Pin 2014-03

ISSUE 19
HDD in NYC
the lowdown
MARCH 2014
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CONTENTS
STATS GROUP
38
26
53
54
The EPRS revolution
Event calendar
56
Fixing Pipeline Problems
Advertisers index
EUROPE REVIEW
REGULARS
ISSUE 19 | MARCH 2014

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4
6
64
64
64
From the Editor

World wrap
Coming in future issues
PROJECTS IN FOCUS
Proposed pipelines in Canada
INTERVIEW
10
In conversation with Richard Williamson
INDUSTRY NEWS
14
18
22
24
25
Ultrasonic in-line inspection: enhancing

deepwater pre-commissioning
58
Evolving the east: constructing the

Northern Caspian Pipeline System
60
Controlling wax in the Gudrun Oil Export

Pipeline
RISK MANAGEMENT
62
Is formal risk assessment helping me?
DEXPTS: making pigging a real-time event

Disposable pig transmitter efficiency
Turbo pumps for Iraqi strategic pipeline
Practical pigging in Houston
Pipelines International goes digital
TRENCHLESS TECHNOLOGY
26
30
44
A pipeline state of mind

River crossing with Direct Pipe
PIPELINES INTERNATIONAL
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AVAILABLE NOW
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PROJECTS
32
Managing Pressure, Minimising Risk
Tecno Plug | Emergency Pipeline Repair Isolation System
Connecting Italy: the Zimella Cervignano

pipeline project
VACUUM LIFTERS
38
Vacuworx: expanding to support the

industry
STATS partner with major operators in the development and support of Emergency Pipeline Repair
Isolation Systems to minimise the downtime of damaged subsea pipelines. STATS provide rapid response,
reducing environmental and commercial impact and enabling early resumption of production.
EVENT REVIEW
40
PPIM Houston pulls record crowds
REHAB, REPAIR AND CORROSION
44
48
52
Conquering subsea corrosion with IFL

Measuring anomalies with the 3D Toolbox
Cleaning pig elements: a new concept
PIPELINES INTERNATIONAL | MARCH 2014
www.statsgroup.com
FROM THE EDITOR
Editor-in-Chief:
John Tiratsoo
Managing Editor:
Lyndsie Clark
Associate Editor:
Anna Tupicoff
Journalist:
Josie Emanuel
Sales Manager:
Tim Thompson
Senior Account Manager: David Marsh
Sales Representative:
David Entringer
Creative Director:
Michelle Cross
Acting Design Manager: Bianca Botter
Senior Designer:
Katrina Rolfe
Events Manager:
Luke Rowohlt
Publisher:
Zelda Tupicoff
ISSUE 19
MARCH 2014
Pulling the 30 inch

pipeline from Jersey City,
NJ, to Manhatten, NY. See
page 26 for more details
HDD in NYC
the lowdown
ISSN: 1837-1167
long, long time ago, when the internet

was fresh and young, and Google and
its sibling search engines were still
babes-in-arms, and Google Chrome was only a
twinkle in Larry Pages and Sergei Brins eyes, the
editorial office was introduced to a game called
Google Roulette. The point was to set Google a
search task using a sensible word or phrase (not
just random words) to see if this could result in
only a single Google result. The editorial team
recalls that it got close to success with Arctic
pipeline, which produced two search results.
Type in the same phrase now and youll get
endless references, some of which (thanks to the
Urban Dictionary) give us far more information
than we want to know. (However, type in north
pole oil pipeline and only three results come up,
so maybe our talent for Google Roulette is not
totally dissipated.)
This rather light-hearted introduction does,
however, have a serious and interesting point,
illustrated by the number of results search
engines provide. Even bearing in mind the
sophistication of search engines, the huge
increase in results for a search on Arctic pipelines
illustrates the point that more and more work is
being done in this area. While the Arctic may not
be the final frontier of pipeline engineering, it is
pretty close, and plans in Canada and Russia to
exploit hydrocarbons in this region will soon lead
to pipeline construction, both on- and offshore.
The Journal of Pipeline Engineering,
Pipelines Internationals sister publication,
published a number of papers in a special
Arctic issue in 2009, reviewing issues to do with
design and how to avoid damage by ice
scouring (from icebergs). In the Journals June
2014 issue, Professor Andrew Palmer of the
National University of Singapore, and a
respected authority on all aspects of Arctic
engineering, will publish a review paper to
update readers on current thinking. As he points
out, substantial reserves of both gas and oil lie
under the Arctic seas, and pipelines will be
required to bring them ashore and transport
them onward to markets in the south. The pace
of development will depend on demand and
competing sources, such as shale gas and
hydrates. There will be some special issues
peculiar to the Arctic, notably ice-gouging,
strudel scour, subsea permafrost, and sea-ice
forces. Several construction methods are
available, and a sensible choice between them

depends on ice conditions at different seasons
of the year, water depth, and the availability of
specialised equipment.
Professor Palmer concludes by pointing out
that there is a lot of marine pipeline engineering
and construction to be done in the Arctic, even
though the ambitious projects proposed in the
1970s seem unlikely to materialise for decades. It
will be essential to look for robust and
straightforward design and construction
engineering techniques that can resist a
demanding environment. Climate change may
lengthen the season of open water or thin ice,
and make it practicable to apply the conventional
methods of marine pipeline construction.
The March issue of the Journal is due for
publication shortly, and details of this issue
and the full archive can be found at
www.j-pipe-eng.com
John Tiratsoo
Editor-in-Chief
December, 2013
Subscribe to
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today!
See page 49 for
more details.
Vol.12, No.4
Journal of
Pipeline Engineering
incorporating
The Journal of Pipeline Integrity
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WORLD WRAP
WORLD WRAP
SOCAR pumps its own oil via BTC pipeline
$US1.87 billion for Canadian pipeline expansions

Pembina Pipeline Corporation has reached binding commercial agreements to proceed with constructing
approximately $US1.87 billion in pipeline expansions in Canada. The Phase III Expansion is underpinned by long-term
take-or-pay transportation services agreements with 30 customers in Pembinas operating areas, and is expected to be
in service between late 2016 and mid-2017, subject to environmental and regulatory approvals. The core of the Phase III
Expansion will entail constructing a new 270 km, 24 inch diameter pipeline from Fox Creek, Alberta, to the Edmonton,
Alberta area, which is expected to have an initial capacity of 320 Mbbl/d and an ultimate capacity of over 500 Mbbl/d
with the addition of midpoint pump stations. The total 540 km long expansion will follow and expand upon certain
segments of the companys existing pipeline systems from Taylor, British Columbia, southeast to Edmonton to fulfil
capacity needs for Pembinas customers, with priority being placed on areas where debottlenecking is essential.
Azerbaijans state oil company has started transportation of its

crude oil through the Baku Tbilisi Ceyhan oil pipeline. The
pipeline runs from the Azeri Chirag Guneshli oil field in the
Caspian Sea to the Mediterranean Sea. The State Oil Company of
the Azerbaijan Republic (SOCAR) has also signed a new
agreement with Russian company Transneft. After lengthy
negotiations on the resumption of oil transportation via the
Baku Novorossiysk oil pipeline, which runs from the Sangachal
Terminal near Baku to the Novorossiysk terminal at the Black Sea
coast in Russia, SOCAR and Transneft signed a new deal based on
mutually beneficial terms and conditions.
Transco pipeline receives binding commitments

Williams Partners Transco pipeline system has received binding
commitments from nine shippers for 100 per cent of the 1.7 million
dekatherms of firm transportation capacity under its proposed Atlantic
Sunrise expansion project. The project includes 15-year shipper
commitments from producers, local distribution companies, and power
generators. The project represents infrastructure that will connect new
supplies of natural gas in the Marcellus producing region in NE
Pennsylvania with growing demand centres along the Atlantic Seaboard
in the US. Williams Partners expects to bring Atlantic Sunrise into service
in the second half of 2017, assuming all necessary regulatory approvals
are received in a timely manner.
Ecopetrol awards $US272 million

Colombia contract
Colombian company Ecopetrol has
awarded a multi-year pipeline
maintenance contract to the Pipeline
Maintenance Alliance. The contract
includes works and maintenance for five
years on approximately 900 km of oil
pipelines in the south of Colombia, with
an option for an additional two years.
Work was expected to begin in December
2013. The Pipeline Maintenance Alliance is
owned by Colombian company Mecnicos
Asociados SA (70 per cent) and Mexican
company Empresas ICA (30 per cent).
Penspen awarded feasibility study

contract for pipeline
Penspen has been awarded a contract to
undertake a feasibility study for the
Kampala Kigali segment of the
Eldoret Kampala Kigali Pipeline in East
Africa. An initiative of the Kenyan,
Ugandan, and Rwandan governments, the
pipeline will deliver refined petroleum
products from Kampala, Uganda, to Kigali,
Rwanda, eliminating the need for current
road-tanker transport. Upon completion in
2017, the Eldoret-Kampala-Kigali Pipeline
will offer economic and environmental
benefits by safely and efficiently delivering
petroleum products to countries in East
Africa and the Great Lakes Region. The
pipeline is one of several projects of the
Tripartite Initiative (between Kenya,
Uganda, and Rwanda) that aims to
accelerate regional development in the
area through investment in infrastructure,
trade and economic integration projects.
To stay informed on this news and more, subscribe to the Pipelines International Update
Shah Deniz FID paves way for gas link with Europe
The Shah Deniz consortium recently announced the final investment
decision (FID) for the Stage II development of the Shah Deniz gas field in
the Caspian Sea, offshore Azerbaijan. This decision triggers plans to
expand the South Caucasus Pipeline through Azerbaijan and Georgia, to
construct the Trans-Anatolian Gas Pipeline (TANAP) across Turkey, and to
construct the Trans-Adriatic Pipeline (TAP) across Greece, Albania, and
into Italy. Together these projects, as well as gas transmission
infrastructure to Bulgaria, will create a new southern gas corridor to
Europe. The total cost of the Shah Deniz Stage II and South Caucasus
Pipeline expansion projects will be approximately $US28 billion. 16 Bcm/a
of gas produced from the Shah Deniz field will be transported 3,500 km to
provide energy for millions of consumers in Georgia, Turkey, Greece,
Bulgaria, and Italy. First gas is targeted for late 2018 to Georgia and Turkey,
with first deliveries to Europe to follow approximately a year later.
Iraq Turkey oil pipeline complete

Genel Energy, an independent oil and gas company with exploration activities in the
Kurdistan Region of Iraq, has completed the pipeline infrastructure to export Kurdish
crude oil to Turkey. During the fourth quarter of 2013, the final phase of the Kurdistan
Region of Iraq (KRI) independent export pipeline infrastructure from Dohuk to Fishkabur
was completed and tied-in to the Iraq Turkey Pipeline via a new metering station
within the KRI, the company recently announced in a trading and operations update.
Since then, commissioning and line-fill operations have been progressing. Test flows
commenced in December 2013, and first KRI oil through the new pipeline reached
Ceyhan in Turkey early in 2014. Genel expects that the pipeline system will be fully
commissioned during the second quarter of 2014, once required upgrades to pumping
stations on the KRI section of the pipeline are completed.
Fortescue announces new WA gas pipeline, transportation agreement

Fortescue Metals Group has signed a long-term gas-transportation agreement for the
delivery of gas to reduce operating costs at its Pilbara operations in Western Australia.
Gas will be delivered via the existing Dampier to Bunbury Natural Gas Pipeline
(DBNGP) and the new Fortescue River Gas Pipeline (FRGP) to the power station at
Fortescues Solomon Hub, 60 km north of Tom Price, WA. The 270 km pipeline will be
built, owned, and operated by the FRGP joint venture, owned by the DBP Development
Group, a wholly-owned subsidiary of DUET Group, and TEC Pilbara, a wholly-owned
subsidiary of TransAlta Corporation. Monadelphous Group has been awarded the
construction contract for the pipeline, valued at approximately $US90.2 million, which
in turn is expected to save Fortescue approximately $US20.2 million per year, and is set
to be operational in early-2015.
PROJECTS IN FOCUS
PROJECTS IN FOCUS
Proposed pipelines in Canada

Pipelines are booming in Canada, with proposals for more than 14 major new or
expanded oil and gas pipeline projects, many currently in the hands of Canadas
National Energy Board. Pipelines International looks at some of the major
proposed pipelines in Canada.
The National Energy Board (NEB) is the body
responsible for regulating interprovincial and
international pipelines.
ENBRIDGE MAINLINE EXPANSIONS

(LINE 67)
NORTHERN GATEWAY
Proponent: Enbridge Energy Partners
Projected cost: $U 6.5 billion
Projected cost: $US0.4 billion for Line 61 and 67
Product: Petroleum and condensate
Product: crude oil
Volume: 520,000 bbl/d
Volume: Alberta Clipper (Line 67) current capacity 450,000 bbl/d, to be

expanded to 570,000 bbl/d (first phase), to 800,000 bbl/d in future
Dimensions: 1,177 km
Proponent: Enbridge Inc.
Projected in-service date: NEB recently approved the project,

subject to 209 conditions. Enbridge must now seek approval
from the federal government, which has 180 days to review
the project.
Dimensions: Line 67 is a 914 mm diameter pipeline. The Canadian

portion is 1,078 km.
The Canadian Energy Pipeline Association (CEPA)

represents Canadas transmission pipeline companies.
Projected in-service date: July 2014 (Phase 1). NEB approval for
Phase 2 was granted in February 2014.
Ontario (16%)
KEYSTONE XL
Pipelines added more than

$US7.9 billion to Canadas GDP in 2012.
Alberta received just under half of this
benefit, followed by Saskatchewan and
Ontario.
Proponent: TransCanada Corporation

Projected cost: $US5.3 billion
Product: Crude oil
Volume: 830,000 bbl/d
Dimensions: 1,897 km, 36 inch diameter
$US7.9
billion
Saskatchewan (19%)
Alberta (45%)
Projected in-service date: 2015

Will support the significant growth of crude oil
production in the United States by allowing American
oil producers more access to the large refining
markets found in the American Midwest and along
the U.S Gulf Coast.
TRANS MOUNTAIN
EXPANSION
CEPA members transport 97% of

Canadas daily natural gas and onshore
crude oil production from producing
regions to markets throughout Canada
and the United States.
BRITISH COLUMBIA
Kitimat
Saskatchewan (20%)
Volume: Will carry 1 million bbl/d from Alberta and

Saskatchewan to refineries in Eastern Canada.
Dimensions: 4,600 km
Ontario (21%)
Projected in-service date: Final regulatory approval expected

in Q4 2015; in service 2018.
Pipelines sustained an
estimated 25,000
full-time equivalent
jobs and generated
about $US1.7 billion in
labour income in 2012.
LINE 9B REVERSAL
Proponent: Enbridge Inc.
Projected cost: $US110 million (Line 9 Project)
Product: Mainly light crude oil. Shippers will be permitted to
ship crude oil blends that meet Enbridges quality
specifications and filed with the NEB.
Volume: Enbridge is proposing to expand the capacity of
Line 9B from 240,000-300,000 bbl/d.
Dimensions: Line 9 is an existing 762 mm diameter pipeline.
Line 9B is a 639 km section of Line 9.
MANITOBA
Dimensions: 1,150 km in length,

Diameter: 827 km of 610 mm pipe,
150 km of 914 mm pipe, and 170 km
of 762 mm pipe
Product: Crude oil
25,000
jobs
Fort McMurray
Volume: will increase capacity from

300- 890,000 bbl/d
Projected cost: $US12 billion
Peace River
Product: Crude oil, condensate
Projected in-service date: Trans

Mountain filed an application with
the NEB on 16 December 2013.
Filing of the application will initiate
a regulatory review of the
proposed expansion facilities. If
the regulatory application process
is successful, construction of the
new pipeline could begin as early
as 2015/2016. The expanded
pipeline would be operational in
late 2017.
Proponent: TransCanada Corporation
ALBERTA
Proponent: Kinder Morgan

Projected cost: $US5.4 billion
97%
ENERGY EAST PIPELINE
Of the 25,019 full time equivalent (FTE) jobs supported

across Canada:
almost 3,000
Alberta (30%)
FTE jobs were
created in
British
Columbia.
Edmonton
Projected in-service date: NEB approved the Line 9B Reversal

and Line 9 Capacity Expansion project in March 2014. The
reason for the reversal is to take advantage of cheaper
western Canadian crude oil in comparison to foreign oil.
SASKATCHEWAN
QUEBEC
Hardisty
Vancouver
Calgary
ONTARIO
Quebec
Regina
Lvis
Moosomin
Pipelines by numbers
Saint
John
Winnipeg
Gretna
Montreal
1853
115,000 km
3 million
830,000 km
$US75 billion
Canadas
pipeline
history
dates back
to this date
Network of underground
energy transmission
pipelines that operate
every day transporting
oil and natural gas.
Barrels of crude oil

transported by transmission
pipelines in Canada every
day the equivalent of 200
Olympic-sized swimming pools
Estimate of Canadas
underground natural gas
and liquids pipeline network
(gathering, transmission
and delivery lines)
Value of Canadian crude oil

and natural gas exports in
2012 most of which was
transported by pipeline
Ottowa
Toronto
ADDITIONAL PROPOSED PIPELINES:

TransCanada coastal gas link
TransCanada Prince Rupert Gas Transmission
97%
The percentage of
Canadian natural gas
and crude oil production
transported by
transmission pipelines
TransCanada MacKenzie Valley

Spectra Energy BC Natural Gas Transportation
NOVA Gas Transmission Ltds North Motney Mainline system
Enbridge Woodland Pipeline Extension Project
(Source for infographics: The Economic Impacts from Operations of Canadas Energy
Pipelines report 2012.)
INTERVIEW
In conversation with
Richard Williamson
For nearly a century, US-based pipeline services company T.D. Williamson, Inc. (TDW) has been a trusted
supplier of pigging, inspection, line intervention, and repair products and services to the pipeline
industry. Pipelines International spoke with Chairman of the TDW Board Richard Williamson about the
companys beginnings, the importance of getting hands-on experience, and the future of the global
pipeline industry.
ith a career that has spanned work in the field as a technician

and engineer to operational management roles, Richard
Williamson is one of the stalwarts of the pipeline industry.
The grandson of TDW founder T.D. Williamson, Mr Williamson was
effectively born into the industry, and spent childhood weekends at his
fathers office, getting a sense of the business. His first hands-on taste of
the industry came during his high school years, when he helped to turn
around service equipment that was going out into the field.
An early introduction to industry

Mr Williamson cites his early exposure to a variety of pipeline
professionals as a source of invaluable insight into the industry.
I worked alongside people who cared for pipelines as their
vocation those who worked in the field and the district officers to the
project engineers and managers. I was learning the heart of the industry
as it is experienced by the people whose days and nights revolved
around assuring that the pipeline operated safely and that its customers
were being served.
Mr Williamson joined the family business in 1971, and was first
introduced to the pigging product side of the business, and then into
planning and business development. In 1976 he spent a year in the field
as a technician, doing hot tapping and plugging work. Mr Williamson
remembers this period as an enriching experience, a chance to work
alongside pipeliners and to understand their challenges and
uncertainties.
Its truly transforming to have a hands-on sense of how the
industry operates. Youre out there helping people, seeing the wide
range of issues and challenges that they have to address every single
day. It helps you reset your expectations when working directly with all
who serve the industry from owners and operators, to people like
ourselves who help the pipeline operators build, manage and operate
the pipeline safely.
The TDW evolution

The family business was established by Mr Williamsons
grandfather in 1920, originally founded as an electrical contracting firm
serving the emerging petroleum industrys need for power. By 1930, the
company had expanded into providing general oilfield products and
services.
By the 1930s, pipelines were being built in North America to move
crude oil cross-country a new thing at that time directly to major
10
Chairman of the TDW Board Richard Williamson.
refining centres. These pipelines required regular cleaning to remove

paraffin deposits.
In 1940 the War Emergency Pipeline Office was formed to construct
pipelines essential to assure the safe and reliable delivery of crude oil to
the major refining centres in the northeast of the US. The Big Inch and
Little Big Inch (24 and 20 inch) pipelines were the first of a new
generation of large-diameter pipelines, and pipeline scrapers had not
yet been developed for that size requirement. TDW was asked to
develop a pipeline scraper capable of effectively meeting the needs of
the large-diameter piping system.
They needed a better product to scrape the pipe walls. The director
of the War Emergency Pipeline Office came to my grandfather and said
We need something that can survive the rigours of operating in these
larger pipelines and clean much better what can you come up with?
CONTINUED ON PAGE 12
INTERVIEW
INTERVIEW
CONTINUED FROM PAGE 10
My grandfather assigned the mission to my father and a young engineer

who had recently joined our company. They started by talking to the
pipeline operators to better understand the challenges, began looking
for new solutions, and came up with the steel, mandrel-bodied tool we
know today as the pipeline pig.
It was at this point that TDW moved away from the electrification
business and forged itself as a pipeline service company, maintaining
its commitment to customer service and to creating innovative solutions
to address the industrys more critical needs.
Then, as now, we just listen to our customers and develop products
and services to help them solve their problems, says Mr Williamson.
The 1950s saw the introduction of hot tapping and STOPPLE
plugging as a unique and innovative solution to support line
intervention needs of the domestic and increasingly international
transmission pipeline markets.
Under my grandfather's continued leadership, we formed a
manufacturing and service company in Canada, and intensified our
efforts to get to know key international pipeline operators better. We
also began a dialogue with key gas distribution operators in the US,
Canada, the UK, and France that led to the later develop of the
SHORTSTOPP system as a solution for line intervention needs of
medium-pressure pipeline systems, explains Mr Williamson.
Work for the next several decades included working on a number of
major global projects, such as the high-pressure gas grids in the UK and
the Netherlands, as well as working on pipelines in France, Russia,

North Africa, the Middle East, India and Australia. TDW was also
present at various stages of development of pipelines in Japan and
South Korea, as they began to bring in LNG from the Middle East.
It was during these years that my father took over the reins of the
family business, recalls Mr Williamson, and together with A.B. Steen
and others that led our technical, marketing and operating teams,
began to build the life-long partnerships with pipeline operators across
the globe that have been a key part of TDW's history.
In his many years in the industry, Mr Williamson has seen the
industry change, and believes service companies such as TDW face an
ever more critical role in todays pipeline industry, whose future
continues to be driven by the global economics of the energy industry.
Ageing pipe, more construction and operating challenges, and rising
expectations as well as economic challenges for the operator mean that
they cant do everything by themselves that they used to do. Roles are
shifting, and more outsourcing is occurring, explains Mr Williamson.
The pipeline industry is substantially self-funded. It is an ongoing
challenge for operators to meet the maintenance and capacity
expansion needs of their customers. Whether they are regional,
national or international pipeline operators, their ability to fund and
operate their business is becoming more and more limited. They have to
be more particular about what they invest in, not only in terms of pipe
in the ground, but also the processes and people that manage the
Its truly transforming to have a hands-on

sense of how the industry operates. Youre
out there helping people, seeing the wide
range of issues and challenges that they
have to address every single day. It helps
you reset your expectations when working
directly with all who serve the industry
from owners and operators, to people like
ourselves who help the pipeline operators
build, manage and operate the pipeline
safely.
RICHARD WILLIAMSON, TDW BOARD CHAIRMAN.
critical assets and oversee operations. Increasingly they are saying Can
we meet these needs in some other way? and that some other way,
over time, has become service companies such as TDW.
A global community
Founded in 1920 by T.D. Williamson Sr., The Petroleum Electric Company eventually became the pipeline services company now known as TDW.
12
Having worked on pipeline projects across the globe, Mr Williamson

believes that one of the key challenges is learning to deal with the
variety of conditions and differences in pipeline operational needs and
management practices.
When we go into a customers location, there will be a blending of
the very old and the new, of the latest technology and, of course, a
variety of legacy issues. Youll find operating practices that are in
various stages of development as they migrate to what they will need to
better manage their assets.
The advantage of a company like ours is that having worked with
pipeline operators globally for more than 70 years, we have seen and
learned to work with a broader range of technologies and operating and
management practices. Just as important to us has been the opportunity
to work with succeeding generations of leadership among the
owner/operators we have learned from them, as well as helping them
develop their own next generation of leaders.
Despite the different methods of operation that he has encountered,
it is the similarities among industry members that Mr Williamson feels
ties the industry together.
I am impressed at how the values and culture of the pipeline
operators and the service companies that serve and support them
around the world are so close. People may dress and talk differently and
eat different things, but when you get down to it, our core values and
business cultures are very much aligned. I believe it's because the
industry that we are in provides very basic needs to our communities
its a real public trust for us all to be able to work in our industry. The
companies that have survived as operators and service companies have
done so because they implicitly understand and are committed to our

common mission to serve our many communities around the globe.
Working for the future of the pipeline industry

While he cites sharing and transfer of information as integral to the
pipeline industry, Mr Williamson believes that one of the key challenges
for the industry is to continue to foster a focus on knowledge sharing.
Shared knowledge is a challenge in any field knowledge
management and transfer really is something that people just have to
find a way to do. The opportunity to spend any sort of time on a
pipeline, to go out and live the experience as an operator, is so
transformational.
Mr Williamson understands the ongoing challenge that the industry
faces to train and develop leaders in all technical and operational
sectors of our industry.
This mission continues to be shared among the volunteer
leadership of the American Society of Mechanical Engineers, American
Gas Association, Interstate Natural Gas Association of America,
National Association of Corrosion Engineers, American Pipeline
Institute, and many other professional and trade associations, as well
as others that serve to underpin our industry. Our personal and
corporate engagement in these associations continues to support
continued improvement in operational effectiveness and more
importantly, our shared commitment to our common mission to serve
our communities well.
Mr Williamson also stresses the importance of collaboration and
shared learning between industry and professional associations,
providing the opportunity for pipeline professionals to take on important
critical projects for study and review. He lists the Pipeline Pigging and
Integrity Management (PPIM) Conference as a good example of the
industry dialogue that goes on from a pipeline integrity standpoint.
With these sorts of activities you build communities within
communities, where intensity of learning and sharing can take place
the dilemma in the pipeline industry is theres just not enough of that
taking place.
An important part of the challenge of creating communities within
the industry, explains Mr Williamson, is cultivating the next generation
of pipeline professionals.
You have the subject matter experts, who are the foundation of our
industry and provide leadership on matters critical to our companies
and to the industry, and then there are those that are maybe five years
away from taking on comparable roles. Our challenge as managers is to
assure that we continue to provide opportunities for the younger
generation to work alongside our senior leaders, so that they can gain
experience as well ask the questions that challenge us all to get better.
Awareness turns to knowledge, to skill and to mastery but none of us
really know what the roadmap is like. Part of the challenge is that we
have come out of a period of large numbers the Baby Boomers.
Theres no way well have the time or the people to replace them in the
next decade, following the same career development model that we
experienced.
And for these newcomers to the industry, Mr Williamsons
advice is succinct: Get out of the office and learn the industry for
yourself.
13
INDUSTRY NEWS
DEXPTS: making pigging a

real-time event
During a pig-run, information on current speed and position of a pig is crucial. Dutch pipeline operator
Gasunie and manufacturer Dexter have developed a system to provide this information continuously and
in real-time to the operators.
EXPTS, a real-time pig-tracking

system, provides an information basis
for decision-making by operators and
pig-tracking engineers, and reduces
manpower requirements. In case of a stuck or
lost pig, the recorded data will reduce time
and costs spent on search operations.
DEXPTS capabilities
DEXPTS consists of several mobile field
units, an internet platform, and any computer
or laptop with access to the internet. The
installation of the system requires the
brick-sized DEXPTS units to be placed along
the line at variable intervals. A magnetmounted vibration sensor is connected to the

pipeline or any fixed structure on the pipe,
and a pressure sensor can also be connected.
Once installed, the field units will go into
sleep mode, and will be remotely awoken by
the operator when the first pig-run starts. In
active mode, the field units will start collecting
and analysing vibration data. After processing,
relevant vibration information and pressure
data will be sent to a server through the
mobile phone network.
The data is displayed in real time on the
user interface, which allows the operator to
monitor vibration and pressure information

from several field units at the same time. Via
the user interface, all units can be switched
to active, stand-by, or sleep modes. The
web-based user interface has an integrated
log, allowing the operator to document all
relevant operational notes, and also allows
third parties to monitor the pig run when
required.
Vibration information reveals each
joint-weld or feature passed by the pig, from
which the actual speed can be derived. Pig
stops, short-pipe spools (such as bends), and
valve stations can also be identified.
The passage of a pig past pipe welds.
14
INDUSTRY NEWS
Pressure information indicates the differential

pressure over the pig, and is also a clear signal
of when a pig stops.
Once a pig passes a field unit, the abrupt
rise in pressure is a clear indicator of pig
passage.
DEXPTS in a nutshell:
Provides real-time information on position
and speed of the pig:
Supports operational decision making
during a pig run;
Supports learning/improving operations
each subsequent pig run.
A secure database with vibration and

pressure data can:
Direct (costly) search operations, and is an
insurance premium;
Automate of the tracking process;
Improve objectivity;
Reduce manpower requirements; and,
Enable other parties (such as the dispatch
department) to monitor pig-run progress.
For more information on the DEXPTS by

Dexter, visit www.dexter.eu
The web-based user interface.
DID YOU KNOW?

Since 1999, Dexter has come across many situations where no ready-to-use solutions were available and something new had to be
developed. As a response to these missing links in the industry, Dexter started creating its own solutions and, eventually, producing these
on a regular basis. Dexter has been the manufacturer of a continuously expanding line of dome cameras for hazardous areas since 2005.
DEX PTS Exib PIG Tracking System
Bakkenzuigerstraat 40
1333 HA Almere
The Netherlands
P.O. Box 60063
1320 AB Almere
16
PL TU ST
B .NVS.
Tel: +31 (0)36 - 53 68 216

Fax: +31 (0)36 - 53 67 161
E-mail: info@dexter.eu
Website: www.dexter.eu
B V
Internet
cloud
server
Laptop
Laptop
DEXPTS eld
INDUSTRY NEWS
Disposable pig transmitter efficiency

By Ryan Sikes, Outside Sales, Pigs Unlimited, Houston, TX, USA
Within an industry that is ever-advancing, it seems new technology is everywhere. New products, new
designs, and new ideas seem to be all of the buzz. It is rare that a company hits the nail on the head, and
gets it right an economical solution that works.
n the pipeline industry, three things matter: effectiveness,

availability, and cost. Pigs Unlimited International offers all three,
with the new line of disposable pig transmitters a solution to some
of the many problems of the conventional transmitters on the market
today, all with a price range of $US320 to $US500.
In the past, most operators would rent expensive transmitters to
manage job costs. Typically, rental is charged by the day, and is sometimes
upwards of $US100 a day. The problem is that the transmitter may only be
used once for a short period, but it can sit on the job site for days or weeks,
proving costly for companies.
For close to the cost of a rental, it is now possible to own a transmitter

which can be re-used for as long as the battery lasts.
Lets face it damage to rental equipment is frequent. Operators often
end up paying the price of a brand new conventional unit due to damage
or loss. Pipeline operations and locations are hard on everything, with
transmitters often lost, left, or destroyed at job sites.
The number-one reason a transmitter is used is so that if the pig
becomes stuck, the operator can readily locate it. Would you want
thousands of dollars stuck in the pipeline? What about those
disappearing pigs we all hear horror stories about? The ones that seem to
DISPOSABLE TRANSMITTERS
PORTABLE NON-INTRUSIVE PIG DETECTOR
Capable of detecting both industry standard ELF

(16Hz - 30Hz) transmitters as well as magnets with
ultra-high noise immunity
100% Non-Intrusive
Portable
High brightness LEDs
(Visible in direct sunlight)
Cost effective replacement
to Mechanical Detectors
Up to 1,000 Hours of run time

Continuous or Pulsed Signal
Buy for the price you would rent
Fully sealed and U/L rated explosion proof
Lower financial liability of damaging transmitter
Maintenance free
X-SD $320
SD $400
MD $500
RS-PIGSIG $1,250
DISTRIBUTORS WANTED
Email: sales@pigsunlimited.com Tel: 281-351-2749
Fax: 281-351-4658 Toll-free: 800-578-7436
www.pigsunlimited.com
18
INDUSTRY NEWS
vanish. Do you really want thousands of dollars in rental equipment to

vanish with it?
Dont let the word disposable scare you the functionality is equal to,
or exceeds, regular transmitters. Designed with efficiency in mind, the life
of the transmitters can be conserved and used for multiple runs by simply
inserting them into their storage containers.
Depending on size, they are capable of running for up to 1000 hours,
which is twice the battery life of conventional transmitters. Just because it
is a new design does not mean that it is a new concept. The general
technology of all transmitters is the same they transmit a signal, which is
picked up by a receiver.
So whats different? Pigs Unlimiteds disposable transmitters and all of
their components are encapsulated in a U/L rated, explosion-proof body,
giving you not only the safest transmitter that money can buy, but the
most reliable. There are no batteries to change, O-rings, threads, or parts
to maintain or be concerned with, making the disposable transmitters the
only true maintenance-free transmitter on the market.
In the ever-changing pipeline industry, it is good to stick to companies
that you trust to provide a product that does what it is supposed to and
Pigs Unlimited has been providing just that for
20 years.
A Pigs Unlimited sealed transmitter.
To find out more about Pigs Unlimited, visit www.pigsunlimited.com
20
A conventional unit that was breached by fluid in the pipeline, causing total failure.
INDUSTRY NEWS
Turbo pumps for Iraqi strategic

pipeline
A multi-million dollar contract has been awarded to Ruhrpumpen to provide two turbo pumps for the
crude oil pumping station in Habbaniya, Iraq one of many pumping stations worldwide that utilises
Ruhrpumpen pipeline pumps.
he contract was undertaken by

Ruhrpumpen and Siemens AG in favour
of the main engineering, procurement,
and construction contractor Progetti Europa
& Global SpA (PEG) for the supply and
installation of turbo pump trains powered by
Siemens SGT-400 gas turbines. The Iraq Oil
Projects Co. (SCOP) will hand over the station
to the client, South Oil Co (SOC), after a
successful run.
The pumps will be installed at the new

Habbaniya (PS4) station located along the Iraqi
Strategic Pipeline, enhancing the transfer of
crude oil to terminals and storage destinations.
Both of the pumps type ZLM I 530/08
have a flow of 24,656 gallons per minute, and
a head of 505 m, with a rated power of 10,326
horsepower. The pumps were successfully
tested at the Ruhrpumpen manufacturing plant
in Germany, and have already been delivered to
the client. The pre-test operation was conducted

in March 2013, and the pumps will be in
operation by the end of March 2014.
With its new project in Habbaniya,
Ruhrpumpen is proud to expand its partnership
with the Iraqi oil and gas industry. Ruhrpumpen
has worked extensively in Iraq for more than 40
years, and this latest contract will further the
countrys progress in resource management by
facilitating the efficient transfer of crude oil.
For more information, contact Angie Gallegos at agallegos@ruhrpumpen.com, or visit www.ruhrpumpen.com
Halfwave AS | Fjordveien 1 | NO-1363, Hvik | Norway | Phone: + 47 95 81 86 80 | Email: mail@halfwave.com
The turbo pump.
22
www.halfwave.com
INDUSTRY NEWS
FLIPBOOK
Practical pigging in Houston

By John Tiratsoo, Editor-in-Chief, Pipelines International and Journal of Pipeline Engineering.
Mid-November 2013 saw the Practical Pigging Training Course, organised by Tiratsoo Technical and
Clarion Technical Conferences, being held at Greenes Energy Groups test loop in Houston, USA.
enerously hosted by Greene's Energy

Group (GEG) who along with Inline
Devices provided the pigs that were
used on the course, the programme of lectures
and practical demonstrations for the course
had been put together by Peter Smith and
Nancy Leek of UK-based consulting engineer
Penspen in the UK. This edition of the course
followed on from a series of similar courses
held elsewhere in Houston and at CTDUTs
research facility in Rio de Janeiro, where it had
first been run in April, 2010.
The newly constructed test loop at GEG is
formed from 335 m of 6 inch standard wall
piping rated to 100 bar working pressure and
138 bar test pressure. The loop, constructed
during 2013, includes 3D bend radii, a 37 m
underground section, two replaceable 3 m
spools for deflect detection, and the option of
using vertical launch and receive traps; it has
also been designed to include various
features for equipment and instrumentation
hook-up. Speaking recently, GEG Vice
President Tom Sawyer said We are pleased
to open a pipeline training and test loop
operation. This new facility reinforces our
commitment to proactively providing
continual education and training to the
energy industry as a whole.
As with previous editions of the course,
the programme combined classroom lectures
and practical demonstrations of running a
number of tools, from foam and cleaning pigs
to Inline Devices magnetic flux leakage
(MFL) tool. Delegates were able to see for
themselves the issues involved with accurate
pig tracking (its not easy!), as well as
witnessing the commissioning and
decommissioning of the intelligent tool, and
the subsequent real-time interpretation of its
survey results. For half a day during the
course programme, the delegates went
off-site to visit Inline Devices nearby facility,
where they were given a detailed introduction
to the companys range of MFL and other
inspection equipment, which they later were
able to see in action.
24
One of the unique aspects of the GEG test

loop is its vertical launch-and-receive tower. The
design of the loop cleverly accommodates the
ability to rapidly reconfigure launching and
receiving from the horizontal to the vertical
traps, and delegates were able to witness the
MFL tool being launched from the 10 m high
tower, simulating conditions on an offshore
platform.
While, for safety reasons, it is not
appropriate for delegates in this course to
operate the pig traps themselves, it is clear that
the course provides a very useful overview of all
that goes into organising and running real tools
in real situations. Pig traps and their design and
operation can be explained in detail, pigs can be
examined before and after runs, and further
activities such as actual pig tracking and
location of above-ground markers (AGMs) can
be undertaken in practice. The programme, put
together by Penspen, provided ample
opportunity for detailed questions and
discussion, and as a result influenced also,
perhaps, by GEGs delicious parting barbecue
delegates left feeling that the five-day course
had given them a valuable insight into the
world of real pigging.
Delegates at Inline Devices having the MFL tool

explained to them; on the floor is an AGM that is
being used to demonstrate how the tool sees it as it
passes by.
Pipelines International goes digital

Pipelines International has created a digital magazine to complement the hard-copy publication, opening
up a digital platform with new opportunities for companies to interact and develop relationships with
their clients.
n January 2012, only 0.02 per cent of

readers accessed the Pipelines
International website via mobile device. In
January 2014, 15 per cent of readers accessed
our website with a smart phone or tablet.
Its evident that the way people use
technology is changing rapidly, and
responding to these changes is a crucial part
of maintaining relevance to your audience in a
digital age.
Creating a digital magazine to run
alongside our hardcover publication is about
giving our readers and advertisers options.
The digital version provides a catalogue of
accomplishments and products for those in
the industry to show to clients and co-workers

what their business is achieving.
The digital version not only responds to
the changing consumer behaviour of wanting
a way to review publications digitally, but also
offers a number of practical solutions, such as:
Easy to reference when on-site or when the
hardcover publication isnt available
Contains search functionality to look-up
projects, people, or products quickly
Invites readers to be prosumers, sharing

articles they like on social-network sites
Encourages readers to click with ease onto
supplier pages, directories, and other
external reference points.
Readers can view the magazine from an
iPad, iPhone, or a device using the Android
operating system (in Flash), as well as their
trusty PC or laptop.
Contact Pipelines International to discuss the combined print and digital strategy that
would best serve your company. Phone Lisa Feagan on +61 3 9248 5100 or email
lfeagan@gs-press.com.au
This issue of Pipelines International is the third edition of the magazine also available as
a digital copy. Make sure you subscribe to our enewsletter at
www.pipelinesinternational.com/newsletter to receive notifications on when each digital
edition of the magazine will be available.
Pig tracking the traditional way.
The MFL tool being launched into the vertical pig

launcher. The tool is encased in a non-magnetic
cassette to prevent magnets holding it in the trap.
THE NEXT EDITIONS OF THE PRACTICAL PIGGING TRAINING COURSE IN 2014:

31 March4 April at Greenes Energy Group, Houston
35 June at KTN, Norway (slanted to offshore pigging activities)
1719 June at A.Hak, Netherlands (slanted to onshore pigging activities)
15 September at CTDUT, Rio de Janeiro
25
A pipeline state of mind
The platform installation to support the Hudson River horizontal directional drill in Jersey City, New Jersey.
The first new natural gas pipeline to be built into Manhattan in more than 40 years, the New JerseyNew
York Expansion Project is designed to bring customers in the region 800 MMcf/d of natural gas supplies,
as well as economic and environmental benefits. Pipelines International speaks with Spectra Energy
about contending with New York Citys roadways and waterways along the pipelines right-of-way, and the
use of technology and safety features that resulted in a successful, state-of-the-art project.
residential properties. Underground

construction, specifically horizontal
directional drilling (HDD), allowed the
company to design a pipeline route through
the densely populated urban areas with
minimal impact on the community. The
technique also added an additional layer of
safety due to the depth that the pipe is buried
below the grounds surface.
Challenges of the big city
onstruction of the New Jersey New

York Expansion Project, an extension of
Spectra Energys Texas Eastern and
Algonquin Gas Transmission systems, began
in July 2012, with the pipeline becoming
commercially available on 1 November 2013.
The project consisted of the construction
of approximately:
24 km of new 30 inch diameter pipeline;
The replacement of approximately 8 km of
12 inch diameter and 20 inch diameter
pipeline, with new 42 inch diameter
pipeline;
The construction of new meter and
regulating stations; and,

Modifications to existing facilities.
The NJNY Expansion Project was needed
to address energy demand growth, deliver cost
savings and economic value, and to address
the environmental imperatives of the region.
The pipeline directly benefits New Jersey, a
state that will require an additional
850 MMcf/d of natural gas by 2019.
Minimising impact on residents

Spectra Energy spent the five years prior to
construction speaking with stakeholders and
officials, planning, designing, and
constructing the pipeline, to ensure it was

completed safely, efficiently, and to the
highest standards.
The project team held more than 350
meetings with government officials, agencies,
municipal officials, landowners, community
organisations, and key stakeholders to solicit
the communitys input and get a real sense as
to how the pipeline could be constructed with
minimal disturbance to the community.
As a result, Spectra Energy made
numerous changes and designed the project
route, which runs entirely through commercial
and industrial areas, to avoid direct impact on
Spectra Energys engineers were asked to

work within limited space to reduce the
impact on the community, to work
co-operatively with numerous utilities and
transit authorities, and to construct beneath
some of the most robust commercial
waterways in the world.
One-third of the pipeline route was
designed using HDD technology which helped
the company construct the pipeline below
waterways without impeding the traffic flow
on the Hudson River or the Kill Van Kull, and
other critical waterways. Spectra Energys Kill
Van Kull HDD is the longest 30 inch HDD in
North American history at just over 2,469 m.

Another major engineering feat was the
pipeline crossing beneath the Hudson River
into Manhattan.
The project was constructed within public
roadways and commercial/industrial areas,
and parallel to existing utility rights-of-way.
The first step for in-street construction was
to co-ordinate the work with each municipal
Police Department. Proper traffic control was
then installed, and traffic was detoured or
directed around the construction area during
the installation process according to
traffic-management plans filed with the
Federal Energy Regulatory Commission. The
working area along any street was typically
244 m to 305 m long, and met the requirements
of the municipal road-opening permits that
were issued for the project. All construction
activities were limited to the section, and the
work area moved along the street as
construction advanced and while normal
traffic continued.
Pavement over the proposed trench was
cut and removed, and the trench was then
excavated using a combination of a backhoe

and hand shovelling to dig around existing
utilities. Once completed, the pipe was
installed, welded (with each weld x-rayed for
quality), and then coated with impervious
material. All existing utilities that were
exposed during excavation were supported at
their existing elevations to avoid damage, and
this support was maintained until the backfill
of the pipeline trench was completed.
No trench was left unprotected overnight,
as the trench was backfilled or steel plated to
ensure public safety. Control density fill (CDF),
also known as flowable fill, was used to fill the
trench to 12 inches over the pipe. The backfill
was compacted properly to roadway
specifications to ensure the roadway
supported the traffic load.
A successful operation
The NJNY Expansion Project was
constructed to federal regulations and
industry standards, and uses advanced,
high-resistant, steel and modern safety
features, including remote-control valves and
26
27
the ability to use robotic in-line monitoring

devices. With over three million man-hours of
work, the project compiled a total recordable
safety incident rate of 0.79, which is below the
pipeline construction industry standard of 1.3.
Successfully completing this pipeline is a
testament to our ability to secure, permit and
execute on large and complex growth
projects, explains Spectra Energy President
and Chief Executive Officer Greg Ebel.
Weve built the first natural gas pipeline
into Manhattan in more than 40 years, one
that will supply the region with safe,
affordable, clean, domestic natural gas.
Completing this pipeline is a great
accomplishment, and one in which our team
can take great pride.
CENTRALIZER & SPACER SYSTEMS
FOR THE DRILLING & CIVIL CONSTRUCTION INDUSTRIES

Centered & restrained
Spacer comprised of the same
HDX 65 segment (65mm runners)
Non-centered &
restrained
Spacer comprised of
HDX 125 segments
(125mm runners) above
the pipe and HDX 65
segments (65mm runners)
below pipe
A lasting effect on energy costs

Prior to the completion of this project,
New Jersey residents were paying about 3.5
times more for energy than their neighbours in
Pennsylvania. Natural gas produces 45 per cent
less carbon dioxide than coal and 30 per cent
less carbon dioxide than fuel oil, so when
natural gas replaces these sources of energy,
the air will be much cleaner. Spectra Energy
estimates that this project will eliminate
6 MMt/a of carbon dioxide by using
cleaner-burning domestic natural gas the
equivalent to taking one million cars off the
road. Air pollution does not respect state
boundaries so the environmental effects of
burning fuel oil in New York City make their
way into New Jersey, too.
The NJNY Expansion Project also helps
solve the regional bottleneck constraints that
cause spikes in natural gas and electricity
prices. The project provides enough safe,
reliable energy to heat the equivalent of more
than an additional two million homes per day.
Non-centered & restrained
Spacer comprised of HDX 65 segments

(65mm runners) above pipe and HDX 125
segments (125mm runners) below pipe
Meet the challenges head on

Handles Steel, DICL, MSCL, Concrete & HDPE pipe plus
contents 4 up to 63 OD and beyond
Positions pipe within casing for customised centering or
restraining
Minimizes running friction and drag on very low coefficient of friction wear pads with superior abrasion
resistance properties
Resists chemical and oils and maintains strength even if
immersed for long periods of time
Arrests vibration transfer from outer casing and reduces
point loading via unique load sharing runner system
Contains no lead or metal parts, fully compatible with
municipal water applications
Warehouse locations:
Sydney NSW, Australia
Bunbury WA, Australia
Dallas TX, USA
The Kill Van Kull HDD 30 inch pipe string and site layout.
The natural gas in this pipeline will

warm homes, cook food and keep businesses
running in New Jersey and New York for years
to come. Customers in the region could save
$US700 million in energy costs each year
while also replacing fuel oil with domestic
and cleaner-burning natural gas, said
Spectra Energys President US Transmission
and Storage Bill Yardley.
The tide began to turn as soon as the
project commenced flowing natural gas
HDX Series Spacer
in fact, it began the day before it went into

service. On 31 October 2013, natural gas
prices in Manhattan were nearly 40 cents
cheaper than in Louisiana something that
hasnt occurred in eight years. The Spectra
Energy pipeline has effectively doubled the
amount of natural gas flowing into
Manhattan, and lower natural gas prices
should encourage a welcome shift away from
fuel oil heating towards cleaner, more
efficient natural gas.
PIPELINE CONSTRUCTION DELIVERS ARCHAEOLOGICAL DISCOVERY

As part of Spectra Energys cultural resource assessment work associated with the NJ NY Expansion Project, the company discovered a
remarkable archaeological site, dating back at least 5,000 years, designated the Old Place Neck Site. With painstaking care, the Spectra
Energy Project team excavated more than 557.42 square metres, uncovering a unique timeline of the regions history from Native
American tribes to colonial Dutch settlers to 18th- and 19th-century activity. In all, more than 24,000 artifacts were recovered, ranging
from stone tools to cooking utensils and ceramics.
The discovery adds a new and noteworthy dimension to the archaeological record of New York City, which, due to its vast urbanisation,
has been relatively under-documented. Analysis of Native American artifacts from the site included radiocarbon dating, examination of
residues and use wear on stone tools, and soil samples all of which contribute to a more complete account of New York Citys past.
In the spirit of sharing the lessons of history, Spectra Energy developed a multifaceted public outreach and education programme, telling
the story of this exciting discovery and the areas rich past via video, school lesson plans, educational materials, and interpretive
museum displays.
28
Australian & International Customers

+61 8 9725 4678
sales@kwikzip.com
USA Customers
+1 972 790 0160
usa@kwikzip.com
w w w.k wik zip .com
View of the site works from afar.
The Herrenknecht microtunnelling machine which formed part of the Direct Pipe system.
River crossing with Direct Pipe

By Patrick ODonoghue, Michels Trenchless Crossing Manager/Direct Pipe, Calgary, AB, Canada
Michels Canada completed the first installation using the Direct Pipe method in Canada when it
completed a 342 m crossing under the Beaver River.
he Beaver River installation is part of

the Inter Pipeline Cold Lake and Polaris
Expansion programme, which includes
installation of approximately 840 km of
underground pipeline and seven pump
stations, and is located approximately 20 km
NE of Bonnyville, Alberta, Canada.
The Direct Pipe method was first used in
2007 to cross the River Rhine in Germany.
Unlike horizontal directional drilling (HDD),
Direct Pipe is a single-pipe installation that
combines microtunnelling and a thrusting
system to directly install the product pipe. It is
an efficient method for use on projects where
30
geotechnical challenges would not be a good

fit for HDD, such as unconsolidated sand,
gravel, and cobbles; or where access is limited
at both sides of a crossing.
Michels and project partners Inter Pipeline
and Complete Crossings Solutions had started
preliminary design and planning close to a year
before beginning work on the project in
August,2013. Site set-up was completed in
approximately two weeks and Michels brokethrough to exit on 2 September (the Labour Day
weekend).
Michels used the Direct Pipe system that
combined a Herrenknecht pipe thruster with a
Herrenknecht microtunnelling machine. The

system is operated from the surface by an
operator who monitors and corrects alignment
changes and simultaneously controls the
tunnelling head and thrusting unit. The cutting
head and product pipe are kept within
pre-determined design parameters. The
microtunnelling head removes material from
the cutting face and returns it to a cleaning
plant that separates mined material from the
drilling mud, which is recycled back to the
cutting head.
A gripper thrust system clamps onto the
pre-tested 42 inch product pipe and pushes it
into the borehole. The thrusting system is

designed to maintain the integrity of the pipe
and pipe coating while thrusting. The borehole
is supported continuously by the product pipe,
and with lower fluid pressures and volumes, the
Direct Pipe method is favoured over other
trenchless applications in unconsolidated
shallow installations.
Michels Direct Pipe installation
complements its existing tools for trenchless
crossings and pipelaying for installations of
3060 inch diameters in the US and Canada.
The Cold Lake and Polaris expansion
programme, which was announced in July 2012,
was formalised with the signing of binding
Transportation Services Agreements in early
2013. The system expansion will provide
blended bitumen transportation service from
the production areas to Hardisty, Alberta, and
diluent transportation services from
Edmonton to three major oil sands projects in
the Christina Lake area.
On the Cold Lake pipeline system, two new
pump stations are being added at the Foster
Creek production site, and a new pipeline
connection will be built to the Narrows Lake
oil sands development. In addition, the
existing Foster Creek extension will be
twinned with a new 36 inch diameter pipeline

and the Cold Lake mainline from La Corey to
Hardisty will be twinned with a new 42 inch
diameter pipeline. In total, approximately
400 km of new pipeline will be added to the
Cold Lake system.
On the Polaris system, a major new 30 inch
diameter pipeline will be constructed from the
Edmonton area to the Christina Lake oil sands

project. In addition to this approximately
340 km new-build project, 100 km of smaller
diameter pipelines will be constructed to
provide connections to the Foster Creek and
Narrows Lake oil sands projects and several
diluent receipt points at the Edmonton
market hub.
Pipe ready for installation.
31
PROJECTS
Streicher is carrying out two sections of a 56 inch pipeline for SNAM Rete Gas. This is the biggest pipeline project that the company has ever undertaken.
Connecting Italy: the Zimella

Cervignano pipeline project
The largest pipeline in Italy, the Zimella Cervignano Pipeline Project, is currently under construction by
Max Streicher S.p.A.
he project involves the construction of

a natural gas pipeline across the Po
Valley River in northern Italy, which
aims to strengthen the national transport
network as part of the Snam Rete Gas Network
Programme.
Streicher is constructing pipeline spreads
2 and 3 of the four spreads being contracted by
Snam Rete Gas. The project is split into a series
of operations; the new pipeline that is being
constructed will replace the existing pipeline
and have a larger diameter than its
predecessor, and the adaptation of the lines of
various diameters will guarantee connection
to new energy users.
Streicher began construction of spread

3 in November 2012, while spread 2 began in
November 2013. The company expects to complete
both pipeline spreads by the end of 2015.
Project scope
The 56 inch Zimella Cervignano pipeline
has a total length of 170 km, with a steel grade
of EN-L450/MB, equivalent to API 5L grade
X-65. The pipes are spirally welded, and have
internal and external coatings. The external
coating is polyethylene-based, with a
thickness of 3.0 mm.
Streichers contracts comprise construction
of the pipelines in the table on the next page.
Po Valley: the new energy centre

The Zimella Cervignano project will
strengthen the existing facilities from east to
west along the Po Valley by increasing
pipeline transport capacity. This infrastructure
will connect the sources of supply located in
the NE and central north regions of Italy, with
the natural gas consumption centres and
storages in the NW regions. The project will
provide an increased supply of gas to enhance
the local supply sources of the NW region.
Energy consumption in the NW of Italy
amounts to more than 40 per cent of the
annual national consumption, while supply
sources located in the region do not exceed
32
PROJECTS
Main Pipeline (56 inch) :
Secondary Pipelines:
Removal of existing lines:
Spread 2
L = 42.37 km DN 1400 (56 inch) DP (differential

pressure) = 75 bar
Spread 3
L = 53.1km DN 1400 (56 inch) DP = 75 bar
Spread 2
L = 21.66 km of various diameters
Spread 3
L = 24.47 km of various diameters
Spread 2
L = 37.77 km DN 850 (34 inch)
Spread 3
L = 52.32 km DN 850 (34 inch)
20 per cent of the countrys total.

Energy operators are turning their focus to
the NE and central north regions of Italy to
ensure future demand coverage, so the
transport of natural gas across the Po Valley is
expected to increase in the coming years.
With this in mind, the increase in transport
capacity along the Po Valley will ensure
flexibility of supply in the NW. For technical
reasons, and due to the progressive
urbanisation of the Emilia, Veneto, and
Lombardy areas, the gas pipeline will also
replace the existing 34 inch Tarvisio Sergnano
pipeline and the 30 inch Sergnano Mortara
pipeline, both of which are located in the area.
INTERNATIONAL PIPELINE CONFERENCE & EXPOSITION

CHALLENGING PIPELINE PERFORMANCE
A unique pipeline project

The Po Valley is one of the most urbanised
and populated regions in Italy; the majority of
the Italian industrial production takes place in
the area, in addition to agricultural production
which includes vineyards, orchards,
vegetables, corn and wheat. This has affected
the design and construction of the pipeline
project.
The agricultural activities require
substantial irrigation. This presents challenges
when establishing the pipeline right-of-way
and trenching for pipeline construction, as
many farmers still use the ancient
field-flooding technique to irrigate, which
INTERNATIONAL PIPELINE CONFERENCE & EXPOSITION
The pipes are 56 inches in diameter.
THE CONFERENCE
September 29 - October 3, 2014
The Hyatt Regency Hotel & TELUS Convention Centre

Calgary, Alberta, Canada
The definitive conference for

pipeline professionals. Dont miss
this five-day experience!
200
1,500
Network with over 1,500

industry professionals
at sessions and official
functions.
Connect with 5,000

registrants technical
leaders and business
executives.
5,000
Conference Patrons
Participate at the worlds leading

marketplace for pipeline
technology and services!
300
Join representatives
from 45 countries
spanning the globe.
Source from a global

marketplace converging
from 30+ countries.
@IPC_Calgary
TELUS Convention Centre

Calgary, Alberta, Canada
Visit 200 companies

exhibiting todays
foremost technologies,
products and services.
internationalpipelineconference.com
34
September 30 - October 2, 2014
Attend 13 Technical
Tracks with 300+
presentations, keynotes
and tutorials.
45
Up to 350 workers are involved in the construction, of which 200 are Streicher employees.
THE EXPOSITION
Media Sponsor
30
internationalpipelineexposition.com
@petroleumshow
Major Exposition Sponsors
PROJECTS
means the area is characterised by damp soil.

Damp soil represents a big challenge:
Streicher chose to use drainage where soil
conditions allowed, and wells for the
remaining sections of the pipeline route. This
technique required deployment of a large
number of dewatering pumps.
In addition, a large number of
archaeological sites of interest from
prehistoric, Roman, and medieval times have
since been discovered within the right-of-way.
enters a new age

Introducing the flipbook
Ensuring safety on the line

Due to the highly populated area through
which the pipeline route passes, considerable
importance has been placed on taking health,
safety, and environment (HSE) measures to
mitigate the impact of the project on the
population and the environment. To manage
this, Snam Rete Gas has contracted a specialist
company to monitor the environmental impact
of the project.
Some of the safety techniques put in place
by Streicher in the construction of spreads 2
and 3 are based on the subsoil features. The
subsoil consists of a simple structure,
composed of continuous layers of sand,
gravel, silts, and clays, all with variable
thicknesses which contribute to the formation
of the regions aquifers. For this reason,
Streicher decided to use sheet-piling for all
trenches deeper than 3.5 m, where it is not
possible to provide a trench with sloping
sides.
To ensure hazard prevention during the
welding process (both semi-automatic and
manual welding are being used) Streicher is
also using welding helmets with powered
air-purifying respiratory systems to protect
welders during welding, cutting, and grinding,
as well as providing clean, filtered air for long
work shifts.
Obstacles overcome
More than 100 crossings in less than 95 km
of the main 56 inch pipeline required
alternative installation methods, as the
pipeline construction route crossed existing
infrastructure such as pipelines, streets,
highways, and railways, and natural
36
The soil in the region south of Lake Garda is pebbly and sandy, but primarily damp, which requires considerable
preparation prior to laying the pipeline.
obstacles, such as rivers and protected areas.

All of these crossings required trenchless
techniques in order to preserve the subsurface
and minimise the impact of the project on the
surrounding environment.
The trenchless crossings on spreads 2 and
3 include the following:
90 thrust borings
4 stainless steel micro-tunnels
7 concrete micro-tunnels
2 direct-pipe drills
The direct-pipe drilling project is
considered the most challenging phase of the
Zimella-Cervignano Pipeline. This technique
was implemented after the refusal by the park

authority to allow laying of approximately
1,500 m of pipe across an environmentallyprotected area. Streicher proposed the
innovative trenchless solution using two
direct-pipe drills of 750 m each and a junction
point inside the protected area.
Direct-pipe drilling is a unique technique
developed by Herrenknecht, combining the
advantages of microtunnelling and HDD
technologies. The prefabricated pipeline is
installed and the required borehole excavated
at the same time, which allows an efficient
and economic installation of the pipeline.
Renew today and receive your subscription in our new

interactive digital flipbook format, as well as in print.
www.pipelinesinternational.com/subscribe
VACUUM LIFTERS
VACUUM LIFTERS
Pipe handlers with a task at hand get excited about what were
building, Mr Solomon says, adding that he understands what new
opportunities will mean to the vacuum-lifting equipment industry. Hes
ready to do the heavy lifting without cutting corners, because its always
about safety and taking care of people.
When we start talks with large contractors, most of them tell us
that when going after a job, they are presented with an introductory
questionnaire covering who they are, their sales, and the positions of their
support teams. Weve created a business model that speaks to what
contractors are doing, regardless of where they are at in the world the
demand is there.
Vacuworx recently announced plans to invest $US10 million in a
training and outreach facility to better serve local customers, as well as
distributors and international clients who visit the manufacturers US plant
and headquarters.
From financing and rental options to customer service and
no-holiday parts departments the smallest component to a finished
piece of equipment contractors depend on access to proper resources in
their local communities, explains Mr Solomon.
Once a customer tags the work, he needs the equipment yesterday. If a
manufacturer says sure, Ill get it to you in six to 12 weeks, then
excitement tends to wane. If someone needs 15 vacuum lifters and pads,
were capable of meeting that demand and want to be ready for more. Were
ready for what were creating and the industry were helping to develop.
FASTER. SAFER. SMARTER.
For more information Vacuworxs products, visit www.vacuworx.com

Vacuworx lowering pipe into a line.
Vacuworx: expanding to support

the industry
Laying the groundwork to move precious natural resources is rigorous work that requires a firm grasp
on the latest techniques to handle sound business decisions, as well as physical terrains that span
hundreds, even thousands, of miles.
ith new entry points forming for pipeline contractors in

established and emerging markets around the world,
decision-makers who rely heavily on skilled labourers
outfitted with the appropriate tools also depend on solid relationships
and steadfast resources.
As demand for oil transportation and other pipeline utilities
heats-up worldwide, Tulsa-based Vacuworxs President and CEO Bill
Solomon says his vacuum-lifting technology company is committed to
doubling down on expanding inventories and developing distribution
networks in North America, Australia, Europe, and wherever the
industry leads.
Mr Solomon, who strives to keep the wheels of pipeline-related
commerce turning as fast and efficiently as possible, founded Vacuworx
in 1999 to help contractors safely move all sizes of pipe and other
materials in and around staging areas and along rights-of-way. The
38
company designs both its RC and MC line of lifters to make use of a

vacuum tank beam that doubles as a spreader bar, along with a
reservoir tank, a rotator, and vacuum pads capable of handling just
about any diameter of coated or non-coated pipe.
The machines attachable to carriers such as excavators, cranes,
and wheel loaders boast lifting capacities from 320 tonnes, and
have been reported to increase load and unload cycles in multiples of
seven, or even 12, compared with traditional material-handling
methods.
Mr Solomon is determined to lead the way in what he says is still a
young industry with enormous potential for growth. He notes that for
his customers, the days of stringing and installing pipe via hooks,
hoists, and choker belts are long gone. Vacuworx has tripled the size of
its inventories over the past three years, and today operates in the US,
Pacific Rim, Canada, Latin America, Africa, and Europe.
Vacuworx provides the safest heavy-duty

vacuum lifting equipment in the industry.
Our products cut project times in half with
a fraction of the ground personnel required
by conventional methods. Vacuworx helps
you work... Faster. Safer. Smarter.
A train being unloaded by Vacuworx.
+1-918-259-3050 | requests@vacuworx.com | vacuworx.com

10105 East 55th Place, Tulsa, Oklahoma 74146 USA
PI_V_Half_MAR.indd 1
39
2/12/14 12:44 PM
EVENT REVIEW
EVENT REVIEW
President of Marketing Florian Mauerer also

spoke, noting how impressed he was with the
passion and enthusiasm that was shared by
all of the conference attendees, and
commented on the privilege he felt to be a
member of an industry that clearly exhibits a
commitment to the care of its assets, its
employees, but most importantly, to the
communities that rely on the important work
carried out by those attending PPIM.
We, Rosen, really want to share the
passion we have in helping asset owners and
operators meet safety and compliance best
practices and industry requirements,
protecting the life of the asset and, where
possible, extending that life to maximize the
return on investment by optimising the assets
operational efficiency and performance,
Mr Mauerer said.
For the first time in this series of events,
delegates experienced a multi-track conference
programme, designed to allow discussion of a
wider variety of topics concerning pipeline
BJ Lowe addresses event attendees.
A PPIM conference speaker addressing the crowd.
Rosen Executive Vice President of Marketing Florian Mauerer addresses

conference delegates.
PPIM Houston pulls record crowds

This years 26th annual Pipeline Pigging and Integrity Management Conference and Exhibition was the
biggest yet, with more than 2,200 attendees, 29 presentations, 26 nations represented, and an extended
exhibition holding a record 108 company exhibitors.
rganised by Clarion Technical

Conferences and Tiratsoo Technical (a
division of Great Southern Press), the
Pipeline Pigging and Integrity Management
Conference and Exhibition (PPIM) was held
from 1013 February 2013 at the Marriott
Westchase, Houston, Texas, USA.
The best and brightest in the pigging
industry gathered at the only event in the
world that is tailored specifically to the
pigging industry. The event has a unique
structure of training programmes, a two-track,
two-day conference programme, and an
exhibition, that allows the whole pigging
40
industry to gather in one place.

With the support of Platinum Sponsor
Rosen, Gold Sponsors SGS PfiNDE, NDT
Global, RCS, and Silver Sponsors A.Hak
Industrial Services, N-Spec Pipelines Services,
and Halfwave, the event attracted a record
number of delegates and trade visitors.
In-depth training courses preceded the
conference and exhibition, providing
attendees with the technical knowledge
required to ensure the safest pipeline
infrastructure. The conference and exhibition
officially commenced with an Exhibition
Opening Reception on Tuesday night, at which
exhibitors and delegates enjoyed a drink and

networking with companies and attendees,
sponsored by Platinum Sponsor Rosen.
A conference programme like no

other
PPIM delegates packed-out the Marriott
Grand Ballroom on Wednesday morning, eager
to hear the first papers on the Conference
programme.
Clarions BJ Lowe and Tiratsoo Technicals
John Tiratsoo welcomed everyone to the
conference, thanking the delegates for their
continuous support. Rosen Executive Vice
41
EVENTS REVIEW
EVENTS REVIEW
management and engineering. Topics included

new technologies, case studies, management
systems, integrity and data assessment, and
risk management.
colleagues and friends to catch up, and also

make new connections in a relaxed setting.
Exhibiting companies included Quest Integrity
Group, A.Hak, Allan Edwards, Applus RTD,
CDI, Precision Pigging, Milbar, Enduro, GE Oil
& Gas, Girard Industries, Mears Group, NDT,
Rosen, STATS Group, and TD Williamson.
A bustling exhibition
The Exhibition included three lively
exhibition halls featuring all of the latest
pipeline inspection technology, rehabilitation
and maintenance equipment, including
cleaning and calliper pigs, ILI tools, brushes,
non-destructive testing equipment, and more.
The Exhibition gave delegates and trade
visitors one-on-one contact with pipeline
pigging and inspection equipment
manufacturers and suppliers.
Attendees were able to form new
partnerships by speaking first-hand with
company representatives who could provide
tailored advice to specific queries.
Kicking off the Exhibition was an opening
reception on Tuesday evening sponsored by
Platinum Sponsor Rosen, at which exhibitors
and delegates enjoyed a drink and quality
networking with companies and attendees.
The Exhibition was also the host to an
evening reception on Wednesday sponsored by
Gold Sponsor NDT Global, which allowed for
In-depth training courses

preceded the conference
and exhibition, providing
attendees with the technical
knowledge required to
ensure the safest pipeline
infrastructure. The
conference and exhibition
officially commenced with
an Exhibition Opening
Reception on Tuesday
night, at which exhibitors
and delegates enjoyed a
drink and networking with
companies and attendees.
See you at PPIM 2015!

The next PPIM Conference will be held
from 912 February 2015 in Houston, Texas.
Companies are already signing-up for
prime exhibition space, eager to be a part of
the biggest event on the pigging and integrity
management calendar.
Make sure you dont miss this opportunity
to be amongst all the major pigging, in-line
inspection, and integrity management service
providers in one place.
Contact Clarions BJ Lowe or visit the PPIM
website to find out how you can be involved.
Attendees networked at the bustling Exhibition.
The Pipelines International team.
bjlowe@clarion.org
www.ppimhouston.com
Head to the Pipelines International
website to see all the photos from the
26th PPIM Conference and Exhibition!
A hands-on demonstration at the Exhibition.
Attendees enjoying the lively Exhibition.
A hands-on demonstration at the Exhibition.
42
43
The projects starting point involved

testing an existing nominal 8 inch
Kevlar-reinforced plastic liner, produced and
manufactured by Raedlinger in Germany for
the utility market. Although this material had
not previously been used for lining subsea
pipelines, the general liner matrix
demonstrated many of the physical attributes
that are necessary requirements for success:
High tensile and good physical properties;
Moderate chemical resistance;
A high degree of flexibility; and,
The ability to be manufactured and
spooled in long lengths.
coating that is necessary to facilitate the steel

weld. As a result, it is common for most subsea
pipelines to be laid without an internal
coating, and an additional thickness of
sacrificial steel is added to the pipe wall
during the design process to compensate for
the calculated rate of corrosion throughout the
pipelines design lifetime.
Unfortunately, corrosion is rarely a linear

phenomenon, and certain types of corrosion
can cause damage to the pipe wall much more
quickly than has been allowed for at the
design stage. Pitting, grooving, cracking, or
crevicing to the interior pipeline wall can
occur in a remarkably short time: for instance,
a pipeline installed with a 20-year design life
Liner qualification and

development
The main Samarang Complex (offshore Malaysia).
Conquering subsea corrosion with IFL

IFL Global Project Director and Chairman of Anticorrosion Protective Systems Robert Walters discusses
the Petronas-sponsored development of the revolutionary infield liners subsea pipeline rehabilitation
system, and its likely impact on global markets.
etronas Carigali (PCSB) owns and

operates an extensive network of
subsea pipelines offshore Malaysia, in
the South China Sea.
Many of these pipelines are between
several hundred meters and several kilometers
in length, and are in varying water depths
running from platform to platform or platform
to onshore facilities.
Internal corrosion, due in large part to
sulphate-reducing bacteria (SRB), can cause
pipelines to have a relatively short lifetime.
Historically, this has resulted in replacement
becoming necessary in as little as four years.
The relatively short lifetime and frequent
replacement requirements represent
44
substantial capital expenditure for PCSB. To

reduce this, and to extend the life expectancy
of its existing pipelines, PCSB initiated a
project to develop in-situ corrosion barriers
that could be successfully deployed for use in
both its new and its existing pipelines.
Historically, there has not been a viable
method of installing such a corrosion barrier
within a subsea pipeline. As a result, the
design and development of infield liners (IFL)
project was instigated.
The development of IFL

The project began in April 2011, operating
under the joint management of Petronas and
Anticorrosion Protective Systems, globally
recognised as a pipeline rehabilitation

specialist engineer and contractor. The project
team delivered a market-ready product in two
years.
The IFL research and development
projects objective was to develop the
materials and technology necessary to
successfully install plastic liners into existing
and new carbon-steel subsea pipelines, used
for the transport of corrosive hydrocarbons in
which SRB are one of the principal sources of
corrosion. The IFL protects the internal pipe
wall from corrosion, and offers a secondary
containment capability in the event of a
rupture of or damage to the outer wall of the
pipeline.
The qualification of the liner was

undertaken in accordance with the API
Recommended 15S Qualification of Spoolable
Reinforced Plastic Line Pipe (first edition
March 2006), with further reference to the
applicable ASTM test standards, API 17 series,
and NACE standards. The testing and
qualification procedures were undertaken in a
number of locations in Germany, Norway, and
the United Arab Emirates.
The final enhanced IFL matrix is
comprised of a Solvay Solexis PVDF inner
liner, a tightly woven aramid core, using
Duponts Kevlar fabric, and an outer layer of
abrasive-resistant thermoplastic polyurethane
from BASF. Other versions of the liner are
available for less-aggressive service
conditions, such as water reinjection and gas
transmission.
All the principal objectives of the project
were fulfilled, and a new enhanced version of
the IFL has now been developed. Performance
testing has been undertaken which has
justified the use of IFL in aggressive, hot, sour
hydrocarbon service conditions of up to 120
degrees Celsius, with the liners exhibiting a
stand-alone burst capability of up to 120 Bar.
Industry motivation
The majority of subsea pipelines are
constructed from carbon steel, and are laid by
laybarge, during which single or double joints
of steel pipe are welded together and lowered
to the seabed. After completion of the welding
process, crews on the barge make-up the
external corrosion protection and infill the
missing concrete protection. It is not possible,
however, to make-up any damage that may be
caused to the internal coating by the welding
process, or infill any cut-back to the internal
Launching of the main liner.
45
may experience failure after as little as four

years in service.
IFL offers the pipeline industry a viable,
fast, economical option to pipeline
replacement, and it can be used for the
rehabilitation of an existing subsea pipeline
where:
1. It is desirable to extend the service life of
the pipeline beyond that for which it was
originally designed.
2. Unforeseen operational parameters, such
as CO or SRB corrosion, have caused the
pipeline to reach the end of its useful life
ahead of schedule. The pipeline may or
may not, at that point, have already been
shut-down and abandoned for safety and/
or environmental reasons.
3. Routine inspection of the pipeline has
shown that greater-than-anticipated
corrosion is taking place. Unless corrosion
is arrested, the pipeline will fail at some
predictable point in the future, at a time
which is less than the design life.
4. In instances where the pipeline has been
decommissioned or abandoned due to
integrity-related issues.
Overall, pipeline liner lengths are
dependent upon the pipeline diameter,
configuration, and number of short-radius
bends. However, trials have indicated that the
rehabilitation of a typical 6 inch or 8 inch
diameter hydrocarbon flowline could be
feasible over distances of up to 10 km.
Replacing a pipeline, and abandoning or
removing the old one, normally requires a
major engineering, procurement, and
installation campaign and an equally major
capital expense.
The insertion of an IFL into a defective
pipeline is a process of far less magnitude in
terms of planning, implementation, and
expense. As for project turn-around, with IFL
it may be possible to achieve in weeks what
may otherwise take years with conventional
pipelay replacement, especially if the
necessary pipelay barges for conventional
laybarge are not located in the region.
The inflation of the liner.
IFL installation procedure
The APS crew on installation vessel.
46
A thorough inspection of the existing

subsea pipeline prior to the detailed planning
of any IFL rehabilitation project is a
mandatory prerequisite, as is the collation of
all data relative to the operating parameters
and conditions. Inspections can be carried out
by intelligent pigs or external remoteinspection tools, such as the MTM Aqua.
This information is used to assess the

general condition and remaining wall
thickness of the existing pipeline, and to verify
the IFL size requirement in the event that an
enhanced tight-fit high-pressure liner is
required.
Prior to the offshore deployment of the IFL
installation spread, the host pipeline will have
been decommissioned, cleaned, and gauged,
ready for the liner insertion.
The IFL material, although manufactured
with a circular profile, can be temporarily
flattened for transportation and reeled onto a
transportation drum that can be sized so as to
fit into a conventional shipping container.
Each drum can be loaded with up to 5 km of
IFL, dependent upon the liner diameter. These
drums are then shipped to an onshore
location, usually a marine supply base, where
they are further processed into a folded liner
format prior to finally being sent offshore for
installation.
The liner-installation process is extremely
fast, operating at approximately 10 m/minute,
providing for the insertion of a typical 2 km
liner in a period of about 3.5 hours.
The IFL drum is, wherever practical,
installed on an offshore platform; where
necessary, it can also be located on the deck of
a work boat from where the liner can be
unspooled.
A feeder cable will have been fired through
the pipeline during the final cleaning and
gauging procedure, and this is used to pull
back the liner installation winch cable for
connection to a towing head, which is located
on the leading end of the liner.
During the engineering phase of the
pipeline rehabilitation project, the specific
winching loads necessary for the liner
insertion are carefully analysed using
proprietary IFL software. The winch packs
used for the actual installation process are
equipped with load cells and over-ride devices
so that, in the event of greater-than-predicted
loads being experienced during the winching,

the operator is alert to the situation and the
devices can be set to automatically cut out at a
given load if the engineered safety factor
relative to the liner yield strength is
approached. In reality, for most liner
insertions in the 0.5 5 km range, the
insertion forces are no more than one tenth of
the liners tensile yield strength.
The IFL liner in tight-fit configuration.
Prior to the liner installation, the IFL

end-termination coupling devices are installed
at the end flange locations. Once the IFL liner
has been drawn through the entire pipeline, it
is then re-rounded by filling with either air or
water. The liner, which is manufactured to the
same diameter as that of the host pipeline
bore, then expands to form an intimate fit with

the inner wall of the host pipe.
With the liner fully re-rounded against the
wall of the host pipeline, the last task is the
installation of the end-termination inserts,
which ensure reliable compression seals and
restraint at the liner ends. The re-lined
pipeline can then be hydrotested in the
conventional manner and all topside pipe
work can be reconnected, following which the
pipeline is then ready for re-commissioning
and for its new, extended life of operation.
The future
The IFL development project has
successfully achieved its primary goal, having
delivered to Petronas a viable alternative to
the replacement of deteriorated offshore
pipelines.
Following the successful conclusion of the

IFL development work, APS has already
installed several liners for Petronas subsea
pipeline network in Malaysia, and recommissioning of the previously shut-down
pipelines took place in the summer of 2013.
Petronas is favouring the option of
pipeline rehabilitation over that of new-lay
pipeline replacement, and in so doing, will be
able to drastically reduce its offshore
operational costs.
The intention is to make IFL available
globally during 2014 through a licensed
commercialisation process, and many pipeline
operators world-wide have already expressed
interest in this revolutionary subsea pipeline
rehabilitation system, for which major
anticipated cost savings compared to new lay
are the main driving factor.
To find out more information about IFL technology, visit www.apsdubai.com
The liner-installation process

is extremely fast, operating
at approximately 10 m/
minute, providing for the
insertion of a typical 2 km
liner in a period of about 3.5
hours.
47
Measuring anomalies with the

3D Toolbox
By Matthew Bellis, CEO, Seikowave, Lexington, KT, USA
Pipelines are the safest, most effective method of transporting oil and natural gas. In order to maintain
pipeline safety, monitoring systems are installed to ensure a rapid response in the event of a failure,
and in-line inspection (ILI) tools are used to locate and identify defects to enable corrective action that
prevents failures.
LI tools generally incorporate

sophisticated inspection technologies into
a tool that moves inside a pipeline; the
inspection technologies typically measure
parameters that can be used to calculate the
current wall thickness of the pipeline at
specific points. Sophisticated software
determines the type and severity of anomalies,
such as corrosion or dents, and helps the
operator of the pipeline determine what if
any corrective action is required. Because of
the measurement uncertainty associated with
ILI data, direct inspection of anomalies is
frequently required to verify their severity.
Direct assessment often requires
excavation of a portion of a pipeline. Given the
frequency of anomalies identified in ILI runs,
it is not uncommon for a pipeline to require
several hundred excavations annually at a cost
of tens of millions of dollars. Once the pipeline
is excavated and the pipe surface is prepared,
the anomaly can be inspected. After spending
millions of dollars in monitoring and safety
systems, ILI runs, and excavation costs, the
severity of most anomalies is determined
through manual measurements using a pit
gauge.
Figure 1: Pipeline anomaly measurement using a

pit gauge.
48
An alternative method of measuring

anomalies on pipelines uses the 3D Toolbox,
an analytical software package paired with a
3D imaging system that is based on a
technique commonly referred to as structured
light illumination. Once the 3D data is
acquired, the data is then analysed for areas of
metal loss. Measurement error can be
introduced in either the 3D data acquisition or
the 3D analysis step.
Accurate 3D measurements form the basis
for determining metal loss and metal
deformations. However, accurate 3D
measurements are not sufficient to determine
the extent and impact of damage on a
pipeline, as the original condition of the pipe
needs to serve as a baseline for the 3D
analysis. With the 3D measurement

representing the current condition of the pipe,
the data are separated into both damaged and
undamaged regions of the pipe. Once the
undamaged points have been identified, these
points can be used to form surfaces, which
then become the reference against which
damaged areas are measured to determine the
extent of metal loss or metal deformation. As
Figure 2 shows, the overall process is:
1. Acquisition of the raw 3D data;
2. Analysis of the 3D data, including
establishing the reference surface (shown in
green), determining defect areas and depths,
and calculating the river-bottom profile;
3. Generate RSTRENG calculation and
report.
All measurements have errors. The table

on the right is a summary of the major sources
of error associated with the use of 3D data to
determine metal loss and metal deformations.
In order to determine the measurement
errors, known values must be established.
For this study, a co-ordinate measurement
machine (CMM) was used to accurately
measure the surface of pipes with corrosion
and pipes with dents. The CMM
measurements were traceable to National
Institute of Standards (NIST) and were
accurate to within 0.04 milli-inch (mils), or 1
micrometer (m). Because the accuracy of the
CMM was expected to be almost two orders of
magnitude better than for all the other
techniques, all CMM measurements were
considered to be the true value. Five areas
were investigated in this study: three areas of
corrosion, and two pipes with dents. In
addition, ten defects were selected in each
area of corrosion. The deepest point for each
of the ten defects was measured by a
conventional pit gauge, the 3D Toolbox, a 3D
structured light system from Seikowave, and
the CMM. The CMM was programmed to take
Process step
3D data acquisition
3D data analysis
Source of error
Comments
Random noise in the camera

pixels
Typically a function of
temperature
Random noise in the imageprojection system
Associated with the digital nature

of pattern projection
Ambient light
Can cause saturation of camera

pixels
Improper separation of
undamaged area from damaged
area
Improper generation of surfaces
Can result in inappropriate

reference surfaces and errors in
both metal-loss and deformation
calculations
Table 1: Sources of error.
data in a rectangular array with a

circumferential pitch of 50 mil (1270 m) and
an axial pitch of 100 mil (2540 m). Because
the CMM was not programmed to search for
the deepest points of corrosion, there was
some probability that the CMM data might
not measure the deepest point for all defects.
The errors associated with the data from all
five errors were in agreement. For brevity, this
article will focus on presenting data from one
of the corrosion samples.
The pit gauge data was acquired over the

course of a day. The CMM data took more than
three days to acquire. All data using the 3D
Toolbox was acquired within a few hours.
Figure 3 shows a comparison of the CMM
data points and the 3D Toolbox data points.
Within a one square inch area, there are
200 CMM points. In this same area, the 3D
Figure 2: Pipeline measurement using the 3D Toolbox.
49

Toolbox produces a 3D model with 2,500

points. Overall, the agreement between the
CMM data and the 3D Toolbox data is within
4 mils (101.6 m) for 77 per cent of the data;
90 per cent of the data was within 6 mils
(152.4 m). The major deviations occur in
areas where the sampling frequency of the
CMM was not high enough to capture the
change in the shape of the pipe; typically, this
occurred in areas where corrosion was present.
While the comparison between the CMM
and the 3D Toolbox data showed excellent
agreement, this result did not verify whether
or not the 3D Toolbox could accurately
determine metal loss. To verify this, the 3D
Toolbox analysis software was used to
determine the depth at ten specific locations.
The depth values calculated by the 3D Toolbox
analysis software were then compared to the
depth measurements made by the CMM. The
3D Toolbox and CMM depth measurements
were also compared to pit gauge
measurements.
acquiring and analysing 3D data of corrosion,

dents, and other pipeline defects. This study
focused on establishing the error of the raw
data collected by the 3D Toolbox and the depth
calculations determined by the 3D Toolbox
analysis software. Unlike most 3D imaging
systems where error is reported on a global
basis this study focused on determining error
on a point-by-point basis. This is necessary
because maximum allowable operating
pressure (MAOP) calculations are driven by the
deepest points of corrosion, and not by an
average metal loss over a large area.
Consequently, understanding the error

associated with individual measurement points
is critical to determining if the MAOP
calculations are valid and, ultimately, if the
pipeline is safe.
Based on the data, the deviations from the
CMM points were determined to have an
average value of zero and a standard deviation
of 4 mils (101.6m). The ability of the 3D
Toolbox to accurately determine the depth of a
corrosion pit was calculated to be within
2.2 mils (55.9 m) of the CMM, on average.
technical
JOURNAL OF
PIPELINE
Conclusion
The 3D Toolbox is a measurement system

that comprises of a 3D imaging system, the 3D
digital pit gauge, and a set of software tools for
ENGINEERING
CM
MY
CY
CMY
Figure 5: Comparison of the 3D data from the CMM and the data measured with the pit gauge for area 2A. The
average deviation between the pit gauge and the CMM was 5.3 mils (134.6 m) and the standard deviation was
4.3 mils (109.2 m).
If you are a pipeline engineer,

The Journal of Pipeline Engineering
is a vital tool that will keep you
up-to-date on the latest technical
research around the world.
Digitally published four times a year,
it stands alone as the premier technical
publication for the pipeline industry.
Figure 3: Comparison between CMM points and 3D

Toolbox points.
As a peer-reviewed journal it provides

quality information to keep you at the
forefront of industry developments.
Subscription is just $US350 per year
and also includes access to the
electronic archive.
Visit the website to subscribe today.
www.j-pipe-eng.com
Figure 4: Area 2A with the pit gauge measurements
indicated for each of the ten locations.
50
Figure 6: Analysis of area 2A using the 3D Toolbox: the specific locations that corresponded to the CMM
measurements were identified and measured. The average error between the CMM and the 3D Toolbox measurements
was 2.2 mils (55.9 m) and the standard deviation was 0.7 mils (17.8 m).
Cleaning pig elements: a new concept

By J.R. Morgan, Sales Manager, Enduro Pipeline Services, Tulsa, OK, USA
Over the decades, the cleaning of pigs and the elements attached to them has evolved to accommodate
the specific requirements for cleaning a pipeline in a safe and effective manner. A new method for using
pencil brushes has been developed to meet unique design requirements of pipeline projects.
ormally pencil brushes are assembled

around a metal flange, which is then
attached to the cleaning pig. While
this is the standard method of using pencil
brushes and has proven to be effective for
cleaning, some pipeline cleaning projects
require unique types of pig design to meet the
desired outcome.
Some cleaning projects involve the need to
adequately clean internally-lined pipelines and
pipelines that require a pig and its cleaning
elements to be more forgiving, to lessen the
pigs drag and expand its capabilities with
traversing heavy-wall pipe and reduceddiameter fittings without stopping or causing
damage to the pig or the pipeline. With these
specifics in mind, a new method for using
pencil brushes was developed.
Pencil brush innovation

By taking the standard cantilever spring
arm typically used for flat-wire-block
brushes and engineering a urethane block to
hold the individual pencil brushes, a new
concept for cleaning with pencil brushes has
been introduced. Mounting the special pencil
brush unit on a spring arm which attaches to
the pig body brings several advantages over
the traditional flanged-mounted pencil
brushes: improved brush pressure, increased
number of restrictions that the pig can safely
pass through, the ability to replace the
individual pencil brush as opposed to the
entire flange assembly, ease of interchanging
carbon-steel brushes with synthetic brushes,
enhanced cleaning performance, and
continuous contact with the pipe wall
resulting from the brushes ability to float on
the spring arm.
By design, the mechanical assembly that

supports the pencil brush block allows for 360
degrees of internal pipe wall coverage and
variable outward impact from bristle to pipe
wall, depending on the type of spring that is
used for any given application. For instance,
the amount of force from bristle to pipe wall in
a pipeline that is internally lined must differ
from one the force for a pipeline that is not
internally lined; the amount of force required
for effective cleaning is achieved by the type of
coil-spring used on the cantilever arm
assembly. These benefits cannot be achieved
with the traditional flange-mounted pencil
brush design. In addition, synthetic pencil
brushes should be used while pigging an
internally lined pipeline, while carbon steel or
stainless steel brushes should be used in
pipelines without linings .
After extensive testing and numerous runs
with the cantilever pencil brush assembly,
feedback indicates the results obtained have
exceeded the pigging operators expectations.
Several pig designs have been developed that
incorporate the spring-loaded pencil brush
system: the pig design and the type of pencil
brush (synthetic or carbon steel) were chosen
by identifying the specific needs for a
particular pigging project, and matching those
needs with the correct type of pig brush
assembly. Knowing the pipeline parameters
prior to pig selection is vital for achieving the
desired outcome of any pigging project, and
will ensure successful cleaning results.
Employing the correct pig and cleaning
elements on a routine basis will ultimately
enhance any given pipelines throughput and
will help maintain that pipelines integrity.
Isolation technology has been developed by STATS Group to facilitate the repair of unpiggable pipeline
defects. This new development (patent pending) allows local placement of piggable remote isolation
tools at either side of an unpiggable defect, allowing safe removal and replacement of the damaged
section without depressurising or flooding the entire pipeline.
The Enduro pencil brush.
After extensive testing

and numerous runs with
the cantilever pencil
brush assembly, feedback
indicates the results
obtained have exceeded
the pigging operators
expectations.
Enduro Pipeline Services, Inc is a full member of the Pigging Products & Services Association.
52
The EPRS revolution
espite good pipeline design and

integrity management schemes,
pipelines can and do get damaged and
need to be repaired. The damage could be
caused by a number of factors such as a
dragged anchor, landslide, iceberg impact,
fatigue, or stress cracking. The resulting damage
may be unpiggable in the form of a buckle or
dent, with or without rupturing the line.
Following an inspection of the pipeline and
assessment of the defect, repair may require
replacement of a section.
Without suitable double-block isolation
tools installed locally at both sides of the
damaged section, it would be necessary to flood
and depressurise the pipeline to allow safe
removal of the damaged section, and perform
the repair by installing a new section.
Depending on the availability of
emergency-repair equipment, the time to return
a pipeline to service could be more than one
year. However, with appropriate planning and
investment in equipment, including isolation
tools and procedures, this could be reduced to
approximately six weeks.
A pipelines out-of-service time, following an
incident, can be reduced with strategic
investment in specific elements of an
emergency pipeline repair system (EPRS).
The time to repair can be reduced to
approximately 68 months simply by
developing detailed procedures for potential
repair scenarios and procurement of long-lead
items, large forgings for clamps or mechanical
connectors, and replacement pipe and flanges
all reduce the reaction time.
Further substantial time savings can be
achieved if the EPRS equipment has been
manufactured and kept in a state of readiness
for emergency deployment. This could

potentially reduce a pipelines out-of-service
time to less than 100 days.
Even with an EPRS in place, if suitable
isolation tools are not available, the time from
incident to resumed production can be over
3 months. The decommissioning (flooding and
depressurising) and re-commissioning (leak
testing/dewatering) stages will take a significant
proportion of the out-of-service time,
potentially more than 60 per cent of the
downtime.
However, with pre-invested isolation tools
available, the pipeline return-to-service time will
be reduced, potentially down to less than six
weeks. Additional benefits from this investment
include a safer worksite, minimising content
discharge to the environment, and reducing
inventory losses. The prevention of seawater
ingress negates the need for a timely
dewatering and drying programme, reducing
the time to repair and ensuring production
outage is minimised.
In 2012, STATS was awarded a 10-year
contract to design, manufacture, test, and
supply a new range of high-integrity Remote
Tecno Plugs for 32 inch, 34 inch, and 38 inch
pipelines. These tools provide double-blockand-bleed isolation, and form part of Qatargas
EPRS for production facilities in the Arabian
Gulfs North Field, where gas and condensate
are transported by pipelines to Ras Laffan City
for export.
Since then, Tecno Plugs have been
developed (designed, manufactured, and
qualified) that can be pigged towards an
unpiggable line defect from both sides, or to
pass through a dent with a bore restriction of
10 per cent of the pipeline. The Tecno Plug
provides fail-safe double-block-and-vent

capability, with both seals being fully selfenergised and independently tested and
monitored. The seal annulus provides a
zero-energy zone, with no trapped pressure.
STATS patent-pending bypass system allows an
isolation to be installed on both sides of the
damaged section, providing a safe environment
to carry out a quick and effective repair of
subsea pipelines, reducing environmental and
commercial impact, and enabling early
resumption of production.
Tecno Plugs pigged to either side of an unpiggable

defect.
The EPRS Tecno Plug.
To find out more about STATS Tecno Plugs, visit www.statsgroup.com
53
Ultrasonic in-line inspection:

enhancing deepwater pre-commissioning
Mark Slaughter, Global Product Line Manager ILI, Weatherford P&SS, Houston, TX, USA
The cost of deepwater pipeline repair makes inspection accuracy critical to assessing pipeline integrity.
During a recent pipeline project in the Mediterranean, advanced ultrasonic wall-measurement technology
was used to achieve a new level of baseline survey accuracy.
oble Energys long-distance, deepwater

Tamar pipeline project is a subsea gas
production and transportation system
that connects the deepwater gas field in the
Mediterranean Sea to an offshore receiving and
processing platform linked to the existing
Mari-B Platform.
A new Weatherford solution was
successfully employed for the Tamar pipeline
project, using ultrasonic in-line inspection
(ILI) tools and specialised subsea
commissioning technology to mechanically
displace and introduce pipeline fluids. These
deepwater operations pose logistical and
technical challenges that typically require a
significant amount of vessel time, support,
and budget.
Conducted in conjunction with
pre-commissioning operations, the ILI also
helped eliminate logistical and scheduling
constraints for overall project success.
The Tamar projects challenges and

solutions involved subsea flooding, testing,
and MEG injection; dewatering, MEG
conditioning and nitrogen purging; and
baseline inspection of the systems 16 inch
tieback. The inspection was successfully
conducted using Weatherfords latest
generation of highly accurate ultrasonic wall
measurement (UTWM) tools.
Pre-commissioning operations were
successfully conducted using Weatherfords
Denizen subsea pre-commissioning system.
Flooding, cleaning, and gauging the twin 147
km, 16 inch diameter, pipelines was done from
a vessel at the shallow end of the 2401,700 m
water depth run.
ILI surveys were conducted during the
flooding operations. A caliper tool was used to
verify the minimum bore, followed by a UTWM
tool for the wall thickness baseline survey.
After the inspection, dewatering operations

were conducted for all 5 km of the Tamar
in-field and tieback pipelines.
Tight scheduling constraints for the
subsea launch presented a challenge for the
16 inch UTWM inspections. Normally, there
would have been sufficient battery life to run
the inspection tool; in this case, however, the
time needed for a subsea launch required a
delayed activation.
The ILI tool first had to be inserted into the
pipeline launcher receiver (PLR) onboard the
vessel. A vessel crane moved the launcher
with the ILI tool to the pipeline end manifold,
and a hydraulic lock secured the pipeline end
termination to the pipeline. A remotelyoperated vehicle was used to turn the subsea
valves and launch the pig.
This time-consuming process increased the
risk of delays that could drain battery life and
54
cause a failed run. To account for the time and

unforeseen delays, a two-hour window was built
into the schedule. This resulted in a 12-hour
delayed activation from the time the tool was
inserted into the PLR on board the vessel. The
delay was programmed into the system, and the
inspection was successfully conducted.
Ultrasonic inspection
Non-destructive ultrasound testing has
been used for ILI since the 1980s. The
technology measures wall thickness based on
ultrasound compression waves directed into
the pipe wall. Ultrasonic transducers
positioned at 90 degrees to the pipe wall use
an impulse-echo mode to transmit an
acoustic wave and receive return echoes.
These echoes can be analysed to represent
the locations of the internal and external pipe
wall, and metallurgical anomalies such as
laminations.
A UTWM baseline inspection identifies
and classifies non-injurious signals such as
mid-wall laminations and other mill-related
anomalies; a baseline corrosion survey
provides wall-loss sizing data. Greater
accuracy is important when assessing
anomalies, assigning risk, and prioritising
maintenance and expenses. Accurate anomaly
classification and sizing is particularly
valuable when comparing baseline data to
future inspection results and integrity
Deepwater challenge
Gas in the Tamar field comes from five
high flow-rate subsea wells produced through
separate in-field flowlines to a subsea
manifold. Dual subsea pipelines transport
production from the subsea manifold
approximately 149 km to the Tamar Offshore
Receiving and Processing Platform. The
processed gas is delivered to the existing
Ashdod onshore terminal for gas sales into the
Israel natural gas pipeline.
Weatherfords Pipeline and Specialty
Services group was contracted to provide the
pipeline pre-commissioning and inspection,
including tieback pipelines, monoethylene
glycol (MEG) pipelines, in-field flowlines,
gas- and condensate-injection pipelines,
Tamar sales gas export pipeline, and utility
pipelines. Integration of these services
through a single contractor was key to
reducing logistical and scheduling constraints
for overall project success.
A vessel crane performing subsea PLT-ILI delivery.
The Tamar field layout.
measures such as engineering assessments

and determining growth rates. For deepwater
subsea lines, where normal onshore
non-destructive examination validation
practices are cost prohibitive, accuracy is key
to managing costs.
Compared to magnetic-flux-leakage (MFL)
tools, ultrasonic technology yields better
sizing accuracy in determining wall loss and
pipe-wall thickness because ultrasonic
pulse-echo physics are a more direct
measurement of wall loss. In some cases,
however, MFL is a better solution, because it
can be more forgiving of dirt, debris, rough
internal pipe surfaces, and waxy liquids. This
necessitates a comprehensive pre-inspection
assessment prior to selection of the
appropriate technology.
Importance of accuracy
Accurate measurement of wall thickness
directly influences the calculation of a
corrosion-feature failure pressure. MFL tools
do not typically measure wall thickness, but
instead infer it from several sources, including
API pipe specification, pipeline construction
data, and/or estimated variations in the
magnetic field. This provides only a relative
assessment due to pipeline data inaccuracies,
or difficulty in obtaining data because of asset
ownership transfers, unavailable data, or
unrecorded pipeline reroutes and modifications.
Inferred measurements also do not

consider wall thickness tolerances from the
pipe mill. As a result, an MFL corrosion
wall-loss depth-measurement depends on a
relative measurement of the pipe wall, which
decreases the sizing accuracy beyond the
normal ILI tool sizing tolerance. This is
because, in addition to tolerances associated
with tool anomaly sizing, there are also
tolerances associated with the actual
pipe-spool wall thickness from the mill.
Acceptable tolerances from the mill can be
as high as 10 per cent for pipe-wall
thicknesses between 515 mm in welded
pipelines; the tolerances for pipe walls greater
than or equal to 15 mm are 15 per cent in
welded pipe. These pipe-mill tolerances and
the high corrosion-anomaly sizing tolerances of
an MFL tool, mean the calculated failure
pressure from an ILI survey can be significantly
over or under, as the result of sizing
inaccuracies caused by quantifying depths as a
percentage of the assumed wall thickness.
Greater corrosion-sizing accuracy also
provides better data to feed an assessment
standard, such as B31G, modified B31G, or
RSTRENG effective-area assessment, the
preferred method for determining the
remaining strength of the pipe. Of the three,
the RSTRENG effective-area assessment has
the most accurate results based on actual
versus predicted burst-pressure tests.
New sensor technology in the current
Weatherford UTWM devices helps enhance
detection and accuracy capabilities to limit the
occurrence of echo loss due to adverse
pipeline conditions. This loss has been
demonstrated over many years of experience.
Engineering tests and field-work data
analysis to API 11636 standards have shown the
new sensor technology improves sensitivity and
reduces signal degradation, and this advance is
critical to achieving successful deepwater
subsea baseline surveys. The same sensor
technology is used for in-line crack inspection,
with accurate sizing results that can be used for
API 5797 integrity-assessment methodologies.
Deepwater inspection solution

Deepwater inspection using ultrasonic
technology provided the Tamar project with
the accuracy demanded for subsea operations.
Conducted in concert with the precommissioning, the inspection ensured
pipeline integrity while helping to achieve
high levels of logistical and scheduling
efficiency.
55
ARE YOU UP TO SPEED?

www.clarion.org
0 0 0 2 0 1 4
TRAINING
TRAINING COURSES 2014
ESTREL HOTEL, BERLIN, GERMANY

OCTOBER 2124 2014 www.clarion.org/fpp/fpp-2014
Following the success of the 2012 event, the Fixing Pipeline Problems conference 2014 is back to help you
solve your pipeline rehabilitation issues.
aking place from 2124 October 2014 at

the Estrel Hotel, Berlin, Germany, the
event will see delegates learn from top
industry professionals from around the world.
The international event and its
accompanying exhibition will provide both a
forum for discussion as well as a platform to
showcase the industrys latest achievements.
A wide variety of issues concerning pipeline
rehabilitation will be covered, ranging from
the initial stages of evaluation of a pipeline's
condition, to the steps required to undertake
rehabilitation of the structure to ensure its
continued fitness-for-purpose and prolong its
economic lifetime.
The Fixing Pipeline Problems (FPP)
conference programme will be divided into
the following broad areas of interest:

Repair and rehabilitation practices and
technologies;
Pipeline rehabilitation project case
studies;
Internal issues including black powder,
microbial corrosion;
External issues including coatings,
DCVG, direct assessment;
Inspection internal and external;
and,
Integrity assessment.
A host of opportunities
The event will not only discuss the latest
developments in the industry, but also to
showcase some of the industry's latest
achievements, and to provide an unmatched

opportunity for both networking and
learning.
The conference programme will be of
relevance to all involved in the operation and
lifetime planning of pipelines that transport
all types of hazardous hydrocarbons both
on- and offshore, in particular oil and gas, as
well as to those involved in their regulation
and safety.
Sign up for training courses

Two pre-conference courses will be
offered on 2122 October:
Performing Pipeline Rehabilitation
Pipeline Repair, Hot Tapping, and
In-Service Welding.
CALL FOR PAPERS NOW OPEN

The call for papers for the FPP conference is now open event organisers Tiratsoo Technical and Houston-based Clarion Technical Conferences
invite you to submit a proposal for your paper to be presented and published in the conference programme.
Proposals should include an abstract of no more than 200 words, accompanied by the authors complete contact information and
affiliation, and should be sent to:
John Tiratsoo, Director
Tiratsoo Technical, PO Box 21, Beaconsfield, HP9 1NS UK
Onshore Pipeline Engineering
Onshore Practical Pigging Training
31 March4 April 2014, Houston, Texas

28 April2 May 2014, Newcastle, United Kingdom
Presented by Professor Phil Hopkins & Dr Roger King
1719 June 2014, Tricht, The Netherlands

Presented by Penspen & A.Hak Industrial Services
This first-hand and practical training course provides a wideranging overview of all aspects of pigging operations for onshore
pipelines.
This course is a formal introduction to pipeline engineering

and will cover everything from pipeline engineering basics to
material selection, pipeline corrosion, and the repair and integrity
management of those pipelines.
The site is A.Hak Industrial Services test loop facility in Tricht, The
Netherlands. The facility has a 15 m, 12 inch water-driven pipeline,
and a second 150 m, 24 inch line under construction.
Defect Assessment in Pipelines
Subsea Practical Pigging Training
29 April1 May 2014, Newcastle, United Kingdom

Presented by Professor Phil Hopkins
2014
This course will present the latest defect-assessment methods to
pipeline engineers and managers. These methods will range from
simple, quick, assessment methods, to the more-detailed fitness-forpurpose analysis.
Practical Pigging Operations
35 June 2014, Bergen, Norway

Presented by Penspen & KTN
A three-day training course covering the practical aspects of

pipeline pigging. This training course, being held at KTNs facility
in Bergen, Norway, will provide a wide-ranging overview of all
oshore aspects of pigging operations.
The syllabus includes both hands-on exercises using the KTN test
loop, as well as classroom instruction, and full documentation.
31 March4 April 2014, Houston, Texas

Presented by Penspen, Mears and Greenes Energy Group
Practical Pigging Training
This hands-on training course provides a wide-ranging overview of

all aspects of pigging operations.
15 September 2014, Rio de Janeiro, Brazil

Presented by Penspen & CTDUT
The course takes place at Greenes Energy Groups water-driven

pipeline test loop facility in Houston. During the five days, the
participants typically participate in up to nine dierent runs of
various tools.
This training course provides the opportunity to get first-hand

knowledge and experience a wide-ranging overview of all aspects
of pigging operations. The course will be held at the CTDUT facility
adjacent to Petrobas Duque de Caxias refinery, near Rio de Janeiro.
The course uses CTDUTs 14 inch, 120 m long, water and
nitrogen/air-driven test loop at the site. During the five days, the
participants typically perform up to nine dierent runs of various
tools.
Working with a faculty of 38 leading industry experts, Clarion and Tiratsoo Technical are privileged to provide some of the best available
industry based technical training courses for those working in the oil and gas pipeline industry, both onshore and oshore.
Complete syllabus and registration details for each course are available at:
For more information contact John Tiratsoo on +44 1494 675139 or e-mail: jtiratsoo@gs-press.com
The deadline for abstract submission is 12 May, 2014, and final papers are required by 22 September, 2014.
56
www.clarion.org
www.tiratsootechnical.com
EUROPE REVIEW
EUROPE REVIEW
Evolving the east: constructing the

Northern Caspian Pipeline System
The Northern Caspian Pipeline System, operated by Russias largest oil company, Lukoil, is currently
under construction, and is expected to be commissioned in May 2015.
he Northern Caspian Pipeline System

consists of onshore and offshore oil and
gas pipelines, transporting product
from the Vladimir Filanovsky oil field and the
Yury Korchagin gas field.
Offshore challenges
The subsea section comprises a 12.8 inch
diameter inter-field oil pipeline and 16 inch
diameter gas pipeline both 40 km in length
which will connect the V.Filanovsky and
Yu.Korchagin fields. The pipelines have a
1.51.7 inch cement coating.
The subsea export section comprises a
522 inch, 124 km oil pipeline and a 28 inch,
134 km gas pipeline, both of which connect
the V.Filanovsky oil field to the landfall. All
the pipes used were manufactured and
The Korchagin platform producing oil in winter.
58
concrete-coated at Russian pipe plants.

The contractor for the inter-field
pipelaying was Bumi Armada Caspian, and
Saipem SpA is laying the export pipelines. In
2013, 77 km of the subsea oil pipeline and
61 km of the subsea gas pipeline were
constructed, as well as 40 km of the inter-field
oil pipeline and 40 km of the inter-field gas
pipeline.
Lukoil expects that in the 10 years
following 2015, four more fields will be
constructed, expanding the total pipeline
system to more than 1,500 km.
Onshore facilities
The onshore section comprises a 28 inch
diameter, 263.3 km long gas pipeline running
from the landfall to Lukoils Stavrolen
gas-processing plant. The capacity of the

pipeline is expected to reach 8 Bcf/a, and it is
scheduled to be commissioned in May, 2015.
The gas pipeline will be equipped with a
leak-detection system as well as with technical
security devices.
This gas pipeline will be used to transport
the associated petroleum gas from the North
Caspian fields for conversion into polyethylene
and polypropylene at the gas-processing
plant, part of the chemical complex that is
being constructed by the company at the
Stavrolen industrial site. In addition, the
marketable gas from the gas chemical complex
will be transported to the Gazprom
transmission system.
Lukoil also plans to construct power
transmission lines along the pipeline route,
including 22 transformer substations, 24

control points, telecommunication lines, and
other infrastructure facilities.
The Russian firm NefteGazMontazh was
awarded the construction contract, with the
Russian company VolgogradNIPImorneft
designing the onshore facilities.
The onshore facilities will be located in the
Republic of Kalmykia near the Komsomolskaya
oil-pumping station, owned by the Caspian
Pipeline Consortium, approximately 60 km
away from the Caspian coast. The facilities
will be connected to the Komsomolskaya
pump station by two 530 mm diameter oil
pipelines. The facilities will include four tanks
with a capacity of 20 Mcm each, equipped
with an automated fire-fighting system, an
oil-metering unit, three oil-heating units, an
automated gas-distributing plant, treatment
facilities, a fire station, a satellite station, a
rotation camp, and a number of other
production facilities to ensure safe operations.
Construction of the onshore oil-intake
facilities from the Northern Caspian fields is to
be completed by mid-2015.
The first stage of Filanovsky construction has been completed.
Pipelaying at sea.
59
EUROPE REVIEW
REVIEW
Controlling wax in the Gudrun Oil

Export Pipeline
Aidan ODonoghue, Pipeline Research Ltd, Glasgow, UK
The Gudrun field, located 55 km north of Sleipner in the North Sea, contains both oil and gas, and Statoil
plans to develop this field with the oil and gas transported to Sleipner in separate pipelines for onward
export to Krst, Norway. Controlling wax deposition in the oil line is essential for efficient operation of
the system.
he oil and gas export lines to Sleipner are

multi-diameter, and as such, special care
must be taken in the design and selection
of any pre-commissioning (RFO), operational,
and inspection pigs for the system.
The oil line is 10 inch x 12 inch with 10 inch
risers and a 12 inch pipeline, where wax is
expected to deposit. This deserves special
attention in order to control this wax, and initial
pigging frequency will be weekly. The diameter
change is 23 per cent, and the challenge is to
clean the wax from the large-bore pipeline as
effectively as possible. By their nature, dualdiameter pigs are not aggressive in the
large-bore pipeline. Pig design, development,
and testing have been performed to establish a
more aggressive pig for this pipeline without
compromising its ability to negotiate the line.
In 2007, Statoil initiated a research and

development programme to examine wax
removal from oil and condensate pipelines, with
a focus on the recovery of heavily waxed
pipelines, wax control in dual-diameter lines,
and wax removal and transport in gas-dominated
two-phase pipelines. The results of the findings
of this work have been used to address the
practical application the Gudrun Oil Export
10 inch x 12 inch line.
The pig design for Gudrun operational
pigging for wax management resulted from the
design of the pre-commissioning pigs
(flooding, cleaning, and gauging/dewatering),
with an increase in aggression along with
input from new styles of scraper elements
from the de-waxing research and development
project.
The pig is made up of a tow module and

an aggressive trailing module. The tow
module is an aggressive version of the
flooding, cleaning, and gauging pig with
thicker guide discs, for example. The trailer
module is an aggressive brush module, with
specialist brushes to withstand the change in
diameter to allow good scraping in the large
pipe bore.
In the trials for the Gudrun operational pig,
a number of trailer modules were tested:

Tipped brushes;

Spring steel scrapers; and,

Torsion springs.All were trialled and
all were successful, but the torsion springstyle module was considered to be the best for
ploughing up the wax and preparing it for
removal by the next pig.
Permanent
Launcher
The operation of the torsion springs are

shown in Figure 3. By its very nature, a torsion
spring is ideal for dual-diameter pigging in
general, as large angular deflections can be
accommodated (90, 180, even 270 degrees
rotation). Pre-tension can be designed-in, thus
maximising the force on the pipeline wall in the
large bore.
The large deflection and small contact area
with the wax makes it ideal for any diameter
change and penetration of hard wax deposits.
Monitoring the Gudrun Oil Export Pipeline
pigging will help to provide valuable feedback
on the success of this design. The aim is to try to
keep the line clean for hydraulic efficiency, and
also for inspection of the line every five years:
There is a data logger provided for the
Gudrun Oil Export Pipeline pigs which can
indicate the build-up of wax in the line
(increased differential pressure, reduced
vibration, etc.). It is expected that a baseline
run will be performed at the start of the
project and then followed up with other
data-logger runs two or three times per
year. This will help to establish the success
of the Gudrun pig aggression;
The ability of the pig bypass system (high
area in 12 inch and low area in 10 inch)

will be assessed. The pig uses the 10 inch
sealing discs to control bypass in the small
diameter line, and higher bypass will be
used than would normally be possible.
The pig is also designed to flush wax off
the body but this will only be assessed on
receipt;
The maintenance requirements for these
pigs can be assessed based on the wear
and tear on the various components
such as discs, springs, and other
components.
For Gudrun, the pig and data logger will be
used to optimise the pigging frequency over
time. This concept could then also be applied to
other dual-diameter waxy pipelines in the
future, and allow control of such wax deposits.
12 inch
position
To do this will require good records from

Gudrun to establish if such an optimisation is
possible.
The torsion springs work by ploughing into
hard wax deposits and preparing them for
removal by subsequent pigs running through
the line. Populating the trailer module with
more and more springs can be done to increase
the aggression.
The graphs in Figure 5 show data logger
output during the initial run to remove a short
section of 6 mm thick hard wax (top plot), and
the second run (lower plot). The reduction in
differential pressure over the hard wax zone
shows that the majority of the wax has been
removed. By comparing this to a base-case run
in the line, it is possible to monitor the pigs
ability to control wax in the line.
Captive position
with pre-tension
10 inch position
Spring
as-supplied
Permanent
Receiver
Figure 2: Final Gudrun OE operational pig.
Sleipner Topsides
Figure 3: Action of the torsion springs.
Gudrun
Sleipner A
Gudrun 10 inch x 12 inch Oil Export Pipeline - Schematic
Gudrun Topsides
ESV
Wax
Reducer
Sleipner Riser
Reducer
Waxy zone
in large bore
12 inch line
Gudrun Riser
Gudrun Oil Export Pipeline, 57 km

Figure 4: Action of torsion springs on a thick hard wax
during trials.
Figure 1: Overview of the Gudrun Oil Export Pipeline.
60
Wax
removed
Figure 5: Two dewaxing pig runs during tests (using the data logger).
61
RISK MANAGEMENT
Is formal risk assessment

helping me?
By W. Kent Muhlbauer, WKM Consultancy, LLC, Houston, TX, USA
Ever consider that true risk management sometimes occurs only at the lower levels of some pipeline
organisations? That is, personnel performing field activities are in effect setting risk levels for the
company. Their choices of day-to-day activities are essentially driving risk management and thereby
establishing corporate risk levels. This is not just theoretical real choices are being made. While there
are regulations and company-specific procedures to control certain actions, the on-the-ground team is
often relied upon to prioritise, allocate, act, and request additional resources based on its perceptions.
ortunately, we have a generally savvy

workforce that usually makes good
choices. But why would top company
executives choose to delegate company-wide
risk-management decision-making, in effect
abdicating their own power to manage the risk
of the organisation?1
In at least one sense this delegation of
risk-management decision-making is a good
thing. Those most knowledgeable about
location-specific conditions and characteristics
are often in the best position to make certain
decisions. They are the subject-matter experts in
the pipelines often-highly-variable immediate
environment.
But such distributed control also has its
weaknesses. In its risk assessments, the field
team may not use all of the available
information, such as inline inspection (ILI)
details, operational data, learnings from other
pipelines, etc. The team may also not use a
formal structure to find and manage the
non-obvious risks. Even if it does use formal
techniques, without a centralised view of risks
across the entire organisation, imbalances are
certain to occur.
So, if the alternative is not superior, then
why is centralised risk management not the
standard? At least one explanation lies in the
perceived accuracy and usefulness of risk
assessments. Some risk issues are very apparent
and no formal assessment is needed to
understand them. Good inspection techniques
take much subjectivity out of certain resource
allocations: a list of identified critical anomalies
is like a ringing telephone that must be
answered. The fix-the-obvious opportunities for
risk management are hopefully fully addressed
62
in inspection follow-ups and in the day-to-day

operations and management (O&M). A regional
approach can be very efficient in managing
obvious risk issues.
However, there are other risks and riskreduction opportunities that are not so obvious.
Humans can judge a thing based on a subjective
and simultaneous interpretation of a handful of
factors maybe 3-5. Real risk scenarios,
however, may involve a dozen or more factors.
Remember, many modern pipeline incidents
are of the Perfect Storm type rare chains of
events, often involving multiple improbable
and non-apparent factors, lead to the incident.
This is where formality is needed. The formal
risk assessment when done properly, finds
those highly improbable scenarios, involving
multiple, non-intuitive, overlapping issues
that can generate the Perfect Storm event.
The previously unrecognised event is now
revealed and quantified.
How can upper levels in the organisation
gain the risk understanding required to be fully
engaged in risk management? By knowing the
risk associated with every asset. The corporatelevel decision-maker should seek a portfolio view
of the companys assets, showing all costs of
ownership. Just as with a portfolio of stocks
and bonds, each asset ties-up capital and has
carrying costs. The revenue streams, capital
cost, the O&M costs, tax liabilities, etc, have
always been well understood. The riskcost
perhaps not as much. Most know that risk is
part of the cost of ownership but how many
really use that knowledge in everyday decisionmaking? The key lies in reliable risk
assessments whose results truly represent real
world cost of ownership risks. Then, and only
then, is the top-level decision-maker in a

position to most efficiently allocate resources
across the entire organisation.
So, in a moment of self-evaluation, perhaps
this question arises: is your risk assessment
helping you? Some may answer sure, I get a
checkmark on my regulatory audit form, but
most recognise that so much more is at stake.
Beyond regulatory compliance, how much value
emerges from the risk assessment effort? Some
must admit that their assessments are mostly
window-dressing, and not really helping
decision-making. Perhaps their risk assessment
is only documenting what is already
perceived. There is some value in such
documentation but there should also be
some ah-ha moments. After all, the whole
point of a formal risk assessment is to provide
the structure that can and does reveal the
otherwise unknown.
1 I credit this powerful phrase abdicating risk
management to my colleagues at Jana Labs.
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EVENTS FOR 2014:
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Inspection of offshore
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30 April2 May 2014
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1216 May 2014
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1214 May 2014
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23 June 2014
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26 June 2014
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ISSUE 19

Protecting your assets,

Pioneering Underground Technologies

The EPRS revolution

Fixing Pipeline Problems

ISSUE 19 | MARCH 2014

From the Editor

Coming in future issues

Proposed pipelines in Canada

In conversation with Richard Williamson

Ultrasonic in-line inspection: enhancing

Evolving the east: constructing the

Controlling wax in the Gudrun Oil Export

Is formal risk assessment helping me?

DEXPTS: making pigging a real-time event

A pipeline state of mind

Managing Pressure, Minimising Risk

Tecno Plug | Emergency Pipeline Repair Isolation System

Connecting Italy: the Zimella Cervignano

Vacuworx: expanding to support the

PPIM Houston pulls record crowds

REHAB, REPAIR AND CORROSION

Conquering subsea corrosion with IFL

PIPELINES INTERNATIONAL | MARCH 2014

FROM THE EDITOR

Pulling the 30 inch

long, long time ago, when the internet

available, and a sensible choice between them

Great Southern Press

Clarion Technical Publishers

FREE Pipelines International

Remember to email your news, views and article ideas to

PIPELINES INTERNATIONAL | MARCH 2014

ALLU D-SERIES FOR PIPELINES

SOCAR pumps its own oil via BTC pipeline

$US1.87 billion for Canadian pipeline expansions

Azerbaijans state oil company has started transportation of its

Transco pipeline receives binding commitments

Ecopetrol awards $US272 million

Penspen awarded feasibility study

PIPELINES INTERNATIONAL | MARCH 2014

Iraq Turkey oil pipeline complete

Fortescue announces new WA gas pipeline, transportation agreement

Proposed pipelines in Canada

ENBRIDGE MAINLINE EXPANSIONS

Proponent: Enbridge Energy Partners

Projected cost: $U 6.5 billion

Projected cost: $US0.4 billion for Line 61 and 67

Product: Petroleum and condensate

Product: crude oil

Volume: 520,000 bbl/d

Volume: Alberta Clipper (Line 67) current capacity 450,000 bbl/d, to be

Proponent: Enbridge Inc.

Projected in-service date: NEB recently approved the project,

Dimensions: Line 67 is a 914 mm diameter pipeline. The Canadian

The Canadian Energy Pipeline Association (CEPA)

Pipelines added more than

Proponent: TransCanada Corporation

Projected in-service date: 2015

CEPA members transport 97% of

Volume: Will carry 1 million bbl/d from Alberta and

Projected in-service date: Final regulatory approval expected

Dimensions: 1,150 km in length,