiratsoo Technical, a division of Great Southern Press, are organising the Unpiggable Pipeline Solutions Forum, to be held at the Houston Marriott Westchase Hotel, Texas, USA, from 3031 March 2011. This two-day Forum will address capabilities and guidance concerning tools for corrosion and mechanical damage inspection of unpiggable oil, gas and hazardous liquids pipelines. The Forum will focus on existing technologies as well as
those currently in research and development. Advances and best practices in aboveground remote assessments, guided wave technologies, and internal corrosion direct assessment methods will form a significant part of the programme. Live-line access techniques, combined with low-flow restriction robotic and wireline-powered internal inspection tools, will also be a special focus, especially for pipeline segments that cannot be taken out of service when further integrity inspections are required.
The event programme is planned to comprise of three sessions and a total of 15 to 20 presentations, including a roundtable open forum discussion. The Forum will also include an exhibition, where delegates will be able to view the latest in unpiggable products and services.
The Unpiggable Pipeline Solutions Forum will run from 3031 March 2011. Register now visit www.clarion.org
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