WORLD PIPELINES

Volume 15 Number 12 - December 2015

DECEMBER 2015

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Contents
WORLD PIPELINES | VOLUME 15 | NUMBER 12 | DECEMBER 2015

03. Editor's comment

Drilling demand in Australia. 40. Making it on the big screen
Ole Kristensen, EIVA, Denmark.
05. Pipeline news
Celebrating France's 40th anniversary of its first contract for gas supply; the MENTORING
TAPI pipeline is finally under contruction; Energy East pipeline provides a 47. The forgotten art of mentoring
new hope for Canada; plus an IPLOCA convention report. Michelle Unger, ROSEN Group, and Phil Hopkins, Phil Hopkins Ltd.

REGIONAL REVIEW FLOW METERING

12. Roundup, roundup: global pipeline projects 55. Implementing leak detection strategies
Oil and gas prices have fallen drastically in 2015. Due to an abundance of Dr. Gregor Brown, Cameron, UK.
supply and reduced consumption, global energy markets have had to find 59. Tracking lost gas levels
more economical ways of transporting oil and gas and put an abundance of Benjamin Fuentes, Thermo Fisher Scientific, and Toby O’Brien, Enable Midstream
pipeline projects on hold. Dr. Hooman Peimani seeks to summarise the major Partners.
global pipeline projects and how they have been affected.
PROCESS INSTRUMENTS
63. Rethinking interface detection
Paul Limpitlaw, Siemens AG, USA.

SOFTWARE AND DATA MANAGEMENT

67. A new era of monitoring
Nigel Jones, VAE Controls, Czech Republic.
76. Reducing the impact of cyber attacks
ROUNDUP, Tony Berning, OPSWAT, USA.
ROUNDUP: COMPRESSOR TECHNOLOGY
global pipeline projects P
erhaps 2015 will be remembered as an exceptional year in the contemporary history of the global energy
markets. Starting from the preceding year, oil and gas prices have fallen to atypical levels after experiencing

80. Advancing reciprocating compressors

Oil and gas prices have fallen drastically in 2015. Due to an abundance of
supply and reduced consumption, global energy markets have had to find more
about one and a half decades of increase. The phenomenal price decline has been caused in short by an
abundance of oil and gas supplies, way above the global demand, thanks to a large and growing number of
suppliers and lower-than expected global consumption. Lowering economic activities, sluggish growth or recession
in the decade-long troubled European countries, recession in Japan, below-projected growth rate in China, and poor

PAGE
economic performance of many energy-producers such as Canada and Venezuela have negatively affected energy
economical ways of transporting oil and gas and put an abundance of pipeline demand. Economic meltdown in many Arab countries due to inter-state – but mainly intra-state – armed conflicts

Amin Almasi discusses reciprocating compressor technologies for pipeline

and various sanctions on more than a handful of countries to include Iran have all decreased their purchasing power.
projects on hold. Dr. Hooman Peimani seeks to summarise the major global

12
This has been translated to lower economic activities in the major western economies; declining energy consumption
pipeline projects and how they have been affected. with a varying extent has been the logical outcome.

12 13
compression stations.
84. Fouling compressors
Stephen Hiner, CLARCOR Industrial Air, UK.

CONSTRUCTION PROJECTS ROUNDUP PRODUCT NEWS

21. Haute pipeline projects 87. HDD and crossings equipment product news
Thomas Garcon, Max Streicher GmbH & Co. KG aA, Germany. Vermeer, USA and Tracto-Technik, Germany.
26. Working hands-free
James Woodall, Intoware, UK.

COVER STORY SEASON's

31. Raising the bar
Todd Razor, Vacuworx, USA. GREETINGS
OFFSHORE OPERATIONS
35. Scanning for subsea integrity
Scott Gray, Seatronics, UK.
WORLD PIPELINES

Volume 15 Number 12 - December 2015

DECEMBER 2015

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

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Comment
DRIVING DEMAND IN AUSTRALIA
A
new gas pipeline in Australia is to
be built connecting the Northern
Territory (NT) and the east coast.
Jemena has won the contract to
construct the 623 km pipeline, which will run
from Tennant Creek, NT to Mt Isa in
Queensland. Proposed routing of the
pipeline followed two distinct camps: the
northern route won over a potentially more
costly and time-consuming southern route.
The southern option would have sent the
pipeline on a longer journey from Alice
Springs to Moomba and would have incurred
extra costs of up to AUS$1.3 billion.
So, with the
northern route decided
upon and Jemena
(jointly owned by the
THE EAST
State Grid Corporation
of China and Singapore
COAST OF
Power) signed up to AUSTRALIA’S
construct, gas flow is
expected to begin in GAS MARKET IS
CHANGING
2018.
Dubbed as the
North East Gas
Interconnector (NEGI),
SIGNIFICANTLY
the AUS$800 million
pipeline has been designed to spur
development of the NT gas sector, which
brings to mind a certain ‘which comes first, the
chicken or the egg?’ question. By building NEGI,
it is hoped that untapped gas reserves in NT
will be exploited and will move the territory
into a new phase of economic strength. The
theory holds that the pipeline will be a conduit
for giant untapped offshore NT gas fields,
delivering NT gas to customers in the
southeast. Critics argue that any gas extracted
from these fields will go to export markets
from Darwin in the form of LNG (more on that
later) and that the pipeline will probably
transport gas from closer-to-shore fields and
existing onshore fields near Alice Springs.
The NT is estimated to have over
200 trillion ft3 of gas, which the government
has been heralding as sufficient to power
Australia for more than 200 years. Jemena
has pledged to build a further pipeline link,
between Mt Isa and the Wallumbilla hub in
Queensland, once the NT gas reserves have
been proven and established. At the
moment, Moomba is the main hub for gas
supply: the northern route decision could
mean extra costs for building up processing
infrastructure at the new end-point of the
pipeline. The east coast of Australia’s gas
market is changing significantly, with LNG
exports on the increase, rising gas prices and
declining future gas demand expected from
industrial users.
It is hoped that NEGI will fill a gap in the
national grid and revitalise the east coast
market.
A final thought on NEGI: it will be built
at no cost to taxpayers, due to commercial
contracts already in place that secure the
volumes required to support the project. The
foundation customer is Incitec Pivot, which
has committed to buying 30 TJ/d of gas (as
part of a 10 year contract), which amounts to
a quarter of the
pipeline’s capacity.
Incitec is Australia’s
biggest
manufacturer of
fertiliser and will
use the gas at its Mt
Isa plant. For the
last few years, gas
supply has been a
problem for the
company, as well as
rising gas costs.
In other
Australia news, Inpex has completed its
subsea pipeline that forms part of the
Ichthys LNG project. The pipeline connects
the offshore Ichthys gas condensate field to
an LNG processing facility near Darwin, NT
and has been labelled a record breaker, as it
is the longest subsea pipeline in the
southern hemisphere (889 km) and the third
longest in the world, albeit a fair way
behind the holders of first and second
position, Nord Stream (1224 km) and
Langeled (1166 km) respectively. The Ichthys
project is expected to have an operational
life of 40 years, during which it will produce
8.9 million tpy of LNG and 1.6 million tpy of
LPG, plus 100 000 bpd of condensate.
Operations are now underway to connect
up the pipeline to the onshore plant, and to
establish and moor offshore facilities at the
field (which sits in the Timor Sea off the
northern coast of Western Australia).
These mega projects aren’t without risk:
how will the global fall in LNG prices affect
Ichthys? Will gas reserves in the NT stand up
to the scale of NEGI and will the financing
structure on NEGI pipeline mean higher
tariffs? We shall see whether Ichthys, and
the untapped NT gas reserves, can come
good for Australia.
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World News
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Bakken pipeline update
Testifying at a hearing for the proposed Bakken pipeline, Monica
Howard – Director of Environmental Services for Energy Transfer
Partners – told state regulators there would be “no net loss of
wetlands” as a result of the proposed pipeline. She testified that
there will be “very robust” post-construction monitoring to
ensure restoration of lands in Iowa where the pipeline is
constructed.
“There is no anticipated long-term effect” on water quality
and fish communities, Howard said. She added, “We are going
above and beyond regulation” in protecting the environment.
Some rivers will be crossed using HDD, while in other cases
there will be an “open cut” or a ditch dug across streams and
other waterways, Howard said. Restoration work would be done
afterward and the environmental impacts from such crossings are
“extremely miniscule,” she said.
The three member Iowa Utilities Board met on 16 November at
the Boone County Fairgrounds in Boone for the start of evidentiary
hearings over several days. Comments will be heard from
representatives for Dakota Access LLC, the company that wants to
build the pipeline. Parties opposed to the pipeline are also
scheduled to speak, including affected landowners. The board is
expected to issue a decision in December or early next year.
In related news, fresh figures from the North Dakota Pipeline
Authority show that, for the first time in several years, more oil is
leaving Bakken well sites by pipeline and that trend is expected to
continue. An estimated 441 644 bpd of oil left well sites by truck
in April, while 725 743 bpd were transported by gathering
pipelines to either a transmission pipeline or a rail-loading
terminal.
Joint interest in crude pipeline
Saddlehorn Pipeline Company, LLC announced that it is combining
projects with Grand Mesa Pipeline, LLC for the construction of a
20 in. undivided joint interest pipeline, which begins approximately
20 miles north of Saddlehorn’s Platteville, Colorado origin at a
junction near Grand Mesa’s Lucerne, Colorado origin. The joint
interest pipeline will deliver various grades of crude oil from the DJ
Basin to storage facilities in Cushing, Oklahoma.
As part of the joint interest, Saddlehorn and Grand Mesa will
share the costs for the pipeline that is currently under construction.
The initial capacity of the pipeline is expected to be 340 000 bpd,
with Saddlehorn owning 190 000 bpd and Grand Mesa owning
150 000 bpd. The companies will be responsible for their own
commercial activities, including customer relationships, contract terms
and tariff structure, with respect to their interest in the pipeline.
Saddlehorn is able to expand the maximum capacity of the
pipeline to exceed 450 000 bpd in the future at its sole discretion and
cost. Saddlehorn would own all the incremental capacity from any
expansion. Grand Mesa will retain ownership of its previously
acquired pipeline easements from Lucerne to Cushing for the
potential future development of transportation projects, involving
petroleum commodities other than crude oil and condensate. With
the consent and participation of Saddlehorn, the parties may consider
future opportunities using these easements for projects involving the
Tougher environmental assessments in store for
Canada
For existing oilsands pipeline proposals, Canada’s Environment
Minister Catherine McKenna has promised tougher environmental
assessments, amongst comments on climate change and greenhouse
gas emissions targets.
McKenna was in Paris the week of 9 November for a ministerial
meeting to prepare for the United Nations (UN) conference, stated
that Canada is bringing a more constructive outlook to the
international negotiations.
“People are extraordinarily happy to see that Canada is seated at
the table, and that Canada accepts the scientific evidence that
climate change is one of the greatest threats of our time and will be
doing our part,” McKenna explained.
McKenna said the federal government will make climate change a
diplomatic priority at upcoming world meetings. Canada’s newly
appointed Prime Minister Justin Trudeau has promised to put a price
on carbon, establish national emissions-reduction targets, and add
more teeth to environmental reviews for energy projects.
The new Liberal government has so far refused to set a carbon
reduction target and will consult with the provinces before putting in
place a national plan.
McKenna, an international trade lawyer who worked with the UN
in negotiating a peace agreement in East Timor, has hinted that any
target the Liberals set could potentially include greenhouse gas
regulations on the nation’s oil and gas industry, and that the
government’s promise to adopt grittier environmental assessments
could apply to pipeline projects already under review. McKenna has
stated that oil and gas companies are “recognising that they need to
be doing more.”
transportation of crude oil and condensate.
Saddlehorn will own origin points at Platteville – including
1 million bbls of storage – and Carr (Colorado), as well as the pipeline
segment from Carr to the Lucerne junction. Grand Mesa will own
origin points both at Lucerne and Riverside (Colorado), as well as the
pipeline segment between Lucerne and Riverside.
Magellan is serving as construction manager and operator of the
pipeline system. Saddlehorn expects to spend approximately
US$650 million on the undivided joint interest pipeline and the
additional assets it will own, compared to previous spending
estimates of up to US$950 million. When the pipeline is in service,
operating costs will be allocated to Saddlehorn and Grand Mesa
based on their proportionate ownership interest and throughput.
“Combining projects makes strong economic sense by reducing
overall construction and operating costs and better aligning pipeline
capacity with current DJ Basin production while allowing for future
growth when market conditions improve,” said Michael Mears,
Magellan’s Chief Executive Officer, on behalf of Saddlehorn.
Pipeline installation began in early October for the Platteville-to-
Cushing segment of the pipeline, which is expected to be operational
during mid 2016. Right-of-way acquisition is currently in progress for
the Carr-to-Platteville segment, which is expected to be operational
in the 4Q16.
DECEMBER 2015 / World Pipelines 5
 IN BRIEF
UK
The largest ever controlled release of carbon
dioxide from an underwater pipeline will be
conducted at DNV GL’s Spadeadam centre as
part of an international JIP called Sub-C-O2.
Sweden
The munitions object seen near the Nord
Stream 2 pipeline on 6 November has been
successfully cleared and disposed of by the
Swedish Armed Forces.
Australia
Central Petroleum Ltd. praised the decision
to build the North East Gas Interconnector
as a huge step forward for the Northern
Territory gas industry and the development
of a more competitive gas supply into a
critically tight Australian domestic gas
market.
Norway
Statoil has received consent from the
Petroleum Safety Authority Norway to use
the Edvard Grieg oil pipeline. The oil pipeline
system was designed and built to transport
stabilised oil from the Edvard Grieg facility
to the Grane oil pipeline.
USA
Magellan Midstream Partners have resumed
operations of its crude oil pipeline after
42 000 gal. spill in Oklahoma on 5 November.
And the award goes to..
The 2015 IPLOCA Health and Safety
Award, sponsored by Chevron, was
presented to Max Streicher S.p.A.,
represented by Harald Dresp and
Giovanni Muriana, in recognition of their
Belt system.
The third IPLOCA Corporate Social
Responsibility Award, sponsored by Total,
was presented to Technip, represented by
Mesut Sahin and Yasar Pakel, in
recognition of their work on their
Encouraging a Fair Return for All policy.
The 2015 IPLOCA New Technologies
Award, sponsored by BP, was presented
to Denys and Selmers, represented by Luc
Hoppenbrouwers, Johan van Wassenhove
and Bart Appelman, in recognition of their
work on their onshore automatic vacuum
field joint blasting.
6 World Pipelines / DECEMBER 2015
World News
FOR MORE NEWS VISIT HTTP://WWW.ENERGYGLOBAL.COM/PIPELINES/
International Pipe Line and Offshore Contractors Association
convention: a recap
The 49th IPLOCA Convention saw the leading global players in the pipeline construction
industry gather in Singapore. The event takes place over five days and registration is
restricted to IPLOCA Regular Members, Associate Members, Academic Members, Honorary
Members, Media Partners and guests of IPLOCA.
The convention, attended by 510 participants, was the second to be held in Singapore; the
convention met there for the first time in 1989.
The Open General Meetings on Thursday and Friday included presentations on a wide
variety of subjects including the history of Singapore; the feasibility of new pipeline projects
in the new macro-economic environment; trends in international upstream M&A in a
depressed oil price market; efficient deepwater seabed intervention; pipeline projects in Saudi
Arabia and high pressure water transmission pipelines.
Members also attended the Annual General Meeting and presentations of three industry
Awards (see sidebar).
The popular tour programme this year focused on the highlights of this cosmopolitan and
culturally diverse city. There was a cultural tour; a morning visit to Singapore Zoo and a night
safari; visits to the Gardens by the Bay with their award winning horticulture domes and awe-
inspiring architectural design; tours to the Botanic Gardens and Sentosa Island, including the
world’s largest aquarium.
New board members for 2016
EUROPE CENTRAL: Jan Koop (Bohlen- Bolander (Fluor) and Scot Fluharty (Mears
Doyen) {Treasurer} and Mesut Sahin Group).
(Technip). DIRECTORS-AT-LARGE: Doug Evans (GIE),
EUROPE EASTERN: Iosif Panchak Willem Maats (Maats), Jim Frith (McConnell
(Stroygazmontazh) and Haldun Iyidil (Limak). Dowell), Bruno Maerten (Entrepose), John
EUROPE MEDITERRANEAN: Oliviero Corvi Tikkanen (ShawCor) and Jean-Claude Van de
(Bonatti) and Bruno Guy de Chamisso Wiele (Spiecapag) {Immediate Past
(Spiecapag). President}.
EUROPE NORTHWEST: Andrew Ball (Land
and Marine) {2nd VP} and
Adam Wynne Hughes
(Pipeline Induction Heat).
ASSOCIATE MEMBERS:
Marco Jannuzzi
(Caterpillar), Steve
Sumner (The Lincoln
Electric Co.) and Doug
Fabick (PipeLine
Machinery International).
LATIN AMERICA: Ruben
Kuri (ARENDAL) {1st VP}
and Ebbo Laenge
(Conduto).
MIDDLE EAST & AFRICA:
Georges Hage (The C.A.T.
Group) and Najib Khoury
(Left to right)
(CCC). Front row: Jan Koop, Rubén Kuri, Atul Punj, Andrew Ball, Jean Claude
EAST & FAR EAST: Atul Van de Wiele, Juan Arzuaga.
Punj (Punj Lloyd) Second row: Jim Frith, Mesut Sahin, Haldun Iyidil, Georges Hage, Bruno
{President} and Ma Maerten, Marco Jannuzzi, Ma Chunqing.
Third row: John Tikkanen, Iosif Panchak, Doug Evans, Adam Wynne
Chunqing (China
Hughes, Wilhelm Maats, Oliviero Corvi.
Petroleum Pipeline). Fourth row: Ebbo Laenge, Steve Sumner, Larry Bolander, Scot Fluharty,
AMERICA NORTH: Larry Doug Fabick, Najib Khoury, Bruno Guy de Chamisso.
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Events DIARY
World News
FOR FURTHER INFORMATION ON EVENTS VISIT WWW.ENERGYGLOBAL.COM/EVENTS

Save the date: TAPI Energy East pipeline: a new

19 - 21 January 2016 construction hope?
European Oil and Gas Conference
Turkmenistan and Afghanistan have Following US President Barack Obama’s
Vienna, Austria
come to an agreement to launch rejection of TransCanada Corp.’s Keystone XL
http://www.europeangas-conference.
com/ the construction of TAPI – a pipeline project, attention is turning to the
proposed 1735 km natural gas chances that another pipeline will get built.
8 - 11 February 2016 pipeline that will transport its According to industry analysts, the
33 billion m3/y of flow from prospects for Energy East – a 4600 km
PPIM
Turkmenistan through Afghanistan, pipeline running between Alberta and New
Houston, USA
Pakistan, and India. Brunswick (both Canadian provinces) – have
http://www.clarion.org/
Though Turkmenistan is said to never looked better. New Brunswick’s
hold the fourth largest gas reserve Premier Brian Gallant says he is hopeful that
24 - 26 February 2016
in the world, at present its exports Obama’s rejection of Keystone XL will give
AOG are primarily transported to China. added impetus to an east-west pipeline that
Perth, Australia Gurbanguly Berdymukhamedov flows to his province.
http://aogexpo.com.au/ – the President of Turkmenistan – Gallant has been promoting the pipeline
had discussed the construction of during meetings with Saskatchewan Premier
6 - 10 March 2016 the TAPI pipeline with Afghanistan’s Brad Wall. Gallant has stated that the
NACE Corrosion President Ashraf Ghani during a pipeline project would create thousands of
Vancouver, Canada phone conversation that occured jobs across the country and diversify exports
http://nacecorrosion.org/ on Monday 9 November. to markets around the world.
Berdymukhamedov had Wall says they hope the project moves
20 - 24 March 2016 requested Ghani’s presence at the quickly through the regulatory stages,
2016 No-Dig Show ceremony to mark the construction including consulting with First Nations and
of the pipeline. Ghani has accepted meeting economic and safety tests.
Dallas, USA
Berdymukhamedov’s invitation to The Canadian Liberals under Prime
http://nodigshow.com/
attend the ceremony, which is set Minister Justin Trudeau were supportive of
to take place on 13 December. TransCanada’s Keystone project, and seem to
4 - 8 April 2016
Doubts of construction have support Energy East pipeline; another
Tube Düsseldorf 2016
been previously made due to price- TransCanada crude export proposal.
Düsseldorf, Germany fixing debates and the lack of
http://www.tube.de/ security in the areas where the
pipeline will pass through.
25 - 29 April 2016
Hannover Messe
However, while the construction
of the TAPI pipeline is set to begin
News Highlights
Hannover, Germany soon, it has been predicted that the
http://www.hannovermesse.de/ pipeline will not be operational for
another two yers – expected in
2 - 5 May 2016 December 2018.
Offshore Technology Conference Additionally, Dragon Oil – an
Houston, USA independent international oil and
http://2016.otcnet.org/
gas exploration, development and
production business based in Dubai
23 - 25 May 2016
– has discussed the possibility of
investing US$10 billion in a natural
Pipeline Technology Conference
gas pipeline from Turkmenistan to
Berlin, Germany India. ➤➤ Trans Mountain price tag
http://www.pipeline-conference.com/ report: project still viable?
Dragon Oil’s General Manager in
Turkmenistan, Faisal Rabee Al
29 May - 2 June 2016 Awadhi, stated that discussions on ➤➤ NEB stops HDD operations
Pipe Line Contractors Associaton the TAPI project have “been at NGTL
of Canada ongoing for a long time. But now
Charlottetown, Canada it’s very serious, things have been ➤➤ Pembina: closing the deal
http://www.pipeline.ca/ signed between the countries.
That’s why we have shown our
interest to go in.”

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8 World Pipelines / DECEMBER 2015 http:/ / gettag.mobi

To read more about the articles go to
www.worldpipelines.com
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 Contract News
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New contract for subsea vessel
Farstad Shipping ASA has been awarded a three year contract
with further up to three years options for CSV Far Sentinel by
Subtec S.A. de C.V. for delivery of light construction work, IMR
and other subsea related activities in the Gulf of Mexico.
“This is an important and significant contract for Farstad
Shipping. It proves that even in a very challenging market, we are
able to conclude long-term contracts for our vessels. This
contract secures valuable competence and activity for our
employees,” says CEO Karl-Johan Bakken.
“By this, we have now signed important contracts for both
our subsea new buildings delivered in 2015. We hereby confirm
Farstad Shipping’s strong position into the subsea market, which
is vital for us in the time ahead,” Bakken states.
Commencement of the contract will be within December
2015. The commercial terms of the agreement will be kept
private and confidential between the parties.
Farstad Shipping’s fleet currently consists of 61 vessels
(30 anchor handling tug supply, 25 platform supply and and six
subsea), with one subsea vessel under construction. The
company’s operations are managed from Aalesund, Melbourne,
Perth, Singapore, Macaé and Rio de Janeiro with a total of 2100
employees engaged onshore and offshore. The company’s
strategy is to be a leading quality provider of large, modern
offshore service vessels to the oil industry.
TransCanada to build Mexico’s Tuxpan Tula
pipeline
TransCanada has won a contract to build, own and operate a
US$500 million natural gas pipeline for Mexico’s state-owned
power company. The Tuxpan-Tula pipeline will help meet
Mexico’s increasing demand for natural gas as the country
shifts to the cleaner-burning fuel.
The company says the pipeline should be completed by
4Q17 and it has a 25 year contract with the Comision Federal de
Electricidad to operate the line.
The 250 km, 36 in. pipeline will run from the state of
Veracruz to natural gas power plants in central and western
Mexico, supplying up to 886 million ft3/d of gas.
TransCanada already owns and operates the Tamazunchale
and Guadalajara pipeline systems in Mexico and is working to
complete the Topolobampo and Mazatlan pipelines.
“The Tuxpan-Tula Pipeline demonstrates our continued
commitment to developing Mexico’s energy infrastructure to
meet the need for increased natural gas supply,” said Russ
Girling, TransCanada’s President and Chief Executive Officer.
The pipeline will originate in Tuxpan in the state of Veracruz
and extend through the states of Puebla and Hidalgo, supplying
natural gas to CFE combined-cycle power generating facilities in
each of those jurisdictions as well as to the central and western
regions of Mexico.
The pipeline will serve new power generation facilities as
well as those currently operating with fuel oil, which will be
converted to use natural gas as their base fuel. Construction is
expected to start in 2016.
10 World Pipelines / DECEMBER 2015
Fugro provides underwater services to Total E&P
Under the contract – which runs from July 2015 and includes
extension options for a further two years – Fugro is providing a full
range of ROV services to conduct inspection, repair and
maintenance activities on TEP UK pipelines, subsea assets and
jackets.
Prior to this significant contract award Fugro demonstrated its
ability to support such a contract with a range of quality services,
following the successful completion of both platform and vessel-
based campaigns for TEP UK.
In July 2015, Fugro undertook the Central Graben area ROV
inspection campaign, utilising the ROV support vessel Atlantis
Dweller and its two permanently mobilised ROV systems. The
workscope included cathodic protection, flooded member detection
and high-pressure water jetting services.
The inspection campaign was completed ahead of schedule and
TEP UK has noted the excellent safety culture and efficiency
demonstrated by Fugro.
40th anniversary of first contract for gas supply to
France
Tsarskoye Selo (Pushkinsky District of St. Petersburg) hosted a
ceremony dedicated to the 40th anniversary of signing the first
contract for Russian gas supply to France. Taking part in the event
were Alexey Miller, Chairman of the Gazprom Management
Committee and Gerard Mestrallet, Chief Executive Officer of ENGIE.
“Today we celebrate the 40th anniversary of our co-operation,
40 years of stable supplies of Russian gas to France. This is a clear
testament of constructive, mutually beneficial relations between two
world class companies. We proceed in our co-operation with ENGIE
based on long-term contracts, which constitute an important
element of energy security in France.
“We also celebrate another jubilee – five years ago ENGIE
became a partner in Nord Stream. Today the success of the project
is known to everyone, so in September we and our European
partners, including of course ENGIE, made a decision to construct
Nord Stream 2. The project will bring to the European market
additional 55 billion m3 of Russian gas,” said Alexey Miller.
“We are happy to celebrate with Gazprom the anniversary of
the long-term solid partnership uniting our companies. It has
considerably contributed to developing the European gas industry.
ENGIE’s participation in the Nord Stream 2 project bespeaks our
faith in continuing this co-operation. Natural gas is of key
importance for upgrading the energy sector, particularly, for reaching
the European Union targets to reduce greenhouse gas emissions by
2030,” said Gerard Mestrallet.
During the ceremony Alexey Miller and Gerard Mestrallet signed
an Addendum to the Sales and Purchase Agreement for shares of the
Nord Stream 2 joint project company (JPC), which executes the Nord
Stream 2 project.
The document provides for increasing ENGIE’s stake to 10%.
Thus, once the deals for the purchase of JPC shares by foreign
shareholders are closed, the shareholding structure will be as
follows: Gazprom – 50%, BASF, E.ON, ENGIE, OMV, and Shell – 10%
each.
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 ROUNDUP,
ROUNDUP:
global pipeline projects
Oil and gas prices have fallen drastically in 2015. Due to an abundance of
supply and reduced consumption, global energy markets have had to find more
economical ways of transporting oil and gas and put an abundance of pipeline
projects on hold. Dr. Hooman Peimani seeks to summarise the major global
pipeline projects and how they have been affected.

12
P
erhaps 2015 will be remembered as an exceptional year in the contemporary history of the global energy
markets. Starting from the preceding year, oil and gas prices have fallen to atypical levels after experiencing
about one and a half decades of increase. The phenomenal price decline has been caused in short by an
abundance of oil and gas supplies, way above the global demand, thanks to a large and growing number of
suppliers and lower-than expected global consumption. Lowering economic activities, sluggish growth or recession
in the decade-long troubled European countries, recession in Japan, below-projected growth rate in China, and poor
economic performance of many energy-producers such as Canada and Venezuela have negatively affected energy
demand. Economic meltdown in many Arab countries due to inter-state – but mainly intra-state – armed conflicts
and various sanctions on more than a handful of countries to include Iran have all decreased their purchasing power.
This has been translated to lower economic activities in the major western economies; declining energy consumption
with a varying extent has been the logical outcome.

13
 Phenomenally low prices after years of three (or nearly three)
digit prices have reduced concerns over possible major oil supply
interruptions, as the large number of suppliers have practically
rendered such a scenario unrealistic. Led by Canada and the USA,
the so-called unconventional oil and gas revolutions have been a
major contributing factor to global over-production, dwarfed by
just about all suppliers maximising their conventional oil and gas
production at the same time as newcomers emerge in previously
unthinkable locations (Cuba and Israel).
Certain factors have contributed to the vast availability of
gas supplies, which is set to last in the foreseeable future. A
large and growing amount of piped gas, a major increase in LNG
production thanks to ongoing global capacity expansion projects
(designed to raise annual production capacity by 100 million t by
2018), and the rise of current (e.g. Papua New Guinea since 2014)
and future (Canada and USA) exporters have all contributed.
This certainty about supply availability even under the worst
case scenarios has caused the freefall of oil and gas prices,
despite wars in exporting nations such as Iraq, Yemen and Libya,
and emerging polarisation in the Persian Gulf pitting the Saudi-
led Arab coalition of oil/gas exporters (UAE, Qatar, Kuwait and
Egypt) against Iran over Yemen, Syria and Iraq.
Falling prices has prompted a growing number of cancelled,
delayed, suspended and slowed-down conventional oil and gas
developments, repair, maintenance and LNG liquefaction projects
now spilling over to shale gas and oilsands projects in North
America. Of course, lowering investment in new projects and the
inevitable lowering production at currently operating fields will
likely cause shortages in about a decade or so if the current trend
continues.
Projects
A slow down in pipeline projects, especially in the three
major energy-consuming regions – Asia, Europe and North
America – has been an unsurprising by-product of this situation.
Respective examples include China’s cold feet about signing a
firm agreement with Russia for the Power of Siberia II project, the
delayed Trans-Adriatic Pipeline (TAP) set to start next year, three
years after the Nabucco project was aborted in its favour, and
the unknown fate of the Keystone XL.
Politically-motivated measures have also aggravated this
situation, as reflected in Russia’s cancellation of the South Stream
project in December 2014, when the EU stopped the construction
of its Bulgarian segment on technical grounds (violation of the EU
competition rules), which convinced Moscow on ending a losing
battle with Brussels.
Yet, many other projects have been envisaged, discussed,
agreed and implemented. Russia has been involved in many of
them, even in Europe, notwithstanding the EU’s worsening ties
with Russia, particularly over Ukraine and Syria.
The main arena, however, especially for major interstate
projects, has been Asia. China has remained the major protagonist
as the engine of global growth, whereas India’s domestic projects
have been significant. However, other parts of the world’s largest
and most populous continent have been less active, particularly
West Asia, including the Persian Gulf and Southern Caucasus.
14 World Pipelines / DECEMBER 2015
The Americas have been active mainly in intra-state projects.
The USA has also been pursuing inter-state projects with Mexico.
Its large joint project with Canada (Keystone XL Pipeline) is frozen
only partly on environmental grounds. The recent increase in
domestic conventional and unconventional (shale) oil production
is set to continue its upward course to make the US question the
wisdom of committing the country to long-term imports of more
expensive and pollutive oilsands-based Canadian oil.
Europe has also had its share of pipeline activities, but at a
much lower extent compared to Asia. Added to the previously
discussed factors, the continental ageing population, loss of
economic supremacy to Asia and the Americas late in the 20th
century and growing use of more pollutive, but much cheaper
coal explain this reality. The bulk of its ongoing and future
projects concern gas, namely to replace Russian gas with that of
another supplier, and to decrease its CO2 emissions. The recent
conclusion of the Russian-led Nord Stream II and the growing
continental consumption of coal seem to serve the opposite
objectives.
Pipeline activities have been modest in Africa. Excluding
Algeria, all other North African oil and gas rich countries (such
as Egypt, Libya, Sudan and South Sudan) have been shaken by
the 2010 - 2011 Arab Spring and its aftershocks, giving rise to new
dictatorial regimes and growing terrorist groups.
Asia
China
The East Route gas pipeline
Known as the East Route gas pipeline, the Russian-Chinese Gas
Pipeline (38 billion m3/y) is the largest and most important
ongoing pipeline project of Russia and China, but only forms
a component of their US$400 billion energy deal of 2014. The
project involves constructing a gas transportation system in
each country to be connected at a border. It will aid Russia in
developing its East Siberian gas fields, and will consequently help
sell gas to China for 30 years (38 billion m3/y).
The Russian pipeline for exporting gas to China, the Power
of Siberia GTS (POS), will facilitate gas transportation from
the Irkutsk and Yakutia gas production centres to the existing
pipelines in eastern Siberia, ending in Russia’s Port of Vladivostok
as well as China. As a joint venture of CNPC and Gazprom,
the construction of its first segment – the 3200 km Yakutia-
Khabarovsk-Vladivostok line – will be operational in late 2017.
The second segment – an 800 km Irkutsk Region-Yakutia leg –
will be constructed at a date that has yet to be announced. The
POS is approximately 4000 km, 52 in., transports 61 billion m3/y,
and is being built along the route of the East Siberia Pacific Ocean
(ESPO). China started constructing its extension on 30 June 2015
near the Chinese city of Heihe in the northern province of
Heilongjiang bordering Russia. The CNPC undertaking consists
of northern, southern and central sections passing through six
Chinese provinces (Heilongjiang, Jilin, Liaoning, Hebei, Shandong
and Jiangsu), the Inner Mongolia Autonomous Region, Tianjin and
Shanghai. Beijing will reportedly spend at least US$20 billion on it.
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 China will start receiving Russian gas in 2018 when the entire
East Route gas pipeline is scheduled to go online.
The Central Asian gas pipeline system
The Central Asian gas pipeline system is the world’s largest
ongoing pipeline project consisting of four sections through
which Central Asian gas (mainly Turkmen, but also Kazakh and
Uzbek) will be exported to China. Once fully operational by
2018, it will supply 85 billion m3/y of gas to China, equal to
around 40% of its gas imports.
Lines A and B (each 1830 km; 42 in.; 30 billion m3/y) of the
CNPC’s undertaking became operational in December 2009
and October 2010, respectively. The parallel lines connect
Turkmenistan to southern Kazakhstan through Uzbekistan, and
cross the Kazakh-Chinese border at the border pass of Horgos in
China’s Xinjiang Uyghur Autonomous Region. Line C (1830 km;
48 in.) – which begins on the Turkmenistan-Uzbekistan border –
runs through Kazakhstan and ends in Xinjiang; it went online in
May 2014 as a means of adding 25 billion m3/y to the CAGPS’s
capacity.
Line D (1000 km; 48 in.) – construction of which started in
September 2014 in Tajikistan’s Roudaki district linking Turkmenistan
across Uzbekistan, Tajikistan and Kyrgyzstan to China – will
increase the Central Asian gas pipeline system’s capacity by
30 billion m3/y once completed in 2016.
India      Europe
The construction of the first phase of GAIL Limited’s 2050 km
Jagdishpur-Phulpur-Haldia gas pipeline began in October. The
US$2 billion project will connect eastern India to the national gas
grid by transporting gas to West Bengal, Bihar, Jharkhand, and Uttar
Pradesh. The pipeline consists of a 36 in. 922 km mainline, and
1128 km of spur lines and feeder lines (12 - 30 in.). Its second phase
will double the capacity to 32 million m3/d. The pipeline will
supply gas to industrial sites, such as the Barauni refinery and the
Barauni fertiliser plant.
Iran
Iran will reportedly start constructing three pipelines in the
current Iranian calendar year (started on 21 March 2015) as part
of its plans to increase gas transfer capacity by 300 million m3/d,
while developing more phases of its Persian Gulf South Pars Gas
Field (SPGF). Thus, the sixth cross-country gas pipeline (611 km;
110 million m3/d; US$2 billion) whose first and second sections
have been completed, is the first priority designed for gas exports
to Iraq, Syria, Lebanon and Europe.
The ninth cross-country gas pipeline (1863 km; 110 million  m3/d;
US$6 billion) is being built towards Iran’s northwestern borders,
aimed at increasing Iran’s existing gas exports to Turkey for
supplying Europe in the future.
The eleventh cross-country gas pipeline (1100 km;
100 million m3/d; US$4 billion) will connect the SPGF to Iran’s
northeastern region to enable it to stop relying on the import
of Turkmen gas (30 million m3/d).
Iran-Iraq gas pipelines
Iran’s pipeline project to supply Bagdad was set to go online in
August 2015, but there is no news on its operation. The pipeline
16 World Pipelines / DECEMBER 2015
(100 km; 48 in.) stretches from Charmaleh in Iran’s Ilam province
to Naft-Shahr bordering Iran and Iraq. Reportedly, its extension
to the Iraqi Mansourieh power plant is also finished, leaving a
7 km stretch to Baghdad for completion. Iran will initially
export 4 million m3/d of gas to Iraq, to gradually increase to
35 million  m3/d. In February, Iran started the construction of a
second gas pipeline to Iraq’s southern city of Basra – scheduled
for operation in 2016 – to export an additional 5 million m3/d of
gas to Basra, rising to 30 million m3/d within six years.
Iran-Oman Gas Pipeline
This is the most important future project for both countries, and
would export 28 million m3/d of Iranian gas to Oman for 15 years,
reportedly worth of US$60 billion. The project could become a
reality if the P5+1 Group nuclear agreement is implemented to
lift sanctions on Iran’s energy exports. Iran and Oman have signed
an agreement to study its construction to feed Oman’s LNG
plants. Head of the National Iranian Gas Export Company Alireza
Kameli announced in September that a contract had been signed
with two Iranian gas companies for the project.
The Iranian Offshore Engineering and Construction Company
is in charge of its offshore section, whose contract was also
signed by Director General of Planning and Projects Evaluation of
the Omani Ministry of Oil and Gas, Saif Bin Hamad Al Salmani. Pars
Consulting Engineers deals with the onshore section.
Russia
Nord Stream II
Gazprom and major European energy companies – Germany’s
E.ON and BASF/Wintershall, Austria’s OMV, France’s ENGIE and
Royal Dutch Shell – signed an agreement in Vladivostok on
4 September 2015 to double the Nord Stream gas pipeline’s
current capacity of 55 billion m3/y by constructing a new gas
pipeline system (Nord Stream II), intended to be completed
by 2019. The Nord Stream II will transport gas from Russia to
Germany via twin offshore pipelines – each 1200 km transporting
27.5 billion m3/y – through the Baltic Sea. The New European
Pipeline AG joint venture will implement it, in which Gazprom’s
share is 51%. E.ON, Shell, OMV and BASF/Wintershall each have
10%, with a 9% share for ENGIE.
Nord Stream II is a surprising project as it runs against Brussels’
policy of decreasing the EU’s dependency on Russia and, in fact, it
questions the logic of building the Trans-Adriatic Pipeline in 2016
to serve that very purpose. In helping Russia to bypass Ukraine
for gas exports to the EU, the pipeline project has been called
by Ukrainian Prime Minister Yatsenyuk “anti-Ukrainian and anti-
European”.
Czech Prime Minister Sobotka echoed this by saying the
project would help Russia destabilise Ukraine. Slovak Prime
Minister Fico suggested it was a betrayal, which cost Ukraine and
Slovakia billions of Euros. Finally, the European Commission’s Vice-
President, Maros Sefcovic, questioned how the project fits with
the EU’s energy security and regulatory priorities. In reply, OMV
CEO Seele stressed that the project would increase security of
supply to the EU through “our trustful partnership” with Gazprom.
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 The Turkish Stream Gas Pipeline
The Nord Stream II has affected Russia’s Turkish Stream Gas
Pipeline project, which was designed to replace the South Stream
Pipeline (cancelled by Moscow in December 2014). Gazprom’s
Chairman Alexey Miller and Botas Petroleum Pipeline Corporation’s
Chairman Mehmet Konuk signed an MoI in December 2014 to
enable Russia to increase gas exports to the EU without requiring
Brussels’ approval.
In October, Gazprom announced it was reducing the project’s
capacity from 63 billion m3/y to 32 billion m3/y in favour of the
Nord Stream II, of which 50% would be for Turkey and the rest for
exporting to Europe. Russia seemingly intends to use the South
Stream’s allocated resources. The estimated US$12.5 billon pipeline
will run across the Black Sea from the currently under-construction
Russkaya compressor station near Anapa on the northern coast
of the Black Sea, to Kiyiköy village in the European part of Turkey.
It will further run, via Luleburgaz (delivery point for the Turkish
customers), to the Ipsala border checkpoint on the Turkish-Greek
border, the delivery point for the European customers. Consisting
of four offshore strings (each 910 km), the pipeline will pass 660 km
under the Black Sea within the decided corridor of the South
Stream Pipeline, followed by 250 km within a new corridor towards
the European part of Turkey. The length of the Turkish onshore line
is reportedly 180 km, while that of Greece is unknown.
It is unclear whether the pipeline will become operational in
December 2016 as planned, given a delay in beginning its Turkish
part for which Ankara and Moscow are negotiating.
Norway      Pipeline, whose construction has been delayed for over a decade
Norway completed the Polarled Pipeline (482.4 km, 36 in.;
70 million m3/d) in September to increase its gas exports from the
Norwegian Sea to Europe. It is the deepest pipeline
(1260 m) on the Norwegian continental shelf and the first one on
that shelf to cross the Arctic Circle. The pipeline (approximately
US$0.9 billion) extends from Nyhamna in Møre og Romsdal,
western Norway, to the Aasta Hansteen field in the Norwegian Sea.
Americas
Canada
TransCanada is working on the proposed Eastern Mainline Pipeline
(4600 km) to increase mainly oilsands-based exports to the USA
by converting an existing gas pipeline.
The US$12 billion project would transport 1.1 million bpd of oil
from Alberta and Saskatchewan to refineries and port terminals
in Eastern Canada by converting an existing west-east gas pipeline
and adding an extension to connect it to Canada’s Atlantic ports,
from where oil could be shipped to the US by tankers. The
extension would link Canada’s Ontario-Quebec border to the port
of Saint John, New Brunswick.
TransCanada expects to amend its application for the Eastern
Mainline project by adding a new natural gas pipeline in the
Toronto-Montreal corridor (250 - 300 km) to reflect its agreement
with three Canadian gas distributors opposing the project as it is
affecting their operation.
18 World Pipelines / DECEMBER 2015
USA
Permian-Mexico Pipeline
American ONEOK Partners and Mexican Fermaca Infrastructure
have entered into a 50/50 joint venture to construct a pipeline
for transporting gas from the Permian Basin in West Texas to
Mexico. The US$450 million project connects ONEOK Partners’
ONEOK WesTex Transmission gas pipeline system at Coyanosa,
Texas, to a new international border-crossing connection at
the US-Mexico border near San Elizario, Texas, to be connected
with Fermaca’s Tarahumara gas pipeline. The project includes
approximately 320 km of 30 in. pipeline for transporting up
to 640 million ft3/d of gas with no less than 570 million ft3/d
being transported to Mexico. ONEOK Partners will manage its
construction and operate the pipeline.
The project’s first phase will provide 170 million ft3/d
of capacity, which is scheduled for completion in 1Q16. The
second phase is to increase the pipeline’s available capacity
to 570 million ft3/d in 1Q17. The final phase is to realise
the projected capacity of 640 million ft3/, which is set for
completion in 2019.     
Africa
Algeria
Galsi Gas Pipeline
Algeria and Italy agreed in February to work on the Galsi Gas
due to uncertainty about Italy’s gas demand. Algeria’s Sonatrach
leads the Galsi project consortium with a 41.6% equity interest in
partnership with Edison (20.8%), Enel (15.6%), Hera Trading (10.4%)
and the Sardinia Autonomous Region’s Sfirs (11.6%). Worsening
EU-Russian relations, and uncertainty about Russian gas in the
future, have made Italy committed to the Galsi Gas Pipeline.
With an estimated cost of US$2.5 - 3.96 billion, the project will
enable Algeria to supply gas (8 billon m3/y) to Italy and the rest
of Europe through an approximately 856 km pipeline, of which
565 km will be offshore. A 285 km offshore line connects Algeria’s
Kouduet Draouche on the Mediterranean coast to Porto Botte in
Italy’s Sardinia. This will be connected to an onshore north-south
Sardinian section (300 km) to link to a 280 km offshore section
that will deliver gas to Piombino on the Italian mainland.
Ethiopia and Djibouti
The two neighbours have agreed to construct the Horn of Africa
Pipeline (550 km; 20 in.; 240 000 bpd; US$1.4 - 1.55 billion) to
connect the Djiboutian ports via Dire Dawa to a fuel depot in
Awash, Ethiopia. Planned for completion in three years, Africa’s
Black Rhino Group is expected to manage the pipeline for
transporting refined oil products between the two countries. The
project also includes an import storage facility (950 000 bpd) in
Damerjog, Djibouti linked to a storage terminal in Awash, Ethiopia,
near Addis Ababa. A final investment decision on the project is
expected in 2016.
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 PTC MEMBER CONTENT
HAUTE PIPELINE
Thomas Garcon, Max Streicher GmbH & Co. KG aA, Germany, reviews the
expansion of the French gas pipeline network.
N
atural gas enjoys a place of honour in the European
energy mix. Linked to methane terminals along the
Atlantic and Mediterranean, neighbouring European
networks and underground storages, GRTgaz’s
transport network allows access to diversified supply sources.
It therefore fosters energy security in France and Europe, and
boosts the gas industry’s competitiveness. Subterranean ducts
constitute a safe, unobtrusive and cost-effective means of
transport for natural gas in order to convey large quantities
of energy whilst leaving local activity undisturbed, conserving
landscapes and protecting biodiversity. GRTgaz develops and
strengthens the French gas transport network.
Streicher has been commissioned to execute several
construction lots as part of the Haute de France II and Arc
de Dierrey projects. The pipeline section Haute de France
II (HDF II) runs from the French coastal town of Dunkirk
near the Belgian border to Cuvilly, north of Paris. The Arc
de Dierrey pipeline – which is the second section – runs
from the junction of both pipelines, starting in Cuvilly and
heading southeast toward Voisines in the Champagne-
Ardenne region. In the future, those two pipeline sequences
will significantly expand the French gas pipeline network
along the north-south axis. The neighbouring countries of
Belgium, Germany and Switzerland will also benefit from the
expanded transport infrastructure. Streicher’s employees have
been onsite since April 2013 to realise this major project. So
far, Streicher has used a range of state of the art processes
in order to meet the schedule deadlines in demanding
conditions.
Ecological requirements during construction
of HDF II
HDF II runs through the north of France, an area that is
characterised significantly by its agriculture. This flat and
thinly populated region is very fertile. The pipeline is routed
over great distances in the Picardie region, which is often
21
 referred to as ‘France’s breadbasket’. The work, therefore, must
maintain the quality of the agricultural land.
In March 2013, Streicher began with the construction work
for a 52 km section between Corbie and Cuvilly junction.
Right from the start, Streicher worked closely together with
the French Chambre d’Agriculture in order to conserve the
environment and farmland. Co-ordination with the experts
of the Chambre d’Agriculture was as much part of the daily
work of the project staff as taking daily soil samples along
the pipeline route. These samples provided information about
the humidity content of the ground. If a certain threshold of
ground humidity was exceeded, construction work needed to
be stopped.
Figure 1. Haute de France II, 51.7 km pipeline, DN 1200,
France.
Figure 2. The pipeline Haute de France II runs through the
Picardie region.
22 World Pipelines / DECEMBER 2015
Work had to be stopped regularly due to the heavy
rainfalls in the north of France during spring 2013, and
Streicher employees thus had to manage a number of
logistical challenges.
Trenchless process for many crossings
Streicher employees were not only faced with a rainy spring,
but also approximately 150 open and closed crossings had
to be executed on the section between Corbie and Cuvilly.
This included many roads and third-party pipelines, as well as
the river Somme. Open construction methods for crossings
are rarely an option in ecologically sensitive areas. Therefore,
Streicher relied on various trenchless processes, such as
horizontal directional drilling technology, micro-tunnelling or
the direct pipe process. These trenchless processes reduce
the impact on the environment significantly and satisfy the
ecological requirements in these areas.
High production rates due to modern
welding processes
The Streicher team used the CRC-Evans welding process in
order to efficiently complete the 52 km pipeline, with wall
thicknesses of up to 28.2 mm within the given time frame.
For this process, four burners weld the root of the seam
simultaneously on the inside. Whilst the root is welded from
the top down, the first outside layers are also welded with the
top down seam method. The welding machines are equipped
with double burner systems which allow the simultaneous
welding of two layers at a distance of 10 cm. The production
rates at the building site are thus significantly higher in
comparison with other automated processes. Streicher staff
managed daily peak performances of over 50 welding seams
per day.
The pipeline was commissioned in autumn 2014 after
completion of the pressure tests in December 2013 and
January 2014, and the completion of construction work in
October 2014. Parallel to commissioning the HDF II, Streicher
began work on the first construction lot for Arc de Dierrey in
April 2014; it connects in Cuvilly directly to the HDF II.
Arc de Dierrey: longitudinal drainage
minimises the number of weather-related
construction stops
About 310 km in length and a 1.20 m dia., the future Arc de
Dierrey gas pipeline will link Cuvilly (Oise) with Voisines
(Haute-Marne), thereby crossing three regions (Picardie, Ile-
de-France and Champagne-Ardenne) and five departments
(Oise, Seine-et-Marne, Marne, Aube and Haute-Marne). Arc de
Dierrey is part of a broad development programme for the
transport network in northern and eastern France in order to
enhance network flexibility and accommodate new gas flows
from the Dunkirk methane terminal, to be commissioned
in late 2015. The Streicher team – which consists of about
300 people – was responsible for the execution of the first
construction section between Cuvilly and Betz, completed in
July 2015.
Similar to the construction of HDF II, the Streicher staff
had to comply again with the strict agricultural requirements
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 Investment in
Europe’s energy
infrastructure
Streicher teams carry
out pipeline projects
beyond German borders,
in neighbouring European
countries as well as on
different continents. The
work on HDF II and Arc
de Dierrey constituted
the company’s first
pipeline projects in
France. Command of
the French language by
project management was
a prerequisite in order
be awarded the contract.
Despite this, many Streicher
employees were confronted
with hurdles due to the
Figure 3. Welding process, Haute de France II, 51.7 km pipeline, DN 1200, France. language barrier during
construction work on the
for the subsequent commission of Arc de Dierrey. The two pipelines. The teams were busy interpreting, mostly by
region to the northeast of Paris is more densely populated employees from the Alsace region who speak German and
and accordingly less used for agriculture, yet the quality of French and who were part of every work group.
the soil as the livelihood for local farmers had to be taken The client GRTgaz was particularly satisfied with the clean
into consideration. The experience gathered on the HDF II execution of the work by their partners from Deggendorf
construction site allowed Streicher employees to anticipate and the efficiency of the German-French co-operation. For
potential interruptions caused by weather conditions. The Streicher, the involvement in one of the most important
engineers introduced several longitudinal drainage channels energy infrastructure projects in France is also an involvement
along the pipeline sections before starting the actual in the future of the European energy network.
construction work in order to prevent potential construction
stops due to wet ground as much as possible. This is how Construction work on the next section has
the drainage channels work: the rainwater is gathered in the started
pipeline area and drained in a controlled manner. This way, in This summer, parallel to the completion of the section
the course of construction at Arc de Dierrey, workers had to between Cuvilly and Betz, Streicher also began work on
stop construction due to wet ground only twice. Precipitation construction lot four of the Arc de Dierrey pipeline. The
levels were significantly lower during this project. 64 km long pipeline section runs between the communities
Not only numerous highways had to be tunnelled of Dierrey-Saint-Julie southeast of Paris and Viviers-sur-Artaut
under, but the pipeline also crosses the French motorway in the Champagne region. Previously, Streicher had already
A1, five railway tracks, the wetland of the Aronde and the been commissioned with the detail engineering of this route
river Oise on its way to the southwest between Cuvilly section.
and Betz. As for the construction of the HDF II, controlled Streicher staff is once again faced with several challenges
micro-tunnelling allowed the use of a trenchless process for construction lot four. For example, the route again
to cross under the obstructions, which were up to 800 m crosses several railway lines, but also the Seine. The pipeline
wide. The time frames for most of the crossings were rather builders from Deggendorf are, however, well prepared with
tight. The tunnelling of the rivers had to be done when a combination of experience, technical know-how and the
the water levels were low. The tunnelling of the railway courage to use innovative solutions. This project is further
lines were scheduled for periods of three to five days in expanding the north-south axis of the French natural gas
close consultation with the construction management network.
and the French railway operator SNCF. This tight time
frame required night shifts by Streicher employees. Trains Note
continued to operate at lower speeds whilst the Mr. Hoffmann, Max Streicher, is a member of the Advisory
micro-tunnelling process was carried out. Committee of the Pipeline Technology Conference.

24 World Pipelines / DECEMBER 2015

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WORKING
HANDS-FREE
THE NEXT TECHNOLOGY SHIFT IN THE OIL AND GAS INDUSTRY WILL
INCLUDE WEARABLES, AS JAMES WOODALL, CHIEF EXECUTIVE OFFICER
OF UK-BASED INTOWARE, EXPLAINS.

L
ook closely at the history of the oil and gas industry, and you will find that the pace of
change is never a smooth line. Often, progress happens through periodic leaps driven by
new technologies and processes that are so significant that they alter the way that things
are done and viewed forever. The next technology shift will include wearables.
Today, the oil and gas industry stands on the verge of its next significant technology
progression – one that will have a profound impact on safety, efficiency and cost, and driven
by a blend of specialist mobile devices, context-aware apps and wearable devices. Rather
than a single breakthrough or ‘eureka’ moment, the technology stars have aligned in
a way that these technologies, which have been incubated in the consumer

26
Figure 1. Ruggedised
smart glasses
offer hands-free
communication in
hazardous areas.

27

Figure 2. Mobile technology enables inspection protocols and
data capture that minimise the risk of human error.
technology space, are primed for uptake by industry.
Innovative smart glasses and other wearable devices have
developed to the point that they can now withstand the
harsh environments of pipeline construction and maintenance,
and the emergence of the free and open Android operating
system – which has created a growing marketplace for
enterprise apps and devices – means that highly specialised
and task-specific software now costs tens of thousands of
dollars to create and launch, rather than the millions that big,
proprietary deployments used to entail. And just as important
as these big changes are the continuing advances in supporting
technologies like improved battery life, faster wireless
connectivity, haptic controls and speech recognition software
– all of which will have a major influence on the evolution of
wearable devices in the workplace.
The benefits that these technologies offer can be applied
to virtually any situation within the industry, meaning that for
those companies most willing to innovate have almost a blank
canvas to work from. As hardware and software improves,
so too does the range of different kinds of wearable devices
being created with industries like energy and utilities in mind.
Already there are ruggedised devices available today from
Motorola, that are able to gather and share video and audio
data in the field, and Google is also rumoured to be working
on more substantial second generated versions of Google
Glass. Whilst these are all variations on the smart glasses
theme, other wearables such as health trackers, smartwatches
and sensor-laden ‘smart’ fabrics will also come into play; but
the first devices we are likely to see deployed within the
pipeline sector will be these ruggedised smart glasses, as
the ability to stay connected with colleagues whilst working
hands-free has the most obvious and immediate safety
applications.
The benefits of wearables
Looking at the construction phase of pipeline building,
wearables will help improve communications between control
staff and onsite workers, allowing much better traceability
and workflow monitoring than the paper-based systems that
are still in use today. Wearables and mobile devices provide
workers with crucial information on-demand, allowing them
to call up weather data, schematics, maps, schedules and
28 World Pipelines / DECEMBER 2015
task-specific instructions as required. There is also the ability
to provide over-the-shoulder advice using video and audio
in situations where a worker may need specialist advice or
training – a huge time and resource saving. Built-in cameras
mean workers can show remote colleagues live footage of
faults or problems, letting them diagnose and fix problems
quicker and more efficiently, and crucially helping to reduce
or eliminate costly downtime or rework.
All of these benefits and more can be delivered by
relatively simple technologies that in combination become
a powerful toolset that helps to save time, better manage
resources, and ultimately reduce operational risk. Even small
incremental gains in productivity or improved oversight
become very significant when scaled across a major project
that might involve hundreds of workers onsite for many
months, where delays and missed deadlines come with
unwelcome costs.
Arguably, the potential impact of wearables on pipeline
maintenance is even more significant. With more than
US$1.4 billion spent every year just on the impact of pipeline
corrosion, any ability to identify problems earlier will have
a direct financial and environmental benefit. Whilst the
industry has already created a robust regulatory framework
that seeks to improve the safety of workers and reduce the
environmental risk posed by pipeline failures, these regulations
are often little more than a paper checklist of should-
dos. The problem with traditional checklist and oversight
processes is that the regulations are only as effective as both
their implementation and the quality of the data captured,
meaning the issue of human error is ever-present. Using these
new technologies to remove the reliance on paper and shift
entire processes online gives companies the ability to analyse
and share data in real time, with 100% transparency and
traceability. So with an inspection regime based on a blend
of wearables and mobile devices engineers, field managers,
and geologists charged with inspecting and assessing sites can
quickly process and analyse data and turn it into actionable
results. While it can be seen to be stating the obvious, better
intelligence does lead to better decision making.
IS smartphones are the first step
So with all this amazing technology on hand, why isn’t it
already in widespread use? The simple truth is that upgrade
cycles tend to be measured and not rushed; never more so
when companies have built processes and cultures on tried
and tested (and sometimes outdated) approaches. Innovation
often creates bottom-up change – by this, I mean that
new ideas and technologies emerge and rely on businesses
understanding the potential they offer and taking an educated
risk. Industry-wide demand will come from the top down, at
the point where the benefits of wearables have been clearly
defined and evaluated, and the risk/reward benefit is too great
to ignore.
The emergence of intrinsically safe (IS) smartphones and
tablets is a good example of a technology that matches
industry demand with innovation to deliver a solution to
a longstanding problem. IS smartphones are specifically
designed for use in explosive atmospheres, such as refineries
 or anywhere where petrochemicals or combustible materials
are processed or stored. IS devices must meet special battery
design criteria that eliminate the chance of internal sparking
of high internal temperatures that could cause ignition, and
be completely sealed to prevent the entry of ignitable gas
or dust. So with IS mobiles, the innovations we have seen in
terms of software and specifically Android-based applications
become accessible to the entire workforce, and not just
a percentage. That in turn makes large scale deployment
feasible.
The opportunity presented by tablets and smartphones is
certainly a tantalising one. A survey of oil and gas executives
by The Economist found they expected in five years that 62%
of workers to be using smartphone-based systems, and 56%
using tablets – up from 38% and 26% today. That may not
seem an overly significant increase until you consider that
the same survey found that 18% of workers are still using
paper-based processes. Often the biggest challenge with any
technology shift is overcoming the inertia of sticking to the
same ways of doing things, even more so in industries where
the simplest solution is often the safest.
IS smartphones represent the biggest safety innovation
in years precisely because of this ability to bring up-to-date
working practices into hazard zones where they will make the
most difference. Workers with the latest critical information
at their fingertips will find it easier to understand and comply
with safety policies and established work and maintenance
procedures; this in turn makes it easier to prevent failures,
reduce repair times, and creates a safer working environment.
The introduction of these devices will in turn pave the way
for IS wearable devices, as much of the technology inside
the IS mobile handsets is transferable to smart glasses and
other devices. In a relatively short time period – perhaps
12 - 24 months – we should start to see workers taking full
advantage of the capabilities of this new wave of technology.
Wearables and hands-free working
Whether building pipelines or maintaining and repairing them,
chances are the work will need to be done in a hazardous
Figure 3. Smartphones and IS devices mean that entire workforces can be
connected for the first time.
30 World Pipelines / DECEMBER 2015
and often remote environment, where mistakes can
have human and environmental costs. The ability to
work hands-free in these situations is one of the most
obvious and welcome benefits that wearables offer.
Although smartphones and tablets can be used for many
of the same functions as wearables, engineers cannot
simply take out a mobile with one hand and Google for
information, or check what the hazard alert noise was for.
In these situations having a headset or smartwatch where
notifications and information can be easily visible in a way
that is not distracting is a perfect hands-free alternative.
Plus, being able to use voice controls and two-way video
means that in even in the most challenging locations, a
worker effectively has a whole support crew on-hand.
The ability to shift information access, data input
and communications into a single device that only needs
spoken commands makes wearables such an apposite
technology for the pipeline industry – and the energy
sector as a whole. Taken individually, these benefits may
be helpful, but are certainly not game-changers. But when
packaged together into a device that’s not much bigger or
heavier than conventional safety goggles or a wrist watch,
it becomes something that will lead to a revaluation in the
way many tasks are done.
The future is (nearly) here
Although the time is ripe for the introduction of these
new wearable and mobile technologies into the oil and
gas industry, it is important to not over simplify the
barriers that need to be overcome for it to be widespread.
The emerging devices need to be proven to function in
the harshest conditions over time – which means that
extensive field trials will take some time before a wider
roll-out can even be considered. Then there is the issue of
training, updating existing processes, and even addressing
existing software infrastructure to take advantage of the
much greater wealth of data that will become available.
Finally, in a time of slimmer profit margins and financial
restraint few companies will want to gamble on major
investment until the benefits are tangibly too big
to ignore.
We will see these devices and technologies
in use in industry sooner rather than later.
Reputable analysts from firms including IHS and
IDC predict that in two to three years there
will be millions of wearable devices being used
by the industry – and the majority of these
will be head or wrist-worn, to take advantage
of the hands-free safety aspect. As outlined in
this article, so many pieces of the technology
puzzle have fallen into place – with ruggedised,
intrinsically safe mobiles, the emergence of
Android as a new global standard for enterprise
apps, and the flow of industry-ready wearable
devices from major manufacturers – that it is a
question of when, and not if.
 RAISING
THE BAR
wo companies, working at two ends of the
T distribution of gas pipe for the Victorian Northern
Interconnect Expansion (VNIE) project in Australia,
found efficiencies in material handling using
Vacuworx lifting systems.
The QUBE Energy wharf facilities in Melbourne are the
first stop for coated carbon steel gas pipes from China
being used in the APA Group’s VNIE project. Prior to
discovering Vacuworx, QUBE Energy had been using a third
party crane contractor to unload the 400 mm (16 in.) pipes
from the ships and place them on tractor-trailers bound
for staging points along the project route.
The ‘old way’ of doing things required a crane, a
spreader bar and hooks with straps or chains. Ken Colwell,
an Operations and Project Manager with QUBE Energy
(formerly known as Continental Freight Services and a
division of port logistics services provider QUBE Ports Pty
Ltd.), said that he found that having to hire a crane was a
“repetitive exercise” and less cost efficient than utilising
company-owned assets and personnel.
Cover Story
Vacuum lifting technology improves
efficiency and safety on the VNIE
project in Australia, as Todd Razor,
Vacuworx, USA, explains.
New means and methods
Beginning with the VNIE project, QUBE Energy decided to
lease an MC 5 vacuum lifting system, designed to work
with compact carrier equipment such as wheel loaders or
the forklifts that the company already owned.
“We had the equipment (forklift) onsite,” Colwell said.
“We just needed a way of adapting it to lift the pipe.
That’s where the Vacuworx product was discovered. Now,
instead of dealing with the cost of leasing a crane, we’ve
actually improved our ability to perform more precise lifts
while bolstering safety and lowering our expenses at the
same time.”
Safety and risks
While increasing their productivity on the Port of
Melbourne wharf was important, Colwell noted that the
company was most interested in the safety aspect of
vacuum lifting technology, as it poses less risk to workers
on the ground in nearly all weather conditions. Colwell
stated: “There are no booms overhead or slings and hooks
31
 moving in the air. Everyone can see what’s going on and
now our (work) can continue, even in light of wind or rain.
It’s a much simpler operation.”
QUBE Energy also realised that the Vacuworx lifting
system mitigates damage to pipe coatings. Advanced
features such as 360˚ rotation and wireless remote control
allow for precise placement of materials into scalloped
timber cradles on the tractor-trailers.
Continuing, Colwell explains: “There are no hooks
or collisions. The pipe doesn’t get damaged. The lifter
picks the pipe up in the centre, attaches it and gives our
operator complete control. Now we can get away with a
forklift operator and one spotter … saving on one labour
unit while still achieving the results we need.”
Figure 1. QUBE Energy uses a Vacuworx MC 5 with existing forklift to
handle gas transmission pipe in Port Melbourne.
Figure 2. The Vacuworx MC 5 provides precise placement of 400 mm
(16 in.) pipe as it is loaded onto tractor-trailers.
32 World Pipelines / DECEMBER 2015
Transporting, lifting and unloading
The QUBE Energy team (on average) is able to transport
about 90 pipes over the course of an eight or ten hour
window, with three drivers each making round trip
journeys of approximately 250 km per workday to staging
sites in Tallarook, Benalla and MacDow’s pipe yard in
Wallan.
McConnell Dowell Constructors Pty Ltd. – commonly
referred to as MacDow – is a long-time customer of
Vacuworx. On loop one of the VNIE project, MacDow ran
two Vacuworx RC 10 lifting systems, in conjunction with
Komatsu CP300 excavator host equipment, to unload the
pipe at its yard in Wallan, as well as string a stockpile of
nearly 1700 lengths along the right-of-way.
Darren Hayes, a MacDow Plant and Logistics
Manager responsible for ensuring safety and
efficiency on the company’s sites in Australia,
stated: “We only need an operator and one
additional worker to pick up the pipe and load
or unload a truck. It’s a faster method, which
is among the main reasons we continue to use
Vacuworx’s product.”
Luis Guevara, Vacuworx’s Business Development
Manager in Brisbane, helped provide training to
QUBE Energy for new lifting systems. “I watched
the operator on QUBE’s wharf place his hands on
the MC 5’s wireless remote control for the very
first time. That initial lift appeared so natural,
and it was satisfying to know the lifts we were
performing in Melbourne would be reverse
engineered, so to speak, when MacDow uses an
RC 10 to unload these same trucks in Wallan. It’s
interesting to see both sides of the vacuum lifting
equation from an industrial setting to in the field.”
Because the MC 5 performed so well, QUBE
Energy recently added two RC 10 vacuum lifting
systems to their arsenal; one being used with a 16 t
forklift to unload pipes at Port Melbourne, and the
other being put to work on a Hitachi excavator for
unloading at a laydown yard in Benalla.
The systems
With sales support in Australia, Latin America,
Africa, Russia, Europe and the Middle East,
Vacuworx designs and manufactures vacuum and
hydraulic lifting systems for worldwide distribution
from its facility in Tulsa, Oklahoma. The company’s
RC Series and MC Series material handling systems
– which are built for the oil, gas, water, sewer,
utility and road construction industries – have
lifting capacities ranging from 3 t (6600 lbs) to 20 t
(44 000 lbs).
Vacuworx systems are suitable for in-plant and
in-field material handling applications, including
steel plate, concrete slab, road barriers, HDD drill
stem, and virtually all sizes of concrete, plastic,
fibreglass, steel and cast-iron pipe.
 The VNIE project involves
looping sections of the existing
269 km Victorian Northern
Interconnect (VNI) pipeline.
The VNI pipeline runs from
Wollert (north of Melbourne) to
Barnawatha (south of the Murray
River). The expansion project
involves the construction of
looping sections of the existing
300 mm pipeline with new
400 mm transmission pipes to
increase capacity, as well as
increase compression capacity
north and south of the VNIE.
APA is Australia’s largest natural
gas infrastructure business, owning
and/or operating US$12 billion of
energy assets with gas transmission
pipelines spanning every state and
territory on mainland Australia,
delivering approximately half
of the nation’s gas usage. APA
developed a US$187 million
proposal to expand its Victorian
infrastructure to enable more
gas to flow north into northern
Victoria and New South Wales Figure 3. Tractor-trailers bound for a VNIE staging area are loaded with pipe using a
from southern supply basins. Vacuworx MC 5 vacuum lifting system.

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SCANNING
FOR SUBSEA
INTEGRITY Scott Gray, Seatronics, UK, offers insight into efficient
laser scanning solutions for subsea spool metrology.
U
nderwater laser scanning is an emerging
technology that is increasingly being used
for subsea integrity management due to
the accuracy, precision and cost efficiency
afforded by this innovative technology. Seatronics,
UTEC StarNet and 2G Robotics recently completed
a spool metrology project for Subsea 7 using
underwater laser scanning as part of the overall
solution to achieve the required measurement
accuracy that could not be attained using acoustic
techniques.
Seatronics Ltd. – an Acteon company –
specialises in the rental and sale of marine
electronic equipment for the subsea environment.
Seatronics is committed to strengthening its ability
to supply the latest developments in offshore
and subsea technology to its clients. Through
the development of strategic relationships with
innovative and respected manufacturers, Seatronics
continues to build upon its offerings to provide the
best technologies to cater to the expanding needs
of the subsea industry.
Driven by this commitment to provide industry-
leading technologies, in early 2015 Seatronics
formed an exclusive global sales and distribution
partnership with 2G Robotics – leaders in high
precision subsea measurement technology. 2G
Robotics’ ULS line of underwater laser scanners
has proven to be an excellent complement to
the existing acoustic measurement technology
offered by Seatronics, providing clients with
increased measurement quality at shorter ranges to
better detect and assess damage, develop design
and repair plans, and perform maintenance and
installations.
Spool metrology project
Since forming the partnership, Seatronics and
2G Robotics have collaborated on a number of
integrity management projects, including the recent
35
 spool metrology project for Subsea 7. This project was
part of a major North Sea installation contract. Seatronics
worked closely with the project managers of the contract,
fellow Acteon Company, UTEC StarNet, to provide the
best solution for accomplishing the project objectives.
UTEC StarNet provides high quality, cost-effective,
leading-edge technology solutions for offshore, onshore,
and subsea project needs. The company has an established
reputation for finding optimal solutions for the most
extreme challenges. Recognising the need for greater detail
and accuracy, UTEC StarNet collaborated with Seatronics
and 2G Robotics to co-ordinate the implementation of a
laser scanning approach for the spool metrology.
A hybrid long baseline (LBL)/laser scanning solution
was used to perform the metrology. The metrology was
conducted in the North Sea, at a depth of 90 m. Two of
2G Robotics’ ULS-500 laser systems were mobilised from
Seatronics Aberdeen, along with offshore engineers from
Seatronics, 2G Robotics, and UTEC StarNet to facilitate
with the metrology. The end-customer’s objective was
to design five spool pieces to connect a newly installed
bundle towhead to five previously laid spool pieces. The
bundle towhead had been previously laser scanned as part
of an onshore dimcon survey executed by UTEC StarNet
to provide dimensional control. A work class ROV (WROV)
was used to attach the crane hooks to the protective
concrete mats in order to peel back the mats and expose
approximately 6 m of each spool piece. Saddles, beacons,
transponders, and control spheres were then positioned by
the WROV.
To obtain towhead and spool piece positions and
headings, acoustic LBL was used. Survey specifications,
however, dictated that a 6 m long acoustic baseline
Figure 1. The entire data set was captured in only 3.5 hours.
Figure 2. The laser approach generated a completed 3D
visualisation comprised of 14.6 million points.
36 World Pipelines / DECEMBER 2015
to derive at an acoustic heading was insufficient. 2G
Robotics’ ULS-500 high precision laser scanner provided
the additional dimensional control needed to obtain
the necessary measurement accuracy that could not be
achieved using the aforementioned baseline.
The ULS-500 with rotary actuator and tripod was
deployed by the WROV. A gripping frame was added to
the standard mount location of the ULS-500 so that the
WROV’s manipulators could grab the system to position
it on the seabed. The system was tethered to the WROV,
and the WROV’s Seatronics supplied Gen5 MUX was used
to communicate with topside operators for real time data
acquisition.
The centre flange was positioned within the LBL acoustic
array using the two saddle mounted transponders with control
spheres that were deployed onto the largest of the five spools
by the WROV. To complete the high precision dimensional
control survey of the towhead structure with flanges, 2G
Robotics’ ULS-500 performed 360˚ scans at multiple locations
around the spools, with each scan capturing both the key
flange pipeline components and the control spheres attached
to the two pipeline saddles. The acquired laser data was then
used to quantify the relative positional offset, heading, and
inclination differences of the four other flanges relative to
the centre flange in order to accurately position each flange
within the LBL acoustic array. All data was acquired in real time
by survey engineers on board the vessel with each individual
scan position requiring approximately 20 min. to complete,
with a 15 - 20 min. scan duration for the data collection phase.
Old vs new approaches
Using 2G Robotics’ ULS-500 significantly improved the
cost efficiency of the project. The traditional LBL survey
approach would have required an entire day of operation
to install, remove, and relocate the transponders for
each of the five pipes. With the ULS-500, the metrology
was completed in less than a quarter of the time of a
traditional LBL approach. Since the ULS-500 system is
factory calibrated, no time-consuming and complex
calibrations needed to be completed during deployment,
which reduced mobilisation, fieldwork, and vessel time.
Using a laser scanning approach also meant that less
equipment needed to be deployed to perform the
metrology, which further contributed to the reduced
operational time of the project.
In only eight scans and 3.5 hrs, the ULS-500 captured
highly detailed 3D point cloud model of the flanges,
bundle towhead, beacons, control spheres, and surrounding
environment. Whereas the traditional approach would
have yielded only one point per beacon, the laser scanning
approach generated a complete 3D model comprised of
14.6 million points, notably improving the accuracy for
designing the spools. The accuracy of the model also
means that if additional measurements are needed post-
survey, further surveying is not required. The model serves
as a complete and reliable reference from which to extract
dimensional information, which eliminates the cost of
additional surveys.
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 Figure 3. 3D point cloud model of a spool with flange.
The processing of the data also contributed to
the efficiency of the project. Working with Seatronics
and 2G Robotics, UTEC StarNet processed the data on
behalf of the end client and compiled a comprehensive
report of the results. The six scans were registered
using the control spheres and natural features of the
subsea environment to produce the single, unified 3D
point cloud model of the entire survey area including
all sides of the pipeline termination points. The data
was processed while still onboard the vessel, and was
made available for initial review within 12 hrs of job
completion. This onboard processing enabled preliminary
measurements of the flange orientation and position
to be promptly obtained and fabrication to commence
onshore in a timely manner, allowing for more efficient
asset management.
Innovation continues to transform the subsea
industry. The innovative use of 2G Robotics’ advanced
laser scanning technology coupled with traditional LBL
survey techniques resulted in a highly accurate 3D model
positioned in real world co-ordinates. This accurate
Figure 4. 2G Robotics’ ULS-500 underwater laser scanning
system with rotary actuator.
38 World Pipelines / DECEMBER 2015
3D model provides a more complete understanding of
the subsea flanges in relation to their environment and
enables critical measurements to be easily and repeatedly
captured.
The laser scanning results from this spool metrology
project demonstrate a significant step forward in both
3D data solutions and subsea integrity management. “The
end results were very impressive and the detail within
the point cloud is fantastic,” said Pieter Jansen, Survey
and Subsea Data Manager. “The operational time savings
will be motivation to use this system again. There will no
doubt be many other subsea situations for which highly
accurate dimensional detail is required where 2G Robotics’
laser system would fit in perfectly.”
Seatronics will continue to work with 2G Robotics,
throughout their global bases, in order to provide the
ULS range of laser scanning systems, ensuring customers
continue receiving the highest quality equipment and
employ time-saving techniques. This will allow Seatronics
to remain at the forefront of the marine electronic
equipment supply industry.
Figure 5. TP = transponder; A, B, C, C1, D, E, F, G = eight scan
positions. Only six scan positions were used in the final data
set.
BIG
MAKING IT ON THE

S C R E E N

40
Software solutions for editing and processing spatial data can aid offshore
operations. Ole Kristensen, EIVA, Denmark, explains how pipe inspection video
data can save man-hours on eventing and improve the quality of its information.

P
ipeline inspections based on traditional video
eventing ensure visually detailed results, but they
also have some shortcomings, including having to
spend numerous hours going through the videos as
well as compromising on position accuracy.
NaviModel – the NaviSuite software solution for editing
and processing of data, such as those acquired during
pipeline pre-surveys and inspections – offers a video image
mosaicking and draping tool that addresses these issues and
offers three different view types.
By using strips of video frames (still images) on the 3D
digital terrain model (DTM) along the pipeline, users get
a detailed visualisation of the inspection data, allowing
them to zoom in on areas of interest. This makes it easy
to identify events without having to watch hours of video
streams, which also brings a decrease in the amount of man-
hours spent on eventing. Moreover, the size of the data files
in play is vastly reduced.
Replace raw data with images for more
time-efficient and accurate eventing
With the release of NaviModel 4.0 on 7 September 2015,
it is now also possible to drape the still images generated
from a video or still image camera around the pipe and

41
 onto the pipe object, thereby implementing the video as a
3D object in the DTM.
This is made possible by the use of tools such as an edge
detector based on a technique that works even with limited
position and camera angle data; a stencil DTM divider for
deletion of pipeline points; a gap filler tool for filling in the
gap made by the stencil DTM divider; or a surface arithmetic
tool that allows for creation of a surface based on the
surrounding surface.
The result is a digitally generated virtual pipeline that
corresponds directly to the exact position on the DTM.
Thereby, the software allows for a highly visually realistic
representation of the pipeline that is not affected by any
data noise or potentially flawed data.
This approach combines the best of the two
technologies in play: the video data, now draped still
images representing the pipeline, can be reviewed much
faster, with the DTM providing geocoded data for both the
pipeline and the seabed.
Choose between a total of three different
views
The video image mosaicking tool is also a useful feature
to apply in pre-survey operations, where it is the seabed
and not a pipe that is the focus of the inspection. This is
possible via two additional views for the user to choose
Figure 1. Video image draping in NaviModel 4.0.
Figure 2. Waterfall and mosaic views of video image data in NaviModel
4.0.
42 World Pipelines / DECEMBER 2015
from: a waterfall and mosaic views, which also combine the
video still images, but do not drape them.
Adding to the feature list of the EIVA
NaviSuite Nardoa solution
The video image mosaicking and draping tool constitute an
important feature of the EIVA NaviSuite Nardoa solution
for advanced 3D pipeline inspections. It is a completely
integrated software solution for data acquisition and
processing, offering users a cost-effective workflow and
high-quality inspection results through:
)) Integration of sonar, video and tracker data providing
a detailed and complete data overview throughout the
workflow, synchronised in time, position and reference.
)) Visualisation, processing and analysis in a 3D
environment leading to extensive possibilities.
)) Automatic data cleaning and filtering letting the
software do most of the work quickly and efficiently,
utilising intuitive features such as Kalman filtering and
S-CAN cleaning.
)) Raw data applied throughout the entire inspection
workflow eliminating the risk of errors due to data
conversion and allowing for instant compensation of
errors in the different workflow stages without having
to step back in the process.
NaviSuite Nardoa enables users to save man-hours
and money while delivering high quality, thorough
and comprehensive inspection results to their
customers.
Features include near real time processing of large
data sets, thereby reducing the timeframe of the
inspection job to a minimum. The software does most
of the work, and the man-hours of the team are spent
more efficiently on the details that require a human
hand. Altogether, this translates into a far more cost-
effective inspection workflow.
Scalable solution
The open, modular solution supports all available
software and hardware equipment for subsea pipeline
inspection. It is easily integrated into existing
inspection setup and equipment, enabling users to
create a tool box that fits their needs – by making
use of existing hardware equipment and thus saving
money, or buying new equipment without having to
worry about integration complications.
NaviSuite Nardoa is also scalable in terms of
location and number of users. It is built around a
database network, making it a scalable solution to
match users preferred setup perfectly in terms of
number of users and location.
Multiple users can access and process the data
simultaneously, which reduces the timeframe of the
inspection job. Moreover, the team can be situated
both onboard the inspection vessel and onshore,
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 depending on the specific requirements and options
presented by the project.
Cover the entire inspection workflow with
one software solution utilising raw data
The features offered in the NaviSuite Nardoa solution will
ensure a fast and flexible workflow and inspection results of
the highest quality.
Through the possibility of near real time data processing,
users can produce preliminary reports and thereby carry
out on-the-fly data quality control. This lets them know
straight away if there is a need for recapturing, and virtually
eliminates the risk of insufficient or flawed data.
The software is applied throughout the inspection
process, offering users a comprehensive and advanced tool,
from video data providing an integrated view, and eventing
Figure 3. EIVA NaviSuite Nardoa is a scalable solution in terms
of not just the equipment in play but also the number and
location of users.
Figure 4. The data workflow of NaviSuite Nardoa.
44 World Pipelines / DECEMBER 2015
both during data acquisition and processing, to manual or
automatic data cleaning and generation of digital models of
seabed and pipe or cable in a 3D environment.
The NaviSuite Nardoa solution makes use of raw
data throughout the workflow, offering users complete
traceability and eliminating errors due to data conversion.
This means that they can instantly compensate for data
inconsistencies and sensor inaccuracies without having to
step back in the process, and they can export the data to
any relevant third party software.
Extensive inspection results
The NaviSuite Nardoa is the ideal solution for clients with
high expectations. It allows inspection companies to deliver
high-quality inspection reports shortly after the inspection
vessel arrives at port, as a paper report combining raw data
and 3D models or displayed in a free 3D viewer.
‘High-quality’ covers highly accurate, extensive and
thorough results that are easily comprehended, a key
element being the possibility of 3D visualisation. In sum,
end-clients will get a sound decision-making basis in the
work that follows the delivery of the inspection results.
Accurate time tagging for improved
inspection results
When time accuracy is of pivotal importance to an
inspection operation, the ATTU offers a simple way of
taking the time-tagging feature of the NaviSuite Nardoa
solution to the highest level, as an optional extra.
The ATTU can be applied in any inspection setup that
includes the EIVA NaviPac and NaviScan navigation and data
acquisition software solutions.
Knowing the when and where of sensor data is an
essential element when users want optimum accuracy and
high-quality data of their inspection operations. The ATTU
ensures a time tagging accuracy that is higher than 50 μSec.
The rack-mounted unit enables easy installation into
existing solutions – users simply connect the sensors and
configure the unit in the intuitive web interface.
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THE FORGOTTEN
ART OF mentoring
Emphasising the importance of mentoring,
Michelle Unger, ROSEN Group, and Phil
Hopkins, Phil Hopkins Ltd.,* explain how
knowledge is transferred between a mentor and
mentoree, noting the importance of ‘wisdom’ in
this transfer, and how a mentoring programme
can be introduced into a company.

I
t seems ‘competence’ is becoming the new ‘in’ word in engineering, and engineers
now need to be demonstrably competent to perform their duties. Competence
is obtained from a mixture of experience, training, and mentoring: everybody
understands experience and training, but does everybody understand the concept
of mentoring?
We normally associate mentoring with a personal and trusting relationship
between a more experienced and/or more knowledgeable person, and a less
experienced or less knowledgeable person. The relationship is focused on the
development of the less experienced/knowledgeable person.
Historically, mentoring in business has its roots in the craftsman-apprenticeship
relationship. Artisans learnt everything through mentoring: before books, computers,
etc., mentoring was the only way to transfer knowledge.
Mentoring is still very important: there are clear business benefits from
mentoring, as we know that most successful people in business have benefitted
from a mentor, and mentoring is even more important than training in developing
competencies.
So, what is the problem? Well, mentoring today can be very difficult due to staff
reductions, and over-stretched managers. This means that a resource even more
important in competency development than training may be overlooked.

Influential individuals
Have you ever worked with somebody who has really made a difference to your
career? For example, when you were at school, did a teacher give you good career

*This paper was produced as part of the ROSEN-Phil Hopkins Ltd. partnership.

47

Figure 1. Competence and pipeline integrity.
Figure 2. Competency building blocks.
advice that you still remember? If your answer is ‘yes’, you
have been influenced by a mentor.
The word mentoring comes from a Greek word meaning
enduring. The traditional definition of mentorship comes
from Homer’s poem, The Odyssey. Odysseus (Ulysses)
travelled the world for years at a time. He entrusted Mentor
(Athena, goddess of war and wisdom, disguised as a man)
with the care and education of his son, Telemachus.
Thus, traditional mentoring emerged as a relationship
between an older, wiser and/or more experienced person.
This person functions as a wise teacher and confidante,
coaching, inspiring, protecting, and, helping the mentoree to
realise their aspirations and develop positive qualities.
Mentoring is still essential today, but many companies
do not actively promote it, and many older, wiser staff do
not have the time to mentor. But, it may be the best staff
development tool we have.
Competence
In any profession we need staff who are competent.
Competence is a mix of skills, knowledge, and experience
(Figure 2). Values such as ethical behaviour are also essential
in competency development.
The pipeline industry has always required its staff to
be trained and qualified; for example, the USA Pipeline
Safety Regulations Federal Register Part 49 CFR Subpart
O Section 192.915 (pipeline integrity management) states:
48 World Pipelines / DECEMBER 2015
“... any person who qualifies as a supervisor for
the integrity management programme [must have]
appropriate training or experience in the area for
which the person is responsible ... the integrity
management programme must provide criteria for
the qualification of any person.”
Design standards, such as ASME B31.4 emphasise
the need for competency: “the code is not a design
handbook; it does not eliminate the need for the
designer or for competent engineering judgment.”
The international pipeline standards,
ISO PDTS 12747, now explicitly links competence
to the maintenance of safety (integrity) in an ageing
pipeline (Figure 1).
Competence is now a hot topic in the USA. A crude
oil pipeline owned by Enbridge failed in USA in 2010, with
costs above US$1 billion as of September 2015. The USA
pipeline regulator stated in its report on the failure: “the
management of training and competency is particularly
critical for an organisation such as Enbridge.”1
The evidence above is clear: competence is now on
the agenda in the pipeline industry, but the industry may
be missing a key element of competency. That element is
mentoring.
Competence and mentoring
We become competent by a combination of training,
mentoring, and experience:2
)) Training is simple to understand: it is structured learning
in a skill.
)) Experience is also easy to understand and appreciate: it
involves exposure to a skill over time.
)) But, what is mentoring and how do we obtain it?
Mentoring is simple to visualise, and its purpose easy to
understand. Training involves the transfer of information,
but not knowledge. Knowledge can only be stored in the
human brain – we will cover this in more detail below.
Hence, mentoring is how we transfer knowledge to staff.
No mentoring – no knowledge. We can now conclude that
competence is developed by:
)) Training (structured learning).
)) Mentoring (learning from others).
)) Experience.
But, what is more important? How important is
mentoring compared to, say, training? Well, mentoring
is very important, as it – surprisingly to many people –
may contribute even more to competence than training
(Figure 3).2 Unfortunately, many of our HR/training/talent
management departments fail to recognise its importance,
probably because it is not understood. They may spend
millions of dollars on training their staff, but nothing on
their mentoring.
When developing competence, experience is the most
important element. Figure 3 shows the classic split of

Figure 3. Gaining competence.
70:20:10 to experience:mentoring:training. We can argue
about the split, but the point to emphasise is the inclusion
of mentoring in the split, and that training may be the least
important element of competency.
Understanding mentoring
The confusion with mentoring is often based on
misconceptions; for example, mentoring is not:
)) Parenting (rearing children).
)) Managing (control and command: overseeing the work
of others).
)) Coaching (focus on developing agreed skills).
Mentoring is a focus on the individual, where
knowledge, guidance, and advice is passed onto staff, based
on experience. Mentoring has long been associated with
good business sense:3 Richard Branson said: “What do Larry
Page, Steve Jobs and yours truly have in common? We’ve all
received guidance from mentors. Yes – even the famously
individually minded Apple Founder got by with a little
help, advice and support from time to time. No matter
whom you are, where you’ve come from, or what you have
achieved, a good mentor is an invaluable asset in business.”
We normally associate mentoring with a very
personal, trusting and caring relationship between a more
experienced and/or more knowledgeable person, and a less
experienced or less knowledgeable person. The relationship
is focused on the development of the less experienced/
knowledgeable person. It can be a structured process, but
does not need to be formal.
But a word of warning, mentoring is very difficult. The
US Department of Labour noted that mentoring is the most
complex type of human interaction.4 It is more complex
than teaching, counselling, supervising or coaching. It
is complex, as it has to fulfil many functions within the
mentoring relationship.
What is a mentor and mentoree?
The mentor is often described as a “trusted counsellor or
teacher.”5 He/she needs to be intelligent, knowledgeable,
and wise (more about wisdom later). The mentor may be
50 World Pipelines / DECEMBER 2015
older or may be younger, but they need to have a certain
expertise that develops the mentoree, and have a greater
wisdom.
The mentoree (the one who is being mentored) is
sometimes called a protégé. The word protégé is from the
French verb protogere, meaning to protect. There are many
examples of mentor and mentorees:6
)) Socrates (philosopher, 470 - 399 BC) and Plato
(philosopher and mathematician, 428 - 388 BC).
)) Paul Gauguin (1848 - 1903) and Van Gogh (1853 - 1890).
)) Jay Z and Rihanna.
But few people can mentor, and the mentoring is not
easy:7 “Effective mentoring can be learned, but not taught…
most learn to mentor by experimenting and analysing
success and failure, and many say the process of developing
effective methods of mentoring takes years.”
Mentoring is nothing new
Historically, mentoring in business has its roots in the
craftsman-apprenticeship relationship.8 The artisans learnt
everything through mentoring.9
Mentoring was usually carried out within a management
chain: you had a father as a line manager, and a grandfather
as your manager’s manager. This male bias is a little non-pc,
but that is how it was described. The grandfather was not
directly involved with your line management. This meant
that he/she could be a mentor. Today, this chain often
does not exist.
Mentoring has become a big issue in business in the past
30 years.10 This is probably because it has been forgotten/
stopped but mentoring is a tradition – it is not a new
business tool! Before books, computers, etc., it was the only
way to transfer knowledge.
Mentoring involves transfer of knowledge
The mentor helps the mentoree gain some of his/her
knowledge; therefore, it involves a transfer of knowledge.
Knowledge is transferred from the mentor (the provider) to
the mentoree (the seeker). The provider must want to give,
and the seeker must want to receive. In mentoring, this
transfer is within a personal relationship agreed between
provider and seeker. But, what is knowledge?
Knowledge
Knowledge is information in action:
)) Information is simply a collection or linkage of data
that may form a conclusion following processing/
organisation, and information can be easily stored and
shared. Hence, information can be transferred easily by
training.
)) Knowledge is what we know. Knowledge is based on
data, information, and, experience: it can only be stored
in the brain. Hence, mentoring is an excellent way to
transfer knowledge.
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Figure 4. Relationship hierarchy.
Figure 5. The mentor’s goal.
Wisdom
Knowledge requires experience. The
mentor uses his/her wisdom powers
to facilitate this transfer. Wisdom is
using your knowledge in a correct
and intelligent manner; for example,
we all have the knowledge to manage
money, but many of us can become
bankrupt by making unwise decisions.
Wisdom captures values: the mentor
bases his/her knowledge transfer on
values. There is little to be gained by
being mentored by someone with the
wrong values: a master locksmith or
a safe-blower could mentor a young
Figure 6. The role of a mentor in a
locksmith. Hence, wisdom requires mentoree’s competency management.
more than experience. It also needs
values. So, a mentor needs to be knowledgeable and wise.
Transfer
Many companies believe they can manage and transfer
knowledge by using their intranet, virtual communities, etc.
These platforms are good for managing and distributing
information, but not knowledge. So, how do you store and
transfer knowledge?’
Knowledge can only be stored in the human brain;
therefore, we need to focus on its transfer. Mentoring
allows this transfer from mentor to mentoree. Historically,
knowledge, in particular values and heritage, has been
52 World Pipelines / DECEMBER 2015
transferred from one generation to another by
storytelling: before schools, paper, radio, film,
and the internet, storytelling was the only way
to transfer knowledge of morality, etc.
Today, storytelling is still the best way to
transfer knowledge and values (ask any child)
mainly because all parties are engaged and can
pause and ask for clarifications and perspectives.
These attributes are not present on intranets,
TV programmes, films, YouTube clips, etc.: there
is no personal engagement. Social Media can
overcome this problem as it is a powerful virtual
platform, and involves engagement.
The best stories focus on values: good ones, bad ones,
and future values. The best knowledge transfer aims at
inspiring the mentoree, with the mentor no longer telling
everybody how brilliant he/she is.
Mentoring will mean listening to experienced staff. This
can be good – most of the time – but younger staff may
have to listen to older staff, even when they go on, and on,
and on. What should take 1 min., takes 45 mins. with older
staff, but the wisdom will be within those timescales and
worth the wait.
What about coaching?
Coaching is a one-to-one relationship, involving a series of
conversations, just like mentoring. It may be confidential,
but its main purpose is to identify
opportunities for improved
performance and practical ways
forward. It is important “a coach
is someone who intervenes and is
designed to improve the performance
of an individual in a specific task.”11
This is different from a mentor: a
mentor is a “critical friend, or guide
who is responsible for overseeing
the career and development of
another person outside the normal
manager/subordinate relationship.”11
Coaching has a fixed agenda, related
to a task, with a clear outcome,
usually short-term, and focused on
a competency. Mentoring does not
have a fixed agenda, it is related to
the development of an individual,
without a variable outcome, is long-term, and focused on
the individual.
Linking coaching, mentoring, and friendship
Many mentors and mentorees started in a ‘coaching’
relationship. The main purpose of coaching is to identify
opportunities for improved performance. The chemistry was
right, and this coaching can develop into mentoring. It is
natural for this mentoring to go deeper, and for friendships
to develop (Figure 4). The reverse is also true: it is natural
for coaching and mentoring relationships to end. Indeed,
coaching and mentoring usually have a finite life: a time will
come when the mentoree no longer needs the mentor, or services, but management do not use the services, as
the mentor no longer wants the mentoree. they are confused about its benefit or application.

)) Formal mentoring programmes, with detailed documentation,

Mentoring: formal or informal
can be in place, but never used due to the formality, and lack
programmes?
of understanding of the benefits of mentoring.
How can we ensure mentoring is part of our company’s
culture? How can we introduce mentoring programmes? But whatever the programme, the roles must be clear,
First, we need to decide on a formal or informal programme. and the benefits clearly identified. Also, it is best to focus
Mentoring is usually a relationship between two people, on selecting staff for a mentoring programme who are likely
which can be formal or informal: to stay in the company for a reasonable time: this is for the
)) A formal, structured programme specifies the seeker benefit of both the mentoree and the company.
(mentoree), provider (mentor),
and the knowledge (tasks) to
be transferred. The seeker/
provider relationship is not a
personal one, as the transfer
is bespoke and controlled.
This relationship can be
short-term (say, one year) and
ends when stated goals are
met.

)) Informal mentoring is more

objective-driven (career
development), than task-
driven (increase sales). The
relationship is long-term,
with outcomes that may be
unknown, with only indirect
organisational benefits.
Mentors and mentorees
self-select, and there is no
need for the mentor to be a
specialist.

Short-term, strategic
knowledge transfer can be
formal, as it is easy to define, and
measure progress. This is more
like coaching (see above). Longer
term mentoring will probably be
more informal. Also, you need
to match the mentoring to your
company’s culture. If it is a more
formal culture, you will need to
go more formal, and vice-versa.
The authors have looked at
pipeline engineering companies,
and discovered:
)) Companies often confuse
coaching with mentoring
– indeed one company
described their approach to
mentoring, but it was actually
coaching, where the staff was
assisted in developing skills.

)) Companies can be offered

professional mentoring
Goals of mentoring programmes
Companies will initiate a mentoring programme, but there needs to be
clear, ‘SMART’ objectives. High retention rates? Develop young staff
quickly?
The mentor’s goal is relatively simple: he/she is focused on
developing an individual, and aiming to blend experience, knowledge,
and values (Figure 5).
Whatever the objectives, companies will need to plan, budget, and
execute the programme. Even informal mentoring programmes will
need some guidelines, with clear objectives and values. It will also
need a budget, as mentoring is not cheap.

Working with line management

How does a mentor work with a mentoree’s line management? Is there
a conflict? How can the mentor and manager combine to develop
staff?
Actually, this sounds far more difficult than it is. A manager is
focused on the day-to-day tasks of his/her company, and delivering
the company’s goals. The manager will periodically assess his/her
staffs’ competence, and check development, and set targets. The
mentor can be formally involved in this process, as the mentor is
assisting in competency development, and can check the staff’s
competency assessment, and the manager’s assessment (Figure 6).
Additionally, the mentor can be informally involved in staffs’
periodic performance review (competence and performance reviews
have differing goals), as an adviser on training/experience needs. The
mentor is impartial. The two big advantages of mentoring is that the
company will have competent staff, and the staff will see their careers
develop in a structured manner.

Concluding comments
This article has attempted to remind the reader of the lost art of
mentoring. It has emphasised the crucial role that mentoring plays in
developing staffs’ competencies, and how it is even more important
than training. The article has also noted the increasing emphasis on
demonstrating competency in the pipeline industry.
Historically, and today, successful people have been mentored.
The mentoring is not easy, and it will take up time, but if a company
ignores mentoring, it is not developing its staff. If you do not develop
staff, competencies will suffer.

Bibliography
1. Anon, “Enbridge Incorporated. Hazardous Liquid Pipeline Rupture and Release, Marshall,
Michigan, July 25, 2010”, NTSB Accident Report: NTSB/PAR-12/01, PB2012-916501, July 2012.
2. LOMBARDO, M. M., “Career Architect Development Planner 3rd Edition (The Leadership
Architect Suite),” January, 2000.
3. ROCHE, G. R., “Much ado about mentors”, Harvard Business Review 57 (1), 1979, p. 14 - 28.
4. HENRY, S M., “Does Mentoring Matter? Rethinking Support for New Primary School
Principals”, UMI dissertation, Proquest, USA, July, 2008.
5. HUSSAIN, Z., “The Good Mentoring Guide Changing Attitudes Programme”, Global Synergy
Solutions, 2009.
6. PATEL, S., “Why Every Entrepreneur Needs a Mentor”, Forbes, 11 December 2014, http://
www.forbes.com/sites/sujanpatel/2014/11/12/why-every-entrepreneur-needs-a-mentor/
7. HANDELSMAN, J., et al., “Entering Mentoring” Hewisconsin Programme for Scientific
Teaching, 2005.
8. GAY, B., STEPHENSON, J., “The mentoring dilemma: guidance and/or direction”, Mentoring
and Tutoring, 6 (1), 1998, p. 43 - 54.
9. MONAGHAN, J., LUNT, N., ‘Mentoring; persons, processes, practice and problems’, British
Journal of Educational Studies, Volume 40, Issue 3, 1992.
10. COLLEY, H., “A ‘Rough Guide’ to the History of Mentoring from a Marxist Feminist
Perspective”, Journal of Education for Teaching 28 (3), 2005, p. 257 - 273.
11. KRAM, K. K., “Improving the mentoring process”, Training & Development Journal, Vol 39 (4),
April 1985, p. 40 - 43.
 Dr. Gregor Brown,
Cameron, UK, explains
how leak detection
benefits go way beyond
financial ROI.

Implementing leak
detection strategies
A
recent report by The Associated Press (AP) based on analysis of US federal data
identified that, since 2009, the annual number of significant incidents resulting in
crude oil and refined petroleum pipeline leaks has increased by almost 60%.
Of these leaks, around two-thirds were said to be the result of corrosion or
material welding and equipment failures – issues generally associated with older pipelines.
And if we go back even further, over the last 20 years there have been more than 2000
significant crude oil and refined petroleum pipeline accidents in the USA alone, causing
about US$3 billion in property damage, according to data supplied to AP by the Pipeline
and Hazardous Materials Safety Administration (PHMSA). Add in the costs associated with
cleanup and compensation – and the damage to corporate reputation – and it is clear that
leakage is a big challenge for the industry.

55
 When oil and gas companies think about leakage,
they generally look at four main factors: loss of life and
properties; direct cost of lost product and downtime;
environmental cleanup costs; and fines and lawsuits.
It is no surprise then that there is growing recognition
of the value of implementing a leak detection strategy
that enhances the ability to shut down the pipeline as
quickly as possible, minimise product loss, and reduce
any hazard to the public. Implementing a proven leak
detection strategy also mitigates cleanup costs – which
vary greatly around the world but are by far highest in
the USA, followed by Asia and Europe – and the bill for
compensation. So, on every level, investing automated leak
detection clearly makes sound business sense.
Consider a relatively recent example of what happened
when a 6 in. pipeline 35 miles in length, pumping at the
head-end only, developed a leak – the result was a
20 600 bbl spill. Yet, a line inspection by an automatic
inspection pig 18 days prior to the discovery of the leak
showed no flaws at the leak location. Cleanup costs were
estimated at more than US$4 million.
Had this operator’s pipeline been equipped with high-
accuracy flowmeters and a coupled leak detection system,
the leak could have been detected within three days and
the loss limited to 70 - 116 bbls – a potential savings of
US$2 million in lost product at then current commodity
prices, as well as a massive reduction in cleanup costs.
However, as with every area of this industry, there
are choices – not just in the technology to be employed
for leak detection, but in the way the system is set up
to avoid false alarms. Shutting down a pipeline is an
expensive business – needlessly shutting it down as a
result of a poorly configured detection system not only
costs dollars, it also undermines the entire principle of
rapid and appropriate response.
Leak detection system considerations
By definition, leak detection systems are used by
pipeline operators to identify when a leak occurs so that
Figure 1. Flowmeter at TCPL Keystone.
56 World Pipelines / DECEMBER 2015
appropriate actions can be taken to minimise spill volume
and duration.
A variety of leak detection methodologies exist
including means of physical detection of rupture
events or leaking product as well as methods based on
monitoring the fluid hydraulic behaviour of the pipeline.
An automatic leak detection methodology that compares
volume balance or mass balance at the originating point
of the pipeline with volume or mass at intermediate and
destination stages would be classed as a computational
pipeline monitoring system, covered by Recommended
Practice R1130 of the American Petroleum Institute (API).
In addition to volume balance and mass balance, real
time transient todeling (RTTM) and statistical methods
also are employed. However, whatever the chosen
methodology, they all rely upon capturing reliable and
accurate flow data at strategically important metering
points along the pipeline.
A meter-based detection system is simple in
concept and can be incorporated into the measurement
instrumentation and the software of pipelines with
multiple segments/pump stations, recording volumetric
flow measurements and pressure, temperature, etc. at each
pump station. These provide inputs for leak detection
software, measuring the flow volume entering a segment,
the volume that flows out and any differential as a ± rate
of change. If the equation is unequal by more than a set
threshold, a leak is declared.
Operators need to be concerned about four areas that
typically contribute to leak detection performance metrics.
)) Sensitivity: a composite measure of the size of leak a
system is capable of detecting, and the time required
for the system to issue an alarm in the event a leak of
that size occurring.
)) Reliability: a measure of the ability of a leak detection
system to consistently render accurate decisions about
the existence of a leak on the pipeline (i.e. detect
actual leaks and avoid false alarms).
)) Accuracy: a measure of the system’s
ability to accurately estimate leak
parameters, such as leak flowrate,
total volume lost, leak location, etc.
)) Robustness: a measure of the
leak detection system’s ability to
continue to function and provide
useful information, even under
changing conditions of pipeline
operation or under other less-than-
ideal operating conditions.
Performance criteria linked to these
areas are increasing interest in high-
accuracy ultrasonic flowmeters.
Clamp-on ultrasonic meters
were first applied for leak detection
many years ago and became popular
because of the ease of installation.
However, with the
industry’s growing focus
on higher accuracy
measurement, operators
have come to recognise
the performance
limitations of more basic
technologies and have
moved to multipath
meters. Even here,
though, not all multipath
meters are created
equal; a four-path meter
would require a flow
conditioner to match the
performance of an eight-
path meter.
Ultrasonic technology
– such as the eight-path
meter developed by
measurement technology Figure 2. Graph depicting the false alarm probability that is desired within any segment.
specialists at Cameron
– have been shown to
offer the best performance in supporting a leak detection
strategy, not only because of impressive measurement
accuracy and sensitivity but due to the fact that the
design introduces very little pressure drop in the pipeline.
With no moving parts, sensors interacting non-invasively
with the flow, and in-built redundancy of measurement,
the eight-path meter also has an envious reputation for
reliability and robustness in difficult applications from
nuclear feedwater flows to cryogenic liquefied natural gas
(LNG). What is also particularly valuable to operators is
that ultrasonic technology has the ability to transfer the
calibration of these meters from a central flow laboratory
to the field with the confidence that calibration will not
change over time, something which cannot be guaranteed
with conventional mechanical meters due to the effects
of wear and tear. Moreover, the alternative of trying
to calibrate meters in the field has massive capital and
operational cost implications, hard to justify even when it
involves a high-stakes issue such as leakage.
While leak detection systems are increasingly specified
in new pipeline projects (including the Keystone pipeline),
operators also are aware of their potential in older
infrastructure, where aging assets and corrosion present a
growing risk.
False alarms
The overriding concern for pipeline operators is to keep
the oil flowing, so the spectre of false alarms weighs
heavily. Not only does a detection system rely upon
fundamental flow measurement accuracy, it requires
parameters to be set to reduce the potential for false
alarms, particularly where the policy is for the system to
automatically shut down when an alert is triggered.
It may seem obvious, but it is not always recognised
that the performance of a leak detection system is related
directly to the performance of the flowmeters at the ends
of each segment.
In other words, the accuracy requirements in terms
of maximum measurement uncertainty can be set based
on the desired leak detection threshold or vice-versa.
In Cameron’s experience, the leak detection threshold
typically should be set at three times the estimated
flow measurement uncertainty. Setting the threshold
using this ratio ensures that false alarms are infrequent.
The requirement then is to consider the leak detection
threshold in absolute terms and then select and maintain
the measurement system, such that it has an uncertainty
that is consistent with this ratio. The number of segments
and expectations in terms of false alarm rates also will
influence the actual threshold ratio across a pipeline.
This is expressed in the graph (Figure 2), which shows
the factor that relates the minimum leak threshold to the
flow measurement uncertainty for any one segment as a
function of the number of segments in the system and the
probability of false alarms.
For example, in the case of an operator of a short
pipeline with only one segment willing to tolerate false
alarms at a rate of 0.2 %, the multiplying factor would
be approximately two. This means that if meters are
installed with an expectation of ±0.5% flow measurement
uncertainty, the alarm threshold should be set at no less
than 1%. However, considering an operator of a long
pipeline with 10 segments that is only willing to tolerate
a false alarm rate of 0.01%, then the multiplying factor
would be three. If that operator wanted to set the alarm
threshold to 1%, then they would require flowmeters
capable of delivering results with an uncertainty of less
than ±0.33%.
In this scenario, it is not only the flow measurement
uncertainty that is important, but also the pressure and
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temperature measurement, and how the model copes
with line pack change (volume contained in the pipeline
between meters) and with complexities, such as batching
different products. Therefore, it is important that when
setting the alarm threshold, consideration is given to the
uncertainty of the flowmeters, the other inputs, and the
model assumptions.
The danger of an auto-shutdown prompted by one
measurement outside of normal flow parameters is that
it could be the result of another factor, so operators
of complex pipelines need to be able to take both a
detailed and a broad view of flow data across a wide
sweep of segments. Detailed analysis combined with
operator experience and real time monitoring of system
inputs allows adaptation of leak detection software to
account for instrumentation uncertainties and ‘normal’
flow variations so that there is certainty in identifying true
leakage events.
Benefits of leak detection systems
What is becoming clear is that a leak detection system
is viewed as a high-value protective mechanism by
operators and is based on a premise that goes beyond a
typical ROI analysis, placing product lifecycle over initial
cost, and reliability above all else. Within this context,
ultrasonic measurement systems, though not the lowest
cost solution, are winning market share, thanks to meter
accuracy, negligible pressure loss, and pumping cost
benefits.
The benefits of ultrasonic technology were recognised
by pipeline operator TransCanada when planning the
2148 mile Keystone pipeline. With an initial 39 pumping
stations moving 590 000 bpd (13 800 - 27 400 b/hr),
in a viscosity range of 2 - 700 cSt via a 30 - 36 in. dia.
pipeline, flowmeters were required at each station for
both pump control and as inputs for leak detection.
Located downstream of pumps, the selection of eight-path
ultrasonic meter technology (no flow conditioner required)
eliminated pressure drop at each station, meaning that not
only was an effective leak detection system installed,
but it had the added benefit of saving between
US$1 - 2 million/y in pumping energy costs
with the resultant recurring benefit over 20 years.
Leak detection is a growing priority around the world.
Recent leaks in Mexico, Colombia, China, Canada, and the
US have raised media and public attention, resulting in
ever-tightening regulation and increasing cleanup costs. As
is evident from major pipeline infrastructure projects such
as Keystone, there is an expectation (backed by regulatory
frameworks and punitive damages) that operators will be
good citizens in protecting people and the environment.
When set in this context, investing in the best available
flowmetering technology as part of a leak detection
strategy not only makes sense from a conventional ROI
perspective, it also becomes a tangible expression of
corporate social responsibility.
 Benjamin Fuentes, Thermo Fisher
Scientific, and Toby O’Brien, Enable
Midstream Partners, discuss how
advanced technology and innovative
ideas help improve L&U gas levels.

TRACKING LOST
GAS LEVELS
F orecasting in the oil and gas industry is challenging, and for the
midstream companies tasked with developing and maintaining
transportation and delivery infrastructure, even minor process
inefficiencies or issues can lead to major bottom-line impacts.
But in one critical area of midstream operations – lost and unaccounted
for (L&U) gas – there is an opportunity for organisations to use advanced
monitoring technology to better understand their energy measurement,
ensure accurate calculations and, as a result, achieve improvement, including
higher levels of consistency.
An Oklahoma, USA, based midstream company, Enogex LLC, successfully
used electronic flowmeters to better understand and manage its L&U gas
levels. This approach, which will be outlined in this article, significantly
boosts the company’s overall performance, including its profits.

Embracing analytics
According to IDC Energy Insights, 50% of oil and gas companies will have
advanced analytics capabilities in place by 2016. The consultancy believes
analytics are one of the 10 most important issues for companies that seek
emerging market opportunities and are planning for future growth.

59

Figure 1. Enogex in the field. Photo courtesy of Enable
Midstream Partners.
“Rapid and radical changes in energy
supply and demand require gas companies
to be more agile, resilient and innovative
to retain a competitive edge,” said Jill
Feblowitz, Vice President of IDC Energy
Insights, who helped develop the set of
predictions for the oil and gas industry.
“These decision imperatives will help oil
and gas companies focus their efforts and
deploy technology wisely to meet those
ends.”
Midstream companies are not immune
to these challenges. To overcome them,
these companies must look to better
understand data and how it can inform
their ongoing efforts to maintain Figure 2. Thermo Fisher’s AutoPILOT PRO.
pipelines efficiently while properly Photo courtesy of Thermo Fisher Scientific.
distributing and tracking the flow of
product. Enogex LLC made innovation in
analytics a central part of its new approach.
Enogex’s path
The story behind Enogex’s improved L&U levels started with
a willingness to take a long-range view of its processes in
the early 2000s. (Enogex was previously a subsidiary of OGE
Energy Corp before joining CenterPoint Energy in May 2013
to form a master limited partnership, Enable Midstream.
Enable Midstream is a natural gas pipeline company based
in Oklahoma City that manages more than 12 000 miles
of gathering pipelines and nearly 8000 miles of interstate
pipelines as part of its operation).
For Enogex, significant swings in L&U levels, specifically
from the winter to summer months, initially prompted
executives to audit operations. While levels were well within
the 2% threshold the industry accepts as reasonable, Enogex’s
own 12 month study of data found a difference of more than
1% in L&U gas levels from mid winter to mid summer. At its
60 World Pipelines / DECEMBER 2015
summer peak, Enogex charted L&U levels of approximately
0.85%, while in the winter they recorded levels closer to
-0.40%. A loss or negative L&U has a financial impact in two
ways – at the customer level by paying for gas not actually
received, and then purchasing replacement gas on the spot
market at possibly elevated prices.
The company initially struggled to understand the
fluctuations, which altered the accuracy of the data that
feeds into the electronic flowmeter (EFM) while impacting
its customer service and its ability to set appropriate
transportation and fractionation rates for customers. While
there were potential explanations for those fluctuations –
including seasonal changes in both gas temperature and ground
temperature affecting the physical characteristics of the gas
– Enogex executives wanted to pinpoint the specific causes
and effects of the swings to establish a precise relationship
between the work performed by their field technicians and
subsequent L&U gas levels.
The company engaged a third party to assess its meter
sites, and this included physical meter tube inspections,
review of calibration equipment and
EFM configurations. The consultants
concluded that Enogex’s technicians
required a more thorough understanding
of American Gas Association (AGA)
flowrate equations. Although the
introduction of electronic flow
computers helped the process, Enogex
and its field technicians still needed
to understand flow equations so that
they could conceptualise the resulting
measurement numbers.
Enogex purchased a gas orifice flow
(GOF) program in 2002 and installed
it on the laptops of all measurement
technicians. The new procedures
required technicians to run the program,
as an independent calculation, when
arriving onsite and before leaving a site
after calibration. This process verified
that the EFM was calculating data correctly based on AGA
flow equation factors. The technicians began to understand
the environmental parameters that affect the flow equation
factors, as well as how those factors influence the overall L&U
calculation.
Enogex began to see vast improvements: a new 12 month
study, from 2006 into 2007, displayed a less than 0.7% swing
from mid winter to mid summer. The data made it clear that
the operation was headed in the right direction. This provided
incentive to keep going: executives opted to examine the
data to identify opportunities for more enhancements to their
services and bottom-line benefits, and they determined that a
realistic goal for overall L&U was at or around 0.2%.
In 2007, the company chose to standardise its measurement
protocols on one EFM platform, which included the Thermo
Scientific AutoPILOT and Thermo Scientific AutoMATE flow
computers. In fact, over the course of three years, Enogex
gradually replaced all of its non-Thermo Scientific EFMs. (In
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Figure 3. Thermo Fisher EFM. Photo courtesy of Thermo Fisher
Scientific.
2008, Thermo Fisher launched a new platform, the Thermo
Scientific AutoPILOT PRO, which combined the capabilities of
the AutoPILOT and AutoMATE.) The GOF program provided
the calculation factors that were easily compared to the
calculations made by the EFM and on one screen. The goal
for standardisation was to simplify calculation verification,
troubleshooting and training with the expectation that it could
maintain consistent L&U levels over any 12 month period.
Those expectations were met: a third study, conducted
from February 2009 to February 2010, presented data showing
less than a 0.2% swing from mid winter to mid summer, a
significant improvement upon the 2006 - 2007 analysis. Goals
were lowered to a conservative 0.16% to emphasise the
importance and continued focus on the key behaviors that
drive low L&U.
Behind the technology
The latest generation of EFMs are designed with long-term
hardware and software reliability in mind. With optimal power,
accuracy and ease-of-use, an effectively deployed system
of EFMs enhances flow measurement and enables faster
calculations. But any midstream company seeking efficiency
and maximisation of resources must also be cognisant of their
instrument durability as well; state-of-the-art EFM processors
can withstand extreme environmental conditions, including
6000 volts of lightning and temperature cycling from -40°C to
85°C.
The EFM is in many ways the lifeblood of a midstream
company, and essentially serves as its cash register; technicians
are tasked with ensuring that customers pay for gas received
at the wellhead and tracking gas sold to downstream users or
transporters. Even small measurement errors can equate to
millions of dollars per year.
For Enogex, the AutoPILOT Pro system delivered high
performance as well as peace of mind and confidence in the
gathering and calculation of valuable data. Today, the system
enables per-second flow calculation on up to six meter runs
simultaneously, and it interfaces with both differential signal
devices and linear signal devices. It also features a simplified
62 World Pipelines / DECEMBER 2015
configuration that prevents personnel from spending valuable
time on setup and programming.
Technological advancements have brought more precision
and greater accuracy to applications in the oil and gas industry,
and those benefits – directly or indirectly – have led to critical
cost-savings and more streamlined operations for Enable
Midstream.
Long-lasting impact
More than five years after its initial internal study, which led to
standardising on the AutoPILOT Pro, Enogex has a significant
sample size that can assess its performance, and it is still
maintaining the consistent levels of L&U gas it charted in
2009 - 2010. By that measure alone the program is a success.
Giving field technicians a greater role in understanding
gas measurement calculations and in the decision-making
process is a major reason for the success of the program.
Before standardising on the Thermo Scientific flow computer
platforms, Enogex field personnel could see flow measurement
statistics, but they did not understand where the data came
from or how it impacted L&U results. Once they understood
both the problem and the opportunity in the larger context,
they were much more effective at helping to achieve the
overall goals and objectives of the program.
Now, Enogex technicians use the information displayed
by the EFMs to understand how each data point fits into an
overall flow equation. Seeing the data this way lets technicians
proactively track L&U levels and avoid issues before they
escalate. This has led to long-lasting impacts for Enogex
because now its technicians are an integral part of a solution
for efficient operations and bottom-line accountability.
The impact of having consistency in L&U levels cannot be
overstated for midstream companies and their bottom line.
Maintaining low levels – and keeping them consistent through
changing seasons – allow companies like Enogex to drop their
rates, set up more beneficial commercial deals, and gain and
retain more customers. In the case of Enogex, the success of
the L&U improvements and the positive impact on commercial
and financial gains can be attributed to its attractiveness as
a merger candidate and the eventual formation of Enable
Midstream in 2013.
Conclusion
To be an industry leader and enhance service to its customers,
Enogex officials made the decision to take the long view,
and its planning and patience paid off. A focus on improving
the understanding of L&U gas levels came at a time when
technological innovation was starting to transform the industry.
The companies that adopted such innovation quickly and
correctly thrived. The lesson here for others in the industry is
that small problems can indeed have a major cumulative impact
on operations, but if someone cannot measure and analyse
them, then they cannot fix them either. Enogex recognised an
opportunity to elevate its business to a new level. The Enogex
case study shows that even the smallest of percentage gains
or losses are meaningful and that attention to detail – fuelled
by access to and the mastery of hard data – is smart business
indeed.
 Rethinking
INTERFACE
DETECTION

Interface detection is not a new concept for the pipeline industry. It has always
been critical for operators to identify the hydrocarbon product that is flowing
through a system at a given point. But while the requirement for interface
detection has remained constant over time, the need for higher accuracy, density
measurement and product identification is now driving operators to seek out
instrumentation that offers more than just basic interface functionality.
Paul Limpitlaw, Siemens AG, USA, explains why.

T
oday’s oil and gas industry faces different and
greater challenges than it did in decades past.
Global technological innovation has spawned new
forms of crude oil extraction, including hydraulic
fracturing and subsea drilling, and has led to a dramatic
increase in the number of highly specialised hydrocarbon
products with very similar densities and other identifying
characteristics. At the same time, as the price of a barrel
of oil has continued to plummet, profit margins have been
whittled away and financial pressure on the industry is
mounting rapidly. In this tightening economic environment,
operators must improve efficiency and account for every
drop of product in their pipelines, regardless of how similar
one flowing product may be to the next. This is only
possible with advanced interface detection technology.
As one international oil company with a Malaysia-based
pipeline learned, clamp-on ultrasonic flow measurement is
currently one of the highest-performing and most cost-
efficient methods of interface detection available.
One pipeline, three products
The company owned a pipeline 16 km (10 miles) in length
and with an outer diameter of DN 250 (10 in.), located at
its onshore terminal in Malaysia. The pipe carried three
different hydrocarbon products from offshore vessels to
land-based storage tanks:
) 92 research octane number (RON) unleaded gasoline
with a density of 0.7451 g/cm3.
) 97 RON unleaded gasoline with a density of 0.7762 g/cm3.
) Automotive diesel fuel with a density of 0.870 g/cm3.
With only one pipe transporting everything to storage,
pipeline operators were required to shift constantly
between individual products and water buffers to ensure
adequate separation. At the receiving station, the buffer
materials were discharged into a slop oil treatment
system while the various products were channeled into
their designated tanks. This setup presented several

63
 major drawbacks, including the significant amount of
time required to separate the three products, a constant
risk of product contamination, and high operating costs
associated with the slop oil system.
To enhance operational efficiency and ensure consistent
product quality, the oil company decided to build a
second DN 250 pipeline dedicated solely to transporting
diesel fuel. The existing pipe would continue to carry the
two grades of unleaded gasoline. At the same time, the
company elected to stop using water separation buffers
within the existing pipeline, which meant eliminating the
physical divide between products and monitoring the
interfaces that formed instead.
Sonic signature is the key
The challenge lay in finding the appropriate tool to accurately
and reliably detect interfaces between the two types of
Figure 1. Clamp-on ultrasonic sensors using the wide beam
method.
Figure 2. Clamp-on ultrasonic flowmeters can determine the temperature-
compensated sonic signature of a liquid, which provides an extremely
accurate way to distinguish between hydrocarbon products with very similar
characteristics.
64 World Pipelines / DECEMBER 2015
unleaded gasoline. Since density varies from one liquid to
another, most interface detection equipment analyses the
density of different hydrocarbon products in transit to
identify each liquid and the interfaces separating them.
What made this particular installation so problematic
was the extremely small, and on occasion even
overlapping, density spread between the 92 RON and
97 RON gasolines. For this reason, in their search for
measurement instrumentation to perform interface
detection, the oil company set two very strict
requirements:
)) Extreme sensitivity, making it possible to identify both
grades of gasoline without relying on water or pig
separation.
)) Flow measurement capabilities, enabling operators to
compare the amount of gasoline offloaded from the
vessels against what entered the storage tanks.
During the project planning stage, the oil company first
explored densitometers and Coriolis mass flowmeters, both
of which detect interfaces by measuring density differences
in the flowing liquids. However, in this instance, neither
device proved precise enough to distinguish consistently
between gasolines with such narrow differences in density.
The company next turned to clamp-on ultrasonic
flowmeters, and quickly discovered a key advantage for
interface detection: rather than relying solely on liquid
density to pinpoint which gasoline is currently inside
the pipeline, clamp-on flowmeters are also capable of
measuring sonic velocity, rate of change in sonic velocity,
and temperature – all with a very high degree of precision.
Because the sonic velocity of a hydrocarbon product
changes linearly relative to temperature,
certain clamp-on meters can use these
parameters to find the temperature-
compensated sonic signature of a liquid. This
can be thought of as the liquid’s ‘fingerprint’
in that it is unique and provides an extremely
accurate way to distinguish between products
– even those with extremely similar densities.
With this knowledge in hand, the company
determined that the SITRANS FUH1010
clamp-on ultrasonic flowmeter from Siemens
would be the most appropriate solution to
perform gasoline interface detection on their
Malaysian pipeline.
Ideal clamp-on configuration
Beyond its unique ability to determine sonic
signature, clamp-on technology offers the
benefit of cost-efficient external sensors,
which do not require cutting into the pipe
for installation and can be moved to different
locations along the pipeline as needed. In this
instance, the interface detector was outfitted
with wide beam sensors, which use the pipe wall as a the meter quickly proved itself adept at detecting the
waveguide to inject ultrasonic signals into the media. This indicated ROC correctly and consistently.
method results in a highly focused and coherent signal that The clamp-on interface detection solution has been in
covers a large area of the pipe’s inside diameter, providing place on the Malaysian pipeline for more than a decade,
significant resistance against suspended solids and bubbles. and the owners as well as the pipeline operators remain
The oil company selected a dual-path clamp-on highly satisfied with its performance. Not only is the oil
meter, which improves flow profile averaging by using company saving a substantial amount of money in slop
two pairs of sensors. The sensor pairs were installed on oil treatment every year since the meter has eliminated
the same side of the pipe, also known as reflect mount. the need for water separation buffers, but the operational
This configuration sends the ultrasonic signals through the efficiency of the distribution and storage facilities is
liquid twice, increases the flow sample area, and enables greatly improved.
compensation for cross-flow WP_HALF_AD_AUG.pdf 1 7/15/15 1:42 PM
conditions, all of which contribute
to superior measurement accuracy.
Since changes in the
temperature of a liquid have
a considerable effect on the
liquid’s sonic velocity, a clamp-on
ultrasonic interface detector must
be paired with a very precise
FASTER .
temperature gauge to ensure the
best possible results. This is of SAFER.
SMARTE R.
particular importance for a system
measuring liquids with very similar
densities. Accordingly, the meter
was mounted on the Malaysian
pipeline with 1000Ω platinum
insert resistance temperature
detectors (RTDs), which measure
with greater precision than their
clamp-on counterparts and
optimise the performance of the
interface detector. The insert RTDs
were connected directly to the
flow transmitter, eliminating the
need for – and the expense of – a
separate temperature transmitter.
The interface detector was set
to analyse the sonic velocity and
temperature of the gasoline flowing
through the pipeline and identify a
rate of change (ROC) in the sonic
signature of greater than 4 m
(13 ft) for every 15 secs. If the ROC
exceeded this value within a 15 sec.
time period, the meter interpreted
the change as an interface and
energised a relay. The relay then
sent a signal to the electrical valve
channeling a particular grade of
gasoline to the correct storage
tank, prompting the tank to open
or close. Despite the similar and
sometimes identical densities of
the hydrocarbon products being
transported through the pipe, VACUWORx.COM
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 Nigel Jones, VAE Controls,
Czech Republic, takes a look
A new era of at the evolution of pipeline
automation and controls.

MONITORING
T
he pace of evolution in automation in the past few years has accelerated, and developments
and enhancements abound. This has had to match the requirements of local and international
standards and legislation meshed into a product that meets industry requirements.
In the early 1970s, microprocessor control had taken a quantum leap into a solid state
medium, Honeywell had developed a total distribution control (TDC) system, and everyone was utilising
both pneumatic, relay, or a hybrid of both. In theory, this meant better control, fewer errors, better
management and reduced down time and maintenance. It was absorbed into all facets of energy markets,

67
 and other manufactures developed similar processor systems
for process control. As a result, pipeline monitoring control
was bought into a new era.
Overview of drivers/controllers
Company requirements/standards are overlaid by the national
and international regulations and acts that are in place.
These are further endowed by the guidance documents and
engineering global standards that are utilised. In addition,
health and safety and environmental regulations/controls
must be implemented.
The usage of circulating ‘buzz terminology’ – such as
‘lifecycle’, ‘holistic approach’, ‘best in class’ and ‘evolutionary’
– all add to the soup of technology and engineering solutions.
It is important to ‘cut through the layers’ to find the real
solutions and deliverables in a practical augmented approach.
The challenges faced by the oil and gas industry, such
as the dramatic drop in crude pricing, is reflected in major
corporations protecting their shares and market position with
acquisitions.
On a micro/macro level, certain processes must be
pursued when developing a project from concept onwards,
such as FEED project process flow. In addition, HAZOP and risk
Figure 1. Skids loading for transportation.
Figure 2. Flow computer system.
68 World Pipelines / DECEMBER 2015
assessments are key elements and within this process there
is normally an evaluation of the CAPEX spend over time in
operation, and not just as a pure banking elements, such as
return on investment (ROI) or net present value (NPV). This is
where the myriad of available programmes/data assimilation
facilitate this important part of total project costs.
This article will look at two models – total cost of
ownership (TCO) and lifecycle costs (LCC). Essentially, both
terms equate to similar methods of evaluating the value of an
investment project wise.
CAPEX vs OPEX
Over time OPEX costs can well exceed CAPEX costs, and
here the dynamics are somewhat clouded and data sharing is
sometimes slightly biased to ‘win situations’.
We can breakdown a project into its various phases over
time:
)) Concept/feasibility/budgeting approximation.
)) Pre-FEED.
)) FEED/design costing/final budgeting approvals.
)) Tender (of utilising) documentation, RFQ/ITB.
)) Bid evaluation and maybe further clarifications/
negotiations.
)) Legal contract agreement (FIDIC etc.).
)) Pre-project kick-off/site mobilisation.
)) Project phases leading to snagging/commissioning/hand
over.
)) Operations service/maintenance/repair/upgrades.
Essentially, there are two elements – theoretical and
actual. Under the theoretical banner, you can safely assimilate
the project and its component parts for final ITB/RFQ using
both hard knowledge gained in field, and modelling in its
various guises, and or a combination of both. This equates to
the helpful ‘buzz words’ that are widely used in the industry.
Figure 3. CAPEX/OPEX: the finite balance.
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 Lifecycle modelling
The energy business has evolved many times over in the last
30 years or so, such that most corporations have reduced
internal resources for engineering and projects, taking a
Figure 4. Measuring skids under protection canopy.
Figure 5. SAT completed.
Figure 6. Craning skids into facility.
70 World Pipelines / DECEMBER 2015
preferred line of outsourcing such activities. Consequently,
internal resources tend to be stretched to develop, assimilate
and analyse the projects and, while outsourcing is fine, it
limits internal skills and knowledge.
For the majority of pipeline projects the theoretical
aspects of lifecycle modelling and TCO will concern civil/
mechanical/instrumentation/electrical/IT SCADA (or
alternatives) and communications. This combination is an
eclectic soup of engineering skills and each project has many
challenges. So what is the route for success? Simple, there is
not one!
Through the entire project span, there are plenty of
processes to help assist in project evaluation and cost
assessment. The project can be topped off with lifecycle or
TCO evaluation for the various sections.
Cost reduction process
Figure 7 provides an indication of the level of cost reduction
that can be achieved at various stages of the project. It shows
that as a project moves from strategic planning, the main
decisions that affect the cost of the project have been already
been made.
The best opportunity to achieve significant cost reductions
in lifecycle costs occur during the early concept development
and design phase of any project. At this time, significant
changes can be made for the least cost. At later stages of the
project, many costs have become ‘locked in’ and are not easily
changed. To achieve the maximum benefit available during this
stage of the project it is important to explore the following:
)) A range of alternative solutions.
)) The cost drivers for each alternative.
)) The time period for which the asset will be required.
)) The level and frequency of usage.
)) The maintenance and/or operating arrangements and
costs.
)) Quantification of future cash flows.
)) Quantification of risk.
The concept of the lifecycle of an asset provides a
framework to document and compare alternatives.
Selecting potential project alternatives for
comparison
The intervention (or treatment) alternatives available to be
considered include:
)) Do-nothing – the do-nothing option is literally not
investing any money on any form of maintenance or
renewal, including that recommended by the design
engineer or OEM vendor. This alternative is generally
intended to set a conceptual baseline for asking the
question: “What value does what we do now or what
we plan to do add to extending the life/functionality/
reliability of the asset over doing nothing at all?” Another
way of looking at the core question posed here is: “why
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 should we continue to do what we do or are anticipating
doing?” There are rather rare occasions when do-nothing
is a valid applied approach, such as when an asset is
due to be replaced or shut down in short order and
additional maintenance/capital investment is irrelevant to
keeping it running for the short period before it is to be
decommissioned.
)) Status quo – the status quo option is defined as
maintaining the current operations and maintenance
behaviour – typically that defined by the manufacturer or
the design engineer. It is the realistic baseline case against
which other alternatives are compared.
)) Change levels of service – most lifecycle costing assumes
a constant level of service across options being compared.
When such is not the case (which is not infrequent in
reality), comparisons across alternatives with different
levels of service (that is, different levels of benefit) must
introduce a projected benefits section for each alternative
in addition to the cost projections. This, of course, takes
the analysis into the realm of benefit cost analysis.
)) Dispose – disposal of the asset is retiring the asset at
the end of its useful life. Perhaps the function or level
of service originally desired from the asset is no longer
relevant.

)) Renewal (major repair, rehabilitation or replacement) – )) Pragmatic approach – easier said than done! And even
assessment of different rehabilitation or replacement after your assimilate all information/data you have as
strategies requires an understanding of the costs and these show, sometimes natural elements can override the
longevity of different asset intervention strategies. Each hardest of pre-lifecycle work.
strategy is costed for the expected life of that strategy,
converted to an equivalent present worth, adjusted for It is unlikely that all seven of the alternatives listed above
varying alternative life lengths, and compared to find the are feasible for each analysis and thus the practitioner is
least overall cost. encouraged to reduce the analysed set to only those that are
thought to be feasible.
)) Non-asset solutions – in certain circumstances the non-
asset solution (providing the same level of service without
A pipeline integrated project in reality
a major additional investment) can be a viable alternative
This article has focused on the various aides for assimilating
(for example, using pricing strategies to reduce the
projects through the feasibility to operational stage. The
consumption of water).
challenge has, and always will be, a fine balancing act to get
the most value out of your money. There are many ways
to do this. Hands on experience and information is sadly
often lost with age/retirement, and seeking a balanced,
knowledgeable view is very important and should be aligned
with available technology of tools. The industry benefits
immensely from industrial committees and bodies, such as
the Institute of Energy (formally Institute of Petroleum), just
for the very fact you can meet your contemporaries and can
share information/knowledge. From experience as a customer
and supplier, it would be useful to consider the following:
)) Equipment to be detailed and supplied, does it have
MTBF? If so, is the data from laboratory testing? Or field
installation?
Figure 7. Cost reduction graphical project representation.
)) Ask the bidders for ‘recommended alternatives solutions’
and reasons/rational why.
Table 1. Pipeline capacity upgrade details
)) Establish your bidders credentials. Have they got
8 in. skids 12 in. skids
experience with the servicing of completed project
Product name GASOIL MOGAS technology, with good utilisation of diagnostics
Density at 15˚C 820 - 850 kg/m3 720 - 740 kg/m3 tools and predictive maintenance?
Upstream pressure 6 - 90 bar 30 - 90 bar
)) If a project requires an integrated solution, ensure
Downstream required pressure 4 bar 4 bar
the system components have single sourced
Upstream design pressure Class 600 Class 900 programming and licences, i.e. make sure there is
Downstream design pressure Class 150 Class 150 no third party costs for upgrades/bug fixes, system
Design temperature min 5˚C, max 55˚C min. 5˚C, max. 55˚C changes, etc.
Flowrate 10 - 200 m /hr
3
100 - 500 m3/hr
Error of measurement ≤0.2% ≤0.2% Key specifications of projects
Main pipe connections Flange ANSI 8 in. Flange ANSI 12 in. All projects have the opportunity for assimilating data
Dimension (width x length x height) 8 x 20.5 x 4 8 x 20.5 x 4
and improvement, one key element alongside the front
end design is to try and develop the ‘best in class’
Weight 35 000 kg 35 000 kg
solution using TCO/LCC as a tool. Whilst not large in

72 World Pipelines / DECEMBER 2015

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 financial terms, both of the discussed projects reflect these
factors. The first project is for a well-established operational
pipeline that, due to business drives, needs a capacity upgrade.
This is an interesting project as an investment is in place –
utilising the existing pipeline and adding additional pumping
stations the ROI is far better than investing in new pipeline.
The scope was to provide new fiscal metering systems, again
here is a rather different project requirement that will have
significant business benefits in accurate measuring and fiscal
control for the business, along with pipeline monitoring
and elements of controls. Central systems used were the de
factum standard of SCADA, linking onto existing systems.
Pipeline capacity upgrade including skid
metering systems
General description
The concept evaluation study was to assimilate the best
design and capabilities of potential new pumping stations
along the existing 12 in. pipeline – running from SAE port to
strategic storage depots at refinery area. The 12 in., 741 km
export pipeline has underground sections that run south to
north sub-Sahara. In phase one development, the pipeline
was designed to transport 850 000 tpy of MOGAS and
Typical pipeline codes and standards
include:
) ASME B31.8 – Gas Transmission and Distribution Piping
Systems (US/International Standard).
) ASME B31.4 – Pipeline Transportation Systems for Liquid
Hydrocarbon Pipelines (US/International Standard).
) CSA Z662 – Oil and Gas Pipeline Systems (Canadian
Standards Association).
) NEN 3650 – Requirements for Pipeline Systems (Dutch
Standard).
) AS 2885.1 – Pipelines - Gas and Liquid Petroleum Part 1:
Design and Construction (Australian standard).
) SNiP 2.05.06-85* Trunk Pipelines (Russia, developed by
Vniist).
) VSN 51-3-85 Design of Steel Field Pipelines (Russia,
developed by Vniigaz).
) Bs En 1594 – Gas Supply Systems - Pipelines for
Maximum Operating Pressure Over 16 bar - Functional
Requirements.
) IGE-TD/1 Edition 4 – Recommendation on Transmission
and Distribution Practice - Steel Pipelines for High
Pressure Gas Transmission, May 2001.
) BSI PD 8010 – Code of Practice for Pipelines.
) ISO 13623/En 14161 – Petroleum and Natural Gas
Industries - Pipeline Transportation Systems.
74 World Pipelines / DECEMBER 2015
2.5 million tpy of MOGAS and GASOIL in phase two. Fibre
optic cable was installed in the same trench of the pipeline
for SCADA. The pipeline was constructed and commissioned
in 2005 with only one pumping station and now it is working
on the reverse direction to transport 1 million tpy. Recently,
customer demand for GASOIL drastically increased to about
1.3 million tpy, which is expected to rise further to circa
1.9 million tpy by 2017. Consequently, the scope was to
evaluate engineering concepts for final solution, then move
forward to re-engineer its aforementioned pipeline to meet
the increased demand by adding new pumping stations along
with new metering skids.
In the original design and construction there are four
sectionalised valve stations with intermediate pigging stations.
As these points hook-up facilities were installed for adding
pumping stations.
Metering and control system
The project was commissioned in 2011 and followed an
ITB tendering process with a very detailed specification
of requirements. The 1500 km, 28 in. pipeline has six main
pumping stations running south to north in central Africa.
The scope was to design, manufacture, supply, install and
commission the complete system.
Scope of work
Skids for measurement of the flow at the inlet
and outlet of the pipeline
The skids were designed, produced and delivered in a double
redundant design – two independent parallel metering lines.
They include filtration, pressure reduction and custody
transfer measurement part. The design is for fully functioning
redundant systems (i.e. back-up), allowing for continuity of
operations under any such failure conditions, and servicing
under operational conditions, hence reducing lifecycle costs.
Prover connections are included. The skid consists of a
metal frame onto which pipes, valves, filters, control valves,
pressure safety valves, pressure gauges, drainage system,
Figure 8. Aerial view of site location.
field instrumentation and auxiliary equipment is installed.
Some ball valves are equipped with electrical actuation for
automated flow control selection the mode of operation.
All the ball valves have the double block and bleed (DBB)
design to provide dual isolation and leakage detection. Flow
is measured by mass metres. The design of pressure control
valve is unique because of the high pressure conditions.
Control system for the existing six pumping
stations
The PCS and HMI parts of the proposed system are nearly
identical while the IPS part uses fail-redundant and SIL-
certified components.
Hardware and software equipment:
)) Cabinets.
)) Redundant and failsafe programmable logic controllers
(PLCs) to provide direct control of the technology.
)) Servers for running SCADA system.
)) PC workstations as HMI for SCADA system.
)) Printers and other auxiliary equipment.
The scope of works included turnkey delivery of control
systems for individual pumping stations alongside 12 in. export
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pipeline including their implementation into central
SCADA system.
Pipeline monitoring system
The pipeline is monitored by 32 stations equipped by
remote telemetry units (RTUs). Every station monitors
pressure, temperature and other characteristics of the
fluid and environment. Data is transmitted by fibre
optic, which is built alongside the pipeline. This ensures
reliable and fast data transmission to the central control
room. The complete system also includes a network
management system (to enable also other services on
the fibre optic line), a private telephone exchange, and a
time synchronisation system.
The data is collected in a central server running the
most advanced system, Clear SCADA. The system runs
on two servers in hot stand-by mode to enable high
operational reliability. SCADA clients are both local
and remote. User interface is in a form of dynamic
visualisation, highly advanced system for events logging
and alarming and user-customised reporting. All the
historical data is available, so authorised user can see
any historical data very fast, typically in a form of chart
of graph. Clear SCADA has advanced functionality for
user access rights, obviously protected by username and
password for each user.
76
REDUCING
THE IMPACT OF
CYBER ATTACKS
Tony Berning, OPSWAT, USA, highlights methods of improving
SCADA security to protect oil and gas from cybernetic attacks.
A
ccording to research presented in the 2015
Dell Security Annual Threat report, attacks
on supervisory control and data acquisition
(SCADA) systems rose significantly in 2014,
doubling since the previous year. This does not come as a
surprise to those in the oil and gas sector, who have been
watching the inevitable comingling of previously separate
disciplines, as operational technology (OT) systems like
SCADA come into closer contact with IT, introducing all
the risks associated with exposing systems that were not
originally designed to have outside connectivity to the
internet. The Dell report came on the heels of findings
from the US Industrial Controls Systems Cyber Emergency
Response Team (ICS-CERT) showing that energy was
the most targeted sector for attack among all critical
infrastructure providers.
As attacks become more sophisticated and digital
control systems increase in complexity, levels of
automation, and connection to outside networks, it is
increasingly difficult to prevent threats from impacting
upstream, midstream and downstream oil and gas
operations. Because OT systems for oil and gas were
developed with availability at their core, with integrity
and confidentiality less urgent priorities (AIC vs CIA
security triads), they are often more vulnerable to
intrusion.
Portable media is a major potential vector for cyber
attacks; it is often the most convenient way to transport
files to and from secure areas and remote operations. As
key attack vectors for malware, it is extremely important
that extra attention is placed on securing the portable
media devices that are in use. While imperative to the
77
 protection of energy and other critical infrastructure
providers, securing portable media devices is not easily
done, and there are many requirements that can impact
the portable media security policies for oil and gas
operators. In many cases, there is no single source for
an organisation’s portable media security policy, and
individual facilities within an organisation may require
unique security policies.
This article outlines how to create a secure data
workflow that balances the needs of organisations
attempting to secure their facilities in the face of ageing
OT systems and a rapidly evolving threat landscape. Secure
data workflows must protect intellectual property, limit
the risk of cyber attacks causing supply chain disruptions
or major health, safety and environmental (HSE) disasters,
as well as address the inclusion of portable media when
necessary with the least possible exposure to outside
threats.
Security balancing act
When making decisions about data security policies for oil
and gas facilities, the operational impact of implementing
a more stringent policy must be weighed against the
potential costs of a breach caused by a weaker policy.
The solution for each organisation will vary based on the
requirements necessary to meet their security and business
objectives.
Admittedly, increases in digital security rarely come
without a corresponding increase in operating costs.
These costs include purchasing a security solution,
implementation, and finally managing and maintaining
the solution. Initial costs often also include the physical
infrastructure necessary to deploy the solution, such as
servers, kiosks and networks, as well as the consulting
services that are often required to implement the solution
correctly.
Following the solution deployment there will
be ongoing costs, which include the monitoring and
management of the solution, keeping the solution
up-to-date, and educating employees. Employees must
be trained on the new security policy and associated
procedures, which often results in a temporary reduction
in productivity as they acclimate to the new security
processes and procedures.
That said, these expenditures must be weighed against
the costs of a potential security breach, which can be
enormous. Facilities may be forced to suspend operations
if the breach is serious enough; the monetary impact
of even a temporary shutdown is difficult to calculate
given the nature of the industry. There are also the
remediation costs, the forensics to assess the damage as
well as the removal of any malware that has found its
way into the secure network. Coupled with this is the
significant productivity loss, as employees’ usual workflow
is hampered during the investigation and cleanup effort.
Loss of productivity and/or intellectual property pales
in comparison to the possibility for damage to physical
78 World Pipelines / DECEMBER 2015
systems and catastrophes leading to major HSE losses
when OT is targeted by a cyber attack.
Defining acceptable media and content
Defining a portable media and content strategy is key to a
secure data workflow policy. As with all security programs,
development of a program and policy should consider the
business and technology requirements and limitations of
an organisation.
When developing a secure data workflow policy,
organisations should first define what types of portable
media are acceptable and how they can be used. In
secure facilities, the recommended policy is to restrict
the types of media and files to only those necessary
for employees to perform their jobs successfully. For
example, if there is no reason for USB drives in a facility,
these should be prohibited to eliminate the risk they
introduce. Another facility may decide to only allow
USBs and CD/DVDs, banning other types of portable
media such as external hard drives or unmanaged laptops.
For example, if an external storage device has multiple
partitions or is not a read-only device it could be
classified as a high security risk and therefore not adhere
to the secure data policy.
The same is true for limiting the files that are
permitted by an organisation’s security policy.
Administrators may choose to limit the file types that
are allowed: banning executable files, for instance, while
allowing documents. Administrators could also filter files
based on their properties, limiting files to a specific size
or blocking any encrypted files where a password has not
been provided.
Designing secure data workflows
The secure data workflow policy for oil and gas operators,
especially pertaining to physical media being brought
from an insecure environment into a secure network,
should attempt to reach the highest level of precaution
achievable. The best security policies have multiple layers
of protection, to guard against many types of threats, both
known and unknown. This defence-in-depth strategy will
minimise the risk of any one threat getting past all of the
security layers. A secure data workflow should leverage
threat protection methods including:
)) User authentication and source verification: prevent
unauthorised users or sources from bringing in data and
facilitate logging for future auditing.
)) File type analysis and filtering: prevent risky file types
from entering the facility, including files that have
spoofed extensions.
)) Multiple anti-malware engine scanning: use antivirus
multi-scanning to detect threats that are known by
any of the many commercial anti-malware engines,
and leverage many varying heuristic algorithms to
detect zero-day attacks. This is especially important
in instances where factory acceptance tests limit an
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)) Document sanitisation: further protect against
unknown threats by using sanitisation methods to
strip potential threats out of documents and
images.

A common implementation of the above

referenced data workflow is a kiosk stationed as
a check point at the entrance to secure facilities.
Anyone entering a secure area would be required
to use the kiosks to scan all portable media drives
before the devices are allowed entry. The kiosks
would confirm the user, the source, the file type,
look for any malicious partitions and malware, and
determine whether the device is secure or if it
requires further inspection. An administrator can then
also add enforcement of the specific media devices
that are allowed into the facility. For example,
allowed media devices could be restricted to known,
pre-screened portable media that are trusted to
be ‘clean’. Any files allowed through the secure
data policy above would need to be copied to the
trusted drives before entering the secure facility. This
workflow ensures that no portable media enters a
secure area without first passing through a full data
security analysis.
Common architectures for a kiosk-based secure
data workflow can include: standalone kiosks, kiosks
networked together, and kiosks connected to a
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Jokimäentie 1, 16320 Pennala, Finland
Advancing
reciprocating
compressors
Amin Almasi discusses
reciprocating compressor
technologies for pipeline
compression stations.

80
M
odern high speed reciprocating compressors for
pipeline services are manufactured in an
800 - 1600 rpm speed range; they also offer
superior operational flexibilities using variable
speed operation, usually in a wide speed range.
However, increasingly sophisticated designs and
techniques are required for these modern machines. For
example, some high-speed reciprocating compressors operate
less efficiently than traditional low-speed compressors due
to higher dynamic effects and higher flowrates, which lead
to higher associated flow related losses through cylinder
valves and pulsation control devices. Also, with higher power
reciprocating compressors operating over a relatively large
high speed range, cylinder valve operation could be more
complicated and pulsation amplitudes tend to be significantly
higher. All these lead to higher dynamic losses and high risk
vibrations on the cylinders, cylinder valves and surrounding
piping and facilities. Advanced techniques, such as modern
pulsation control, are needed to accommodate the increase in
compressor power and the range of running speeds as well as
variations in operations.
Reciprocating compressor mechanisms
Basically, a reciprocating compressor consists of three main
mechanical subsets: the cylinder assembly, the crankcase,
and the rotor crankshaft assembly. The counterweight mass
located on the rotor crankshaft is designed to balance the
eccentric masses of the slider crank mechanism, which
predominate in comparison to the residual distributed
unbalance masses due to manufacturing. However, excessive
vibration levels can usually be observed.
The rotor crankshaft assembly should usually be
considered as a flexible body for a proper dynamic simulation
of such a system. Different experiments carried out have
shown that multi-stage balancing procedure is more efficient
than a classical approach, based only on the dynamic
balancing of the rotor crankshaft assembly.
High speed compressors for pipeline services
There is a trend toward the use of high speed reciprocating
compressors in pipeline services. These compressors are
very sensitive to off-design operations. They are more
vulnerable against pulsation issues, valve problems, and
81
 other reciprocating compressor areas of concern. High
speed reciprocating compressors may have experienced
a diminished cylinder performance due to higher than
expected valve losses and pulsation levels.
These high pulsations consequently contribute to the
higher than anticipated vibration levels found on a number
of high speed reciprocating compressors. Internal gas
passage acoustics, cylinder-to-cylinder and cylinder-to-
piping interactions, and nonlinear flow losses, can have a
significant effect on high speed reciprocating compressors.
Variable speed reciprocating compressors
for pipeline services
A variable speed operation is one of the best options
for the capacity control of a reciprocating compressor
in pipeline applications. The capacity of a reciprocating
compressor varies more or less linearly with speed, which
offer an excellent stepless and highly efficient capacity
control opportunity.
Reciprocating compressors often have large load torque
variations with every cycle; some can be up to 50% or the
average torque. In electric driven machines, a reciprocating
compressor is slamming current in and out in order to keep
up with the transient torques. While using flywheels or
large rotor inertia to damp out the load dynamics could
be an option, alternative options should be investigated
to achieve optimum purchase and operation costs. If the
electric motor is being driven by a variable speed drive with
sophisticated drive algorithms – for example, controllers
that can track the load torque variations – then both the
efficiency and transient stability problems can be solved
together.
The other significant factor is the starting problem. The
transient load torque is also present at the start so the
electric motor has to be able to accelerate through the load
transients and be capable of starting when the compressor
is sitting at the highest load.
Pulsation, acoustic and vibration
Pressure pulsations are generated by the reciprocating
action of a piston in any compressor. Considering the
discharge side of a cylinder, the piston moves to compress
the gas. Compressed gas is released into the system in
discrete volumes when the cylinder valves are open, and
regions of rarefaction are formed when the valves are
closed. The same phenomenon occurs on the suction side
when the gas is being drawn into the cylinder. Pressure
waves always travel away from the source at the speed of
sound of the gas.
Because of the cyclic nature of the reciprocating
compressor, compression and rarefaction waves or
pulsations are sent into the downstream and upstream
system at regular intervals. Thus, pulsations are inherent
to all reciprocating compressor systems and cannot be
completely eliminated. Pulsations can produce vibrations.
One key factor to controlling vibration is the understanding
and manipulation of each system’s unique pulsation,
dynamic and acoustical characteristics.
82 World Pipelines / DECEMBER 2015
Cylinder valves
The major factor involved in determining the compression
efficiency of a reciprocating compressor is the valve
operation, and particularly the valve loss or pressure drop
through the inlet and discharge valves. These fluid losses are
a function of many factors such as valve design, gas velocity
passes the valve, gas density, gas composition, pressure,
temperature and many more. The gas velocity that passes
the valve is related to the valve area available in the selected
cylinder valve and the piston speed. In a reciprocating
compressor, the valve’s opening and closing are done in a
calculated (defined) time, so that the frictional turbulence
during opening and closing of the valve in various operating
speeds should be carefully evaluated.
The focuses of the cylinder valve studies are on valve
reliability and valve losses. Since valves can be replaced
and changed (relatively) easily, more suitable valves can be
purchased and used at any time during operation. As rough
indications, three following observations can be made for
cylinder valves:
)) Cylinder valve power loss is usually proportional to the
piston speed cubed. As such, slower speed compressors
with lower piston speeds have the lowest relative valve
loss power.
)) Cylinder valve power loss is usually proportional to the
area of the piston cubed divided by the area of the valve
opening squared. This relationship is greatly impacted by
the number of valve openings on each compressor. As
such, the closer the total valve area is to the piston area
(i.e. the ratio of the piston bore to valve area equals one),
the lower the relative valve losses. This effectively means
more and bigger compressor valves reduce valve loss
power.
)) Cylinder valve power loss is usually proportional to the
ratio of the effective valve area to the actual valve area
opening squared.
The average gas velocity and associated valve loss power
are related to the equivalent valve area. The greater ‘the
effective valve area’ (EVA), the lower the valve loss. The
effective valve area is approximately equal to the most
restrictive opening in the valve. However, the EVA is also
influenced by the flow path of the gas through the valve,
the shape of the valve element, the smoothness of the valve
surfaces, and liquid friction (‘stiction’).
Stepless capacity control
A modern development in the reciprocating compressor
industry is the stepless capacity control system. It is an
advanced and expensive system, which provides superior
options for the right pipeline applications. In the right service
and compressor size, such a stepless capacity control system
can offer a considerable operating cost reduction. This section
focuses on a stepless capacity regulation system for pipeline
reciprocating compressors, usually in the capacity range
between 15% and 100%. This system is based on the so-called
‘reverse flow regulation principle’.
 The principle works by reversing part of the total gas
that has been taken into the cylinder, conveying it back
to the suction chamber by holding the suction valve
open for a controlled and variable proportion of the
compression stroke. Therefore, the discharge capacity
and power reduction are virtually proportional. Such a
stepless capacity control system uses a very sophisticated
hydraulic system to unload the suction valve for a
controlled proportion of the compression stroke. There is
a relationship between the variation of the capacity and
the opening time of the suction valve in a compression
stroke. Thus, this operation needs complicated and
high performance control and hydraulic systems. A new
capacity regulation system usually consists of a hydraulic
unit, a distributor, an unloader system, and a complex
control system. Such a stepless capacity control system
is recommended for a relatively large reciprocating
compressor (say above 1.5 MW) that should operate in
extended periods of part-load operation.
On the other hand, a stepless capacity control
system is a complex and expansive system, which
requires special operation and maintenance. The
commissioning, repair, maintenance and overhaul of
such a system is costly and can only be done by direct
involvement of stepless capacity control sub-vendor
specialist(s), of which are associated with significant
costs and complexity. A stepless capacity control system
is only recommended for large pipeline compressors
with operation profiles that required such a wide range
and flexible capacity control. It is not recommended
for small and medium size reciprocating compressors
in ordinary pipeline services, which most of the time
will work at full-load or defined simple part-load
steps. A stepless capacity control system is a modern,
complicated and expensive capacity control device that
should only be used in the right applications.
Frame lubrication
Frame (crankcase) lubrication systems typically use an
oil system that is entirely separate from the compressor
cylinder and rod-packing lubrication system. The oil
viscosity used in the reciprocating compressor frame is
typically an ISO VG 100 or ISO VG 150. The latter thought
is more common. Some rust and oxidation preventive
additives and an anti-wear additive could also be
employed.
Small reciprocating compressors – which are
sometimes used in large numbers in some pipeline
applications – may use the same lubrication oil as their
drivers, if driven by an engine. For instance, natural gas
engine oil is typically used in small gas engine driven
reciprocating compressors because it is readily available.
Cylinder and packing lubrication
In some cases, different oil to the one used for the frame
lubrication is required. In other words, sometimes the gas
composition and cylinder operating conditions require
an independent cylinder lubrication oil supply; a separate
(independent) force-feed lubrication oil system for cylinder and
packing lubrication.
The cylinder lubrication oil injection pressures are set at
the mean pressures of the inlet, and discharge pressures of
each cylinder. Synthetic lubrication oils with more consistent,
controlled chemical structures than petroleum lubrication oil,
are usually used as oil lubrication for cylinders and packing.
This improves predictability of viscosity and thermal stability.
Synthetic lubrication oils can be designed with better oxidation
resistance, better lubricity, better film strength, natural
detergency, lower volatility, and results in decreased operating
temperatures. These attributes can help to decrease cylinder
feed rate requirements. Justification for the use of synthetic
lubrication oils for cylinder/packing applications is based on
energy savings, reduced lubricant usage, increased component
life, decreased equipment downtime, and reduced maintenance.
Since the quantity of oil lubrication used in cylinder/packing
is very low, it is easily justified to use them for such critical
applications.
Too much lubrication oil is as bad as too little. Over-
lubrication can result in excessive oil carryover into the gas
stream, and increased quantities of deposits in the valves and gas
passages. Valve component breakage and packing failures have
been reported as symptoms of over lubrication. As the result, the
packaging malfunction could occur which may force the packing
rings to lift off of the rod enough to form a leak path. Increased
gas leakage then results in packing and rod overheating – a rod
and packing case can turn blue even though the lubrication
appears sufficient.
Even when the proper rate and type of lubrication oil are in
use, dirt and foreign matter in the gas will prevent the lubrication
oil from performing properly. Suction separator and inlet gas debris
strainers with a maximum 50μ opening are recommended. Proper
maintenance of the inlet screens is required.
Suction separators
Reciprocating compressors are more easily damaged by liquid
droplet carryover or solid particles than other compressors,
as they can cause serious damage. Carryover liquid droplets
may accumulate in cylinders and cause valve or piston damage.
Suction separators or suction knockout drums are used to
remove liquid droplet, solids and dirt carryover in gases and to
thus protect the reciprocating compressor. Most compressor
suction separators are arranged vertically.
As an indication, basic principles used to separate liquid
droplets from a gas stream are:
)) Using the momentum difference between gas and liquid
droplets (or solid particles).
)) Using the density difference between gas and liquid droplets.
)) Coalescing small droplets into large ones for easier removal.
Inlet deflector (or diverter) is used at the inlet nozzle to force
incoming feed to change direction. Large liquid droplets will not
change direction as easily as a gas, and will be displaced here.
This device uses the momentum difference between gas and
liquid droplets. The arrangement is effective to treat a two-phase
feed containing both gas and liquid.
DECEMBER 2015 / World Pipelines 83
FOULING
COMPRESSORS
To stop gas turbine
compressor blades from
fouling, an effective filter
is necessary. Stephen
Hiner, CLARCOR Industrial
Air, UK, explains how to
optimise gas turbine
availability and reliability
with proper air filtration.
E
ffective filtration solutions reduce fouling of gas turbine compressor
blades – this is a proven fact. Two fundamental ways to prevent fouling
which can be detrimental to a turbine’s performance include: installing
(H)EPA (EN1822:2009) filters that virtually eliminate fine particles from
entering the turbine inlet, or installing hydrophobic and advanced coated filters
to stop sticky particles from reaching the turbine compressor blades - which in
turn, also deters fine particulate from sticking.
Compressor fouling is mainly caused by particulates that are smaller than two
microns, which attach themselves to the blades. These do not cause permanent
damage, but do affect the aerodynamics and performance of the turbine. When
these contaminants build up, the operator eventually needs to take the turbine
offline to wash it and restore its performance. In oil and gas applications, taking
the turbine offline can have a huge cost impact on the operation.
Significantly increasing the time between offline washes or even eliminating
the need for them, therefore, has a great deal of commercial advantage. Where
the process has particularly high value, an LNG train for example, the cost of an
improved filtration system that reduces offline wash cycles is almost immediately
returned.

Types of filters
(H)EPA filters offer an obvious solution. In an ideal world all gas turbine inlet
systems would be fitted with filter houses designed to be large enough to
accommodate traditional (H)EPA filters that stop virtually all particulate
contaminants from entering and fouling the machine. In reality, however, most
existing and even new gas turbine filter houses are too small for (H)EPA filters to
operate at their optimum flowrates and as such, their use can create operational
issues.
When installing a (H)EPA filter, a number of other factors need to be
considered. The filter construction needs to be robust enough to withstand the
harsher conditions experienced in oil and gas installations compared with, for
example, HVAC applications. With most (H)EPA filter media being very delicate,
this can be a challenge to achieve. The impact of other environmental factors
also needs to be assessed. If there is moisture present in the air flow into the
turbine, fine (H)EPA filters can be particularly sensitive to this and may quickly
become temporarily blocked. This can create a sharp increase in differential
pressure that results in unexpected outages and, in extreme cases as the turbine
struggles to get the air flow it needs, can even cause damage to the filter house
itself. Corrosive elements that can cause permanent corrosive damage to turbine
internal parts, such as salt and other waterborne contaminants will not by default
be stopped by this type of filter unless it has been specifically designed to do so.
In contrast, the use of hydrophobic and advanced fibre coatings when applied
to filters with more traditional F8/F9 (EN779:2012) filter efficiency ratings, virtually
eliminate sticky contaminants and have been proven to significantly reduce – and
even eliminate – compressor fouling. With the use of this technology, turbines
have been shown to maintain their performance between water wash cycles,
giving operators the opportunity to increase system availability and process and
production output, without any of the possible operational side effects that
may be experienced with the use of (H)EPA filters. Filters with hydrophobic and
advanced fibre coatings further stop liquid phase corrosives that can permanently
damage the gas turbine.

Altair PRO
Robust modern gas turbine filtration solutions appropriate to oil and gas
applications are currently available, which have been designed to handle mixtures
of fine dust with moisture and other liquid contaminants. They are available in
high efficiency ratings including (H)EPA10 and above, to handle fine particulate,
while hydrophobic and advanced coatings give them properties to remove
sticky contaminants and also protect against the effects of moisture and liquid

85
 corrosives within the system. Solutions such as CLARCOR
Industrial Air’s altair® PRO filter have been specifically designed
and optimised for these types of applications and can be fitted
into a wide range of new, retrofit or existing installations, with
efficiencies ranging from F8 to (H)EPA12 and covering all common,
vCell static and cartridge pulse filters.
Particularly in offshore installations, turbine inlets tend
to be smaller with higher air flows that require a filtration
solution to match the flow of the system while remaining
compact for optimum use of valuable platform footprint. The
ideal filter solution needs to provide high efficiency coupled
with hydrophobic properties, as well as long service life and
be compact to fit within existing filter houses or where there
is restricted space for installation. Modern high performing
filters with vastly increased small particle efficiencies and
hydrophobic properties can now be directly retrofitted into
existing gas turbine fleets that utilise traditional high velocity
systems allowing operators to achieve the same pressure loss
performance while still maintaining a high velocity system.
Figure 1. Real world gas turbine running data shows reduced compressor fouling
when using coated filter media vs traditional media over time.
Figure 2. With the use of traditional filters (left), evidence of significant fouling
and signs of corrosion are an indication of imminent decreased compressor
performance. By contrast, filters with proper hydrophobic and advanced coating
properties helped maintain a clean compressor (right) that keeps the gas turbine
operating at a high level.
86 World Pipelines / DECEMBER 2015
Conditions in oil and gas installations can be exceptionally
challenging. High volumes of sand in desert areas, salt and
moisture in offshore and coastal regions, and – in some parts of
the world – extreme low temperatures with snow and ice, may
need to be factored into the filter selection and filter house
design. The filter media and construction of the filter itself needs
to be robust under these conditions and strategies employed to
specifically address the different environmental elements at an
individual site.
Taking geographical areas that are subjected to extreme
cold, snow and ice as an example; pulse filter systems offer the
operator the ability to remove the snow and ice. The filters
themselves, however, should be specifically designed and tested
for use in low temperatures to ensure correct operation is still
possible and damage does not occur through embrittlement of
filter media for example. Filter manufacturers can help with this
and all other types of harsh condition planning, to ensure an
operator gets the most from their filtration solution so that their
gas turbine remains protected with its availability optimised.
Each gas turbine installation will have its
own specific requirements and challenges, often
with combined environmental factors that
need to be managed such as moisture, dust and
salt. The resulting solution has to balance the
prevailing and changing conditions experienced
along with space available, accessibility for
maintenance, turbine availability requirements
and budget to obtain the best return on
investment.
Summary
Filtration solutions should be selected and
designed to handle local environmental
conditions to afford the best protection to
the gas turbine. Efficiency rating is one factor,
but there are many other elements to consider
including sensitivity to moisture, liquid corrosive
preventative properties, robustness of design
and ability to handle multiple environmental
challenges.
Extensive field trials using a range of robust
F8 to (H)EPA12 efficiency rated filters with
hydrophobic and advanced fibre coatings,
such as the altair PRO vCells and cartridge
filters from CLARCOR Industrial Air, have been
proven to produce significant reductions in
gas turbine degradation between compressor
washes, leading to greater availability, maintained
power output and increased time between
offline washes. This demonstrated, repeated
performance offers many operational benefits
and gives operators the potential to significantly
increase system availability and operating profit.
The cost of an optimised gas turbine inlet
filtration solution should be assessed against all
lifetime operational and maintenance costs. The
modern filtration technology available today,
designed for the specific challenges faced by
many oil and gas installations most often gives
excellent return on investment.
Product News Vermeer D40x55 S3 Drill.

HDD
& crossings
Vermeer, USA needed for training. This includes a digital display, improved
onboard diagnostics and common joystick controls. The system
The Vermeer D40x55 S3 Navigator® horizontal directional drill design uses a power distribution module that reduces the amount
(HDD) adds more punch and drilling force over its predecessor of wiring and fuses for greater reliability. A DigiTrak® AuroraTM
– the D36x50 Series II Navigator HDD – to offer contractors interactive, full colour touchscreen display delivers real time,
premium performance, class-leading cycle times and flexible rod easy to view location information, bore plans; and more to help
options. increase operator productivity.
“Contractors considered the D36x50 Series II as one of the An onboard self-diagnostic system empowers contractors to
most versatile drills in the industry, and the D40x55 S3 is built on make machine adjustments when required and helps to maximise
this versatile platform,” said Jon Kuyers, Senior Global Product productivity. The InSiteTM Fleet remote monitoring system comes
Manager, Underground, for Vermeer. “This machine packs more standard on the D40x55 S3 and is available now.
torque and pullback force into the same footprint, offering
contractors a machine that can efficiently complete a wide range
of work ranging from 2 - 16 in. (5 - 40.6 cm) in diameter.”
Speed, simplicity and sound are the trademarks of the
Vermeer S3 generation of directional drills. With 40 000 lb
(177.9 kN) of thrust/pullback and 5500 ft-lb (7458 Nm) of
rotational torque, the D40x55 S3 offers a more than 10% increase
in thrust and rotation over its predecessor, the D36x50 Series II –
helping to maximise productivity.
A 104 dBA guaranteed sound power level and an operator
ear rating of 82.9 dBA make this drill significantly quieter than its
predecessor – which makes for a quieter working environment
with less neighborhood disturbance and easier communication
among the crew. The D40x55 S3 features a carriage speed of
188 ft/min. (57.3 m/min.) – which is 7% faster than its predecessor
– helping contractors install more linear ft/d.
Versatility is at the heart of the D40x55 S3, allowing
contractors to select the ideal drill configuration for the specific
need. They can choose from three drill rod options: 10 ft (3 m) rod
in 2.38 in. (6 cm) or 2.63 in. (6.7 cm) dia. and 15 ft (4.6 m) rod with a
2.63 in. (6.7 cm) dia.
A 140 hp (104 kW), liquid-cooled, turbocharged diesel John
Deere 4045 4.5L Tier 4-compliant engine delivers robust power,
while a redesigned excavator-style climate controlled cab allows
operators better visibility, more legroom and greater comfort in
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A common control system benefits drill operators with the
ability to operate a variety of Vermeer drills and lessens the time A common control system benefits drill operators.

DECEMBER 2015 / World Pipelines 87

 Advertisers’ Tracto-Technik, Germany
Directory The Grundodrill 11 XP was launched in early September at the
NordBau trade fair in Germany, and is the latest addition to the TT
range of horizontal directional drilling rigs.
Advertiser Page With strong and robust engineering, the 11XP has been
10th Annual Midstream Summit 2016 46 designed for inner city use and for bores in the most confined
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ALLU Finland Oy 79 such as close proximity to buildings, along narrow paths, in
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American Augers 43
Boasting a high performance eco-friendly engine, with
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Fully automatic rod exchange, automatic drilling and paddle mode
DENSO GmbH 37 and it has a total weight of only 7.9 t, which makes it extremely
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Features include:
Dhatec, A ShawCor Company 45
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DMI International 53 Bentonite flow capacity.
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Holdtight Solutions, Inc. 71 operations.
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IPLOCA 46
in tough ground conditions).

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Schoenbeck GmbH & Co. KG 61 components.
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Socotherm 9

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T.D. Williamson 11

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Tulsa Rig Iron 73

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 To Pipeline
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