WorldPipelines August 2015

WORLD PIPELINES
Volume 15 Number 8 - August 2015

AUGUST 2015
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Contents
WORLD PIPELINES | VOLUME 15 | NUMBER 8 | AUGUST 2015
03. Editor's comment AUTOMATION & CONTROL

Agency and urgency. 98. Overcoming automation hurdles
05. Pipeline news Will Leonard, ABB Limited, UK.
IP pipeline update; news on Turkish Stream; potential 'Arctic Gateway' pipeline; 105. An appetite for energy
and more. Steven Robinson, EMEA Oil & Gas Industry Leader, Rockwell Automation, UK.
REGIONAL REVIEW PIPELINE INTEGRITY FOCUS: PHMSA
12. Gas woes in Europe 109. Know the rules
Political and economic issues are complicating the development of new gas Jeff Foote, Director Pipeline Integrity Technology, T.D. Williamson, USA.
pipelines to serve Europe, as Gordon Cope explains.
PIPELINE INTEGRITY
18. Nord Stream: four years on
Ruurd Hoekstra, Maintenance Director at Nord Stream AG. 113. A growing concern
Norman J. Moriber, P.E., Mears Group, Inc., USA.
25. The role of the Southern Gas Corridor
Dr. Stefan Buerkle and Charlotte Huebner, ILF Consulting Engineers, Germany. WELD TESTING
121. Advanced inspection
IPLOCA MEMBER CONTRIBUTION André Lamarre and Andréanne Potvin, Olympus, USA.
29. The principles of workplace prosperity NATURAL GAS PIPELINES
Jim Frith, Director of McConnell Dowell and IPLOCA Director, East & Far East.
127. Taking out black powder
Roger Simonson, Black Powder Solutions, Canada.
33 contractors’ directory
COATINGS TECHNOLOGIES
132. The strongest link
Featuring: AB Kauno Dujotiekio Statyba (KDS), Arc Energy Resources, Fred Allen and Steve Drew, Axalta Coating Systems.
Arendal, Baker Hughes Process and Pipeline Services (PPS), Consolidated
Contractors Company (CCC), Continental Fabrication Services, CRC-Evans, 141. The offshore coating technique
CRTS, DENSO GmbH, Denys, Dhatec, Erciyas Steel Pipe Co., Essar Projects, Renato Sanchez, Engineering Manager, and Caroline A. Fisher, Technical
Gulf Interstate Engineering Company, Hoelscher Wasserbau GmbH, Writer, CRTS, Inc., USA.
J. Murphy & Sons Limited, Land & Marine Engineering Limited, LCS Cable
Cranes, Mears Group, Inc., OT Industries-KVV Contracting Company Ltd, 145. A comparison of composites
Punj Lloyd Group, S.A.L.P. S.p.A, Seal For Life Industries, Serimax, Sicilsaldo Garrett Brustkern, Clock Spring, USA.
S.p.A. and Nuova Ghizzoni S.p.A., SICIM S.p.A., STATS Group, Techint
Engineering & Construction, Tesmec, and Winn & Coales International. HDD
149. Tunnelling under the River Elbe
Sipko Dotinga, A.Hak Drillcon, the Netherlands.
ONSHORE PIPELINES - OFFSHORE PIPELINES - TURNKEY CONSTRUCTION - HORIZONTAL DIRECTIONAL DRILLING - COMPRESSOR STATIONS - WELDING - FINANCE, STRATEGY & ANALYSIS - FEASIBILITY STUDIES - TERMINALS - RESEARCH & DEVELOPMENT - MAINTENANCE - REHAB
contractors’
directory
contractors’ directory EQUIPMENT SAFETY
154. Combating onsite hazards
Jason Holland, HSE Manager, Continental Pipeline and Facility Ltd, Canada.
161. Staying safe on slopes
Welcome to the
2015 edition of
Peter Kinsey, Pipeline Construction HAZID specialist.
the Contractors’
Directory: our
annual report
on the major oil
and gas pipeline
conatractors.
Each company
PRECOMMISSIONING
entry offers
168. The line to completion

a glimpse into
their recent
activities, with
project updates,
Mark Lacey, Operations Director, HTC Ltd, UK.

upcoming work
schedules and
capabilities
guides.
The smarter choice for

handling coated pipe. faster. safer. smarter.
WP_Cover.indd 1 7/15/15 3:42 PM
WORLD PIPELINES
Volume 15 Number 8 - August 2015

AUGUST 2015
ON THIS MONTH'S COVER Reader enquiries [www.energyglobal.com]
Worldwide Machinery Pipeline Division provided SUPERIOR SPD-350 padding machines

and a SUPERIOR SPD-450 padding machine for Strike Construction out of Spring, Texas
ISSN 1472-7390
and Pumpco, Inc. out of Giddings, Texas. The Sunoco project, which consisted of 279
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Member of ABC Audit Bureau of Circulations

The best
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or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this for your pipe
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the articles or the advertisements. Printed in the UK.

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Comment
AGENCY AND URGENCY
T
EDITOR he first episode of the first season “Do you think it’s a passing grade? Is it a ‘C’? a
Elizabeth Corner of HBO’s ‘The Newsroom’, which ‘B’? ... Did you do what you were asked to
elizabeth.corner@worldpipelines.com
premiered in 2012, focused on do? What’s the schedule? Are you going to
MANAGING EDITOR fictionalised breaking news finish at the end of this year?” and it goes on.
James Little coverage of the tragic Deepwater Horizon Cummings testified in writing that the
james.little@worldpipelines.com blowout and oil spill in 2010. The coup for PHMSA is on the case: “we share your
EDITORIAL ASSISTANT Will McAvoy’s news team is tracking down concern and sense of urgency... we have a
Stephanie Roker an employee of the Minerals Management plan to complete every one of these
stephanie.roker@worldpipelines.com
Service (MMS – now defunct). On air, Will mandates.”
ADVERTISEMENT DIRECTOR extricates from the employee an admission Concerns about reporting and pipeline
Rod Hardy
rod.hardy@worldpipelines.com that only 56 inspectors were in charge of safety are particularly under the spotlight in
overseeing the 35 591 oil wells in the Gulf: the US this summer, following a spill from a
ADVERTISEMENT MANAGER
Chris Lethbridge ‘“That’s 635 wells for each inspector. The Plains All American pipeline in California on
chris.lethbridge@worldpipelines.com wells are required to be inspected once a 19 May that leaked some 340 000 l of oil,
ADVERTISEMENT SALES EXECUTIVE month – is that some of which
Will Pownall correct?” reached the Pacific
will.pownall@worldpipelines.com
PRODUCTION yes.”
“The drilling wells,
CUMMINGS IS Ocean. The House
Energy and
Stephen North
stephen.north@worldpipelines.com
“Is it possible with FACING CRITICISM Commerce
so few inspectors and Committee has
CIRCULATION MANAGER so many wells, to FOR THE asked for Plains to
Victoria McConnell
victoria.mcconnell@worldpipelines.com
properly inspect each
platform as
AGENCY’S provide detailed
information on the
SUBSCRIPTIONS
Laura Cowell
scheduled?” FAILURE TO maintenance of the
laura.cowell@worldpipelines.com
OFFICE ADMINISTRATOR
“Our – our budget’s
very limited.” ENACT A FULL failed pipeline.
One member of
Jo Repton
jo.repton@palladian-publications.com
“A single inspector
would have to
16 OUT OF THE the committee
expressed concern
WEBSITE MANAGER thoroughly review two 42 MEASURES that some of the
Tom Fullerton wells a day, six days a un-implemented
tom.fullerton@worldpipelines.com
week for a year.” parts of the 2011 mandate could have made a
WEBSITE EDITOR “I know.”’ difference in the recent California spill – for
Callum O’Reilly
callum.oreilly@worldpipelines.com I was reminded of this grilling when I read instance, the requirement that pipeline
reports about the recent questioning of Stacy operators notify the National Response
DIGITAL EDITORIAL ASSISTANT
Joseph Green Cummings, the interim Director of the Pipeline Center within one hour of confirming the
Joseph.green@worldpipelines.com and Hazardous Materials Safety Agency existence of a spill. Records seem to show
PUBLISHER (PHMSA). PHMSA is the US Department of that Plains called almost three hours after a
Nigel Hardy Transport agency responsible for the spill was detected.
approximately 2.5 million miles of oil and gas It’s PHMSA’s sense of urgency that is
Palladian Publications Ltd, pipeline in the US. Cummings has been under being called into question at the moment: is
15 South Street, Farnham, Surrey, fire about the slow rollout of new the agency pushing through new regulations
GU9 7QU, ENGLAND congressionally ordered safeguards. In 2011, quickly enough and is it reacting to growing
Tel: +44 (0) 1252 718 999
Fax: +44 (0) 1252 718 992 Congress gave PHMSA 42 mandates public concern over pipelines?
Website: www.energyglobal.com concerning the use of leak detection systems Pipeline operators are asked to take
Email: enquiries@energyglobal.com on pipelines, the use of automatic and remote- voluntary steps to promote safety while
control shut-off valves and new directions on PHMSA works on implementing reports and
Annual subscription £60 UK including postage/£75/
e105 overseas (postage airmail)/US$120 USA/Canada how quickly pipeline operators must notify regulatory framework, and this can be hit
(postage airmail). Special two year discounted rate: the authorities in the event of a spill. and miss: operators can be hesitant to
£96 UK including postage/£120/e168 overseas
(postage airmail)/US$192 USA/Canada (postage The regulator is yet to carry out all of commit to new rules in light of short
airmail). Claims for non receipt of issues must be the mandates; in fact, Cummings is facing reauthorisation terms. Why follow through
made within three months of publication of the issue
or they will not be honoured without charge. criticism for the agency’s failure to enact a with proposed rulemaking if you think the
Applicable only to USA & Canada:
full 16 out of the 42 measures. goalposts might have moved by the time you
World Pipelines (ISSN No: 1472-7390, At a hearing in mid July, members of the finish?
USPS No: 020-988) is published monthly by
Palladian Publications Ltd, GBR and distributed in
House Energy and Power Subcommittee Here’s one reason why: news teams are
the USA by Asendia USA, 17B S Middlesex Ave, (part of the Energy and Commerce always watching.
Monroe NJ 08831. Periodicals postage paid New
Brunswick, NJ and additional mailing offices.
Committee) questioned Cummings on the For more on PHMSAs integrity
POSTMASTER: send address changes to World delays. “How do you grade your verification process, turn to the T.D.
Pipelines, 701C Ashland Ave, Folcroft PA 19032
performance?” Rep David McKinley asked. Williamson article on p.109.
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IP pipe receives boost as sanctions Turkish Stream update

end Amidst Greece’s economic travails, the country has committed to working
The Iran-Pakistan (IP) pipeline may benefit from with Russia on the proposed Turkish Stream pipeline.
the recent nuclear deal, in which Iran agreed The 1100 km pipeline will comprise four lines, with a capacity of up to
with world powers to curb its nuclear 63 billion m3/yr of gas. Approximately 16 billion m3/yr will be supplied to
programme. As a result, Iran is preparing for the Turkey, while the remaining 47 billion m3/yr will go to a hub on the Greek-
unwinding of sanctions, which is expected within Turkish border to be transported onwards to Europe.
the next six months. Turkish Stream will replace the South Stream project, which Russia
The ‘peace pipeline’ has been on the drawing suspended in December.
board for years and may now move forward Greek Prime Minister Alexis Tsipras reshuffled his Cabinet following
given Iran’s re-entry into the international bailout negotiations, replacing government members who voted against
community. further austerity. Energy Minister Panagiotis Lafazanis was replaced with Labor
Iran has been eager to build a natural gas Policy chief Panos Skourletis.
pipeline to Pakistan and India, a project that Skourletis backs Lafazanis’ position, saying that Greece supports the joint
would benefit all three countries. construction of a pipeline with Russia which will be part of Turkish Stream in
The removal of economic sanctions on Iran Greek territory.
will clear the way for Pakistan to pursue the “We support the plan for the construction of the Greek-Russian gas
ambitious gas pipeline, which is designed to import pipeline on our territory. It opens new opportunities for us, which should be
up to US$2.5 billion/yr worth of Iranian gas. used,” Skourletis said.
Iran completed its section of the pipeline on Lafazanis had repeatedly said that Greece would support the Russian gas
its territory in 2013, but the remaining route pipeline.
through Pakistan has been blocked due to In related news, Russia’s South Stream Transport BV, wholly owned by
international pressure. state energy firm Gazprom, has cancelled contract with Italian engineer
The US has always backed an alternative Saipem to lay the subsea pipes for Turkish Stream.
route, which would run from gas fields in In March 2014, Saipem won a US$2.2 billion contract to build the first line
Turkmenistan through Afghanistan, connecting to of the 931 km South Stream pipeline, and it secured another US$440 million
Pakistan and India (the Trans Afghanistan pipeline: contract for supporting work the following month. In May 2015, amid the
TAPI). negotiations between Gazprom and Botas over the price of the gas to be
Pakistan’s Petroleum Minister Shahid Khaqan supplied through Turkish stream, Gazprom instructed Saipem to begin
Abbasi stated to press: “We need gas. Iran has the construction, and the Castoro Sei was towed from Bulgaria towards Anapa, on
world’s second-largest gas reserves.” He said the Russia’s Black Sea coast. Saipem is reported to be owed US$300 million for
Iranian pipeline will eventually provide a peak of the time the Castoro Sei and another vessel lay idle during the South Stream
750 million ft3/d of gas once it is fully operational suspension.
by 2020.
In the meantime, energy-starved Pakistan has Russia accused of annexing part of BP pipeline
started construction work on its 700 km pipeline
to import LNG from China. Georgia has accused Russia of violating international law following the
The project will be jointly funded by Pakistan erection of a new ‘border’ in the disputed South Ossetia region, which brings
and China. a part of a BP-operated oil pipeline under Russian rule.
Chinese funds will benefit Pakistan and allow The annexation means that Russia has grabbed a 1.5 km long section of a
it to complete its Iran-Pakistan gas pipeline critical oil export pipeline in Georgia for the separatist territory of South
project, Abbasi said. Abbasi stated mid July that Ossetia.
the Chinese-funded LNG terminal at Gwadar and Stretching from Azerbaijan’s Caspian Sea shore to Georgia’s Black Sea coast,
the 700 km long pipeline linked to it as part of the Western Route Export pipeline has a capacity of 100 000 bpd of oil. It is
the China-Pakistan Economic Corridor (CPEC), second in size to the Baku-Tbilisi-Ceyhan (BTC) pipeline.
which is expected to be ready by the end of 2017, Russia recognised South Ossetia’s independence from Georgia back in 2008
can actually double up as well and become the and Russian troops have been putting up fences and demarcation signage in the
Iran-Pakistan gas pipeline as well. area. Tbilisi has protested against the continued ‘creeping annexation.’
Analysts surmise that the China pipeline was British Petroleum Georgia told press that it plans to reroute the fenced-in
designed with the clear intent that it could section of the pipeline as part of routine maintenance. “The situation is not
eventually be dovetailed into the Iran-Pakistan new and we have effectively had it since 2008,” said spokesperson Tamila
pipeline project once the sanctions against Iran Chantladze. She said BP has yet to experience any obstacles when operating
were lifted. the pipeline.
AUGUST 2015 / World Pipelines 5

In BRIEF
World News
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Tennessee pipeline downsized NWT proposes ‘Arctic

USA Kinder Morgan has announced plans to Gateway’
Opponents of the proposed PennEast downsize the pipeline diameter for its Canada’s Northwest Territories
pipeline are claiming a victory after the Tennessee Gas Pipeline. The pipeline will (NWT) government has recently been
US State Department of Environmental feature 30 in. pipes instead of 36 in. This also discussing the possibility of an Arctic
Protection said it doesn’t have enough reduces the size of a proposed compressor crude oil pipeline route.
information to evaluate the permits station in New Ipswich. David Ramsay, the territory’s
needed to build the US$1.2 billion “The company will now file an amended Minister of Industry, has stated that
natural gas pipeline. resource report with FERC that will indicate the pipeline is one alternative to the
the 30 in. configuration,” said Allen Fore, shipping of crude oil to the east,
USA Kinder Morgan Vice President for Public south, and west, due to the delays of
MPLX – a partnership controlled by Affairs. the other pipelines.
Marathon Petroleum Corp., a refinery “We have always said we won’t Though Ramsay did not disclose
and pipeline company – will buy overbuild. We want to build to serve the the companies with whom he had
MarkWest Energy Partners LP for US$15. natural gas needs of the region. At this point met with regarding the pipeline, he
billion. The deal will combine two we are comfortable with a 30 in. pipeline as stated: “we’ll see where it all goes,
companies. satisfying the customers we have secured but right now you don’t see too
Nigeria and the customers we are looking to secure.” much happening in the way of
The company announced mid July that Keystone or Energy East or Northern
Oodua Peoples Congress (OPC) could its board of directors had approved a Gateway… the north may, in fact, at
sue the Nigerian National Petroleum US$3.3 billion investment based on the some point be a viable option.”
Corporation (NNPC) over its failure to smaller diameter. David Ramsay and NWT Premier
pay N$1.9 billion as debt accruing for the The amended pipeline proposal means Bob McLeod have for some time
protection of pipelines contract that a compressor station planned for New been pushing the concept of an
terminated over a month ago. Ipswich in New Hampshire will be cut nearly ‘Arctic Gateway’ pipeline, which
USA in half, from 80 000 hp to 41 000, according could see Alberta crude moved north
A US State taskforce has called for a to Fore, although the same amount of land for shipment from a port on the
series of independent studies of the will be required for the compressor and the Beaufort Sea coast.
risks, alternatives and costs of an oil- pipeline itself. A spokesperson for Enbridge
related disaster from Line 5, the oil The project is designed to transport low- confirmed company representatives
pipeline that crosses the Straits of cost natural gas from the Marcellus shale had met with Ramsay, but gave no
Mackinac at the top of Lake Michigan. formation in Pennsylvania to Dracut, further details.
Massachusetts. The approved project is much McLeod said the region has a
Nigeria smaller in total capacity than the 2.2 billion ft3/d CAN$3 billion infrastructure deficit
Twelve people died and three were originally planned. However, it still allows that is keeping resources locked in
injured in an explosion during repair Tennessee Gas to expand in the future to the the ground and preventing economic
work at an Eni SpA crude oil pipeline in larger capacity if customer demand grows, development that would bring jobs
Nigeria. according to a company spokesman. and prosperity.
USA
A test facility that can help identify and
prevent potentially catastrophic Statoil to sell stake in TAP project
pipeline failures around the world has Norway’s Statoil is to sell its 20 % stake Snam has suggested that it could take
opened for business. The US$1.5 million in the Trans Adriatic gas pipeline (TAP) a stake of up to 20% in the TAP
Technology Development Centre in project that will carry gas from project. SOCAR is understood to
Houston was created by the PRCI Azerbaijan to Europe, the President of prefer that a collection of companies
(Pipeline Research Council International). Azeri state energy firm SOCAR has buys the stake.
Colombia announced. TAP’s other shareholders are BP
The 870 km pipeline will connect (20%), SOCAR (20%), Belgium’s Fluxys
Colombia’s Farc guerrillas bombed a with the Trans Anatolian Pipeline (19%), Spain’s Enagas (16%) and Swiss
new section of an oil pipeline, after a (TANAP) near the Turkish-Greek border company Axpo (5%).
first attack that spilled 10 000 bbls of oil at Kipoi, cross Greece and Albania and Statoil has already sold its shares in
into rivers and streams in Nariño the Adriatic Sea, before reaching Azerbaijan’s Shah Deniz gas field as well
province. southern Italy. as the South Caucasus Pipeline (SCP) to
Italian gas infrastructure company SOCAR, BP and Malaysia’s Petronas.
6 World Pipelines / AUGUST 2015

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Events DIARY
World News
FOR FURTHER INFORMATION ON EVENTS VISIT WWW.ENERGYGLOBAL.COM/EVENTS
PGNiG’s play for Yamal Nexen leak investigated

24 - 26 August 2015 Poland’s natural gas giant PGNiG’s unit Nexen Energy apologised this month for
The Pipeline + Energy Expo
has filed for a green light from the anti- a major leak in an Alberta pipeline. The
monopoly office UOKiK to take over company reported that a warning
Tulsa, USA
Bartimpex and its gas-trading unit, which system failed to detect the leak.
http://pipelineenergyexpo.com/
controls a 4% stake in EuRoPol Gaz and is At a press conference, Ron Bailey,
the owner of the Polish stretch of the the company’s Senior Vice President of
Yamal natural gas pipeline. Canadian operations, said the company
8 - 11 September 2015
PGNiG currently holds a 48% stake in is investigating what caused the pipeline
Offshore Europe EuRoPol Gaz, on a par with Russian gas to rupture and why the system failed.
Aberdeen, UK giant Gazprom. A contractor discovered the leak on
http://www.offshore-europe.co.uk/ The motion was filed by PGNiG’s unit 15 July about 35 km southeast of Fort
GAS Assets Management. McMurray. Nexen shut down the
PGNiG has been embroiled in a long pipeline but approximately 5 million l of
14 - 17 September 2015 struggle to gain control over the company, bitumen, produced water and sand was
Turbomachinery Pump Symposia which is of strategic importance in the spilled.
Houston, USA context of ongoing energy disputes The company’s automated
http://pumpturbo.tamu.edu/ between the EU and Russia. monitoring system allegedly failed to
Yamal passes through four countries, report the breach. The affected area is
22 - 24 September 2015
Russia, Belarus, Poland and Germany. about 16 000 m2.
The EU treats the pipeline as a priority Oilsands emulsion surged out of a
Rio Pipeline Conference
Trans-European Networks (TEN) investment hole that looked like a ‘fish mouth’, even
Rio de Janeiro, Brazil project. Construction began in 1994 and it though it was a high-pressure, double-
http://www.ibp.org.br/ has a capacity of 32.9 billion m3/yr. walled pipeline that had been installed
In May, Siemens was awarded a less than nine months ago, according to
service and maintenance contract for the Bailey. He added that the pipeline was
5 - 9 October 2015 turbo-compressors operating at five double-walled to provide insulation for
49th IPLOCA Annual Convention compressor stations in Poland along the the steam-bitumen mixture, operating at
Singapore Yamal pipeline. 100˚C, over the 10 km distance.
http://iploca.com/
27 - 29 October 2015
OTC Brasil 2015
Rio de Janeiro, Brazil
Forties restrictions
A restriction has been placed on the
News Highlights
http://www.otcbrasil.org/
amount of oil that can be put
through the North Sea’s Forties
27 - 30 October 2015
crude oil pipeline system (UK).
Gastech Conference and Exhibition BP is the operator of the Forties
Singapore Pipeline System (FPS). This year
http://www.gastechsingapore.com/ marks the 40th anniversary for the
FPS, which was inaugurated in 1975
by the Queen.
9 - 12 November 2015 Analsyts speculate that the
ADIPEC change in pressure could be due to
Abu Dhabi, UAE work at the Kinneil processing plant,
http://www.adipec.com/ which handles unstabilised crude. ➤➤ FERC issues EIS for
When two trains are offline at Magnolia LNG and Lake
Kinneil, the remaining train is Charles expansion projects.
9 - 12 November 2015 normally unable to process all the
crude coming through the FPS, ➤➤ GE Oil & Gas and CLH Group
Fabtech
depending on shipper demand. sign contract.
Chicago, USA
Loadings of Forties crude will
http://www.fabtechexpo.com/ ➤➤ Fall in oil company merger
slow to 348 000 bpd in August, as a
number of fields undergo
activity.
maintenance.
8 World Pipelines / AUGUST 2015 To read more about the articles go to

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Contract News
TO KEEP UP-TO-DATE ON CONTRACTS VISIT WWW.ENERGYGLOBAL.COM
Technip secures TAP project management STATS wins Middle East contracts
Technip has been awarded a project management consultancy STATS Group has been awarded an emergency pipeline repair
(PMC) services contract by Trans-Adriatic pipeline (TAP), which is a system (EPRS) contract, worth in excess of £6.5 million. The
joint-venture between BP, SOCAR, Statoil, Fluxys, Enagás and Axpo. contract is for ten years work with a major LNG operator in the
Technip will help oversee development of the onshore portion Middle East.
of the construction of the Trans-Adriatic pipeline from Greece to STATS Group’s scope of work for this new contract includes
Albania and on to Italy. The French company swill work primarily designing, manufacturing and testing pipeline isolation and
from its offices in Rome and those of the TAP pipeline consortium intervention equipment for a range of pipeline sizes – from 16 -
in Switzerland. 38 in. The contract includes the supply of double block and
BP, leading Azeri developments alongside a state-backed energy bleed isolation tools, subsea monitoring and communication
company, has awarded more than US$1 billion in development systems, 32 in. and 38 in. BISEP intervention tools, and hot tapping
contracts since selecting the TAP as its option for Shah Deniz in equipment.
2013. Installation of isolation and intervention tooling suites will
TAP is designed to transport natural gas from the second phase provide positive isolation and a safe environment to carry out
of the Shah Deniz natural gas field off the coast of Azerbaijan as effective repair on subsea and onshore pipelines, if they are
early as 2019. Technip said the terms of its contract expire in the damaged.
1Q2020. STATS’ Middle East Business Development Manager, Vikas
Riccardo Moizo, Senior Vice President of Technip PMC, stated: Shangari said: “STATS has executed in excess of 40 isolation
“this contract is an important milestone for Technip PMC. With this projects in the Middle East, ranging from 2 - 48 in. on oil, gas and
award, Technip will be able to reaffirm its strong project utility pipeline systems.” STATS’ Middle East Regional Director,
management capabilities, through the execution of a very Angus Bowie, said: “Our original contract with Qatargas has now
prestigious project.” been followed with this significant award by another major
Technip’s scope of work will cover overall project and site operator in the Middle East.”
management, procurement and subcontracting for all the EPC
packages throughout the engineering, procurement and
construction phases, and warranty management and the project IBM teams up with Columbia Pipeline
close-out. IBM has signed a technology agreement, worth approximately
US$180 million, to support Columbia Pipeline Group’s (CPG)
Sempra Energy awarded Chihuahua gas growth. The agreement is a five year IT services agreement
including cloud, mobile, analytics and security technologies.
project On 1 July, CPG completed the separation of its natural gas
Sempra Energy has announced that its Mexican unit pipeline, midstream and storage business from energy infrastructure
Infraestructura Energética Nova, S.A.B. de C.V. (IENOVA), through company, NiSource Inc. As a stand-alone independent company,
its subsidiary Gasoducto de Aguaprieta S. de R. L. de C.V., has CPG is expanding its operations to serve customers and markets. Its
been awarded a natural gas transportation contract in net asset investments are expected to grow from approximately
Chihuahua by the Comisión Federal de Electricidad. US$4.6 billion in 2015 to US$13.5 billion by 2020.
The project will comprise a header facility with a capacity of IBM will deliver a range of services to provide the technology
3 billion ft3/d of natural gas and an approximately 14 mile infrastructure CPG requires to operate as an independent business
pipeline with a capacity of 1135 million ft3/d of natural gas. The and support its growth plans. Under the technology agreement,
pipeline will provide natural gas to the Norte III Combined Cycle IBM will move CPG’s IT infrastructure and business applications –
Power Generation Plant and will interconnect with Gasoductos human resources, billing and finance, pipeline operations and IT
de Chihuahua, Tarahumara and Samalayuca-Sásabe pipelines. management – from NiSource’s data centres and into a private
The estimated US$108 million project is expected to be in cloud in an IBM data centre. From the centre, IBM will separate
operation in early 2017. CPG’s networks from NiSource and manage its integrated IT
“This award demonstrates IEnova’s capacity and experience environment.
to generate value through our projects,” said Carlos Ruiz The technology will utilise IBM’s QRadar Security Intelligence
Sacristán, Chairman and CEO of IEnova. “We are pleased to Platform. This will provide a unified structure for integrating
contribute to the development of the energy infrastructure of security information with event management, log management,
Mexico, and continue to strengthen our company’s presence in anomaly detection, incident forensics and configuration and
the country.” vulnerability management.
IEnova develops, builds and operates energy infrastructure Bob Skaggs, CEO for CPG said: “IBM has been a long-time
in Mexico. As of 2014, the company invested more than technology partner for NiSource, providing solutions and services
US$3.5 billion in operating assets and projects under construction that have helped that company become an energy leader in the US.
in Mexico, being one of the largest private energy companies in As an independent business, we are counting on IBM to help
the country. IEnova is the first energy infrastructure company to provide the continued strong enterprise technology support CPG
be listed in the Mexican Stock Exchange. needs.”

OPERATIONOFFSHORE.COM
#operationoffshore
T.D. WILLIAMSON / MCG PRODUCTIONS PRESENT“OPERATION OFFSHORE”

m MARK SIM, TODD BEADLE, GORDON BLAIR, ALEXEY TUGANOV, ANTON KOVALENKO, LAURENT FABRY, TAMMY WISENBAKER,
KEVIN MCNAUGHTON, PAOLA CORRALES, STEVE APPLETON, ALEXANDRE PETRAGLIA, /ROLF GUNNAR LIE
DIRECTORS LARRY RYAN, GEORGE LIM DIRECTORS JEFF WILSON, GARY ANDERSON x MIKE BENJAMIN, CHAD FLETCHER THE STORY RISK ON THE PLATFORM
DEVELOPMENT TECHNICAL BASED ON
© Copyright 2015 T.D. Williamson, Inc

GAS woes in
EUROPE
E
urope consumes a lot of natural gas. According to the the Brookings Institution, a US think tank. “In light of the Ukrainian
US Energy Information Administration (EIA), the European concerns, there is a sentiment to diversify away from Russia. It is
continent (including all EU members plus Turkey, Norway, not a vital issue to many European countries, but there are some in
Switzerland, and the non-EU Balkan states), consumed Eastern Europe where it is a real important issue because they have
18.7 trillion ft3 of natural gas in 2013, or approximately 51 billion ft3/d. few alternative supplies.”
Roughly one-third of that gas was produced internally, mostly A partial alternative has existed for several decades. In addition
from large fields in the North Sea and adjacent lands. Norway, to abundant oil, Northern Africa is blessed with huge reserves
which is not an EU member (but of natural gas. Europe is already
belongs to NATO) also supplies a lot; served by a series of pipelines that
about 23%. The single largest external cross the Mediterranean and deliver
supplier, however, is Russia, with Political and over 5 billion ft3/d of gas to Spain
about 30% (5.7 trillion ft3, or and Italy.
15 billion ft3/d) of this volume. economic issues are Since the Arab Spring, however,
And there lies the rub. For many
years, the majority of exports from
complicating the the above-ground risks in countries
such as Libya have risen exponentially.
Russia to the EU came through the development of new Even in currently stable countries
Ukraine (in some years, as much as like Algeria, there is little appetite
80%). Starting in 2006, however, gas pipelines to serve for new pipelines. The Galsi project
arguments over pricing and payments
of gas consumed in the Ukraine have
Europe, as Gordon is a proposed 700 million ft3/d line
that would run from Algeria through
led to periodic cessations of onward Cope explains. Sardinia to northern Italy. Sardinian
deliveries to European consumers. environmentalists have objected
Although the threat of blockages to the impact the multibillion line
has eased somewhat with the 2011 would have on the island’s local
opening of the Nord Stream system (which delivers gas from Russia ecology. More trenchantly, backers in Algeria are concerned that
to Germany directly via the Baltic Sea), the situation worsened competition from other lines might undermine the economics
dramatically with Russia’s seizure of the Crimea and subsequent of the scheme, and are waiting to see what might transpire with
war against the Ukraine. The EIA estimates that 16% of all gas competitors.
consumed in the European continent passes through that blighted Alternate potential sources also exist within the European
land. “There are a lot of politics and geopolitics involved,” says continent. Shale gas, for instance, holds tremendous potential. In
Tim Boersma, a fellow and Acting Director in the Energy Security 2013, the UK Department of Energy and Climate Change (DECC)
and Climate Initiative, part of the Foreign Policy programme at issued a British Geological Survey that estimated the Bowland
shale and Hodder shale (in the north of England) held 1328 trillion ft3 stable member of the EU with an established gas line network, it
in place. The EIA has estimated that 26 trillion ft3 are technically also stands to benefit from further projects, such as TAP.
recoverable. Industry analysis suggests shale in Lancashire alone Italy’s gas sector has been under a cloud lately due to
could deliver £6 billion of gas a year for the next three decades. allegations of bribery. Eni, Italy’s largest energy company, and
According to the EIA, the Ukraine contains 42 trillion ft3 of shale gas. Sonatrach, Algeria’s leading energy firm, are under investigation
Shale gas development in Europe faces several hurdles, by prosecutors in Milan. Italy, which relies on Algeria for about
however. In the UK, the government is generally favourable to the one-third of its gas needs, and Algeria, which relies on oil and gas
unconventional resource, but environmentalists and local residents exports for one-third of its GDP, are worried that revelations might
are concerned about development. Various moratoria, blockades, sour their vital relationship.
occupations and demonstrations have hindered exploration Turkey sees itself as an energy hub in the Middle East. It already
programmes. The Ukraine has seen exploration agreements fall by hosts the BTC (Baku Tbilisi Ceyhan) oil line, the Trans Caucasus
the wayside as fighting drags on. Other barriers, including the lack line that runs from Azerbaijan, and the 1.4 billion ft3/d Blue Stream
of a continent-wide pipeline network and jurisdictional agreements, line that runs from under the Black Sea to Turkey. It is also greatly
pushes out its arrival to market by at least a decade. expanding its TANAP network. In addition, it rests astride European
The most efficient and economical vehicle for supplying onshore access for potential supplies from Iran, Kurdistan and other
Europe’s long-term need for natural gas rests with tapping into Middle Eastern producers.
large conventional fields and delivering that gas by large-diameter Although it is a member of NATO, Turkey maintains friendly
pipeline. “For years, there has been interest in a southern corridor relations with Russia. In December, 2014, it hosted a state visit from
that would avoid the Ukraine and deliver non-Russian gas to President Putin where it underscored its pragmatic approach to
Europe,” says Boersma. geopolitics. While Russia’s incursion into Crimea has high political
Several front-runners have emerged (see proposed ramifications with NATO, Turkey’s concerns are focused more to
Mediterranean region pipelines sidebar) and Azerbaijan is the most the south, where ISIL is overrunning Iraq, Syria is convulsed with an
viable gas source. The Shah Deniz gas field sits offshore in the extended civil war, and an independent Kurdistan acts as a beacon
Caspian Sea about 70 km southeast of Baku. Discovered in 1999, the for Turkish Kurds. Energy projects with Russia, such as expanding
field is estimated to hold up to 40 trillion ft3 of gas. Operated by BP, the Blue Stream line or building the Turk Stream line, are strictly
the field produces almost 1 billion ft3/d. The gas is shipped along business. “Turkey and Russia are increasing cooperation in order to
the 692 km South Caucasus Pipeline, supplying Azerbaijan, Georgia stimulate economic growth and supply affordable energy,” says
and Turkey. Boersma.
Phase 2 of the Shah Deniz gas field is currently underway. When Bulgaria consumes approximately 250 million ft3/d of natural
completed in 2018, the US$28 billion project will add an additional gas, 95% of which comes from Russia. Bulgaria began seeking to
16 billion m3/yr of gas to current production. Of that, 6 billion diversify supply sources after suffering a two-week cessation of
m3/ yr will go to Turkey, and 10 billion m3/yr to Europe via TANAP deliveries in 2009 during a dispute between the Ukraine and Russia.
through Turkey, which is currently being upgraded and extended at The cancellation of the South Stream project, which would have
a cost of approximately US$17 billion. crossed the Black Sea and made land-fall in Bulgaria, eliminated a
non-Ukraine route.
Economics vs politics Bulgaria is thus keen to construct the Interconnector Greece-
In Europe, pipelines and politics are inextricably intertwined; the Bulgaria (IGB). The IGB is a proposed 182 km, 32 in. OD spur line
economic rationale for a project is frequently suborned to political with a capacity of 300 million ft3/d that will run from the partially
considerations. completed Interconnector Turkey Greece Italy (ITGI) pipeline
While Greece stands to benefit from TAP as both a secure system that is designed to carry gas from Turkey to Greece and,
source of gas and a multibillion source of jobs, its parlous state of eventually, under the Adriatic to Italy. Bulgaria already has an
finances means it is in divestiture, rather than investment, mode. agreement with Azerbaijan to purchase up to 100 million ft3/d,
SOCAR, Azerbaijan’s state oil company, recently purchased a 66% and is looking to add to its commitments from Phase 2 of the Shah
stake in DESFA, the Greek gas transmission network operator, Deniz field. Talks are also underway to further distribute IGB gas to
for US$609 million. According to reports, approximately half Romania; the IGB spur line capacity has the potential to be bumped
the proceeds have been earmarked to aid Greece’s sclerotic to 500 million ft3/d.
economy. On the downside, Bulgaria is a corruption-riddled country.
On the plus side, Greece can always count on Russia to muddy According to the European Anti-Fraud Office (OLAF), more than
its relationship with the US and EU. One of the aspects that may one-third of all probes into alleged corruption involving EU cash
have scuppered South Stream is the EU ‘Third Energy Package’ occurred in Romania, Hungary and Bulgaria (the money is mostly
policy that prohibits one company from both owning the pipeline related to structural funding). While the issue, per se, does not
and its contents. Russia has been recently touting Turk Stream, affect delivery of gas to the rest of Europe, if payment problems
which would run under the Black Sea to the Turkey-Greece border, and opaque contracts take hold within Bulgaria’s borders, then
circumventing the EU policy. According to reports, Russia has financial complications may ensue.
been wooing Greece’s support for the project with a US$5 billion
incentive. Problems
Italy has benefited tremendously from African gas. It is one Wider political and economic issues complicate development
of the EU’s largest consumers (almost 7 billion ft3/d) and collects of new gas sources and pipelines to serve Europe. The war in the
healthy tariffs for transmission to jurisdictions further north. As a Ukraine, largely instigated by Putin and stoked by ethnic-heritage

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proxies in the regions bordering Russia, is likely to drag on for the
foreseeable future. Although sanctions have bitten deeply into Russia’s
economy, Putin has shown little inclination to back down, and continues Proposed Mediterranean region
to posture aggressively toward other EU border nations. Until a political pipelines
deal is brokered, the situation has the potential to evolve in ways that A mix of economic and geopolitical factors are driving a
have impact on the gas supply in Europe. host of gas pipeline proposals in the Mediterranean region.
An important consequence may have already transpired. In early South Stream Transport
2015, the EU’s competition commissioner, Margrethe Vestager, issued a ) South Stream Transport was proposed by Gazprom
‘statement of objections’ to Gazprom. According to the EU, Gazprom is and OMV of Austria as a route that would effectively
‘pursuing an overall strategy to partition central and eastern European bypass the Ukraine. The project envisioned four
parallel lines that would have a total of over
gas markets.’ The EU asserts that Gazprom curbs customers’ ability
5 billion ft3/d capacity when ultimately completed
to resell gas, which allows it to charge ‘unfair prices’ in five countries: in 2017. The network was to run 910 km across the
Bulgaria, Poland and the Baltic states of Estonia, Latvia and Lithuania. Black Sea from Russia to Bulgaria. In early 2014, South
In addition, the EU alleges that Gazprom used its market position to Stream issued pipe procurements and contracted to
leverage control of the Yamal pipeline in Poland, and to arm-twist lay the first line. In late 2014, however, President Putin
Bulgaria into supporting South Stream. Many of the charges stem from announced the cancellation of the project while on a
the launch of the EU’s Third Energy Package. state visit to Turkey.
Gazprom, which has denied any wrongdoing, has several options, Turkish Stream
ranging from reaching a settlement to ignoring the EU’s authority. The ) The Turkish Stream project was announced by
latter would be an unwise move, as the EU competition commissioner President Putin during his state visit to Turkey in
possesses the authority to issue multibillion fines up to 10% of its December, the same time that the South Stream
US$40 billion annual turnover. Although the charges were compiled project was cancelled. The route is similar to the
prior to the seizure of Crimea, President Putin has vilified the move South Stream path across the Black Sea, only it lands
as a western plot aimed solely at Russia. The EU has countered that a further south, in Turkey, and would connect to the
similar statement of objections has also been laid by the competition TANAP network. Turkish Stream is envisioned to
commissioner against Google (which did not invade anyone). Expect deliver 1.4 billion ft3/d to the Turkish market, and
5 billion ft3/d onward to Europe. The project does an
much posturing and manoeuvring in the coming months; regardless of
end-run around the Ukraine and the EU’s Third Energy
the outcome, the gas giant will be on its heels in its major export market Package. Tentative start-up has been pegged at 2020.
for some time to come.
On the economic front, over the last several years, LNG imports Trans Adriatic Pipeline (TAP)
into Europe have been falling as Asian demand drove prices up. But the ) Backed by BP, Statoil, SOCAR and Total, the TAP line
recent decline in oil prices and lower demand in China have seen prices has been selected by the Shah Denis Consortium
drop by 50%, to the point where LNG imports are once again increasing. (SDC) to transport gas to Europe. The line will have
a capacity of approximately 2 billion ft3/yr. It will
As long as these two market trends remain in place, LNG will have a
deliver supplies to Bulgaria, Albania, the former
dampening effect on proposed pipeline projects. Yugoslavia, Italy and possibly Germany, France, and
Austria. The project is in the advanced engineering
The future and procurement stage, with ball valves and other
While no one can ever imagine a Europe free of geopolitical ruckus, major components under order.
economic considerations do occasionally reign. The Southern Corridor
Galsi
expansion and extension currently underway promises the imminent
) The Galsi project is a 700 million ft3/d line that
arrival of gas from Azerbaijan’s Shah Deniz field. Depending on various
would run from Algeria through Sardinia to northern
price and demand scenarios, it is not unreasonable to assume that some Italy. Environmentalists have objected to the impact
of the other proposals will reach fruition, as well. the multi-billion line would have on Sardinia’s
But even if all the proposed pipelines were built (a tremendously big ecology. Backers in Algeria are concerned that
if), their combined capacity would only dent the amount of gas that is competition from other lines might undermine
currently imported from Russia. While it might be politically expedient the economics, and are waiting to see what might
to talk up pipeline alternatives, in reality, any comprehensive move to transpire with competitors.
replace 15 billion ft3/d would require immense investments and decades East Mediterranean
of work. ) Recent discoveries of over 30 trillion ft3 of gas in
Rather, it would seem, other market forces may already be solving offshore regions controlled by Israel and Cyprus,
some of the problem. Since 2009, the EU has been working to mitigate have given rise to various monetisation schemes. The
supply disruptions through integration of its energy network. Better East Mediterranean pipeline is a proposal to connect
infrastructure connections and new LNG terminals (such as the one the fields to Italy through an offshore pipeline that
that recently opened in Lithuania) mean fewer countries are vulnerable passes through Greek Waters. Although the EC has
to point-source disruptions. Gazprom can no longer offer preferential expressed interest, the 675 km line would cost in
rates to one country and not others; even if they tried, EU members can excess of US$20 billion, making it economically
unviable.
pass their savings on. While new supply sources are always welcome,
sometimes, simply pulling together is the best way to avoid being pulled
apart.

Dedication
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Nord Stream:
FOUR
YEARS
ON
H o e kstra,
Ruur d
e D i r e ctor at
a i n t e nanc t a l k s about
M G,
r d S t r eam A aintenance
No m
n t e g r i ty and the No
rd
i ie s f o r ow
strateg s pipeline: h
ga ling
Stream perator tack rity
o g
is the a g e s of inte
ts t
the firs nagement?
ma
F
ollowing the construction of the Nord Stream
Pipeline from 2010 through 2012, Nord Stream AG
has transitioned from being a project company
to the operator of the 1224 km twin pipeline gas
transportation system connecting Portovaya on the Russian
Baltic coast with Lubmin, Germany. As an operator, Nord
Stream AG is focusing on safely and reliably maintaining its
main asset: the gas transportation system.
How is Nord Stream approaching integrity

management for its pipeline?
Now that we are in the operations phase, integrity
management – preserving the asset for long term operation
– is the central engineering function within Nord Stream.
We view integrity management as a holistic process,
covering functions within the whole company, from
compliance through financial departments. We began
setting up the operations-phase integrity management
during the project phase and it follows a standard
quality process: Plan-do-check-act.
The first thought in terms of integrity
management is: what could happen that
endangers integrity, what would be the
consequences and what is required to
remedy the situation? We conducted
a risk assessment, which in itself is a
Figure 1. Statoil administered PRS

hyperbaric welding system, as used
for HWTI on Nord Stream Line 1 and
2 during their construction.
19
process involving many functions within the company, each activities, a significant pipeline repair event is not expected
contributing a perspective to the assessment, financial, during the pipeline system’s design life of 50 years.
management of changes to the system, inspection and For repair and remedial works, we are putting a lot of
associated personnel and equipment requirements, efforts into readiness.
environmental and social implications. The important thing We introduced a repair preparedness strategy designed
is: you need data to assess the condition of pipelines – so to guarantee a level of preparedness and response capability
inspections are obviously central to integrity management. in the event of an incident, to ensure that the asset can be
recovered safely back to its normal operational performance
What is Nord Stream doing in terms in an efficient and reliable manner.
inspections and what has Nord Stream done We started with upfront development of procedures
so far? for a spectrum of possible repair cases and set up an
For identified risk scenarios, an Integrity Management Plan organisational structure including internal functions for
is designed: which surveys and inspections are needed to repair and qualified and trained personnel with the expertise
gather what data; how to properly assess the results and to implement repairs in accordance to best industry practice.
what remedial measures and repairs are needed in each An important part is also ensuring the availability of
case, including what preparation is needed to ensure repair necessary spares and upfront investment in long lead items
readiness. of repair equipment to be stored and maintained for the
Inspections are undertaken regularly to gather data on pipeline operational life. We are storing a variety of spare
the condition of the pipeline and its components, and the parts and 450 (equivalent to approximately 5.5 km) spare
subsequent data is analysed by us and our contractors in pipes near the landfalls for repair cases.
order to assess whether any remedial work is required. Agreements with appropriate industry specialist
We conducted the baseline surveys, both external contractors are also a key element.
by ROV and internal with an intelligent pig, in 2013. Both
confirmed that the pipeline is in ‘factory new’ condition. Who is Nord Stream partnering with to
Last year, we conducted the first follow-up external ensure repair capabilities?
inspection by ROV, both visual and geophysical. We Nord Stream has secured the services of specialised offshore
compared the results to the baseline to see how the pipeline construction company Saipem as Main Repair Contractor
is behaving under continuous operation conditions. As (MRC).
expected, the pipeline is settling into the seabed. We also The MRC, together with Nord Stream’s own in-house
checked for foreign objects in the vicinity of the pipelines technical specialist support, has conducted significant
and found nothing unusual. levels of detailed engineering to develop the necessary
As expected, we are seeing that the pipeline is operational procedures and definition of equipment needs
overgrown with small mussels in certain depths, forming an to ensure that, in the event of an incident, MRC is ‘ready to
artificial reef for the species. act’ to return the pipeline system back to full operational
We will conduct further external surveys in summer 2015, capacity. Saipem has the inherent advantage that it was the
to continually monitor the geophysical stability and position. main contractor involved in the construction of the offshore
pipeline system and therefore has the familiarity. It can also
How is Nord Stream setting up its repair potentially provide the necessary types of marine vessel
readiness and capabilities? spread to undertake recovery and repair of the damaged
Thanks to a comprehensively engineered design; a high section of the pipeline.
standard of material used for pipeline construction; carefully Another significant element of the Nord Stream Repair
planned routing; and regular inspection and maintenance Strategy is its membership to the Pipeline Repair and Subsea
Intervention (PRSI) Pool,
which is administered
Table 1. Different repair service types defined in the repair strategy, for which procedures were developed by Statoil. Through the
and specialised partners and equipment are contracted membership, Nord Stream
Type of service Reference description has access to a range of
Type 1
FIRST REACTION + DAMAGE ASSESSMENT specialised services and
External inspection equipment technically
MAINTENANCE/REMEDIAL WORKS suited for performing
Type 2 e.g. rock placement for stabilisation; free span correction; large diameter subsea
pipeline protection; anode replacement; other
repairs, including a
LOCAL DAMAGE REPAIR
Type 3 remotely operable habitat,
Externally fitted 48 in. dia. repair clamp
pipeline support frames
Type 4 SHORT DAMAGE REPAIR
and auxiliary support
Section replacement up to 2 pipe joints ~24 m
systems which were
Type 5 LONG DAMAGE REPAIR
already deployed for

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the hyperbaric weld tie-in of the 48 in. diameter pipeline Specific tooling developed by TDW for Nord Stream
sections. AG includes SmartPlug isolation tools, pipeline recovery
Further suppliers were contracted to develop specialised tools (PRT) with dewatering and pig catcher functionality
equipment, among them Oil States Industries and TDW and pipeline end sealing plugs (PEPs), all suited for 48 in.
Offshore Services. diameter. These would be used if major offshore repairs with
the need to isolate sections of the pipeline.
What special tools have been developed? Other specialist tooling and equipment developments
We have invested in the development of tools and are through 2015 into 2016 include a clamp-on pig stopper and
currently in the delivery and system integration testing (SIT) SmartPlug launcher (CPS/CSL), an activated sealing pig (ASP),
phases of a full complement of state of the art pipeline subsea mechanical tie-in flange assemblies, as well as a
repair tools. liquid/gas separator.
We are also in the process of
developing two structural and pressure
containment pipeline repair clamps,
which can be externally fitted over an
area of damage in order to provide a
permanent repair solution. Here we
partnered with Oil States Industries. For
the installation of the repair clamps, we
designed a dedicated installation system,
which suspends the clamp and positions
it precisely over the pipeline for
installation. It can be operated by ROV
and can be used in depth up to 214 m.
Now that Nord Stream has

been in operation for almost
four years, what are the first
learnings from a maintenance
perspective?
The conditions in the Baltic Sea are
Figure 2. The Nord Stream pipeline integrity management process defines the certainly unique – as is our pipeline.
company’s approach to mitigating risk and maintaining safe and reliable operational Nord Stream is the longest large-
integrity of the pipeline system. diameter gas pipeline built to-date.
However, the pipeline technology and
maintenance have been tried and tested
in the North Sea and elsewhere. So there
were no surprises.
The results of our surveys show that
the pipeline is in good condition: as
expected, material integrity shows no
sign of corrosion. The pipeline shows
the expected signs of settling into the
seabed from its own weight and slight
shifts.
What we learned is that it has
certainly paid off to start setting up
organisational structures, find expert
personnel and contract suppliers early
on. Also important was to instil into the
organisation a sense that the cause of
integrity management and maintaining an
asset goes beyond checking for corrosion
but includes many functions within the
company. Everyone is pulling in the same
Figure 3. 48 in. pipeline recovery tool (PRT) during factory acceptance testing at TDW. direction on this.

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The role of the
SOUTHERN
GAS CORRIDOR
Dr. Stefan Buerkle and Charlotte Huebner, ILF Consulting Engineers, Germany,
give an update on the gas transmission landscape in southeastern Europe and South
Caucasus with particular reference to the Southern Gas Corridor.
T
he Ukraine crisis has intensified debates on Europe’s security
of gas supply. Referring to the European Commission’s (EC)
2020 Energy strategy, European security of gas supply is only
to be achieved by the diversification of external gas routes to
the EU market and by increasing flexibility in the internal gas market by
developing interconnecting infrastructure.1
In 2013, the EU-28 member states imported 66% of its overall gas
consumption.2 Europe’s gas dependency has increased over the last
years, mainly due to the dwindling of domestic production of natural
gas, and this trend is likely to continue in the long run, despite the
persistently low demand. Since the financial crisis and with the push to
Figure 1. An overview of gas

pipeline projects in the Southern
Gas Corridor.
25
the route of the Baku-Tbilisi-Ceyhan (BTC)
crude oil pipeline.
Since 2006, the SCP (692 km, 42 in.) has
been jointly operated by BP and Statoil to
supply markets in Turkey and Georgia. The
current SCPX project involves the looping
of the SCP in Azerbaijan and partially in
Georgia, as well as the construction of
two new compressor stations in Georgia
to increase the overall capacity to
23 billion m3/yr.10
TANAP is now being constructed. It is one
of the longest pipeline projects in the world
at over 1841 km in length, 56 in. diameter
Figure 2. EU gas supply in 2014. and 16 billion m3/yr capacity, with a planned
expansion to 31 billion m3/yr. The ground-
breaking ceremony for TANAP – the longest
renewable energies, gas demand had dropped from almost and most expensive element of the Southern Gas Corridor
522 billion m3 in 2010 to 461 billion m3 in 2013.3 At the same – in the city of Kars north-east of Turkey in March this
time, according to the International Energy Agency (IEA) year, marked a major milestone in the Southern Gas
Europe’s gas production in 2020 is expected to be 25% Corridor’s development.
below its 2010 level.4 As a consequence, EU gas import The impressive, US$10 billion pipeline,11 which includes
requirements are to increase by almost one-third between a Marmara sea crossing section as well as multiple
2014 and 2020.5 compressor stations, will cross the whole country from
In order to meet EU demand, gas is currently imported east to west, traversing 20 provinces, 67 districts and nearly
through three large corridors: the eastern corridor from 600 villages and mountains up to 2800 m above sea level.
Russia, the northern corridor from Norway, and the TANAP is being developed by a consortium consisting of
Mediterranean corridor from Libya and Algeria. In addition, SOCAR, BOTAS, and BP. ILF Consulting Engineers, a German
LNG is imported, with Qatar and Algeria being Europe’s engineering consultant with 35 years of project history in
leading LNG providers. Imports from the US have also Turkey was awarded the Project Management and Owner’s
been growing since the shale gas boom.6 LNG supplies Engineering (PMOE) contract in the initial phases of the
are expected to further grow over the next five years and project and now continues to support the integrated
Europe is set to offer an important outlet.7 management team of TANAP, while an EPCM contract was
awarded to WorleyParsons Resources and Energy, London.
The Southern Gas Corridor – Turkey will receive 6 billion m3/yr from TANAP.
diversification of gas supplies to European Starting at the border to Greece, TAP will transport the
markets remaining 10 billion m3/yr, which is destined for Europe
A fourth gas entry route, the Southern Gas Corridor, across 870 km via Albania and the Adriatic Sea to Italy.
carrying Caspian gas and potentially gas from the Middle According to the Front-End Engineering Design (FEED) for
East and Central Asia, has been recognised by the EC for the pipeline, which was completed by ILF in 2012, phase
its strategic importance in terms of EU’s energy security.8 one of TAP will have a capacity of 10 billion m3/ yr.
This megaproject, which requires approximately US$45 However, the pipeline system is designed so that its
billion of investment,9 involves the construction of three capacity can be doubled to 20 billion m3/yr in a potential
major pipeline sections, in total stretching across 3500 phase two.
km to provide an export route to Europe for Azerbaijan’s By the end of 2015, major procurement contracts will
offshore Shah Deniz 2 gas field in the Caspian Sea: the be awarded. With the Italian government having signed its
South Caucasus Pipeline (SCP), the Trans-Anatolian Gas final approval, the construction of the pipeline is expected
Pipeline (TANAP) and Trans-Adriatic Pipeline (TAP). SCP is to start in 2016. First gas is expected to be delivered in
already in place, but requires capacity extensions, while 2020.12
TANAP and TAP are yet to be constructed. TAP was preferred as the western extension by the
As the main source of supply to the Southern Gas TANAP shareholders over the Nabucco West project,
Corridor, BP’s Shah Deniz 2 gas field will deliver 16 billion which was designed to cross Bulgaria, Romania, and
m3/yr of gas through the Sangachal Terminal in Baku, Hungary and to finish in Austria. TAP joint venture’s
Azerbaijan into the expanded South Caucasus Pipeline shareholders are BP (20%), SOCAR (20%), Statoil (20%),
(SCPX), which runs via Tbilisi to Erzurum in Turkey along Fluxys (19%), Enagás (16%) and Axpo (5%).

TAP will be connected to the Italian natural gas grid So far, all negotiations have only involved one
and Azeri gas is expected to reach further countries in 16 billion m3 pipeline.15 According to Turkish Energy
Western Europe, including but not limited to Austria, Minister, Taner Yildiz, Gazprom has already delivered
Germany and France or Switzerland. co-ordinates for the routing of the onshore section.16
The pipeline is expected to be laid onshore near the
Supplying Balkan and eastern European Turkish village of Kiyikoy and will then be connected
countries: demand for interconnecting gas with the Turkish-Greek gas hub at the border checkpoint
infrastructure at Ipsala.17 Russia and Greece have signed an MoU on
To guarantee security of supply, particularly for those the extension of Turkish Stream from this point onwards
Balkan and central european countries that are suffering through Greek territory.18 According to IHS (2015), it is not
from single-source dependency from Russian gas, TAP will expected that Turkish Stream would impact the Southern
include reverse flow features, allowing gas to be diverted Gas Corridor project, with all investments under way and
from Italy to these countries.13 There are also discussions firm long-term contracts signed.19
to connect the TAP to regional pipeline systems such as
the planned 5 billion m3/yr Ionian Adriatic Pipeline (IAP) in Future outlook
order to supply Montenegro, Bosnia and Herzegovina and Future gas supplies to Europe along the southern corridor
Croatia. Also, Eastring has been proposed to interconnect and further developments on the eastern corridor clearly
gas infrastructure between Bulgaria, Romania, Hungary and depend on Turkey’s path towards becoming a major gas
Slovakia. transit country.
The construction of LNG receiving terminals on As announced in December 2013 by the Shah Deniz
the Adriatic shore may also support the diversification consortium, 100% of the initial capacities of both TANAP
of sources of supply to the Balkan countries, which and TAP are secured by 25 year long-term agreements.
could be cut off from the TAP bypass. This has found Nevertheless, there are speculations as to what extent
support in the EC. To promote a more flexible and other regional players might supply TANAP in addition to
integrated internal gas market, the EC has identified the committed amount delivered by Azerbaijan.
so-called ‘Projects of Common Interests’ (PCI) including In 2013, Turkmenistan and Turkey agreed on connecting
interconnecting infrastructure, LNG terminals and reverse Turkmen gas supplies to TANAP. However, plans for the
flow pipelines, which are benefiting from EU funding and Trans-Caspian Pipeline to bring Turkmen gas to the EU
other incentives. across the Caspian Sea needs to be realised before this
As an example: to diversify imports from Russia to can happen. This remains difficult due to political and
Bulgaria, the following interconnectors are planned: legal disputes regarding Caspian seawater boundaries.
Interconnection Bulgaria-Romania (IBR); Interconnection Turkmenistan has rather shifted its export strategy to
Greece-Bulgaria (IGB); Interconnection Turkey-Bulgaria China.20
(ITB); and Interconnection Bulgaria- Serbia (IBS). With Iran having a 10% stake in the Shah Deniz
Consortium through Naftiran Intertrade Company (NICO)
The rise of the Turkish Stream – a subsidiary of National Iranian Oil Company – post-
While the EU plans to diversify its gas imports, Russia sanctions Iran might have a future role in the Southern
is looking to expand its exports to Europe. Russia is Gas Corridor.21 Besides transporting gas though TANAP, a
moreover planning to bypass Ukraine as a gas transit potential revival of the Iran-Turkey-Europe (ITE) pipeline
country and to reduce its transit dependency with a might be also possible. However, as forecasted by BMI,
targeted exit by 2019.14 Therefore, northern and southern there is only limited export potential until 2025 due to
bypass-routes are being considered. On the one hand, this internal demand, the lack of spare gas for exports, and
has become evident with the recent agreement between absence of production and export infrastructure.22 The
Gazprom and its partners to expand its Nord Stream Kurdistan Regional Government in Iraq (KRG) also has the
pipeline across the Baltic Sea to Germany. On the other potential to supply Turkey with gas. Until now, disputes
hand, Turkish Stream has been launched. This pipeline with the Federal Iraqi Government regarding outstanding
connection through the Black Sea redirects the former payments have impeded investments and the development
South Stream project to Turkey, after the EU’s Third of necessary treatment and export infrastructure, for
Energy Package impeded its realisation on EU territory on example an Erbil-Ceyhan gas pipeline.
legal grounds. Initially, the EC expected a rather ambitious supply
Gazprom and BOTAS have signed a memorandum rate of roughly 10 - 20% of EU gas demand by 2020
of understanding (MoU) for the construction of a new (45 - 90 billion m3/yr) from the Southern Gas Corridor.23 It
gas pipeline, 1090 km in length with an overall capacity has become clear, though, that these targets will not be met,
63 billion m3/yr for all four pipes, to run on the bottom of at least in the foreseeable future. Initially, TANAP will have
the Black Sea basin to the Turkey-Greece border. a capacity of 16 billion m3/yr when entering Turkey, which is

planned to be expanded to 31 billion m3/yr by 2031. Because attended Ministerial Meeting in Baku’ available at https://ec.europa.
eu/energy/en/news/southern-gas-corridor-vice-president-
6 billion m3/yr of Azeri gas are to be used for domestic %C5%A1ef%C4%8Dovi%C4%8D-attended-ministerial-meeting-baku,
consumption in Turkey, only a remaining 10 billion m3/yr accessed on 30.06.2015.
will be crossing the border to Greece for further transport 9. TAP Ag, 2015, http://www.tap-ag.com/, accessed on 30.06.2015.
10. BP, 2015, http://www.tap-ag.com/, accessed on 30.06.2015.
to Europe. This corresponds to only about 2% of the total 11. APA, 2015 http://en.apa.az/xeber_foundation_of_tanap___s_turkish_
European gas demand, and will therefore not radically part_to_be_224480.html, accessed on 30.06.2015.
12. TAP Ag, 2015, http://www.tap-ag.com/, accessed on 30.06.2015.
change EU security of gas supply for now. Nevertheless, the 13. HAFNER, 2015, ‘The Southern Gas Corridor and the EU Gas Security of
Southern Gas Corridor is a significant step towards a more Supply: What’s Next? The Caspian Report’, available at http://www.
caspian-report.com/the-southern-gas-corridor-and-the-eu-gas-security-
diversified gas supply architecture in Europe. of-supply-whats-next, accessed on 30.06.2015.
Once the political and financial obstacles and 14. Gazprom Deputy CEO Alexander Medvedev stated: “We will not export
infrastructure bottlenecks are overcome, there is gas via Ukraine after 2019. The customers will get gas at (newly) agreed
delivery points,”available at: http://www.euractiv.com/sections/
enormous potential for expansion in terms of existing energy/gazprom-reaffirmsplans-bypass-ukraine-2019-315264, accessed
pipeline capacities and new supply routes. on 30.06.2015.
15. Press release, Office of the Prime Minister, 15.06.2015, available at:
http://www.byegm.gov.tr/english/agenda/route-defined-for-turkish-
References stream-awaiting-finalapproval/ 81352, accessed on 30.06.2015.
1. EU Commission, 2010, ‘Energy infrastructure priorities for 2020 and 16. Sputnik, 2015, available at: http://sputniknews.com/
beyond – A Blueprint for an integrated European energy network’, business/20150615/1023396248.html#ixzz3e9w58BZT, accessed
available at: https://ec.europa.eu/energy/sites/ener/files/ 30.06.2015.
documents/2011_energy_infrastructure_en.pdf, accessed 30.06.2015; 17. Reuters, 2015, ‘Greece, Russia to cooperate on Turkish Stream pipeline’,
repeated recently in the Energy Union Framework Strategy, 2015. available at: http://www.reuters.com/article/2015/06/19/energy-
2. EU Commission, 2015, ‘Imports and secure supplies’, available at: http:// russiagreece-idUSR4N0XJ00220150619, accessed 30.06.2015.
ec.europa.eu/energy/en/topics/imports-and-secure-supplies, accessed 18. IHS, 2015, Eurasia Transportation Forum Summit, 25.06.2015 Istanbul.
30.06.2015. 19. Ibid.
3. Eurogas, 2011/2015 ‘Press Release - Evolution of Gas Consumption 20. ECFR, 2015, ‘Europe’s alternatives to Russian gas’, available at: http://
2010’ and ‘Press Release- New Eurogas data confirms dynamic EU gas www.ecfr.eu/article/commentary_europes_alternatives_to_russian_
market’; estimated gas demand based on EU-27 Gas consumption in 2010 gas311666, accessed on 30.06.2015.
and EU-28 Gas consumption in 2013; due to warm weather EU-28 gas 21. Natural Gas Europe, 2015, ‘Removal of Sanctions from Iran: What does
consumption has dropped to 409 billion m3 in 2014. it promise for the Southern Gas Corridor?’ available at: http://www.
4. International Energy Agency, 2015, ‘Medium- Term Gas Market Report naturalgaseurope.com/removal-of-iran-sanctions-and-southern-gas-
2015’. corridor-23389, accessed on 30.06.2015.
5. Ibid. 22. BMI, 2015, ‘Iran-Europe: No gas export market to 2024’.
6. Eurogas, 2014, ‘Eurogas Statistical Report, 2014’. 23. EU Commission, 2010, ‘Energy infrastructure priorities for 2020 and
7. International Energy Agency, 2015, ‘Medium- Term Gas Market Report beyond – A Blueprint for an integrated European energy network’,
2015’. available at: https://ec.europa.eu/energy/sites/ener/files/
8. EU Commission, 2015, ‘Southern Gas Corridor: Vice-President Sefcovic documents/2011_energy_infrastructure_en.pdf, accessed 30.06.2015.
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Jim Frith, Director of McConnell
Dowell and IPLOCA Director, East &
Far East, discusses how to manage a
healthy construction company through
the ups and downs of a business cycle.
Figure 1. Value compass.
The principles of
WORKPLACE
PROSPERITY
T
he construction industry is renowned for its cycles; one minute we are searching for work to keep
our people challenged, the next we are searching for skilled people to deliver the volume of work
on offer. ‘Feast or famine’ is a commonly used phrase.
In a growth phase, an organisation’s culture will be tested by the pressure of expansion and can
become fractured. In a shrinking market, with its job insecurity and uncertainty, a company may experience
instability, loss of skills and morale. In both these scenarios, the performance of an organisation (financial,
quality, safety, etc.) will suffer.
A successful business is one that is able to mitigate the negative effects of change using its own unique
strategies and attributes. These may include a balanced portfolio approach utilising geographic and/or
29
capability diversity to smooth the cyclic effect, or an culture is visible leadership backed up by consistent
acquisition to facilitate expansion and a move into growth communication and activity around that platform.
markets. An internal launch by the group’s Chief Executive
These are valid approaches, however one thing Officer, an executive roadshow to all offices, and a
is certain, change and the negative impacts it can renamed and re-launched internal employee magazine
have on a business are devastating if poorly managed. and intranet underpinned the initiative. The group
Strong leadership and decisive management are crucial incorporated its values in its annual business planning
throughout these turbulent times. process that, together with a revision to all its internal
As a successful pipeline constructor in Australasia and and external marketing collateral, delivered the message
a prominent multidiscipline general contractor for more out to all corners of the business. As a result, the group’s
than 50 years, McConnell Dowell knows all too well the corporate communications are now clearer and more
business cycle and its impact on performance. Its blueprint consistent, helping engage its employees and build a
for success is based on three key principles. These positive narrative around the future of the company.
principles have helped the company prosper through feast To continue the momentum McConnell Dowell is
and famine, and can be applied to any business. developing a new employee reward and recognition
programme called the MVPs (standing for McConnell
Nurturing the right culture Dowell values programme, but a nice play on most
Every organisation, regardless of size, industry, ownership valuable player) and revising its employee performance
or structure, has its own unique culture. It is a distinctive management programme to embrace these values in staff
mix of attitudes, behaviours, expectations and beliefs key performance indicators.
that define it – concisely described as ‘how things are Despite the current tough business conditions, the
done around here’. Some organisations have mastered the shift in attitude and behaviour has been very positive
complexities of culture and proactively nurture it; while with internal surveys showing a marked improvement in
others let it evolve naturally and, well, hope for the best! its staff’s engagement and alignment with the company’s
McConnell Dowell understands that during turbulent culture, purpose and future direction. This bodes well for
times, it has been and will continue to be its culture, and any tough times ahead.
the attitude and behaviours of its employees, that will
ensure the group’s continued success. Ensuring organisational simplicity
For example, to address a contracting market in Agility and flexibility are primary attributes of today’s
Australia in 2013, McConnell Dowell launched a major successful organisations; an organisation that adapts and
initiative called ‘mobilising optimism’, a proactive change the quickest will be the most likely to prosper.
programme to re-engage its employees and ignite While there are numerous contributors to
positivity throughout the organisation. The initiative organisational agility and flexibility, McConnell
started with a review of what the group calls its cultural Dowell believes that a fundamental ingredient is an
platform: its vision, purpose, values and behaviours. appropriate organisational structure. Nothing hinders
Engaging a cross section of employees from all parts of agility and flexibility more than a complex organisation
the group, this review was undertaken to ensure it had the that negatively impacts team and individual clarity,
same meaning and relevance regardless of who you were accountability and responsiveness.
or your role in the company: As a company with over 50 years of continuous
)) The vision statement was tested and revised to operations, McConnell Dowell has been through numerous
the aspirational: ‘to be leaders in infrastructure structural changes. From discipline based to regional
development.’ based to matrix, the group has experienced all types of
structures and understands what works and what does not.
)) The purpose statement was revised to the outward While there is no universal right or wrong answer to
looking and externally focused: ‘building better structure, the underlying principle is to keep it as simple as you
communities through safe, smart, and efficient can, regardless of the phase of the business cycle you are in.
infrastructure.’
Single lines of reporting, minimal layers top-to-bottom
)) The values and behaviours were refreshed and restated and clearly articulated individual and team accountabilities
as five strong verbs: ‘lead, grow, deliver, sustain and are the group’s fundamental ingredients of a simple
protect.’ These values capture the essence of what organisation.
McConnell Dowell does and how it achieves this And one final thing on structure, as a company expands
across every dimension of its business. The group also and contracts through the cycles, it is often tempting to
developed its ‘value compass’ as a simple, visual tool to make structural changes in response. McConnell Dowell’s
help communicate and reinforce this message (Figure 1). advice is that wherever possible, flex and change the skill
levels and resources within the current structure to meet
However, establishing a relevant cultural platform the market, not the structure itself. Keep it simple but also
was only the first step. Crucial to any shift in workplace keep it stable.

22
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Innovation based. Employee owned. Expect more.

Systems that serve, not stifle growth phase in Australia, the group’s systems had become
A common problem with companies that have gone clogged and confusing.
through significant growth is bureaucracy. As the In response, an initiative called ‘back to basics’ was
organisation gets bigger, more layers of control are launched. This brought together functional teams from
often applied. The workplace can become overrun with across the business each tasked with reviewing, revising,
processes, procedures and forms that stifle agility and simplifying and unifying the group’s procedures. The teams
flexibility and disempower people. After almost a decade used the globally recognised Australian Business Excellence
of continuous growth, McConnell Dowell found itself Framework to provide a structure for the process and to
moving in that direction and acted decisively to address ensure a consistent approach was applied throughout the
the situation. initiative.
McConnell Dowell has always prided itself on its ISO The results have been significant. McConnell Dowell
accredited, integrated management system (McConnell has achieved a 31% reduction in core MMS documentation,
Dowell Management System or MMS). The MMS provides removing a total of 527 documents. This reduction has
the framework for achieving compliance with statutory, been achieved by consolidation, simplification or removal
regulatory, corporate requirements, and applicable codes of old, outdated and obsolete documents. In the same
and standard. It specifies processes and procedures for period the group has also refreshed and loaded 88 new,
control of risks and hazards, and the impact of activities simplified documents into MMS for use. The group’s
on the environment. It also focuses on client satisfaction focus moving forward is consolidation and streamlining
and continual improvement. It has been used to effectively of its OHS procedures and safe work instructions, and to
manage most of McConnell Dowell’s projects, from the generate standard operating procedures that are more
small sub US$5 million projects through to the mega user-friendly, easier to implement in the field and improve
pipeline developments like APLNG in Queensland (Figure 2) delivery quality.
and the Fourth Transmission Pipeline project in Thailand. In addition to the focus on MMS, McConnell Dowell
Recently, a comprehensive internal audit of the system also mobilised a small business improvement team to
found a proliferation of duplicated, redundant and out identify, analyse and improve existing business systems
of date procedures. On reflection, through the recent with the aim of simplification, cost reduction and
quality improvement. So far this team has managed the
development of a standardised opportunity tracking
system and a unified HR system to manage employees
throughout the various stages of their careers with
the group. Both these system changes have delivered
significant paperwork reduction and enhanced
management transparency and control.
The ‘back to basics’ theme has really taken hold in
McConnell Dowell with all employees embracing the drive
to simplify its business, remove bureaucracy and focus on
what the group does best, which is delivering outstanding
projects for its clients and the community.
Summary
Change is inevitable and the ups and downs in the
construction sector are a part of life. The organisations
that survive and prosper are those that embrace some core
principles that they believe in and are proven to work,
regardless of the external environment.
For McConnell Dowell these principles involve
nurturing a strong, positive culture; ensuring the group’s
organisational structure is simple and making sure its
systems and procedures are empowering its people, not
hindering them with bureaucracy.
McConnell Dowell believes that these principles
can work for any business and recommend that
leadership teams across the industry do a health check
on their organisation against these three strategies. An
improvement in any or all of these areas, will deliver a
Figure 2. MMS has been effectively used in mega pipeline positive impact on your organisation regardless of where it
developments, such as APLNG in Queensland.
may be in the business cycle.

contractors’
directory
The smarter choice for

handling coated pipe. f as t e r . s af e r . s m a r t e r .
Enthusiasts in
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© Régine Mahaux
www.denys.com
NSHORE PIPELINES - OFFSHORE PIPELINES - TURNKEY CONSTRUCTION - HORIZONTAL DIRECTIONAL DRILLING - COMPRESSOR STATIONS - WELDING -
TATIONS - WELDING - FINANCE, STRATEGY & ANALYSIS - FEASIBILITY STUDIES - TERMINALS - RESEARCH & DEVELOPMENT - MAINTENANCE - REHAB
contractors’ directory
Welcome to the
2015 edition of
the Contractors’
Directory: our
annual report
on the major oil
and gas pipeline
contractors.
Each company
entry offers
a glimpse into
their recent
activities, with
project updates,
upcoming work
schedules and
capabilities
guides.
NSHORE PIPELINES - OFFSHORE PIPELINES - TURNKEY CONSTRUCTION - HORIZONTAL DIRECTIONAL DRILLING - COMPRESSOR STATIONS - WELDING -
TATIONS - WELDING - FINANCE, STRATEGY & ANALYSIS - FEASIBILITY STUDIES - TERMINALS - RESEARCH & DEVELOPMENT - MAINTENANCE - REHAB
AB Kauno Dujotiekio Statyba (KDS)
W
ONSHORE
PIPELINES
ith its deep experience and Here are just a few of the construction projects
commitment to delivering quality, cost- that KDS is working on or has completed:
effective pipeline construction services F Klaipėda–Kuršėnai DN800 gas transmission
by embracing new technologies, AB pipeline. Total length: 111 km, MOP: 5.4 MPa,
OFFSHORE
PIPELINES Kauno Dujotiekio Statyba (KDS) of Lithuania is now Lithuania.
the largest pipeline construction contractor in the
Baltic States. F Tauragė–Klaipėda DN400 gas transmission
Throughout the past 50 years, KDS has carried pipeline. Total length: 36 km, MOP: 5.4 MPa,
out more than 100 pipeline construction projects Lithuania.
TURNKEY
CONSTRUCTION
for major oil and gas operators. To achieve this, KDS F Jauniūnai gas compressor station.
draws not only upon its experienced staff, but its 433 000 00 nm3/hr, 3 x 11.5 MW compressors,
considerable fleet of construction and installation Lithuania.
machinery, transportation vehicles, and state-of-
HORIZONTAL the-art automatic welding systems. Its commitment F Szczecin-Lwówek DN700 gas transmission
DIRECTIONAL to excellence continues to nurture success, with pipeline. Total length: 38.6 km, MOP: 8.4 MPa,
DRILLING
increasing demand for its services. During the past Poland.
10 years, KDS completed 35 pipeline construction
F Kolnik-Gdansk DN500 gas transmission pipeline.
projects. Total length: 4.5 km, MOP: 8.4 Mpa, Poland.
KDS offers a variety of services, but its primary
COMPRESSOR focus is on EPC pipeline construction, and gas
STATIONS
compressor and distribution stations.
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
ipeda-
on the 111 km Kla
ed 30 00 we lds in just six months
KDS has complet
.
Kursenai pipeline
34
2015
ONSHORE
PIPELINES
OFFSHORE
PIPELINES
TURNKEY
CONSTRUCTION
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
KDS uses the Magnatech Pipeliner

II to automatically weld pipes and
fittings, quickly and efficiently.
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Pre-heating the pipe in

preparation for girth weld
coating is essential to achieve
a superior weld.
35
2015
Arc Energy Resources
C
ONSHORE
PIPELINES orrosion in oil and gas pipelines can lead to section. Another recent endorsement of the company’s
a waste of precious natural resources and position as an international specialist is the presentation
billion dollar losses. H2S, dissolved CO2 and to the company’s Managing Director Alan Robinson of
various chlorides are all present in fossil fuels an award as the 2014 Best Welding Coordinator by the
delivered from subsea oil and gas fields and while a European Federation for Welding, Joining and Cutting
OFFSHORE
PIPELINES sour service at high temperature is extremely corrosive, (EWF).
the same service at high pressure is very erosive. A Arc Energy Resources is one of the UK’s leading
combination of the two is a potentially expensive and specialists in weld overlay cladding and fabrication
hazardous situation. for the oil and gas industry. The company’s expertise
TURNKEY Gloucestershire-based Arc Energy Resources was provides protection against corrosion and wear for a
CONSTRUCTION
founded more than 20 years ago to provide specialist variety of process and pipeline equipment for use in any
weld overlay cladding and fabrication services to the hostile environment.
oil and gas, defence and nuclear industries. Today, The company has made a major investment in two new
it employs 75 people and has an impressive list of rotating head welding machines to increase productivity.
HORIZONTAL accreditations including ASME U and U2 Stamps, ISO Commenting on the investment, Arc Energy Managing
DIRECTIONAL 9001:2008, ISO 14001:2004, Investors in People Bronze Director Alan Robinson says success in winning several new
DRILLING
award and OHSAS 18001:2007. The company is now one contracts prompted a review of the company’s capacity
of the only weld overlay cladding specialists in the UK to handle orders for cladding large and/or complex
with ISO 3834-2 certification from The Welding Institute components.
(TWI).
COMPRESSOR Arc Energy Resources is approved as a supplier
STATIONS
of specialist weld overlay cladding services to many
leading manufacturers of subsea systems,
equipment and technologies required to
explore, drill and develop offshore oil
WELDING and gas fields throughout the world. The
diversity of work the company can handle
sets it apart from many others, as it is
able to supply the full skill set. The need
for an in-depth understanding of so many
FINANCE,
STRATEGY disciplines, and their equally wide and
& ANALYSIS
demanding quality standards, requires vast
knowledge and experience.
Arc Energy’s team of welders and
fabricators are qualified to internationally
FEASIBILITY recognised standards and specifications.
STUDIES
A broad portfolio of base metal/cladding
combinations has been qualified to all
international standards, including ASME IX,
API 6A, ISO, DNV OS F-101 and NACE. In
TERMINALS addition, Arc Energy offers in-house test
weld, heat treatment, and PMI and NDT
facilities.
Among the advanced handling
equipment available to customers are two
RESEARCH &
DEVELOPMENT Rotating Head welding machines installed at
a cost of £500 000 to increase productivity
and extending the scope of work the
company can handle. The investment
expands and enhances Arc Energy’s ability to
MAINTENANCE
handle complicated component geometries
for the full or partial cladding and
fabrication of a huge range of component
sizes weighing up to 15 t.
REHAB The business offers high levels of
technical support to its clients. It maintains One of two rotating
an active welding engineering department head welding machines
and a dedicated research and development installed at a cost of
£500 000.
36
2015
Arendal
W
ONSHORE
PIPELINES ith a firm belief that trust is built,
not given, Arendal continues to build
trust with each passionately executed
project.
The company profitably creates, builds, finances
OFFSHORE
PIPELINES and owns infrastructure projects for society’s growth.
With almost 20 years in the industry, Arendal has
collaborated in infrastructure and services projects. In
addition, it has successfully set up plants, pipelines and
TURNKEY offshore works.
CONSTRUCTION
Arendal’s capacity stands out for its
comprehensive management of projects;
meeting the most stringent requirements
of blue chip clients worldwide in areas of
HORIZONTAL quality, safety and completion of work on
DIRECTIONAL schedule and within budget.
DRILLING
Recent oil and gas pipeline projects:
F Engineering, procurement and
construction contract – Los Ramones
II Norte (consortium with Odebrecht
COMPRESSOR & Techint) (48 in. x 481 km pipeline)
STATIONS
for TAG Pipelines Norte (Pemex Gas y
Petroquímica Básica subsidiary).
F 36 in. x 27 km Trinidad-Cactus gas

.
pipeline for Pemex Exploración y Expansion, 2014
WELDING
for the M ay ak an Gas Pipeline
Producción at the ‘Cactus CPG’. HDD
F Engineering, procurement and

construction of the Mayakan gas
FINANCE,
pipeline expansion (30 in. x 75.9 km).
STRATEGY
& ANALYSIS F 30 in. x 160 km gas pipeline Morelos
Gas.
FEASIBILITY
STUDIES
Quick facts:
F Arendal is the largest horizontal directional
drilling contractor in Mexico.
F Arendal actively participates in investment

TERMINALS projects and concessions providing a 360°
service; including financing, design, procurement
and construction, as well as long-term operation
and maintenance.
RESEARCH & F Arendal have been engaged in the construction

DEVELOPMENT of 90% of the combined cycle plants in Mexico
during the last decade.
F Arendal is one of the main mexican IPC

companies, with technical expertise in its fields.
MAINTENANCE It has also maintained an exceptional track-
record and created a project portfolio comprised
by a wide range of complex procedures and
technologies executed in every region of the
REHAB
country.
38
2015
ONSHORE
PIPELINES
OFFSHORE
PIPELINES
TURNKEY
CONSTRUCTION
HORIZONTAL
DIRECTIONAL
DRILLING
HDD for the Trinidad-Cactus Gas Pipeline, 2014. COMPRESSOR

STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
HDD for the

39
2015
Trinidad-Cactus Gas
Pipeline, 2014. contractors’ directory
Baker Hughes Process and Pipeline Services (PPS)
T
ONSHORE
PIPELINES
he Baker Hughes Process and Pipeline Baker Hughes PPS has introduced many
Services (PPS) team is a leading worldwide groundbreaking services to the process and pipeline
service provider for process and pipeline industry, including nitrogen-helium leak testing,
precommissioning, maintenance and inspection foam inerting and hybrid cool-down technology for
OFFSHORE
PIPELINES applications. For more than 40 years, the team’s expert process plants. The team’s new gas transfer and mobile
staff of highly trained professionals, who are located flaring services reduce greenhouse gas emissions and
in more than 40 bases worldwide, have responded its services help global operators improve pipeline
promptly and reliably to its clients’ needs. The team efficiency; reduce product-to-market time; reduce
TURNKEY uses the industry’s largest fleet of process and pipeline health, safety and environmental (HSE) risk; and meet
CONSTRUCTION
advanced technologies to effectively clean, dry, test regulatory standards.
and inspect process and pipeline systems. Services offered include pipeline pre-
commissioning, flooding, hydrostatic
testing, cleaning, drying and product
HORIZONTAL commissioning. The group’s pipeline
DIRECTIONAL maintenance services include inline
DRILLING
filtration and separation, gel pigging,
chemical and mechanical cleaning,
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
tion services more
enhanced inline inspec
VECTRA™ SENSOR7 e com ple x ano malies.
ntify and siz
accurately locate, ide
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
40
2015
ONSHORE
PIPELINES
nitrogen purging, online pigging, temporary pumping F Chuandongbei, China – in early March 2015, Baker
packages and product transfer; and its pipeline Hughes PPS was awarded a two year contract for
inspection services include caliper, inertial geometry, pipeline and process precommissioning services
on a major onshore sour gas project for Chevron
cathodic protection surveys, crack detection and metal
in China. Baker Hughes will perform pipeline OFFSHORE
loss using magnetic flux leakage (MFL) and ultrasonic PIPELINES
precommissioning services such as mechanical
technologies, and fit-for-purpose evaluations.
cleaning and drying, caliper and magnetic flux
Baker Hughes’ services are available to the natural leakage (MFL) inspection, and nitrogen-helium leak
gas, crude oil, refined products, and petrochemical testing to ensure valve steams are leak-free. Process
industries in major oil producing areas across the globe. precommissioning services include remedial bolting TURNKEY
CONSTRUCTION
Ongoing oil and gas projects include: and nitrogen-helium leak testing of plant and well
F Gorgon Project, Western Australia – the Baker pads.
Hughes PPS team recently completed dewatering
and purging the Jansz 6, 8 and 34 in. pipeline system F Shah Deniz, Azerbaijan – engineering work is
from Barrow Island to the Jansz field, as part of the ongoing in London with BP, relating to the pipeline HORIZONTAL
Chevron Gorgon project. This significant milestone, precommissioning aspects of the Stage 2 Full-field DIRECTIONAL
DRILLING
which was on a critical path for the project, allows Development Project. This development will deliver
Chevron to move forward with critical downstream gas into Europe via a network of significant new gas
construction operations. pipelines.
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Baker Hughes successfully

completed dewatering and
purging as part of the Gorgon
pipeline pre-commissioning
project.
41
2015
Consolidated Contractors Company (CCC)
C
ONSHORE
PIPELINES onsolidated Contractors Company (CCC) is a of soil strata, terrain, and topographic details, different
multinational construction company established types of climate and weather conditions and multiple
in 1952 and considered one of the leading welding technologies.
international specialised contractors. Ongoing oil and gas pipeline projects:
CCC is ISO 9001:2008 certified and provides F Kuwait Lower Fars Heavy Oil Development: EPC of
OFFSHORE
PIPELINES engineering, project management, procurement and 400 km of main pipelines connecting the new plant in
construction services for the oil and gas, petrochemical, North Kuwait with the existing facilities in the south,
industrial plants, civil works, municipal works, housing and EPC of the Production Support Complex.
and high quality buildings. The company has a worldwide
turnover of over US$4.6 billion and currently employs over F Thailand Fourth Transmission Pipeline Project,
TURNKEY
CONSTRUCTION
140 000 personnel worldwide. CCC is presently ranked 24th completion of works: EPC of 42 in. x 298 km gas
pipeline, including open cuts, 62 bored crossings, 27
among The Top 250 International Contractors and 3rd in
HDDs, 18 block valve stations and two facilities.
the Middle East, according to the Engineering News Record
Magazine. Recently completed oil and gas pipeline projects:
HORIZONTAL CCC has participated in the construction of some F APLNG Pipelines Australia: EPC of 667 km (18 - 42 in.)
DIRECTIONAL of the most complex oil and gas pipelines in the Middle
DRILLING of coal seam gas pipelines in Queensland, including
East, Azerbaijan, Mozambique, South Africa, Madagascar, four valve stations, 13 scraper stations and various
Botswana, Thailand and Australia. facilities for each pipeline. The pipeline network and
The scope covered by CCC includes complete plant transmission lines deliver approximately 1500 TJ/d of
construction including all mechanical, civil, electrical, CSG from the gas fields in the Surat and Bowen Basin
COMPRESSOR instrumentation and pre-commissioning works in in Central Queensland to the ConocoPhillips-operated
STATIONS
petrochemical, refineries, oil and gas related projects, LNG plant at Laird Point, Curtis Island near Gladstone,
industrial plants, loading and off-loading terminals. Australia.
Working within the pipeline division is a
sizeable team of engineers specialised in the
WELDING construction of pipelines and associated surface
facilities. These facilities include pumping or
booster stations, metering stations, launching and
receiving stations, valve stations, monitoring and
automated control, cathodic protection, testing
FINANCE,
STRATEGY and commissioning, and maintenance.
& ANALYSIS
The pipeline projects executed involved
several pipeline diameters ranging from
10 - 56 in., steel and non-steel pipelines, various
types of coating and joint coating, different types
FEASIBILITY
STUDIES
APLNG Gas Pipelines, Australia.
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Fourth Transmission
42
2015
contractors’ directory Gas Pipeline,

Thailand.
THE BEST
PROTECTION FOR
A LIFETIME
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Continental Fabrication Services
A
ONSHORE
PIPELINES
world-class pipeline fabrication shop meeting rigorous requirements for processes and
conveniently located in north-central documenting practices.
Missouri delivers more than pipeline CFS has successfully worked with major
facilities, launchers, receivers, valve pipeline operators and facility contractors, and
OFFSHORE
PIPELINES settings and manifolds. has developed a reputation for delivering high
Continental Fabrication Services (CFS) delivers quality products in a timely manner. The CFS team
the confidence that comes with knowing each job has extensive experience handling fabrication for
is built exactly to specifications by an experienced, pump stations, compressor stations, meter stations
TURNKEY reliable team. and regulator stations as well as mainline and
CONSTRUCTION
CFS, located in Carrollton, Missouri, specialises distribution pipelines.
in pipe fabrication for oil, natural gas and products CFS’ experienced crew and project managers
pipeline construction. Customers can count on are extensively trained, certified and experienced
CFS to efficiently and precisely complete orders, in advanced techniques for welding, hydrotesting,
HORIZONTAL including welding, testing, coating/painting,
DIRECTIONAL delivery and documentation.
DRILLING
The company has a sophisticated plant
capable of building pipeline facilities that
range from 2 - 48 in. dia. and up to 120 ft in
length. The recently renovated and expanded
COMPRESSOR fabrication shop also has a spacious gravelled
STATIONS
50 acre laydown yard for the safe, protected
storage of materials and finished products.
CFS’ fleet of expandable flat deck and step
deck trailers, are capable of transporting
WELDING fabricated facilities to installation destinations
throughout North America from Carrollton, a
pipeline hub.
CFS’ staff has systematically honed and
implemented a comprehensive protocol for
FINANCE,
STRATEGY all facets of its operations. The company
& ANALYSIS
has earned ISO 9001:2008 certification by process.
fabrication
rta nt st ep in CFS pipe
impo
Painting is an
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
CFS crew members

weld a pipe to the
customer’s exact
44
2015
contractors’ directory specifications.

SAFETY
AT WORK.
Utilizing proven Cranesmart™ technology, PipeLine Machinery International (PLM) supports the pipeline
industry with the first wireless load monitoring indicator (LMI) system for pipelayers – delivering a safer and more
efficient jobsite. With precise load management data available to operators at all times, the system significantly
reduces the potential for costly and dangerous overloading, tip-overs, roll-overs and other jobsite accidents. It also
provides safer working conditions for ground personnel and reduces equipment damage due to overloading and
extreme steep slope operations. Let’s work together.
ELIMINATE GUESSWORK INCREASE SAFETY QUALITY AT WORK

The Pipelayer System provides operators with Real-time load data prevents jobsite accidents, Delivers accurate information needed to produce
the precise load management information they tip-overs, roll-overs and equipment damage due to quality work by preventing stress on welds and
need to get the job done safely and efficiently. overloading and extreme steep slope operations. pipe damage due to rough handling.
USA: +1-713-939-0007
Canada: +1-780-377-0336
China: +1-86-10-5960-1509
Netherlands: +31-70-353-8279
Australia: +61-423-394-730
www.plmcat.com Your Global Partner for Pipeline Solutions
© 2015 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
company name
Continental Fabrication Services Continued
ONSHORE
PIPELINES coating, painting, and QA/QC practices. The QA/ Expertise and experience combine to form CFS’
QC team inspects material before any fabrication high quality, efficient and timely fabrication team
begins to make sure it is without defect and that shares a common goal of providing clients with
up to customers’ standards, and establishes a the most complete, cost effective and timely delivery
documentation record, which is maintained until of pre-fabricated assemblies in the industry.
OFFSHORE
PIPELINES the product arrives for installation. Recently completed or ongoing oil and gas
CFS’ team includes a Professional Engineer, QA/ pipeline projects:
QC Auditor and Certified Welding Inspector. All
F Six 36 in. pump stations.
welding procedures are documented, tested, and
TURNKEY surpass ASME and API 1104 standards. Coating and F Three 24 in. pump stations.
CONSTRUCTION
painting work is completed and documented by
NACE certified personnel. F Hydrotested 5000 ft of 26 in. pipe.
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
A complete pipe is ready to be shipped to a job site.
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
CFS crew members

weld a pipe to the
46
2015
customer¹s exact
contractors’ directory specifications.
ENABLING
WORLDWIDE
TRANSMISSION OF OIL
AND GAS
By offering the complete range of project

life-cycle services, ILF Consulting
Engineers provides the best
techno-economic solution for our
customers, with proven excellence on
early project phases.
For project management, engineering,

consulting and field services, ILF is your
trusted advisor for oil & gas pipeline
projects.
Do your projects require large diameter,

long distance pipelines? Does your routing
include challenging terrain and difficult
soil conditions?
We are able and willing to tackle the most

challenging boundary conditions for
optimizing and designing the most
technically demanding pipeline systems
in the world.
We are contributing to the success of

the Trans Anatolian Natural Gas Pipeline
Project (TANAP), Trans Adriatic Pipeline
(TAP) and South Caucasus Gas Pipeline
(SCP/X/FX).
Family owned and managed, ILF is a

completely independent enterprise.
Our values are not driven by stock price
performance.
Continuous growth for almost 50 years

and thousands of successful international
projects must be a clear testimony of
customer satisfaction.
www.ilf.com
ad_ILF.indd 1 13.07.2015 12:09:44

CRC-Evans
C
ONSHORE
PIPELINES RC-Evans is involved in almost every aspect of CRC-Evans’ engineering, design, and technical staffs
onshore and offshore pipeline construction, continually analyse all equipment and construction
helping clients around the world build better methodology, ensuring that our approach is the most
pipelines and reduce costs. efficient solution available.
The company’s pipeline equipment meets not only If a pipeline can be built through it, CRC-Evans
OFFSHORE
PIPELINES the requirements of today, but also the future of pipeline can help you get there. The toughest conditions, the
projects. With over 80 years of experience, CRC-Evans narrowest right-of-ways, the rockiest spoils, long or short
has built and sold more diameter pipeline benders runs, diameters of all sizes – CRC-Evans can take on any
than most other companies in the world. Due to this and every challenge. From high productivity bending
TURNKEY vast experience, it has a stable financial background to systems to remote-controlled self-loading padding
CONSTRUCTION
provide you the best services. CRC-Evans’ worldwide
network of offices and agents is a plus when it comes
to service. On the end, the company’s equipment has a
higher resale value than most of our competition when
HORIZONTAL your project is finished.
DIRECTIONAL CRC-Evans represents the world’s largest group of
DRILLING
pipeline construction companies. The market leader
in each of its core businesses, CRC-Evans has offices
around the world, providing each of its customers
with the most extensive infrastructure and resources
COMPRESSOR in the industry.
STATIONS
As the pipeline industry faces formidable
challenges in boosting productivity, efficiency, and
profitability, CRC-Evans has always stayed at the
forefront of technological innovation. CRC-Evans
WELDING holds 129 patents and has been instrumental in
developing many of the industry’s most effective Pipeline weldi
ng.
technologies.
Table 1. Onshore east projects

FINANCE,
STRATEGY Project Project Contractor Location Length (km) No. of welds Dia. (in.) Year
& ANALYSIS type started
Onshore Khazzan Project TOCO Oman 60 3200 36 2015
Arc de Dierrey Lot 4 2015
Onshore Max Streicher GmbH France 60 3150 48
(WIP)
FEASIBILITY Onshore RGZ-3 ENAC Algeria 116 9250 42 2015
STUDIES
Onshore TANAP Lot 01 Fernas Inşaat a.ş Turkey 375 25 000 56 2015
Onshore TANAP Lot 03 Tefken Turkey 600 40 000 56 2015
Offshore PRP3/APP/HRD Leighton-Welspun India 6100 6 - 18 2014
Onshore Arc de Dierrey Lot 1 Max Streicher France 60 2500 48 2014
TERMINALS
Onshore Arc de Dierrey Lot 3 Spiecapag - A. Hak France 63 3160 48 2014
Onshore Krechba-Hassi R’mel Cosinder Canalisation Algeria 231 8000 48 2014
Los Ramones FASE II 2014
Onshore Nuona Ghizzoni Mexico 220 510 42
SVR
RESEARCH &
DEVELOPMENT GR5 Ø 48 in. Krechba- 2014
Onshore COSIDER Canalisation Algeria 201 8500 48
H’rmel IDT II
Offshore GDF Suez CECON North Sea 64 4368 8 - 10 2013
Offshore BG Knarr Subsea 7 18 1800 Misc. 2013
Onshore OB 3 Nestoil Nigeria 600 7000 48 2013
MAINTENANCE
Onshore Central Asia Phase - C CPP KZ Kazakhstan 235 19 505 48 2013
Kazakhstan-Gina 2013
Onshore KSS Kazakhstan 350 31 000 48
Pipeline
Offshore Boyla Technip 13 2051 8 - 16 2013
REHAB 6, 8, 9, 10, 2014
Offshore Moho Nord Technip Congo 227 18 651
16
Offshore Shah Deniz Technip Azerbaijan 380 31 154 6 - 32 2015
Offshore South Stream Saipem Bulgaria 638 52 350 32 2015
48
2015
FASTER .
SAFER.
SMARTE R.
Vacuworx Lifting Systems are the smarter choice for handling coated pipe. Wireless
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CRC-Evans
company name
continued
ONSHORE
PIPELINES machines, CRC-Evans offers the right equipment
for any application.
Around the world, CRC-Evans keeps pipeline
projects moving forward every day, from
bending and handling to ditch and pipe padding.
OFFSHORE
PIPELINES Backed by a unique system of engineering and
support programmes, the company’s turnkey
approach to pipeline construction helps boost
productivity throughout every phase of your PIH premises.
TURNKEY project.
CONSTRUCTION
Table 2. Onshore west projects

Project Project Contractor Location Material Length No. of Dia. Year started Services
type (km) welds (in.)
HORIZONTAL Los Ramones Dec 2014 -

DIRECTIONAL Onshore AOT Mexico X-70 167 8233 42 Welding, pipeline
Spread 1 current
DRILLING
Los Ramones March 2015 -
Onshore AOT Mexico X-70 123 5881 42 Welding, pipeline
Spread 4 current
Esconida Nov 2014 -

Onshore Bechtel Chile X-70 167 14 755 42 Welding
Water Supply current
COMPRESSOR Michels Aug 2014 -
STATIONS Onshore E2H Canada X-70 63 2625 36 Welding, coating
Canada finished
Michels Jan 2015 -
Onshore GTA Canada X-70 42 567 36/42 Welding
Canada finished
July 2014 -
Onshore Pembina Midwest Canada X-70 6.6 388 54 Welding
WELDING finished
May 2014 -
Onshore Eastern Access Precision USA X-70 80.4 3150 30 Welding, coating
finished
July 2014 -
Onshore Bolivia Speicapag Bolivia X-70 102 8083 30 Welding
finished
FINANCE,
STRATEGY Chinchaga 483, 550, July 2014 -
Onshore Surerus Canada 38 1573 36 Welding, coating
& ANALYSIS Loop 690 finished
April 2014 - Welding, coating,
Onshore Net Mexico Willbros Texas X-70 209 8778 42, 48
finished pipeline
Price Feb 2015 -
Onshore Line 78 Canada X-70 128 5415 36 Coating, welding
Gregory current
FEASIBILITY
STUDIES Nov 2014 -
Onshore Grand Rapids Ledcor Canada X-70 83 3695 20 Coating
current
Sept 2014 -
onshore E2H Midwest Canada X-70 77 3348 36 Coating
finsished
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
50
2015
contractors’ directory Pipe bending.

The new Ultra 8c ™
The capability and performance

your market demands.
FMC Technologies’ Ultra 8c ultrasonic flowmeter shares the advanced technology

of the next generation Smith Meter® Ultra Series meters. With its touchscreen
interface, upgradable memory and high-speed processor, the Ultra 8c provides
cutting-edge performance and diagnostic ability. And with additional measurement
paths, the Ultra 8c has even better cross-flow and swirl compensation for improved
accuracy and repeatability. Whether for leak detection or custody transfer, the
Ultra 8c gives you the assurance of superior performance in the field even for the
most viscous crude oils in today’s market.
For more information visit www.fmctechnologies.com/ultrawp
Copyright © FMC Technologies, Inc. All Rights Reserved.
www.fmctechnologies.com
CRTS
C
ONSHORE
PIPELINES RTS, Inc. is committed to preventing internal 1000 m inside the pipe while maintaining full, untethered
pipeline corrosion by making new pipelines’ control.
weakest links become the strongest links. CRTS’ Protecting assets in the Gulf of Arabia was
robotic equipment applies protective coatings accomplished after CRTS internally cleaned, coated and
to internal field joints, strengthening and complementing inspected 12 543 field joints on a laybarge using SP 9888
OFFSHORE
PIPELINES typical corrosion prevention methods such as internal liquid coating. Protecting this vital 36 in. sour gas pipeline
and external pipe coating. Internal field joints are cleaned in the Hasbah and Arabiyah fields required additional
and coated, and real-time video reveals any defects special equipment, such as line-up clamp
before any product is attachments; and pipe rotators and a
TURNKEY in the pipe. The group’s safety winch were designed and built by
CONSTRUCTION
innovative inspection CRTS and transported to the offshore
techniques detect flaws site.
in pipeline coatings before Coating internal field joints of
any product enters the factory-coated pipe provides end-
HORIZONTAL pipeline. to-end corrosion protection for all
DIRECTIONAL After cleaning and types of pipelines including natural
DRILLING
coating the internal field gas, crude oil, potable water and
joints, CRTS provides salt water. CRTS maintains strict
state of the art visual, high quality standards on all robotic
voltage holiday and dry film machinery and coating services
COMPRESSOR thickness inspection services to meet and exceed customer
STATIONS
that incorporate real-time expectations of 100% defect-free
video. The inspection robot coating application. CRTS, Inc. is an
also contains technology ISO 9001:2008 certified company
to view and record the and a wholly-owned subsidiary of
WELDING radial location of any Aegion, Inc.
coating holidays and displays
parent-coating damage,
debris, failed field-applied n prevention
m et ry allows corrosio
C4 8 te le ive data up to
couplings and other send and rece
FINANCE, equipment to
anomalies. CRTS’ unique the pipe.
STRATEGY
& ANALYSIS 1000 m into
custom coating equipment
allows coating of internal
field joints on fittings, such
as 3D radius elbows and
FEASIBILITY induction bends and on
STUDIES
projects with steep slopes.
The group’s global
customers rely on its
robotic technology to
TERMINALS ensure pipeline integrity
for offshore and onshore
projects around the world.
Currently, an 8 in. oil
line in the Middle East is
RESEARCH &
DEVELOPMENT undergoing internal field
joint coating in a pipeline
with a 0.5 in. wall thickness.
The wall thickness required
developing new equipment
MAINTENANCE
capable of navigating in very
tight spaces and our wireless
telemetry provides superior
results. C48 telemetry
REHAB allows equipment to coat
internal field joints as far as
Custom-built rotators handle

52
2015
contractors’ directory immense pipes both onshore

and offshore.
Quality – a global language. BERG EUROPIPE Corp. © Wes
erW
ind
Our sales office in Houston, Texas

The most diverse requirements spur us on. Our clients challenge us
+1 713 - 465 - 1600
as the market-leading producer of large-diameter pipes. Together,
www.bergeuropipe.com
we realize momentous projects all over the world. Quality is a
language everybody understands – everywhere.
BERG EUROPIPE. Integrity beyond compliance.™
The EUROPIPE Group on the internet: www.europipe.com

DENSO GmbH
ONSHORE
PIPELINES
F
ounded in 1922, DENSO GmbH
Germany is the inventor and a
quality leader of anti-corrosion
OFFSHORE
PIPELINES coatings for joints and pipelines.
Its core business consists of
the development and production
of co-extruded 3-ply PE/Butyl-
TURNKEY tapes, heat shrinkable sleeves with
CONSTRUCTION
innovative hotmelt and mastic
technology, petrolatum-tapes,
jetty pile protection systems,
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
SOMAT
® -11.
MP and DEN
N SO LE N®-AS30/-R20
with DE
Rehabilitation
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Inspection of coating applied in the

early 1980s. DENSOLEN®-AS40:
54 successful after more than 30 years of

2015
contractors’ directory application.

ONSHORE
PIPELINES
polyurethane coatings, bitumen profiles, as well as Due to several proven long-term experiences
sealing technology for infrastructures. with DENSO’s self amalgamating tapes, the tapes are
The multinational group looks back on a very used worldwide for rehabilitation projects and new
OFFSHORE
successful corporate history. Following the founding pipeline constructions. PIPELINES
of the company more than 90 years ago, DENSO’s No other company has a longer experience in
success story commenced with the world’s first corrosion protection for pipelines – DENSO GmbH
anti-corrosion product for pipelines, the petrolatum- Germany stands for more than 90 years of quality,
tape (DENSO®-Tape), which was patented in 1927. tradition and innovation. TURNKEY
CONSTRUCTION
Continuous research and development have resulted DENSO GmbH and DEKOTEC GmbH, both part of
in many patents and innovative products for road the DENSO Group Germany, offer a wide range of
construction and protection against corrosion. corrosion prevention products, all made in Germany,
to the highest quality standards.
Recently, DENSO GmbH was HORIZONTAL
contracted to perform quality coating DIRECTIONAL
DRILLING
services for large international clients
around the world, such as Open Grid
Europe (Germany), Gaz de France (France),
Indian Oil Corporation (India), State
Company Oil Projects (Iraq) and Sasol COMPRESSOR
STATIONS
(South Africa).
The projects required the supply of
the company’s DENSOLEN® Tape Systems,
DEKOTEC® Heat Shrinkable Sleeves and
DENSOLID® Polyurethane Coatings, as WELDING
well as instruction training and technical
consulting.
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
DENSOLID ®-HDD
waiting for drilli MAINTENANCE
ng.
REHAB
55
2015
Denys
D
ONSHORE
PIPELINES
enys is a multi-specialist construction group, Denys can assure the engineering, procurement and
active in underground services since 1923 and construction and has gained considerable experience in
building oil and gas pipelines since 1955. Denys is projects requiring financing, operations and maintenance
one of the major pipeline contractors in Europe. (such as BOOT and PPP projects). The company has the
OFFSHORE
PIPELINES The head office is based in Ghent, Belgium, and the in-house expertise, personnel and plant for all the main
company has subsidiaries in several European and African activities, be it civil or mechanical. This includes the
countries and in the Middle East. trenchless crossing of highways, rivers, or
any other obstacles by tunnelling or HDD.
TURNKEY It is thus possible to build a pipeline with
CONSTRUCTION
a minimum of subcontracting or, when
circumstances require, Denys can act as a
general contractor.
Whatever the scope and whoever
HORIZONTAL the client, Denys guarantees a customer-
DIRECTIONAL oriented service focused on safety,
DRILLING
quality and environment. Through
the years the company has also built
a strong reputation for completing
projects in time and to the entire
COMPRESSOR satisfaction of its clients.
STATIONS
WELDING
eline (58 km,

00 natural gas pip
nc e/ Ar c de Di errey 5, ND 12
GRTgaz: Fra ut and Voisines.
n Viviers-sur-Arta
68 bar), betwee
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Gasunie: the
Netherlands – several
diameters: framework
56 agreements (LSC and

2015
contractors’ directory RAP) for the natural

gas pipelines.
ONSHORE
PIPELINES
For Denys it is not only important to be able to build

the client‘s project but to go beyond and to offer the
client solutions the client never imagined. The company
OFFSHORE
believes that if you can dream it, we can build it. This PIPELINES
vision has enabled projects to be realised in innovative and
competitive ways, ensuring the company keeps ahead of its
competitors.
With exceptional technological know-how and an TURNKEY
CONSTRUCTION
impressive fleet of equipment, Denys currently builds
pipelines in Europe, Africa and the Middle East. In the near
future, Denys will also be able to make a difference in other
regions of the world.
Major projects completed in 2014 include: HORIZONTAL
DIRECTIONAL
F GRTgaz: France/Arc de Dierrey 2 (Betz – La Chapelle- DRILLING
Moutils) – ND 1200 natural gas pipeline.
F GRTgaz: France/Connantre – ND 200 natural gas

pipeline.
COMPRESSOR
F Gasunie: the Netherlands/Angerlo-Ulft – several STATIONS
diameters: GNIP renovation programme.
F Gasunie: the Netherlands/Westfrisia – ND 150:

GRTgaz: France/Arc de Dierrey 5, ND 1200 natural gas
deviation of a natural gas pipeline around the future
pipeline (58 km, 68 bar), between Viviers-sur-Artaut and Westfrisiaweg. WELDING
Voisines.
F Gasunie: the Netherlands/Rijswijk-Monster – several
diameters: GNIP renovation programme.
F Gasunie: the Netherlands – several diameters: FINANCE,

framework agreements (LSC and RAP) for the natural STRATEGY
& ANALYSIS
gas pipelines.
Ongoing projects are:

F GRTgaz: France/Arc de Dierrey 5, ND 1200 natural gas
pipeline between Viviers-sur-Artaut and Voisines. FEASIBILITY
STUDIES
F GRTgaz: France/Artère des Flandres, ND 900 natural
gas pipeline between Pitgam and Hondschoote.
F Fluxys: Belgium/Alveringem-Maldegem, ND 900 natural

TERMINALS
gas pipeline between Alveringem and Hooglede.
F Gasunie: the Netherlands/GNIP renovation programme

– Ede-Wolfheze: several diameters.
F Gasunie: the Netherlands/GNIP renovation programme RESEARCH &

DEVELOPMENT
– renovation of three measurement and control
stations in Ewijk, Bemelen and Zuid Kraaijert.
F Fluxys: Belgium/Cluster Ghent South – ND 250 and

300 restructuring of the gas pipeline network in the
MAINTENANCE
southern part of Ghent. Constructing, replacing,
taking out of service of the high and low pressure gas
pipelines.
F Gasunie: the Netherlands – several diameters:

REHAB
framework agreements (LSC and RAP) for the natural
gas pipelines.
57
2015
Dhatec
D
ONSHORE F Pipe storage.
PIPELINES hatec specialises in developing and
manufacturing products that maintain pipe F Pipe handling.
quality during all logistics, showing companies
how they can guarantee a safe, efficient and F Pipe coating.
damage free delivery of their pipe through the entire
OFFSHORE F Consultative services.
PIPELINES supply chain.
In a project’s supply chain, accidents and damages Recently completed or ongoing oil and gas pipeline
occur during the logistics of pipes. Dhatec made a projects include:
significant contribution to preventing such damages F Dhatec developed pipe closure and pipe-end
TURNKEY by organising safe and damage free pipe logistics. The protection solutions for a major pipeline project in
CONSTRUCTION
company’s products and technical support improve the the Caspian Sea.
quality, efficiency and safety of the processes. With this
expertise, Dhatec assists project managers in organising F Dhatec is engineering new Coupling models for a
the logistics of pipeline projects. coating plant in Mexico.
HORIZONTAL Dhatec prides itself on innovation, quality, flexibility F Dhatec designed a complete product range of
DIRECTIONAL and customer satisfaction. Based on these strengths
DRILLING Connecting Couplings to connect pup pieces
the development department is in constant evolution. with nominal length pipes in co-operation with
Existing products are continuously being customised manufacturers and coaters from Europe and the US.
to comply with the latest demands and specifications
– the company’s daily work involves special sizes and F Dhatec designed a new storage solution for a
COMPRESSOR extreme conditions. In addition, Dhatec offers rental spoolbase in Angola.
STATIONS
and recycling possibilities of its products to stimulate
F Dhatec equipped 50 trucks with pipe raisers in
sustainability.
Colombia for transporting 1600 mm pipes.
Dhatec offers over 3000 products in the following
categories:
WELDING
F Pipe preservation.
F Pipe transport.
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
bia.
on a truck in Colom
Pipe Raisers applied
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
Pipe stack applied

with Plug Breathable
REHAB Membrane.
Connecting Coupling in use.
58
2015
ERCİYAS Steel Pipe Co.
E
ONSHORE F Various other SONATRACH projects including but not
PIPELINES RCIYAS Steel Pipe Co. was founded with the vision
limited to GK1, GK3, GEM Phase II, Medgaz, SP2-SP3/
to design, develop, produce and export cutting-
OB1.
edge steel pipes. ERCIYAS manufactures spirally
welded steel line pipes (HSAW), with all types of F Sonelgaz-GREO Project: 336 km Ø28 in. X70 PSL 2 gas
specified coatings with diameters ranging from Ø10 in. pipes.
OFFSHORE
PIPELINES (273.1 mm) to Ø160 in. (4064 mm) and wall thickness
ranging from 0.157 in. (4 mm) to 1.38 in. (35 mm). The pipes F Vattenfall: 6.25 km Ø56 in. x 21.6 mm L555MB (API 5L
can be designed and produced using the highest steel X80 PSL 2) gas pipes.
grades available up to API 5L X-100. F REN Gasodutos S.A., Zubair Oil Field Development
TURNKEY Equipped with all the quality certificates, ERCIYAS Project of ENI (South Oil Company of Iraq): 68 km Ø16
CONSTRUCTION
diligently carries out all kinds of non-destructive and in. to Ø28 in. x 70 PSL 2 gas pipes.
destructive tests in its own state-of-the-art laboratories.
ERCIYAS is the only company in all of Europe, North F Gas storage project in Swiss: 4 km Ø56 in. x 25.5 mm
America and the Middle East with an annual capacity of L485MB (API 5L X70 PSL 2).
HORIZONTAL 450 000 t under one single roof. The 820 research and
DIRECTIONAL F Natural gas pipeline project in Georgia: 120 km Ø28 in.
development projects completed within the last five
DRILLING X60 PSL 2.
years are a testament to the company’s dedication to the
latest technology. Together with a commitment to the F Gas pipeline projects with NET4GAS, s.r.o. in Czech
strictest quality measures, competitive pricing, as well as Republic.
geographical advantages, ERCIYAS has risen to the ranks
COMPRESSOR of being not only the number one pipe exporter in Turkey, F Gas pipes for Petrofac, Algeria: 74 km Ø24 in. x 10.1 –
STATIONS API 5L x 70 m – PSL 2.
but also the 25th biggest exporter in the entire country.
In addition to its capability to mass produce within a F Gas project in Lithuanian 40 km Ø32 in. x 8.8 – L415 ME
limited time span, ERCIYAS is also capable of delivering (API 5L x 60 m) – PSL 2.
the toughest projects (such as 20 in. [Ø 508 mm] OD x
WELDING 1 in. [25.4 mm] w.t. with API 5L X-60 material) due to its
ownership of the strongest machines in the world.
Recently completed or ongoing oil and gas pipeline
projects:
FINANCE, F The US$10 - 11 billion Trans Anatolian Natural Gas
STRATEGY Pipeline (TANAP) project will be carring 16 billion m3 of
& ANALYSIS
natural gas from the Caspian sea to the Europe for the
energy security of EU. TANAP Project specifications:
145 km Ø56 in. x 19.45 – API 5L x 70 m – PSL 2 and 35
km Ø48 in. x 16.67 – API 5L x 70 m – PSL – 2.
FEASIBILITY
STUDIES
Greo Gas Pipeline
Project.
GK3 Project, Algeria.
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
60
2015
Essar Projects
E
ONSHORE F Chennai Trichy Madurai product pipeline (India) –
PIPELINES ssar Projects is a global engineering, procurement
683 km x 10/12/14 in.
and construction (EPC) company that is
headquartered in Dubai, UAE. It offers a unique, F Inter Refinery product pipeline (Abu Dhabi) – 189 km
collaborative end-to-end project development x 28 in.
and delivery model for major projects back integrated
OFFSHORE
PIPELINES into the supply chain, and forward integrated into the Pipeline projects under execution:
operator’s mind set through its sister company links. F Salaya Mathura Product Line (India) – 416 km x 28 in.
Essar Projects offers its expertise to a number of
industries, including oil and gas (upstream, midstream, F Habshan to Al Ruwais Condensate pipeline (Abu
TURNKEY downstream, cross country pipelines and terminals). Dhabi) – 110 km x 24 in.
CONSTRUCTION
The company has over four decades of experience
in delivering projects and operates across regions Essar Projects is also certified for ISO 9001:2000, ISO
through wholly owned subsidiaries. It has a presence in 14001:2004 and OHSAS 18001:2007.
over 20 countries spread across five continents.
HORIZONTAL Essar Projects has a large in house engineering and
DIRECTIONAL procurement division, operates extensive fabrication
DRILLING
facilities and a large construction equipment bank.
It has built a refining capacity of 20 million tpy, laid
more than 4000 km of onshore and offshore pipelines
and erected refurbished offshore platforms.
COMPRESSOR Completed gas pipeline projects include:
STATIONS
F Bharuch Jamnagar pipeline (India) – 190 km x 30 in.
F Vijaipur Dadri pipeline (India) – 330 km x 48 in.
WELDING Completed product line projects are:

F Vadinar Bina crude oil pipeline (India) – 503 km x
24 in. Essar Projects’ Abu Dhabi project: pipe shifting in progress
during HDD.
F Mundra Delhi product pipeline (India) – 550 km
FINANCE, x 18 in.
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Pipeline execution work in

progress, Madagascar.
62
2015
Bridging the gap between Key Services
‘what if’ and ‘when’... Weld testing & qualification
Chemical analysis
Located in the Exova Aberdeen laboratory, we
provide a fully equipped testing facility with Coatings
welding capabilities and certification to meet
your requirements. Corrosion
Engineering Critical Assessment
Forensic failure investigations
Immersion Ultrasonic Testing (IUT)

Exova can help you get where you’re going, Metallurgical testing
get in touch to discuss your needs.
Pipeline testing
Europe Americas
t. +44 (0) 330 222 0321 t. + 1 866 263 9268
e. europe@exova.com e. americas@Exova.com
w. www.exova.com
Company
Gulf Interstate Engineering Company
ONSHORE
PIPELINES
B
ased in Houston, Texas, Gulf Interstate Gulf has designed and engineered more than 100 000 miles
Engineering Company (Gulf) provides quality of pipeline systems and nearly 6 million hp of pump and
project management, engineering and design, compression facilities across five continents.
OFFSHORE
PIPELINES GIS, materials management and construction Gulf emphasises a strong commitment to future
management services to the worldwide oil and gas endeavours and diversification that will grow and advance
industry. Since its formation in 1953, Gulf has achieved the company. The company strives to have the best in
a reputation for producing practical, cost-effective and class infrastructure, with its continued multimillion dollar
TURNKEY unique solutions to complex projects. investment in new businesses and technology systems.
CONSTRUCTION
Gulf specialises in the project management, engineering These efforts, and Gulf’s team of talented experts, are the
and design of pipeline systems – a focus that covers reason why the company continues to be a market leader
onshore pipelines, gathering systems, production facilities, in the pipeline industry.
pump and compressor stations, storage terminals and Gulf’s worldwide experience has led its project teams
HORIZONTAL loading facilities. Gulf’s experience and capabilities to complete projects in some of nature’s most extreme
DIRECTIONAL encompass all aspects of oil and gas production from the conditions, from the frozen tundra of Alaska, to the searing
DRILLING
wellhead to the export terminal. Throughout its history, deserts of the Middle East.
With the nation’s ageing pipeline systems and the
continued need to transport oil and gas, Gulf
has seen an increase in rehabilitation and
COMPRESSOR integrity projects, and modernisation of critical
STATIONS
pipeline infrastructure projects. Gulf has recently
executed pipeline and facility projects for PG&E,
Spectra, TransCanada, NiSource, Enterprise
Products, EQT, Iroquois, FutureGen, Arendal,
WELDING Enbridge, Anadarko, Williams, DCP, ExxonMobil,
Kinder Morgan, ROSPAN, TNK-BP, TOTAL and
Columbia, just to name a few.
Gulf’s international portfolio continues to
grow with recent work in Russia, Mexico, Canada,
FINANCE,
STRATEGY Uganda and Kenya.
& ANALYSIS Gulf’s professio
nals are know
and are experts n for their exte
in engineering nsive experienc
production facil all aspects of oi e,
ities, transporta l and gas
facilities. tion systems an
d storage
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Gulf utilises its state-of-the art GIS

system to provide solutions to your
most challenging projects.
64
2015
Products you know,
manufacturing you trust.
Delivering high quality valves, closures
and pumps for over 60 years.
We are a leading provider of products used throughout the global midstream
distribution and transmission markets. Our ASME “U” certified Yale™
and Sentry™ closures, full range of API 6D valves, and Moyno™ line of
progressing cavity pumps are engineered to meet your needs.
For more information visit nov.com/Midstream or email us

at Midstream@nov.com
© 2014 National Oilwell Varco I All rights reserved

Hoelscher Wasserbau GmbH
H
ONSHORE
PIPELINES
oelscher Wasserbau GmbH is a family-owned high-iron-groundwater is used as inlet process water for
business operating internationally and rooted pipeline pigging.
in Haren, a provincial town located in the
OFFSHORE
Lower Saxon district of Emsland near the NEL (Nordeuropäische Erdgasleitung) Pipeline,
PIPELINES Dutch border, Germany. More than 450 employees at Germany
eight German locations provide services in the areas of 3500 well points, 110 000 m of horizontal dewatering,
dewatering, environmental engineering, well drilling and supply and installation of a treatment system for
groundwater management. The company, which is known contaminated process water with flowrates ranging
TURNKEY for its employee-friendly personnel policies, is highly from 100 - 600 m³/hr.
CONSTRUCTION
experienced both in the construction of infrastructural
and industrial facilities and in energy and environmental OPAL Pipeline, Germany
engineering. The OPAL pipeline was constructed in Germany from 2009
The company is represented internationally by for two years. The 470 km pipeline was split into
HORIZONTAL BUDWUG in Poland, Reinders Wessemius in the
DIRECTIONAL Netherlands, and Uniquip Hoelscher in Qatar. There are
DRILLING
additional locations in Romania, Italy,
Denmark and the UK. Furthermore,
the subsidiary SL – Service & Logistik,
responsible for maintenance and
COMPRESSOR logistics services for construction sites
STATIONS
– is also part of the corporate group
and works exclusively for Hoelscher
Wasserbau.
The company is servicing around
WELDING 800 construction sites per year,
including large scale projects like the
OPAL Pipeline (the Baltic Sea Pipeline
Link).
The scope of services provided by
FINANCE,
STRATEGY Hoelscher Wasserbau includes:
& ANALYSIS
F Dewatering.
peline project.
F Groundwater control. tre at me nt pl ant at a gas pi
Groundwater
F Groundwater management.
FEASIBILITY
STUDIES
F Well drilling.
F Water treatment.
TERMINALS Recently completed or ongoing oil and gas pipeline

projects:
TENP Pipeline
The TENP Pipeline project involved the treatment of
RESEARCH &
DEVELOPMENT pigging process water from gas pipelines for the client
(Trans Europe Naturgas Pipeline, Essen) in Müllheim,
Baden/Germany. The scope of work included supply
and installation of a treatment system for contaminated
process water with flowrates ranging from 600 - 700 m³/hr.
MAINTENANCE
It also covered upkeep, maintenance and 24/7 operation
of system for removal of petroleum hydrocarbons and
BTEX from used process water, as well as regulation
of its pH level. The individual treatment steps – i.e.
REHAB neutralisation and activated carbon adsorption – are
designed in a modular configuration. Supply and Installation of horizonal drain for
installation of a de-iron unit for treatment of pipeline ditch dewatering.
66
2015
ONSHORE
PIPELINES
14 sections, of which Hoelscher Wasserbau was awarded most difficult requirements in terms of groundwater
10 sections for the dewatering works. For this project, management.
the company supplied five deep well drilling rigs, two For dealing with the very high permeability,
wellpoint drilling rigs, four trenchers for the installation of and as a consequence of high flowrates of pumped
OFFSHORE
horizontal dewatering, fifteen 4 x 4 trucks, 10 maintenance groundwater, a double trenched horizontal pipe PIPELINES
vans, 30 pick-up trucks along with 100 employees. The system of 72 000 m was installed. The groundwater
company installed over 5000 wellpoints, 95 000 m of had a high content of iron. To avoid discharging
horizontal dewatering and 1600 deep wells to allow dry water with high iron content into channels or rivers,
and safe excavation of the pipeline. This was the largest it was necessary to treat the water in de-ironing TURNKEY
CONSTRUCTION
running construction site in Germany that required major plants. In areas were de-ironing would have been very
dewatering resources, which Hoelscher Wasserbau expensive, the groundwater was transferred within
supplied. a closed system to a re-infiltration system and then
infiltrated back into the aquifer. This was achieved by
Angerlo-Beuningen Pipeline, the Netherlands using the HW-DSI jet suction infiltration system. In HORIZONTAL
As part of the north-south pipeline route, the total, 16 million m³ of groundwater has been rejected DIRECTIONAL
DRILLING
Angerlo-Beuningen section was the part with the into the ground.
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
67
2015
J. Murphy & Sons Limited
J
ONSHORE
PIPELINES
. Murphy & Sons Limited is a leading multi- F Corrib Gas Pipeline Project – one of the most
disciplined engineering and construction significant engineering projects ever undertaken in
company with a rich heritage of safe, innovative Ireland, to lay onshore pipelines from the landfall
and sustainable solutions to the most complex site at Glengad to the Bellanboy Bridge Gas Terminal
OFFSHORE
PIPELINES in infrastructure challenges. including inserting 5 km of 508 x 27.1 mm DNV Grd
With over 4000 employees and with offices in 485 (X70) linepipe.
the UK, Ireland, Canada, Australia and the Middle
East, Murphy has been helping clients build more F Harefield to Southall Gas Pipeline – engineering,
procurement, construction and commissioning
TURNKEY resilient infrastructure for more than 60 years in the
CONSTRUCTION of 18 x 1220 mm carbon steel gas pipeline and
civil engineering, tunnelling, rail, energy, water and
connection into existing installations at both
wastewater, pipelines, building, highways, public realm
Harefield and Southall. The project included
and security, and piling sectors. insertion of the pipeline within 2.25 km of segmental
Recently completed or ongoing oil and gas pipeline tunnels, using blown recycled glass sand as an
HORIZONTAL projects: alternative to cementious grouts for filling the
DIRECTIONAL
DRILLING F Laggan Tormore Onshore Condensate Pipeline – annulus.
installation and testing of the 8 in. duplex stainless
steel condensate pipeline, that runs from the new F Easington to Ganstead – design and construction of
Total Shetland gas plant to the existing BP Sullom 32.2 km, 1220 mm carbon steel gas pipeline from the
Voe Terminal, for Total E&P and BP. Easington Terminal to the above ground installation
COMPRESSOR at Ganstead, together with civil mechanical and
STATIONS F Brecon to Tirley Natural Gas Transmission Pipeline electrical works associated with the construction of
Project – engineering, procurement and construction two pig trap installations.
of a 109 x 1220 mm carbon steel gas pipeline,
20 km across south Wales and 89 km into England, F Easington to Paull – construction of 24 km x
was an important part of National Grid’s major 1220 mm carbon steel gas pipeline from the
WELDING
infrastructure programme to supply the UK with Easington Terminal to the above ground installation
around 20% of its required gas supplies. The project at Paull, together with civil mechanical and electrical
also included construction of the Tirley pressure works associated with the construction of two pig
reduction station, one of the largest in the UK. trap installations.
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
Brecon to Tirley
Natural Gas
REHAB Transmission Pipeline
providing the UK with
20% of its required
gas supplies.
68
2015
Land & Marine Engineering Limited
ONSHORE
PIPELINES
L
and & Marine Engineering Limited is a leading F Luanda, Angola – working with its client PMI, the
engineering and construction company that first phase of the project involved the design,
designs and delivers large and small-scale installation and testing of twin 20 in. x 800 m
OFFSHORE
PIPELINES projects and services internationally, thus long pipelines offshore to a new 250 000 dwt
helping to shape a better environment in which to tanker CBM. An anchored multi-cat was used to
live. install the PLEM and pipelines. The pipelines were
Founded in 1953 and based in Bromborough flooded and tested in April 2015. Once a new tank
TURNKEY in the northwest of England, Land & Marine has farm, onshore berth and access channel have been
CONSTRUCTION
been overcoming the toughest engineering and dredged, the pipelines will be repositioned and
construction challenges within a wide business the second phase is scheduled to take place in
portfolio that includes energy, power and process 2016.
plant, storage tanks, pipelines and trenchless F 800 t linear winch build – currently completing
HORIZONTAL technology, as well as its traditional marine business. the assembly and commissioning of two new
DIRECTIONAL Land & Marine is a wholly-owned subsidiary of
DRILLING 800 t linear winches. The structural frame is of
J. Murphy & Sons Limited – a leading multi-disciplined modular design and innovative handling systems
engineering and construction company with a rich have been incorporated to allow the wedges to
heritage of safe, innovative and sustainable solutions to be withdrawn for socket passing without the need
the most complex infrastructure challenges. to remove the grip box lid. This is a major advance
COMPRESSOR Recently completed or ongoing oil and gas in linear winch technology.
STATIONS
pipeline projects include:
F Harrowside outfall – design and
installation of a 1 km long, 2.1 m dia.
PE outfall is underway near Blackpool
WELDING
in northwest England. This fast track
project is scheduled to be completed
at the end of September 2015.
F Barrow Terminals Project – work

has been completed on the Barrow
FINANCE,
STRATEGY Terminals Project, which involved
& ANALYSIS the construction of a 900 mm dia. x
25 mm wall thickness pipeline for the
particularly complex connection of the
South Morecambe trunk line to the
FEASIBILITY North Morecambe Terminal.
STUDIES
pipelines in
Angola 2015: PLEM attached to twin 20 in.
preparation for dawn pipe pull.
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Tensioning 24 in. Class 900 pipework at North Morecambe Terminal, Barrow.
70
2015
ONSHORE
PIPELINES
OFFSHORE
PIPELINES
TURNKEY
CONSTRUCTION
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Installation of pre-fabricated pipe spools,

36 in. isolation valves and pig receiver
with concrete apron and plinths at North
Morecambe Terminal, Barrow.
71
2015
LCS Cable Cranes
L
ONSHORE
PIPELINES CS Cable Cranes offers innovative solutions for the
construction of oil and gas pipelines in steep and
inaccessible terrain. By using specialised equipment, A crane unit of LCS is
the Austrian company enables the laying of pipes transporting a 46 in. pipe.
where it seems impossible.
OFFSHORE
PIPELINES Highly technological and proven cable crane systems
are applied on steep mountain ranges, on rock faces and
in the middle of the rain forest. The crane
systems work like material ropeways and are
TURNKEY able to transport all kinds of heavy material,
CONSTRUCTION
such as pipes, machinery, excavators, padding
material and sandblasting equipment, with
the highest precision along the route of the
pipeline, where it can be unloaded at any point
HORIZONTAL of the track.
DIRECTIONAL LCS’s material-ropeways are capable of
DRILLING
carrying loads that exceed 20 t along distances
of more than 3 km and with a speed of up to
7 m/sec.
The cable crane system consists basically
COMPRESSOR of one or multiple track ropes, towers, a haul
STATIONS
rope, a haul winch and a crane unit. It is installed
exactly above the determined route for the in inclined terrain.
The pipe is precisely laid
pipeline and works similar to a material-ropeway:
at the loading station loads are lifted by a
WELDING crane unit. Consequently, being attached to the
crane unit and pending on mid-air, they are pulled by the
powerful haul-winches towards the designated position,
where they are lowered and unloaded. Thanks to the
double lifting systems, pipes can be inclined and therefore
FINANCE,
STRATEGY perfectly placed in their welding position. Transport
& ANALYSIS
buckets are used to transport padding material – they are
unloaded easily by inclining them.
Using the cable crane systems as a method for the
laying of pipes in steep terrain gives several advantages.
FEASIBILITY A very narrow ROW reduces the environmental impact
STUDIES
significantly since cable cranes only require a width of 8 m
(reducible if necessary) and less access roads need to be
constructed. Consequently, even cost savings can be made
due to less re-instatement and road-construction costs.
TERMINALS In sometimes removing completely
the need for heavy machinery to
work on steep slopes, operators are
not exposed to risks, as all material
is transported by air to its final
RESEARCH &
DEVELOPMENT destination.
The systems are applicable in all
kind of terrain; it does not matter if
routes run vertically or horizontally to
the slope, are straight or include curves.
MAINTENANCE
The cranes are readily available
and flexible solutions that are based
on a modular system. Nevertheless,
an accurate project management
REHAB including analysis, planning, installation,
implementation and operation of the
onmentally friendly
ntribute to an envir
crane systems by LCS professionals is Narrow ROWs co
indispensable. construction.
72
2015
ONSHORE
Recently completed or ongoing oil and gas pipeline PIPELINES
projects:
LCS has attested the capability of its cable
cranes constructing pipelines in steep areas
exceeding 70°, in rocky sectors (e.g. at the East
OFFSHORE
West Pipeline, India) on sandy surfaces, in the PIPELINES
middle of the rainforest, in cold and snowy
regions as well as during the rain period in the
tropics. The systems permit an extension of the
working period – work can be performed in the TURNKEY
CONSTRUCTION
winter time and rainy season.
LCS has realised diverse pipeline projects all
over the world, solving a variety of transportation
challenges – from the rain forest in Latin America
(OCP Pipeline, Ecuador) to pipelines in desert-like HORIZONTAL
terrain (ADCOP Pipeline, Abu Dhabi). DIRECTIONAL
Pipes and all kind of material and DRILLING
equipment can be During the last few years, LCS has contributed
transported into steep slopes.
to the construction of pipelines all over the world,
e.g. at the Tamazunchale gas pipeline in Mexico,
where a 70° steep rock face was overcome with
the help of a crane system of LCS. COMPRESSOR
STATIONS
LCS was also involved in the construction of the
Zawtika onshore pipeline in Myanmar, delivering several
cable crane systems as well as taking over the full
construction service on critical sections of the pipeline
route. Among others, LCS is currently collaborating in WELDING
the construction of the Peruvian pipeline Gasoducto Sur
Peruano.
Padding in inaccessible FINANCE,

areas is done with the help STRATEGY
& ANALYSIS
of transport buckets.
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
73
2015
Mears Group
M
ONSHORE
PIPELINES
Mears Group is the leading provider of This long drill’s entry point was onshore near a
horizontal directional drilling (HDD) services neighborhood beach and exiting offshore in water depth
with a focus on value-added projects – of approximately 25 ft. Mears’ Prime 1.1 million lb rig was
design/build and engineering, procurement setup at the onshore entry location. The pilot hole was
OFFSHORE
PIPELINES and construction (EPC) – where HDD is a critical factor. drilled inside of a pre-driven 48 in. casing with a 14 in.
Serving the oil and gas, electrical and water/ centralised casing.
wastewater industries, its mission is to be the industries’
first choice as a partner; problem solver, collaborative and
TURNKEY has the technical ability and resources to produce safe,
CONSTRUCTION
high quality work. Mears HDD operates over 25 rigs with
capacities of up to 1.3 million lb of pullback.
Mears Group, along with a large specialised project
team, finalised a challenging gas transmission installation
HORIZONTAL for a major gas company. The installation required Mears to
DIRECTIONAL perform a horizontal directional drill (HDD) shore approach
DRILLING
at a length of 5346 ft. The installation of the 26 in. gas
transmission line required connection into a dual 18 in. hot
tap (tying into a pressurised system).
COMPRESSOR
STATIONS
rig at project site.
Mears’ 1.1 million lb
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
74
2015
ONSHORE
PIPELINES
Extensive planning and execution included mobilisation
of marine and HDD equipment and personnel; pre-pipeline
installation work; offshore HDD site preparation; pipelay
of HDD pipe string; pre-commissioning of the HDD pipe
OFFSHORE
section; HDD product installation; burial of the pipeline; PIPELINES
tie-in spools; and final pre-commissioning of the entire
pipeline section.
This was an enormous accomplishment requiring
creative project planning and co-ordination among the TURNKEY
CONSTRUCTION
entire team of professionals.
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
WELDING
View of barge from

Aerial view of barge with 140 000 lb rig during drilling beach at dawn.
operations.
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
Overview of project
site at entry side of
drill. TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
75
2015
OT Industries-KVV Contracting Company Ltd A member company of OT INDUSTRIES Group
K
ONSHORE
PIPELINES
VV is the largest and most experienced quality. Another strength is lowering-in operations
pipeline contractor in Hungary and the with tie-in welding works.
Central European Region. The company was The established and properly operated integrated
founded in 1954 for building the Hungarian management system (QMS/EMS/OHS) ensures the
OFFSHORE
PIPELINES high pressure oil and gas transmission pipeline fulfilment of requirements of the quality assurance,
network. environmental protection and occupational health
Besides domestic work, significant projects were and safety during the realisation of administrative
completed by KVV in partnership with local and/ and project implementation processes of the
TURNKEY or international companies in abroad countries company.
CONSTRUCTION
too (Iraq, Kuwait, Kazakhstan, Germany, Croatia,
Belarus, Poland, Georgia/FSU, Slovenia and
Romania).
KVV offers the following services to pipeline
HORIZONTAL operators and other clients:
DIRECTIONAL
DRILLING F Installation of high pressure hydrocarbon
transmission cross-country pipelines and
stations (up to 56 in. dia.).
F Diagnostical tests and rehabilitation of pipeline.

COMPRESSOR
STATIONS F Installation and maintenance of cathodic
corrosion protection systems.
F Installation of telecommunication cable

networks.
WELDING
DN600, X60, 26 km
F Diagnostical tests, rehabilitation, repair, Black Forest Gas Pipeline Project,
any, 201 5: weld ing one of the first tie-in joints
construction and cleaning of storage tanks. in Germ
on the project.
F Destructive and non-destructive material tests in
FINANCE, accredited laboratory.
STRATEGY
& ANALYSIS
KVV is capable of installing 200 km large
diameter pipeline annually, working simultaneously
on three to four projects with the deployment of its
own construction management staff supplemented
FEASIBILITY with the necessary labour forces and the company’s
STUDIES
own, well maintained construction equipment and
machines.
The company’s key strength is the mechanised
welding of large diameter pipelines, which
TERMINALS eventuates excellent production rates and welding
Table 1. Completed projects

RESEARCH & Customer Project name Diameter Length Material grade Year
DEVELOPMENT
Vecsés – State Border of Hungary/ 2013 - 2014
OTF Zrt. Hungary 32 in. 92 km L485MB
Slovakia Gas Pipeline.
Reconstruction of Friendship-I
Crude Oil Pipeline;
MOL Nyrt. Hungary 18 in. 120 km L415MB 2014 - 2015
MAINTENANCE Replacement of Százhalombatta
HU/SK State Border Section
Table 2. Ongoing projects

Customer Project name Diameter Length Material grade Start grade
REHAB
Construction of natural gas
TERRANETS BW Transmission Pipeline ‘Black Forest’. February
24 in. 26.3 km L415MB
Germany Section Ettlingen-Leonberg Lot II 2015
(Ettlingen- Neulingen)
76
2015
ONSHORE
PIPELINES
OFFSHORE
PIPELINES
TURNKEY
CONSTRUCTION
HORIZONTAL
DIRECTIONAL
DRILLING
Friendship-I Crude Oil Pipeline Project DN450, X60, 120 km

in Hungary 2014 - 2015: tie-in welding in a dewatered trench.
Hungary-Slovakia Interconnecto
r Gas Pipeline Project, DN800, COMPRESSOR
X70, 92 km in Hungary, 2013 STATIONS
- 2014: tie-in welding.
WELDING
Black Forest Gas Pipeline Project:

tie-in welding and lowering-in,
group’s machinery ready for work
commencement. FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
77
2015
Punj Lloyd Group
P
ONSHORE
PIPELINES
unj Lloyd Group, a US$1.8 billion diversified From pipelines, tanks and terminals to refineries
international conglomerate, offers EPC and power plants, even to renewables, airports, rail
services in energy and infrastructure sectors transit systems to expressways, the group offers EPC
along with engineering and manufacturing solutions across a wide spectrum of businesses. A
OFFSHORE
PIPELINES capabilities in the defence sector. dynamic enterprise, the group explores and pursues
The group’s three brands – Punj Lloyd and PL opportunities in
Engineering headquartered in India, and
Sembawang Engineers & Constructors in
TURNKEY Singapore, with their own subsidiaries
CONSTRUCTION
and joint ventures – converge to offer
complementary services, rich experience,
and best practices from across the globe.
The group has 23 international offices and
HORIZONTAL entities across the Middle East, the Caspian,
DIRECTIONAL Asia Pacific, Africa, South Asia, China and
DRILLING
Europe.
COMPRESSOR
STATIONS
Laying the Myanmar-

China Oil and Gas
Deen Dayal Field
Pipeline. g of pipeline in sea,
Preparation for lowerin
for GSPC.
Development Project
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
78
2015
ONSHORE
PIPELINES
markets globally. Partnering with the best in their quality and environment, accolades and recognition
own arena, Punj Lloyd brings technology and quality from industry bodies and clients, its ability to manage
to clients worldwide and reiterates its belief of operations in diverse industries and economies, long-
delivering the best in services and manufacturing. An term relationships with globally renowned clients
OFFSHORE
excellent track record for successful completion of and the ability to mobilise financial resources. Punj PIPELINES
projects within tight schedules lends credibility to Lloyd’s large fleet of equipment gives it an edge over
the group, encouraging clients to trust it with repeat its competitors.
orders. Recently completed or ongoing oil and gas
The skilled multicultural workforce, consisting pipeline projects: TURNKEY
CONSTRUCTION
of 9295 employees, has the experience of working F Tie-in work for client Abu Dhabi Company for
in different geographies and diverse terrain, onshore oil operations. The scope of work for
empowering the group to aggressively pursue this project includes engineering, procurement
its vigorous plans. The group’s key strengths are and construction of 750 km flowlines and 160 well
its varied experience, rich knowledge of local head tie-ins in Asab, Sahil and Shah areas. HORIZONTAL
conditions, high standards of health, safety, DIRECTIONAL
DRILLING
F Dahej-Hazira pipeline project for Oil and Natural
Gas Corporation Limited (ONGC). Scope of work
includes the engineering, procurement
and construction of 12 in. dia., 99 km
pipeline on LSTK basis. The scope of COMPRESSOR
work also includes HDD and other STATIONS
facilities.
F Myanmar-China Oil and Gas Pipeline

for South East Asia Crude Oil & Gas
Pipeline Company Ltd. The scope of WELDING
work includes detailed engineering,
laying of 40 in. dia., 205 km gas pipeline
and 32 in. dia., 183 km oil pipeline. The
project includes a 5.56 km offshore
portion too. Both oil and gas pipelines FINANCE,
STRATEGY
have been commissioned. & ANALYSIS
F WO-16 Cluster & SB-14 pipeline

project for Oil & Natural Gas
Deen Dayal Fi Corporation Limited (ONGC), India.
eld Developm
ent Project for G FEASIBILITY
SPC. The scope of work includes survey,
STUDIES
design, engineering, procurement,
modifications etc on existing
facilities and hook-up, testing, pre-
commissioning and commissioning for
the laying of 122 km rigid submarine TERMINALS
pipelines.
F Submarine pipeline project for Deen Dayal Field

Development Project for Gujarat State Petroleum
Corporation Limited’s (GSPC) KG-OSN-2001/3 RESEARCH &
exploration block on east coast. The scope of DEVELOPMENT
work includes project management, surveys (pre-
engineering, pre-construction/pre-installation
and post-installation), residual/detailed
engineering, procurement, pre-commissioning,
MAINTENANCE
startup and commissioning of following: 20 in. dia.
multi-phase pipeline of 24.5 km length (21.5 km
submarine section and 3 km onshore section),
and associated above ground facilities at LFP
and OGT namely slug catcher, pig receiver, close REHAB
blow down drum, valves etc including associated
electrical and instrumentation work for 20 in.
multi-phase pipeline.
79
2015
S.A.L.P. S.p.A.
S
ONSHORE
PIPELINES .A.L.P. S.p.A. can be considered among the major Cold bending of 56 in.,
Italian pipeline construction companies. In Italy, 21.8 mm w.t. pipeline.
the company is qualified and certified by the SRG’s project Zimella –
major gas networks: Snam Rete Gas (SRG), Eni Cervignano gas pipeline
1400 mm (56 in.), 75 bar,
and Società Gasdotti Italia (SGI), as having technical and LOT 1.
OFFSHORE
PIPELINES management competence to perform high pressure
pipeline construction.
The know-how and capability, together with the large
quantity of up-to-date technological equipment, enables
TURNKEY the company to execute complex projects that require
CONSTRUCTION
timely delivery and quality.
S.A.L.P. can efficiently and safely perform all activities
concerning the realisation of oil and gas pipelines in all soil
conditions, ensuring competitiveness and competence,
HORIZONTAL and is an experienced company for maintenance activities
DIRECTIONAL concerning live oil and gas pipelines and related auxiliary
DRILLING
installations.
S.A.L.P. can weld 30 - 56 in. line by means of automatic
welding and can also provide NDT AUT and SAUT (phased
array and TOFD).
COMPRESSOR Lately, S.A.L.P. is specialising in hot tapping activities
STATIONS
for oil and gas pipelines with high service pressure.
projects:
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
re
t-tee welded on flowline befo
Welding of split-tee and spli nten anc e and revamping
s pro ject mai
hot-tapping activities. Eni’
REHAB Val D’Agri Oilfield.
of flowlines and facilities in
Automatic line welding of 600 mm

(24 in. dia.) 9.7 mm w.t pipeline.
80 TIGF’s EPC project Artère de l’Adour,

2015
contractors’ directory France.

F In Veneto (Italy), for SRG, S.A.L.P. is completing the final ONSHORE
PIPELINES
construction activities of project Zimella – Cervignano
gas pipeline Lot 1 and facilities: 1400 mm (56 in. dia.),
75 bar and 45 678 km in length.
F In Sicily (Italy), for SRG, S.A.L.P. has completed Phase OFFSHORE

1 and is carrying out Phase 2 of civic, mechanical and PIPELINES
electro-instrumental works related to the revamping of
the Mazara del Vallo Station.
F In Molise (Italy), for SRG, S.A.L.P. is realising the line of

TURNKEY
Biccari – Campochiaro gas pipeline Lot 2: 1200 mm CONSTRUCTION
(48 in. dia.) 75 bar and 25 764 km in length and the
construction activities of facilities
soon will start.
F In Basilicata (Italy), S.A.L.P. is HORIZONTAL

carrying out the maintenance DIRECTIONAL
DRILLING
and revamping of flowlines and
facilities in Val D’Agri oilfield for
Eni.
F In southwest France, S.A.L.P. COMPRESSOR

is currently engaged in the STATIONS
construction of gas pipelines and
facilities Artère de l’Adour in a
JV with DLE Spécialités for TIGF:
600 mm (24 in. dia.), 85 barg and
WELDING
96.8 km in length.
F In Kurdistan, S.A.L.P. is carrying

out flowlines for ORYX
Petroleum including flowlines
70 bar 150 (6 in. dia.) in total FINANCE,
STRATEGY
length 18 km; 200 mm (8 in. & ANALYSIS
dia.) total length 8 km; 300 mm
Flowlines 150 mm (6 in.), (12 in. dia.) in total length 12 km;
200 mm (8 in.),
300 mm (12 in.) 400 mm and 400 mm (16 in. dia.) in total
(16 in.). ORYX
Petroleum’s EPC project pro length 1.2 km.
vision of buried FEASIBILITY
pipelines and flowlines, Kur
distan. STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Lowering-in of 600 mm (24 in. dia.) 9.7 mm w.t pipeline. TIGF’s

EPC project Artère de l’Adour, France.
81
2015
Seal For Life Industries
S
ONSHORE
PIPELINES eal For Life Industries is a full subsidiary of Berry water. An interactive history describes obsolete methods,
Plastics Corporation, USA, and encompasses a tested methods and innovative solutions to corrosion and
number of leading industry brands. The group’s sealing issues. Novel thinking and the constant quest for
headquarters are located in Stadskanaal, the innovation are the leading principles that bind together all
Netherlands, with a number of offices around the world, the partners of Seal For Life Industries.
OFFSHORE
PIPELINES enabling it to give its customers the highest levels Stopaq, part of Seal For Life Industries and its legacy
of support. Seal For Life attaches great value to the companies, has served the industry for more than 50 years and is
integration of its partners, and pursues close and mutually at the forefront of innovation and development, with advanced
rewarding relationships with customers and business capabilities and more than tens of thousands of systems installed.
TURNKEY partners alike. The following is a summary of pipeline projects that
CONSTRUCTION
As a synergetic grouping of individual corrosion have been successfully installed with Stopaq systems
prevention brands, Seal For Life offers a powerful based on a corrosion prevention layer and a second
combination of experience, technologies and know-how. mechanical protection layer:
The company’s technologies and products are F 2013: GasUnie N.V. – Beverwijk project 3400 field joints
HORIZONTAL approved, specified and deployed by many of the x 48 in. by VSH.
DIRECTIONAL largest players in different markets worldwide. External
DRILLING
evaluations and test reports have confirmed the
characteristic properties of its
unique self-healing, visco-elastic
technology, tapes, shrinkable sleeves
COMPRESSOR and polymeric anodes according the
STATIONS
recognised standards ISO 21809-3 and
ISO 15589-1.
The group actively seek out other
innovative companies, in order to
WELDING share experiences and partner in new
developments. This allows it to move
forward with new technologies,
innovations and structures.
At the centre of Seal For Life’s
FINANCE,
STRATEGY vision is sustainability – long-term
& ANALYSIS
viability and success can only
be founded on the sustainable
production and offering of
environmentally friendly sealing and
FEASIBILITY anti-corrosion solutions.
STUDIES
As such, it creates sustainable,
risk-free products from both health
and safety and environmental
perspectives. This means immediate
TERMINALS and permanent adhesion without
extensive, expensive or dangerous
surface preparation. Safe and easy-
to-apply applications are inherent in
the company’s products, reflecting
RESEARCH &
DEVELOPMENT its belief that it should be safe for
anyone to apply them.
The Seal For Life Industries
Experience Centre is located in
Stadskanaal, a relatively small
MAINTENANCE
community in the north of the
Netherlands. The centre welcomes
many visitors, including business
partners, students and governmental
REHAB authorities who are provided with a
thorough overview of what happens
around pipes above and below Renovation of casings, injection of Stopaq
ground, as well as above and under casing filler into annulus space, turn-key
application, Polish Gas Company.
82
2015
ONSHORE
F 2013: Shell Norgron project 1800 field joints x 48 in. PIPELINES
onshore pipeline by A-Hak.
F 2013: Saudi Aramco Safaniya project 6500 field joints

by McDermott.
OFFSHORE
F 2012 - 2014: Saudi Aramco Wasit project, 42 500 field PIPELINES
joints by Saipem.
F 2012 - 2013: KJO Hout project, 7500 field joints by

McDermott. TURNKEY
CONSTRUCTION
F 2011: Saudi Aramco Manifa Offshore project, 7380
field joints by Valentine Marine.
F 2010 - 2011: GasUnie N.V., 22 500 field joints 48 in.

onshore gas pipeline, A. Hak/Nacap/VSH. HORIZONTAL
Fieldjoint coating DIRECTIONAL
application of CZH+
48 in. gas pipeline, high impact shield DRILLING
North South Pipelin to
e, Gasunie Netherla
ns.
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
Rope access application offshore platform, Splashzone X-Knot, FEASIBILITY

Woodside Australia. STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
Stopaq CZH and moisture curing outerglass shield. REHAB
Shell Mosmorran,
UK, refinery piping
H-beams renovation and structural
without blasting an
primers. d liquid curing
83
2015
Serimax
S
ONSHORE
PIPELINES erimax is a world-leading welding solutions provider F Subsea7 (Borealis), Ehra North Ph. II, Nigeria – three
and has been at the cutting edge of welding Saturnax stations, 970 welds both 11 and 13 in.
technology for over 40 years. The company offers
fully integrated welding and fabrication solutions Recently completed/ongoing onshore projects:
for offshore and onshore projects. Operating in the most F Spac Artère des Flandres – two Saturnax stations for
OFFSHORE
PIPELINES extreme conditions and challenging environments, Serimax GRT Gaz France, 21.887 km 36 in. (14.6 mm, L485MB),
tailors each project to the specific requirements of its sweet service.
clients.
F Al Royaba UA-6 Pipeline seg. II – two Saturnax stations
Serimax carries one of the largest fleets of specialised for Saudi Aramco, Saudi Arabia, 51.75 km 48 in. (9.5 mm,
TURNKEY pipeline welding equipment in the world and has an X60) 38.25 km 46 in. (9.5 mm, X60), all sweet service.
CONSTRUCTION
unrivalled pool of welding specialists across five regional
hubs, along with its centralised global welding technology F Bonatti Kashagan – three Saturnax stations for NCOC
group. Kazakhstan, 6884 welds, 28 in. (19 mm, Clad 625).
Backed by its experience and capacity to continuously
F Denys Arc de Dierrey for GRTGAZ France – three
HORIZONTAL innovate, Serimax remains the market leader, where
DIRECTIONAL Saturnax stations, 2806 welds 48 in. (13 - 22.7 mm,
DRILLING consistent results are commonplace. The company’s track
L485MB), sweet service.
record is testimony as the world leader of excellence in
offshore, land, subsea and fabrication welding.
Serimax’s clear strategy enables it to develop
technologically advanced welding solutions –
COMPRESSOR taking welding from an art to a science. Offering
STATIONS
fit-for-purpose equipment, providing experts who
work both safely and efficiently whilst managing
turnkey projects, the company’s goal is to create
and deliver both innovative and high performance
WELDING industrial solutions to ensure success.
Serimax endeavours to answer your most
complex challenges, by providing groundbreaking
technology.
Recently completed/ongoing offshore projects:
FINANCE,
STRATEGY F COOEC for PTTEP, Zawtika Phase 1B, Myanmar –
& ANALYSIS
three Saturnax stations, 45 km of 18 in. welds,
s, Arc de Dierry, France.
14 km of 14 in welds, 30 flanges of 14 and 18 in., all Onshore welding solution
severe sour service, 4966 welds.
FEASIBILITY F Subsea 7 (Borealis) for

STUDIES PTTEP, Ten Subsea7,
Ghana – 35.5 km of
8.62 in. welds, 33.8 km
10.75 in. welds, 3199
welds.
TERMINALS
F Sapura Acergy (Sapura
3000) for Total,
Maharaja Lela, Brunei –
three Saturnax stations,
RESEARCH &
DEVELOPMENT 849 welds all 18 in.
F TL Offshore for PGN

Kepodang, Indonesia –
three Saturnax stations,
MAINTENANCE 16 174 welds of 14 in.,
195.9 km.
F Technip Marine (G1201)

for SSPC, Malikai,
REHAB Malysia – four Saturnax
stations, 7816 welds of 8
and 10 in. Saturnax 09 J-Lay welding operations on board Subsea 7 Borealis in the Gulf of Mexico.
84
2015
Sicilsaldo S.p.A. and Nuova Ghizzoni S.p.A. group
T
ONSHORE
PIPELINES he group Sicilsaldo S.p.A. and Nuova Ghizzoni
S.p.A. provides engineering, procurement,
project management and construction services
of pipelines and plants up to 60 in.
The companies have a proven track record of
OFFSHORE
PIPELINES experiences, capabilities and high competences since
the 1950’s.
Core business:
F Construction of onshore pipelines up to 60 in.
TURNKEY
CONSTRUCTION F Construction of plants and stations.
Key activities:
F Civil, mechanical and electrical works.
HORIZONTAL
DIRECTIONAL F Manual and automatic welding.
DRILLING
F Lowering.
F Hydrotesting and drying.
COMPRESSOR F Horizontal directional drilling.

STATIONS
F Pre-commissioning and commissioning.
Experience:
F 250 projects executed in the last 25 years: pipeline
WELDING projects, compressor stations and underground
storage plants.
OPAL project,
F 20 million in. of executed welds. lowering of 56 in.
pipeline, Germany.
FINANCE, F 10 000 km of installed pipeline.
STRATEGY
& ANALYSIS
Table 1. Recently completed or ongoing oil and gas pipeline projects

Project Start/finish Client Country Diameter Length Products Pressure
FEASIBILITY date (mm) (km) (bar)
STUDIES
Pipeline Busso - Paliano Lot 2A 01.06.2015 SGI Italy 500 35 Gas 75
ongoing
Pipeline El-Encino - Topolobampo 01.08.2014 Saimexicana Mexico 760 54 Gas 75
ongoing S.A. de C.V.
TERMINALS
Construction of Gas Pipeline Ramal - Tula 01.01.2015 Grupo Cocomex Mexico 760 18 Gas 75
ongoing
Electrical and instrumental work for 01.04.2014 Saimexicana Mexico 760 n/a Gas 75
compressor and metering stations ongoing S.A. de C.V.
RESEARCH & Minerbio compressor station - TC7 20.04.2015 Stogit Italy n/a n/a n/a n/a
DEVELOPMENT ongoing
Pipeline Gavi - Pietralvezzara 04.11.2014 Snam Rete Gas Italy 600 26 Gas 75
ongoing
Pipeline Derivation for Sestri Levante - 04.08.2014 Snam Rete Gas Italy 400 1.4 Gas 70
Variation of Campegli ongoing
MAINTENANCE
Pipeline Busso - Paliano Lot 3 20.01.2014 SGI Italy 500 40 Gas 75
30.04.2015
Trabajos para la construcción de gasoducto 01.08.2014 ICA Fluor Mexico 1050 107 Gas 80
Los Ramones Fase II Sur - Fruente 3 ongoing
REHAB 01.03.2011
Revamping Compressor Station Enna Snam Rete Gas Italy 1200 n/a Gas 75
ongoing
1.03.2011
Poggio Renatico-Cremona Snam Rete Gas Italy 1200 118 Gas 75
31.12.2014
86
2015
ONSHORE
PIPELINES
OFFSHORE
PIPELINES
TURNKEY
CONSTRUCTION
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
in. pipeline, Italy.

ject, welding of 48
Massafra-Biccari pro REHAB
Gas gathering
treatment plan
t, Algeria.
87
2015
SICIM S.p.A
S
ONSHORE F Contract for construction, testing, commissioning and
PIPELINES ICIM S.p.A. has been one of the top pipeline
start up of the ‘Oleoducto Bicentenario de Colombia’
contractors since 1962. Historically operating as a
Phase 1 Section Araguaney – Banadia. 230 km, 42 in. dia.,
contractor, mainly for Snam Rete Gas in Italy, it has
for OBC – Colombia.
become a global player offering general services
such as project management, engineering, commissioning Some of the works in progress include:
OFFSHORE
PIPELINES and start-up for oil and gas pipelines, as well as F Maintenance and revamping of offshore platforms in
construction of oil, gas and water pipelines on land and Loango for Eni Congo SA.
shallow water (all diameters); installation of compressor
stations, pumping stations and gas/oil separation and F Flowlines installation for the EPC pipelines installation,
TURNKEY processing plants; production and treatment plants; civil Zubair Oil Field Project, for Eni – Iraq.
CONSTRUCTION
works, site preparations, foundation works (industrial
F Mafumeira-4 – pipeline installation, mechanical and
buildings, environmental services). painting works, for Petromar – Angola.
In its 53 years in business, SICIM has installed over
10 000 km of pipelines and 24 000 t of plant piping and F Sonora Pipeline Corridor. Sonora (Sasabe-Guaymas)/
HORIZONTAL structural steel. Sinaloa (Guaymas-El Oro) – Mexico. 831 km,
DIRECTIONAL SICIM’s headquarters in Busseto, near Parma, are the 30/36 in. dia., for Gasoducto de Aguaprieta – Mexico.
DRILLING
nerve centre of a global network of offices, projects and
F Various construction contracts inside Tengiz Camp for
contracts. The company co-ordinates work at project
Tengizchevroil – Kazakhstan.
offices in Spain, France, Ireland, UK, Germany, Libya, Congo,
Cameroon, Angola, Mozambique, Turkey, United Arab F Los Ramones Fase II Sur. Tramo I Y II. 183 km, 42 in. dia.,
COMPRESSOR Emirates, Kazakhstan, Turkmenistan, Iraq, Mexico, Colombia, for ICA FLUOR – Mexico.
STATIONS
Perù and Canada, as well as throughout Italy.
SICIM has recently completed the construction of: F Construction works for the turnkey EPC pipeline project
Gasoducto Sur. 454 km, 24/32 in.
F Tamazunchale Gas Pipeline. 233 km, 36/30 in. dia.,
dia., for Consorcio Constructor
for Transportadora
WELDING Ductos del Sur – Perù.
de Gas Natural
de la Huasteca, F Construction of the Trans
S. de R.L. de C.V. Anatolian Natural Gas
– Mexico. Pipeline (TANAP), LOT 2. 450
km, 56 in. dia., for TANAP
FINANCE, F Chihuahua
STRATEGY DOĞALGAZ İLETİM A.Ş. –
& ANALYSIS Natural Gas
Turkey.
Transmission
Pipeline. 381 km, F El Encino – La Laguna Gas
36 in. dia., for Pipeline. 464.9 km, 42/20/16
TARAHUMARA in. dia., for Fermaca –
FEASIBILITY
STUDIES PIPELINE S. de R.L. Mexico.
de C.V. – Mexico.
ks.
Project Wor
Tr ea tm en t Facilities
Onshore
Litchendjili m), Congo.
nt : Bo sc ongo (Saipe
Clie
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
Lowering in for the Sonora Pipeline Corridor. Client:
Gasoducto de Aguaprieta, Mexico.
REHAB
Construction of a section of the
88 Tamazunchale gas pipeline on

2015
contractors’ directory a rock-face with the help of a

cable crane system.
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STATS Group
S
ONSHORE
PIPELINES TATS Group is a specialist engineering company STATS Group operates throughout the world
and service provider that operates in the field through a network of operational bases and
of piping, pipeline integrity and maintenance. support offices.
The group’s comprehensive range of products Recently completed oil and gas pipeline
and services enable piping and pipeline isolation, projects:
OFFSHORE
PIPELINES intervention, repair, subsea and shutdown services. F Two subsea Remote Tecno Plugs™ provided
Innovative solutions and proprietary technologies double block isolation allowing installation
include: and leak testing of SSIV’s and pipe spools
F Tecno Plug™ high pressure pipeline isolation – on the 36 in. Forties Pipeline System in the
TURNKEY the Tecno Plug provides fail-safe double block North Sea, UK.
CONSTRUCTION
and bleed pipeline isolation for high pressure
applications while the system remains live and at F 16 in. gas pipeline isolated by Remote Tecno
operating pressure. Dual seals provide a zero-energy Plug to facilitate launcher valve replacement
zone to enable maintenance work to be carried out in Oman.
HORIZONTAL safely and efficiently while meeting industry-led F 30 in. gas pipeline and 32 in. gas trunk line
DIRECTIONAL double block and bleed requirements. simultaneous isolations using Remote Tecno
DRILLING
F BISEP™ high pressure intervention and isolation – Plug allowing MOV and SDV replacement
pipeline intervention and isolation can be achieved during E11R-C shutdown, offshore Sarawak,
using STATS patented leak-tight BISEP. The BISEP Malaysia.
provides fail-safe double block and bleed isolation
COMPRESSOR
STATIONS deployed through a single full bore hot tap
penetration – no additional bleed ports. The BISEP
contains dual energised seals and the annulus zero-
energy zone proves and monitors the seal integrity
before and during intervention work.
WELDING
F Emergency pipeline repair isolation systems
– STATS partner with major operators in the
development and support of emergency pipeline
repair isolation systems to minimise the downtime
FINANCE, of damaged pipelines. Investment in an emergency
STRATEGY
& ANALYSIS pipeline repair system will reduce environmental
and commercial impact and enable early resumption
of production in the event of an emergency repair.
F Inline weld test tool: localised pressure testing –

FEASIBILITY inline weld test tools provide a fast and efficient
STUDIES
method of verifying the integrity of welds or n of gas
provided 20 week isolatio
joints by reducing system down-time, minimising 30 in. Remote Tecno Plug anc e whi le mai ntaining
e mainten
environmental impact and increasing worksite terminal receiver to allow valv
safety. Additionally, these tools can be used to production at 120 bar.
TERMINALS provide a verified atmospheric barrier adjacent to
the hot work source.
F E-PEP™: hydrostatic testing – pipe end plugs

provide a fast and efficient method of installing
RESEARCH & temporary test caps on plain end pipe for
DEVELOPMENT hydrostatic testing up to 500 bar. The patented
E-PEP reduces time and material costs, minimises
environmental impact and improves productivity.
Robustly designed to sustain the rigours of a
fabrication yard environment.
MAINTENANCE
The STATS philosophy is to deliver innovation,

value and rapid response to our clients which will:
F Enhance safety and environmental performance.
REHAB
F Reduce system or plant downtime.
F Extend facility life.

erated subsea
a 32 in. ROV op
AT S de sig ne d, built and tested
ST
receiver.
pig launcher and
90
2015
ONSHORE
PIPELINES
OFFSHORE
PIPELINES
TURNKEY
CONSTRUCTION
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
Two double 16 in. BISEP isolations, one month

apart. BISEP isolation of a natural gas pipeline
91
2015
to facilitate a valve installation and spool contractors’ directory

replacement in Canada.
Techint Engineering & Construction
T
ONSHORE F Techint is reaching the completion of the Ethane
PIPELINES echint Engineering & Construction provides
Transport System project in Mexico. This pipeline
solutions for large-scale projects at a global
was designed to bring ethane to the Etileno XXI plant,
level. through Ciudad Pemex, Nuevo Pemex, Cactus and
Thanks to its broad experience and local Cangrejeras across 220 km.
roots in the countries where it operates, Techint is able
OFFSHORE
PIPELINES to develop high complexity works, including engineering, F Techint was awarded the construction of the second
procurement, construction, operational and management phase of the Northeast Gas Pipeline in Argentina,
services, while protecting the environment and ensuring which will bring natural gas to more than 3 million
the welfare of the communities. people in remote geographical zones. The section
TURNKEY Through its several engineering centres around the Techint is developing is 320 km long and has a
CONSTRUCTION
world, Techint can develop feasibility studies and basic diameter of 24 in.
and detailed engineering, bringing best-in-class technology
and constructability solutions to its costumers.
With 70 years of experience and 19 500 employees
HORIZONTAL worldwide, the company has completed more than 3500
DIRECTIONAL projects in America, Europe, Middle East and Africa.
DRILLING
projects:
F The company is executing an EPC contract in
consortium with Odebrecht and Arendal for the Los
COMPRESSOR Ramones II project in Nuevo Leon, Tamauilipas, and
STATIONS
San Luis de Potosí, Mexico. The works include two
compression stations, 14 mainline valves, five pig-
Techint strengthens its leadership
launcher traps, five pig-receiving traps and a 450 km, in the segment with Los
Ramones II pipeline.
42 in. dia. natural gas pipeline.
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
REHAB
HDD in Tonalá River, Ethane

Pipeline Project.
92
2015
Lift your expectations
www.elite-lifting.com • info@schoenbeck-maschinen.de
Phone: +49 5721 994439-26 • Fax: +49 5721 994439-23
Tesmec
S
ONSHORE
PIPELINES
ince 1984, Tesmec has been leader in the Tesmec Trenchers are very well positioned in
engineering, manufacturing and marketing of Mexico as well, where contractors utilise them on oil
hard rock trenchers. The group’s product range and gas projects in both the northern andsouthern part
includes chainsaw trenchers, rocksaw trenchers, of the country.
OFFSHORE
PIPELINES bucket wheel trenchers and surface miners. Alberta’s oilsands (Athabasca Basin) and pipelines are
Contractors all over the world have come to rely the Canadian breeding ground for Tesmec’s large bucket
on Tesmec Trenchers for their toughest projects. From wheels (1175 BW, 1375 BW, 1575 BW). Due to the large
reliable energy projects to dry utilities, and from heavy size of these pipelines and the softer nature of the soil,
TURNKEY civil to oil and gas and waterlines, Tesmec Trenchers Tesmec bucket wheels will get the job done.
CONSTRUCTION
have the upper hand and get the job done. Tesmec has just delivered a 1675 chainsaw trencher
Tesmec Trenchers are involved in several pipeline to a State owned company for a 48 in. gas pipeline in
projects all over the world. In the US, pipeline Algeria; this 130 t class trencher will be used to open a
contractors employ ultra low speed chain trenchers 1.80 cm width ditch in a hard rocky area in the Sahara
HORIZONTAL (M3HD/M5HD) in the Marcellus/Utica Shale and the desert.
DIRECTIONAL Permian Basin, while bucket wheels and/or hydrostatic In the Middle East, Tesmec trenchers are chosen
DRILLING
chainsaws are found in the Bakken Shale, Powder River for oil and gas as well as water pipelines projects for
Basin, and Eagle Ford Shale. major clients in Saudi Arabia and in Qatar, due to cost
efficiency, safety and productivity provided by the
Tesmec machines.
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
Tesmec 1575 Bucket Wheel trencher digging a 36 in.

FEASIBILITY gas pipeline in Mexico.
STUDIES
cher in South Africa at

Tesmec 1475 chainsaw tren
work in NMPP project.
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
rk for
heel trencher at wo
REHAB Tesmec Bucket W
the US .
Ruby Pipeline in
Tesmec M5 chainsaw trencher

digging in Del Rio, Texas (gas
94
2015
contractors’ directory pipeline).

We’ve brought hydrostatic testing
into the digital age.
No more spinning weights or leveling instruments. INTRODUCING The
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process technologies
A trusted leader in measurement & calibration solutions.

meriam.com 1.216.281.1100
Winn & Coales International
W
ONSHORE
PIPELINES
inn & Coales International has been for a variety of above and below ground corrosion
providing corrosion prevention prevention applications. The coatings can easily be
solutions since 1929. Winn & Coales’ applied in high and low temperature environments
early association with corrosion and they are also great for protecting girth welds,
OFFSHORE
PIPELINES prevention was the manufacture in the UK under tie-ins, cadwells, fittings, fabrications repairs to FBE
license of Denso Tape, a flexible petrolatum tape. and rehabilitation to existing pipelines. The Protal
It now provides a wide range of Denso corrosion coatings are high build, up to 50 mm in one coat.
prevention and sealing products to a multitude of Recent oil and gas pipeline projects:
TURNKEY industries. F Derry Gas Pipeline, Northern Ireland: pipeline
CONSTRUCTION
With strategic manufacturing and distribution protected with the Denso Steelcoat 100/400
plants in the UK, US, Canada, South Africa and System.
Australia, it can provide quality, cost-effective
products, quickly delivered to where they are
HORIZONTAL needed most.
DIRECTIONAL The Winn & Coales Denso product range
DRILLING
comprises liquid coatings
and tapes for buried
and exposed pipeline
protection, marine pile
COMPRESSOR rehabilitation systems
STATIONS
and chemical and abrasion
resistant linings for full
internal and external
storage tank protection.
WELDING For over 25 years the
company’s Protal epoxy
liquid coatings have been
used to protect major
oil and gas pipelines. The
FINANCE,
STRATEGY Protal coatings can be
& ANALYSIS
applied by brush or spray
method and include fast
cure, high build epoxies
FEASIBILITY eline, Canada.

STUDIES Pembina NPS 20 Pip
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
i, UAE.
peline, Duba
REHAB Liquid Fuel Pi
96
2015
F Liquid Fuel Pipeline, Dubai, UAE: ONSHORE
PIPELINES
pipeline protected with Denso
Protal 7200 liquid coating.
F Pembina NPS 20 Pipeline,

Suncor Energy High
Canada: pipeline protected
Pressure Pipeline, OFFSHORE
with Denso Protal 7125 and Canada. PIPELINES
the Denso Interface Coating
System.
F Suncor Energy High Pressure

TURNKEY
Pipeline, Canada: pipeline CONSTRUCTION
protected with the Denso
Petrolatum Tape System.
HORIZONTAL
DIRECTIONAL
DRILLING
COMPRESSOR
STATIONS
WELDING
FINANCE,
STRATEGY
& ANALYSIS
FEASIBILITY
STUDIES
TERMINALS
RESEARCH &
DEVELOPMENT
MAINTENANCE
Derry Gas
Pipeline,
Northern
Ireland. REHAB
97
2015
OVERCOMING
automation hurdles
Automating the world’s

pipelines is a challenging
task, as Will Leonard,
ABB Limited, UK,
explains.
A
utomating the world’s pipelines is a
hugely challenging task. Many hurdles
need to be overcome, not only those
presented by technology but also the
challenges of hostile geographical and political
environments.
To be successful takes commitment,
experience, a track record and technical solutions
that extend from designing, manufacturing,
installing and commissioning control,
instrumentation, telecommunications and
electrical systems through to a complete and
integrated scope of supply capability that ranges
from electrification to optimisation and safety
systems.
98
99
Caspian Sea where ABB technology is deployed on eight offshore
platforms. ABB estimates that well over one million man hours of
operational support, post commissioning, has been invested over
the past 11 years in this region alone.
Fulfilling industry requirements

A core strength of an automation and electrical contractor is the
ability to manage the overall value chain, making sure all parties
deliver against their commitments in a timely and cost-effective
manner. This is the role of the main electrical, automation and
telecoms contractor, and, according to ARC’s Harry Forbes: “For
years, ABB has cultivated its capability to serve major projects
as the main automation contractor. The electric power, motor
Figure 1. Automating the world’s pipelines is a challenging and drive capabilities across the ABB Group augment its process
task. automation expertise, making the firm an attractive choice when
capital projects require large or complex electric power systems.”
The focus of the main automation contractor (MAC)
throughout these pipeline projects is three fold: to ensure
compliance with all health and safety regulations and business
and commercial governance; to review project risks to ensure
schedules are met and alignment is achieved with all third parties
through good interface management; and to maximise the
facilities available locally for manufacture and production of key
systems such as local equipment rooms and cabinet builds.
Leading technology
Critical to the success of an automation project is the platform
from which the entire installation is controlled. A report by ARC
Advisory Group shows that ABB has retained its leading position
in the worldwide distributed control system (DCS) market,
Figure 2. Extended operator workplace provides a base for particularly in Latin America, Europe, Middle East and Africa
collaborative operation.
(EMEA). The report says it is also the worldwide leader in key
global verticals including oil and gas, pulp and paper, mining and
metals. A fact reinforced by a global Frost & Sullivan report, which
shows for the total DCS market in the oil and gas industry, ABB
remains clear market leader.
At the heart of this success is System 800xA, which the
industry acknowledges as the most capable automation platform
on the market today, providing reliability, scalability and
flexibility. It offers integration and connectivity to plant systems,
applications and devices. Over 8000 systems have been installed
since 2004.
The system provides all the required pipeline control
functions as standard including aspects like point of control
(PoC); a feature developed specifically for the BTC and SCP
pipelines. It was designed to cater for operational requirements
that emerged during project execution. It is now a standard and
Figure 3. Sangachal Terminal.
highly configurable function that sets System 800xA apart from its
contemporaries.
To play in this tough arena takes a lot of dedicated resources. PoC supports the transfer of authority to operate sections
As a result, ABB has several centres of excellence strategically of process plant (i.e. a single plant item or a complete pipeline
located around the world. The UK centre is appointed for oil, gas station) between central and local station control rooms.
and chemicals projects worldwide. PoC meets almost any pipeline operational requirement and
ABB was chosen for the South Caucasus Pipeline (SCP), SCPx automatically maintains the integrity of the alarm management
and BTC projects including the design, build, testing and project system. Control functions (including the exclusive ability to
management for the major onshore terminal and two export acknowledge locally generated alarms) at normally unattended
pipelines for transporting crude oil and natural gas from the stations can be quickly and safely transferred from the central

www.logstor.com
control room to local operational staff on request. The
Typical pipeline project requirements
central control room retains view only access until the
control is transferred back. SCP and SCPx pipelines
Another innovation is the extended operator Integrated control and safety system (ICSS) for all new areas
workplace (EOW), which provides a base for collaborative consisting:
operation. It provides a common operational look and )) Process control system (PCS) controllers and marshalling.
feel, not just from a control room operator perspective, )) Safety instrumented system (SIS) controllers and marshalling for
but from a maintenance management and optimisation emergency and process shutdown.
view. EOW transforms control rooms to collaboration
centres by ensuring that managers and engineers easily )) Fire and gas (F&G) controllers and marshalling for process fire and
gas monitoring.
create powerful co-operative environments using
packaged solutions. )) Fibre optic switches and transceivers for connection of the system
Using common operator graphic displays and asset to the existing network.
management leads to enhanced operator effectiveness )) Upgrade of ystem 800xA software from the existing SCP system to
and higher availability. Large screens and monitors, desks, SV5.1 and conversion of the existing graphics displays.
lighting, speakers and cameras are all integrated into
a total control room environment that combines full )) Prototype system cabinets for seismic resilience testing.
comfort and ergonomics. )) Portable test system for third party interface testing.
A good control system should directly integrate a
host of telecoms, automation and SCADA, and manage BTC pipeline
all associated interfaces. It should provide the user with )) System 800xA based integrated control and safety system (ICSS).
a fully integrated solution that provides total visibility of )) Pipeline control and safety system.
all operational aspects across the entire pipeline facility,
from one end of the pipeline to the other. Such a single, )) Over 50 000 I/O signals.
fully integrated system solution reduces interfaces that are )) Communications backbone.
costly to implement and maintain.
)) Satellite backup link.
Among the telecoms that are of interest to pipeline
projects and which should be integrated within a control )) System 800xA HMI workstations.
system are: )) Leak detection system.
)) CCTV.
)) Remote maintenance.
)) PA/GA. )) Asset management.
)) Access control systems. )) Telecommunications system solutions.
)) Intrusion/leak detection. QCLNG – Queensland, Australia
Upstream development. Project: pipeline and compression control.
)) Metrological system. 33 fabricated local equipment rooms fitted out with:
)) Radar. )) ABB 800xA DCS, ESD & F&G.
)) Telecoms equipment, access control, PIDS, CCTV, PAGA, network
)) Navigation.
switches, LAN/WAN,CTV system, PA/GA system, PABX/
)) GMDSS (MF/HF radio and beacons). telephony, transmission – fibre, access control and security
system, meteorological monitoring, structured cabling.
)) VHF radio.
)) Central processing plants (4xCPPs).
)) UHF radio. )) 21 field compression stations (21xFCSs).
)) Transmission backbone. )) Pipeline including eight mainline valves (MLV) stations.
)) Data networking. )) Power management system.

)) Migration of Honeywell Experion system.
)) PABX/telephony.
)) Upstream control room Chinchilla.
)) IP telephony.
)) Integrated collaborative environment room Brisbane.
)) Telecoms management systems.
)) Backup control room Windibri.
)) WiFi/WLAN. )) Interface to 2000 RTU wellheads in Phase 1 with a further 2000 in
Phase 2.
)) Satellite communications.

Project scheduling techniques supported by experienced and qualified professional
A significant role of the MAC is to deliver turnkey projects competent resources and proven systems and tools.
through integrated services including multi-disciplinary The focus of the approach is ensuring that the project
engineering, procurement, installation, commissioning and scope is well defined at the outset, that the work is planned
start-up, maintenance engineering and global service. All of in advance of execution activities, that responsibilities are
which have a significant impact on project scheduling. Add to identified and agreed upon between all participants and that
this the challenges of difficult and time-consuming customs detailed project-specific plans covering all aspects of the work
controls and inland freight management in various countries are established, implemented and followed.
around the world and the task becomes clear.
Lifecycle service and support
Cost-risk-schedule Once a pipeline is installed and commissioned, it must be
Overcoming these challenges requires an execution supported by a well-established, long-term service support
methodology that is based on modern project management infrastructure in the region, together with the ability to apply
WP_HALF_AD_AUG.pdf 1 7/15/15 1:42 PM
expertise remotely.
ABB ensures that all operational
assets are fully aligned to its
lifecycle programme to safeguard all
technologies from obsolescence. An
example is the upgrade of the initial
FASTER . SCP gas pipeline, being delivered in

conjunction with the SCPx project.
Providing long-term healthcare
SAFER. for the pipeline projects often means
setting up a local office to assist with
SMARTE R.
these activities. The office needs to be
equipped with enhanced engineering
and staging facilities together with
significant system test equipment.
A healthcare contract involves the
active management of the systems
and ensures maximum lifecycle
benefit to the operator. It includes full
technical support to keep the systems
operational and working at optimum
levels; engineering cover on each of
the major assets – offshore platforms,
onshore terminals, oil and gas export
pipelines; design and implementation
of system modifications; plus the
supply and management of spare parts.
A dedicated and locally based
contract manager should be employed
to provide a good understanding of
customer needs, regular reporting
on system status and be driven by
continuous improvement.
A healthcare technical lead
engineer should provide maintenance
and enhancement of the system,
modifications and upgrades, and
consistent standards across assets.
For the Caspian project, ABB’s
office in Baku, Azerbaijan hosts
a development and test system.
The healthcare contract includes
maintenance of this system as well as
training of key operational staff.
VACUWORx.COM
An appetite for
Steven Robinson, EMEA Oil & Gas Industry Leader, Rockwell

Automation, UK, presents a recipe of integration, information and
safety in automation technology for the global pipeline industry.
P
ipelines and automation have been hand in glove since the
very first pipelines sought to reduce the manpower required to
move raw energy from source to destination. But now that a
global network of pipelines pass underground, above ground and
undersea, what can the latest solutions offer to improve efficiency and
safety as demand rises ever higher?
Simplicity
The needs of pipeline operators and owners do not really change; to safely
deliver the highest volume available at the lowest cost possible. Put like
that, it is remarkably simple. Keeping things as simple as they possibly can
be is a great approach to automation technology too. It is certainly central
to the way we approach our customers’ needs at Rockwell Automation.
Take a recent customer in Canada as an example. Having added an
extension to a pipeline, they were keen to increase oil volumes. It is a
simple problem and requires a simple solution – but as with many such
projects, the stakes are very high. In fact, in this case, shutting down the
pipeline altogether incurred a cost of CAN$700 000/d. The solution
105
was to put in larger pumps and higher horsepower drives – in records for determining shipped product, system performance
fact, 4160 V variable speed drives with modulation rectifiers for and operational strategy while helping to monitor and control
motor control. The modern variable speed drive offers not only the quality of crude oil received into the pipeline, minimise
the performance requirement, but reduced energy consumption operating and maintenance costs, and help increase overall
and improved reliability. Importantly for the customer in system reliability.
question, this was delivered and commissioned across four Again, the reliability and durability of the modern hardware
separate sites in a very short window by experienced engineers solutions, alongside powerful processors, memory and software
from a global solutions team. are at the root of the advantages offered by a modern
automation solution. The best solutions also allow ease of
Information flow programming and configuration and a worldwide customer
Keeping that simplicity thought in mind, arguably the biggest support network as well as easy installation and configuration
development in what automation technology can deliver in protocols, with detailed installation manuals and on hand 24/7
recent years has as much to do with the flow of information as customer support. As with any infrastructure of this kind, one of
it does with the flow of oil or gas. the primary aims of the installation is maximum possible uptime
The information age has by no means passed the world and a global spares carrying capacity from your vendor is also a
of pipelines by. The whole oil and gas industry has seen the great advantage.
benefits that increased data collection and visualisation has to
offer, and the right automation vendor can now offer bespoke Real-time visualisation
DCS solutions that are built from ‘off-the-shelf’ technologies, Real-time information exchange is critical to making real-time
which simply integrate with existing equipment via modern business decisions – decisions that improve responsiveness,
standardised communication protocols. One huge advantage increase productivity, reduce costs and helps verify regulatory
to this is the standardisation of engineering requirements in compliance. With a modern, integrated suite of scalable,
upgrading systems – particularly when the vendor’s systems can modular software applications, pipeline operators have access
work with existing assets from other manufacturers. to all the information needed to configure, control and optimise
Managing assets as large and complex as pipelines tends to production. Surpassing traditional DCS functionality, the latest
mean that the flow of information over great distances is very solutions also meet system, control and plant-wide information
important. In the case of the next example of a recent project, needs from a globally distributed database.
an expansion programme became an opportunity to improve Simple, user friendly interfaces can provide an operator with
both information and oil flow. all the tools necessary to operate the plant with high resolution
The customer in this case was a major oil pipeline graphic displays tailored to specific needs. Operators can view
consortium looking to manage its pipelines as efficiently individual pipes or flows and the complete system in real-time,
as possible. The pipeline, which began shipping crude oil to build comparisons and assess how production is running. With
to international markets in 2001, had an initial capacity of access to historical data, using reporting and playback tools,
28.2 million tpy. An expansion project, (10 new pump stations, six pipeline operators are also empowered to constantly monitor
new 100 000 m3 storage tanks, a third offshore loading system situation analyses from process and safety condition data against
and some pipe replacement) will allow the consortium to examples of when the system was running most efficiently. This
increase its initial capacity 2.5 times, reaching its original design can also help to indicate where elements of the system may not
capacity of approximately 67 million tpy. Using a more familiar be reaching peak performance and highlight issues before they
metric, full expansion will see a capacity of at least 1.4 million cause expensive downtime.
bpd with the potential for 1.6 million bpd.
The capacity figures are truly astronomical but, it has to be Safety and optimisation
said, are not out of the ordinary for the oil and gas business. I’ve mentioned the high financial stakes associated with
However, what does present a major challenge, especially for downtime for numerous customers, but safety failures can
pipeline control and automation, is the geographical scale of the have catastrophic consequences. Modern systems offer the
construction. Controlling 1500 km of pipeline is no mean feat. opportunity to improve safety and reach safety legislation
The consortium’s stockholders came to a common decision requirements in such a way as to make pipelines more efficient.
to use programmable automation controllers (PACs). In total, This final project example demonstrates how.
the pipeline uses 200 of them located in five pump stations, The customer in this case is a gas extraction and production
87 block valves and in the marine terminal and tank farm. The plant located off the European coast. The site comprises two
PACS are complemented by Ethernet modules, ControlNet offshore platforms, coupled to an onshore central control room
modules and 1756-series I/O Modules. The SCADA pipeline (CCR). The facility’s role is to treat gas using existing pipelines
management system links all the structural elements using high- that connect the onshore treatment plants to the offshore
speed fibre optics in combination with a satellite backup along platforms. The customer needed to implement a control system
the pipeline’s entire route. It is used to manage unattended or and an emergency shut down and fire and gas (ESD/F&G)
remote facilities and give centralised control of the pipeline solution for the offshore platforms and the onshore CCR. The
system. It also provides leak detection and dynamic modelling key objective of the installation was to create a user-friendly,
online as well as a training simulator and dynamic model offline. integrated control and safety system (ICSS) that provides the
The SCADA operational interface also generates reports and highest availability and reliability according to IEC 61511 SIL3 rules.

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of an ICSS on both offshore platforms and in the onshore Coming back to the original question then, what can automation
CCR operator stations. The aim was to obtain maximum technology offer the web of global pipelines feeding the
production flexibility by using triple modular redundant (TMR) world’s appetite for energy; the answer is that it can offer much.
solutions. The integration of the complete ICSS installed Modern automation solutions can carry the advantages of
on both platforms and onshore control room was achieved traditional DCS without ‘locking in’ the specific engineering and
through a radio link and a satellite backup link. The CCR was systems knowledge required to operate them. Some solutions
fitted a process control software system which has three providers can also offer much more than the products you
operator work stations and an engineering work station with buy – with global engineering teams, 24/7 support, spares
redundancy and hot backup. The control system hardware management and help with the design and integration of the
comprised a PAC in Hot Backup, with I/O, serial link and technology, benefits for both capital expenditure and operation
ControlNet cards, alongside Ethernet cards and switches. The expenditure can be enjoyed. Safety systems are now built into
safety system comprised a trusted SIL 3 in hot backup, with the functionality of automation solutions and can be considered
I/O and remote communication cards and Ethernet cards a way of delivering efficiencies in themselves, as they integrate
and switches. The SCADA/HMI is formed of three operator into the control system and can offer reduced failure rates
stations, an engineering work station, a redundant server for and associated downtime. Further, with the rapid changes to
data acquisition, a historian server for data warehousing, a how data can be leveraged to provide critical information to
terminal server for WAN connection and a GPS clock for time operators as well as historical and best-practice comparisons
synchronisation. Finally, the control system software formed and virtualisation capabilities, operators now have a better
the platform for the complete visualisation and management window into their processes than ever before. Not to mention
solution coupled to the radio and satellite links. the means to control it and make decisions in real-tine to
The expected results of the new system include a reduction optimise performance.
in maintenance and operational costs while maintaining Put simply, rapid advancements in automation and control
production capacity. The ease of use of the new system with technology is making it easier and safer than ever before to
TMR has also provided engineering and commissioning savings. improve the functionality and efficiency of pipelines and
After a year of operation, the ICSS system was performing associated systems. And with more and more pipelines under
very well with no performance loss and with noticeably less construction to feed the growing global appetite for energy, it’s
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Jeff Foote,
Director Pipeline Integrity Technology,
T.D. Williamson, USA, looks at how
companies can comply with PHMSA’s new
integrity verification process.
N
ew regulations from the Pipeline Hazardous Materials agency’s proposed integrity verification process (IVP), the
Safety Administration (PHMSA) are a lot like those pending regulation means that all gas transmission operators
first grey hairs that inevitably come with age – even will eventually have to integrate new methodologies into
though you expect them, they can still sneak up on their integrity management programmes and be ready for
you. Take, for example, PHMSA’s Advisory Bulletin 2012-06. agency audits.
This bulletin was PHMSA’s notice to US natural gas Although the bulletin was issued more than two years
transmission operators about the changes they will be ago, the timetable for compliance remains unknown. No
required to make when verifying and reporting operating one can say with certainty when IVP will go into effect. Even
specifications for maximum allowable operating pressure the comment period, originally expected for early 2015, has
(MAOP) and maximum operating pressure (MOP). Part of the turned into a moving target.
109
Figure 1. Representation of pipe joints with similar characteristics.
None of this, however, absolves operators from )) Deformation or geometry inspection (DEF), which
their future responsibility. IVP is on its way. So while the identifies bore and long seam trim characteristics.
expectation is clear, the possibility still exists that the )) High field axial magnetic flux leakage (MFL), used to
proposed rule could catch operators off-guard. confirm magnetic properties.
The best bet to avoid a sneak attack is through advanced
planning and preparation. That is why even though the )) SpirALL® MFL, which distinguishes differences in long seam
regulation is not a reality yet, many operators are looking to characteristics.
get a head start.
)) Radial/IDOD (internal/external discrimination) used to
identify additional characteristics related to the internal
All pipe joints are not created equal
pipe wall.
Among the requirements of PHMSA’s ADB-2012-06 is the
validation of material records. In many cases, however, those In a certain sense, MDS allows operators to go back
records are either insufficient, have been lost over time, or in time: The platform can identify carbon steel pipe joint
were never kept in the first place. characteristics based on the manufacturing or milling process,
So this leaves operators asking two questions: Is it possible information that can unlock the mystery of what a large
for me to satisfy the IVP requirements without incurring all of section or even an entire pipeline is made of.
the associated costs of extensive excavations and laboratory As Harris explains, pipe joints with similar manufacturing
testing? And, if so, can I accomplish the same results through or milling should share certain similar material properties.
non-destructive methods alone? MDS can be used to identify common characteristics of a
The answer to both questions is yes. “The solution representative sample of pipe joints, producing information
is twofold,” says Chuck Harris, Manager, Strategic that can be validated by the PMI process and then applied
Commercialisation at T.D. Williamson (TDW). “First, inline more broadly.
inspection (ILI) with a comprehensive technology like the “Let’s say MDS has allowed you to identify 1000 similar
multiple dataset platform, (MDS) to classify pipe joints by joints that are grouped together in what we’ll call a bin,” Harris
their characteristics. Second, following the integrity report, says. “It would be possible, and it’s our objective, to allow a
verification of materials through the positive materials subset of those 1000 joints to be validated by PMI and apply
identification (PMI) process.” the findings to all 1000.
As the market’s most comprehensive inspection platform, “This could then be used as the basis for identifying
MDS is comprised of a robust combination of complementary material characteristics for all of the joints in an entire bin.
technologies. When specifically applied to IVP requirements, In other words, by validating a subset of joints, we could
MDS provides the following: determine the characteristics of all of them,” Harris adds.
)) Low field magnetic flux leakage (LFM), the foundational The result is the foundation for establishing complete
dataset for grouping pipe joints. LFM reveals mechanical material records where none exist. And not only will that fulfil
characteristics related to manufacturing and milling future PHMSA rules, it can keep operators from looking over
through background gauss levels and microstructure their shoulders for surprises – and maybe stave off a few grey
changes. hairs in the process.

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Norman J. Moriber, P.E., Mears
Group, Inc., USA, documents the best
practices for estimating corrosion
growth rates associated with exposure
to specific soil resistivity ranges.
n important consideration in any pipeline integrity

management plan is the estimation of external
corrosion growth rates.
Soil resistivity is the most commonly used indicator
of the environment’s ability to support the electrochemical
reactions that are a part of all corrosion mechanisms. Other
factors and corrosion mechanisms that can affect the corrosion
rate in a soil environment may include, but are not necessarily
limited to, the following:
)) Microbiologically influenced corrosion (MIC).
)) Elevated temperatures.
)) Stray current.
)) AC corrosion.
)) Acidity (low pH).
)) Structure configuration (e.g., crevice corrosion).
)) Simple stresses.
)) Oxygen or other chemical concentrations.
)) Long line galvanic cells.
)) Underdeposit corrosion.
)) Stress corrosion cracking (SCC).
113
Figures 1 - 7 show corrosion attributable to several of these Electrical shielding encompasses conditions that do not
corrosion mechanisms, with their characteristic morphologies. actually affect the corrosion rates of the general soil environment;
These factors are typically localised rather than systemic. Where rather, they create a separate environment for portions of the
the root cause analysis identifies additional factors as contributors pipe surface and prevent the distribution of cathodic protection
to metal loss, appropriate solutions should be developed by current into those areas. The most common conditions that cause
qualified individuals. In general, the application of cathodic electrical shielding include disbonded coating, other dielectric
protection (CP) is the most effective corrosion control method barriers around the pipe, non-conductive rock formations or
to address metallic surfaces that are not isolated from the soil geological features, and intervening metallic structures such as
environment by protective coatings (i.e., at coating flaws). CP parallel pipelines or shorted casings.
alone may not be the most practical approach to all factors or
combinations of factors. For example, stray current influences, Effect of CP
whether static or dynamic, are often best controlled at the source The following citations are not intended to summarise or critique
rather than attempting to overpower them with CP. the related CP criteria. Rather, they are intended to demonstrate
The recognised standard of the corrosion control industry is that the definition of ‘effective cathodic protection’ as a reduction
that effective control, and specifically effective CP, is achieved of the corrosion rate to less than 1 mil/yr is fundamental to
when the corrosion rate is reduced to less than 0.025 mm/yr the historical research and generally accepted throughout the
(1 mil/yr). corrosion control industry.
Some of the factors listed above may require increased In the Cathodic Protection 2 Education Course, NACE
protective current densities to achieve the recognised CP criteria. International has recognised the generally accepted industry
Others may require modifications to the criteria – for example, definition of effective corrosion control: under the ‘Basis of
the International Standards Organisation (ISO) has established a RP0169 Criteria’ section (now SP0169), regarding the -850 mVCSE
polarised potential criterion of -950 mV (additional 100 mV of polarisation criterion, the text states “it is generally agreed that
polarisation) in the presence of active MIC to achieve a reduction this criterion reduces corrosion to approximately 1 mil/yr.”
in the corrosion rate to less than 1 mil/yr. NACE International’s Standard Practice, SP0169-2013, ‘Control
of External Corrosion on Underground or Submerged Metallic
Piping Systems’ states, “a commonly used benchmark for effective
external corrosion control is a reduction in the corrosion rate to
0.025 mm/yr (1 mil/yr) or less.”
850 mV negative polarised pipe-to-soil

potential
In order to provide a consistent basis for comparison of
experimental results, the classic research adopted the common
definition of effective CP as the reduction of corrosion rates to
less than 1 mil/yr (0.025 mm/yr). Some of the more significant
examples follow:
)) Schwerdtfeger & McDorman, 19521: “the corrosion rate had
reached a negligible value…this value is associated with
Figure 1. General corrosion. corrosion rates that are less than 1 mil/yr.”
)) Thompson and Barlo2: “corrosion is assumed to be mitigated

when the corrosion rate falls below 1 mil/yr.”
Table 1. Table SP-B1 (adapted from ASME B31.8S)6

Corrosion rate (mil/yr) Soil resistivity (OHM-CM)
3 >15 000 + no active corrosion
6 1000 - 15 000 and/or active corrosion
12 <1000 (worst case)
Table 2. Table 11.6 rough current requirements for CP of steel

(excerpted from Peabody, p. 499)7
Conditions for bare steel Current required (mA/m2)
In moving seawater 100 - 160
In quiet seawater 55 - 85
Figure 2. A-C corrosion. In earth 10 - 30

)) Hoey and Cohen3: “the corrosion rate is not reduced to corrosion rates. ASME’s B31.8S is among the most commonly used
negligible values, although nominally near 1 mil/yr over guidelines for estimating corrosion rates based on soil resistivity.
temperatures from 75 - 198˚F.”
ASME B31.8S
)) AGA’s Interim Report4: Includes “polarised potential…to obtain The text of ASME B31.8S6 states that environmental characteristics
a corrosion rate of 1 mil/yr”; and, at the bottom of Page ES-2, such as soil resistivity should be measured during direct
“regarding the criteria, assuming protection has been achieved
examinations. This document further states that this data “can be
with a corrosion rate of 1 mil/yr.”
used to estimate corrosion rates” (Table 1).
However, no technical support for these values is offered;
100 mV of cathodic polarisation and there is no reference to the source of this table. Immediately
This research adopted the same definition of effective CP. Some following the table, it is stated that, “If the operator can provide a
of the more significant examples follow: sound technical basis for using other corrosion rates or estimates
)) AGA’s five year study on polarisation of coupons4: “the general based (on) direct examination measurements, the actual rate can
corrosion rates were typically less than…1 mil/yr.” be used in-lieu of those shown in the above table.” Furthermore, it
appears unreasonable to assign a corrosion rate as great as 3 mil/
)) Zdunek and Barlo5: “…found that the amount of polarisation yr to a site where soil corrosivity would typically be classified as
required to reduce the corrosion rate to (1 mil/yr)” and the non-corrosive (no active corrosion).
plot of the “effect of temperature on the level of polarisation
for (1 mil/yr) corrosion rate.” NACE International
Peabody’s Control of Pipeline Corrosion7 includes Table 2. The
Therefore, if effective CP can be demonstrated throughout a consumption rate of pipeline steel is 20 lb per ampere-year. Based
pipeline segment by close interval potential survey (CIS), coupon on a density of 7.89 g/cm3, the corrosion rate conversion factor
data, or other means, then it is appropriate to use a growth rate of is 1 microampere/cm2 = 0.454 mil/yr. It is reasonable to assume
1 mil/yr going forward. It is required that the contributing factors that the range of protective current requirements must be at least
to the observed metal loss have been identified during root cause as large as the anticipated corrosion currents for the conditions
analysis and effectively mitigated. The projected corrosion rates described. Therefore, the corresponding corrosion rates have been
may also be applied to locations that have not been directly calculated (Table 3).
examined, but which are subject to the same influences. Comparison with the values presented in Table SP-B1 from
It is important to note that achieving the 1 mil/yr growth B31.8S (Table 1) suggests that the ASME rates are excessively
rate expected with effective CP might not be the appropriate conservative. The B31.8S corrosion rate for high resistivity soil with
objective for all pipelines. Factors such as the condition, critical
function, age, and intended service life of a specific pipeline Table 3. Estimated current requirements for CP of steel and
will affect the corrosion rate that can be tolerated and must be corrosion rates (adapted from Peabody, p. 499)7
considered. Conditions affecting Protective current Corrosion rate (mil/

bare steel required (mA/m2) yr)
Locations with ineffective CP In moving seawater 100 - 160 4.54 - 7.264

Where effective CP cannot be established but the corrosivity In quiet seawater 55 - 85 2.497 - 3.859
of the soil environment may be adequately represented by In earth 10 - 30 0.454 - 1.362
its resistivity, alternative methods must be used to estimate
Table 4. Effect of resistivity on corrosion (excerpted from
FHWA-NHI -00-044, p. 9)8
Aggressiveness Resistivity (OHM-CM)
Very corrosive <700
Corrosive 7000 - 2000
Moderately corrosive 2000 - 5000
Mildly corrosive 5000 - 10 000
Non corrosive >10 000
Table 5. Effect of resistivity on corrosion (adapted from FHWA-

NHI -00-044, p. 9)8
Aggressiveness Resistivity (OHM-CM) Corrosion rate
(mil/yr)
Very corrosive <700 <2.43
Corrosive 7000 - 2000 <1.95
Moderately corrosive 2000 - 5000 <1.56
Mildly corrosive 5000 - 10 000 <1.25
Figure 3. A-C stray current corrosion. Non corrosive >10 000 1

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no active corrosion would correspond to the behaviour of steel in industry accepted definition that the corrosion rate in a ‘non
quiet seawater, rather than in soil; and the worst-case rates in low corrosive’ environment must be less than 1 mil/yr.
resistivity soil are greater than those in moving seawater. Comparison with the values presented in Table 1 suggests that
the ASME rates are excessively conservative. Again, the B31.8S
USDOT and NBS corrosion rate for high resistivity soil with no active corrosion is
In USDOT Publication No. FHWA-NHI-00-044, Corrosion greater than the calculated corrosion rate in the most aggressive
Degradation of Soil Reinforcements for Mechanically Stabilised category from Table 5.
Earth Walls and Reinforced Soil Slopes8, Effect of Resistivity on
Corrosion, is presented here as Table 4. These classifications of Summary
aggressiveness categories are similar to those used throughout Accurate root cause analysis is critical for any metal loss observed
the corrosion control industry. In the original document, the during direct examinations. Where the factors that contributed to
text immediately following this table states, “from the National the metal loss have been or can be successfully mitigated (such as
Bureau of Standards (NBS) data...a rough estimate can be made by effective cathodic protection), substantial technical validation
that suggests corrosion rates are roughly increased by 25% in exists to support the use of a corrosion rate no greater than 1 mil/
each successive aggressiveness range, all other conditions being yr for estimating pit growth.
essentially equal.” Accordingly, the values in the corrosion rate In the absence of documented compliance with SP0169, or
column of Table 5 have been calculated, beginning with the when other factors identified by root cause analysis have not been
adequately addressed, the guidelines of B31.8S may be used to
estimate corrosion growth rates.
The commonly-used guidelines for estimating corrosion
rates based on soil resistivity are excessively conservative and
are not adequately justified with supporting data. Where root
cause analysis identifies soil corrosion as the dominant corrosion
mechanism, B31.8S permits the use of other corrosion rates with
Figure 4. D-C stray current FBE undercut.
a sound technical basis. The calculated corrosion rates in Tables
3 and 5, based on the Peabody and DOT/NBS data, suggest that
a reasonable maximum corrosion rate in relatively uniform soils
would be approximately 2.5 mils/yr.
References
1. SCHWERDTFEGER, W. J., and MCDORMAN, O.N., National Bureau of Standards,
‘Potential and Current Requirements for the Cathodic Protection of Steels in Soils’
Corrosion 8, 11, 1952.
2. THOMPSON, N. G., and BARLO, T. J., ‘Fundamental Process of Cathodically Protecting
Steel Pipelines’, International Gas Research Conference, 1983.
3. HOEY, G. R., and COHEN, M., ‘Cathodic Protection of Iron in the Temperature Range of
25-92˚C,’ Corrosion 14, 4, 1958.
4. BARLO, T.J., American Gas Association Interim Report, PR-151-163, ‘Field Testing the
Criteria for Cathodic Protection’, 1987.
5. ZDUNEK, A.D., and BARLO, T.J., ‘Effect of Temperature on Cathodic Protection Criteria’
Materials Performance 31, 11, 1992.
6. DRAKE, J. A. et al, American Society of Mechanical Engineers, B31.8S ‘Supplement to
B31.8 on Managing System Integrity of Gas Pipelines, 2001.
7. BIANCHETTI, R.L, et al, Peabody’s Control of Pipeline Corrosion by A.W. Peabody,
published by NACE Press, 2001.
Figure 5. Non D-C stray current coating ‘lift-off’. 8. ELIAS, V., USDOT Publication No. FHWA-NHI-00-044. ‘Corrosion Degradation of Soil
Reinforcements for Mechanically Stabilized Earth Walls and Reinforced Soil Slopes’,
2000.
Figure 6. Localised pitting corrosion. Figure 7. Localised pitting corrosion.

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André Lamarre and Andréanne Potvin,
Olympus, USA, explain why new
ultrasonic techniques are contributing
significantly to the integrity of CRA-clad
pipeline.
D
uring pipeline construction in the field, automated ultrasonic testing is used
to inspect carbon steel girth welds with high accuracy, offering significant
advantages over radiography. CRA-clad pipelines are increasingly used for
the transport of hot and corrosive materials because of the higher resistance
to corrosion provided by the corrosion resistant alloys (CRA). However, the layer of
protection that these alloys provide also impedes effective ultrasonic inspection of
dissimilar girth welds in the pipeline. The industry has been searching for a simple and
reliable solution to this particular challenge.
121
Figure 1. Olympus PipeWIZARD system in operation (left); Olympus PipeWIZARD strip chart imaging showing indications (right).
The quality of the weld between the receiver (Figure 3), and the depth
two sections of pipe is critical to of the crack is defined using simple
ensuring the integrity of a pipeline. For trigonometry. The use of the B scan
years, radiography was the method of facilitates interpretation of the signal
choice to verify the integrity of these and increases the probability of flaw
welds. More recently, the development detection.
of automated ultrasonic testing (AUT)
techniques, including phased array and Advantages over RT
time-of-flight diffraction (TOFD), has While radiography (RT) is the most
significantly improved the efficiency of commonly used technology in
ultrasonic inspection, advantageously the industry, it has major safety,
replacing RT in many applications. environmental, and licensing
Unfortunately, when applied to limitations, plus limited capability
CRA-clad welds, AUT has presented for detecting critical planar defects.
certain limitations and more advanced In contrast, AUT offers a higher
tools had to be developed. probability of detection of critical
planar defects, plus the capability to
Advanced automated accurately locate them. In particular,
ultrasonic testing the capability of AUT to vertically
An automated ultrasonic in-situ system size defects permits the use of
consists of a pair of phased array more accurate fracture mechanics
probes that generate multiple beams calculations, relaxing the acceptance
to cover specific zones of the weld criteria for critical flaw length. This
(zone discrimination technique), and results in less frequent need for weld
a pair of TOFD probes for volumetric repair, representing significant savings
inspection. These are mounted on a for pipeline contractors. In addition,
fully automated scanner. The weld is AUT does not require the use of
inspected in its entirety in a single pass, Figure 2. Effects of the CRA-clad layer and chemicals or radiation protection
weld on ultrasnic shear waves.
and the results are immediately shown procedures. AUT inspection is also
on screen. Inspectors, benefitting from faster than radiography. Furthermore,
easy-to-interpret strip chart imaging, are able perform a quick AUT is now recognised by many international standards as a
assessment of the quality of the weld. replacement for RT.
Phased array technology is based on the capacity to
electronically modify ultrasonic beams generated by probes CRA-clad pipeline
that contain multiple small elements. When these elements CRAs are very effective, but they are costly. To limit the
are excited using different time delays (focal laws), the beams cost of pipeline construction, only the inside wall of the
are steered at different angles and focused at specific depths. pipes are lined with a layer of CRA material with enhanced
Time-of-flight diffraction (TOFD) is an ultrasonic technique properties. Depending on the environmental conditions,
that relies on the property of cracks and similar defects to various combinations of materials and thicknesses can be
diffract energy when impinged by ultrasonic beams. Two used; for example, a layer of Inconel clad on a carbon steel
ultrasonic transducers, one transmitter and one receiver, pipe. The CRA can be bonded to the inside of the pipe using a
work in tandem to inspect the volume of a weld. When a metallurgical (clad) or a mechanical (lined) process. The same
crack is present in the weld, its tips diffract waves back to CRA material is also used in the weld that joins pipes together

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to construct the line. Because velocity, grain structure, configuration eliminates interface echoes, as well as dead
and other properties of the CRA material differ from the zones resulting from wedge echo, and it generates more
parent material, these types of manufacturing and assembly energy and less noise in the inspection data. This optimised
processes raise new challenges in the inspection strategies of configuration inspects the surface and volume with the same
pipeline girth welds. probe and wedge, ensuring full coverage. When mounted
on a fully automated scanner, two dual linear array probes
CRA-clad pipeline inspection challenges (one positioned on each side of the weld) are capable of
Ultrasonic inspection of dissimilar girth welds in CRA-clad performing the inspection in only one pass.
piping poses a particular challenge. As the material of the The weld is separated into different zones: the root, the
clad layer (Inconel, stainless steel, etc.) differs from that of volume, and the upper area (including the cap). The DLA probe
the parent material (carbon steel), the characteristics of the inspects the volume with longitudinal waves that penetrate
interface between these materials makes the pulse rebound the weld, interrogating the opposite portion of the weld, to
on the internal wall (ID) of the pipe unpredictable or even identify lack of fusion at the weld bevel. High angle LW and
unusable. In addition, the anisotropic structure of the cladding surface waves interrogate the upper part of the weld, including
and the weld creates ultrasonic mode conversion and erratic the surface, while the root is inspected with lower LW angles.
beam orientations. Consequently, high precision techniques All these angles are grouped together into one easy-to-read
such as zone discrimination cannot be used. Pulse-echo testing view called a sector scan.
using the second leg of the ultrasonic beam is impossible, Optimised DLA configurations have been tested on
which makes inspection of the cap and its subsurface different pipe configurations with different clad types and
extremely challenging. thicknesses. In Figure 4, the DLA probe has detected flaws
located at the weld root position, at the weld bevel, and a
CRA-clad pipeline inspection solution surface notch located in the upper portion of the opposite
The solution developed for CRA-clad inspection is based on side of the weld. In all of these cases, detection was achieved
the use of dual linear arrays (DLA). Coverage of the full volume while the ultrasonic beams travelled through the weld.
and surface of the weld can be obtained by performing a Generally, the DLA configuration has the capability to
sectorial scan with DLA probes using longitudinal waves (LW). penetrate the weld with minimal distortion, enabling full
A DLA probe is basically a dual element probe, though inspection of the weld. However, it is important to test and
with one linear array as the transmitter and one linear array optimise the inspection for the pipe configuration to be
as the receiver, separated by acoustic insulation. This dual inspected.
Conclusion
Recent progress in the development of AUT techniques
addresses challenging applications such as CRA-clad pipeline.
The use of dual linear arrays increases the penetration of
ultrasonic beams in dissimilar girth welds, enabling full
inspection of the weld, from the root to the surface, with
only two DLA probes. Combined with high performance
instrumentation and easy-to-comprehend software imaging,
DLA eases the work of the operator and brings all the
advantages of AUT to this industry.
New advanced ultrasonic techniques contribute
significantly to the integrity of pipelines. When used during
pipeline construction, these techniques optimise the accuracy,
speed and reliability of ultrasonic inspection.
In addition, these techniques have shown to be reliable
Figure 3. Olympus dual linear array probe configuration.
replacements for radiography in ensuring pipeline integrity.
Figure 4. Sector scan imaging of flaws in the root, the weld bevel, and the cap.

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TAKING
OUT BLACK
POWDER
ExxonMobil reports that natural gas will be
the fastest growing major fuel in the world
by 2040. Roger Simonson, Black Powder
Solutions, Canada, discusses how advanced
magnetic separators make a clean fuel
cleaner.
I
t is abundant around the world, affordable, extremely versatile and
cleaner than alternatives as a fuel for global power generation.
The transportation industry has also started using ‘cleaner’ natural
gas to power the vehicles moving people and materials from place
to place. Many fleets are switching from diesel or gasoline to compressed
natural gas (CNG), liquefied propane gas (LPG) or liquefied natural gas (LNG)
in order to reduce the emissions from burning these fuels.
The US Environmental Protection Agency calculated the potential
benefits of LNG versus diesel-based fuel on the inherently cleaner-burning
127
characteristics of natural gas. The EPA summarised them in Clean When the contaminated gas enters gas plants, LNG plants
Alternative Fuels: Liquefied Natural Gas. and infrastructure used by end users to supply CNG or produce
Fleets using LNG: power, it causes damage to every component it contacts.
)) Produce half the particulate matter of average diesel vehicles. As soon as a pipeline begins to transport gas or hydrocarbon
fluid, there will be some moisture in the flow. With minor changes
)) Significantly reduce carbon monoxide emissions. in atmospheric temperature or pressure, water vapour condenses
on the inside of the pipe and more black powder is formed. That
)) Reduce nitrogen oxide and volatile organic hydrocarbon
is all it takes to begin the damaging cycle.
emissions by 50% or more.
Black powder is a hazardous, ferrous (iron-based) substance
)) Potentially reduce carbon dioxide emissions 25% depending that looks like black sand. It is created when condensation triggers
on the source of the natural gas. the production of iron sulfides and iron oxides from the carbon
steel pipe walls. It builds up in bends and curves during low flow
)) Drastically reduce toxic and carcinogenic pollutants. and can then suddenly come down the pipe in large volumes
)) Increase methane emissions (not a benefit).
during high production times.
Dew point monitoring is employed to predict condensation
in specific pipeline locations at certain times. Essentially, it is
Is it really clean? weather monitoring. Based on moisture forecasts, preventative
Despite the fact that natural gas burns cleaner than many other measures can be taken to minimise black powder, but this is never
fuels, the pipelines that carry it from extraction to distribution enough to eliminate it outright.
unfortunately also carry what is known as ‘black powder Once the contamination process begins, it is very difficult to
contamination.’ stop it. As a result product is degraded and production values
Very abrasive and suspended in the gas, black powder will are reduced from premature pump failures, turbine/compressor
erode pipeline walls while damaging compression components, component wear and tear, premature wear of transmission lines,
valves and meters. plugging of meters and traditional filters and seizing of valves.
Black powder, as it flows down gas pipelines, damages
compressors, orifice meters, instrumentation, control valves,
turbines and other essential components. As an example of
the replacement cost associated with damage caused by black
powder, a dry seal failure can run in excess of US$80 000 per seal,
plus the associated downtime.
Traditional methods of removing black powder

Chemical flushing and pigging are used to remove black powder.
These are very expensive methods. Traditional depth media
filtration is also employed on gas pipelines and is costly to
operate and only efficient down to 3 µm in size. It is important
to note the majority of black powder is less than 1 µm in dry gas
lines. Separators and cyclones are also employed with efficiencies
down to 8 µm in size.
Figure 1. LNG is marketed globally as a clean, alternative fuel. Ongoing attempts to deal with black powder in gas pipelines
using traditional depth media filtration have had no lasting
success. Although this filtration is in place on many pipelines, it is
inefficient. The black powder will continue to do its damage, as it
is too fine to be trapped. Traditional filters easily become clogged
and go into ‘bypass’ mode, allowing the flow of contaminated gas
or liquid to resume.
Black powder particles can be as large as 100+ µm. In wet gas,
though, the majority are 10 µm or less. In dry gas, black powder
particles are typically 3 µm to sub-micron in size. As a result, black
powder in gas transmission lines and processing systems cannot
be trapped by traditional depth media filtration, which captures
particles that are 8 µm in size or larger.
These ‘old school’ filters get clogged easily and then restrict
flow, slowing down the movement of liquid and gas product,
negatively impacting transmission and overall operations. When
flow is impeded, additional horsepower is typically brought in to
increase velocity, but this approach adds unnecessary cost while
Figure 2. Every pipeline risks black powder contamination from stressing systems that must work harder to move product through
startup. clogged networks.

When traditional depth media filters are combined with BPS scrubbers
separators and cyclones, as is often the case with wet gas, the Designed for inline filtration on rotating equipment, scrubbers are
result can be little more than a very expensive array of under installed to remove black powder contamination prior to existing
performing filtration technologies. filtration, pumps or return lines.
How to take out black powder BPS separators

Despite the difficulties of managing black powder contamination, With new, powerful, rare earth magnetic technology, separators
it is simply too destructive to ignore. protect the pump and components, retain flow rates and
Calgary based Black Powder Solutions (BPS) has taken on eliminate black powder.
the challenge. BPS has designed and manufactures the most
advanced environmentally friendly industrial magnetic separation BPS sampling stations
technology on the market. It has won international praise from Installed on transmission lines, these slipstream stations sample
customers for its results. flow to remove black powder contamination, and to indicate how
The Black Powder Magnetic Separator System is currently much of it is flowing through your transmission line.
capable of taking out 99+% of black powder (ferrous and non-
ferrous) down to sub-micron levels. It was developed as a stronger BPS dispenser filters
alternative to traditional filtration and as a definitive yes to the These filters remove black powder contamination before fuelling
question: “is anybody going to do anything about black powder?” engines for mobile and stationary equipment, furnaces and power
The solution builds on the effectiveness of magnetic (vs plant applications.
depth media) filtration. It utilises rare earth technology (for more
powerful magnetic fields) to increase its separation strength. In International results
natural gas and hydrocarbon transmission lines, it successfully EDP is Portugal’s power generation and distribution leader, with
enables the separation of black powder during operation, with no major, additional business operations in Spain, Latin America, the
flow restriction, to sub-micron levels. US, Brazil, Africa and Macau.
Self-cleaning with minimal maintenance and negligible In March 2014, EDP Gás in Porto, Portugal was experiencing
consumables, the automated systems do not require increased high volumes of black powder plugging off the traditional depth
horsepower to maintain flow velocities. They operate redundantly media filter systems on its 6 in. gas transmission line, flowing
in isolated locations and can be managed remotely with 2500 - 3616 m3/hr.
electronic communications. This meant poor quality product and jeopardised system
Recommended for employment before compressor, metering components. Due to the situation, EDP decided to install a
and pumping stations as well as chemical gas plants and refineries, magnetic separator prior to the filters on the line.
BPS products will result in increased operational time, reduced Arlindo Pinto dos Santos, EDP’s Technical Director, is “pleased
maintenance costs and clean product for end users. In addition to with the overall performance of the solution,” having removed
custom ‘enterprise’ solutions, the product line currently includes: 95% of the black powder contamination during the first week
after installation.
BPS automatic separator system EDP’s Return on Investment will continue with reductions in
This is a full system approach to removing black powder from the cost of maintenance, labour and replacement parts as well as
natural gas and hydrocarbon fluid lines to sub-micron levels with delivery of a cleaner product.
minimal flow restriction. Safe and effective, it is the solution of In 2008 in Northern Italy, high levels of black powder
choice for commercial gas infrastructure, including large-scale contamination were found in the glycol circulation pumps at the
power generation systems. Solutions are custom designed. Stogit Forma Gas Storage Compression Station. The contaminants
were too fine for the existing, traditional Y-strainers to remove.
These Y-strainers were installed before the pumps.
Alex Priori of Renox (BPS’s distributor in Italy) suggested
installing magnetic separators on the Y-strainers of six pumps as a
test to remove the black powder.
While these six pumps have operated without incident since
installing the products, the others have experienced breakdowns.
BPS has also delivered black powder separation solutions
to Brazil’s CTDUT Pipeline Technology Centre; Italy’s largest gas
company, Snam Rete; and Texas, US based Transmontaigne. BPS
has finetuned its filtration capabilities in a number of additional
areas outside of natural gas management. Its hydrocarbon fluid
and rotating equipment filtration solutions, for example, have
elicited favourable response from companies that include CTDUT
Figure 3. Magnetic separators can be used in upstream, (Brazil), Kinder Morgan (Canada), Petrobras (Brazil), Taminco (US)
midstream and downstream applications. and Alliance Pipeline (Canada), among others.

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Fred Allen and Steve Drew,
Axalta Coating Systems, describe
the process by which a dual-layer
FBE coating system can be applied
to field joints by flame spray.
132
A
significant challenge in pipeline construction is
to ensure that the field joints are adequately
protected from corrosion. This generally
involves the application of a suitable coating
system on the girth weld area and a cathodic impressed
current along the pipeline. Whilst there are a number of
different types of coatings available for field joints, one
of the most effective is a dual-layer fusion-bonded epoxy
(FBE) powder coating system given its compatibility with
cathodic protection current and a combination of high
performance properties, including damage resistance and
corrosion resistance. Dual-layer FBE is a widely recognised
system for coating field joints1 with an extensive
commercial project track record.
The field joint coating is often perceived as the
weakest link in pipeline corrosion protection. Although the
range of materials currently used for field joint coatings
is considerable, some of these are now internationally
specified.2 However, this has not always been the case.3 )) Three-layer polypropylene together with FBE primer
Field coatings that are most commonly used include: and adhesive, extruded or spray applied.
)) Liquid epoxy coatings.
)) Polymeric tapes, wax based or bituminous.
)) Liquid polyurethane coatings.
)) Heat shrink sleeves (HSS) over liquid epoxy primer.
)) Liquid epoxy-urethane coatings.
)) Fusion bonded epoxy powder (FBE), single- and dual-layer.
The field joint coating must provide excellent

corrosion protection, be compatible with the parent
coating system on the linepipe and with the applied
cathodic protection system.4 One of the most widely used
coating systems is heat shrink sleeves (HSS) applied over
a liquid epoxy primer. The liquid primer is used to cover
the substrate metal and to ensure good coverage of the
weld seam. Alternatively, a hot-melt adhesive may be
used to provide adhesion and additional anti-corrosion
performance.5 However, problems may occur with the HSS
due to tenting and air entrapment around the weld seam
and overlaps can also be problematic.
Coating application equipment –

preheating and post-curing
Figure 1. Application of first layer of Axalta FBE powder The time pressures in pipeline construction both onshore
coating. and offshore mean that the field joint coating application
process has to be particularly rapid, and the key aspect of
this is to ensure rapid heating of the pipe, particularly for
application of FBE powders. In practice, the most common
method to achieve this is with the use of induction coils,
in a clamshell arrangement around the pipe. However, the
rate of heating and the extent to which the pipe is fully
heated to the correct temperature across the field joint
area and through the thickness of the steel is critical. It is
often difficult to control these parameters with induction
heating in the field. Subsequent failure of the field joint
coating and problems during its application are often
associated with incorrect application temperature. Some
of these problems are highlighted in Table 1.
An alternate method of heating is infrared radiation,
and the correct selection of the appropriate wavelength
range offers some significant advantages over induction
heating. Of the three wavelength ranges typically available
Figure 2. Application of second layer of Axalta FBE coating – long, medium, and short – longer wavelengths offer
system. a more precise temperature control but result in longer
heat-up times. Shorter wavelengths give a
very fast heat-up rate but present difficulties
Table 1. Common problems with field joint coating application
in stabilising the temperature once the target
Type of field joint Problem Cause
temperature is reached.
coating
The best combination of properties is
Failure to adhere Insufficient heating
presented by medium wavelength infrared
Burnt outer layer Excessive heating
Heat shrink sleeves
Failure to shrink sleeves evenly Uneven heating
(MWIR). This heating range has lower power
Trapped air Insufficient heating requirements than induction heating and
Failure to adhere Undercure therefore is not only lower cost but also
Trapped air/foaming Application temp. too high is a smaller size unit. In the case of the
FBE
Inadequate cure Insufficient heating equipment manufactured by XIOM Scotland,
the MWIR heating unit is lightweight and can
Liquid coatings
Poor adhesion Undercuring be easily handled manually without the need
Post application cracking Undercuring for lifting equipment for pipe diameters from

4 in. OD up to 30 in. OD. The unit is designed such that a it can be used to coat field joints on pipelines in areas
single unit is capable of heating a range of different pipe where conventional induction heating and FBE application
diameters. equipment may not be suitable.
The heating unit and control unit are mounted on a
support frame that is clamped on to the pipe that spans Coating application – flame spray
the field joint area. The heating unit is wheel-mounted, The most common method of application of FBE powder
which allows it to be moved along the support rail to heat coatings to field joints is with electrostatic spray.
the field joint and to permit easy access for inspection of However, an alternative method such as flame spray
the joint. The entire support frame is also wheel-mounted provides a viable option, as it allows a more precise
so that the heating system can be moved to the next field control of film thickness and, with manual application,
joint without the need to lift it from the pipe. This gives allows field joints to be coated in difficult-to-access
the equipment excellent flexibility as well as the ability areas during main pipeline construction as well as during
to cover an area greater than one field joint width. The pipeline rehabilitation.
small size and portability of the equipment means that In the equipment package designed by XIOM Scotland
the flame spray guns are capable of an FBE powder output
of 7 kg/hr, and are powered by a mixture of compressed
air, oxygen and propane gas. This combination gives a
clean and controlled application of the FBE powder with
around 98% transfer efficiency. A single operator can easily
handle the coating application on smaller diameter pipes
up to around 20 in. OD, but for larger diameter pipes, up
to 30 in. OD, it is preferable to use two operators, spraying
in tandem, on opposite sides of the pipe.
Central Asia
A major multinational oil and gas company, with extensive
interests in central Asia, planned the construction of
further insulated pipelines with an external coating system,
comprising dual-layer FBE powder coating, together with
polyurethane foam thermal insulation encased in a hard
polyethylene outer sleeve. The dual-layer FBE system
Figure 3. Preheating of grit blasted line pipe joint to 180°C was composed of Nap-Gard® 7-2500 from Axalta Coating
using XIOM Scotland flame spray equipment prior to Systems as an anti-corrosion first layer, and Nap-Gard
application of Axalta FBE dual-layer coating stystem.
Gold 7-2504 as a high temperature resistant, moisture-
barrier topcoat. This dual
powder system (DPS) met
Table 2. Inspection summary for field joint PQ the requirements for a
Test description Test method Acceptance criteria
Result coating that could offer
Nap-Gard 7-2500 + 7-2504 a high degree of both
Flexibility at: -30˚C
CSA Z245.20-14,
1.1˚/PDL, no cracking Pass 1.8˚/PDL (*) damage resistance and
0˚C 1.7˚/PDL, no cracking Pass 1.8˚/PDL (*) corrosion protection up
Clause 12.11
25˚C 1.7˚/PDL, no cracking Pass 4.6˚/PDL (*)
to the 120˚C maximum
Cathodic
CSA Z245.20-14, 8 mm max. radial design temperature of the
disbondment 4.8 mm avg.
48 hr, 95˚C, 1.5V
Clause 12.8 disbondment pipeline and also in the
extremely severe ambient
Hot water soak CSA Z245.20-14,
48 hr, 95˚C; adhesion Clause 12.14
Rating 1 - 2 Rating 2 temperature conditions in
the region that ranges from
CSA Z245.20-14,
Impact resistance
Clause 12.12 1.5 J, no holidays Pass, no holidays -30˚C in winter to 45˚C in
at 25˚C
(ASTM G14) summer. The terrain through
Hardness – shore D ASTM D2240-74 85 - 90 Pass 90 which the pipelines passes
Penetration
includes extensive swampy
ASTM G17 Max. 25 μm at 25˚C 12.7 μm areas that necessitated the
resistance
Degree of cure
requirement for the external
CSA Z245.20-14, coating system to provide
(TA instruments -2˚C < ΔTg < 3˚C ΔTg -0.03˚C avg.
Clause 12.7
Q100) excellent resistance to
water penetration.
Note (*): The project specification requires 2% strain flexibility at -30˚C and 3% at 0˚C/25˚C. This equates to
1.1˚/per pipe diameter length (PDL) and 1.7˚/PDL respectively.
The presence of thermal
insulation on the linepipe

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required the use of a field joint coating process that )) Flexibility at temperatures between -30 - 25˚C, to
could successfully and efficiently apply the selected reflect the range of local winter/summer temperatures.
FBE DPS system with accurate control of temperature
)) Hardness, Shore D.
and without damaging or degrading the insulation or
existing linepipe coatings. The pipeline owner allows the )) Penetration resistance at 25˚C.
use of liquid coatings on the girth welds but prefers and
recommends the use of single- or dual-layer FBE to match The PQT test results are summarised in Table 2. The
the respective FBE coating system on the linepipe. degree of cure of the Nap-Gard 7-2500 plus Nap-Gard
Gold 7-2504 dual powder system was evaluated by
Coating application process measuring the difference in glass transition temperature
The planned pipeline network in central Asia involved (ΔT g) between successive scans (T g3 and T g4) of the upper
pipes of varying diameters, from 4 - 28 in. OD. For the layer of Nap-Gard Gold 7-2504 on a TA Instruments
Procedure Qualification Test (PQT) described, the pipeline Q100 differential scanning calorimeter. The average ΔT g
owner selected pipes from a 11.4 km pipeline with 219.1 value over three separate scans was -0.03˚C indicating
mm OD and 9.75 mm WT. It was very important to ensure a very high degree of cure and well within the specified
that the field joints were given the same degree of ΔT g 5˚C range. The cathodic disbondment and hot
corrosion protection as the linepipe and so the Nap-Gard water immersion results were also well within the
Gold DPS FBE system was selected. The use of a field specified limits and again indicated a very high level of
joint coating identical to that on the line pipe along the conversion.
length of a pipeline ensures the optimum compatibility, The Nap-Gard Gold Dual powder system is designed for
and the use of DPS FBE in particular overcomes the high performance in very harsh conditions and its excellent
issues of delamination seen with other field joint coating mechanical properties are conclusively demonstrated in
technologies.6 the PQT test results. The system exhibits an impressive
The thermal insulation on the field joint areas of the combination of low temperature flexibility and mechanical
pipes selected for the PQT was cut back and sealed with damage resistance as shown by the excellent values for the
heat shrink sleeves. Each field joint was preheated with Shore D hardness and penetration resistance.
the XIOM MWIR heating unit to 60˚C, and grit blasted
to a surface roughness profile of 75±10 μm and a surface Conclusions
cleanliness of Sa2½ (ISO 8501-1:2007). The MWIR heating The use of Dual Powder System FBE powder coatings on
unit was again moved over the field joint area and the joint pipeline field joints to match the same external coating
was heated to 155˚C. The heating unit was moved to one system on mainline pipe, and applied and cured by a
side and the field joint was flame spray coated first with combination of flame spray and MW infrared heating, is
300 - 350 μm Nap-Gard 7-2500 and then with demonstrated to offer a high performance solution to
300 -350 μm Nap-Gard Gold 7-2504. The total film address the issue of long-term corrosion protection. The
thickness over a series of three field joints coated was in practical flexibility of this coating and coating application
the range 635 - 680 μm. The MWIR heating unit was again system presents a viable and cost-effective alternative
moved over the field joint area and the applied coatings to existing field joint coating technology, particularly on
were post-cured at 203±3˚C for three minutes. Visual thermally insulated pipelines.
assessment indicated that the resulting coating system was
References
smooth with an even golden colour. 1. KEHR, J., “Fusion Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion
Protection”, NACE International, 2003, Houston, USA.
2. International Standards Organisation publication, “Petroleum and natural
Results and discussion gas industries – External coatings for buried or submerged pipelines used in
Sample panels and pipe ring samples were cut from the pipeline transportation systems - Part 3: Field joint coatings”, ISO 21809-3:
2008.
coated field joints and were tested in accordance with
3. MODARSKI, J. G., and WONG, D., “New Developments in Joint Coating and
the procedures of the Canadian Standards Association Field Repair Technology”, NACE International, CORROSION 98, 22 - 27
specification CSA Z245.20-147 and ASTM International test March 1998, San Diego, USA.
4. KEHR, J., “Fusion Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion
methods. The range of tests in the project specification Protection”, NACE International, 2003, Houston, USA.
to be carried out on the field joint coating are designed 5. MALLOZZI, M. and PEREZ, M., 18th International Conference on Pipeline
Protection, Antwerp, 4 - 6 November, 2009.
to highlight the adhesion and damage resistance of the 6. MELOT, D., PAUGA<, G., and ROCHE, M., “Disbondment of Pipeline Coatings
coating system and comprise the following: and their Consequence on Corrosion Risks”, 17th International Conference
on Pipeline Protection, Edinburgh, 17 - 19 October 2007.
)) Cathodic disbondment at 95˚C, to reflect the elevated 7. Canadian Standards Association publication, CSA Z245.20-14, “Plant-applied
operating temperature of the pipeline. external coatings for steel pipe”, Toronto, Canada, 2014.
)) Hot water immersion resistance at 95˚C, for similar Acknowledgement

assessment. Ian Archer, Managing Director, XIOM.

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www.gastechsingapore.com/World-pipelines
THE
OFFSHORE Renato Sanchez, Engineering
COATING
Manager, and Caroline A.
Fisher, Technical Writer, CRTS,
Inc., USA, examine the use of
internal field joint coatings in
TECHNIQUE unique, offshore locations.
W
hen building a pipeline of nearly 13 000 welds, inspection and monitoring; corrosion prevention coatings do
corrosion management is naturally part of the however add many benefits such as:
design. Unfortunately, while the majority of )) Maintain product purity.
pipelines are built with reasonable monitoring and
inspection plans in place, little attention is paid to the bare steel )) Increase pipeline longevity.
on the internal field joints (IFJs) where leaks and internal corrosion
)) Reduce internal corrosion.
often occur. This bare steel represents approximately 2% of the
entire pipeline, yet easily becomes the pipeline’s weakest link if )) Reduce pipeline flow friction, which minimises pressure drop.
not protected.
To prevent internal corrosion, one of the largest oil )) Reduce pipe wall thickness requirements.
companies in the world awarded CRTS an offshore project in
)) Diminish or eliminate pipeline leaks.
the Gulf of Arabia near Qatar in 2012. This pipeline crosses the
Hasbah and Arabiyah gas fields and CRTS completed its corrosion )) Protect the environment from leaks, ruptures or spills.
prevention services in January 2015. The operation was based at
the company’s facility in Abqaiq, Kingdom of Saudi Arabia, and These benefits are inherent to the parent coating of
at that time was the largest project ever awarded to CRTS. Why pipelines, but when also applied to the internal field joint, they
was IFJ coating chosen over other corrosion prevention methods? create seamless, defect-free protection from internal corrosion.
Corroded, leaking pipelines on the ocean floor are not a viable These benefits also address the gravity of internal corrosion
option for owners or the environment. Coating the IFJs provides consequences: deepwater pipelines need defect-free, continuous
the most mitigation for the money. internal coatings to complement the expensive and complicated
methods of monitoring and inspection.
Preventing corrosion from the inside out
Designing a pipeline to endure a lifetime means employing Customised equipment for best practice
corrosion prevention techniques that do more than meet the The sheer number of welds and impact on the marine
minimum standards; the pipeline should have built-in measures, environment with a project of this size is enough to warrant
such as corrosion prevention coatings, that prevent corrosion or specialised equipment and testing. The complexity of keeping
greatly mitigate it. Built-in prevention does not exclude future equipment running efficiently while performing also warranted
141
exceptional design. While the customised equipment may seem Besides building coating equipment for the IFJs, CRTS
excessive at the outset, the long-term OPEX savings, protected perfected a recovery system in case any equipment rolled to the
public and marine environment demonstrate that every detail is bottom of the S-bend. Although CRTS has coated thousands of
essential. offshore IFJs with no mishaps, the customer was adamant that a
Offshore, there are electronic challenges: the robotic recovery system be in place, a safety practice approved by CRTS.
equipment uses telemetry and it had to be robust enough to A few simple mechanical components were added to the crawler
transmit not only through external welding-generated electrical features, such as a delatching mechanism for the 10 000 lb of
noise, but also through a massive internal laser welding lineup equipment. CRTS also designed a safety winch as a fail-safe for
clamp. Altogether, 60 printed circuit boards and 11 microprocessor retrieving runaway equipment. As expected, it was never used.
boards were onboard each set of robotic equipment.
There are also mechanical challenges unique to offshore Preparing the IFJ for coating
work: CRTS engineers designed offshore-rated lifting frames for One of the main benefits of remotely controlled robotic
all of its robotic equipment, which included equipment baskets equipment is that it identifies uncoatable (corrosion inviting)
and compressor frames. The frames were designed in Tulsa and welds at the beginning of the corrosion prevention process. The
fabricated and load tested in our Abqaiq, Saudi Arabia location. wireless video system identified weld imperfections at the root
Six sets of equipment were made, each set consisting of a crawler, pass, which made correcting them much simpler than finding
battery cart, cleaner, vacuum and liquid coater. In total, with more them after all the welding passes had been completed. The visual
than 100 45Ah batteries on each set of equipment, nearly US$1 million inspection of the welding root pass is a valuable tool, regardless
was spent on batteries alone. of whether the pipe is coated or not (CRTS has performed this
Moving heavy pipe safely and efficiently is a safety concern on function for clad steel). Cutting out pipe is one of the most
a laybarge. CRTS designed pipe rotators that were used to rotate expensive activities on a lay barge, especially if the faulty section
the 36 in. pipe with a 1 5/8 in. wall. Each pipe piece was 80 ft long is not found until after the pipe has been internally coated and is
and was covered with 4 - 6 in. of concrete coating. These massive about to enter the stinger.
rotators had a lifting capacity of 50 t and were used to rotate the Preventing corrosion by applying coatings is easy; preparing
pipe during the preblasting process, which collects and recycles the pipe surface for coating takes stringent effort. Since each
the abrasive blasting media. weld is a potential source of corrosion due to its protrusion
into the flow stream, before the pipe was welded together,
handheld abrasive blasting equipment was used to create a
surface roughness on the cutback area that met the coating
manufacturer’s standard.
Once the surface roughness was measured and approved,
the pipe was loaded onto the ready rack, then entered the first
station, the bead stall. After this pipe was welded to another pipe,
the cleaner and vacuum robots worked in tandem to provide the
foundation of seamless internal corrosion prevention: superior
surface preparation.
The robotic cleaner uses a high speed cleaning wheel
Figure 1. This train of equipment cleaned and coated nearly to remove weld slag and other impurities generated by the
13 000 internal field joints on a Middle East offshore project. welding process. The cleaner applied abrasive to the IFJ and then
Figure 3. CRTS field technicians use telemetry to communicate

with its robotic equipment while it is inside the pipe. This
Figure 2. Factory-coated pipe strengthened with coated wireless communication includes receiving video and
internal field joints enters the Arabian Gulf. equipment parameters data from the equipment cameras.

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vacuumed and recycled the abrasive for use on the next IFJ. A has infinite ratio adjustment with its range, allowing its use with
visual inspection using an onboard camera ensured the proper many different types of materials. The coating operator set the
level of cleanliness was achieved and no debris remained. The IFJ pump speeds and oscillation distances to accommodate the pipe’s
surface was then ready to receive the protective coating. cutback lengths. This, along with its independent heat controls
for the material components, allowed for mixing and application
Coating the IFJ conditions as recommended by the coating manufacturer.
CRTS’ coaters are the heart of internal corrosion prevention and The liquid coater was also outfitted with wireless telemetry
one of the most complex machines that CRTS designs and builds. and video to allow remote operations. These features enabled
Years of design and testing have culminated in machinery that the operator to remotely send the liquid coater to each IFJ for
uses various coating heads to precisely apply both FBE and liquid coating. The camera lets the operator view the weld to ensure
coatings on offshore and onshore projects. For this project, the it’s coatable (no abrasive or welding residue); line up to the
customer chose SP 9888, a two-part liquid epoxy, to protect the weld; trigger and observe the actual coating sequence. Another
nearly 13 000 submerged IFJs. The plural component liquid coater feature of the onboard camera is that it allows for instant visual
inspection of the IFJ. Inspecting
the coated IFJ at this stage meant
that if a coated weld had any
visual defects, it could be repaired
before any product entered the
pipe. CRTS also has a fusion-bond
epoxy coater for FBE projects.
Conclusion
CRTS applies its robotic
technology to address the high
cost of monitoring, repairing and
rehabilitating pipelines by using
a simple process of cleaning,
coating and inspecting internal
field joints and, if requested, the
internal length of the pipeline. This
foundation of internal corrosion
prevention attempts to benefit
the pipe owner, the public and
the environment by addressing
corrosion before it has a chance to
form and wreak havoc on assets.
This seamless corrosion
prevention system works
alongside factory-coated pipe to
meet PHMSA’s goal of reducing
“the occurrence of defects that
can lead to corrosion-induced
failures.”1 While this PHMSA
report focuses mainly on US
transportation pipelines, it is a goal
worthy of any pipeline project.
Part of the reduction goal
on CRTS’ part is designing and
building equipment that works
efficiently with the project’s
geographical and other challenges.
For this particular customer, the
additional preventive measures
will result in lowered OPEX and
repairs over a lengthy lifetime of
production.
Reference
1. Fact Sheet: Internal Corrosion. Retrieved
from: http://primis.phmsa.dot.gov/
comm/FactSheets/FSInternalCorrosion.
C
omposite materials are chosen over traditional materials for a
number of reasons in industrial and manufacturing industries.
Composites are a combination of two materials that are very
different in chemical or physical makeup. Within the past several
decades, composites have become very popular in the industry of high
pressure pipeline and process piping repair industries. Composite technology
Garrett Brustkern, saves time and money in areas other than material cost. They allow a pipe
to be repaired non-intrusively, eliminating the
Clock Spring, USA, need to remove the line from service in
compares the attributes order to cut and replace, or reduce
of wet cloth and stiff the pressure while performing
a repair with the
cloth composites.
145
line in operation. There is no heavy equipment required specifically the ‘stiff uniaxial’ composite. Stiffness, or, the
or expensive skilled labour costs. Some composite repair modulus of elasticity, is represented in the figure as the
systems will achieve full cure in two hours then be ready slope of each line. The slope can be considered stiffness
for re-coat then backfill. However, not all composites are because it displays how much each material will strain for
created equally. There are attributes of each system that a given amount of stress.
affect its installation, performance, and durability.
There is, however, one commonality that every Different composites architectures
composite system shares, and that is the method in which A point of distinction needs to be made between the
they repair anomalies in pipe wall. The concept is similar different composites architectures. All composites are
to that of a steel sleeve, a high modulus filler material composed of a strength member and a bonding matrix. For
is used to transfer the stress experienced in a defect in high pressure pipeline applications, the strength member
the pipe to the encompassing sleeve/wrap. This filler is typically ‘E-glass’ or electrical grade glass fibres.
material, held in place by the outer sleeve, prevents the E-glass was selected for most rigid composite sleeves
damaged area from bulging and subsequently fracturing. because of its high strength (tensile strength of 500 ksi),
In a situation where a pipe is subjected to a high electrical properties, availability, and compatibility
enough stress, the steel enters what is called a plastic with the selected resin (matrix). An isophtalic polyester
region, in which the steel will experience a large strain resin is sometimes chosen as the matrix due to its low
in relation to the amount of additional stress (this is moisture absorption, excellent resistance to chemicals,
represented by the nearly horizontal section of steel line and good thermal properties. To create this stiff uniaxial
in Figure 1). It is in this region that the composite takes composite, 600 000 strands of the E-glass are combined
up the load felt by the steel and begins to assume any with the liquid isophthalic polyester resin, wound around
added stress, preventing the steel from fracturing. Due to a cylindrical mandrel then allowed to air cure. Hardening
the inherent nature of most composite systems designed in this orientation allows the composite to retain a
for high pressure pipeline repair, they are less stiff than cylindrical shape memory, and in turn it will conform
steel, and that is why they do not perform until the steel snugly to the pipe without introducing any kinks or stress
begins to deform plastically. This can be seen in Figure 1, concentrations in the composite’s strength members
(fibres). This specific architecture is deemed ‘uniaxial’
because all of the fibres are oriented in one direction, the
‘hoop’ direction. The fibres are continuous strands around
the entire cylindrical sleeve, which is eight revolutions
or ‘layers’ around the pipe. Figure 2 shows the essential
pieces of a rigid composite repair: the composite sleeve,
the adhesive between each layer2 and on the pipe, and
the high stiffness filler material.3
The ‘stiff cloth’ architecture is similar to the previous
example in that the glass fibres are combined with a liquid
resin, wound on a cylindrical mandrel, and then allowed
to air cure. The difference being the strength member is a
Figure 1. Graph showing steel subjected to stress.
Figure 3. Tensile strength and modules of elasticity were

Figure 2. Rigid composite repair. analysed.

woven fibreglass cloth where fibres are oriented in both The manufactured state of ‘wet cloth’ composites is
the ‘hoop’ and ‘axial’ directions. entirely in the hands of the installer, in contrast to stiff
This difference in fibre architecture results in composites that can be manufactured to a controlled,
drastically different mechanical properties. The two designed state. Therefore, in a wet lay composite it is
composites have comparable tensile strengths, but as difficult to control the ratio of resin to glass, the degree
can be seen in Figure 1, the woven cloth has a much of resin saturation, the alignment of the glass, and
lower modulus of elasticity. This modulus is the physical consistency of tension in the repair.
stiffness of the material. The minimum required modulus Similar to the stiff cloth, wet applied cloth is also
for an effective long term repair is 5 x 106 psi, and as not stiff enough to safely control bulging in a steel pipe.
illustrated above, the stiff uniaxial composite has a Woven or knitted cloth composites are not stiff enough
modulus of approximately 6.3 x
106 psi whereas the stiff cloth’s
modulus is only 3.5 x 106.
Wet cloth vs stiff cloth

There are many advantages to
these pre-cured composites,
but most important is the fact
that they can be manufactured
in a controlled environment,
and then shipped to the jobsite
where they are secured to
the pipe with a high strength
adhesive. Manufacturing in a
controlled environment with
strict QA/QC procedures
ensures that every repair sleeve
is made to certain design
specifications (such as glass to
resin ratio) that are required to
result in a long lasting, durable
product. The difference with a
wet cloth composite is that it
is manufactured on the pipe,
where many environmental
factors could potentially
sabotage the composite
material structure. Wet cloth
composites are made in the
field by combining a woven or
No permits No trenching
knitted fibreglass cloth with a
liquid epoxy. This wetted cloth
is then wrapped around the
pipe, and cures in this position.
During the cure stage of the No conduits No programming
composite, environmental
WIRELESS I/O
factors inadvertently can
enter the epoxy resin, such
as moisture, dust, and other
flying debris. Contaminates to
the composite structure can Bi-Directional Point-to-Point Deploys Quickly
allow moisture absorption and
are detrimental to durability.
Additionally, the uniformity of For more information,
the composite’s thickness will visit psft.com/A65
depend entirely on the quality
of application by the installer.
Where Automation Connects
+1-661-716-5100
A S I A PA C I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L AT I N A M E R I C A | N O R T H A M E R I C A
due to the room for mobility that the fibres inadvertently pipeline operator. Apparent tensile strength and modulus
have in such an architecture. of elasticity were the two main mechanical properties
Stiff uniaxial composites are stiffer than cloths analysed. The wet wrap showed an average tensile
because the fibres are pre-tensioned as they are wound strength of 28.38 ksi and an average modulus of 1.34 x
around a cylindrical mandrel, meaning that there is no 10 6 psi. Stiff sleeves showed an average tensile strength
room for the fibres to stretch. of 34.6 ksi and an average modulus of 4.47 x 106 psi.
Note the much lower modulus for the wet wrap. It
Independent test measures should also be noted that these values are a bit lower
Independent testing of the two major types of than those previously mentioned due to the nature of
composites (stiff and wet) was completed by a major the independent testing. Another important result of
the testing showed that after
exposure to water, the wet-
lay demonstrated a significant
reduction in strength whereas
the stiff sleeve was unaffected.
This finding is most likely due
to woven cloth’s ability to
allow moisture to wick into the
composite.
Summary
If the operating pressure of a
given pipe is low enough, there
are advantages of the wet cloth
over stiff composites. The main
advantage of a wet-lay is that
they can be wrapped around
geometries other than straight
sections of pipe, such as bends,
tees, and nozzles. They are
also not restricted to a certain
diameter of pipe, whereas the
stiff composites are prefabricated
to fit a specific size. Wet lays
can be incredibly effective
for corrosion mitigation, rock
shielding, and abrasion resistance.
They provide many advantages
when used as a coating. However,
they must be carefully examined
when used as a repair on high
pressure pipelines.
References
1. GRI –95/0072 “Engineering Properties
of Clock Spring® For Repair of Defects
in Transmission Pipelines”, Northwestern
University/ Nicor Technologies.
2. GRI-98/0032 “Field Validation of
Composite Repair of Gas Transmission
Pipelines”-Final Report-Gas Technology
Institute, 1700 South Mount Prospect
Road, DesPlaines, IL 60018-1804.
3. Internal Clock Spring Report, Bell
Evaluation Laboratories, Houston, Texas
4. MATEER, M. W., and J. Chang, (January
1 2005), Performance of Pipeline
Composite Repair Sleeves, NACE
International.
5. POWERS, B. D., Composite Repairs- They
are not all the same!, Houston, Texas.
Sipko Dotinga,
A.Hak Drillcon, the
TUNNELLING Netherlands, discusses
UNDER
how technical
challenges were
overcome on one of the
largest microtunnelling
projects in the world.
THE RIVER ELBE

I
n the north of Germany, the existing natural gas pipeline network is being optimised and renewed for securing regional gas
supply, and in future also to Scandinavia. For this reason, Gasunie Deutschland had to close a decisive gap in the system by
crossing the River Elbe, the waterway to the Port of Hamburg, near the village of Hetlingen. Two parallel pipelines of 750 mm
dia. and a length of 1500 m each had to be constructed.
Gasunie has a long standing relation with A.Hak. The Dutch contractor has completed numerous pipeline construction, HDD,
Direct-Pipe and microtunnelling contracts for Gasunie. Gasunie’s appreciation of A.Hak’s spirit of ‘Giving it our all’ and its confidence
in the contractor’s getting-it-done-mentality, finally landed A.Hak Drillcon the main contract for tunnelling the River Elbe.
Figure 1. Start shaft on Hetlingen. 149

After thorough engineering and analysis, it was Steering, surveying and monitoring
concluded that the soil conditions and geological Thanks to laser navigation technology supplied by
features were too challenging for conventionally drilled Herrenknecht’s subsidiary VMT, the jobsite crew managed
crossings. Therefore, a concrete tunnel had to be made to steer the AVND-2400 right along the specified route and
to accommodate these two pipelines. Furthermore, in precisely into the target shaft.
anticipation of an increasing draft of the container vessels The navigation of the TBM was controlled by means of
sailing to Hamburg, the tunnel had to be laid at a significant VMT’s SLS Microtunnelling LT system. This system is based
depth under the surface. With these challenges ahead, on the technology of a ride-on laser, which is a proven and
A.Hak Drillcon took on this task. continuously perfected VMT navigation technology.
Initially the contract was awarded to a consortium of The TBM’s programmable logic controller (PLC) was
contractors, each contributing its specific expertise. However, continuously connected to the control systems on the surface,
after a forced restructuring of the consortium, the entire facilitating an uninterrupted data collection of all available
contract was diverted to A.Hak Drillcon. machine data.
On 4 December 2014, A.Hak Drillcon’s AVN 2400 tunnel In order to use this large inflow of data effectively and
boring making (TBM) concluded the subsurface drilling, when evaluate it, the web-based data management system IRIS
it emerged in the reception shaft on Lühesand Island near the Microtunnel fitted excellently. This system has been developed
South bank of River Elbe. in co-operation between VMT and the ITC Engineering GmbH
In an impressive timespan of less than 4 months, the access & Co KG, and proved very valuable and useful.
to the Port of Hamburg was traversed with a 3 m dia. concrete In this system the accumulating data can be recorded
casing at a depth of 33 m under the surface. and processed in various fields. This project is specifically for
Even before the project started, all parties involved were engineering and navigation data, as well as the connection
aware of the huge technical challenges associated with the to a GeoScanner (acoustic measurement system for the
construction. The diversified ground ranged from sandy gravel determination of particle sizes and distribution of the
soil with stones through layers of boulder clay featuring larger transported material on the conveyor line) as well as the
rocks to layers of clay, which tends to be very sticky. This was realisation of an automatic alarming when limits are exceeded.
exacerbated by high water pressures of up to 4 bar.
Project-specific machine modification for 4 bar
Challenging soil conditions water pressure
Most challenging for the tunnelling works were the varying soil Before the machine was mobilised and launched, special
conditions along the route, with the cutting head negotiating inspections and modifications had to be done. The main
itself through clay, marl, cobbles, boulders and sand as it bearing of the cutting head was inspected by videoscope
propelled its way forward. The tunnelling profile was designed analysis, and found to be in order to complete the drilling
to consistently drill into the most adequate layers, which without further maintenance.
resulted in a number of level and angle adjustments along the Then the machine had to be adapted to withstand the
track. Despite these alternating levels and angles, a profoundly water pressure of approximately 4 bar due to the depth under
analysed buoyancy and bentonite lubrication system kept the the water surface. The main bearing sealing was modified,
pushing forces well within the predetermined limits. and the entrance door to access the cutting head had to be
The machine also encountered large boulders when it had modified to withstand this pressure. All was done thoroughly
reached almost 200 m into the route. But as such geological and no problems of any kind have arisen during the tunnelling
conditions had in fact been anticipated, the jobsite team operations.
swiftly overcame these obstacles thanks to their experience
and thorough preparations. Miner’s patron Saint Barbara celebration
On 22 October 2014, peak ‘depth’ was reached at half the
distance. This milestone occasion after an impressive tunnelling
speed was marked in the miner’s tradition by having the miner’s
patron Saint Barbara celebration on the jobsite.
Bentonite
During the project, professional consultancy was obtained
from the supplier of the bentonite for the most optimal
drilling fluids in the various phases of the project, based on
the available soil investigations. Stability tests were carried out
with the soil samples, at the drilling location.
For the front of the tunnel machine, Cebogel OCMA
was used because of its good carrying capacity, high gel
strength and an excellent filtercake capability. Since drilling
had to be done through different soil layers, of which some
of them had cracks, this product was considered most
Figure 2. Immobilisation of the shield on Lühesand Island.
suitable. Furthermore, Cebogel OCMA is also easy to use in

combination with a recycling machine because it does not integrated gas and fire alarm and provides an access control
have extra additives, which can obstruct the screens. The into the shaft via RFID tags.
drilling fluid was checked continuously during mixing, upon
return to the recycling unit, and then finally when it came Gas pipelines pull-in
out of the recycler. When necessary, the mud-engineer Upon completion of the concrete tunnel, the two 750 mm gas
could instruct to adjust the bentonite content, increase it or pipelines were pulled into the tunnel with assistance of one of
dilute it. A.Hak Drillcon’s HDD rigs. The drill rod was led into the tunnel,
For the lubrication of the tunnel, Tunnel-gel Plus in connected to the pulling head of the pipelines, and supported by
combination with some additives was used. PAC-L has been carriages, the pipelines were pulled into the tunnel towards the
added to give a stronger filtercake in the several formations, HDD rig.
which had to be passed. When the formation became too
coarse, a fibre (IPR-007) in combination with the PAC-L was Grouting after completion
added to the bentonite, which sealed the coarse formation When the pipelines and the HDPE conduits assembly had been
completely. The fibre fixes the coarse formation and creates a pulled into the tunnel, a final inspection took place. Then upon
kind of spider web, reducing the pores). The bentonite and the acceptance of the pull-in operation, the empty space between the
PAC-L can easily attach themselves to the fibre and seal the assembly and the tunnel was filled entirely with grout, rendering
formation. two gas pipelines and the conduits as encased in one solid
During the drilling it was noted that, when adding a concrete underpass under River Elbe.
lubricant (IDP-605) to the bentonite, the friction was reduced
by half. In addition to using the correct type of bentonite, the A high profile project
total fluids system resulted in extremely low pushing forces A high profile project has been completed successfully. This
and drilling speeds of up to 40 m/day. tunnel ranks amongst the largest microtunnelling projects in the
world!
Inter-jack stations: available but not used
Since the geological conditions were expected to be complex,
it was decided to install inter-jack stations at approximately
every 150 m. In case of unexpected circumstances, which could
cause temporary increase in pushing force, then the inter-jack
stations would be available for support. However, none of
the stations has been required for such complementary push
force. Only after a temporary suspension of the pushing during
replacement of the cutting disks the inter-jack stations were
used to assist in the resumption of the pushing.
Underwater cutting disks replacement

At a distance of 178 m from the starting point, it became
clear that the cutting disks needed replacement. As the
disks are placed in front of the machine, whilst the machine
is submerged under the river’s soil, divers had to enter the
machine’s head front door to access the disk slots and replace
the disks.
Stringent safety requirements

The HSE requirements for an accessible subsurface tunnel
of this length were obviously significant and stringent.
Maintenance and inspection crew were entering the tunnel on
a daily basis, up to the machine at the end of the tunnel. For
the purpose of increasing safety, A.Hak Drillcon has used an
entire range of navigation, survey and monitoring technology
from Herrenknecht’s subsidiary VMT. Using IRIS.microtunnel,
a webbased data management and monitoring system, it was,
among other things, possible to permanently monitor all
support pressures while comparing them in parallel with the
fluctuating tides of the Elbe.
The safety concept of the site is realised through the
communication infrastructure HADES: The wireless and fibre-
based system is a supplier of video images and gas detection
values, provides the network connection for the installed
Figure 3. Emerging in the reception shaft on Lühesand Island.
geoscanne, equips the staff on site with mobile phone and

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Figure 1. Pipeline
equipment is operated
in demanding
conditions. Trained and
skilled operators are the
key to project success.
hazards
Operator training programmes are
essential. Jason Holland,
HSE Manager, Continental Pipeline
and Facility Ltd, Canada, presents the
various steps involved in creating an
effective training course.
P
ipeline machines, dozers, excavators, side booms,
‘yellow iron’, are the back bone of our industry.
Without them, we could not complete or even start a
pipeline project. Although incidents involving pipeline
machines are rare, the consequences can be catastrophic.
Pain and suffering for employees and their families, company
loss and damage to reputation are all possible consequences
of machine incidents. We have all heard stories of operators
being killed when their machine over-turned or the pickup
that was destroyed when a piece of equipment backed over
it, but how do we prevent these and similar incidents from
occurring? Operator training programmes and competency
evaluations can be implemented and utilised to reduce the
occurrence of these incidents.
The importance of machine operator training and
competency cannot be overstated. In almost all regulatory
regimes the law requires machine operators to be ‘qualified’
or ‘deemed competent’. But what does this mean? Who is
qualified to deem an operator competent? Well, there is no
silver bullet for this one, but you do have some options.

to pipeline equipment
operation, such as the
American Society of
Mechanical Engineers
Standard ASME B30.14 Side
Boom Tractors. This standard
is full of information on side
boom operations including
qualifications for operators
and inspection requirements.
Client requirements are
also a good source of
information. Many large
pipeline operators have
specific procedures or
standard operating practices
that they expect equipment
operators to know and
follow while working on
their spreads, which will add
value to your training. Most
Figure 2. Ensure the operator sees you before entering the safety zone. health and safety legislation
requires that equipment be
operated in accordance with
manufacturer’s recommendations contained within the
machine’s manual; including the manufacturer’s instructions
in your training programme is a must. Lastly, your
training needs to be include your company’s policies and
expectations on how machine operators use and care for
your equipment. Once you have developed your training
programme you then have a standard to evaluate machine
operators against in order to deem them competent. As
with every training programme, there needs to a practical
component that allows the machine operators to take
the knowledge they gained from classroom education and
apply it in the field in a controlled environment under the
watchful eye of an experienced operator.
Figure 3. Pipeline operations are often within a machine’s Deeming competency

safety zone. The age old question; who is qualified to deem pipeline
equipment operators competent? This is one of those chicken
In-house training programme and the egg scenarios. Remember that someone had to be
An in-house training programme is effective but can also be the examiner for the first drivers test. Safety regulators often
very costly and time consuming. The advantage of creating define a qualified person as someone who is knowledgeable in
your own in-house course is that it will reflect your company’s their area of work, the hazards involved, and the methods to
culture and way of doing business. The key is getting the control those hazards. Once you have developed your training
right people together to build and implement a training programme using regulatory requirements, industry standards,
programme. Building a training course is not something that best practices and machine manufacturer’s instructions for
should be left up to the company’s safety department to the safe use of the equipment, you have pretty much covered
create in isolation; it needs to involve experienced operators, those bases. This is where having experienced operators
equipment managers and mechanics to ensure the programme involved in developing your training really pays off. Having
reflects real world operations. your experienced operators demonstrate the competencies
So, what should be included in your training course? that they helped develop as part of the training programme
Start with the legislated requirements in your jurisdiction allows you to ‘test drive’ your programme to ensure you
or the jurisdictions in which you operate, always default have it right. Then the operators who helped develop the
to the highest standard. By doing so, you are always programme act as your evaluators to assess the rest of your
compliant.Next, look to any consensus standards relating machine operators.

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Third party training providers Machine safety zones
There are several companies that specialise in pipeline A way to protect workers from injury while working with pipeline
equipment training and competency evaluations. The courses equipment is the use of machine safety zones. A machine safety
they provide can be tailored to your specific equipment zone includes the maximum reach of the machines boom, stick,
and operations. Some even offer computer based training counter weight or other attachment plus a buffer distance for
modules that increases training flexibility. Most third party 360˚ around a machine. Workers are instructed to stay out of
training providers will come to your project and work with the safety zone unless a specific task requires them to be within
your equipment and operators onsite, which for many pipeline the zone. Any worker that is required to enter the safety zone
contractors is a very attractive option. must first make eye contact with the operator. Once the worker
has made eye contact with the operator, they would then signal
the operator that they wish to enter the safety zone. If it is safe
for the worker to enter, the operator would then idle down
the machine, place any applicable attachments on the ground
and then signal the worker that it is ok to enter. If an operator
notices a worker who enters his machine’s safety zone without
first notifying him and receiving permission to enter, the operator
would stop operations and sound the machines horn if equipped,
to provide a friendly reminder to the worker that they have
entered a potential danger area.
Working inside the safety zone

A majority of the pipeline work such as stringing of pipe,
excavating of existing pipelines, stabbing and spacing of pipe
for welding, requires workers to be within close proximity of
working machinery and often well inside the machine’s safety
zone. In these scenarios, a specific job safety analysis (JSA) or
safe work practice (SWP) relating to the work needs to be in
place and reviewed with all workers involved with the specific
task. The JSA or SWP should detail at a minimum the number
of workers involved, the communication methods to be used
and personal protective equipment required. The review of
the JSA or SWP should be completed during the first tailgate/
safety meeting before starting the particular task or job. To
avoid confusion about who is giving signal to the operator,
one person should always be designated as the spotter or
signal person for the equipment operator. Working near
above-ground piping, power lines and other equipment also
requires a person to be assigned to work with the machine
Figure 4. Clear communication between operator and spotter is operator as a spotter. The purpose of the spotter is to alert
paramount.
Figure 5. Steep terrain requires ROPS equipment and good Figure 6. FOPS protects operators when moving materials.
training. Handrails provide fall protection during servicing.

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Unmatched Performance and Proven Results

the operator when they are approaching any other equipment safety of pipeline equipment operations. Excavators and
or facilities and to signal the operator either by hand signals other equipment can now be fitted with warning devices
or sounding a warning horn to prevent unintended contact that detect high voltage power lines and provide both an
occurring. The spotter will also assist the operator in audio and visual warning signal to the operator when a
monitoring the machines safety zone and warn others if they machine encroaches on the limits of approach for a high
get too close. Clear communication between the operator voltage line. Load monitoring indicators (LMIs) and anti-
and spotter is critical. two-block devices once only available for cranes are now
available for side booms tractors. These units provide
Engineering controls boom operators with information on hook weight, boom
We all know that engineering controls are most effective overhang, machine slope, and machine capacity under its
when it comes to keeping workers safe when operating current configuration. They also provide an audio warning
pipeline machinery. With today’s technology there are alarm to the boom operator when the machine is at or near
a number of options that can improve and enhance the its maximum capacity which will prevent equipment damage
and boom tip over incidents. The
anti-two-block device also provides
audio and visual alarms to the boom
operator to prevent inadvertent
contact of the hanging blocks
preventing cable and sheave damage
and possible equipment failure that
could endanger pipeline ground
crews. Roll-over protective structures
(ROPS) are available for most sizes and
configurations of side booms now.
ROPS used in conjunction with seat
belts can reduce or even eliminate
serious injuries and operator deaths in
the event of roll overs involving both
crawler tractors and side booms.
Excavators are one of the
most versatile pieces of pipeline
equipment. Fitting an excavator with
a falling objects protective structure
(FOPS) will help protect the operator
from injury by preventing falling or
flying objects from penetrating the
excavator cab. These structures can
also provide additional protection
to the operator in the event of a
tip over as they provide addition
strength to the machine’s cab area.
Falls from pipeline equipment are
a common cause of injury. Ensuring
equipment is fitted with appropriate
MIDSTREAM & UPSTREAM SOLUTIONS handrails, guardrails, steps and foot
holds especially in areas that are
routinely accessed by operators
Pipeline and plant construction is one of STREICHER’s core competencies. As an EPC-con- for service and inspection. This can
tractor for oil and gas pipelines and plants as well as water pipelines and pipelines for
greatly reduce fall from equipment
chemical products, STREICHER carries out all services from planning and construction to
commissioning and maintenance. The business sector “Drilling Technology” manufactures injuries.
drilling rigs for hydrocarbon and geothermal exploration as well as HDD rigs for trench- Working around pipeline machinery
less pipe laying. The sector “Drilling Technology” works closely together with the drilling will always have its hazards. At
contractor DrillTec GUT GmbH Großbohr- und Umwelttechnik, a subsidiary of STREICHER. Continental Pipeline, one of its core
values is to ‘do the right thing’. Ensuring
The STREICHER Group, with approx. 3,500 employees worldwide, undertakes large-scale that every reasonable precaution to
projects in different sectors, such as Pipelines & Plants, Mechanical Engineering, Civil & protect operators and ground crews
Structural Engineering and Construction Material. when working with pipeline machinery
is always the right thing to do.
MAX STREICHER GmbH & Co. KG aA · Schwaigerbreite 17 · 94469 Deggendorf · Germany
T +49 (0) 991 330-231 · E info@streicher.de · www streicher.de
Drilltec GUT GmbH Großbohr- und Umwelttechnik
Josef-Wallner-Str. 10 · 94469 Deggendorf · Germany
T +49 (0) 991 37212 - 400· E info@drilltec.de · www drilltec.de
World-Pipelines-Magazine_IPLOCA-Issue_2015.indd 1 16.06.2015 10:28:05

Staying safe
ON SLOPES
Peter Kinsey, Pipeline Construction HAZID
specialist, considers the safe operation of heavy
equipment on steep slopes.
M
any pipeline construction projects
in mountainous terrain experience
spectacular accidents involving
equipment loss of stability and
rollovers, due to unrecognised and uncontrolled
stability issues, while heavy equipment is working
on steep slopes.
Pipeliners are frequently required to operate
heavy equipment on extreme slopes, where
worksite risks, compared to flat terrain, increase
exponentially. Safe lifting, transporting heavy
Figure 1. Pipeline
construction in
mountainous terrain.
loads, and parking heavy equipment on a steep slope isolated slopes requires adherence to a safe work
requires detailed planning and is work for competent procedure which, in its preparation, has considered the
and experienced supervisors and operators who possess hazards and details a system of controls to mitigate the
a specific knowledge and skill set, as described in this risks in the absence of supervisory control.
article. In mountainous terrain, each slope should be measured
The worksites and access roads on slopes are distant separately to identify how steep it is. Slopes are measured
from management offices and supervision and usually in two ways, not to be interchanged: degrees of slope (as
vehicle drivers and heavy equipment operators find an angle of inclination to the horizontal), or percentage
themselves facing steep slopes alone. Identifying and of grade, (which is in terms of length of rise or drop, per
managing the risk of ascending or descending these length of horizontal distance).
Once the slopes are measured, a safe work procedure
will require the classification of the different degrees
of slope from zero to extreme. A simple system, which
works well, is to colour code the different classifications
of slopes on a project road access and ROW map. Onsite,
colour coded physical markers are erected at the top and
bottom of the slopes:
)) 0 - 7° normal slope – classified green.
)) 7 - 15° medium slope – classified yellow.
)) Above 15 - 25° steep slope – classified blue.
)) Above 25° extreme slope – classified red.
The defining degrees for each classification of

slope varies from project to project, at the discretion,
experience and confidence of the contractor’s
Figure 2. Blocking of tracks with skids when parking on slope.
Figure 4. Retractable device to secure the load close to boom

Figure 3. Strung pipe joints prevented from sliding down slope. when ascending or descending a slope.

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)) Operation of heavy equipment on red and blue slopes
management staff. Each colour defines the management’s
is undertaken under the additional control of a permit
specific instructions to drivers and operators.
to work signed off by the project superintendent,
Maps are distributed to all project drivers. The requiring for example: dead man winch tractors
significance of colour coding on the project map is supporting equipment on winch lines and/or prepared
explained to all drivers and operators at their orientation. horizontal work platforms.
The different colours are associated with mandatory
compliance to specific instructions, such as: Safe operation
)) Access is denied to vehicles at all times on red slopes. Some safe rules of thumb for operation of heavy
equipment on slopes:
)) On yellow slopes, in deteriorating weather conditions, )) Safe operation on steep and extreme slopes may
such as reduced visibility (<20 m, rain, snow, frost or require strict attention to fluid level requirement. The
ice), passage is restricted to off-road authorised and maximum fore and aft slope on which some tractors
project certified trained drivers and permitted only will have acceptable lubrication is 45° slope.
if the slope is padded with gravel and permission
is granted by the driver or operators’ immediate )) Working on softer soil conditions and working on
supervisor. slopes can greatly reduce a side boom’s load capacity.
)) All operation of heavy equipment on yellow, red, )) Those side booms facing the greatest risk on slopes are
and blue slopes is permitted by project authorised, the front-end bending, set-up, prep and test support
competent and experienced operators, only under the tractors carrying single joints, prep machines and test
direct supervision of their foreman. heads.
)) Side booms should be equipped with short reach

booms for work on steep slopes.
)) Reduce the speed of travel on slopes – at higher

speeds, inertia forces tend to make the tractor less
stable.
)) Roughness of terrain or surface – compensation should

be made where the terrain or surface is uneven.
)) Nature of surface – disturbed or backfilled soil may

give way with the weight of the tractor. Rocky surfaces
may promote side slipping of tractor.
)) Parking equipment on hills – set parking brake lever;

turn sideways to slope; dozers drop blade, dig in corner
bit, side booms park with counterweights up-slope.
Figure 5. Water filled pipe joint serving as an anchor for winch )) When there is 5 in. or more of frost in the ground, a
tractor or pipe section on an extreme slope. tractor may lose traction and slide off the ROW out
of control. The grouser shoes will require corking –
application of ice lugs.
)) Track slippage due to excessive loads may cause the

downhill track to ‘dig in’, increasing angle of tractor.
)) Implements hitched to the drawbar decreases weight

on the uphill track.
)) Height of hitch on tractor – when a high draw bar is

used the tractor is less stable than with a standard
drawbar.
)) Side booms working as single units on side hills should

be operated with counterweights up hill to maintain
stability, which keeps the centre of gravity (C of G)
plumb line falling inside the tracks.
)) As the boom overhang increases, the tractor becomes

Figure 6. Pipe section secured on steep slope.
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the slope and soil conditions more unstable, in which
case winching and anchoring may be required.
)) Pipe sections and/or dead man winch tractor may need

to be secured with an anchor such as a water filled,
buried pipe joint, a D8/10, Excavator or 594 side boom.
A dead man tractor should be of sufficient size and
equipped with an adequate winch assembly to hold and
support the side boom tractor working on the slope, in
the event that the side boom being supported loses all
power. The dead man winch tractor should be secured
whenever possible to a fixed object further up the
slope for additional safety.
)) Single strung pipe joints may need to be prevented

from sliding down slope.
Figure 7. Consequences of not winterizing your equipment in
sub-zero weather. Boom operators
When operating side booms on slopes, the stability of
the tractor is the major concern. There is no such thing as
drive by numbers. Operating a side boom on a steep slope
is an acquired skill, a seat of the pants operation. There
is no hard and fast formula for where a load should be
carried – boomed up or out. It has to be boomed out far
enough away from the tractor so as not to tip the machine
fore or aft but not so far as to turn the machine away
from its direction of travel. Evaluating the competency of
side boom operator is essential.
It is vital for the individual operator to have
confidence in his supervisor, who will give him/her
direction, the mechanical serviceability of his machine, and
his own ability. On steep slopes, it is vital to have ample
winching capacity on hand. The need for a winch line
should be assessed early and attached well before there is
no other option. The hard-bar harness is the best selection
Figure 8. The hard-bar harness provides best tractor stability. for securing the side boom to the winch line hook.
The wrong attachment point on the tractor can upset
the balance of the tractor under load. Winch tractor
)) When the side boom climbs a slope, an unsecured load operators must be unquestionably competent. Descending
may hang far enough back to cause an upward and downhill, operators must select a gear that will prevent
rearward shift of the C of G, which can fall dangerously excessive speed and be trained and competent in cross
close to the tipping point. Securing the load to the steering in the event of unexpected loss of traction on the
boom maintains the C of G within the base of the
slope which can occur unexpectedly with minimal rain and
tractor and within acceptable limits.
the right soil conditions.
)) Stalling or inadvertent shutting off of the engine may Boom operators packing prep machines must be
result in loss of control and runaway of an older model cautious when climbing or descending steep hills – weight
tractor with hydraulically assisted, mechanical-linkage of end prep machine hanging off at an angle to the boom
brakes. Have the breaks adjusted to manufacturer can pull a side boom tractor over.
specifications before deployment to slope work areas. Parking equipment on hills – set parking brake lever;
turn sideways to slope; dozers drop blade, dig in corner
)) Breaking over the crest of a hill too quickly, where bit.
the distance the boom head travels is greater than the If you leave equipment unattended always push the
distance the tractor travels, causes the load to swing
safety lever down, which locks the transmission on the
forward since the boom head speed is momentarily
transmission shifter tower.
greater than the ground speed of the tractor. This rapid
When operating on steep slopes, boom operators must
shift in load may cause the tractor to tip over.
not leave their equipment unattended. Boom operators
)) When equipment is not in use/standby position during must stay on their equipment at all times.
construction on a 15 - 17˚ slope, it will have its tracks
blocked with wooden skids, earth berms or other
Notes
method, unless soil conditions or the weather make http://www.pipe-line-safety.com

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• Regional Q&A on
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W
hether constructing a new pipeline for oil, gas or water use, revalidating or up-rating existing
pipelines, the only viable, practical method of ensuring the pipeline is free of defects is to carry
out a hydrostatic pressure test.
During the pipeline planning and design stage the requirements and effects of hydrotesting
should be a major consideration – it is impractical to design and construct a large diameter cross-country
pipeline where there is no water source to supply the hydrotest medium. Similarly, process pipework that
cannot be drained of water will present significant drying problems during pre-commissioning.
In preparation for pre-commissioning operations, a hydrotest plan should be developed to assess and
confirm the number and lengths of test sections based on topography practical location for test section
tie-in points, available water extraction and disposal locations and access to the spread for the installation of
equipment.
Elevations, static heads and test pressures for individual sections must be assessed to ensure that sections
are not under or over tested for the pipe material, in compliance with the appropriate specification.
Roles, responsibilities and competencies must be defined, contact details and
emergency procedure documents listed. The requirement for statutory notification
to the local authorities and landowners of the intention to test must be identified for
each section and a programme of works developed.
The line to
COMPLETION Mark Lacey, Operations
Director, HTC Ltd, UK, gives an
overview of the essential activities
required when pre-commisioning
cross-country pipelines.
168
The UK Environment Agency (SEPA Scotland) requires )) Flooding – filling the section with water in preparation for
abstraction and disposal licences for volumes exceeding hydrotest.
100 m3/d. Intention to abstract water will require notification
to the public through the media up to six months prior to )) Hydrotesting – to prove the structural integrity of the
pipeline section.
abstraction. Detail is required by the EA of water volumes,
flowrates, method of measurement, locations for and )) Dewatering – post hydrotest removal of water.
total quantities for abstraction and return. Restrictions
on abstraction due to low river flows can have adverse Cleaning
consequences to a project if pre-commissioning is delayed. Swabbing is the first pigging operation to be undertaken on a
It is therefore important to assess early the requirements for newly constructed pipeline section to remove construction
hydrotesting and impact to the construction programme. debris and prove the ‘piggability’ of the section. The initial
From the hydrotest plan, equipment required to undertake swab run should always be carried out using a hi-seal
the works can be sourced. Supply pumps, water storage bi-directional pig. The pig, driven by compressed air, is
capacity, flooding pumps, number of compressors etc, with efficient at debris and water removal and a single run is usually
the required operating parameters will all be identified from sufficient for cleaning purposes at this stage.
the plan. Any block valves should be excluded from the section
Operations for each individual test section will generally to avoid pushing debris into valve seats. Should the pig
consist of the following: become stuck (usually on smaller diameter pipelines, caused
)) Cleaning or swabbing – to remove construction debris and by skids, wedges, etc. on bends) it can be returned to its
prove piggability. launch point by reversing the injection point of compressed
air. The pig may then be retrieved, fitted with a transmitter
)) Gauging – to prove the internal bore of the pipeline is free and re-launched, tracking its location at way points until the
from dents and buckles. obstruction is again reached. Prior to re-launching, water
should be injected in front of the pig in an attempt to loosen
the obstruction. Should the pig still become stuck, its location
can be identified, the pipe excavated and chopped, and the
obstruction removed. The section will then be tied-in and the
swab run repeated until successfully received.
The initial swab run is usually successful, providing care
has been taken to provide night-caps during construction.
After successful swabbing, the gauge run can then be
undertaken.
Gauging
The section is ‘gauged’ to ensure the internal bore is free from
dents and buckles. The standard gauging pig is a two-cup
pig fitted with a gauge plate to the front of the rear sealing
rubber. For pipe diameters >900 NB a hi-seal bi-directional pig
should be used as the two-cup type pig rubbers will struggle
Figure 1. Two-cup gauging pig.
Figure 2. Hi-seal 2 x 4 bi-directional pig. Figure 3. Damage to aluminium gauge plate.

to maintain the plate centrally in the pipeline due to the In order to discover the location of any dent the gauge
weight of the pig. pig is re-run, this time fitted with a steel plate and transmitter.
The gauge plate diameter is sized to 95% of the minimum The pig is tracked until the defect is reached and the pig
internal bore of the pipeline or fittings, subject to a minimum stopped by the steel plate. The pipe is then excavated, pig
clearance of 25 mm on diameter (dependant on specification and dent removed and a new section of pipe inserted. The
used). cause of the dent must also be determined and removed. The
Should a pipeline section contain a dent or buckle the gauge run is then repeated end-to-end until a satisfactory
passage of the pig may not necessarily be impeded but ‘clean’ plate is received.
damage to the plate will be apparent on retrieval (Figure 3).
Filling
The pipeline section must be completely filled with water
prior to hydrotest. Care must be taken in assessing the profile
of the section and sufficient back-pressure inserted in front of
the pigs prior to launch to prevent the pigs ‘running away’ on
downhill sections due to the weight of water behind.
Lack of back-pressure has led to sections becoming air-
locked, necessitating the use of high pressure compressors to
overcome the combined effects of multiple static heads in
order to retrieve the pig and empty the pipeline.
Fill pumps should have sufficient capacity for the flowrate
required and adequate head to efficiently fill an individual
test section and overcome static head produced by multiple
sections requiring transfer filling from a single source.
Two pigs, separated by a slug of water, are normally
sufficient to fill a section for hydrotest. In the event that water
supply is restricted (it has been known to take nine days to fill
10 km 900 NB pipeline) additional pigs and extra back-pressure
should be considered to satisfactorily fill the section.
Water is pumped from its source to a break tank to
allow any air entrained in the water to dissipate before being
pumped into the pipeline. The water should be filtered and
metered. Samples for testing should be taken as evidence to
the quality of the water.
When transfer filling across multiple sections steel pipe
must be used between sections. Short flexible hose should
only be used as kicker lines to launch pigs from test ends.
Flowrates must be monitored and recorded as evidence
Figure 4. Discharge of water slug – note the steel transfer pipe that the abstraction licence conditions have not been
and kicker hose between test sections. breached. Pressures at both ends of the pipeline must be
monitored and logged.
Filling rates will vary, dependent on the size of the source.
In the UK abstraction is usually limited to a maximum of
50 l/sec. (180 m3/hr). The nominal fill rate for a test section is
1 km/hr in order to achieve a satisfactory fill.
Upon receipt of the filling pigs the water slug between
them is discharged, usually to the excavation or to settlement
lagoons.
Hydrostatic testing
Training and a demonstration of competencies is of major
importance to clients. As well as undergoing in-house and
on-the-job training, employees are required to complete
several different levels of externally recognised training
courses before being permitted to work onsite. The
competence of an individual must be recorded, a CV
maintained and approval sought at high level within the gas
Figure 5. Hydrotest and tie-in point between test sections.
industry to gain access to and work on certain sites.

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Each individual section hydrotest should be risk assessed for type of protection over test end or permanent pipe
and the operation controlled by a method statement. As fittings.
stated previously, safety of personnel, other contractors Equipment used for hydrotesting should be sufficiently
and the public is of paramount importance when carrying rated for its safe operation with a built-in safety factor over
out a pressure test. that of the test pressure.
The main hazard associated with pressure testing is Equipment must be maintained good condition.
the unintentional release of stored energy. The risk of this hydraulic hoses must have a suitable working pressure
happening is engineered out to a certain extent by the use above that of the test pressure applied and must be
of sufficiently rated pipe material of the correct grade and inspected immediately before use as well as undergoing
material quality. The other obvious method of ensuring visual internal and external inspection and pressure testing
safety is to remove the risk to personnel. This is achieved to 1.5 times its working pressure, every six months. Hoses
by excluding access along the pipeline spread to farmers, visibly damaged, exposing the steel braid, should be
construction workers, walkers, etc for the duration of the discarded.
hydrotest and maintaining a safe distance for hydrotest For large volume test sections where high volume/high
personnel. Where the pipeline section terminates at pressure pumps are needed to pressurise to test pressure,
installations the protection of any live gas plant within the steel pipe should be used between the pump and test end.
vicinity of the pipe under test must be addressed. Blast Short flexible hydraulic hose should connect either end
effects and distance of projectile travel can be estimated of the pipe to remove vibration from the pump and avoid
(UK HSE GS4 Safety in Pressure Testing) to assess the need fracturing the pressurising pipework. All hoses should be
anchored at intervals along their length to avoid whip in the
event of hose failure.
Provided the controls assessed as required by the
risk assessment are in place hydrotesting should be an
uneventful operation.
The pressurising pump output, section volume, ∆V/∆P
(incremental change in volume/pressure), static head and
test pressure are calculated for each test section. For
pipelines designed to operate at a design factor of <0.3 the
test pressure is 1.5 x MAOP, with the pressure applied to
the highest point of the section. For pipelines designed to
operate at a design factor of >0.3 the test pressure is 105%
SMYS for the weakest (light wall) pipe section, with the
pressure applied to the lowest point of the test section.
Pressurisation is undertaken in stages. The air content
of the test section is assessed when pressurising from static
head to 50% design pressure. The air content of the test
section should not exceed 0.2% of the fill volume.
Figure 6. Pipeline tie-in to HDD section. If the air content is acceptable pressurisation may
continue to the test pressure. A ∆V/∆P plot must be
maintained. Should the rate of pressurisation deviate
by +/-10% from that expected the cause should be
investigated.
Care should be taken when approaching test pressure to
closely monitor the ∆V/∆P plot for signs of double-stroking
(twice the calculated ∆V/∆P) and pipe yield.
Once test pressure is achieved, readings of pressure,
pipe wall and ground temperature are taken at regular
intervals for the test duration. The criteria for test
acceptance is that there should be no observed pressure
variation, other than that accounted for by changes in
ground and pipe wall temperature. When testing to yield,
the allowable loss should not exceed 0.2 bar G over the last
three hours of the test.
Dewatering
Dewatering can be a hazardous operation due to air/
Figure 7. HDD pre-test string
water mixture if operations are uncontrolled. High pressure

compressed air may be necessary to overcome static
heads and propel the dewatering pigs.
The filling pigs are propelled back to their original
position and water is discharged usually back to source.
Dewatering lines should be as short as possible and
connected to an open-topped break tank. Water may
then be pumped back to source in a controlled manner.
The static head of the section must be maintained
during dewatering. This will reduce as dewatering
progresses (unless dewatering up hill) and back-pressure
is reduced as the operation progresses until the line is
dewatered.
Operations to completion
Once individual sections are dewatered they are tied-in,
joints coated and back-filled and the completed pipeline
shall is then pigged end to end as follows:
)) Final swab – further removal of debris from tie-in
activities.
)) Final gauging – to prove the internal bore of the

pipeline is free from dents and buckles following
tie-in and final backfill.
)) Magnetic pigging – to remove grinding fines post

tie-in.
)) Geometric survey – to produce a record of the

internal bore of the pipeline (may be excluded, if
final gauging is accepted as a geometric survey).
Drying
The final pigging operations should be undertaken
using desiccant dry air to reduce final drying times.
Compressed air is passed through desiccant air dryers to
produce a dew point typically better than -40˚C DP.
Drying is undertaken to prevent corrosion, prevent
contamination of the gas and reduce hydrate formation.
The use of hi-seal bi-directional pigs (combined
with soft foam swab pigs for diameters <450 mm dia.),
propelled by super dry air is continued until a dry, dusty
pig is received. Final drying is achieved by blowing
through the pipeline until a plateau is achieved and the
dewpoint of air exhausted is approximate to that being
injected.
The pipeline is then left to ‘soak’ for a minimum
period of 12 hours and final dew points are to be taken.
The acceptance criteria is that the final dewpoint that
is taken should be better than -20˚C DP and there is no
significant decay from the initial readings taken.
Other activities required when pre-commissioning
cross-country pipelines to completion:
)) Pre-testing of HDD pipe and pipe used for final
tie-ins.
)) Testing and drying of installations (AGIs).
)) Testing of fabrications and spools.

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Challenger 175 28
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Corinth Pipeworks SA 61
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ILF 47 Universal Pegasus International 143
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WorldPipelines August 2015

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WORLD PIPELINES

Volume 15 Number 8 - August 2015

03. Editor's comment AUTOMATION & CONTROL

168. The line to completion

Mark Lacey, Operations Director, HTC Ltd, UK.

The smarter choice for

Volume 15 Number 8 - August 2015

ON THIS MONTH'S COVER Reader enquiries [www.energyglobal.com]

Worldwide Machinery Pipeline Division provided SUPERIOR SPD-350 padding machines

Member of ABC Audit Bureau of Circulations

the articles or the advertisements. Printed in the UK.

M583CH on CAT D8R LGP

We carry weight in the industry

Sidebooms.com I MidwesternPipeline.com I 011-918-858-4234

Our smallest machine is a big deal

IP pipe receives boost as sanctions Turkish Stream update

AUGUST 2015 / World Pipelines 5

Tennessee pipeline downsized NWT proposes ‘Arctic

6 World Pipelines / AUGUST 2015

our own. Two of the world’s largest pipe coating providers,

To see how Shawcor’s field joint and mainline coating systems

PGNiG’s play for Yamal Nexen leak investigated

8 World Pipelines / AUGUST 2015 To read more about the articles go to

WE PUT INNOVATIVE TECHNOLOGIES TO

10 World Pipelines / AUGUST 2015

T.D. WILLIAMSON / MCG PRODUCTIONS PRESENT“OPERATION OFFSHORE”

© Copyright 2015 T.D. Williamson, Inc

14 World Pipelines / AUGUST 2015

Nature is our greatest asset. It needs to be preserved and

NDT Global provides pipeline inspections with a top first run

16 World Pipelines / AUGUST 2015

Offshore Onshore Spoolbase Custom Coating

Field Joint Pipeline Induction Heat (PIH) provide specialist field

Custom Coating of a wide range of field joint coating materials.

PIH also provide Custom Coating services for the

Services application of the latest Thermal Insulation solutions

Pipeline Induction Heat Ltd, Burnley, UK

How is Nord Stream approaching integrity

Figure 1. Statoil administered PRS

20 World Pipelines / AUGUST 2015

Now that Nord Stream has

22 World Pipelines / AUGUST 2015

For 60 years, Gulf has been the

Are You Up to the Challenge?

*As ranked by ENR in the 2014 issue

Figure 1. An overview of gas

26 World Pipelines / AUGUST 2015

AUGUST 2015 / World Pipelines 27

Making the world a cleaner place...

Figure 1. Value compass.

30 World Pipelines / AUGUST 2015

Coating System 2010 2014

“the tape that’s not a tape“

Innovation based. Employee owned. Expect more.

32 World Pipelines / AUGUST 2015

The smarter choice for

KDS uses the Magnatech Pipeliner

Pre-heating the pipe in

F 36 in. x 27 km Trinidad-Cactus gas

F Engineering, procurement and

F Arendal actively participates in investment

RESEARCH & F Arendal have been engaged in the construction

F Arendal is one of the main mexican IPC

HDD for the Trinidad-Cactus Gas Pipeline, 2014. COMPRESSOR