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ISSUE 003
MARCH 2010
Sakhalin
Offshore Trenchless Technology Middle East
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CONTENTS
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REGULARS
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teChniCal
ISSUE 003 | MARCH 2010

United KingdoM (Editorial and Technical) PO Box 21 Beaconseld, Bucks HP9 1NS United Kingdom Tel: +44 1494 675139 Fax: +44 1494 670155 United States (Sales) 11111 Katy Freeway, Suite 910 Houston, Texas 77079 United States of America Tel: +1 713 973 5773 Fax: +1 713 973 5777 Australia (Sales and Subscriptions) GPO Box 4967 Melbourne, Victoria 3001 Australia Tel: +61 3 9248 5100 Fax: +61 3 9602 2708
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From the Editor Pipes & People Advertisers Index
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historY
In-line with the latest inspection issues Pipelayer safety made simple CEPA: addressing Canadas pipeline issues European oil pipeline integrity: third-party up, corrosion down Transport of CO2 for carbon capture and storage Unied approach increases level of submarine pipeline integrity PLUTO Pipeline Vision in green: carbon budgeting on the South Wales Gas Pipeline PPIM puts pigs on show in Texas PPIM heads to Asia! Industry gears up for IPCE Events list BJ Services announces Gemini tool Telvent assists regulatory compliance in Canada Smartpipe launches ProSCAN laser prole scanner GL Noble goes with the ow
industrY news Meet the assoCiation
Subscription form Coming in future issues
AROUND THE WORLD
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saFetY
Petrobras tunnels its way to Brazils largest gas pipeline Ruby Pipeline has green credentials APLNG pipeline contract awarded Durban Gauteng to secure South Africas energy future Croatia modernises its gas transmission system Shaybah Abqaiq Pipeline nears completion World Wrap Project briefs Pipeline projects in the Middle East Heating up in India: the Mangala to Salaya oil pipeline Constructing Sakhalin Islands pipeline network Delving to the bottom of the Mediterranean: Galsi Pipeline Subsea pipeline communication challenges Analysing Alberta HDD Crossings on the great pipeline of China Oil Search: achieving safety in PNG
integritY
PoliCY & oPinion
standards
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events
REGION REVIEW: Middle east ProJeCts
environMent
query@pipelinesinternational.com www.pipelinesinternational.com
The publishers welcome editorial contributions from interested parties. However, the publishers do not accept responsibility for the content of these contributions and the views contained therein which will not necessarily be the views of the publishers. The publishers do not accept responsibility for any claims made by advertisers. Unless explicitly stated otherwise in writing, by providing editorial material to Great Southern Press (GSP), including text and images you are providing permission for that material to be subsequently used by GSP, whole or in part, edited or unchanged, alone or in combination with other material in any publication or format in print or online or howsoever distributed, whether produced by GSP and its agents and associates or another party to whom GSP has provided permission.
oFFshore terrain review
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PRODUCTS & SERVICES
trenChless teChnologY
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PIpELINES INTERNATIONAL | MARCH 2010
FROM THE EDITOR
Editor-in-Chief: Associate Editor: Product Manager: Journalists: Sales Manager: Sales Representative: Design Manager: Designers: Publisher:
John Tiratsoo Lyndsie Mewett Scott Pearce Stephanie Clancy Julia Cooke Anne Rees Tim Thompson David Entringer Michelle Bottger Sandra Noke Stephanie Rose Venysia Kurniawan Benjamin Lazaro Chris Bland
ISSUE 003
MARCH 2010
Sakhalin
Offshore Trenchless Technology Middle East
Cover shows workers on the Sakhalin 2 Pipeline Project, located on Russias Sakhalin Island, checking the integrity of an induction-heat applied eld-joint coating.
ISSN: 1837-1167
uring recent factory and site visits Pipelines International has had the opportunity of talking with various key people in the oil and gas pipeline industry about the technology used on pipeline construction and pipeline maintenance. The amount of new high-quality, stateof-the-art technology currently available allows pipeline owners and operators to realise the full potential of modern advances in both materials and technology. With investment in new oil and gas pipeline projects at an all-time high, it is important that the industry takes advantage of the best technology currently available. Research bodies around the world are continuously making breakthroughs with new materials and techniques and, in many cases, it is taking far too long for these to be accepted. An example of a major risk factor that the pipeline industry regularly faces is the use of outdated coating and cathodic protection (CP) systems. Companies invest millions of dollars on new pipeline projects in which the cost of the CP system is less than 0.5 per cent of the total investment, an almost negligible amount. CP is a valuable tool and, if installed correctly, will protect and extend the lifetime of the pipeline, as well as other infrastructures to which it is applied. If we look at who the decision makers are and their involvement in preparing the tender documents for the purchase of a CP system, there appears to be three main levels, with two different objectives. A companys Board is looking for a good reliable product, while relying on its CP engineers advice; the companys CP engineer wants the best product available, irrespective of price; nally, the nance department looks at obtaining the cheapest option, and is willing to compromise on quality. The result is that, in many cases, the lowest tender is taken, irrespective of effectiveness and reliability. The difference in the quality of CP equipment is perfectly apparent, and the results can be seen on many projects. One of the basic elements of a CP system is the anode; despite their importance, anodes are produced to many varying qualities and from various sources around the world. Anodes with very short lifespans (of only three or four years) are being produced in the worlds less-regulated developing markets. At the other end of the scale, companies such as
German Cathodic Protection (which has been producing and installing anodes for over two decades) can quote instances in the North African oil elds and elsewhere where its anodes were installed in the 1980s and are still satisfactorily working today. A recent survey of some of these anodes showed that they had only used 5060 per cent of their potential lifespan, which means that they will probably still be working upwards of 30 years after installation. If one looks at the original cost of these anodes and compares their expected lifetime with cheaper, though shorter-lived units, there should be no discussion as to which sort should be installed. The same comments can be applied to pipeline coatings. While it is accepted that there is always a creative tension between best quality and best price, choosing the cheapest option is often choosing the worst option. In a recent report, the European Pipeline Research Group (EPRG) points out that there are nine generally-used coatings suitable for pipeline protection, ranging from hot-applied bitumen to three-layer polyethylene and three-layer polypropylene. EPRG further lists the ideal properties for a pipeline coating, which include impermeability, resistance to cathodic disbondment, delamination, cracking, and the ability to withstand wet/dry soil cycles and stone penetration. As with CP systems, there are products available to suit all budgets, but only a few will actually meet the long-term needs of the pipeline operator who wants to avoid the costly effects of external corrosion. Among these products is the polyisobutene-based wrapping tape produced by Stopaq of the Netherlands, which the company says meets all of the EPRG criteria, and which is designed to provide a long-term molecular bond to the pipelines external surface. This material is now being widely used in new construction projects by Dutch pipeline operators Gasunie and NAM, as well as in China and elsewhere, and as we will be reporting in the next issue on the Gasunie North-South Pipeline, which is currently under construction.
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May 10-14 May 17-21 May 17-21 Pipeline Defect Origination, Characterization and Sizing (Houston) Deepwater Riser Engineering Course (Houston) Onshore Pipeline Engineering (Houston) Natural Gas Odorization (Houston) May 25-26 June 7-8
Training courses mid 2010
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Introduction to Excavation Inspection & Applied NDE for Pipeline Integrity Assessment (Houston) Defect Assessment in Pipelines (Houston) ILI Data Interpretation (Houston)
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2010
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Working with a faculty of some 38 leading industry experts, Clarion and Tiratsoo Technical are privileged to provide some of the best available industry based technical training courses for those working in the oil and gas pipeline industry, both onshore and oshore.
Complete syllabus and registration details for each course are available at:
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AROUND THE WORLD
Petrobras tunnels its way to Brazils largest gas pipeline

Petrobras has inaugurated Brazils largest capacity pipeline, the 179 km Cabinas Reduc III (Gasduc III) gas pipeline, after tunnelling 3,758 m through Santana Mountain.
ith a transportation capacity of 40 MMcm/d, the 38 inch diameter Gasduc III project is South Americas largest diameter and Brazils largest capacity gas pipeline surpassing the 32 inch diameter Gasbol Pipeline, which runs from Bolivia to Brazil and has a capacity of 30 MMcm/d of gas. The 179 km Gasduc III Pipeline runs through eight municipalities in Rio de Janeiro and construction required 73 water crossings, 56 road, railway and existing pipe crossings, as well as the drilling of two horizontal directional drills.
Engineering challenges
To avoid vegetation suppression in the Atlantic Forest and preserve the habitat of animals under the threat of extinction, Petrobras decided that a tunnel would be constructed under the Santana Mountain in the municipality of Cachoeiras de Macacu in the Sao Joao River Basin. The tunnel measures 3,758 m long, 6.2 m in height and 7.2 m wide. All of the material
removed during the construction of the tunnel was used to reinstate areas that had already been cleared before work had begun. A 25 MMcm/d capacity compressor station was constructed at one end of the pipeline, in the city of Duque de Caxias, while capacity was increased to 40 MMcm/d at the Cabinas Terminal in Macae at the opposite end. In August 2008, Odetech a joint venture of Odebrecht and Techint Engenharia signed a contract with Petrobras subsidiary Transportadora Associada de Gs (TAG), to build and install the trunk line and bre optic system for the pipeline. At the peak of the project, between August and September 2009, there were 2,800 people working on the pipeline.
nations biggest gas consuming region. Gasduc III interconnects Brazils main natural gas processing terminal at Cabinas, to natural gas Hub 2, located in Duque de Caxias. Hub 2 operates as a gas pipeline interconnection point for the Japeri Reduc, Reduc Volta Redonda, and Reduc Belo Horizonte gas pipelines, as well as a gas pipeline to an LNG terminal in Guanabara Bay, allowing greater exibility in the supply of southeastern Brazils gas market.
Connecting Brazil
The Gasduc III Pipeline is an important project for Brazil, designed to boost both supply exibility and transportation capacity of natural gas to meet the increasing demands of the southeastern markets, the
Workers stand next to the large diameter pipe.
The Gasduc III Pipeline.
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AROUND THE WORLD
Ruby Pipeline has green credentials

Only one regulatory hurdle remains before Ruby Pipeline LLC can begin construction on its 1,078 km Ruby Pipeline after Federal Energy Regulatory Commission staff in the United States concluded that adverse environmental affects could be kept to a minimum.
taff from the US Federal Energy Regulatory Commission (FERC) have issued the nal environmental impact statement (EIS) for the project. FERC staff found that although the pipelines construction would have adverse impacts on the environment, most of these would be reduced to less-than-signicant levels with the implementation of Ruby Pipeline LLCs proposed mitigation measures; additional measures and agreements being discussed by Ruby and other agencies related to permitting conservation agreements; and, the additional measures that the FERC recommend in the EIS. According to Ruby, the need for the project arises from a growing demand for natural gas in Nevada and on the West Coast, coupled with a decrease in supply from foreign sources and an increase in supply from the Rocky Mountains. The project is designed to transport up to 1.5 Bcf/d of gas through a 42 inch diameter pipeline beginning at the Opal Hub in Wyoming and terminating at an interconnect, located at Malin, Oregon, near Californias northern border.
Finding the best way through

The proposed Ruby Pipeline route
traverses southwest through Wyoming before entering Utah, passing near the town of Woodruff, and crossing through the Cache National Forest and Wasatch Front at Brigham City. From there, the pipeline will continue north of the Great Salt Lake before entering Nevada, where it will cross the state south of the Humboldt National Forest and north of the Black Rock Wilderness before heading northwest into Oregon near the California/Nevada border. The pipeline will then cross the Fremont National Forest and Bryant Mountain before ending east of Malin. Delivery interconnects are anticipated with the Paiute Pipeline, Tuscarora Gas Pipeline, Gas Transmission Northwest Pipeline and Pacic Gas & Electrics assets, each of which transport gas to local utlilties in Nevada, California and Oregon. Ruby has said that the route was selected based on terrain and constructibility requirements, and follows existing rights-ofway to minimise impacts on environmentally sensitive areas where possible. During the mapping phase, wetlands and culturally important sites were identied. The company has engaged Ecology & Environment Inc to monitor environmentally sensitive areas, and Environmental Planning Group and Pacic
Legacy to monitor culturally sensitive areas during the construction process. Ruby expects FERC approval in April 2010 and construction of the pipeline is scheduled to begin in May or June 2010.
Constructing from east to west

US Pipeline, based in Houston, is to construct the Wyoming portion of the pipeline and a portion of the eastern Utah spread, to Milepost 60; Associated Pipeline Contractors will construct the Cache segment and a portion of the Box Elder spread in Utah from mileposts 60112. US Pipeline will then construct the remaining spread mileage in Utah and extend into Nevada to Milepost 294, north of Elko. Precision has been contracted for the portion of the pipeline that begins at Milepost 294, and extends to a point in Washoe County, Nevada, to Milepost 549. From there, Rockford Corporation will construct the nal spread to the terminus at Malin, Oregon. All work on the spreads will be conducted simultaneously. During the projects peak, Ruby will be employing more than 4,000 workers. The pipeline is scheduled to be in commercial operation by 1 March 2011.
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AROUND THE WORLD
APLNG pipeline contract awarded

Australia Pacific LNG (APLNG) joint venture partners Origin Energy and ConocoPhillips have awarded a consortium of McConnell Dowell and Consolidated Contractors a contract to build the 450 km gas transmission pipeline for the APLNG Project, to be located in Queensland, Australia.
he APLNG Project is designed to transport coal seam gas (CSG) from Australias largest reserves in the Surat and Bowen basins, Queensland, to a proposed 14 MMt/a LNG processing plant to be constructed at Laird Point on Curtis Island, Gladstone. CSG will be piped to the LNG plant, where it will then be exported to Asia Pacic and other international markets. The scope of the works for the APLNG Pipeline includes the design, engineering and construction of the pipeline. The pipeline is proposed to start near Miles, in South East Queensland, and continue north through the Banana Shire before turning east toward Gladstone, located on the states coast. A number of alternative pipeline routes have been examined, with the nal pipeline route to be made in consultation with landowners and local communities, and involve a thorough constraints analysis. The minimum burial depth for the pipeline is 900 mm under normal conditions, 1,200 mm under road crossing and 2,000 mm under both railway crossings and water courses and creeks. The pipeline will have a design pressure of 15.3 MPa with a capacity of 1,250 TJ/d of gas. The diameter of the pipeline will be 42 inches, and a nal decision is expected to be made during the detail design phase. Subject to a nal investment decision, scheduled for the end of 2010, construction on the pipeline will start in late 2011 with completion by the end of 2013.
Upstream operator Origin Energy Executive General Manager Paul Zealand said that the design studies for the upstream facilities and pipeline had been undertaken, and detailed engineering and preparatory works will continue.
Both the pipeline and the upstream contracts are scalable to include the entire 450 km gas transmission pipeline construction and a portion of the gas production facilities for the project, Mr Zealand said.
Coal seam gas compressor station located at Spring Gully in the Surat Basin. Image courtesy of Origin Energy.
APLNG proposed pipeline route. Image courtesy of Origin Energy.
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AROUND THE WORLD
Durban Gauteng to secure South Africas energy future

A new multi-product pipeline running between Durban and Gauteng, South Africa, is scheduled to come online in the third quarter of 2010 to relieve capacity constraints on South Africas petroleum supply chain.
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n 2007, Transnet (formerly Petronet) received a construction licence from the National Energy Regulator of South Africa (NERSA) to construct and operate the 544 km, 24 inch diameter Durban to Gauteng Pipeline and an associated 160 km, 16 inch diameter inland pipeline network. The project involves the replacement and expansion of the Durban to Johannesburg Pipeline, which transports rened petroleum products from two reneries in Durban, as well as imported rened petroleum products from storage facilities located in the Port of Durban. The new pipeline will include three pump stations and the construction of storage terminals in Durban and Johannesburg.
Construction continues on the Durban to Gauteng Pipeline.
A joint venture between Arup and WorleyParsons was awarded the engineering, procurement and construction management contract for the project, and the coated line pipe has been supplied by South Africas Impumeleo Pipeline. A joint venture between Frances
Spiecapag and South Africas Group Five was awarded the construction contract in May 2008, with Spiecapag acting as operational leader for the project. In January 2010, Transnet made an application to NERSA to amend the conditions of its licence to operate the petroleum pipeline system. If approved, the amendment would allow Transnet to operate portions of its new multiproduct pipeline ahead of the initial target completion date of December 2011, outlined in the current licence. Transnet has stated that although the entire pipeline will not be completed until December 2011, segments of the pipeline will be ready for operation at the end of June 2010.
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Sept. 27 Oct. 1, 2010 The Hyatt Regency Hotel Calgary, Alberta, Canada 14 Technical Tracks with over 300 quality papers Highly informative Tutorials International presenters and keynote speakers Panel Sessions Poster Sessions Student Paper Competition Networking opportunity luncheons & receptions
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AROUND THE WORLD
UPCOMING CONFERENCES
International Forum on the Transportation of CO2 for CCS
29 30 June 2010 Hilton Hotel, Newcastle, UK
The First International Forum on the Transportation of CO2 for CCS (carbon capture and storage) is organised by Newcastle University in partnership with Tiratsoo Technical and Clarion Technical Conferences. The event is supported by the Carbon Capture and Storage Association. As the world looks for solutions to carbon emissions, this forum will discuss the most critical element in CCS the transportation of CO2 from its source to its storage location. While there is signicant experience with CO2 transportation, CO2 from anthropogenic sources, such as power stations, has a wide array of issues that must be solved. These issues will be discussed. If you are interested in the rapidly expanding area of CO2 pipelines, you cannot afford to miss this forum.
Croatia modernises its gas transmission system

Following the completion of the 300 km Vodnjan Umag gas pipeline, Croatia has entered into the final stage of the construction and modernisation of its gas transmission system.
roatias gas transmission system operator Plinacro adopted a ten-year development plan to construct and modernise its gas transmission system, to be undertaken in three phases from 2002 to 2011. The second phase involved the construction of gas pipelines across three separate regions central and eastern Croatia, the Pula Karlovac region, and the Lika and Dalmazia regions. The 113 km Pula Karlovac section was constructed in 2006 and connects the north Adriatic gas elds to Croatias gas pipeline system. The new pipeline enables the supply of Adriatic gas to the Croatian market, and opens up the possibility of gasication of the Istarska, Primorso-Goranska, and Karlovacka areas. A connection to the proposed Lika and Dalmazia gas pipeline is also planned. Italian pipeline construction company Ghizzoni completed construction works on the Vodnjan Umag pipeline, in the Pula Karlovac region, in late January, and has now commenced construction works in the Lika and Dalmazia region, while the pipeline activities in the central and eastern region are currently in the development phase.
Vodnjan Umag gas pipeline

Ghizzoni had to overcome challenging engineering conditions including the crossing of the Limski canal, which extends 15 km inland from the Adriatic Sea. The crossing point, with a width of 860 m and a maximum depth of 36 m, was chosen to have the minimum environmental and technical impact, and the crossing was undertaken using a towed plough to bury the prefabricated pipe as it was pulled across the canal. Three parallel pipeline sections, each approximately 300 m long, were initially set on rollers on one bank of the canal at spacings of between 10 and 18 m. The pipeline pull-back was carried out using a Tesmec CO 3543 electric-powered winch with 40 tonne pull-back capacity. At the conclusion of pull-back operations, Ghizzoni carried out non-destructive tests on the welded joints and the coating, a preliminary hydraulic test, and a caliper pig run, to ensure the integrity of the installed pipeline.
Construction commences on Lika and Dalmazia tranmission systems

Ghizzoni commenced construction on sections 2 and 3 of the Lika and Dalmazia gas transmission system on 1 November 2009, comprising 175 km of transmission pipeline to be constructed in the region. Sections 2 and 3 will allow the Lika-Senj area to be connected to the main Croatian pipeline system, enabling gasication of a large part of the region and a subsequent decrease in its reliance on electric power. Construction of these sections is scheduled to be completed by 31 October 2010.
For more information visit www.clarion.org
Evaluation, Rehabilitation & Repair of Pipelines Conference and Exhibition

18 21 October 2010 Berlin Marriot Hotel, Berlin
If you are interested in extending the life of pipelines via rehabilitation, make sure you dont miss the premier conference dedicated to the eld. The event will cover pipeline rehabilitation, ranging from the initial stages of evaluation of a pipelines condition to the steps required to undertake rehabilitation to ensure its continued tness-forpurpose and prolong its economic lifetime. With over 60 per cent of the worlds major oil and gas transmission pipelines now more than 50 years old rehabilitation is an increasingly important aspect to pipeline engineering, operations and construction. Hear the latest advances, network with experts and see the latest evaluation and rehabilitation technology up close.
Above and right: Pipeline pull-back operations for the Limski canal crossing.
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Visit www.piperehabconf.com for more information

AROUND THE WORLD
Shaybah Abqaiq Pipeline nears completion

Construction work to expand the second Shaybah Abqaiq oil pipeline (SHBAB-2) at Saudi Arabias Shaybah Oil Field is nearing completion.
he 217 km Shaybah Abqaiq Pipeline have been faced during the construction will connect a new plant, which process. Stroytranzgaz has been executing separates gas and oil at Shaybah, to the contract under extreme desert conditions, an existing pipeline that carries crude oil to a which have required the use of a full processing facility at Abqaiq. mobilisation schedule to navigate through The existing 640 km SHBAB-1 pipeline 3 m deep sand dunes and sand storms. transports crude to Abqaiq from the other According to Stroytranzgaz, executing three gas and oil separation plants located in this project has required the company to Shaybah. adapt to complicated work conditions In 2007, Saudi Aramco awarded the and intricate local legislation. Project contract to construct the SHBAB-2 pipeline to administration and quality management Stroytransgaz, the rst Russian company to had to be developed in order to meet win a contract from Saudi Aramco. Saudi Aramcos standards, maintain high Under the agreement, Stroytranzgaz has productivity and ensure environmental been building and engineering the pipeline, protection. averaging a welding rate of up to 2 km of In order to provide accommodation pipeline per day. Construction management for its team of multi-national workers, is being carried out from an office in Shaybah. Stroytranzgaz constructed four villages along ads 5473 3m 2:2004-06-01HR 7/12/09 15:11 A number of advert environmental challenges the pipeline route. Page 1
The SHBAB 2 pipeline project under construction.
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WORLD WRAp
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Bison Pipeline receives FERC green

The United States Federal Energy Regulatory Commission (FERC) has issued its nal environmental impact statement (EIS) for the Bison Gas Pipeline. TransCanada subsidiary Bison Pipeline has proposed the project, which includes approximately 486 km of 30 inch diameter natural gas transmission pipeline extending northeast from Wyoming, through Montana to North Dakota.
Putin opens Stage 1 ESO Pipeline Castoro 6 enroute to lay rst Nord Stream pipeline
The pipelay vessel Castoro 6 has started its journey to the Baltic Sea where construction of the Nord Stream Pipeline will commence in the Swedish Exclusive Economic Zone, about 60 km off the coast of the Swedish island of Gotland. The 48 inch diameter pipeline is scheduled to start transporting natural gas to Europe from 2011. Russian Prime Minister Vladimir Putin has opened the rst stage of Transnefts Eastern Siberian Oil (ESO) Pipeline at a ceremony held at the port of Kozmino on Russias Pacic Coast. The rst stage of the pipeline runs 2,757 km from Taishet, Irskutsk Region, via Yakutia to Skovorodino in the Amur Region. The second stage of the ESO will run 2,100 km from Skovoridino to the Pacic coast.
Arad Szeged Gas Pipeline nears completion

FGSZ has completed the 47 km Hungarian section of the 109 km Arad Szeged Gas Pipeline, which will connect the natural gas transmission systems of Hungary and Romania. Approximately 37 km of the 62 km Romanian section of the pipeline being constructed by Transgaz has also been completed and the cross-border section of the pipeline is expected to be complete by 30 September 2010.
Brazils Paulinia Jacutinga gas pipeline begins service

Petrobras has brought its 93 km Paulinia to Jacutinga Gas Pipeline located in Brazils sixth biggest gas consuming state, Minas Gerais online. The pipeline transports gas from Natural Gas Hub 3, located in Paulinia, to towns in the southern area of the state, and has a capacity of 5 MMcm/d of gas.
EPSCC contract awarded for OUR Pipeline

Total E&P Nigeria Limited has signed an engineering, procurement, supply, construction and commissioning (EPSCC) contract with Zakhem Baywood Joint Venture Limited for the 45.6 km Obite Ubeta Rumuji (OUR) Pipeline, Nigeria. The 42 inch diameter pipeline will increase the transportation capacity of gas produced from Oil Mining Licence 58, located onshore Nigeria, approximately 85 km northwest of Port Harcourt in the Niger Delta.
Nairobi Eldoret Pipeline on track for 2011 start-up

The 325 km multiproduct Nairobi Eldoret Pipeline will be completed in 2011, according to Kenya Pipeline Company Chief Manager Technical Engineer Elias Karum. The new pipeline is currently under construction and will have an initial capacity of 7.5 MMbbl/d of oil, which will be increased to 12.7 MMbbl/d of oil when the project is complete.
GNEA Pipeline will be extended

A 70 km extension to the Gasoducto del Noreste (GNEA) gas pipeline has been approved by Argentinas Planning Minister Julio De Vido. The GNEA has been designed to bring gas 1,182 km from Bolivia to the Argentinean provinces of Misiones, Corrientes, Chaco and Santiago del Estero.
To stay informed on all this news and more, subscribe to the Pipelines International Update
www.pipelinesinternational.com
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pROJECT BRIEFS
PIpES AND pEOpLE
Project briefs
Dzhubga Lazarevskoye Sochi Pipeline
PROPONENT: OAO Gazprom, 16 Nametkina Street, Moscow, GSP-7, Russian Federation. Tel: +7 495 719 30 01 PROJECT SCOPE: The 177 km Dzhubga Lazarevskoye Sochi Pipeline will run along the Black Sea coastal line, approximately 4.5 km away from the shore, to the Kudepsta gas distribution station near Sochi. The pipeline is designed to meet the increased energy demands of Sochi the host city of the 2014 Olympic Games. PROJECT UPDATE: Pre-construction operations for the offshore section of the pipeline are nearing completion and approximately half of the onshore section of pipeline has been welded, trenched, and backlled. PIPELINE LENGTH: 177 km including a 159.5 km offshore section PIPELINE CAPACITY: 3.8 Bcm/a of gas EXPECTED COMPLETION DATE: Second quarter 2010
Pipes & People

New Marketing Director at GAIL
Shri PraBhat Singh has been appointed the Director (Marketing) of GAIL. A past General Manager of GAILs Exploration and Production Department, since April 2006 Shri Singh has been leading the Upstream Business Development and Strategy Divisions in British Gas. He has 29 years of experience in the hydrocarbon industry, and in his previous position at GAIL made a major contribution to the execution of the worlds longest LPG pipeline project, from Jamnagar to Loni, which traverses the Indian states of Gujarat, Rajasthan, Haryana, Delhi and Uttar Pradesh.
y (left) Manager for OSD Canada Martin Axelb ration and President and CEO of Gemini Corpo Doug Lautermilch.
David Entringer.
Mumbai High Field Pipeline Replacement Project (PRP-2)

PROPONENT: Oil and Natural Gas Corporation (ONGC), Tel Bhavan, Dehradun 248 003, India. Tel: +91 35 275 9561 PROJECT SCOPE: The $US750 million Pipeline Replacement Project 2 (PRP-2) requires the installation of over 220 km of 624 inch diameter pipelines, both rigid and exible, along with pipeline crossings, risers, topsides modications and testing and pre-commissioning activities in the Mumbai High eld. PROJECT UPDATE: In February 2010, Leighton Internationals 130 m long pipelay vessel, the Leighton Eclipse, nished laying the nal lines of an 80 km pipeline section for PRP-2. PIPELINE LENGTH: Approximately 220 km EXPECTED COMPLETION DATE: 2012
Tamazunchale-San Luis de la Paz Pipeline

PROPONENT: Pemex Gas y Petroqumica Bsica, Marina Nacional, 329 Torre Ejecutiva Piso 17, Col. Huasteca, C.P. 11311, Mxico. Tel: +52 55 1944 5005. PROJECT SCOPE: The proposed pipeline will transport gas from the Chicontepec Gas Field, located in Veracruz and Puebla, the Altamira terminal and/or the Burgos Basin to central and western Mexico. PROJECT UPDATE: A public bidding for the construction and operation of the pipeline is scheduled for 2010 according to a gas sector forecast released by Mexicos energy ministry. PIPELINE LENGTH: Approximately 300 km PIPELINE CAPACITY: 400 cm/d of gas EXPECTED COMPLETION DATE: 2012
OSD and Gemini sign Teaming Agreement

OSD Pipelines has announced a Teaming Agreement with Gemini Corporation in Calgary, Canada. Established in Australia in 1998, OSD specialises in all aspects of pipeline and pipeline facilities development and operation, and has been operating in Calgary since 2007. Gemini is based in Calgary and has 27 years of experience in the Canadian oil and gas industry. This agreement will allow the two companies to work together on a number of projects, providing OSD with a stronger base of operations in Canada and offering clients an experienced team to deliver combined pipeline and facilities projects.
Pipelines International opens Houston ofce

Great Southern Press, publishers of Pipelines International have opened a new office in Houston, Texas. Headed up by David Entringer (pictured), the Houston office will allow us to serve the needs of US-based customers with even greater efficiency. David will also work with clients from rest of North America, South America and Europe. David is a lifelong Houston local and graduate of Texas A&M. He has previously worked in procurement in the energy industry and looks forward to getting to know all our North American-based readers and advertisers. David will be at a range of upcoming events including IPC in Calgary and can be contacted on +1 713 973 5773 or via email dentringer@gs-press.com With offices in London, UK; Melbourne, Australia, and now Houston, USA; Great Southern Press brings a truly global perspective to the pipeline industry and Pipeline International magazine.
Shri Prabhat Singh.
Flexlife opens Kuala Lumpur base

Scottish FlexiBle pipe company Flexlife has opened an international base in Kuala Lumpur, as part of its programme to expand into key locations for the oil and gas industry. Azmir Ahmed, who has an extensive background in exible pipe manufacturing, has been appointed the Business Development Manager for the new office. Flexlife specialises in the manufacture of exible pipe products and subsea integrity management. Since being established in 2007, the company has completed work for Apache North Sea, Hess, Statoil, and Maersk in the North Sea and international locations. It is intended that a second international base will be opened in Brazil by mid-2010.
BJ Services appoints new Gulf Coast Area Manager

Kyle RuZick has been appointed the new Gulf Coast Area Manager of BJ Services Company Mr Ruzick, who has worked in the process and pipeline sector for 20 years, joined BJ Services as West Africa Operations Manager in 2003, and later acted as Area Manager for the Northern North Sea and Nigeria. Mr Ruzick will be responsible for all process and pipeline service operations, business development initiatives and nancial management throughout the Gulf of Mexico region. He intends to relocate to the companys headquarters to Houston, Texas, in mid-2010. For further information, contact Process and Pipeline Services General Manager Lindsay Link via email llink@bjservices.co.uk
Elba Express Pipeline

PROPONENT: El Paso Corporation, 1001 Louisiana Street, Houston, Texas, 77002, United States. Tel: +1 713 420 2600. PROJECT SCOPE: The Elba Express Pipeline transports natural gas supplies from the 1.75 Bcf/d capacity Elba Island LNG terminal to markets in the southeastern and eastern United States. PROJECT UPDATE: The pipeline was put into service on 1 March 2010 along with the expansion of the Elba Island LNG receiving terminal near Savannah, Georgia. PIPELINE LENGTH: 306 km PIPELINE CAPACITY: 945 MMcf/d COMPLETION DATE: 1 March 2010
New President at Willbros US Construction

KeVin Fox has been appointed the new President of Willbros US Construction, a branch of the Willbros Group that provides construction, maintenance and speciality services to the US pipeline industry. Prior to this appointment, Mr Fox served as President of Willbros Engineering, and has 23 years of engineering, project management and integrated service delivery experience. He joined Willbros in 1991 as an engineer.
CorrecTIon: In the September, 2009, edition of Pipelines International, a picture in the Nord Stream Pipeline article was run with an incorrect caption. The picture, which featured on page 36, does not depict the inspection of welded sections of automatic ultrasonic equipment as the caption suggests. Instead, it features submerged-arc double-joint welding.
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A S I A - PA C I F I C
8-11 NOVEMBER 2010

CROWNE PLAZA HOTEL KUALA LUMPUR, MALAYSIA
The world renowned Pipeline Pigging and Integrity Management Conference will come to Asia for the very first time in 2010. Building upon the many years of success in Houston, the Asia Pacific Pipeline Pigging and Integrity Management Conference will allow pipeline professionals in the region access to an exciting program of papers, great networking events and the latest technology on display at the exhibition. If you are responsible for the management of oil and gas pipelines, make sure you dont miss this event.
Pipeline projects in the Middle East

By Stephanie Clancy
Shifting sands, salt marshes, extreme heat, storms, and complex intergovernmental relations, are some of the challenges confronting the pipeline industry in the Middle East. Despite these challenges, a wealth of significant pipeline projects are proposed or currently underway in the region. Here, Pipelines International provides a snapshot of industry activity.
CONTINUED ON PAGE 24
Plan to be there: www.clarion.org or call us at +1 713 521 5929
CONFERENCE TRAINING COURSES EXHIBITION

ORGANIZED BY SUPPORTED BY
The 640 km SHBAB-1 oil pipeline, shown under construction, is currently being extended via the Shaybah Abqaiq 2 oil pipeline project, due for completion this year. Image courtesy of Saudi Aramco.
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Saudi Arabia
audi Aramco has awarded an engineering, procurement, construction (EPC) and commissioning contract to the Nacap-Suedrohrbau joint venture to construct the 506 km, 30 inch diameter Ras Tanura Riyadh multiproduct pipeline from reneries in Ras Tanura to Riyadh in central Saudi Arabia, as well as install three pump stations, metering systems, substation buildings and maintenance. The project is expected to be completed by December 2011. Saudi Aramco has also awarded Jacobs Engineering Group a contract to develop the associated pipelines as part of the Arabiyah Gas Development Programme, which will facilitate the production and processing of up to 2.5 Bcf/d of gas from the Arabiyah and Hasbah offshore sour gas elds. There are four associated pipelines: two offshore pipelines connecting the gas platforms to the tie-in platform of 24 km and 36 km, a 110 km offshore pipeline to transport gas to the Manifa processing facility, and a 100 km onshore pipeline carrying gas to the Berri gas plant. The project is expected to be completed in 2015. J Ray McDermott is undertaking pipeline construction at Saudi Aramcos offshore Karan gas eld, in the Khuff region. The gas eld development involves a 110 km subsea pipeline from the eld to onshore processing facilities at the Khursaniyah gas plant. The project is expected to be complete by the fourth quarter of 2011. Meanwhile Stroytransgaz is nearing completion of construction works to expand the second Shaybah Abqaiq oil pipeline (SHBAB-2). The 217 km pipeline will connect a new plant, which separates gas and oil at Shaybah, to an existing pipeline that carries crude oil to a processing facility at Abqaiq. The existing 640 km SHBAB-1 pipeline transports crude oil to Abqaiq from three gas and oil separation plants located in Shaybah.
Dolphin Energy has com pleted the Taweelah Fujairah Pipeline in the UAE. Image courtesy of Dophin Energy.
while Germanys ILF Consulting Engineers is managing the project. Trial operation of the pipeline is estimated to start by the end of 2010, while the whole project is expected to be completed in August 2011. BJ Process and Pipeline Services has successfully completed a pipeline precommissioning operation for the Atlantis development, which comprises a wellhead platform that feeds a stand-alone pipeline extending 75 km to shore. The contract was completed for Global Industries, the installation contractor for the offshore section of the development.
Oman
Oman and India are examining the possibility of constructing a 28 inch diameter, 1,100 km subsea gas pipeline that could signicantly boost Indias energy industry. The pipeline would be constructed at a maximum depth of 3,500 m, and is expected to have a capacity of 20 Bcm/a.
Iran
Iran and Pakistan have signed the nal agreement to launch the construction of the $US3.2 billion Iran Pakistan (IP) onshore gas pipeline. The two countries signed an Operational Agreement and a Heads of Agreement (HoA), which includes a provision for Indias possible participation in the project at a later date, in March 2010.
Nabucco and Arab Gas PIpelIne To lInK THe MIddle EasT? The Turkish Parliament has ratied a 2008 agreement with European Union states regarding the nations participation in the construction of the 3,300 km Nabucco pipeline. The $US10.6 billion Nabucco pipeline will draw gas from the Caspian region Azerbaijan, Turkmenistan and Kazakhstan as well as Georgia and Iraq. From the point where it connects into Turkeys pipeline network, the Nabucco pipeline will run 3,300 km to a distribution hub in Baumgarten, Austria, potentially delivering up to 31 Bcm/a of natural gas to Europe. Tying into the Nabucco project is the 36 inch diameter, 1,200 km Arab Gas Pipeline, which will transport Egyptian gas through Jordan and Syria to Turkey once completed. Construction has been completed on part of the pipeline, extending from Arish in Egypt, passing through Aqaba in Jordan, Damascus and Banias, both in Syria. Phase 2 of the pipeline will run to Turkey, and commissioning of the entire pipeline is planned for 2011. Lebanon will also tap into the network, having signed an agreement with Egypt for 600 MMcm/a, while Iraq will be integral in keeping supplies of gas owing into the network.
Ras Laffan Gas Plant, located in UAE.
Qatar
Turkey is in negotiations to discuss the development of the Qatar Turkey pipeline. The pipeline would run from Doha to Istanbul, a distance of approximately 2,500 km. The pipeline would carry Qatari gas to the Mediterranean Sea, crossing Saudi Arabia, Jordan and Syria, and may link to the proposed Nabucco gas pipeline.
Turkey is in negotiations to discuss the development of the Qatar Turkey pipeline. The pipeline would run from Doha to Istanbul, a distance of approximately 2,500 km.
United Arab Emirates

In February 2010, Abu Dhabi Company for Onshore Oil Operations (ADCO) awarded a contract worth approximately $US683 million to National Petroleum Construction Company (NPCC) for the construction of a 950 km oil pipeline in the United Arab Emirates (UAE). NPCC will perform the EPC for the new pipeline, as well as production well tie-ins and owlines that will connect the eld to four new production facilities. The contract is expected to be executed in 30 months to increase the capacity of the Bab eld from 1.4 MMbbl/d to 1.8 MMbbl/d by 2017. Dolphin Energy has completed the commissioning of early gas facilities in August 2009 at the gas receiving station associated with the Taweelah Fujairah gas pipeline. The 240 km Taweelah Fujairah pipeline will carry gas from the Taweelah gas terminal on the Persian Gulf coast, to treatment facilities in the emirate of Fujairah near the Oman border. The project is set to be completed later this year. In January 2010, UAE-based construction rm Dodsal secured contracts worth over $US160 million to construct two gas pipelines in Abu Dhabi. The rst contract is for the replacement of a 100 km, 36 inch diameter pipeline linking Abu Dhabi Gas
Bahrain
Bahrain and Saudi Aramco are discussing the construction of a new oil pipeline between Bahrain and Saudi Arabia. Exceeding 100 km in length, the projected $US350 million pipeline project was expected to commence construction by the end of 2009; it has, however, been delayed until later this year.
Industries (GASCO) Thamma C production facilities in the northeast to the rms Asab eld in the south. The contract is worth approximately $US85 million. The second EPC contract includes construction of the 45 km, 48 inch diameter Mirfa Habshan nitrogen pipeline. Part of the joint venture industrial gas scheme by Abu Dhabi National Oil Company (ADNOC) and Germanys Linde, this pipeline will link Mirfa, in west Abu Dhabi, with the Habshan oil eld, located in the south of the capital. China National Petroleum Corporation (CNPC) and International Petroleum Investment Company (IPIC) have signed an EPC contract for the Abu Dhabi crude oil pipeline project. The project will involve the construction of a 400 km, 48 inch diameter pipeline, which will run from the Habshan oil eld in the west to the Fujairah Port in the east, and will have a designed delivery capacity of 1.5 MMbbl/d and a maximum capacity of 1.8 MMbbl/d. WorleyParsons has been awarded the front-end engineering and design contract,
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Iran will deliver 750 MMcf/d of gas to Pakistan for the next 25 years via the 900 km, 42 inch diameter gas pipeline, which will run from the Assaluyen gas eld in southern Iran, to Pakistan. The pipeline is scheduled to become operational by 2015. In addition, Iran is planning to construct a 350 km pipeline from its Tabriz renery to Armenia to increase gasoline and gas exports to the country. Iranian Deputy Oil Minister Noureddin Shahnazi-Zadeh said the two countries have agreed on a contract for the construction of the pipeline and a gas terminal to be located on the border shared
by the two countries. The pipeline has been under discussion since 2007. Iran has completed initial studies for the construction of the 1,550 km NekaJask pipeline. The pipeline has a planned transmission capacity of 1 MMbbl/d of oil and a storage capacity of 20 MMbbl. The pipeline will travel between the Caspian Sea port of Neka to the Gulf of Oman port of Jask. The project is targeting crude oil supplies from Kazakhstans large Kashagan eld, but will also offer Russia, Turkmenistan and Azerbaijan the opportunity to export to the Arabian Sea.
Construction has commenced on the Iranian section of the 56 inch diameter, 1,740 km Pars pipeline that will run to Turkey and on to consumers in Europe. The pipeline is designed to boost exports to Turkey and Europe from the western region of the country by transporting sweet gas produced from Irans South Pars eld. The pipeline will have an initial capacity of 37 Bcm/a. The State Oil Company of Azerbaijan Republic (SOCAR) intends to build a 200 km gas export pipeline to Iran. The new pipeline, to be funded by SOCAR, is expected to be 200 km in length and have a gas transmission capacity of 6.57 Bcm/a. Construction works are scheduled for later in 2010, with operation expected in 2012.
Jordan
Egypt has given preliminary approval to send Jordan approximately 500 MMcm/a of gas through the 1,200 km, 36 inch diameter Arab Gas Pipeline. Egypt currently exports between 5.7 MMcm/d and 7.1 MMcm/d of natural gas to Jordan.
A manifold of pipelines at the Hawiyah project in Saudi Arabia. Image courtesy of Saudi Aramco.
Egypt and Jordan have been linked since 2003 by the Arab Gas Pipeline, which extends from Arish in Egypt, passing through Aqaba, Damascus and Banias. The pipeline is currently used to export Egyptian natural gas to Jordan, Lebanon and Syria and commissioning of the entire pipeline is planned for 2011.
s in erous oil and gas pipeline Company operates num y. The National Iranian Oil pan Com Oil ian Iran the National Iran. Image courtesy of
Israel
The Natural Gas Pipeline Company has announced that it will construct a 37 km gas pipeline to Jerusalem. The company estimates that the planning process for the new pipeline will take approximately two years and that the natural gas will be delivered by a distribution company to be set up in the future. Negotiations continue between the Israeli Government and the Druze communities situated along the pipeline route. Director General of the Prime Ministers Office Eyal Gabbai is handling the talks for the government.
The 36 inch diameter Arab Gas Pipeline Project Phase 2 will run 62 km from the Turkish-Syrian border to Alenno, the site of the pressure reduction and metering station. The project will be completed in 18 months. In March 2010, Syria announced that a working group would be created to discuss the construction of a new 150 km gas pipeline between Azerbaijan and Syria. The working group is to consider technical, commercial issues related to the export of approximately 1 Bcm/a of gas from Azerbaijan to Syria. It is expected that 90 km of the pipeline will be situated in Syria, and completion is planned for the end of 2011.
Iran will deliver 750 MMcf/d of gas to Pakistan for the next 25 years via the 900 km, 42 inch diameter gas pipeline, which will run from the Assaluyen gas field in southern Iran, to Pakistan.
Iraq
In November 2009, an agreement was reached between the Baghdad and Amman administrations to construct a pipeline between Iraq and Jordan. The pipeline will carry Iraqi oil to Jordans Aqaba port, traversing a distance of approximately 600 km. Iraq currently exports 4 MMbbl/a of oil through the approximately 600 km Kirkuk Yumurtalk pipeline, and via Basra in tankers.
Syria
A compressor station, located at the Safaniya Gas Plant, Saudi Arabia. Image courtesy of Saudi Aramco.
In 2008, Stroytransgaz and the Syrian Gas Company signed an EPC contract for the Arab Gas Pipeline Project Phase 2 in Syria.
Turkey hopes to renew an agreement to operate a 941 km Kirkuk to Ceyhan oil pipeline for another 15 to 20 years. The pipeline project comprises two parallel pipelines, which transport oil from elds around Kirkuk, Iraq, to the Mediterranean port of Ceyhan in Turkey, and have a total capacity of 500,000 bbl/d of oil. The rst pipeline was commissioned in 1977 and the second in 1987. The pipelines are jointly operated by Iraq and Turkeys respective national oil companies.
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Construction works on a section of the pipeline.
Top: The Mangala to Salaya Pipeline runs from the Mangala Processing Terminal. Bottom: Pipe stringing on the right-of-way.
A rail crossing underway on the project.
Heating up in India: the Mangala to Salaya oil pipeline

Cairn India has recently completed construction of the worlds longest continuously heated and insulated pipeline, located in western India and crossing the states of Rajasthan and Gujarat.
he 590 km Mangala to Salaya Pipeline runs between the Mangala Processing Terminal (MPT) and Salaya, and forms a section of the 24 inch diameter, 670 km Mangala to Bhogat oil pipeline. Proposed by a joint venture between Cairn India and ONGC to extend from the MPT, Rajasthan, to Bhogat in Gujarat, the pipeline runs via the districts of Jalore, Banaskantha, Patan, Ahmedabad, Surendranagar, Rajkot, and Jamnagar. Cairn India has been exploring hydrocarbon resources in the state of Rajasthan for more than ten years. The pipeline was conceived in 2005 to facilitate the early production from these elds, and JP Kenny was engaged to complete a concept design. The Mangala to Salaya section commenced construction in July 2008, and was completed in December 2009. The Salaya to Bhogat section of the pipeline is still to be constructed. Approvals and
PIpe sTaTs
Pipe material: Mild steel API 5L - X65 Oil pipeline coating: Fusion-bonded epoxy/high-build liquid epoxy, thick insulation, and a thick high-density polyethylene jacket Gas pipeline coating: Multilayer polyethylene augmented by a cathodic protection system Burial depth: 1 m minimum
The pipeline project activities provide employment to persons of different skills and trades. The local population is being given preference regarding employment. During construction of the project, temporary employment to unskilled and semi-skilled labourers was provided. During the operational phase, we plan to develop and train local community members to provide services such as security, administration and maintenance, the Cairn India spokesperson continued.
land purchase have been completed and construction is to commence shortly. The unique nature of the Rajasthan crude requires the pipeline to be heated to ensure the continuous ow of oil. To achieve this 35 intermediate power feeding/heating stations, each with a capacity of 1 MW, have been constructed at 20 km intervals along the length of the pipeline. Captive power facilities are located at all heating stations and at the oil terminals at Viramgam and Bhogat in Gujarat. A skin-effect, heat-tracing system has been installed along the periphery of the pipeline. A polyurethane foam insulation system with a high density polyethylene jacket has also been installed around the crude oil pipeline to prevent heat loss from the pipeline to the environment. Other works associated with the pipeline include an 8 inch diameter gas line, running parallel to the pipeline along most of its length, starting from the Raageshwari
gas eld in the Rajasthan Block. Storage, handling and pumping stations are located at the Viramgam terminal along with a diluent mixing facility at the Bhogat terminal.
Sourcing locally
This is the rst project of its kind in the country and possibly one of the most challenging undertaken in the world, said a Cairn India spokesperson. Nearly 80 per cent of the contracts to construct the pipeline have been awarded to Indian companies. The integrated engineering, procurement and construction contract for the pipeline was carried out by Larson & Toubro, while the pipes have come from the Jindal Saw Mill at Mudra. Certain sections of the pipeline were constructed by Punj Lloyd to ensure faster execution and optimum utilisation of resources. More than 4,000 contractor personnel have been employed on the project.
Challenges
The Managala to Bhogat Pipeline corridor traverses two states and eight districts and required the acquisition of approximately 670 km of right-of-way (RoW), involving the daunting task of impinging on the land of nearly 50,000 landowners. Cairn India put in place a dedicated team to address social
issues and gain the support of the locals residing along the length of the pipeline route. Programmes were undertaken to educate stakeholders about the signicance of the project and various measures that are being taken to protect the asset. Other issues identied included the movement of heavy machinery in remote areas, weather-related issues such as water-logging in the pipeline trench, and overcoming the challenges of major river, canal, rail, and road crossings. Each crossing was unique: some of the river crossings contained water, while others were dry except in the monsoon season. In addition, some of the canals crossed were unlined whereas others had bed and banks protected with boulder-pitched cement lining. Railway crossings included single and double tracks, and the road crossings included all types of minor and major district roads, as well as state and national highways. The majority of the crossings also involved crossing existing utilities, including optical bre cables, power lines, and drainage ditches around the RoW of the facility to be crossed. Third-party pipelines to be crossed included water and hydrocarbon pipelines, both in and out of service. All major road, railway and canal crossings were undertaken using an augerboring machine. These obstacles, combined with a tight project schedule, strict statutory requirements, inaccessibility of the crossing sites, and extreme weather conditions,
coupled with the desired safety and integrity of pipelines, posed a major challenge for both the design and construction teams the Cairn India spokesperson said.
Hot to go
At the time of writing, commissioning of the Mangala to Salaya Pipeline section was underway, and construction activity at the Viramgam Terminal, the 35 above-ground installations, and the Salaya Terminal were all at an advanced stage. Cairn India said that approvals for the Salaya to Bhogat Pipeline section had been obtained and the necessary land purchase had been completed. Bhogat lies on the Gujarat coast and provides further exibility in terms of future offtake volumes. Previous modes of oil transportation, including road transport, have been susceptible to the vagaries of poor roads, traffic congestion, and shortages. This generally results in interrupted supplies of the hydrocarbons to the consumers. The pipeline, once commissioned, will ensure an uninterrupted availability of these products to the market, in the required quantity at the required place and at the required time, Cairn India said. Transportation of crude oil by pipeline is comparatively less costly than by other modes of transport, both in terms of capital and operating costs. If a good network of pipelines is implemented throughout the country, this will ensure that there are cost savings in transporting crude.
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Constructing Sakhalin Islands pipeline network

The Sakhalin 2 Pipeline Project is one of the largest integrated oil and gas developments in the world. Located on Sakhalin Island, in the far east of Russia, construction of the project was completed in freezing temperatures and over many seismic fault lines.
he Sakhalin 2 Pipeline Project involved the construction of offshore and onshore pipelines as part of the overall development of the Piltun-Astokhskoye and Lunskoye oil and gas elds, offshore Sakhalin Island in the Sea of Okhotsk, north of Japan. Construction of the pipelines began in early 2004, and was completed in 2008, with commissioning taking place in 2009. At the peak of construction, around 8,000 people were employed on the project, approximately 30 per cent of whom were Sakhaliners, with most of the others being from mainland Russia. Around 500 expatriate employees, from Europe, the Americas, and Australia, also worked on the project.
Project scope
The pipe used for the project ranged between 14 and 48 inches in diameter, with wall thicknesses varying from 7.1 to 30.2 mm, and made from X52, X60, X65, and X70 steel. The onshore pipelines totalled 1,600 km in length, and 300 km of offshore pipelines were constructed. The Sakhalin pipelines are located in three main groups between the offshore platforms, situated to the northeast of Sakhalin Island in water depths of up to 50 m, and an onshore processing plant situated near the coast in the northeast of the island and an LNG plant in the south of the island. The northern offshore area has an ice season of six to seven months, whereas the southern part of the island is subject to a shorter ice season and less severe conditions, which allow the year-round export of LNG and crude oil from the island. The two northern groups of the pipelines transport oil, gas, and condensate in single and multi-phase states from three offshore production platforms to the onshore processing plant, where the well streams are separated and treated. There is also a pipeline from the onshore processing plant to Lunskoye-A, the most
southerly offshore platform of the elds, transporting regenerated mono-ethylene glycol (MEG) back to the platform for re-use in the multi-phase pipeline. The third group of pipelines transports gas and oil from the onshore processing plant to the LNG plant and the oil export terminal in the south of the island. Another crude oil loading pipeline runs from the oil terminal to a singlebuoy mooring of the tanker-loading unit. The pipeline facilities include approximately 150 block-valve stations and 19 pig trap stations, as well as a bre optic cable for communication and control purposes running the length of the lines. The offshore pipelines also involved the installation of seven platforms risers and three shore approaches. Special sections for the onshore pipelines were needed for approximately 700 road crossings, 1,100 water crossings, 18 rail crossings, 19 active seismic fault crossings, 80 electrical transmission line crossings, and more than 100 underground services crossings, as well as more than 70 unstable ground areas (landslides, mudslides, and avalanches).
Constructing pipelines on Sakhalin Island

The Sakhalin project was Russias rst offshore development, which meant that during construction, the existing regulatory framework for the energy sector was still geared to onshore development activities. Sakhalin Energys Robert Boulstridge says that this made construction particularly challenging in terms of the necessary requirements for permits and authorisations. In addition, the construction of the pipelines was characterised by various seasonal limitations. These included the end of the winter thaw period, which is approximately one month long, and makes it impossible to work in many areas.
The Sakhalin 2 Pipeline Project involved the construction of both onshore and offshore pipelines.
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In the case of many peat/bog areas, it was only possible to excavate and lay pipe in the middle of winter when the ground was frozen, Mr Boulstridge says. Similarly, work on crossings of salmon rivers was limited by various designated spawning season constraints and these were different for different salmon species and in different locations on the island. The ground on Sakhalin is frozen for approximately four to ve months of the year. The weather on Sakhalin can be very harsh with normal mid-winter daytime temperatures of -20 to -40C. These temperatures posed obvious personal safety hazards, and ordinary manual activities became very difficult. In order to mitigate the hazard to workers, warm shelters were provided on the work site so that workers could have a break from the cold every two hours. While snow isnt too frequent on Sakhalin, when it occurs it is often as one to three day blizzards, resulting in large quantities of snow being deposited in a very short period. This made all roads impassable until cleared and access to off-road sites was blocked for considerable periods, says Mr Boulstridge. Horizontal directional drilling (HDD) was used to cross six watercourses with 12 individual HDDs between 5001,000 m in length, for the 20 inch, 24 inch, and 48 inch pipelines.
Because the crossings were designed for a 1,000 year return period, which involves potential ground movement and pipe displacements of up to 4.6 m, the pipelines have been designed to withstand large movements by deforming without rupture or loss of containment. Crossings are congured in a dog-leg shape, over a length of approximately 1 km, and cross the faults at specic angles, typically 45C, to minimise compression stress on the pipe. The crossings are characterised by very shallow trench sides, with an inll of a mixture of special round-particle-shaped sand, and lightweight expanded clay aggregate to allow the pipeline to move out of the trench with minimal resistance, says Mr Boulstridge. In addition, the detailed design aspects were complicated by the need to avoid water build-up in the trenches to avoid freezing, and increased resistance to movement. This was fullled by using self-draining or waterproof designs, which included the use of impermeable layers, compartmentalised sections, and complex drainage systems, as well as surface insulation material to minimise the pipe and backll temperature fall during the winter periods.
Low temperatures and deep snow were managed via thermal clothing, warm shelters, journey management rules in relation to travelling alone, and emergency survival kits in vehicles. An additional safety hazard on Sakhalin Island was the signicant occurrence of unexploded ordnance remaining from World War II. This affected most of the onshore pipeline route, particularly in the southern half of the island. A specialised contractor, in combination with the Russian military, cleared huge areas of pipeline right-of-way, station areas, and camp/storage sites.
Preserving the environment

There were several important environmental challenges in relation to both ora and fauna. Offshore, the main environmental consideration was the western grey whale. Some major re-scheduling and re-routeing of the pipeline was necessary to avoid any potential impact on the whales, as monitored by international experts on the Western Grey Whale Advisory Panel. Rerouteing around the main whale feeding areas was required, as was maintaining low noise levels from all vessels and work activities in the vicinity of the feeding areas. Onshore, the route passes along the outer part of two nature-reserve areas and these required special pipeline construction techniques and treatment of the ora. In addition, a rare species of orchid along some parts of the route was protected from damage. The onshore environmental challenges to fauna concerned the following: The Stellars sea eagle protection of nesting sites and the control of noise levels during the breeding season; Migrating reindeer migration routes were kept open to avoid affecting the migration patterns; Salmon spawning hundreds of sensitive salmon rivers were crossed in restricted time periods to minimise impact on the spawning grounds; and, Sakhalin dunlin, Aleutian tern and Spotted greenshank protective measures were necessary to avoid disruption to nesting habitats during certain periods of the year. More than 100 cultural heritage sites were identied along the pipeline route, and these were either bypassed by a re-route or protected from the main construction activities until archaeological excavations and studies had been completed. This resulted in more than 30,000 archaeological nds, many of them crucial for understanding the prehistoric age.
Safety on Sakhalin
The pipeline construction involved location-specic hazards, which needed to be managed, including: Crossing and working on ice, ice bridges, etc.; Very unstable landslide areas; Swamp areas; Pipe string instability on poor ground conditions, and particularly on slopes; Encounters with bears, particularly during non-noisy, survey-type activities; and, Encroachment into no-go areas where unexploded ordnance had not been cleared. A focused action plan was developed to focus attention and efforts on the four main topic areas of safety concern, which were identied as drivers, vehicles, site supervision, and subcontractor management. Each topic had a senior management sponsor and a designated leader. This approach, coupled with strict consequence management, had a positive effect on incident frequencies and severities. The existing road traffic culture was not conducive to safe road travel. The projectspecic controls comprised compulsory defensive driving tests, vehicle inspection/ testing, seat-belt xing, seat-belt wearing compliance, speed-limit compliance, and daily alcohol testing for professional drivers. A eet of road transport monitors was used to control speeding, alcohol misuse, and other offences.
Securing seismicity
A large part of the onshore pipeline route passes through areas of landslides, mudows, and avalanches. The general engineering approach in these areas was to estimate the unstable slip-plane locations and install the pipelines below this level. This necessitated the removal of large volumes of material on some occasions, says Mr Boulstridge. Seismic fault crossings constituted the most difficult technical aspect of the pipeline engineering design, taking several years to complete due to the complexities of the fault systems, as well as developing the designs for each individual crossing. There are two main fault systems on Sakhalin: the Goromay Fault and the Kliuchevskoi Fault. The design objective was to minimise the number of fault crossings, despite the fact that the pipeline route runs parallel to the Kliuchevskoi Fault over much of its length. The nal design incorporated one crossing of the Goromay Fault and 18 crossings of the Kliuchevskoi Fault. Fault movement does not normally occur at surface level when the seismic event has a magnitude of less than 6.5, but Sakhalin has experienced events with magnitudes greater than this, Mr Boulstridge says.
The Sakhalin pipelines route.
At the peak of construction, around 8,000 people were employed on the pipeline project.
The Sakhalin 2 project was successfully completed in challenging environments both onshore and offshore.
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OFFSHORE TERRAIN REVIEW
Delving to the bottom of the Mediterranean: Galsi Pipeline

Construction on the Galsi Pipeline is scheduled to begin in 2011, and will see pipeline constructed at depths of 2,824 m the maximum depth ever reached by a subsea gas pipeline.
he Galsi Pipeline will provide a new source of natural gas for Italy with the goal of guaranteeing a secure energy resource and supplying Sardinia with natural gas. The pipeline will begin 21 km east of Annaba in Algeria, at the location of a proposed compressor station where gas will be brought to the correct pressure for injection into the subsea pipeline. The pipeline will then cross 280 km from Algeria to Italy, of which approximately 100 km will be laid at a depth of 2,800 m, before reaching Sardinia at Porto Botte. At Porto Botte the gas pressure will be reduced, and a 48 inch diameter pipeline will traverse Sardinia from south to north for approximately 300 km to reach Olbia. At Olbia the gas will be compressed again in the second compressor station for injection into the 32 inch subsea pipeline, which will be constructed at a maximum depth of 850 m. After a marine crossing of 275 km the Galsi Pipeline will terminate at Piombino, Tuscany, where it will connect to the Italian gas distribution network. Not only is the 8 Bcm/a capacity pipeline to be constructed in very deep waters, but it will require a heavy wall thickness of pipe to withstand collapse. This in turn requires a construction contractor with unique capabilities.
Left: Olbia compressor station layout. Middle: A schematic of the terrain to be crossed by the Galsi Pipeline. Below: An autonomous underwater vehicle employed by Fugro for the Galsi Detailed Marine Survey.
Extreme depths
JP Kenny completed front-end engineering and design for the pipeline in 2009. The onshore pipeline is to be made of carbon steel with a minimum thickness of 16.1 mm, while the offshore pipeline will have a thickness of between 18 and 37 mm. Galsi Project Manager Arcangelo Perrone says The extreme water depths in which the pipeline is to be installed and the large diameter of the pipe means that the pipe wall needs to be very thick to be able to withstand collapse due to external pressure. In order to contain the wall thickness and weight, X70 pipe has been selected and the fabrication tolerances have been reduced compared to the standard. These sizes and thicknesses are the limit of production capacity of many pipe mills, and presently only a couple have conrmed the capacity, says Mr Perrone. Other mills would require expansions, upgrades or retooling to provide pipe for the project.
Eight offshore and near-shore vessels were employed to complete the marine survey, which took ten months to complete. Selecting a suitable route for the onshore Sardinia section of pipeline was challenging due to a number of environmental restrictions, including protected archaeological sites, which ran through the proposed route. Contractor DAppolonia completed many environmental studies to avoid the most sensitive areas.
Challenges for construction

Once ready for construction, pipe will be welded on a moving platform and lowered gradually onto the sea oor via a laybarge. Pipe installation methods will include both S-lay and J-lay methods. The S-lay method can be used in both shallow water and deepwater pipelines up to a depth of 3,000 m. The pipe is welded horizontally and lowered into the sea supported by a curved pontoon structure known as a stinger, which forms an elongated S. The J-lay system is used to lay pipelines at depths between 400 and 3,500 m. The pipe is welded in a vertical position and lowered onto the sea oor without the use of a support structure, thus forming a J shape. Mr Perrone says that the extreme water
depth and the large diameter of pipe limit the number of contractors that have the technology and capability to lay the pipeline. The project will induce most contractors to upgrade their pipelay vessel, he says. Other operations in deep water for both offshore sections of the pipeline, including shore crossings, span corrections by trenching and rock dumping, will also require the review and possible upgrade of equipment. Similarly, pipeline repair and retrieval equipment will have to be upgraded, says Mr Perrone.
A dedicated team
In addition to personnel from JP Kenny, Fugro and DAppolonia, Galsi has a team of 20 consultants that is dedicated to the project. Construction of the pipeline is expected to commence in 2011 and be complete in 2014. Mr Perrone says The Galsi Pipeline has been recognised as a strategic and very important project not only by both countries, Italy and Algeria, but also from the European Union because it will provide a new direct, secure and economically competitive line for the supply of natural gas. The team of experts is engaged to lead this project to realisation and to achieve a great feat of technology and engineering.
The pipeline will consist of three sections:

A 285 km, 26 inch diameter offshore pipeline running from Algeria to Sardinia, constructed at depths of up to 2,824 m; A 272 km, 48 inch pipeline located onshore Sardinia; and, A 280 km, 32 inch diameter Sardinia to Tuscany offshore section.
Selecting a pipeline route

Fugro was contracted to undertake detailed marine surveys to identify the route of the pipeline. The complex morphology of the seabed, characterised by steep continental margin slopes, meant that selecting a route for the pipeline was a difficult task.
Environmental studies are completed for the subsea pipeline.
Galsi timeline
2001
Sonatrach, Enelpower and Wintershall sign a protocol of agreement for the constitution of a company to study the feasibility of a gas pipeline from Algeria to Italy via Sardinia.
2002
Eos Energia and Edison join the protocol agreement.
2003
Galsi S.p.A is formed.
20032006
A technical, economic and legal feasibility study on the pipeline is developed. 20 December 2006: Feasibility study completed, Galsi decides to proceed with the project.
2007
Front-end engineering and design, and detailed marine survey begins. 7 November 2007: Snam Rete Gas and Galsi sign a Memorandum of Understanding for the construction of the Italian section of the pipeline. 14 November 2007: The Prime Minister of Italy and Algeria sign a bilateral agreement for the construction of the pipeline. February 2008: Wintershall sells its
2008
30 September 2008: Galsi and Snam Rete Gas sign a denitive agreement for the construction of the Italian section of the pipeline. stake in the project to the other Galsi consortium members.
2009
FEED is completed and further environmental studies are developed for the authorisation procedure. begin.
2011
Construction of the pipeline is scheduled to
2014
Construction of the pipeline is scheduled to be completed.
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TRENCHLESS TECHNOLOGY
Subsea pipeline communication challenges

More and more subsea pipelines are being laid and, as time progresses, exploration and production is taking place in deeper waters. Some offshore pigging providers are now planning for operations down to 5,000 m as operators find that more traditional techniques will no longer meet the demand.
Analysing Alberta HDD

By Jim Murphy, WorleyParsons; Glen Fyfe, Pembina Pipelines; Trevor Giesbrecht, WorleyParsons; and Wes Dyck, WorleyParsons.
Pembina Pipelines completed the construction of a pipeline project to supply oil pipeline services to one of the new oil sands mines in northern Alberta, western Canada, in 2008. Near the middle a horizontal directional drill was required due to access, environmental and land constraints encountered.
eveloping tracking and signalling pigs to work at extreme depths creates new challenges. Pre-commissioning pigs pass along subsea pipelines and may be pre-installed into launchers months and sometimes a year, in advance of ooding, cleaning, gauging, and testing operations. Subsea pigging provider Online Electronics says that pressure rating, battery life, and delayed-activation techniques are examples of the parameters that need to be met to ensure the integrity of pigging equipment matches the intended purpose.
Deep water pigging in Brazil

In 2009, Petrobras developed the Hybrido gas eld, offshore Brazil. The eld development involved the installation of 141 km of exible and rigid lines in four different elds in the Santos, Espirito Santos and Campos basins. Subsea 7 was contracted to install and commission the pipelines. This eld involved water depths of more than 2,000 m, over 100 km from shore. Online Electronics supplied pig-tracking, signalling, and data-logging equipment that enabled proof of launch, proof of receipt, and a means of tracking pigs. All products delivered met the battery-life requirement by incorporating pressure-switch activation where appropriate, while also complying with the necessary pressure rating. Petrobras safety standards require that any subsea pipeline is fully tested to one-anda-half times its operating pressure. Online Electronics temperature and pressure subsea data-logging system was used to monitor, record and report pressure and temperature data for each pipeline hydrotest. Its function is to secure the data while freeing up the support vessel to continue to the next phase of operations. Online Electronics said that the technology supplied had to conrm that various events had taken place in the interests of optimum operational efficiency and optimal vessel utilisation.
embina Pipelines Trust operates approximately 8,350 km of pipelines in British Columbia and Alberta. The company was awarded the contract to supply pipeline services to the oil sands project. The pipeline project included the completion of ve pipeline loops along the Alberta Oil Sands Pipeline (AOSPL). Existing AOSPL rights-of-way (RoWs) were used wherever possible to limit the quantity of new disturbance caused by the pipeline project. One of the loops, dubbed the Horizon Pipeline Project involved the looping of approximately 129 km of 24 and 30 inch diameter pipe, construction of which started in 2006. One of the ve new pipeline loops was
the 17.3 km NPS24 Pine Creek Loop, which followed the existing pipeline corridor through the environmentally sensitive La Biche Wildland Provincial Park. This loop involved the crossing of two water bodies, the La Biche River at the north boundary of the Park and Pine Creek at the south boundary. Due to the protected status of the La Biche River Wildland Park, no additional RoW was being granted within the Park. WorleyParsons attempted to design a horizontal directional drilling (HDD) crossing with this restriction in mind but could not achieve the desired results based on the following: The existing AOSPL RoW conguration was designed to accommodate the
previously installed trenched crossing. There were changes in horizontal direction, both upstream and downstream of the crossing. A number of adjacent pipelines within the area had to be crossed along the HDD path. The minimum design radius of curvature of the drill required clearance from the bottom of Pine Creek and the required entry and exit angles. Ledcor Pipelines was awarded the mainline contract for the Horizon Pipeline Project. Ledcor subsequently awarded the HDD subcontract to Direct Horizontal of Stoney Plain, Alberta.
Online Electronics 4000SD unit.
Providing solutions with depth

To best contribute to the success of operations, such as those at the Hybrido eld, Online Electronics said that it has to understand, from information supplied by its clients, the logistics of each project. A method statement or pipeline pig monitoring and testing philosophy statement is then prepared and the appropriate equipment can be offered, for example acoustic, electromagnetic (EM), magnetic or ultrasonic solutions to best suit the demands of the project. Different systems work better in different areas. EM technology operates well in gas-lled, buried pipelines and in pipe-in-pipe installations. Acoustic systems have a greater detection range. Magnets can be used where there is inadequate space to house transmitters or pingers. Ultrasound is a very effective method for pig signalling in topside applications.
Online Electronics said that its 4000SD unit can be strapped to a receiver prior to deployment or attached to a receiver by a remotely operated vehicle, which can then interrogate the unit after all the pigs have arrived. An acoustic modem or high-power beacons can be added to enable conrmation of events to remote locations up to 8 km away. In addition, the company said that its gauging-run integrity data system transmits data through a pipe wall, giving conrmation of the condition of a gauging plate with the time of an event if the plate has been damaged. This enables the client to continue with the hydrotest immediately after the completion of the gauging pig run, avoiding the need to recover the pigs to manually inspect the plate, saving a lot of vessel time.
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Analysing the HDD path

The soil within the HDD crossing at Pine Creek was assumed to be a soft formation based on feedback from the drilling contractor, which included the difficulty experienced with downhole steering and the results of a geotechnical investigation. Analysis of the drill path was completed using the Von Mises method. There are a number of methods available for calculating the combined stress within an HDD path: the Tresca, Von Mises, and limit-states approaches are all recognised within the CSA Z662 oil and gas pipeline systems standard, and offer varying degrees of conservatism. Regardless of the method chosen, stress is analysed for a pipeline within the HDD path for the maximum operational conditions. The presence of applied loads in more than one direction results in a much more complex state of stress than for applied loads in only one direction (uniaxial). The predominant stresses in pipelines are typically biaxial, with internal pressure acting in the circumferential (hoop) direction and thermal loads and beam bending acting in the longitudinal direction. The yielding of the steel under these conditions is considerably more complex, and there are two widely accepted approaches for determining the combination of stress in various directions that result in yielding of ductile material (such as steel); the two approaches are the Tresca theory and the Von Mises theory. The combined stress according to CSA Z662 is a biaxial stress, which is a combination of hoop stress due to internal pressure, and longitudinal stress due to bending of the pipe to achieve the curved shape of the HDD path added to the stress imposed on the pipeline due to thermal differential. A large positive thermal differential, together with internal pressure, is typically the worst case.
The Pine Creek crossing

The resultant minimum acceptable radius for the Pine Creek crossing was determined to be 385 m, a marginal improvement on the previous 425 m. The 385 m radius would need to be compared to the calculated minimum radius of the drill path after completion of the 36 inch ream. The ream was completed two days later. Entec analysed the drill profile data and calculated a minimum dog-leg radius of 284 m, with a number of other radii less than 385 m. The subsequent survey
tool run was completed later in the same day. Entec analysed these results and calculated a minimum radius of 170 m with a number of other radii less than 385 m. The ever-decreasing calculated minimum radius confirmed that the progression of the calculations was from conservative to more realistic. Pembina and its construction manager subsequently decided to pull the NPS24 pipe into the hole and the project team agreed to continue analysing the available information to determine if in fact the 36 inch reamed drill path was acceptable. First, the project team completed a sensitivity analysis to determine if reducing the maximum operating pressure of the pipeline or increasing the pipe grade would be a viable alternative. After careful review, the required maximum operating pressure reduction to 4,400 kPa, or a pipe grade increase to 545 MPa, would still not be sufficient to provide acceptability for the Pine Creek crossing. The next and only viable alternative for analysing the crossing was to determine the absolute stress level within the pipe at this location. The Tresca and Von Mises methods are both stress-based, conservatively not accounting for the nonlinear steel properties. Due to tight-bend radii determined in the eld, the group agreed to undertake a third method of analysis: a non-linear strain analysis, which is permitted by CSA Z662 Annex C as a limitstate design approach. This strain analysis is much more complex than either of the stress methods, but it also is a more rational and usually less-restrictive approach. Determination of the longitudinal strain with non-linear steel properties and subject to biaxial stresses was performed with a niteelement computer program. Subsequent to the very detailed review of the stresses involved in this installation, the current drill alignment was supported by WorleyParsons Calgary, based on the maximum calculated strain being below the maximum allowable strain for the crossing using limit-states analysis. WorleyParsons used the minimum drill path radius of 170 m and compared the strain at this location to the maximum strain allowable for the NPS24 crossing pipe. The results were deemed acceptable as per the above discussion. In addition, WorleyParsons recommended
Crossings on the great pipeline of China

Direct Horizontal Rig AA 440,000 lb.
Chinas 8,704 km Second West East Gas Pipeline is one of the largest pipelines currently under construction. The pipeline crosses many different terrains, some of which require specialist installation techniques. One of Chinas main specialist manufacturers, Drillto, provided a horizontal directional drilling rig to complete a 510 m crossing of an environmentally sensitive area along the pipeline route.
Successful pipe pull.
The pipeline construction site.
running a geometry pig through the crossing within two years of the start of pipeline operation to verify the geometry of the pipe within the crossing and reconrm the results of the limit-states analysis. The purpose of this article is not to support less conservative analysis as a general rule for HDD installations but rather, given the difficult circumstances encountered at the site, to illustrate that this method of analysis is applicable and required in certain circumstances. HDD installations of pipelines beneath pipeline route obstructions are technically challenging, as are the determination of the construction stresses. These installations are such that future repair and clean-up if a problem develops are not possible or are extremely difficult due to the location and depth of these installations. Therefore, a conservative approach to the design provides some assurance that problems should not occur at this type of crossing.
hina National Petroleum Corporation commenced construction of the $US23.3 billion project in late 2008. The scope of works involves the construction of an 8,704 km gas pipeline that will connect Horgos, in the Xinjian Uygur Autonomous Region, with the Hong Kong Special Administrative Region after traversing 14 provinces, autonomous regions, and municipalities. The trunk pipeline is estimated to cost $US10.3 billion, while the network is expected to cost $US13 billion. The project has been divided into eastern and western sections with Zhongwei, in the Ningxia Hui Autonomous Region, designated as the pipelines midpoint. The western section, running 2,461 km from Horgos to Zhongwei, commenced construction in February 2008 and the majority of the welding is now complete. The eastern section, running 2,477 km from Zhongwei to Guangzhou, and with a design pressure of 10 MPa, commenced construction in December 2008. The eastern section will connect to the Turkmenistan China Gas Pipeline, which is also currently under construction and is scheduled to be commissioned in 2011. When completed in 2011, the Second WestEast Gas Pipeline will have a capacity of 30 Bcm/a of gas.
Drillto's HDD rig in action.
HDD in Tianjin
The Tianjin Pipeline Bureau planned the installation of pipe near the Tianjin West Outer Ring No.10 Bridge district. The crossing started on 16 May 2009, with the pipeline pull-back completed on 6 June 2009. Horizontal directional drilling (HDD) was chosen for the pipeline installation under approximately 400 m of green belt land, as well as under a canal and neighbouring high-tension electricity pylons. The length of the directional drilling crossing was 510 m, with a design depth of 15 m.
This article is an edited version of a paper entitled Does the HDD reaming pass remove extreme alignment dog-legs: a case history by James P. Murphy, Glen Fyfe, Trevor Giesbrecht and Wes Dyck presented at No-Dig 2009 in Toronto, Canada.
Project contractor Mr Xing identied one of the major challenges of the crossing. The main difficulty was overcoming the strong electric eld interference from the highvoltage lines, which changed the magnetic declinations we use to guide the drill head. The river banks in the green belt area were smooth, and the river is approximately 110 m wide and 4 m deep. Ground conditions along the crossing path consisted of clay and sand at varying depths. In order to place precisely the drilling rigs, the entry and exit points of the drill path needed to be set along the routes central axis. Mr Xing said that it was very difficult to set out the central axis due to the
dense vegetation of the green belt, and GPS was used to overcome this challenge. The completion of the pilot hole, the key to the entire crossing, used a ZT-150 HDD rig. The bore was guided under the river with the SST system, using the shore as a reference point. After the river crossing, ground tracking was used to guide the bore path. Accuracy of the entry and exit points is fundamental to the success of HDD crossings. In this case measurements were taken frequently and trial holes were dug to avoid interference with existing utilities. The drill bit broke through along the centre-line with a 6 angle an indication
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Xinjian Uygur Bejing Zhongwei Tianjin
SAFETY
Oil Search: achieving safety in PNG

Shanghai
Active in Papua New Guinea since 1929, Oil Search Ltd is the countrys largest oil and gas producer, operating all of Papua New Guineas producing oil and gas fields. Developing these fields has required the installation of infrastructure through hazardous terrain. Here, Projects Superintendent Ian Black explains the safety measures that the company has developed to ensure a successful project.
SST drill path diagram.
Hong Kong
of the projects success. The pilot hole was completed in a straightforward manner, in part due to continuous adjustment of the drill pump volume and accurate control of the muds viscosity with bentonite drilling uid. A number of passes were completed with the reamer, increasing the diameter of the pilot hole to a nal diameter of 1,000 mm. Throughout the reaming process, adjustments to the mud displacement, control of the pull-back speed, and close attention to the pump pressure, torque, and the back-drag force ensured the successful completion of the crossing. The pull-back of the product pipe similarly depended upon careful observation of the drill rig tension, and control of the torque, mud back pressure, and the pull-back speed.
Conclusion
Mr Xing said that lessons learned for future construction projects include paying close attention to the drilling rig, mud back pressure, and promptly adjusting the mud. The Second West East Gas Pipeline is expected to increase the share of natural gas in Chinas energy consumption by one to two per cent. It is expected to play a signicant role in boosting the countrys domestic natural gas demand, facilitate the improvement of Chinas manufacturing industry, improve the nations energy structure, and promote economic and social development in the regions through which the pipeline route passes.
HDD MaChinerY stats

Machinery: Drillto Trenchless Company ZT-150 horizontal directional drill Pull-back force: 1,500 KN Thrust force: 1,500 KN Incidence angle: 10 18
The main difficulty was overcoming the strong electric field interference from the high-voltage lines, which changed the magnetic declinations we use to guide the drill head. - Mr Xing
The biggest pull-back diameter: 1,200 mm Maximum through distance: 2,000 m Drilling rig structure: Crawler
il Search currently operates around 40,000 boe/d of production from seven elds in Papua New Guinea (PNG), with an additional 400 MMcf/d of gas processing and re-injection. The company is also a major stakeholder in the ExxonMobil operated PNG LNG Project, which is set to produce approximately 6.6 MMt/a of LNG once completed. In 1998 Oil Search took over operatorship of the Hides gas-to-electricity project and, in late 2003, took over operatorship of the Kutubu, Gobe and Moran oil elds, immediately embarking upon projects to develop the North West Moran (NWM) and South East Mananda (SEM) elds. The SEM and NWM projects saw over 500 new people come into the eld to construct new owlines and facilities in rugged and inaccessible jungle. This workforce included many local landowners, and Australian and Asian contractors, most living in bush camps accessible only by helicopter. The 100, 150 and 200 mm diameter owlines were constructed above ground from pipe bent offsite and strung by helicopter into narrow, hand-cleared rightsof-way (RoWs). All traffic along the RoWs was by foot or helicopter. To add to the construction challenges, the SEM project required the construction of a 470 m long pipeline suspension bridge over a gorge more than 400 m deep. These development projects, coinciding with an increase in drilling activity, led to an increase in Oil Searchs incident rates. Approximately halfway through these projects, with around 1.5 million man-hours remaining, the combined projects had a total recordable incident frequency rate (TRIFR) of nine incidents per million man hours. This was substantially better than international pipeline industry performance standards, both at that time and today, but signicantly higher than the rest of Oil Searchs PNG operations.
Above and below: Construction of the Hegigio Gorge Bridge on the South East Mananda Project.
There were also several high-potential, near-miss incidents experienced. These near-miss incidents, combined with the substantial increase in incident rates, led to Oil Search assuming a more direct health, safety, and environment management role on the projects. In order to do this the company deployed a team of experienced people from its seismic and production operations. This team worked closely with all contractors, their supervisors and the workforce, and focused heavily on risk assessment, job hazard analysis (JHA), incident investigation, and direct workforce engagement through PNG citizen safety officers. This programme resulted in a signicant drop in incident rates, by approximately half in the second half of the project despite mobilisation of multiple new crews to recover schedule. The projects were
Flowline construction; pipe supports installed and waiting for helicopter stringing of pipe bent to suit.
completed with a TRIFR of seven and zero lost-time incidents (LTIs) from the more than 3 million man-hours worked. In a subsequent project to hook up two new Moran oil eld wells the implementation of the safety management practices developed on SEM and NWM resulted in a low rate of construction incidents, with a TRIFR of 2.5. Tragically, however, a helicopter crash resulted in three fatalities, permanent incapacitation of the pilot, and injuries to three other workers on this project.
A new tactic
After the completion of these projects in 2006, Oil Search decided to roll its various project delivery functions into a single team
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SAFETY
Water line construction for drilling operations pipe is delivered to small stockpiles by Chinook; stringing and jointing is by hand.
Oil Searchs safety performance benchmarks well against comparable Australian and international industry groups. Construction HSE performance is now leading rather than trailing Oil Search company performance. The above graph compares the standards of Oil Search, the Australian Petroleum Production & Exploration Association, and the International Association of Oil & Gas Producers.
A typical remote area well site. Helicopter load constraints drive equipment selection.
covering such diverse works as process plant and pipeline construction, corrosion and integrity management, well-pad civil works, in-eld civil construction and maintenance, infrastructure construction, and delivery of community infrastructure under a tax-credit scheme. These legacy teams had diverse safety cultures and a wide range of safety compliance and performance levels. In forming the unied projects team, the decision was taken to homogenise the groups safety culture and practices through a back-to-basics approach (dubbed the KISS programme) that focused on the following elements: Planning: making time in each project to plan upfront, particularly risk assessment, logistics and training; Risk assessment: ensuring a risk assessment is undertaken for every project and that this forms the basis of site-management plans and supervisor tasking. The result of the risk assessment, typically in the form of a site-specic safety plan, is rolled out in a supervisor pre-commencement meeting between Oil Search and contractor(s); Work face tools: a strong focus on the basic JHA and step-back 5x5 tools; Review: supervisor safety tours, STOP and hazard identication cards, and ensuring that the workforce actively participates in these with results that are fed back to the workforce; and, Incident investigation: a strong emphasis was placed on near-miss incident investigation.
The results of this approach and the intensive mentoring of Oil Search and contractor supervisors by the Projects Departments HSE team (made up largely of the same team deployed to the SEM and NWM projects) gave rise to a dramatic improvement in lead indicator performance matched by a year-on-year drop in incident rates from a TRIFR of seven in 2006, to a TRIFR of one in 2009. In 2008, Oil Search mobilised a major new contractor for non-construction work in PNG. Many of the lessons learned from past mobilisations were applied in this process. Despite this, incident rates in that area of the business rose sharply for a short period and reached as high as a TRIFR of 35 during mobilisation before stabilising around a TRIFR of 15 after a years work. Looking back at the mobilisation, the following was noted: The contractor observed that, while its supervisors knew the required outcomes, they did not always know how to achieve them (tools/tactics). Training is now (often) followed by onsite mentoring by the trainers; High turnover of supervisors: requiring signicant re-training; Poor quality of incident investigation: training provided, but not always successfully used by supervisors; Supervisors were often poor at recognising hazardous situations, often because they were engaged in assisting in the performance of the task and not taking the higher-level supervisors overview due to workforce skill level and communication difficulties; The workforce was keener to please the boss than work safely: if combined with
poor supervisor communication this was shown to be potentially very hazardous; A cloud of responsibility was identied, where several supervisors observed hazardous activity but none thought they were in charge; and Poor quality JHAs: needed to audit more heavily. A concerted effort by Oil Search and the contractor to address these issues resulted in the 12-month moving average TRIFR for this contractor dropping to below four by the end of 2009 and continuing to improve.
Projects delivered safely

Since assuming operatorship of the PNG oil elds in 2003, Oil Search has achieved outstanding results in HSE management. The graph demonstrates that the companys combined TRIFR for production, drilling, seismic, and project operations has been consistently world-class and benchmarks well with international oil and gas producers performance, albeit as described above this improvement in performance has not been without setbacks. Oil Search is currently mobilising for multiple projects worth approximately $US400 million as part of the PNG LNG Project. These include projects to extend the life of the oil export system pipelines and offshore facility to suit storage and export of condensate from the main upstream gas processing plant, as well as modications to the main oil-processing facilities to enable gas export. This work will again introduce new contractors and hundreds of new people to Oil Searchs PNG operations. Oil Search is currently working with those contractors to apply its lessons learned and set the foundation for incident-free project delivery.
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TECHNICAL
TECHNICAL
In-line with the latest inspection issues

The first two papers published in the March 2010 edition of the Journal of Pipeline Engineering discuss aspects of the common theme of in-line inspections (ILI) and their analyses. Both were presented at the recent Pipeline Pigging and Integrity Management conference in Houston, Texas.
Providing strong linepipe

Development and commercialisation of high-strength linepipe, by Hitoshi Asahi, Takuya Hara, Eiji Tsuru, and Hiroshi Morimoto, Nippon Steel Corporation, Futtsu, Japan. The development and commercialisation of high-strength linepipe is described by authors from Nippon Steel in Japan in a further paper in the Journal. To meet the increasing worldwide demand, it is becoming necessary to transport gas from remote areas to consumers over longer distances and through large diameter pipelines while keeping the costs as low as possible. The thinner the pipeline wall thickness that can be made by using high-strength steel, the greater the reduction will be in pipeline construction costs. The manufacture of high-strength, large diameter, linepipe made using the UOE process from X100 and X120 steel started toward the end of the 1990s, and has now reached the stage of large-scale testing for practical application and commercial use. At the same time, an ability to accommodate deformation that has not been required for linepipe previously, has recently become a design criterion for pipelines that pass through areas of permafrost, or areas of seismic or other ground-moving activities, and this therefore necessitates the use of strain-based design. This paper reviews the present state of commercialisation and standardisation, the basic pipe production technology, and the properties and laying technology for such high-strength linepipe. For a cross country pipeline, the linepipe weight linearly decreases with increasing pipe strength, irrespective of the operation pressure and pipe diameter, which is rare for structural steel products. The authors point out that in such a large-scale project, the linepipe cost can be signicantly reduced by using a higher strength grade, which will also provide cost savings in both logistics and pipelaying. As a consequence, the development of X100 was initiated partly by Shells request to major pipe manufactures in 1994 to see what could be achieved. Subsequently, the development of X120 was the result of a number of joint research projects between ExxonMobil and pipe manufacturers. By 2000, pipe development had advanced and small-scale laying tests and operational trials were being undertaken, in an addition to full-scale gas burst tests. In 2007, X90, X100, and X120 were standardised as ISO3183 and API 5L, and the era of high-strength pipelines is now widely anticipated.
X100 under pressure

Production and development update of X100 for strain-based design applications, by Andreas Liessem, Rene Rueter, and Martin Pant, Europipe GmbH, Muelheim, Germany, and Volker Schwinn, AktienGesellschaft der Dillinger Httenwerke, Dillingen, Germany. Andreas Liessem of Europipe in Germany and his co-authors continue the above theme with their paper on the production and development of X100 for strain-based design application. They echo the important point that the use of highstrength steels is of considerable interest for long-distance gas transmission pipelines as the material promises both economic benets as well as greater resistance to ground movements and seismic activities. The technology required for such regions necessitates a strain-based design: low Y/Tratios, adequate uniform elongation, and the shape of the stress-strain curves are of vital importance, and are nowadays at the centre of the efforts for such developments. Another issue is that the pipes themselves are heated during application of the coating. This factor, in combination with the cold deformation that is needed during manufacture, affects the specic mechanical properties relevant to strain-based design and, as a consequence, recent specications include test requirements after simulation of coating application. The authors go on to describe the application of X100 pipe to the 300 km long North Central Corridor pipeline project in Alberta, Canada, for which Europipe manufactured 2.5 km of 42 inch diameter X100 linepipe with 14.3 mm wall thickness. The paper also gives an update of the development status of the material for strainbased design applications.
n the rst, Dr Ted Anderson of the Quest Integrity Group based in Boulder, Colorado, United States, looks at advanced assessment of pipeline integrity using ILI data, while in the second, Guy Desjardins of his eponymous consultancy based in Calgary, Canada reviews the detection of active corrosion from repeated ILI runs.
Advancing integrity
Advanced assessment of pipeline integrity using ILI data by Dr Ted L Anderson, Quest Integrity Group, Boulder, Colorado, USA. Dr Anderson points out that the considerable improvements in ILI and computing technology, coupled with the emergence of tness-for-service standards, have created an opportunity to advance pipeline integrity assessment, and his paper describes novel approaches for assessing cracks, wall loss, and dents in pipelines using data from ILI tools. Crack-detection ILI tools that rely on shear-wave ultrasonic thickness (UT) measurement have improved signicantly in both detection probability and sizing accuracy. The combination of advanced modelling, employing realistic fracturemechanics models that use 3D elasticplastic nite element analysis, and reliable ILI provides a superior alternative to hydrostatic testing for ensuring pipeline integrity. ILI tools that measure wall loss with compression-wave UT provide superior results compared to magnetic ux leakage (MFL) tools, outputting a digital map of individual thickness readings, which is ideally suited to effective area assessment methods such as RSTRENG and the API 579 Level 2 remaining strength factor calculation. Dr Anderson describes how his rm has developed software that can rapidly process large quantities of ILI wall-loss data and evaluate the maximum allowable
operation pressure (MAOP) at discrete locations. The ranking of these MAOP values serves as a rational and rapid means for prioritising the severity of corrosion throughout the line. Dents that are introduced during fabrication, installation, or by a third party are among the most common source of failure in pipelines. Traditional assessments are based on a simplistic characterisation of the dent (for example, the ratio of the dent depth to the pipe diameter), combined with a simple empirical equation. An advanced dent assessment that combines a detailed mapping of the dent from ILI data (either UT or a calliper pig) with 3D elastic-plastic nite element analysis has been developed. This dimensionally accurate 3D model of the dented pipe can be subjected to cyclic loading, and its remaining life can then be computed through a proprietary low-cycle fatigue damage model. Dr Andersons paper shows how this advanced methodology can be applied to interacting anomalies such as dent/gouge and dent/crack combinations.
The statistics of in-line inspection

Detection of active corrosion from repeated ILI runs, by Guy Desjardins, Desjardins Integrity, Calgary, Alberta, Canada. Repeated ILIs of transmission pipelines have been used for many years to estimate corrosion rates, although the calculation of a corrosion rate from a direct comparison of ILI anomalies is often contaminated with ILI measurement errors. Mr Desjardins introduces an alternative procedure for detecting the presence of active corrosion by examining various statistical properties of the data. While the statistics do not estimate the corrosion rate, he points out that they can indicate the presence of active corrosion. Once this has been identied, the operator is then able to address each location appropriately.
This article highlights some of the papers published in the current issue of the Journal of Pipeline Engineering. Abstracts of the complete contents and subscription information can be found at www.j-pipe-eng.com
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45
INDUSTRY NEWS
The Pipelayer System.
Pipelayer safety made simple

PipeLine Machinery International has recently teamed up with Cranesmart to become the exclusive distributor of the Pipelayer System, the industrys first wireless load monitoring indicator system for pipelayers.
aterpillars global pipeline equipment dealer PipeLine Machinery International (PLM) will act as distributor for the Pipelayer System, which consists of a load pin, boom angle indicator, four-axis slope indicator and optional antitwo block function. Information is relayed from wireless transmitters to an easy-to-read, cabmounted display panel. The display panel shows boom overhang, load on the hook, percentage of permissible rated load and maximum rated load. When operating in out-of-level ground conditions, the display indicates the slope in degrees and can be programmed to provide tipping alarms. At the push of a button the system also provides information on tip height, boom angle, boom length, parts-of-line and detailed four-axis ground slope indication. PLM Equipment Services Manager Lindley Imeson said We are pleased to
provide this state-of-the-art load monitoring system for the pipeline industry. Safety is our customers highest priority and Cranesmarts Pipelayer System meets these needs head-on. Until now, operators have had to trust their gut feeling on challenging lift and lower-in operations. The Pipelayer System eliminates the guesswork while enhancing their skill, providing them with the immediate, accurate information needed to perform safely and efficiently.
Jobsite safety
The Pipelayer System will enable contractors to manage a safer and more efficient job site. With precise load management details available to operators at all times, the system signicantly reduces the potential for costly and dangerous overloading, tip-overs, roll-overs and other job site accidents. The use of these operator aids will also enhance safer working
conditions for ground personnel and reduce equipment damage due to overloading and extremely steep slope operations. Best practices in the industry include a Job Safety Analysis before each shift, said Mr Imeson. For the lowering-in crew, this will mean a review of the slope and ground conditions in the area of work for the day. Knowing the ground slope angle will guide the decision for either standard operating or anchoring to another tractor for stability on the slope. Ground conditions come into play as well. Whether the working pad is stable, compacted soil or loose rolling rock can make a big difference in tight tolerance situations. With the Pipelayer System, the operator immediately knows if his machine track has changed the operating angle so he can make the necessary adjustments before trouble begins.
ONE WORLD. ONE FOCUS. ONE NAME.

2008 Caterpillar All Rights Reserved CAT, CATERPILLAR, ACERT, their respective logos, SystemOne, Caterpillar Yellow and 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.
PipeLine Machinery International (PLM) supports the global needs of mainline pipeline construction customers with one-stop access to the most extensive pipeline machinery expertise in the business. New and used PLM-supplied Caterpillar machines are now operating around the world delivering maximum productivity and reliability, together with industry-leading technology in the areas of environmental compliance, safety and ease of operation.
www.plmcat.com
46
INDUSTRY NEWS
MEET THE ASSOCIATION
CEPA: addressing Canadas pipeline issues

Established in 1993, the Canadian Energy Pipelines Association facilitates industry collaboration on issues such as safety, pipeline integrity, best practices, and the long-term stability and competitiveness for the nations transmission pipeline sector. Association President Brenda Kenny speaks to Pipelines International about current activities and issues.
oday, the Canadian Energy Pipelines Association (CEPA) represents 11 large transmission pipeline companies and other technical and associate members that have an interest in pipeline integrity and environment issues. CEPA President Brenda Kenny says that the association has experienced considerable growth over the last two decades. In particular, in the mid-1990s, stress-corrosion cracking was a challenging technical issue in Canada and a fairly signicant concern. It created a really important drive to collaborate and come together, and through that we felt that there were various factors to work together on, such as common standards and best practices. Dr Kenny says that CEPA currently has over 150 routine volunteer technical experts that address a variety of issues from accounting practices through to climate change. Its been a very effective way to share information and pool knowledge to help solve problems, says Dr Kenny. There is certainly the benet of looking ahead to areas of future concern that would be difficult to handle by any one company, and through CEPA we can also reach beyond our own sector. For example, last year we did a lot of work across the value chain. We worked with upstream partners and downstream partners on the Energy Framework Initiative. The framework outlines key elements of an integrated energy policy framework for Canada, focusing on sustainable development. Through that initiative we collaborated with a number of stakeholders to consider the way in which to talk about energy, the environment and the economy, and some of the main policy areas that need to be solved for that, says Dr Kenny.
Key issues
Dr Kenny says that the environment, regulation and land access are key issues that face the Canadian pipeline industry. Regulation and how decisions are made around critical infrastructure is a key area, Dr Kenny explains. How decisions are taken in the public interest drives how to be sensible about regulation. In addition, Dr Kenny says that the interception between land use and infrastructure is important to CEPA. In Canada, we have an increasing population encroachment on rights-of-way (RoW) in areas that used to be very remote. She says that this boosts the need for strict pipeline-integrity and riskmanagement systems. In particular, the association is completing a lot of work on damage prevention. Approximately half of Canadas safety incidents are related to thirdparty damage, and while the nation has dial-before-you-dig laws in place, Dr Kenny says that the enforcement is relatively weak. Its a very different risk-management issue involving human behaviour as opposed to pipeline integrity issues, which are highly technical. We need to use different tools to attack each one well, she says.
Left and right: Caterpillars pipelayers are reliable and sturdy machines.
The Pipelayer System also offers optional anti-two block protection. This feature includes a simple, wireless anti-two block switch, which swivels freely to travel in the direction of the wire rope, utilising a chain and trigger weight to sense block position. During intricate tie-in and valve setting operations, the boom operator is concentrating on lining up the pipe ends for welders working on the pipe, said Mr Imeson. With their focus completely on the pipe, the proximity of the two blocks can go unnoticed. If the blocks hit, abrupt movement of the pipe may occur, causing safety concerns and equipment damage. The anti-two block function provides audible and visual alarms on the display panel just before the two hanging blocks come together, helping eliminate unnecessary damage to blocks and boom, wire rope and winches. The anti-two block system is also an important safety aid, protecting personnel working below the hook from dangerously abrupt mid-air load movements.
Reliability
Pipeliners are often working in some of the most challenging conditions of any major construction project, said Mr Imeson. As equipment services providers, we have to do all we can to keep the construction process going. Reliability and serviceability are paramount. Thats why we chose the Cranesmart Pipelayer System as our recommended load monitoring system. The Pipelayer System has been engineered specically for pipelayers and the pipeline environment. Electronics are temperature tested to perform accurately from -40 to +60 Celsius, and the glasslled nylon and high-grade stainless steel components are rugged enough to withstand the demands of heavy equipment and continual outdoor use. With no exposed wires or other mechanical relays, the Pipelayer Systems solid construction and no moving parts ensures increased reliability over other load monitoring indicator (LMI) systems, which can be bulky, difficult to install, hard to manage and less accurate. Because the system is wireless, it can be serviced remotely 24 hours, seven days a week, thorough Cranesmarts phone system. If service issues require replacement parts, the company can usually resolve the malfunction within 24 to 48 hours, minimising downtime. Cranesmart also offers free lifetime replacement of the systems ve-year batteries.
Compliance
There has been recent speculation that LMI systems will become mandatory on pipelaying equipment in the near future. The Pipelayer System has been designed for the simplest adaptation to LMI compliance as possible. With this new arrangement, all future-dated pipelayer machine orders will be coming out of the Caterpillar factory Cranesmart ready for installation, said Mr Imeson. PLM is also standing by and ready to arrange installation of the Pipelayer System on existing machines as customers require. Systems are shipped complete with simple instructions and all the mounting hardware required for quick installation. Most installs can be completed in as little as two hours, without the assistance of specialised tools or service technicians, minimising installation costs. The RAM display mounting kit can be installed in the most convenient and visible location on any pipelayer. The Pipelayer System can easily be retrotted to pipelaying equipment, with original equipment manufacturer load chart information programmed to each model of pipelayer. Caterpillar and its dealer network are committed to providing customers with the technology platforms needed to improve job safety and efficiency. PLMs new Cranesmart Pipelayer System can assist with equipping pipeline spreads with the right technology to ensure construction companies have a leading reputation for quality and safety.
Dr Brenda Kenny.
In Jasper Park the big issue was big animals like caribou and grizzly bears being able to move freely on a landscape. It had nothing to do with the pipeline, but it was something that the pipeline construction could actually help with, and produce new and safe pathways so that the animals could move and breed. Dr Kenny claries, Thats a very specic ecosystem issue, but it goes to the heart of how you execute projects and Im sure in any region you can identify environmental challenges and collaborate on how pipeline companies can help in solving those.
Working with stakeholders

We are nding that there is a lot more up-front planning and collaboration to nd ingenious ways to leave positive legacies, says Dr Kenny. She points to managing impacts to the environment as an area where collaboration is important. One good example of that was a major pipeline project in a protected national park in the Rockies here in Canada; the pipeline company going through there worked with environmental groups to address broad ecosystem problems as opposed to focusing just on the RoW.
Moving ahead
Dr Kenny says that it is important for pipeline companies in Canada, and around the world, to address a triple bottom line. Be really clear about what sustainable development really is, and address those environmental issues, meet those social needs, and do it in a way that is economically efficient. Thats what CEPA aims to do and I think we need to move forward on the sophistication of how to do that and communicate effectively so that stakeholders understand what we stand for and how we can do that.
WHaT Is an anTI-Two blocK funcTIon?

Anti-two block refers to a device that alarms when the hook block approaches the sheave on a crane or pipelayer system. The function may also actuate hydraulic or air lockouts.
For more information on CEPA visit www.cepa.com
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49
INTEGRITY
INTEGRITY
Cold and total pipelines inventory ('000 km)
25 20 15 10 5 0
1000 800 600 400 200 0
Published in November 2009, the latest report by the European oil pipelines management group of CONCAWE shows that there were nine spillage incidents on the network operated by the associations members in 2007, of which two were attributed to corrosion and seven to third-party interference.
Hot pipelines inventory (km)
European oil pipeline integrity: third-party up, corrosion down
40 35 30
Total Crude White products Hot
1600 1400 1200
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Assessing pipeline failure

The current report, entitled Performance of European cross-country oil pipelines: a statistical summary of reported spillages in 2007 and 1971, focuses on CONCAWE members pipeline network, which includes 150 pipeline systems with a total length of 34,721 km (at the time of the report), slightly less than the length of the network in the previous year (see Figure 1). The difference is partly due to corrections to the reported data, and because a few companies did not report and were therefore not included in the 2007 statistics. The reported volume transported in 2007 was 762 MMcm of crude oil and rened products, a gure that has been stable in recent years. The nine spillage incidents reported in 2007 correspond to 0.26 spillages per 1,000 km of pipeline, just under the ve-year average and well below the long-term running average of 0.55 per 1,000 km. The long-term running average has been steadily decreasing
Figure 2: Annual inspections by intelligent pigs 19792007.
6000 5000 Total length inspected % of total
19
20
20
ONCAWE, the European Association for the environment, health and safety in rening and distribution, has collected data on spillages from European cross-country oil pipelines since 1971, and has published annual reports over this period. CONCAWE gathers comprehensive information from the approximately 70 operating companies and joint-ventures that make up its membership. The information is published in a statistical form that provides an important insight into the industry and its increasing integrity over the decades. Outside the United States, there are no such publicly-available data for either oil or gas transmission pipelines, and so the CONCAWE annual reports are of signicant value in establishing trends and providing historical analyses on which to base future decisions. The association is acknowledged for its assistance with this introduction to the report and brief discussion of its ndings.
Total length inspected (km)
4000 3000 2000 1000
12% 9% 6% 3% 0%
Metal loss pig Crack-detection pig Geometry pig
76 sections 18 sections 50 sections
4,418 km 1,195 km 3,687 km
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% of total inventory
over the years from a high of 1.2 per 1,000 km in the mid 1970s. There were no reported res, fatalities, or injuries connected with these spills, and the gross spillage volume was 988 cubic metres, equivalent to 1.3 parts per million of the total volume transported. This corresponds to 28 cubic metres per 1,000 km of pipeline compared to the long-term average of 56 cubic metres. CONCAWE reports that 53 per cent of the spilled volume was recovered or safely disposed of. Most of the pipeline spillages were small, and just over 5 per cent were responsible for half of the gross volume spilled. In the past, the pipelines carrying hot oils such as fuel oil have suffered very severely in Europe from external corrosion. This has been due to design and construction problems, and most have now either been shut down or switched to cold service. The great majority of pipelines now carry unheated petroleum products and crude oil, and only 270 km of heated pipelines were still in service during 2007. There have been no reported spills from hot pipelines in the last ve years of this survey. Of the nine reported incidents in 2007, two were related to corrosion and seven were connected to third-party activities, either accidental or malicious. Over the long term, third-party activity has been regularly responsible for the majority of spillage incidents, although this cause has progressively reduced over the years. Mechanical failure is statistically the second greatest cause of spillages, although
not relevant in 2007, and corrosion (both internal and external) has generally come third in the league table of spillage causes. Interestingly, after considerable progress in reducing the frequency of mechanical failures in the 1970s and 1980s, the mid1990s and beyond has seen an increase in mechanical failures. Most of the European network of pipeline systems operated by CONCAWEs members were constructed in the 1960s and 1970s. In 1971, at the time of the rst report, around 70 per cent of the network was 10 years old or less; by 2007, only 5 per cent was 10 years old or less and 42 per cent was over 40 years old. So far this does not appear to have led to any increase in spillages. The industrys concern to maintain this situation (or improve it) is evidenced by the fact that in 2007, 84 sections were inspected by at least one type of intelligent pig, representing total run length of around 9,300 km. However, most inspection programmes involved running more than one type of pig in the same section, so that the total actual length inspected was 5,281 km 15 per cent of the network. CONCAWE points out that, overall, there is no evidence to show that the ageing of the pipeline system poses any increase in the level of risk. The development and introduction of new inspection tools and techniques will allow these pipelines to continue reliable operation for the foreseeable future, although performance statistics such as these will be necessary to conrm the achievement.
Intelligent inspection
CONCAWE has been collecting data on intelligent pig inspection activities for the last 17 years, including a one-off exercise to collect back data from the time intelligent pigs were first used around 1977. Separate records have been kept for inspections made by metal-loss pigs, crack-detection pigs, and geometry (or calliper) pigs. In 2007, as mentioned, the 84 sections that were inspected by at least one type of intelligent tool covered a 9,300 km, split as seen in Table 1. As shown in Figure 2, the use of intelligent pigs for internal inspection grew steadily up to 1994. They then levelled off for a period during stabilisation of the industry, and resumed an upward trend in 2003, with an average annual pig run total of almost 8,000 km, and an average actual length inspected of 4,890 km over the last ve years. Within the last ten years, a period considered as a reasonable cycle for this type of inspection, 443 out of a total of 699 active sections (63 per cent) have been inspected at least once by at least one type of pig, representing 76 per cent of the total length of the network. Of the balance of pipeline sections, there are certainly some mainly the older ones which were not designed to be pigged or, because of small sizes, small radius bends, or lack of suitable pig launchers or receivers, cannot be intelligent pigged. The relatively recent introduction of pigs to inspect 6 inch diameter pipelines and smaller, and the increasing number of tools available to inspect unpiggable pipelines, means that these problems are diminishing in the network operated by CONCAWEs members. The length of un-inspected pipelines is therefore certainly less than the above gure, and will continue to decrease in future years.
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77
79
81
83
89
87
91
93
99
01
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05 20
85
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19
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19
19
19
97
19
19
19
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Figure 1: CONCAWEs members oil pipelines and categories.
10000 Geometry 8000 Cracks Metal loss
Total length inspected (km)
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79
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83
85
87
99
89
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18% 15%
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Table 1: In 2007, 84 sections of pipeline were inspected by at least one type of intelligent tool, covering a total distance of 9,300 km.
Figure 3: The total proportion of the pipeline network inspected by intelligent pigs 1979 2007 (Images courtesy of CONCAWE).
For more information about CONCAWE visit www.concawe.org
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51
pOLICY & OpINION
pOLICY & OpINION
Transport of CO2 for carbon capture and storage

The subject of CO2 transportation by pipeline is of widespread and increasing importance as many governments and communities worldwide come to terms with the issues of carbon capture and storage for the mitigation of climate change. The transportation aspect is often looked upon as the missing link in a concept that is already being widely embraced.
Newcastle University, UK, in association with Tiratsoo Technical and Houston-based Clarion Technical Conferences, and supported by the UK-based Carbon Capture and Storage Association, is organising the first Conference on the transportation of CO2 by pipeline on 12 July in Newcastle.
ewcastle University, UK, in association with Tiratsoo Technical and Houston-based Clarion Technical Conferences, and supported by the UK-based Carbon Capture and Storage Association, is organising the rst conference on the transportation of CO2 by pipeline on 12 July in Newcastle. This article, prepared with the assistance of Professor Martin Downie and Dr Julia Race of Newcastle University, and Patricia Seevam of BP, provides a brief overview of the subject, and an introduction to some of the technical issues involved. Carbon capture and storage (CCS) is perceived as a short to medium-term measure for closing the energy gap while robust carbon-neutral technologies are developed to provide power in a post-fossil fuel energy era. In recent years the capture technology has developed to the point of viability, and storage has been accepted to be safe and ecologically sound, however relatively little work has been carried out on CO2 transport. In the US, naturally occurring CO2 is routinely transported for considerable distances overland, although mostly through sparsely-populated regions, for the purpose of enhanced oil recovery (EOR). There is also some limited transport of captured, or anthropogenic, CO2. In the UK a number of suitable offshore CO2 reservoirs (or sinks) have been identied in the North and Irish Seas for EOR, or simply for storage. It has been commonly assumed that the transport of CO2 to offshore sinks is straightforward, typically in the North Sea, and may even be able to utilise the existing pipeline infrastructure. However, there are signicant differences between the US experience with clean CO2, and the transport requirements for anthropogenic CO2. The UK, for instance, will be dealing with the latter, mostly from power plants, which will impose constraints on the hydraulics that have not yet been
fully explored. Considerable proportions of the transport system will be subsea, for which there is virtually no experience as yet; there are questions as to the suitability of much of the existing infrastructure and the desirability of using it; and, there is little experience with multi-source transport systems through densely-populated regions. To understand the issues relating to the transport of CO2, it is necessary to be aware of its physical properties. In brief, pure CO2 is a colourless, odourless, and non-ammable substance which can be transported as a solid, liquid, gas, or densephase liquid. The most efficient state of CO2 for pipeline transport is as a dense-phase liquid as, in this phase, the uid has the density of a liquid, but the viscosity of a gas. In this supercritical mode, captured CO2 has to be compressed to a pressure above the critical pressure prior to transport.
Dealing with the impure

CO2 that is captured from power plant and other anthropogenic sources is not pure, and the amount and type of impurities are dependent on the nature of the process and the capture technology used. Currently, there is little published work on transport of CO2 with these impurities, the main effect of which is to change physical properties such as the critical pressure, which can have a dramatic impact on the CO2s hydraulic behaviour. This in turn may change the operating regime of the pipeline, which may have to be operated at a higher pressure than would be required for pure CO2 in order to maintain it as single-phase supercritical or dense-phase. The presence of impurities in the CO2 stream will not only have a signicant effect on the hydraulic parameters such as pressure and temperature, but also on the density and viscosity of the uid, depending on the impurities present. Some combinations, particularly if hydrogen or nitrogen
are present, cause higher pressure and temperature drops for a given pipeline length than others, which has implications for the distance between compressor stations along the pipeline. The pipeline cost increases with the number of compressor stations which, in any event, are not viable for subsea pipelines. Sudden temperature drops can have potential material implications, such as embrittlement, and can also cause hydrate formation, both of which could damage the pipeline. The solvent properties of supercritical CO2 are known to be detrimental to the elastomers commonly used in valves, gaskets, coatings and O-rings, used for sealing purposes. At high pressures the supercritical CO2 diffuses into the elastomers and, when the pressure is reduced, blistering and even explosions can occur as the material decompresses. Many of the elastomeric materials currently used in oil and gas pipelines are therefore not suitable for CO2 transportation. Similarly, in-line inspection (ILI) of CO2 pipelines is problematic, as the supercritical CO2 dissolves the non-metallic components of the cleaning and ILI tools although highdurometer elastomers can be used to reduce the problem, they cannot eliminate it totally. There are other important material issues that will require consideration in CO2 pipeline design. Ductile fracture propagation may be an issue, and the
requirement to consider fracture propagation in CO2 pipelines is included in the federal regulations in the US. For some of the US pipelines, it was concluded that the pipe material did not have sufficient toughness to arrest propagating ductile fractures and therefore crack arrestors were required along these pipelines. This experience highlights the need to dene the toughness limits for equivalent pipeline networks, particularly considering the effect of impurities on the decompression behaviour of the gas, to avoid the costly requirement to t crack arrestors. In the US, the CO2 pipelines were designed-for-purpose. If pipeline re-use is to be adopted in the UK and elsewhere, existing pipelines will have to be assessed extremely carefully bearing all of these factors in mind.
Regulatory issues
In the UK, there is no experience with pipeline transportation of dense-phase CO2, and the design codes and the Pipeline Safety Regulations do not contain any classication for the material that would allow pipelines either onshore or offshore to be designed and constructed. In the US, dense-phase CO2 pipelines have been classied as hazardousliquid pipelines, and are therefore regulated under the US Department of Transportations Code of Federal Regulations 49CFR195. Most operators appear to have designed their pipelines conservatively using the ASME B31.8 code for gas pipelines, as this code is
more restrictive than the hazardous-liquid design code and also takes into account population density in the determination of the maximum allowable stress in the pipeline. All of the currently operating CO2 pipelines are onshore in the US, and many are routed through sparsely-populated areas; the consequence of an accident is therefore likely to be relatively small because the CO2 will dissipate before affecting the local population. However, if networks are to be developed onshore for the collection of CO2 from industry sources in congested countries such as the UK, this will require the routeing of pipelines close to population centres. In the UK pipeline design code, the minimum distance between a pipeline and occupied buildings is dened by the substance being transported. However, supercritical CO2 has not been classied and so, in order for pipeline networks to be designed in the UK at least, regulations need to be put in place to classify supercritical CO2 to allow safe pipeline design both on- and offshore. The programme for the Newcastle Conference will provide the opportunity to expand on many of these areas in detail, as well as to discuss current and future projects and research activities. It is also planned to have an open session intended to discuss formation of an academic and industry network to further progress this important topic.
Details of the programme for the Newcastle Conference are currently being nalised, and will be announced shortly at www.clarion.org
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STANDARDS
STANDARDS
Unified approach increases level of submarine pipeline integrity

By Bente Helen Leinum and Felix Saint-Victor, Det Norske Veritas
Threat group
Design, fabrication and installation threats
Threat
Design errors Fabrication related Installation related
Damage / anomaly
Metal loss Dent Crack Gouge Free span Local buckle Global buckle Displacement Exposure Coating damage Anode damage Metal loss Crack
Table 1. Typical damage and anomalies related to the different threats
Driven by the increasing level of ageing pipelines, more challenging exploration projects, regulatory regimes, a focus on the environment, and requirements for safety and efficiency DNV, together with major oil and gas companies, has developed the worlds first guideline for managing the integrity of offshore pipelines.
he development of the guideline DNV RP-F116: Integrity management of submarine pipeline systems means that the integrity of a subsea pipeline can be managed with a unied and reliable reference for both authorities and the industry. Companies will be able to use their adherence to it as part of documenting their compliance with regulations. For authorities, it provides a useful tool when reviewing or dening their regulatory regime.
Corrosion/erosion threats
Internal corrosion External corrosion Erosion
A joint industry effort

The recommended practice (RP) was developed as a Joint Industry Project (JIP), with DNV, CNOOC, DONG Energy, ENI Group, Gassco, GDF Suez, Norske Shell, SINTEF, and Statoil participating. The JIP started developing RP-F116 in 2007 and the nal document, released in October 2009, provides guidance on how to establish, implement and maintain an integritymanagement system (IMS). The documents main focus is the integrity management process (IMP), which is the combined process of threat identication, risk assessment, planning, monitoring, inspection, and repair.
and monitoring results, and other relevant historical information; and, 4. Mitigation, intervention and repairs activities. Each of these steps, on which RP-F116 provides guidance, needs to be planned in detail, executed, and documented. Prior to a pipeline being put into service, an integrity philosophy should be developed, taking into consideration the pipeline design and how the integrity of the system should be managed and reported.
Integrity management in a lifecycle perspective

Pipeline integrity is established during the concept selection, design, and construction (fabrication and installation) of the pipeline system, and maintained during the operations phase. DNV OS-F101: Submarine pipeline systems gives criteria and guidance with regard to both integrity stages, with its main focus on the rst stage. DNV RP-F116 also gives recommendations for both stages, but mainly addresses maintenance, with particular focus on the IMP. The IMP begins during the established integrity stage and it is carried out continuously throughout the entire life of operation, until abandonment of the pipeline. The choices that are taken in the early design work, such as selection of pipe materials (carbon steel, stainless steels, clad-pipe, etc.), monitoring systems, inhibitor systems, piggability, buried or not-buried, the novelty or robustness of design, and quality of the design/construction/installation phases will be decisive for the inspection and monitoring programme developed and implemented in the operation phase. If a pipeline has been inappropriately designed for its intended use and lifetime, then extra effort will be required during operations to ensure that its performance (regarding safety, environment, ow capacity, etc.) is acceptable. Similarly, an appropriately designed pipeline that is poorly constructed would be expected to experience similar challenges. Further, if design and construction are acceptable but the in-service integrity management is inadequate, early loss of integrity becomes more likely. Integrity is said to be transferred from the development phase to the operations phase: this interface involves the transfer of vital data and information about the system required for safe operation of the pipeline system.
Third-party threats
Trawling interference Anchoring
Vessel impact Dropped objects Vandalism / terrorism Traffic (vehicle impact, vibrations) Other mechanical impact Structural threats Global buckling exposed Global buckling buried End expansion On-bottom stability Static overload Fatigue (vortex-induced vibration, waves or process variations) Natural hazard threats Extreme weather Earthquakes Landslides Ice loads Signicant temperature variations Floods Lightning Incorrect operation threats Incorrect procedures Procedures not implemented Human errors Internal protection system related Interface component related
Metal loss (secondary) Dent Crack Gouge Local buckle Global buckle Displacement Coating damage Anode damage
Addition to DNVs pipeline standard

The RP formally supports and complies with DNVs recognised pipelines standard, according to which 70 per cent of the worlds pipelines are built. However, the recommendations can also be used separately and are also considered relevant for pipelines designed according to other codes such as ISO 13623, API RP 1110, and API RP 1111.
Extension of DNV RP-F116

Crack Free span Local buckle Global buckle Displacement Exposure
Pipeline system integrity

The function of submarine pipeline systems is to efficiently and safely transport a variety of uids. The pipeline systems integrity is dened as the structural/ containment function, which is the systems ability to operate safely and withstand the loads imposed during the pipelines lifecycle. If a system loses this ability, a failure has occurred. The RP denes two main failure modes relating to a pipelines containment/ structural function: Loss of containment leakage or fullbore rupture; and, Gross deformation of the pipe cross section, resulting in either reduced static strength or fatigue strength.
The IMS
In order to ensure the safe operation of its pipeline system, it is required that an operator establishes, implements, and maintains an IMS within its own organisation. The IMS consists of an IMP supported by a number of elements. The IMP consists of the following steps: 1. Integrity management planning including threat identication and assessments of associated risks. This activity provides long and short-term (annual) plans; 2. Performance of inspection, monitoring, and testing activities; 3. Integrity assessment based on inspection
Pipeline system threats and damages/anomalities

An overview of typical threats to a submarine pipeline system (including onshore sections) and associated damage and anomalies is given in Table 1. A thirdparty threat, such as trawling interference, may cause a gouge in the pipeline surface which can, under certain conditions, act as an initiation site for fatigue-crack growth and subsequent rupture. Managing the risk related to such threats is essential for maintaining the integrity of a pipeline system.
Dent Crack Gouge Local buckle Global buckle Displacement Exposure Coating damage Anode damage
Metal loss Coating damage Global buckle Local buckle Anode damage
The objective of the DNV RP-F116 development was to cover the entire pipeline system in consistency with the denition in the DNV OS-F101 offshore standard. However, the need to cover additional aspects in the RP and provide more detailed guidelines has already been identied through presentations at conferences and feedback from early use of the RP. The topics listed below are examples of what has been requested by the industry: Working process for detailed risk assessment of individual threats; Third-party threats inspection, planning, and damage assessments; Key performance indicators for monitoring of the IMS; Corrosion management of in-eld and/or unpiggable pipelines; Shore approach and onshore sections; Flexible pipelines; and, Operations readiness. On 9 March 2010, the industry was invited to attend an industry seminar to discuss relevant topics related to the operation of submarine pipeline systems. The industry was given the opportunity to inuence and contribute to forming the scope of a forthcoming JIP for extending the DNV RP-F116, making the document more comprehensive than it appears at present. More such seminars will take place prior to establishing a scope and issuing a formal JIP during the second quarter of 2010.
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HISTORY
HISTORY
PLUTO Pipeline
The code name PLUTO was coined from the initial letters of Pipe Line Under The Ocean, and referred to the operation of laying subsea pipelines across the English Channel and supplying petrol to the Allied Armies for their advance across France and Belgium into Germany during World War II.
lthough no longer in service, the construction of the PLUTO Pipeline was an amazing feat, involving the collaboration of rival commercial rms, government departments and the armed services, to construct a subsea pipeline, which would deliver more than one million gallons of petrol per day across the English Channel during World War II. Petrol supplies were integral to successful war operations for the troops, and were initially being supplied via four gallon tins in jerricans carried across the beaches. A bulk supply of fuel was necessary and delivery by tanker was then trialled, but hazards such as weather and attack threatened the interruption of supply. It was decided that a pipeline across the Channel was the best form of transportation to ensure a reliable supply of petrol. Conventional construction methods at the depth required would mean that heavy moorings and large craft would be needed, and weather conditions would make construction hazardous. In addition, the time taken to join pipe on a pipelay barge would render enemy interference by sea and air very easy. As such, two new types of oil pipeline were manufactured: The Hartley Anglo-Iranian Siemens (Hais) pipe The Hammick Ellis (Hamel) steel pipe. In order to ensure success, it was suggested that the pipe be made in one complete length so that no stopping would be required when laying the pipe. This required the use of small diameter pipe due to issues of bulk and weight, and a very high working pressure would ensure that a larger amount of petrol would be transported through the pipe.
tape and also to increase exibility. Then, four layers of steel tape were applied. The nished pipe weighed 63 tonnes per nautical mile. The line was made in continuous lengths of 35 nautical miles, coiled direct from the armouring machine into special storage sites to await loading on the ship. Pipe joints were made petrol-tight with petrol-resisting rubber-moulded rings against the lead pipe while at the same time preventing the lead from being distorted or extruded.
of auxiliary vessels were added to the force, whose personnel numbered 100 officers and 1,000 men. The Petroleum Board constructed the land lines and SNO Pluto laid a large number of Hais and Hamel lines across the Solent (the strait separating the Isle of Wight from mainland England).
Construction
Construction of Operation PLUTO began on 12 August 1944. Two Hais pipes and two Hamel pipes were laid during the following weeks. Petrol was pumped across to Cherbourg, but the Allied Armies rapid advance along the French Coast made it necessary to concentrate all efforts on the Dungeness crossing, and the Cherbourg lines were shut down. The Dungeness lines were run to a beach inside the outer harbour of Boulogne, in order to save the time required to clear the heavily mined beach at Ambleteuse, which had previously been chosen. This involved a longer run and a more difficult approach, but the rst was laid in October 1944 and after the technique had been perfected for laying the main lengths of Hais pipe, further lines were laid and commissioned with certainty and without incident. Force Pluto was responsible for laying the line to above low water on each shore, after which the home end was connected with steel pipe to the valves and lters provided on the pump delivery lines, and at the far end to a valve manifold. Eventually 11 Hais and six Hais-Hamel lines were laid with a capacity of more than 4,500 tonnes, or 1,350,000 gallons a day; and, 1 million gallons a day were pumped across for many weeks.
The Hamel pipe

The second novel proposal came at the end of April 1942. When dealing with the Hais pipe it became apparent that the pipe was exible in a long length, although extremely stiff in a short length. Steel pipe, also exible in long lengths, was suggested for making long lengths of line required in one piece. Preliminary work proved that the steel pipe could be bent and pulled off straight, that it could be welded with absolute reliability, and that it could be carried and laid by either the wheel and barge but there was no previous experience as to how bare steel pipe would behave on the bottom of the sea. It was expected that the 3.5 inch diameter low carbon mild steel pipe would have a lifespan of at least six weeks, allowing the delivery of sufficient supplies. Standard 40 foot lengths of pipe were welded to form lengths of 4,000 feet. The pipeline had a wall thickness of 0.212 inches and a weight of 20.21 tonnes per nautical mile. By April 1943, both the Hais and Hamel pipe had been brought successfully through full-scale trials.
Figure 1: Hais pipe diagram.
Figure 2: Map showing the extent of the PLUTO pipeline system.
A new tactic
During June and July 1943, it was decided that the English pipeline system should be extended to both Dungeness and to the Isle of Wight and that pumping stations of 3,500 and 3,000 tonnes per day capacity, respectively, should be constructed at these places. The Isle of Wight to Cherbourg Crossing involved a sea crossing of about 70 nautical miles instead of the 20 or so originally visualised, and made necessary the provision of larger cable ships and loaded down till the axles were awash. Following a successful lay with 3 inch Hais pipe, three more ships were converted and tted with cable gear. Six Thames barges were equipped to handle the shore ends and a large number
The Hais pipe

In 1942, the Anglo-Iranian Oil Co, Siemens Brothers and Co, and (later) rival company Henleys, were enlisted to make a test pipe armoured with steel tape and wire, and a lead covering. Test lengths were laid in deep water off the Clyde, under both severe and easy conditions. Following these tests, six 30 mile long operational lengths of 2 inch diameter
were manufactured for a full-scale trial in the Bristol Channel where conditions of tide and depth of water were more severe than those in the English Channel. Special cable ships were equipped to carry a sufficient length of the pipe. The SS London, a 1,500 tonne coaster, was made available and renamed HMS Holdfast. A pumping station was erected on the sea wall at Queens Dock, Bristol, that connected to the Royal Army Service Corps Bulk Petroleum Cos petrol tanks, and a receiving terminal was constructed in Watermouth Bay, near Ilfracombe. During testing, a German raid on Swansea proved that the pipe would not be damaged by a bomb within 100 feet
and, during a gale, a ship at the Mumbles anchorage dragged the pipe with her anchor. HMS Holdfast had no difficulty in locating the pipe, cutting out the damaged portion, and running in a new length. After further testing, it was found that 3 inch pipe could be produced using existing facilities and that it would deliver 2 times more petrol than the previouslymanufactured 2 inch pipe. The pipe was encased in a lead sheath, manufactured in 700 yard lengths. The sheath was coated in a layer of petroleum residue compound, followed by two layers of compounded paper tape. The wrapping was then followed by one layer of compounded cotton tape to give a bedding for the steel
Success
No Hais pipe that had been satisfactorily laid and commissioned failed. The Hamel pipes on the other hand, while more than fulfilling the original estimate of six weeks of useful life, did fail successively in 77, 52, 55, 112, 55, and 60 days. The loss of petrol between tanks at Dungeness and at Boulogne was, however, less than 1.1 per cent for the whole operation. The Supreme Allied Commander, General Eisenhower, described Pluto in his report as second in daring only to the artificial harbours projects, and wrote, This provided our main supplies of fuel during the winter and spring campaigns
This article has been adapted from a 1945 lecture by A.C. Hartley, then Chief Engineer, Anglo-Iranian Oil Company. It also formed the basis of a lecture to the UK-based Pipeline Industries Guild in 1957.
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ENVIRONMENT
EVENTS
Vision in green: carbon budgeting on the South Wales Gas Pipeline

By James Gavie, Director, RSK Group
The 316 km South Wales Gas Pipeline is a key asset in securing the United Kingdoms future energy supplies, bringing LNG into the existing national transmission system. RSK helped project proponent National Grid assess the size of the pipelines carbon footprint in order to develop a carbon budget for the company to help meet future emissions reduction targets.
n the past, the UK received plentiful natural gas from reserves from the North Sea, but with reserves slowly declining, the country has transitioned from the role of a major gas exporter to being an importer of LNG from overseas. The $US1.6 billion South Wales Gas Pipeline is the largest scale infrastructure project National Grid has ever undertaken, taking three years to construct, with completion achieved in 2007. The 48 inch diameter steel pipeline was built to transport gas between two LNG terminals located near Milford Haven including the proposed South Hook LNG Plant, which will be the worlds largest LNG terminal when completed to National Grids existing national transmission system in Thirley, Gloucestershire. The pipeline project includes a compressor station, which is one of the largest in the UK's energy network.
environmental impacts were minimised. It commissioned RSK to quantify the climate impacts associated with the construction, commissioning and operation of a section of the pipeline running between Felindre and Thirley. The company then used the information collated to develop a carbon budget.
Analysing carbon risks

The natural carbon systems in the affected areas that would be most at risk of impacts from the pipelines construction were also analysed. RSK concentrated particularly on areas where the pipeline route traversed the national parks in the South Wales region. The analysis took particular account of the effects of the pipeline on peat bogs, as these, like trees, act as carbon sinks. Pipeline construction can affect the drainage of the peat bogs through the excavation of carboniferous material critical to peat bog ecosystems. The data gathered were entered into computer models to calculate the carbon generated through commissioning, operating and decommissioning the pipeline. It was found that the development, including its embodied energy and the impacts on natural systems, would only cause a 0.2 per cent increase in the greenhouse gas emissions associated with the combustion of the natural gas supplied by the pipeline.
Carbon budgeting for beginners

A carbon budget measures and sets targets for the total greenhouse gas emissions that can be linked to a project over time, and includes direct impacts such as tree removal and the quantity of gas burnt, as well as indirect effects such as the supply chains carbon footprint. The carbon-related emissions over the life of the project are then evaluated. RSK began with a review of the carbon intensity of the materials used to construct the pipeline, tracking their lifecycles from raw materials through to nal disposal. The company assessed how much embodied energy had been consumed during the production of the raw materials (for example, during quarrying), in processing them (for example, during steel manufacture) and the amount of energy used in transportation and their use and nal disposal. The data was sourced through suppliers and commonly used databases. Wherever possible, source-specic information was acquired, but RSK said that at times, such data were often unavailable in this emerging assessment eld. RSK also calculated the transport emissions associated with the project site using information from the lead contractor such as project schedules.
PPIM puts pigs on show in Texas

A dynamic forum discussing key trends, products and services in the pipeline inspection sector the 22nd Pipeline Pigging and Integrity Management Conference and Exhibition was held in Houston, Texas, from 15 to 18 February 2010.
he Pipeline Pigging and Integrity Management (PPIM) Conference and Exhibition, organised by Tiratsoo Technical, a division of Great Southern Press, and Clarion, drew engineering management and eld operating personnel from both transmission and distribution companies concerned with improved operations and integrity management. The event encompassed training courses, a broad Conference programme, and an Exhibition including 74 companies. Approximately 1,500 people attended, with 400 delegates representing 22 countries enrolled in the Conference and training courses.
Meeting greenhouse targets

The UK Governments carbon reduction will require large organisations to contribute to reducing carbon dioxide emissions by 32 per cent by 2020. In addition to meeting this requirement, National Grid has committed to reducing its greenhouse gases by a further 48 per cent by 2050. The company has gone beyond standard environmental impact assessment obligations to assess the pipeline projects carbon footprint. National Grid said it wanted to understand how much carbon dioxide was being produced directly and indirectly by the pipeline project during construction and operation to ensure that
The future means optimal design, minimal CO2

The South Wales Pipeline project highlighted how pipeline design and construction can be optimised to minimise carbon dioxide releases while still taking into account the exacting specications required to ensure safety is not compromised. Lifecycle analysis provided an important opportunity to encourage greener materials selection and production methods during the design phase of future pipeline projects.
Tiratsoo Technicals John Tiratsoo.
BJ Lowe of Clarion.
Carboniferous a moment in time

The word carboniferous means coal-bearing from the Latin carbo. The Carboniferous period in the Earths history occurred approximately 299359 million years ago, a time of great climate change that produced low sea levels, as well as the formation of glaciers and mountains and the extinction of fauna. Many beds of coal were laid down all over the world during this period. Carboniferous rocks and materials in Europe and eastern North America thus largely consist of repeated sequences of limestone, sandstone, shale, peat and coal beds.
A captivating Conference
Tiratsoo Technical Principal John Tiratsoo chaired the Conference sessions, which included topics such as the importance of pig trap assessment, integrity
PPIM training Courses Seven streams of training courses were run on 15 and 16 February, encompassing topics such as defect management, pigging and in-line inspection, pipeline repair methods, performing pipeline rehabilitation, and pipeline risk management. For information about future courses, visit Clarions website www.clarion.org
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EVENTS
EVENTS
The Conference programme attracted many delegates.
management plans, multi-diameter bi-directional pigging, magnetic-ux leakage (MFL) inspection capabilities, pipeline regulatory updates, performancemanagement assessments and remediation, and unpiggable pipelines. Of particular interest was ViaData LPs David Bull presenting on recent amendments to US pipeline regulations and their affect on pipeline operations. David Russell and Gordon Short from Pipeline Engineering provided a paper on pipeline cleanliness and how new inspection technologies have improved in accuracy for measuring the depth of debris present on a pipe wall. In addition, Bruce Nestleroth from Battelle spoke of a project for which a new sensor was developed to assess external coating. The sensor is also able to work with currently available in-line inspection tools. The Conference programme also included a panel discussion on the cleanliness of pipelines from an owner/operator perspective. Six panellists from different parts of the pipeline industry outlined what clean means to them, which provided a useful insight for contractors to assess what products would best suit their clients needs.
The Exhibition allowed delegates to get hands on with the latest pigging equipment.
many exhibitors already signing on for Houstons 2011 PPIM event on 1417 February, 2011. In addition to the Houston PPIM Conference and Exhibition, PPIM Asia Pacic will be held later this year between 8 and 11 November. The event will be held in Kuala Lumpur, Malaysia, and is the rst time that the event has been organised outside Houston for over a decade.
ASIA
PACIFIC
View PPIM photos! Visit the Pipelines International website to see more photos from the PPIM Conference and Exhibition online www.pipelinesinternational.com/gallery
Parading pigs
In conjunction to the Conference, the well-attended Exhibition highlighted the latest products and services available to the pipeline pigging and inspection industry. Companies displaying products included A.Hak Industrial Services, Apache Pipeline Products, Applus RTD, Baker Hughes Pipeline Management Group, BJ Pipeline Services, DNV, Dresser, Enduro Pipeline Services, GE Oil & Gas, Girard Industries, Hebna Corporation, Knapp Poly Pig, Mears Group, NDT Systems & Services America, Rosen, and T.D. Williamson. Event gold sponsors BJ Pipeline Services and Rosen provided evening drinks and nger food in the Exhibition area during the event giving Conference delegates and Exhibitors alike a chance to talk shop in a relaxed environment or simply unwind with new and old friends.
PPIM heads to Asia!

You dont have to travel to Houston, Texas, to be a part of one of the pipeline industrys most celebrated events the Pipeline Pigging and Integrity Management Conference is coming to you!
ome of the worlds most experienced pipeline designers, engineers, integrity specialists and project managers are preparing to gather at the PPIM Asia Pacic Conference which will run from 811 November 2010 in the Crown Plaza Hotel, Kuala Lumpur, Malaysia to address the most pressing issues facing the pigging and integrity management industry. Running in conjunction with the conference will be a range of comprehensive training courses covering best practice for pipeline engineers, designers and service professionals involved with the maintenance, inspection, and repair of pipelines. The worlds leading pigging, in-line inspection, and integrity management service providers will be on show at the
A range of different equipment was displayed at the Exhibition.
PPIM Exhibition giving you the chance to speak one-on-one with industry colleagues from around the globe. Whether your business is based in Asia or you are looking to establish a greater presence in the Asia Pacic region, the PPIM Asia Pacic Conference is the perfect way to make sure you are up-to-date with the latest industry developments, while creating
and strengthening business alliances in one of the worlds fastest growing economic regions.
Call for papers PPIM AsIa PacIfIc

Be part of the rst PPIM Asia Pacic Conference and submit an abstract. Take advantage of this professional opportunity and make sure you get your submissions in early. Send abstracts accompanied by the authors complete contact information and afliation to: John Tiratsoo, Tiratsoo Technical Email: jtiratsoo@gs-press.com
A bright future for PPIM

The importance of the pipeline inspection industry continues to grow. As 60 per cent of the worlds major oil and gas transmission pipelines are now more than 50 years old, keeping up with the latest inspection and rehabilitation technology is vital. The success of the 22nd PPIM Conference and Exhibition echoed this sentiment, with
The panel session generated much discussion.
Make sure you keep an eye out for more details on PPIM Asia Pacic visit www.clarion.org
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EVENTS
PRODUCT & SERVICES
BJ Services announces Gemini tool
Telvent assists regulatory compliance in Canada

elvent has developed a gas measurement and analysis system (GMAS) designed to assist gas producers in Alberta, Canada, to comply with a measurement and reporting regulation recently introduced by the Energy Resources Conservation Board (ERCB). The regulation, known as the Enhanced Production Audit Program (EPAP), requires gas producers to self-audit and accurately report on natural gas ow. Operators must have infrastructure necessary for compliance to the EPAP in place by 2011. The GMAS system allows Alberta operators to full these new requirements by collecting, reviewing, adjusting and reporting gas ow measurements. It consolidates and standardises data from multiple sources, including enterprise pipeline supervisory control and data acquisition (SCADA) systems, third parties and manual input.
Industry gears up for IPCE

The 8th International Pipeline Conference and Exposition is to be held at the Hyatt Regency Hotel and TELUS Convention Centre, Calgary, Canada, between 27 September and 1 October 2010.
he International Pipeline Conference (IPC), organised by the ASMEs Pipeline Systems Division, held every two years, is an internationally-renowned event. Combined with the Exposition, organised by DMG World Media, the 2010 event again promises an unmatched overview of the latest developments in the oil and gas pipeline industry as well as associated activities. The 14-stream conference programme aims to inform and motivate. Held over ve days, the wide-ranging technical tracks are designed to allow attendees to participate
in discussions with industry experts and leaders in the topic areas of their choice. The conference is organised on a not-forprot basis, with proceeds supporting education initiatives for the pipeline industry. In conjunction with the conference programme, the exhibition will again provide a forum for pipeline professionals to catch up and view over 150 of the industrys most recognised brands. IPCE boasts the worlds largest gathering of pipeline professionals make sure you are one of them!
Make sure You visit the PIpELINES INTERNATIONAL teaM at IPCE! Pipelines International will be on hand to provide an event newsletter and take your photo. Visit the Pipelines International booth to grab the latest copy of the magazine, or talk to John, Scott, David or Lyndsie about opportunities the magazine can provide.
DATE/VENUE
EVENT
CONTACT
J Services has developed the Gemini system a new range of tools that is designed to provide calliper, metal loss and mapping information. The system uses an active speed control with bypass to run in high-speed gas pipelines and obtain corrosion and deformation information without restricting ow or line speed. The Gemini system integrates existing technology developed by BJ Services. Using the triaxial sensor technology found in Vectra tools, it is designed to detect corrosion features, dents, and mechanical damage including cracks, wrinkles, gouging, and metal loss within dents. Also, like the companys Geopig tool, the Gemini system features an inertial mapping unit, which allows it to calculate bending strain information and provide accurate pipeline location information. The Gemini tool can collect more than two terabytes of information about the condition of a pipeline, and operates in conjunction with existing BJ Services viewing and analysis software.
For more information visit www.telvent.com
Smartpipe launches ProSCAN laser profile scanner
19 23 April 2010 Hannover, Germany 3 6 May 2010 Houston, Texas, USA 6 10 June 2010 St Johns Newfoundland, Canada 9 10 June 2010 Jakarta, Indonesia 1 2 July 2010 Newcastle, UK 11 14 September 2010 Darwin, Australia 27 September 1 October 2010 Calgary, Canada 27 September 1 October 2010 Venice, Italy 18 22 October 2010 Berlin, Germany 8 12 November 2010 Kuala Lumpur, Malaysia
Pipeline Technology Conference 2010 Offshore Technology Conference 2010 Pipe Line Contractors Association of Canada Annual Convention IndoPipe 2010 CO2 Transportation 2010 Australian Pipeline Industry Association Annual Convention International Pipeline Conference and Exposition 2010
www.ptc2010.com www.otcnet.org/2010 www.pipeline.ca
For more information visit www.bjservices.com
roSCAN is a new laser mapping system targeted towards pipeline integrity, which is designed to capture large areas of complex corrosion features. Scanning rates of approximately 930 square cubic metre per minute are possible, while capturing accurate, repeatable, high resolution scans Smartpipe's ProSCAN laser. of up to 1,219 points per square cubic metre. Smartpipe Technologies President Darren Hill said, The ProSCAN laser reduces the time required to measure any features found on the pipe, while signicantly increasing the accuracy of the results. Probably the most profound benet of this technology, aside from the time savings, is the ability to accurately correlate with the ILI log.
For more information visit www.smartpipe.net
www.indopipe2010.iee-c.com www.clarion.org www.apia.net.au

www.internationalpipelineconference.com
GL Noble goes with the flow
44th IPLOCA Convention
www.iploca.com
Evaluation and Rehabilitation of Pipelines Conference and Exhibition Pipeline Pigging and Integrity Management Asia Pacic
www.piperehabconf.com www.clarion.org
The Gemini system.
L Noble Denton has introduced its SynerGEE liquid transmission software that can provide short-term operational cost optimisation by simultaneously optimising ow rate, pump station operation, and/or drag reducing agent (DRA) concentration injection for liquids pipelines. A steady-state analysis engine simulates the hydraulics in the pipeline and determines an optimum ow rate, also allowing for model calibration and simulation of what if scenarios. SynerGEEs user interface provides a schematic of the batches and the pipeline, allowing users to view past, present, and future results of the simulation. Variables such as pressure, ow rate, power consumption, and DRA injection rates are selected by the user for display on the results screen. Time and distance charts can also be used to view the results. Standard reporting provides the information needed for operational planning, with set points and equipment change strategies for forthcoming operations.
For more information visit www.gl-nobledenton.com
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REGULAR
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ISSUE 003

DEEP, DEEPER, DEEPEST. WELL GO TO ANY DEPTH FOR YOU.

PIPE COATING DIVISION Incident and Injury Free www.wascoenergy.com

ISSUE 003 | MARCH 2010

From the Editor Pipes & People Advertisers Index

industrY news Meet the assoCiation

Subscription form Coming in future issues

AROUND THE WORLD

PoliCY & oPinion

REGION REVIEW: Middle east ProJeCts

oFFshore terrain review

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PIpELINES INTERNATIONAL | MARCH 2010

FROM THE EDITOR

Are you up to speed?

Training courses mid 2010

Pigging & In-line Inspection (Houston)

June 9-10 June 9-11 June 9-11

John Tiratsoo Editor-in-Chief

September 20-24 September 20-24 September 21-24

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October 18-19 October 18-19

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Petrobras tunnels its way to Brazils largest gas pipeline

Workers stand next to the large diameter pipe.

The Gasduc III Pipeline.

BE PART OF THE 5TH PIPELINE TECHNOLOGY CONFERENCE AT HANNOVER MESSE

the worlds leading showcase for industrial technology

5th Pipeline Technology Conference 19-20 April 2010

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Ruby Pipeline has green credentials

Finding the best way through

Constructing from east to west

Roughrider International Ltd.

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APLNG pipeline contract awarded

APLNG proposed pipeline route. Image courtesy of Origin Energy.

PIpELINES INTERNATIONAL | MARCH 2010

AROUND THE WORLD

Durban Gauteng to secure South Africas energy future

INTERNATIONAL PIPELINE CONFERENCE & EXPOSITION

Construction continues on the Durban to Gauteng Pipeline.

Pipelines in a Changing World

Major Exposition Sponsor

PIpELINES INTERNATIONAL | MARCH 2010

AROUND THE WORLD

Croatia modernises its gas transmission system

Vodnjan Umag gas pipeline

Construction commences on Lika and Dalmazia tranmission systems

For more information visit www.clarion.org

Evaluation, Rehabilitation & Repair of Pipelines Conference and Exhibition

Visit www.piperehabconf.com for more information

AROUND THE WORLD

Shaybah Abqaiq Pipeline nears completion

The SHBAB 2 pipeline project under construction.

3MTM ScotchkoteTM Internal & External Pipe Coatings

3M United Kingdom plc