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CONTENTS
WORLD PIPELINES | VOLUME 23 | NUMBER 5 | MAY 2023
03. Editor's comment
05. Pipeline news
Get up-to-date with current international pipeline stories.
KEYNOTE ARTICLES: SAFETY AND RISK MANAGEMENT
8. Consistent access management
Amit Pawar, VP of Consulting & Services, Xage Security, USA, charts a top
pipeline operator’s journey to cyber harden and meet updated TSA security
directives.
he Colonial Pipeline attack was a wake-up call for
pipeline operators and cybersecurity leaders across
the world. The incident forced the company to halt
operations across its more than 5500 mile pipeline
responsible for transporting gasoline and other fuels from the
Gulf Coast to the New York Metro area. The six-day cost in
downtime caused fuel shortages and price increases.
Since then, increased cyber threats have spurred
action from the US government. New guidelines from
The White House, the Cybersecurity and Infrastructure
Security Agency (CISA), and the Department of Homeland
Security’s Transportation Security Administration (TSA) are
pushing critical industries towards the adoption of zero
trust cybersecurity approaches. Specifically, the TSA’s latest
version of its Pipeline Security directive doubles down on
strict access control and credential management for critical
infrastructure systems. This presents a range of challenges
for pipeline operators with a distributed mix of legacy and
modern equipment.
To address these security and compliance challenges, one
of the top pipeline operators in North America turned to
Xage, a cybersecurity company helping critical infrastructure
organisations adopt zero trust.
The major pipeline operator has thousands of miles of
pipelines transporting natural gas, gasoline, crude oil, carbon
dioxide, and more.
In contrast to perimeter-based security models, the Xage
Fabric delivers zero trust security to cyber-physical systems
with a proactive, easy to implement approach that treats
8 9
13. Never trust. Always verify.
Trevor Dearing, Director of Critical Infrastructure Solutions, Illumio, UK, advises
how pipeline operators can stay ahead of mounting cyber threats.
Extreme
17. Connecting the dots
Jim Francis, Vice President – SMS Consulting, ENTRUST Solutions Group,
USA.
22. A pipeline journey across the Danube River
Camila Sanchez Prado, Horizontal Drilling International (HDI), France.
27. A game-changing solution
Mario Moreno P.Eng., Seal for Life Industries, Canada.
31. Easing fugitive emissions
Ariel Avitan, Co-founder and CCO, Percepto, USA.
PIMS SOFTWARE
35. Digitise then automate
Vicki Knott, CEO and Co-Founder, CruxOCM, USA.
CBP006075
Copyright© Palladian Publications Ltd 2023. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or
by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are
those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in the articles or
the advertisements. Printed in the UK.
31 42 57
FIELD JOINT COATINGS
37. Exploring specialised robotic equipment
Kristopher Kemper, Technical Services Consultant, Association for Materials
Protection and Performance (AMPP), USA.
42. Lasting connections
Paul McShane, Managing Director, CRC Evans, UK.
I
n the world of field joint coating, CRC Evans’ team onshore and offshore pipelines, CRC Evans is now leading
has an enormously successful track record and has the way in developing new procedures and practices and
earned a reputation for undertaking complex projects. innovative technologies that will further optimise delivery.
The company’s full turnkey service capability helps to
ensure the optimised delivery times that customers trust. Enhancing efficiency through automation
The engagement begins early at the materials selection As a market-leader in the offshore application of field joint
stage and continues throughout the project planning coating systems, CRC Evans’ track record spans vertical
and delivery stages, with the support of state-of-the- (J-Lay) and horizontal (S-lay/multi-jointing) techniques,
art equipment, specialist personnel and purpose-built where increasing expectations for quality, reliability, and
coating facilities. Already a leader in the application of shorter installation times requires the constant evolution
anti-corrosion and insulation materials to field joints, for of technologies and methodologies. The growing emphasis
Amit Pawar, VP of
Consulting & Services,
Xage Security, USA,
charts a top pipeline
operator’s journey to
cyber harden and meet
updated TSA security
directives.
the identity of each machine, application, user, and data
stream as its own independent ‘perimeter’. This allows for
granular access policy enforcement and prevents breaches As field joint coating workscopes
before they happen. Zero trust can be delivered as an overlay
on top of the existing systems and network architectures,
become more technically challenging,
making it possible to implement seamlessly in complex OT with larger diameter pipe and deeper
environments. water, companies must adapt, says
Despite the perceived challenges of adopting a zero
trust approach in OT, this pipeline operator was able to
Paul McShane, Managing Director, CRC
quickly reach compliance with access control, credential Evans, UK.
management, and multi-factor authentication (MFA)
requirements. They were able to do so without replacing
or remodelling their existing technology ecosystem, which
is critical for operators with a mix of legacy and modern
infrastructure. With the Xage Fabric, the operator’s strategy
accelerated the pipeline’s zero trust rollout across 700+
sites and 5000+ OT assets. The operator also increased
productivity for its 500+ users with a simplified experience
and single sign-on for all OT assets. The following is an
outline of the steps this operator took to become one of
the first companies to receive TSA-approval and adopt a
zero trust cybersecurity model – all without disrupting the
services that communities rely on every day.
PAGE
Assess and evaluate
As a first crucial step, it was important to assess and
evaluate the operator’s current systems and networks for
PAGE
vulnerabilities and gaps against any federal security guidelines.
8
The operator had a plethora of varying systems, protocols,
Figure 1. Spoolbase in Bintan, Indonesia.
42 43
42
HOT TAPPING AND LINE STOPPING
47. Staying free-flowing
Darran Pledger, STATS Group, UK.
PIPELINE STEELS
53. An economically superior material
Girish Babu Nounchi and Jayaraj Padayachiyar Govindan, Wood Plc, and Shankar
Mohan, Worley.
PIPELINE MACHINERY FOCUS
57. On the edge of innovation
Leonardo Gravina, General Manager, SICIM, Italy.
YOUNG PIPELINERS INTERVIEW
60. Recognising young achievement
Recipients of the 2023 John Tiratsoo Award for Young Achievement,
Cassandra K. Moody and Sarah Newton.
ON THIS MONTH'S COVER
Reader enquiries [www.worldpipelines.com]
STATS SureTap® ST1530-90 hot tap machine providing access for STATS BISEP®
ISSN 1472-7390
double block and bleed line plugging tool. The 30 in. gas pipeline in Northern
Alberta, Canada was operating at 69 bar. STATS hot tapping and plugging
technology is suitable for onshore, topsides or subsea operations and fully
compatible with industry-standard tapping equipment; including fittings,
valves and completion plugs.
www.statsgroup.com
Member of ABC Audit Bureau of Circulations
EDITOR’S COMMENT warm welcome to the May edition of
CONTACT INFORMATION World Pipelines, which includes a
MANAGING EDITOR special section on pipelines in
James Little extreme environments. Since 2015, we
james.little@palladianpublications.com
have published an annual focus on ‘extreme’
EDITORIAL ASSISTANT pipelines, and even hosted online conferences on
Sara Simper the topic, such is the breadth of interest in
sara.simper@palladianpublications.com
pipeline activity in challenging places. Pipeline
SALES DIRECTOR design, construction and operation for extreme
Rod Hardy environments is so interesting because it
rod.hardy@palladianpublications.com
showcases the industry at its best and most
SALES MANAGER cutting edge; difficult conditions push the sector
Chris Lethbridge SENIOR EDITOR Elizabeth Corner
chris.lethbridge@palladianpublications.com to adapt and innovate. In covering extreme topics,
elizabeth.corner@palladianpublications.com
we’ve seen that the necessity of working in extreme
SALES EXECUTIVE or risk-filled environments affects the pipeline industry in different ways.
Daniel Farr
daniel.farr@palladianpublications.com Safety is the primary concern, and all endeavours should work towards addressing risk
and reducing incidents of harm. We have featured articles on working in dangerous weather
PRODUCTION MANAGER
Calli Fabian conditions, handling hazardous chemicals, constructing pipelines on unsafe terrain or at great
calli.fabian@palladianpublications.com depths, navigating the possibility of physical risk, facing local unrest, and more. In any of these
environments, or any worksite that is out of the ordinary, appropriate modifications to safety
EVENTS MANAGER
Louise Cameron protocols and training are essential.
louise.cameron@palladianpublications.com From a financial perspective, working in challenging places can be rewarding for pipeline
DIGITAL EVENTS COORDINATOR personnel: risky jobs command higher wages (although, it must be stated, not in all cases) with
Stirling Viljoen compensation generally rising to offset the potential danger or discomfort experienced.
stirling.viljoen@palladianpublications.com A pipeline operator needs up-to-date risk analysis intelligence in order to ascertain the
DIGITAL CONTENT ASSISTANT current risk to personnel, since this advice can often change in a heartbeat. AKE International’s
Merili Jurivete Global Intake platform contains detailed country profiles updated in real-time, and offers
merili.jurivete@palladianpublications.com emailed intelligence containing risk advisories, daily updates and analytical briefings. Look out for
DIGITAL ADMINISTRATOR AKE’s upcoming article (July 2023 issue), which will offer expert analysis on the current spate of
Leah Jones pipeline incidents in Colombia.
leah.jones@palladianpublications.com Work in extreme environments can also have an impact on the health, safety and livelihood
ADMINISTRATION MANAGER of the communities situated near pipeline routes. These communities need spokespeople and
Laura White I’m always cheering for those who seek to make the relationship between pipeline company
laura.white@palladianpublications.com
and community more harmonious. One such trailblazer is Kaella-Marie Earle, who I have admired
Palladian Publications Ltd, ever since I interviewed her a few years ago, when she won the John Tiratsoo Award for Young
15 South Street, Farnham, Surrey, Achievement, awarded by Young Pipeliners International. In her current role as Engineer-in-
GU9 7QU, UK
Tel: +44 (0) 1252 718 999 Training and Construction Project Manager at Enbridge Gas, she works on the management and
Website: www.worldpipelines.com execution of major pipeline, integrity and storage enhancement projects, and serves as the Vice-
Email: enquiries@worldpipelines.com Chair of the Indigenous Advisory Committee. Her commitment to truth and reconciliation with
Annual subscription £60 UK including postage/£75 overseas Indigenous peoples, and her drive for reconciliation and inclusion going forwards, is impressive.
(postage airmail). Special two year discounted rate: £96 UK
including postage/£120 overseas (postage airmail). Claims
Environmentally, extreme environments are often places where pipeline companies are
for non receipt of issues must be made within three months of most at risk of ‘losing their social license to operate’. The secure backing of insurers and financial
publication of the issue or they will not be honoured without
charge. institutions, along with strong evidence-based mandates for the work in the first place, help
Applicable only to USA & Canada: make these pipeline projects a success for everyone.
World Pipelines (ISSN No: 1472-7390, USPS No: 020-988)
is published monthly by Palladian Publications Ltd, GBR and Finally, politics can never be taken out of the equation: the political decisions of the few
distributed in the USA by Asendia USA, 17B S Middlesex
Ave, Monroe NJ 08831. Periodicals postage paid New
affect the many. The issues of energy independence, national security and climate change often
Brunswick, NJ and additional mailing offices. POSTMASTER: intersect with policy about where to extract natural resources, and how those resources should
send address changes to World Pipelines, 701C Ashland Ave,
Folcroft PA 19032 get to market. The viability of working in an extreme environment can often be determined by
the pressure of political imperatives, rather than simple market forces.
Whatever forces shape the outlook for pipeline projects in these testing environments, let’s
make sure that we forever prioritise safety and wellbeing for optimum project success. Dig in to
the Extreme section at p.17, and let the capable contributors to this special section assume the
risk on your behalf.
The welding and
coating experts
you can trust
Ensure the efficient, on-time delivery of your onshore
and offshore projects with CRC Evans’ market-leading
welding and coating services, technologies and integrated
solutions, and extensive fleet of pipeline equipment

CONNEC T WITH CRC EVANS

crcevans.com enquiries@crce.com @crcevansglobal

americas Europe Middle East Africa Asia Pacific

WORLD NEWS
TC Energy: Keystone oil spill was caused by a fatigue crack
Canada’s TC Energy said a 14 000 bbls oil spill from its Keystone
pipeline in rural Kansas in December was primarily due to a
progressive fatigue crack, which originated during the
construction of the pipeline (Reuters reports).
The Calgary-based company released the findings after
receiving an independent third-party root cause failure analysis
(RCFA), as required by regulators.
Keystone’s spill into a Kansas creek was the biggest US oil
spill in nine years and prompted a 21 day shutdown of a portion
of the 622 000 bpd pipeline, which ships crude from Alberta to
US refineries.
TC said it has recovered 98% of the spilled product from the
pipeline and cleaned up 90% of the Mill Creek shoreline.
“We are unwavering in our commitment to fully remediate
the site and are taking action on the recommendations from the
RCFA,” said Richard Prior, President of Liquids Pipelines at TC
Energy in a statement.
The company said it is now investigating other sites along
‘State actor’ is “absolute main scenario” in Nord Stream blasts
A state actor’s involvement in the damage of the Nord Stream
pipelines last year is the “absolute main scenario”, though
confirming identity will prove difficult, the Swedish prosecutor
investigating the attack said on 6 April.
In September 2022, several unexplained underwater
explosions ruptured the Nord Stream 1 and newly-built Nord
Stream 2 pipelines that link Russia and Germany across the
Baltic Sea. The blasts occurred in the economic zones of
Sweden and Denmark, and both countries say the explosions
were deliberate, but have yet to determine who was
responsible.
The blast in the Swedish zone occurred at a depth of 80 m,
which the Swedish prosecutor said made it complicated to
investigate.
“We believe it will be rather difficult to determine who did
this,” prosecutor Mats Ljungqvist told Reuters in a phone
interview. “The people who did this have probably been aware
that they would leave clues behind and probably took care so
that the evidence would not point in one direction, but in
several directions,” he added. “That makes it difficult to clearly
Cano Limon-Covenas pipeline attacked again
The suspension of pumping operations at Colombia’s Cano
Limon-Covenas oil pipeline will be prolonged after a new
bombing attack damaged its infrastructure in the country’s
Arauca province, oil transportation company Cenit said.
The attack, the ninth this year, took place on Thursday
20 April in the Saravena municipality, prompting the company to
activate its emergency contingency plan to control the
subsequent oil spill and mitigate pollution, said Cenit, a
subsidiary of Colombia’s majority state-owned oil company
Ecopetrol.
“The company calls on the nearby community to refrain
from approaching the site of the incident, until the evaluation,
repair and clean-up operation that is in place is completed,”
Cenit said in a statement. Colombia’s military is working to
Keystone with similar characteristics, performing extra
inspections on 300 miles (482 km) of the pipeline, and reviewing
design guidelines, construction and operations.
TC said the RCFA report found the fatigue crack came from
a girth weld connecting a manufactured elbow fitting to the
section of pipe constructed across Mill Creek. The girth weld
was completed at a fabrication factory and met applicable
standards.
During construction, the pipe segment came under ‘bending
stresses’ that initiated a crack in the girth weld and also led to a
deformation in the elbow fitting and a wrinkle in the adjacent
piping, TC said. The design of the weld transition made the pipe
in that location more susceptible to bending.
“This resulted in the initiation of a circumferential crack in
the weld, which led to failure through operations after over a
decade,” TC said.
The company said the RCFA findings are consistent with its
own investigation released in February.
point to one actor.”
The investigation continues.
Ljungqvist said investigators had been able to determine
what type of explosive had been used and that it ruled out “a
very large number of actors”, but declined to name the
explosive, citing the ongoing nature of the investigation.
While no conclusion has been drawn, there have been a
number of theories as to who blew up the pipelines and how.
Germany has confirmed its investigators raided a ship in January
that may have been used to transport the explosives used to
blow up the pipelines. German media reported the boat could
have been used by a small Ukrainian or pro-Ukrainian group.
Ljungqvist said it could not be completely ruled out that an
independent group, as opposed to a state actor, was behind
the attack, but that it was unlikely.
“There are certain companies that have certain special
missions that mean they could, in theory, carry this out,” he
said. “We don’t rule out anything, but that it is a state actor
who is directly or at least indirectly behind this is of course our
absolute main scenario, given all the circumstances.”
secure the area, Cenit added.
Pumping along the pipeline has been suspended since
14 April due to other attacks, a Cenit spokesperson said, adding
that the restarting of operations will depend on the military’s
ability to secure the area where the attacks took place while
repairs continue.
Cenit did not attribute the attack to any particular group,
but guerrillas of the National Liberation Army (ELN) and FARC
dissidents who reject a 2016 peace deal with the government
operate in the area, according to the military.
The Cano Limon-Covenas pipeline, which can transport up
to 210 000 bpd of oil and runs along Colombia’s northern border
with Venezuela, was attacked 13 times in 2022, leading to fires
and contamination of the surrounding area.
MAY 2023 / World Pipelines 5
 CONTRACT NEWS
EVENTS DIARY Fugro wins contract for extensive Transocean: harsh environment
8 - 11 May 2023 offshore surveys in UAE contract award
Pipeline Technology Conference (ptc) Fugro has been awarded a contract for site Transocean Ltd. has announced contract
Berlin, Germany characterisation services in support of one fixtures for two of its harsh environment
www.pipeline-conference.com of the largest long-term field development semisubmersibles.
programmes in the United Arab Emirates Transocean Endurance was awarded a
(UAE). multi-well plug and abandonment
9 - 11 May 2023 Commencing April 2023, Fugro will contract in Australia with an independent
Canada Gas & LNG Exhibition and
perform a series of offshore surveys operator. The estimated 240 day contract
Conference
including geophysical, geotechnical and ROV is expected to commence in January
Vancouver, Canada
inspections supported by advanced 2024 and contribute approximately
www.canadagaslng.com
engineering and geoconsulting studies to US$91 million in backlog, excluding fees
help inform the FEED. The project consists for mobilisation.
30 May - 1 June 2023 of approximately 600 km pipeline route In Norway, Wintershall DEA exercised
AIEN International Energy Summit assessment with 800 crossings, 49 jacket a one-well option on Transocean Norge.
Miami, USA surveys and island offshore surveys. The well is expected to commence in
www.aien.org/forms/meeting/Microsite/IES2023
Near real-time insights into the ground May 2023 ahead of the existing firm term
conditions will be available using Fugro’s for 60 days and contribute approximately
remote data management solutions, US$22 million in backlog.
13 -15 June 2023 delivered via Fugro’s digital platform.
Global Energy Show 2023
Calgary, Canada
www.globalenergyshow.com
Perma-Pipe announces contract ON OUR
8 - 10 August 2023
Rio Pipeline 2023
awards
Perma-Pipe International Holdings, Inc. has
WEBSITE
Rio de Janeiro, Brazil
announced it has been awarded two • Borusan Mannesmann
contracts with a combined value in excess of finalises acquisition of Berg
www.riopipeline.com.br
US$8 million. The first is to provide insulated
piping for a thermal distribution system on Pipe
5 - 8 September 2023 the campus of Fanshawe College in London,
Gastech 2023 Ontario, Canada. The contract is to supply • Iraq asks Turkey to restart
Singapore Perma-Pipe’s XTRU-THERM® thermally northern oil exports
www.gastechevent.com
insulated piping system.
In addition, Perma-Pipe International • Corinth Pipeworks awarded
Holdings, Inc. announced its subsidiary,
5 - 8 September 2023 Perma-Pipe Middle East LLC, has been contract for the N05-A
SPE Offshore Europe 2023 awarded contracts by China Petroleum & pipeline
Aberdeen, Scotland Chemical Corporation (Sinopec) for the
www.offshore-europe.co.uk provision of thermally insulated pipe and • DNV grows energy
field joints for a project in Uganda.
This project will feed the East African testing capability in the
21 - 22 September 2023 crude oil pipeline (EACOP) transporting oil to Netherlands
Subsea Pipeline Technology the coast in Tanzania. The project will utilise
Congress (SPT 2023) Perma-Pipe’s XTRU-THERM insulation system, • US warns companies over
London, UK a spray-applied polyurethane foam jacketed
www.sptcongress.com with a high-density polyethylene casing. The Russian oil price cap
projects will begin execution in Perma-Pipe’s
new facility in Abu Dhabi, UAE in 3Q23. • Growth expected in AUV
2 - 5 October 2023
ADIPEC 2023
Saleh Sagr, Senior Vice President for and ROV market
Perma-Pipe’s MENA region commented, “I am Follow us on LinkedIn to read more about the
Abu Dhabi, UAE
glad to announce that this important project articles
www.adipec.com
has been assigned to Perma-Pipe. We have linkedin.com/showcase/worldpipelines
recently announced the opening of the new
plant in Abu Dhabi and obtaining this award
is an excellent start.”

6 World Pipelines / MAY 2023

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 he Colonial Pipeline attack was a wake-up call for
pipeline operators and cybersecurity leaders across
the world. The incident forced the company to halt
operations across its more than 5500 mile pipeline
responsible for transporting gasoline and other fuels from the
Gulf Coast to the New York Metro area. The six day cost in
downtime caused fuel shortages and price increases.
Since then, increased cyber threats have spurred
action from the US government. New guidelines from
The White House, the Cybersecurity and Infrastructure
Security Agency (CISA), and the Department of Homeland
Security’s Transportation Security Administration (TSA) are
pushing critical industries towards the adoption of zero
trust cybersecurity approaches. Specifically, the TSA’s latest
version of its Pipeline Security directive doubles down on
strict access control and credential management for critical
infrastructure systems. This presents a range of challenges
for pipeline operators with a distributed mix of legacy and
modern equipment.
To address these security and compliance challenges, one
of the top pipeline operators in North America turned to
Xage, a cybersecurity company helping critical infrastructure
organisations adopt zero trust.
The major pipeline operator has thousands of miles of
pipelines transporting natural gas, gasoline, crude oil, carbon
dioxide, and more.
In contrast to perimeter-based security models, the Xage
Fabric delivers zero trust security to cyber-physical systems
with a proactive, easy to implement approach that treats
8
the identity of each machine, application, user, and data
stream as its own independent ‘perimeter’. This allows for
granular access policy enforcement and prevents breaches
before they happen. Zero trust can be delivered as an overlay
on top of the existing systems and network architectures,
making it possible to implement seamlessly in complex OT
environments.
Despite the perceived challenges of adopting a zero
trust approach in OT, this pipeline operator was able to
quickly reach compliance with access control, credential
management, and multi-factor authentication (MFA)
requirements. They were able to do so without replacing
or remodelling their existing technology ecosystem, which
is critical for operators with a mix of legacy and modern
infrastructure. With the Xage Fabric, the operator’s strategy
accelerated the pipeline’s zero trust rollout across 700+
sites and 5000+ OT assets. The operator also increased
productivity for its 500+ users with a simplified experience
and single sign-on for all OT assets. The following is an
outline of the steps this operator took to become one of
the first companies to receive TSA-approval and adopt a
zero trust cybersecurity model – all without disrupting the
services that communities rely on every day.
Assess and evaluate
As a first crucial step, it was important to assess and
evaluate the operator’s current systems and networks for
vulnerabilities and gaps against any federal security guidelines.
The operator had a plethora of varying systems, protocols,
 Amit Pawar, VP of
Consulting & Services,
Xage Security, USA,
charts a top pipeline
operator’s journey to
cyber harden and meet
updated TSA security
directives.

9
 and control interfaces. These systems were composed of
new devices with robust security controls along with older
legacy devices that had little to no security capabilities. Some
examples include: programmable logic controllers (PLCs),
remote terminal units (RTUs), human machine interfaces
(HMIs), meters, and sensors.
This created a major roadblock for their productivity
and displayed inadequate protection. Specifically, it resulted
in inconsistent access management across their 5000+ OT
systems. There was heavy reliance on shared static device
passwords and group accounts across these varying systems
and assets – posing a gaping vulnerability to breaches.
What’s more, the operator was unable to enforce granular
policies within their Purdue model architecture, a key
framework used to protect OT technologies from malware
and other attacks. The operator’s existing devices were zone-
based so they were unable to restrict access to individual
assets based on employees’ identities. In turn, malicious files
could be accidentally uploaded into the OT environment
by the operator’s 1000+ employees. At this stage, enabling
access to any new employees required firewall policy changes
that could take days to weeks to implement, harming
productivity. Providing access to OT devices via protocols
like virtual network computing (VNC) and remote desktop
protocol (RDP) through firewall rules, at the lowest levels of
their Purdue model implementation, increased security risks
unnecessarily.
Another task at hand was to update multi-factor
authentication (MFA) tactics to meet specific TSA
requirements. If an attacker retrieves a password, an MFA
request usually prevents them from getting any further.
However, the Uber hack by the Lap$sus group showed that
even MFA can be vulnerable under the right circumstances.
Deemed ‘MFA fatigue attacks’, this strategy targets security
professionals by sending multiple MFA requests to a
secondary device, usually in the middle of the night, in hopes
they inadvertently approve access. After passing the single
MFA layer, hackers typically launch malware and attempt to
make their way deeper into the company’s systems to find
valuable assets. In the case of an oil and gas pipeline, that
could give hackers access to systems that run these critical
assets to wreak havoc.
Develop a roadmap to mitigate gaps; and
begin implementation to meet TSA guidelines
Following the assessment, we outlined suggested
technologies and strategies based on gaps, then developed
a roadmap and implementation plan to meet compliance
requirements. In this case, the operator needed a solution
for a zero trust identity verification and access policy
enforcement for all their employees and OT assets that
could be implemented into their systems with ease. The final
implementation plan and roadmap were then sent to the TSA
for review, which was quickly approved by the agency.
To solve their access management problems, we
implemented a scalable and consistent access control
approach across multi-vendor OT systems and synchronised
with Active Directory for single sign-on. Another benefit
10 World Pipelines / MAY 2023
was eliminating static and shared passwords across systems.
To ensure continuous, active operation at all locations, we
enabled a distributed architecture with decentralised policy
enforcement. This provides access management even when
remote sites do not have connectivity to the central site.
Lastly, it was crucial to ensure no single point of security
failure via multi-node architecture, so security services
continue uninterrupted, even if an attacker succeeds in a
partial compromise.
To address concerns with current MFA strategies, Xage
provides a multi-layer MFA tool that puts up a series of
gates, so that if an attacker makes their way into the first
level, they won’t be able to get to the organisation’s more
critical technology. In the case of this pipeline operator,
implementation of multi-layer MFA helps them mitigate any
potential attacks from compromised file uploads via scanning
and blocking malicious files. We made sure that the operator
could verify and control all connections and interactions
between users, devices and apps, whether they come from
inside or outside the network perimeter.
We also recognise that cybersecurity tasks can be taxing
on personnel and staff, particularly when the operator had
disjointed systems at the start. So, we looked to increase
their productivity, costs, and cyber harding without the
expense, disruption and lengthy timescales of replacing their
existing systems. We helped their personnel productivity by
establishing a consistent approach to access management
with single sign-on for all OT assets. We also improved their
access visibility by beginning to log interactions between
users and devices, thus helping to establish reliable audit trails
for investigating security incidents. An added financial bonus:
we lowered application maintenance costs by integrating
their applications and processes with the Xage Fabric.
Support and ongoing assessment
programming
Overall, the operator successfully improved their security
posture with the Xage Fabric rollout while meeting TSA
security requirements. We are continuously covering ongoing
maintenance and improvements for the pipeline operator and
ensuring they’re receiving necessary operational support.
Looking to the future, this operator plans to scale
secure remote access to all their sites to enable technicians,
including authorised third-party technical experts, to work
remotely. With critical infrastructure in need of stronger
protection from threats, all operations across oil and gas will
benefit from independent expertise to accelerate their shift
to proactive cyber-defence strategies and meet security
requirements.
Federal regulations aside, undergoing the necessary shift
from a reactive to proactive zero trust security strategy
is a critical step towards a more secure future for energy
infrastructure. This pipeline operator proved that despite how
distributed and complex OT environments may be, meeting
TSA security requirements quickly and without disruption is
possible. We hope their success will inspire greater adoption
of zero trust security strategies and help curb the effects of a
growing threat landscape.
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 stay
s can
c t ure rator
ru pe
f r ast ine o
c a l In ipel
t i p
f Cri how
o
c t or vises ts.
ire ad ea
g , D U K, er thr
n ,
e ari mio cyb
D llu ng
re vor ns, I ounti
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l f
So ad o
e
ah
he energy sector finds itself
operating against a turbulent
backdrop of soaring electricity
demands, price spikes and an
unrelenting climate crisis. Such
pressures are forcing rapid
digitalisation in the sector
and combined with socio-
economic challenges,
have exposed the
industry to severe
cyberattacks.
Criminal groups
increasingly deploy
disruptive attacks
such as ransomware
against the sector,
risking serious
consequences like
blackouts and fuel
shortages. High-
profile incidents
such as the Colonial
Pipeline attack have
shown how damaging
such attacks can be.

Building up to a
cyber crisis
Today’s heightened level of
cyber risk has been years in
the making, with a confluence of
different factors creating a perfect
storm. Skyrocketing demand is one
primary issue. ExxonMobil estimates
that global energy demand
increased by 15% from 2021 to
2022, driven by developing nations

13
 and international growth in industrialisation. The spike in
demand and an unstable geopolitical climate has also seen
soaring prices, with wholesale gas increasing by more than
400% in 12 months.
The rise in demand has increased pressure to modernise
ageing architecture for generating and delivering energy, with
many operators turning to automation to increase efficiency.
These trends have been exacerbated further by the global
push for environmental energy production, such as the EU’s
proposed changes around hydrogen and the construction of
Europe’s first clean hydrogen, beginning in December 2022.
However, as digitalisation continues, the energy sector
is trapped in a difficult balancing act between operability
and security. With operations reliant on large physical assets
such as refineries and pipelines, building and transforming
infrastructure is a slow process. The sheer scale means that
even minor updates can be daunting with so many systems
involved.
How threat actors exploit complex and ageing
infrastructure
While there is an unavoidable need to update infrastructure,
further digitalisation will also increase cyber risk exposure. As
data processing and grids become more intrinsically interlinked,
the potential for a major IT-side failure impacting energy
delivery increases. Remotely located smart systems are more
difficult to secure with traditional network-based security.
This results in an increasingly complex combination of
traditional IT systems, operational technology (OT), and
connected Internet of Things (IoT) infrastructure. Effectively
monitoring and protecting this mixture of disparate systems
against cyber threats presents a steep challenge, as different
elements are rarely designed to work together.
The outcome is organisations struggling with expansive,
convoluted IT environments that present a large attack
surface for cyberattacks. The complexity means that ageing
infrastructure elements are often overlooked, presenting easy
attack paths for threat actors. In October 2022, for example,
Tata Power suffered a breach due to a discontinued web server
that was still integrated with other systems. The ransomware
gang known as Hive claimed responsibility for the attack
and followed up the initial ransomware infection by leaking
stolen confidential data when Tata apparently refused ransom
demands.
The notorious Colonial Pipeline ransomware incident was
also the work of the criminal gang DarkSide, apparently acting
independently despite allegations of state-backing. The same
group appears to be behind a more recent attack this year on
German oil and gas storage company, Oiltanking, and its sister
company Mabanaft.
Alongside opportunistic criminal gangs, we have seen an
increase in the weaponisation of energy in global, physical,
and cyber conflicts. As critical national infrastructure (CNI), the
energy sector has been targeted in geopolitical conflicts for
some time, with the infamous Stuxnet attack of 2010 being
one of the earliest high-profile examples. More recently, major
attacks on Ukraine’s power grid in 2015 and 2016 during the
earlier conflict with Russia resulted in widespread blackouts.
14 World Pipelines / MAY 2023
Why are pipeline providers being targeted?
Pipeline infrastructure is an attractive target for both
independent criminal gangs and state-backed threat groups
because it is particularly vulnerable to cyber tactics like
ransomware. These attacks are centred around causing as
much disruption to the target as possible by locking down
critical systems and encrypting essential data.
For criminal gangs, the aim is to force the victim into
meeting their ransom demand. These groups know that
pipeline operators will be under intense pressure to pay
up as every minute of downtime will rack up more costs.
The prospect of fuel shortages and other widespread
consequences gives the attacker even more leverage against
the industry. The encryption is also increasingly coupled
with data exfiltration, with attackers stealing large volumes
of data and threatening to leak it unless their payments
are met. This ‘double extortion’ technique has become
a mainstay for ensuring a profit, evident in the Colonial
Pipeline breach, the recent Tata Power incident, and many
others.
Meanwhile, nation-state-level actors will generally seek
to weaken opposing nations and send a message. Such
attacks are an appealing alternative to physical sabotage or
traditional military strikes, as cyber activity has a high level
of deniability. While these adversaries will seek to extort
payments from their victims, the disruption itself is often
the primary goal.
The impact of a serious attack
Whatever the perpetrator’s motivation, the result of a
successful attack on pipeline infrastructure can have serious
impacts that ripple across entire industries and economies.
The Colonial Pipeline system, for example, is responsible for
moving roughly 45% of all fuel consumed on the East Coast
of the US. While the ransomware locked down payment
systems rather than the pumping infrastructure itself, it still
meant that pumping operations ground to a halt. Despite
Colonial Pipeline opting to meet the US$5 million ransom
in the hopes of a swift resolution, the disruption lasted for
nearly a week.
The resulting fuel supply shortage caused widespread
issues across the country. Multiple airports reliant on
the pipeline implemented urgent schedule changes to
compensate. Panic buying set in across several states as
the shutdown dragged on, with filling stations from South
Carolina to Washington DC seeing most of their stations
entirely run out.
The same group’s recent attacks on German storage and
trading firms Oiltanking and Mabanaft saw an immediate
impact on inland supply, with terminals operating at limited
capacity. The attack again appears to have hit payment
systems and impacted a large swath of the fuel distribution
infrastructure.
Rubbing salt into the wound, many of these incidents
also saw large volumes of corporate data stolen and often
publicly leaked online. More than 100 GB of data was stolen
from Colonial Pipeline before the encryption was triggered,
although the Darkside group appeared to have refrained
 from leaking it when the ransom was met. Just over a week
after the Tata Power breach, the perpetrators began leaking
large volumes of data ranging from employees’ personal
information to engineering specs and financial records.
Such incidents are far from one-offs, and each successful
attack and payment encourages further attacks. The
GridEx VI exercise, jointly run by NERC and E-ISAC from
April 2022, shows that future cyberattacks could cause
widespread power outages.
Focusing on limiting cyber threat
disruption
The widespread threat posed by cyberattacks on pipeline
operators has not gone unnoticed. The Colonial Pipeline
attack served as a particular eye-opener on the risk to the
pipeline industry and the impact on supply. The incident
has prompted a sea change in the industry, including several
security directives from the TSA in quick succession with
heightened requirements for pipeline operators.
The new TSA directives require pipeline operators to
focus on maintaining services while under attack. To meet
requirements, operators will need to implement a planned
approach to protecting their pipeline networks. These
requirements include mapping the interdependencies
between the OT and IT systems, segmenting the IT and OT
systems and mitigating vulnerabilities. Operators should
look towards newer technologies, such as zero trust
segmentation, that can help meet multiple requirements
while also driving immediate resilience gains.
Segmentation is the process of dividing the network
environment into separate sections, making it more difficult
for intruders and automated malware alike to travel through
the network and reach critical data and systems. Zero trust
segmentation technology is a more advanced form, coupling
the segmentation approach with the zero trust principle of
‘never trust, always verify’. This means users cannot move
across segments without meeting verification demands such
as multifactor authentication (MFA).
The zero trust approach means the authentication
requirements will fit the asset’s criticality and the risk
involved, enabling legitimate users to pass through
smoothly while blocking unauthorised intruders. Zero trust
segmentation is particularly effective against disruptive and
fast-moving attacks like ransomware, as well as halting or
delaying high-level threat actors seeking to infiltrate deeper
into the network.
Steps for increasing cyber resilience
Globally, there is an increasing need to secure our energy
delivery systems and infrastructure. But with many pipeline
operations comprising sprawling expanses of IT, OT and IoT
systems, it can be challenging to know where to begin to
strengthen cyber resilience.
Operators can cut through much of the complexity
by following an established cybersecurity framework. This
will make it easier to identify priorities and divide the
seemingly impossible task into manageable stages. The
NIST Cybersecurity framework is one of the most widely
16 World Pipelines / MAY 2023
respected and relied-upon examples. It divides improving
security resilience into five key steps:
Identify
Determine what assets are most in need of protection and
prioritise activity accordingly. This requires extensive auditing
to accurately map assets across IT, IoT and OT systems.
Protect
Implement a plan to protect vulnerable areas and replace
or compensate for ageing software or assets like OT
that run on different systems. Limiting connectivity
and communication through technology like zero trust
segmentation is valuable here.
Detect
Ensure capabilities are in place to detect and mitigate
threats already within the network. A combination of tools
such as network detection and response (NDR) and user and
entity behaviour analytics (UEBA) will help to provide an
early warning of abnormal activity.
Respond
The ability to move quickly to contain active threats and
mitigate their impact. A combination of automated and
manual approaches through security operation centre (SOC)
and security orchestration automation and response (SOAR)
is necessary. Segmentation can prevent fast-acting threats
such as ransomware from spreading through the network.
Restore
Finally, being prepared to restore any damaged systems as
quickly as possible. This also includes processes to learn from
attacks and fine-tune processes, technology, and response
playbooks to improve resilience against future incidents.
Moving to a more proactive mindset
Implementing the right technologies and processes will
improve cyber resilience, enabling even the most expansive
and unwieldy pipeline infrastructure to be more tightly
managed and defended against incoming threats. Measures
such as EDR and zero trust segmentation will also help to
shift the organisation to a more focused, proactive approach
to security. The emphasis is on protecting the assets rather
than the network as a whole.
This also leads to a mindset known as ‘assume breach’
– accepting that some form of cyber intrusion is inevitable
and focusing instead on limiting the damage. Even if outer
network defences are breached, technology like zero trust
segmentation can prevent the attack from reaching critical
areas, minimising the chance of a significant disruptive
incident.
With such a vast attack surface and so many threat actors
targeting the sector, pipeline operators will inevitably be
breached at some point. But by being prepared to contain
attacks, organisations will have the best chance of preventing
a breach from spiralling into a major crisis leading to pumping
shutdowns and fuel shortages.
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ENTRUST Solutions Group’s safety
management systems reduce risk before
an incident occurs, says Jim Francis, Vice
President – SMS Consulting, ENTRUST
Solutions Group, USA.
earning to identify,
analyse, and mitigate
potential hazards in the workplace
drives us to take a deeper look into our
safety management systems (SMS). ENTRUST Solutions Group (EN), a leading
national engineering, consulting, and compliance services firm, has experts experienced
in the development, implementation, and improvement of a SMS.
A SMS is a comprehensive, systematic and deliberate approach to managing the safety of the
workforce, assets, and the public. It is focused on proactively identifying and reducing risk. Employees and
stakeholders are empowered to raise concerns and act to mitigate risks, while continuously improving processes,
procedures, performance, and culture.
EN has resources in place to help clients address specific challenges and areas of risk that surface when exercising
the SMS. EN’s data solutions, integrity management, and engineering and design teams can guide businesses in
addressing risks in their workplace and support solutions to mitigate risk.
In 2015, The American Petroleum Institute (API) provided the framework for SMS in the ‘Recommended Practice 1173’.
The team at EN uses key elements from API RP 1173 and other SMS and quality management system (QMS) standards to
work together to drive engagement and accountability in the workplace.
“When you think of the changes to the natural gas and liquids pipeline industry over the last 20 years, we’ve already
developed programmes that have improved safety and compliance,” said Jim Francis, EN’s Vice President of SMS consulting.

17
 “Numerous regulations and the evolution of technology add a
complexity and increased demand to continue to drive SMS to
be better,” he added.
Building a SMS requires continuous focus over a long period
of time. “Implementing SMS is a marathon, not a sprint,” said
Francis, “and it takes dedication, persistence, and fortitude to
be engrained in your culture and business operations.” Often, a
measurable reduction of risk requires multiple cycles of analysis
before it is known if the mitigations are effective. A SMS adds a
layer of control to an evolving environment. EN ensures that SMS
is inclusive of all programmes in the workplace by complementing
and creating an opportunity to improve safety processes.
Risk management
“Risk management is at the heart of a SMS,” said Francis. “It
establishes the need for education, drives goal setting and
creates the basis for continuous improvement.”
Along with all of the factors in a SMS, risk management must
be routine and intentional. This allows all of the compliance
requirements and activities to be measured, establishes the
criteria for the management system, and, because of audits,
measures whether the work is completed as required. Addressing
and analysing risks are to be completed throughout the year and
on purpose. Risk management first starts with a defined set of
procedures that describes how the processes will be executed.
The procedures break down each process into different
components: risk collection, decision-making, risk assessment,
and mitigation planning.
According to Francis, the owner of the risk management
process should meet at least annually with stakeholders to have a
facilitated discussion about the operational risks relevant to their
group.
“The fourth quarter of the year is a great time to reflect on
the performance and experiences of the previous months. By
Figure 1. Risk management is the engine that drives the SMS
process.
18 World Pipelines / MAY 2023
discussing new or changing risks, you can develop a plan for the
upcoming year,” Francis said.
Once a plan has been made for the year, including goals
and objectives, the team can start conducting deep-dive risk
assessments on individual risks. These are facilitated sessions that
thoroughly review a risk, the associated operational controls,
and create a defined improvement plan as an outcome. A risk
management process must be flexible to allow for urgent and
emerging issues. Most risks are identified during the facilitated
and routine execution of the SMS. Evaluating the effectiveness
of controls allows for additional or changing risks that may occur.
At its best, Francis shared, a SMS reduces risk before
an incident occurs. By creating structure and establishing
intentional engagement activities, risk discussion ensures that
the voices of all stakeholder groups are incorporated into a risk
management programme. The outcome of the process creates
clear operational focus for the upcoming year, setting safety
improvement priorities for the enterprise.
The SMS risk management process bridges the gap between
detailed asset-based integrity processes and the high-level
enterprise risk management process. Identifying risks for SMS
allows an examination of all aspects within a company. The
mitigation of these risks provides a closer look at the controls
that are in place and to determine if it is effective at preventing
risks from occurring.
Operational controls
In SMS, operational controls are designed to minimise the
likelihood of a hazard leading to a safety incident. These controls
also help minimise the consequence when an incident occurs.
Francis shared, “The further you go up on the hierarchy of
controls, the solution is more effective at preventing the risk
from occurring. Higher level controls should be outcomes of the
engineering processes and integrity management programmes.”
Operational controls can be found in two forms: preventive
and responsive. A preventive control is intended to keep a
hazard from causing an incident to occur, such as locating a
service line to prevent excavation damage. A responsive control
is intended to minimise the consequence if the incident does
occur, such as having an excess flow valve installed on the
service line, which shuts off the gas before something more
catastrophic can occur.
Understanding the relationship between operational controls
can be challenging due to industry regulations. SMS is at its
best when a company is facilitating intentional and routine risk
assessments. This can include reviewing operational controls and
its effectiveness before an incident occurs.
Francis said, “EN thinks well beyond the compliance
requirements when assessing our operational controls. Controls
should be specific and evidence should be available to prove
compliance.”
Using statistical analysis and sampling tools, EN provides
clients with confidence in the results of the process control
checks. By leveraging tools such as a bow-tie analysis or process
hazard analysis, companies can visually see the relationships.
These analyses involve facilitating small teams in identifying and
documenting which operational control is intended to prevent
or minimise a hazard.
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 Francis said, “Creating a visual map to see the relationship
between the hazards, controls, risks, and outcomes is an
important outcome in a risk assessment. This approach is very
effective when implementing new regulations. Evaluating your
controls through a risk assessment allows you to see the gaps
as you plan for implementing new requirements, particularly
thinking beyond just updating your compliance procedures.”
Figure 2. Annual cycle of an SMS should drive decision-making,
prioritisation, resource planning, and review in a routine and
intentional way.
Figure 3. Author, Jim Francis, facilitating a workshop on safety
management systems.
20 World Pipelines / MAY 2023
Documented controls are a foundation to compliance and
continuous improvement. Without structure or procedures
in place, it is difficult to identify the effectiveness of a risk
assessment.
“One of the more rewarding aspects of mapping your
controls is that it often reveals to individuals who own parts of
a process how what they do affects the work of others,” Francis
said.
Whether it be changes to controls, such as procedures and
training, or changes that directly affect the pipeline system,
there are decisions made every day that have an impact on the
safety of a pipeline system and the stakeholders that operate it.
Safety assurance
The EN team works together with clients to ensure the SMS is
driving the level of performance expected by providing improved
safety and a reduction of risk. Safety assurance makes sure that
SMS is having a positive impact on a company’s safety culture.
Putting a structure in place is key to allowing the measurement
of progress and effectiveness of a SMS against an established
baseline.
Francis said, “It is important to not only show how you are
complying with the SMS requirements, but also demonstrate that
you are reducing risk.”
Auditing is one of the most effective ways to measure risk.
Internal audit processes create a continuous improvement plan
and supports compliance with the requirements. Leveraging an
external resource to perform these audits can provide added value
to a company’s SMS by recommending practices that an internal
audit team may not be privy.
Francis said, “Going beyond compliance is important. It is
good to get an outsider’s perspective to assess the quality of the
process.”
Measuring the effectiveness of risk management is one of the
primary goals of a SMS. A risk management programme should
provide metrics that quantify the change in risk over time. These
measurements reflect the quality of the process, stakeholder
engagement, and leadership commitment to risk management.
Programme level metrics provide continuous measurements
of high-risk processes, such as emergency response times or
excavation damage rates. The performance of stakeholders can
be measured by engagement metrics. These metrics illustrate
participation in continuous improvement events or SMS leadership
meetings.
Measuring risk at an individual level shows progress of the
mitigation efforts over time and evaluates if the mitigations were
effective. Particularly early in the implementation of an SMS when
the risk register is more volatile and more stakeholders are getting
engaged, improvement can be shown even if the aggregate risk
score increases. “Your goal is to quickly be able to communicate
to your leaders whether there are additional actions that need to
be taken to address any emergent issues,” Francis said.
Establishing key performance indicators (KPIs) is also a way to
demonstrate how an SMS is reducing risk and improving safety.
There are multiple elements to how KPIs are leveraged within a
SMS.
SMS programme metrics illustrate progress. These results,
which include implementation progress and audit results, are
typically reported on an annual basis. Risk management metrics
demonstrate the change in risk from the baseline assessment
and previous results. This includes changes in risks associated
with specific areas where mitigation activities were completed.
Engagement metrics measure the level engagement in the
SMS from various stakeholders, such as employees identifying
risks or corrective actions. Pipeline safety programme metrics are
continuous metrics associated with high-risk processes, including
excavation damage rate, emergency response times, and integrity
assessments. These programme-level metrics are actively tracked
and monitored through the year as part of an SMS.
“At EN, we help our clients develop their SMS metrics and
scorecards,” Francis said. “We’ve worked with our clients to
develop systems, metrics, dashboards,
and reports that allow them to see the
effectiveness of their SMS.”
Ensuring that continuous improvement methods are fully
implemented and effective is driven by accountability.
“By having effective, continuous improvement processes and
expecting your teams to use them in their daily work activities,
risk management becomes routine,” Francis said.
Building a quality SMS adds a layer of control to an already
complex environment. EN works together with clients to ensure
the SMS process is efficient in its execution and continuous
growth.
“EN helps clients develop procedures to all aspects of a SMS.
We help connect the dots to all of your existing procedures,
operational control documents, and elements of your
management system,” Francis said.

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22

Camila Sanchez Prado, Horizontal
Drilling International (HDI), France,
outlines a crude oil pipelines
replacement project under the
Danube River.
orizontal Drilling International (HDI), a major
international player in horizontal directional drilling
(HDD) for the energy market, has completed the works
to replace the crude oil import pipelines between
stations C1 - C2 and C3 - C4, including the crossing of the
Danube River and the Borcea branch, by trenchless method,
for CONPET SA, in Romania.
The crossing site was in Fetesti, about 150 km east of
Bucharest. This place is well known by Romanian geologists
and is used as a site for learning for future geologists, since
it has almost all the types of soil that can be found in
Romania (rocky and sandy ground).
The project was carried out jointly by the CIS GAZ
S.A, Romania, as the leader of the association, and HDI.
The contract was concluded on 30 August 2021 for the
design and execution of the works, with a deadline for the
completion on 15 August 2023. The execution of the works
started on 10 May 2022 and was completed four months
ahead of schedule.
The scope of work included the pipe supply; the
welding of six steel pipelines (1250 m of 8 in., 20 in. and
28 in., and 1460 m of 8 in., 20 in. and 28 in.); six horizontal
directional drillings; trench works; and welding from
drilling entry and exit of each 20 in. and 28 in. pipe to the
stations; backfilling; and site reinstatement.
“Reliability of energy transport infrastructure is of
paramount importance, not only with regards to security
of supply but also from an environmental perspective. The
completion of this project, using environmentally friendly
23

Figure 1. The works started on 10 May 2022 and were completed
four months ahead of schedule.
Figure 2. The Handover ceremony took place on 3 April 2023 in
Festite, in the presence of The Minister of Energy, Virgil Popescu,
the Secretary of State George Niculescu, the representatives
of Conpet top management, the General Director of CIS Gaz,
Horaţiu Sebastian Călugăr, the General Director of Horizontal
Drilling International (HDI), Atef Khemiri, as well as local officials
from Ialomiţa and Constanța counties.
techniques, reinforces the security of supply in Romania
while reducing the potential environmental hazard.
“We are proud of our contribution to the successful
delivery of this landmark project”, said Atef Khemiri, HDI’s
Managing Director.
The original undercrossing of the Danube and the
Borcea arm with crude oil transport pipelines was carried
out in two stages, in 1968 and 1978 respectively.
At this time, the pipelines were covered with concrete
and sunk to the bottom of the river, without any
protection.
Given the age of the pipelines, to ensure optimal
conditions for crude oil transport and to avoid the risk
of damage with severe environmental consequences,
modernisation and restoration works have been
implemented.
For the Minister of Energy, Virgil Popescu, it is an
extraordinarily important project as it ensures the
transportation of crude oil from the Black Sea to the
interior (to refineries) and it was an important project from
an environmental point of view.
24 World Pipelines / MAY 2023
CONPET is the operator of the National Petroleum
Transport System by pipelines in Romania and operates
a pipeline network with a length of over 3800 km
throughout the country. This contract is one of the
biggest ever signed by the company, with a total value of
€26.5 million.
The current project scope included 1250 m and 1460 m
long HDD crossings with pipelines of the following
diameters: 8 in., 20 in. and 28 in. A maxi drilling rig of 400 t
capacity was mobilised and successfully executed the
crossings.
Two crossings of 1250 m were completed within a
month (July 2022); the four others (one 1250 m and three
1460 m) were completed in about two months (September
and October 2022). Subsequently, the rest of the pipeline
could be installed by open cut and connected to the
existing network.
The overall scope of work, from design to
commissioning, has been mastered by the project team.
“A good team spirit quickly emerged between the joint
venture stakeholders and its subcontractors, everyone was
there for the same purpose and always with the intention
of helping each other when possible”, said Alcyme
Rambaud, HDI Project Manager.
The Danube River is undercrossed by 10 pipelines, on a
perpendicular corridor on the minor riverbed.
It was not the first time HDI has performed HDD works
under the Danube: the company performed two crossings
for fibre optic cables in a northern section in the 1990s,
with a much smaller diameter and smaller length.
The successful execution of the most recent project
was made possible thanks to the excellence of the
detailed design, which finds its roots in reliable subsoil
characterisation.
In addition to geotechnical boreholes, the
interpretation of the data collected during the geophysical
investigation (electrical and seismic) allowed a better
understanding of the ground conditions along the drilling
routes and subsequent design adjustments in order to
mitigate the risks.
Ground investigations revealed a major rock formation
on the second quarter of the Danube crossing, which was
the called the ‘rock mountain’ by the project team during
project operations.
With those investigations HDI was able to redesign
the drilling by adding a second horizontal tangent to stay
above the rocky area and then go down again to pass
under the river.
“In a global context marked by climate change, global
warming, but also by intense institutional concerns in the
field of climate change, the realisation of this project will
contribute to the security of energy supply in Romania,
in terms of reducing pollution risks. We are happy that
we managed to successfully complete a large-scale
project using the most modern technologies available
internationally”, said Horaţiu Sebastian Călugăr, Cis GAZ
General Manager.
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 Mario Moreno P.Eng.,
Seal for Life Industries, Canada,
discusses revolutionising
pipeline field joint coating with
high flexibility epoxy coatings.

orrosion prevention for underground structures

is essential to ensure their long-term integrity
and reliability. A combination of a durable
coating and cathodic protection (CP) is
necessary for effective corrosion prevention. When
focusing on field joint coatings, there are many
advantages and disadvantages of the different coating
technologies available. We take a look at what those
are and introduce a new epoxy formulation that
promises extraordinary corrosion protection properties
and flexibility.

Background
For optimal corrosion prevention in underground
structures, a robust coating combined with CP is
the recommended approach. The protection cost
comprises both the coating and the CP system.
Since its introduction in 1960, single-layer FBE
has demonstrated remarkable effectiveness as a
pipeline coating. It currently enjoys widespread use
as the preferred pipeline coating in North America
and has a strong following worldwide. Its exceptional
performance characteristics, as well as its track record
of success in underground and undersea applications,
make it an ideal choice for line pipe, fittings, and
e
lin

bends.
pe
pi

However, for field joint coatings there are several

e
th

reasons why liquid epoxies are often preferred over FBE

X
FL

to treat the joints between pipes.

BE
H
sa

Ease of application
nu
Ca

Liquid epoxy is easier to apply than powder FBE

th
wi

epoxy, especially in field conditions. The liquid form

n
io

allows for easier mixing and application, making it

at
lic

more convenient and efficient for use onsite.

ppa
d. er
le ft

Faster cure time

al A
st 1.
in e

Liquid epoxy has a faster cure time than powder FBE

is gur

epoxy. This means that the coating can be applied

Fi

27
 and cured more quickly, reducing the overall downtime for the possess mechanical properties similar to those of the main line
pipeline. coating. This approach helps to promote corrosion protection,
compatibility, uniformity, and reduces the risk of delamination,
Better adhesion stress concentrations, and potential cracking or damage due to
Liquid epoxy has better adhesion properties than powder FBE thermal expansion.
epoxy, particularly in wet or humid conditions. This makes it more Generally, liquid epoxy coatings used for field joint coating
effective in protecting the pipeline against corrosion and other applications must undergo a series of qualification tests before
forms of damage. they can be considered for pipeline use. These tests are
specified in the standard CSA Z 245.20 (plant applied coatings)
More sustainable and CSA Z 245.30 (field applied coatings). The main difference
Liquid epoxy installation requires no force curing or external between the two standards lies in the flexibility value, which is the
energy compared to FBE. Plus the material has minimum waste performance limit between the two. A liquid epoxy that meets
during application. the required flexibility level will also satisfy the other parameters.
In the realm of pipeline engineering, flexibility plays a crucial
In order to ensure the long-term integrity and reliability role in the performance of joint coatings, especially for pipelines
of a pipeline, it is important for the field joint coating to that undergo thermal expansion, ground movement, and other
environmental stresses. The ability of a coating to flex and move
with the pipeline, without experiencing cracking or fracturing, is of
paramount importance. Ideally, both the mainline and field joint
coatings should exhibit similar behaviour and movement patterns.
For instance, let’s consider the flexibility requirements outlined
by CSA Z245.20 (plant applied coatings) and CSA Z245.30 (field
applied coatings). While the former specifies a flexibility limit of
3°/PD, the latter mandates a more stringent limit of 0.75°/PD for
an 18 in. OD pipe (Figure 2).
In the context of field joint coatings, flexibility requirements
differ from those of mainline coatings during installation. This
Figure 2. Bending radius example 18 in. OD pipe.
trade-off exists to enable better performing epoxy coating
systems, as adhesion and cathodic disbondment properties also
Table 1. OEM FBE vs field applied liquid epoxy qualification
significantly impact the coating’s long-term performance. The
requirements
engineering decision is justified, provided no alternatives that offer
Thickness CSA 245.20 CSA 245.30 comparable performance alongside flexibility are available.
System 1A System FC1
To achieve enhanced flexibility, alternative modifiers have
24 hr cathodic < 6.5 mm < 6.5 mm been introduced in the market. One such alternative resin is a
disbondment at
65˚C
polyurethane-epoxy hybrid, which improves the epoxy matrix’s
flexibility through the addition of polyurethane functionality.
28 d cathodic < 8.5 mm < 8.5 mm
However, this solution’s drawback is that the material’s
disbondment at
20°C temperature performance is affected, leading to a compromise in
performance characteristics such as cathodic disbondment test
28 d cathodic < 20 mm (95˚C) < 10 mm (95˚C)
disbondment at results and temperature resistance.
max rated service Canusa, a division of Seal for Life Industries, conducted a
temp benchmarking exercise to compare the performance of epoxy
Flexibility (-30˚C) 2.0˚/PD 0.75˚/PD field joint coatings, which highlighted a significant performance
Flexibility (23˚C) 3.0˚/PD N/A gap between the epoxy-polyurethane hybrid technology and
traditional epoxy field joint coatings.
1.5 J impact No holiday -30˚C No holiday
resistance -30˚C
In the search to meet the requirements for effective corrosion
control and mechanical properties, the development of the next
Adhesion to steel N/A Rate 1
generation of field joint coatings is crucial. CANUSA CPS Division
substrate
of Seal for Life Industries has created a new epoxy formulation
Adhesion to existing N/A Rate 2
that delivers exceptional flexibility and corrosion protection.
coating
Known as HBE FLX, this coating system is based on epoxy polymer
Adhesion to steel Rate 1 - 3 Rate 1 modified with core-shell rubber nanoparticles. These nanoparticles
after hot water
immersion improve the tensile properties, fracture toughness, and glass
(95˚C, 28 d) transition temperature of the epoxy resin. Core-shell FJC epoxy
Adhesion to existing Rate 1 - 3 Rate 2 formulation is patent-pending technology.
coating after hot Core-shell rubber nanoparticles are a type of nanocomposite
water immersion material that consists of an elastic rubber core surrounded by
(75˚C, 28 d) a shell made of another material, such as polymers, metals,

28 World Pipelines / MAY 2023

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 ceramics, or other types of nanoparticles. This technology offers
a promising approach to enhance the mechanical properties of
coatings while maintaining their corrosion resistance.
The performance characteristics of the novel product HBE FLX
in addition to being highly flexible are:
• Excellent adhesion to well-cleaned steel.
• Good chemical resistance.
• Low oxygen permeability.
Figure 3. Cathodic disbondment comparative and T Max.
Figure 4. Flexibility at different temperatures comparative.
Figure 5. Canusa HBE FLX being applied.
30 World Pipelines / MAY 2023
• Non-shielding – works with CP.
• No reported cases of stress-corrosion cracking (SCC) of
pipe coated with FBE (6).
• The coating remains bonded to the extent that it
separates the pipeline steel from an SCC chemical
environment.
• It allows the passage of current in case of bond failure.
• Resistance to biological attack.
• Tough.
• Excellent penetration resistance.
• Good impact resistance.
• Good abrasion resistance.
When it comes to the performance of a coating, several
factors come into play, such as the mixing process, environmental
conditions, and surface preparation. Among these factors, the
ease of application is crucial for the coating to be effective. The
new coating technology offers exceptional ease of application,
with excellent spreadability and sag resistance. The product can be
applied to high dry film thickness without any need for correction
or reapplication, ensuring a consistent dry film thickness for
optimal coating performance.
Coatings in action: Trans Mountain Pipeline
The Trans Mountain pipeline project, which involved expanding
an existing pipeline running from Edmonton, Alberta to Burnaby,
British Columbia, in Canada, was completed during the COVID-19
pandemic, during severe pressure on the supply of construction
materials. The project increased the pipeline’s capacity from
300 000 to 900 000 bpd of oil per, allowing for increased
transportation of crude oil from central Canada to the west coast.
The project incorporated the HBE FLX technology, which was
approved for use and installed in several sections of the pipeline
with great reviews from the application crews. Despite challenging
weather conditions, this new technology proved to be highly
effective.
The successful completion of the Trans Mountain pipeline
project is a significant milestone for the adoption of the HBE FLX
technology in Canada, and is expected to pave the way for its use
in other major projects. The technology’s ability to overcome
difficult environmental conditions and increase pipeline
efficiency makes it a disruptive force in the industry.
Conclusion
The development of the HBE FLX epoxy formulation by
CANUSA CPS Division of Seal for Life Industries is a significant
step forward in pipeline corrosion protection. Its core-shell
rubber nanoparticle technology provides exceptional flexibility
and mechanical properties while maintaining other important
characteristics such as adhesion, chemical resistance, and
non-shielding with CP. The HBE FLX’s ease of application
and consistent dry film thickness make it a highly attractive
option for pipeline coating. By mimicking the behaviour of FBE
and offering outstanding consistency, HBE FLX promises to
ensure the long-term integrity and reliability of underground
structures, particularly on FBE-coated pipes that are expected
to experience thermal cycling, vibration, or mechanical stress.
Overall, this promising solution has the potential to transform
average pipeline performance into excellence.
Autonomous drones and AI-powered data analysis enable a new level of monitoring
fugitive gas emissions, suggests Ariel Avitan, Co-founder and CCO, Percepto, USA.

lthough the moniker carries a certain

outlaw panache, fugitive emissions in the
oil and gas sector are simply leaks and
other irregular releases of volatile organic
compounds (VOCs), including the much-maligned
methane.
Methane emissions are the second-largest
contributor to global warming after carbon dioxide,
and 80 times more warming. The amount of methane
that leaks from industrial sites into the environment
is enormous. The Environmental Protection Agency
estimates that 2 - 3% of gas in the gas supply chain
is lost to leaks – but industry sources and studies
suggest that actual leak rates are far higher.

Figure 1. Percepto’s Air Max flying over a solar power plant to

monitor and inspect operations with the company’s Autonomous
Inspection and Monitoring platform (AIM) to manage the insights
derived from the data collected.

31
 The fact is that fugitive emissions are so common in the
gas sector that, until recently, stakeholders simply accepted
them as a ‘cost of doing business’. But now, US and EU
legislation, market conditions and companies looking to
achieve their environmental, social and governance (ESG)
goals are upending the industry’s ‘laissez-faire’ attitude to
fugitive emissions. Today, gas infrastructure players are far
more concerned about the costs of fugitive emissions. Here’s
why and what’s being done.
Figure 2. Automated drone inspections enable more efficient and more
profitable operations, pointing maintenance crews to the exact location
when repairs are needed.
Figure 3. The Percepto Air Max is designed for inspecting and mapping the most complex
industrial environments, where high accuracy and durability are the top priorities.
Figure 4. The Percepto Air Mobile is used for inspections, maintenance, security and
industrial operations calling for mobility, flexibility and resource-sharing.
32 World Pipelines / MAY 2023
A changing market and regulatory
environment
Passed in August 2022, the landmark Inflation Reduction Act
(IRA) has as much to do with energy as it does with inflation.
The legislation contains a long list of provisions that will
reduce US greenhouse gas (GHG) emissions and speed the
transition to renewable energy.
The IRA aims to lower GHG emissions by around 1 Gt by
2030, and to dramatically reduce particle pollution from fossil
fuels. It accomplishes this reduction through a combined
‘stick and carrot’ approach. On one hand, the Act offers
industries new or enhanced tax credits for decreased-
emission or emission-free technologies.
On the other hand, the IRA introduces a significant
fee on methane emissions. These fines will start at
US$900/t and will grow to US$1500/t by 2028. The
Congressional Budget Office (CBO) estimates that this
fee will raise some US$6.35 billion over the next decade
– which should give an indication of both the prevalence
of the problem, and the relative importance from the US
government’s perspective.
What’s more, the IRA contains very specific
enforcement provisions – requiring the EPA and producers
to calculate emissions baselines. Those exceeding the
limits are subject to the fine, while taking into account a
complex system of exemptions.
The IRA essentially shifts the onus of monitoring
and reporting to oil and gas producers, while imposing
very strict penalties for noncompliance. This significant
tightening of regulatory oversight has oil and gas players
taking a long, hard look at how they’re mitigating fugitive
VOC gas emissions today, and how they
can quickly and dramatically improve the
results of their efforts.
What’s being done today?
The International Energy Agency (IEA)
claims that the largest source of methane
emissions is oil and gas operations –
which lost over 120 Mt of methane
in 2021. Interestingly, the quantity of
methane lost – if recaptured and sold
– would cover Europe’s shortfall of gas
following the recent changes in gas
supply in light of Russia’s war in Ukraine.
This means that even before the IRA
came along, industries had a powerful
incentive to reduce methane emissions.
And indeed, companies have long made
efforts to reduce fugitive methane
emissions via EPA-mandated leak
detection and repair (LDAR) programmes.
Traditionally, LDAR monitoring has
involved either fixed-sensor or manual
roving surveys – which rely on probes
carried by workers. This means that
employees must walk around the plant,
physically inspecting, touching, measuring
 and documenting each relevant
component of each piece of equipment
on a site. These manual inspections are
time-consuming, resource-intensive,
costly, and lengthy – meaning they can’t
be conducted with high frequency. They
are also highly subject to human error.
While this method can have limited
efficacy for facilities in which production
equipment is concentrated in one area,
it is not viable for checking transmission
pipelines or other geographically-
distributed downstream equipment.
What’s more, legacy inspection
methods simply place employees in
harm’s way. Monitoring fugitive gases
requires workers to get up close
and personal with potentially toxic Figure 5. Percepto’s drone charging box stores the Air Max when not in operation,
protecting it and keeping it ready to launch at a moment’s notice.
and explosive materials, or climb
to dangerously located equipment.
Accessing such equipment – if even physically possible – which is mounted on low Earth orbit satellites to measure
may require costly equipment shutdowns. And even newer the absorption of sunlight by methane at high spectral
monitoring technology like handheld optical gas imaging resolution. At a lower altitude, some companies offer
(OGI) cameras, which allow employees to maintain a methane monitoring via fixed-wing aircraft flying over sites
modicum of safe distance from hazards, still require some and LIDAR to measure atmospheric methane concentrations
proximity and thus risk. around production regions and along transmission pipelines.
More advanced methods moving mainstream include The major limitation of orbital or high-altitude solutions is
a Wide-Angle Fabry Perot (WAF-P) imaging spectrometer, that they excel at indicating geographic areas in which there

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 are leaks, and perhaps the extent of those leaks. But they
cannot pinpoint specific leak sources to facilitate immediate
remediation.
Closer to the ground, oil and gas facilities leverage
piloted drones to attempt to locate leaks from a birds-
eye view with less risk than on-the-ground crews. While
these can be effective, piloted drones require skilled pilots,
working in shifts on an employee or outsourced basis –
making them less cost-effective. What’s more, piloted
drones remain subject to human error. Pilot oversight or
distraction can result in missed indicators that can leave
fugitive emissions undetected.
Finally, companies are using vehicle-mounted laser
absorption spectroscopy and other detection techniques
to monitor emissions from the ground. The challenge for
these solutions is that methane and most other VOCs
are gases which generally rise – making the likelihood of
detecting leaks at ground level far lower. Further, oil and gas
equipment tends to rise to heights – often the equivalent
of several building stories. This means that leaks from less
accessible or higher sources would simply go undetected.
Clearly, to meet both the ecological and regulatory
imperatives of fugitive emissions reduction, a different
monitoring and detection paradigm is required.
New tech meeting the challenges of the IRA
The proactivity surrounding fugitive gas emissions is not
driven solely by the penalties in the IRA. It’s also part of a
broader ESG agenda pursued more and more vigorously by
companies across all industries, as the global implications of
ESG issues becomes clearer.
Technology is playing a key role in furthering the cause
of both ESG and regulatory liability mitigation. More
and more energy companies are turning to autonomous
technology to perform routine inspections of tanks,
pipes, equipment and other assets – including monitoring
for fugitive emissions. Autonomous tech enables high-
frequency, ongoing monitoring without human intervention
– accessing assets consistently at the same time of day,
from the same angle, using the same detection equipment.
This enables creation of baselines and trend monitoring over
time – resulting in consistent reports that make comparisons
and measurements simpler.
Autonomous drones with an OGI camera payload are
already in use and successfully detecting fugitive methane
emissions. These drones fly a predefined route on a
predefined, often daily, basis. They can monitor the same
hard-to-access equipment and measure the same leak-prone
assets, day in and day out, in almost any weather conditions.
Because they are AI-powered, autonomous drone
platforms turn the data gathered in the field into
immediately actionable insights on mission-critical
maintenance issues – among them fugitive emissions. Leaks
are detected faster, more accurately, and with far lower
latency – resulting in dramatically lower fugitive emissions
and ultimately lower regulatory fines.
Further, IRA requires oil and gas producers to maintain
a historical timeline of where and when each leak was
34 World Pipelines / MAY 2023
found, when it was fixed, when the repair was completed,
the quality control deployed, and more. Facilities with such
accurate records are less likely to be targeted for audit
enforcement actions. Since the data gathered and analysed
by autonomous intelligent systems is fully auditable, oil
and gas producers using them can prove to regulators the
exact quantity and source of fugitive emissions, how they
remediated each source, and by exactly how much they
reduced fugitive emissions owing to their prompt actions.
Finally, automated inspections translate into overall more
efficient and more profitable operations. When failures
are detected early on, costly unscheduled shutdowns
or accidents are prevented. When repairs are needed,
autonomous platforms can point maintenance crews to the
exact leak location, minimising employee exposure during
repairs and lowering downtime.
Case study: Delek US
Delek US, a diversified downstream energy company,
operates refineries in Texas, Arkansas and Louisiana. In
addition to a crude refining capacity of 302 000 bpd, the
company’s refining segment includes renewables operations
with an annual biodiesel production capacity of some
40 million gal.
As part of the company’s effort to stay ahead of the
digital curve and make their refineries safer and more
efficient, Delek US adopted Percepto autonomous drones
to collect data, and Percepto’s AI-based Autonomous
Inspection and Monitoring platform (AIM) to manage the
insights derived from the data collected.
AIM’s AI-powered change detection framework
provides Delek US a unified view of each refinery, with
reports and insights that are automatically generated and
disseminated to relevant stakeholders on any mobile device.
AIM automates routine inspection, and then offers data
insights to anticipate trends, preventing environmental and
operational failures while meeting efficiency goals.
Delek US adopted Percepto to perform remote,
programmable and autonomous aerial inspections across
its entire refinery operations. Leveraging Percepto’s Air
Max OGI autonomous gas emission detection solution at
its refinery in Tyler, Texas, Delek US later expanded this
solution to its refineries in El Dorado (Arkansas), Big Spring
(Texas), and Krotz Springs (Louisiana). The only drone-in-a-
box with an integrated OGI camera, Air Max OGI is helping
Delek US detect fugitive emissions as they happen –
reducing product loss and streamlining compliance.
Conclusion
The IRA and other emerging legislative initiatives have
changed priorities for oil and gas players – moving fugitive
emissions mitigation to the forefront of executive attention.
Autonomous drones together with AI-powered data
analysis enable a new level of monitoring fugitive VOC gas
emissions. These game-changing solutions offer oil and gas
companies a triple win: find and plug leaks faster and more
efficiently, ensure employee safety, and dramatically lower
regulatory liability.
N
ow that you have smart phone and wifi connections,
your home has become digitised. With this
digitisation you can now start automating seemingly
little things, like the deadbolt on your front door or
your main floor light switches. This automation simplifies your
life and makes your home more efficient. Having an automated
deadbolt that you can control by holding your phone to your
door is super handy when you have an arm load of groceries and
can’t remember which pocket your keys are in. The easier we can
make things, the better we can make things in many ways. It’s time
for us to leverage this mindset of automation to empower control
room operators at our organisations.
The first step of digitising operations for pipeline assets is to
move from pneumatic controls to electric actuation and digital
telemetry. Once those are in place, it is then possible to visualise
the operation from a central location via a SCADA system. Many
pipeline operations across the world have achieved this step,
which greatly reduces the cost of operations and minimises
downtime/outages due to the enhanced visibility into the ‘health’
of the operation. This digitalisation is the first step to empower
those at the heart of it all – our control room operators. If a
control room operator can visualise what’s happening, then they
can react quicker. However, more isn’t always better; we have seen
this with alarm flooding. Control room operators have so much
Vicki Knott, CEO and Co-Founder, CruxOCM, USA, is on a mission to empower control
room operators to automate the energy industry.
information that they are unable to process it, and thus are unable
to react to it, which results in control room operator fatigue,
which in turn is the leading cause of safety and environmental
incidents in our industry. On top of this, humans struggle with
complacency once they become very proficient at tasks. We
must now look to what’s next with regards to technological
development for control rooms in order to unlock the next phase
of safe and efficient operations. This is especially important as we
strive to reach our sustainability goals as per the Paris Agreement.
Automating operational procedures
The next step is to use digital information to automate the
operation. By operation, we mean the procedures, checklists and
rules of thumb that a control room operator executes to operate
the pipeline asset. That may be managing line pack, swings, start-
ups, shutdowns, batch transitions, etc. All the things that are part
of the day-to-day operations of pipeline assets that ensure the
flow of energy to our societies.
Control room operators are much more effective with access
to digital information. However, leveraging automation to create
‘auto-pilot’ capabilities for control room operators will greatly
reduce incidents related to human factors and generate the
efficiency required to meet the initial industrial requirements for
the Paris Agreement.
35
 The benefit to control room operators by automating the
operation of procedures, checklists, and rules of thumb for
pipelines are the following:
) Reaching and maintaining, with substantially reduced variability,
true maximum pipeline capacity rates during all operational
procedures increasing volumetric throughput.
) Increasing pipeline ratability.
) Managing pipeline line pack for gas systems.
) Reducing control room operator commands (aka workload).
) Enabling the highest possible consistency of operations
between control room operators.
) Ensuring maintained line pack during shutdowns, which
increases leak detection integrity for liquid systems.
) Maintaining, with substantially reduced variability, targeted
rates during all operational procedures increasing volumetric
throughput.
) Automatically managing start-ups, swings, shutdowns, and
strips for liquid lines.
These benefits empower control room operators to focus on
the overall operation of the system, ensuring that nominations are
met every day as well as making sure that they are alert and well
rested if there are any safety issues that need their immediate and
full attention. Similar to how Alexa or Google are fully integrated
into your home’s light switches, simple ‘procedures’ such as turning
off all lights on the main floor of the house can be simplified to
“Alexa – turn off lights downstairs”. That feels so simple as it has
many tangible and intangible benefits to both your enjoyment of
your house, as well as the energy usage of it. In short, the easier
we can make things, the better we can make things in many ways.
So how then does automation enhance safety, one would
ask? One of the simple thought exercises that I like to do here is
the following:
Imagine getting on a plane to fly from London to Houston
without a pilot. Not going to do it, are you? Now imagine getting
on a plane to fly from London to Houston without auto-pilot
software. Not going to do that either, are you?
Yet we are operating our world’s critical energy infrastructure
every day without the equivalent of auto-pilot software. Whilst
we do have all of the critical safety limits in place, the way I see it
is yes – we have the guardrails on the highway – but the best way
to drive a car is to stay in the middle of your lane. You really don’t
want to be bouncing your car off the guardrails. Automation of
pipeline operating procedures ensures that you are always driving
the car smoothly in your own lane.
I think it’s obvious from what has been stated that
automation of control room operator procedures is not
replacing control room operators. If anyone has any doubts,
however, I’ll repeat this point again: imagine getting on a plane
to fly from London to Houston without a pilot. You aren’t going
to do it.
36 World Pipelines / MAY 2023
Lowering emissions
Circling back to our global sustainability goals as an industry: oil and
gas Scope 1 emissions account for 8% of greenhouse gas emissions
globally in 2015.1 To play our part in mitigating climate change, the oil
and gas industry must reduce its emissions by at least 3.4 Gt of CO2
equivalent from current operations by 2050, which is approximately
a 90% reduction. If oil and gas usage were to decline rapidly then
this could be an easy target to reach; however, based on the 2022
Annual Energy paper by JP Morgan Chase, oil and gas usage is
forecasted to increase.
The good news is that process changes and operational
adjustments have the potential to be sufficient to achieve our
climate goals. This is where automation comes in. Midstream
crude transport accounts for roughly 5% of the overall oil and gas
Scope 1 emissions. The paper cites electrification as the main way
to achieve our industry section emission reduction goals; however,
I think we need to dig into that more, especially if your pump
stations for liquid lines are already electrified.
Pump stations already electrified for your liquid
pipelines?
Then you need to look at aligning the consumption of energy at
each pump station to the hydraulic profile in real-time. This can be
done with a real-time, continuous recalculation of the hydraulic
profile as a function of the elevation profile and the batch
line up to determine which pumps should be running at which
locations. Many companies have a team of engineers running
these calculations and sending them to the control room every
day; however, converting this calculation into a real-time control
system via automation of which pumps to operate when, there is
a substantial opportunity for efficiency that is currently being left
on the table.
Pump stations not electrified for your liquid
pipelines?
First step is to electrify them; however, if this is not possible and you
have a gas-powered turbine powering the pumps, why not apply the
same strategy as above? The inputs are slightly more complex as you
now must account for the gas consumption of the turbine, but where
there is an algorithm, there is a way to efficiently automate this.
Gas compression stations on gas pipelines?
Gas compressor emissions are a function of the efficiency of
the compressor over time. If line pack on gas pipeline systems is
automatically managed to ensure optimal compressor efficiency
across all compressors, then there are emissions to be saved.
Conclusion
Crux is on the forefront of automation in midstream control rooms,
which is the next step for our industry. We firmly believe that
control room operators are the heart of the operation, and we are
on a mission to empower them to automate the energy industry,
which increases the safety and sustainability for the world’s critical
energy infrastructure.
References
1. www.mckinsey.com/industries/oil-and-gas/our-insights/the-future-is-now-
how-oil-and-gas-companies-can-decarbonize
 With today’s technology, contractors can continuously update
the pipeline owner on the coating project status, says Kristopher
Kemper, Technical Services Consultant, Association for Materials
Protection and Performance (AMPP), USA.
I
n the world of pipelines, there are many corrosion
control challenges that, if not adequately addressed,
can result in a breach of pipeline integrity ranging
from ‘small’ to catastrophic failures. This article
addresses one of those challenge areas: internal field
joint coatings.
Throughout the world, internal pipeline coatings are
used to protect both onshore and offshore pipelines
from corrosion. Most often, 40 ft (12 m) pipe sections
are first factory-coated, transported to a project
location, and then welded together onsite. At this
point, specialised robotic coating equipment is often
required to perform coating of the pipeline’s internal
field joints and inspection of the cured coating. With
properly calibrated equipment and a well-documented
and detailed quality programme, this specialised
equipment can easily clean, coat and inspect 40 field
welds in one day.
The key to effective project planning for
internal pipeline field joint coatings is including the
use of specialised robotic equipment in project
specifications. Specialised robotic equipment designed
and used specifically for internal pipeline field joint
coatings can ensure a high-quality coated field joint
when the equipment is properly calibrated and aligned
with other elements of the project specification.
With the Association for Materials Protection and
Performance’s (AMPP) qualification procedure (QP)
programme, certified coating contractors using
specialised robotic equipment can more effectively
and efficiently work within a project specification and
use the proper quality checks throughout a coating
project. These certified coating contractors can
demonstrate quality process control, management
procedures, safety, health, and environmental
compliance competence.
Specialised robotic equipment has progressed
over the years. Legacy equipment was fashioned from
robotic internal pipeline weld X-ray equipment, and
equipment size constraints forced pipeline owners to
use a minimum size of 8 in. pipe. Today, high-quality
internal field joint coating equipment can provide
solutions to many challenges. With quality monitoring
of several metrics, pipeline as small as 6 in. can be
coated and inspected. On the inspection side, the first
available internal robotic coating equipment used in
the industry had no video capability and was limited
to 250 m weld tie-ins; today, the equipment can
provide a high-definition colour video, with a range of
over 2 km for tie-ins, if required.
Root profiles
One ongoing major concern for internal field joint
coatings is pipeline weld root profiles resulting from
welding specifications that do not account for
internal field joint coatings after a weld is finished.
Previously, pipeline contractors relied on weld X-ray
and the robotic equipment video to confirm a weld
was ready for coating application. Still, there was not
enough precise information to verify that the weld
was ready for coating. With recent technological
improvements, weld laser mapping is available for
use in conjunction with internal robotic equipment.
Weld laser mapping can measure the weld root profile
while showing a three-dimensional picture of the weld
and any imperfections on the surface, giving a true
visual representation to view against the weld replica
standard.1
With this three-dimensional picture, personnel
can consider weld height, sharp edges, undercut and
other aspects of the surface that can cause an internal
field joint coating to fail. Additionally, laser mapping
37
 can ensure that the factory coating cutback area, for the coating
transition, is correct for coating application.
Figure 2 shows where the laser mapping equipment has been
set up to highlight the weld height above 1.5 mm in the colour
red. The graph on the right of Figure 2 shows weld width, weld
height, weld undercut, potential voids/porosity in the weld, sharp
edges, over-roll/overlap, and potential high/low pipe misalignment.
Figure 1. Upstream view of weld (Source: WISKOTS).
Figure 2. Laser mapping and graphing diagrams highlight weld height.
Figure 3. Welding defects that did not pass high-voltage holiday testing.
38 World Pipelines / MAY 2023
Ultimately, this graph shows if a weld will have a possible pinhole
holiday in the coating before the coating is applied.
Figure 3 and 4 show weld defects that failed high-voltage
holiday testing because all weld root profiles must be uniform
with no sharp edges and minimal undercut. The internal field joint
coating industry calls for a weld root profile of 1.5 mm or less. A
weld smoothing tool has been developed that allows defective
welds to become ‘coatable’ welds while also minimising pinhole
holidays in the internal field joint coating, helping to avoid the
need for cutting welds out and rewelding. This technological
advancement can improve quality, minimise failures, and reduce
costs associated with rework.
Figure 4 shows a weld with over-roll/overlap causing a void near
the weld.
Surface profiles
Another historical challenge with weld areas is industry’s inability to
verify the surface cleanliness and surface profile of the bare steel
area prior to coating application. Most project specifications have
relied on open abrasive blasting to ensure the coating cutbacks
and factory coating transition area at the end of the pipe are
adequately prepared before the welding process. Previously, no
equipment was available to verify surface cleanliness or profile. The
possibility of rust formation occurring before the coating is applied
was a reality that often resulted in more rapid coating failures.
With improvements to the equipment over
the years, we can now ensure the surface
profile and cleanliness meet the specification
requirement and the coating manufacturer’s
product data sheet.
Figure 5 shows a weld that has been
smoothed and then robotically abrasive
blasted to a near-white.2 Internal pipeline
steel surface cleaning equipment varies from
company to company, with most equipment
using a centrifugal cleaning head. However,
today’s equipment can use abrasive air blasting
for 6 in. pipes and larger without air hoses
tracking down the pipe. Using abrasive air
blasting, a robotic machine can quickly and
efficiently remove rust or coating from a weld
and cutback area, ensuring a project will not
have additional delays due to high humidity
locations, a pipe submerged in water, or
imperfections in applied coating. The abrasive
air blasting can provide a sharp angular surface
profile, while ensuring the surface meets
the ‘SSPC-SP 5/NACE No. 1-2006, White
Metal Blast Cleaning’ or ‘SSPC-SP 10 /NACE
No. 2-2006, Near-White Metal Blast Cleaning’,
per the SSPC VIS-1 standard, depending
on the steel grit mixture.3,4 If required, new
cleaning equipment can take an un-blasted
steel surface to a blasted surface with a sharp
angular profile within 10 minutes, while older
technology took more than one hour to begin
to make a surface profile. Once the abrasive
blasting process is finished, a vacuum is used
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Figure 4. Welding over-roll/overlap leads to a void near the weld.
Figure 5. Smoothed weld that has been robotically abrasive blasted to a
near-white.
Figure 6. Interior of cleaned steel pipe.
to collect and recycle the steel grit onboard the equipment inside
the pipe, maximising time and efficiency. Using steel grit for surface
preparation inside the pipe, the vacuuming process has been a key
element in ensuring proper adhesion of field joint coatings. The
vacuum can provide a surface dust level of less than Level 2 per
ISO 8502-3:2017, with the proper air filtration while inside the pipe.5
Figure 6 shows a 1 in. wide strip of cleaned steel that was
achieved in just one minute inside a 6 in. pipe.
Powder coatings
On another front, coating application equipment also has
advanced and can now help minimise holiday pinholes in the cured
coating and other coating failures. Equipment can apply powder
coatings and plural component liquid coatings inside a pipe,
40 World Pipelines / MAY 2023
allowing for a more precise coating application and coating
thickness control on the entire circumference of the weld and
cutback area, providing a smooth transition to the factory-
applied pipe coating. The fusion bonded epoxy (FBE) coating
application heating process can even be checked using multiple
thermocouples on the induction coil, ensuring an evenly
controlled heating cycle within the coating specification and
manufacturer’s data sheet.
Changes to the internal robotic powder coating equipment
include onboard quality controls, ensuring the powder’s
moisture content is within the coating manufacturer’s limits.
A machine will stop working if the powder does not flow
properly during the coating application process. Likewise, with
other advances, the liquid coating equipment can heat multiple
component coatings onboard and monitor mix ratios and
coating material flow during the application process, ensuring
the mixed coating will cure to the manufacturer’s requirements.
Inspection
With regards to advances in coating inspection, the robotic
coating inspection equipment can take spot and continuous
dry film thickness readings, per SSPC-PA 2-2022, at the field joint
area, giving high/low and average dry film thickness readings
immediately to the equipment operator.6 High-voltage holiday
inspection has been previously limited to using a ground wire.
Today’s high-voltage inspection machines perform tests without
a ground wire connected to the outside of the pipe. The
high-voltage inspection is usually kept to the field joint area,
but it can now be used for full-line internal holiday inspection
using SP0188-2006.7 A revised version of this standard is nearing
completion as of February 2023, incorporating new research
findings.
With today’s technology, internal field joint coating
contractors can continuously update the pipeline owner onthe
coating project status with daily production and inspection
reports and live video from robotic equipment. The pipeline
owner’s quality team can remotely check when a specific weld
was cleaned, the surface was inspected, the coating was applied,
and when the final inspection was performed, along with the
video. Additionally, internal robotic equipment operators can
remotely check equipment status and troubleshoot equipment
on a project via smartphones, working on the opposite side of
the world.
Conclusion
In summary, the robotic internal field joint coating equipment
used globally today can achieve a high-quality coated internal field
joint when the equipment is used correctly, following the project
specification. With quality checks and balances in the robotic
process, failures in coating applications are minimised.
References
1. store.ampp.org/sp0178-2007-formerly-rp0178-
2. store.ampp.org/sp0615-2015-2
3. store.ampp.org/nace-no-1-sspc-sp-5-white-metal-blast-cl
4. store.ampp.org/nace-no-2-sspc-sp-10-white-metal-blast-cleaning-r
5. www.iso.org/standard/58060.html
6. store.ampp.org/sspc-pa-2-2022-procedure-for-determining-conformance-to-dry-
coating-thickness-requirements
7. store.ampp.org/sp0188-2006
As field joint coating workscopes become more
technically challenging, with larger diameter pipe
and deeper water, companies must adapt, says Paul
McShane, Managing Director, CRC Evans, UK.

Figure 1. Spoolbase in Bintan, Indonesia.

42
I
n the world of field joint coating, CRC Evans’ team
has an enormously successful track record and has
earned a reputation for undertaking complex projects.
The company’s full turnkey service capability helps to
ensure the optimised delivery times that customers trust.
The engagement begins early at the materials selection
stage and continues throughout the project planning
and delivery stages, with the support of state-of-the-
art equipment, specialist personnel and purpose-built
coating facilities. Already a leader in the application of
anti-corrosion and insulation materials to field joints, for
onshore and offshore pipelines, CRC Evans is now leading
the way in developing new procedures and practices and
innovative technologies that will further optimise delivery.
Enhancing efficiency through automation
As a market-leader in the offshore application of field joint
coating systems, CRC Evans’ track record spans vertical
(J-Lay) and horizontal (S-lay/multi-jointing) techniques,
where increasing expectations for quality, reliability, and
shorter installation times requires the constant evolution
of technologies and methodologies. The growing emphasis
43
 on improving sustainability in offshore operations is
driving the demand for increased productivity and
consistency whilst managing high production rates. This
has transformed the company’s approach to R&D towards
technologies and processes that support automation,
which provides fast repeatable cycle times and consistent
quality across the application of materials, whilst the
associated reduction in operator strain and fatigue is
leading to improvements in operational safety.
CRC Evans’ coating technologies already offer
customers an element of automation as they are designed
for consistent results and new initiatives to drive
automation. Such initiatives include the development
of the factory coating preparation (FCP) machine which
automates the cleaning and preparing of FJC line-
pipe chamfer and overlaps. This operation is currently
performed manually using a combination of grinders,
electric planers and scrapers, and can require four
operators depending on the size of the field joint and
target cycle time. With the FCP, these functions can be
carried out from a central panel by one operator who
simultaneously controls other FJC processes, streamlining
both the workscope and support requirements.
Overcoming new challenges
As field joint coating workscopes become more technically
challenging, with larger diameter pipe and deeper water
(J-Lay), generally more testing than shallow water (S-Lay)
companies are having to adapt very quickly. The biggest
Figure 2. The SOLARIS was deployed to ensure precise and consistent
control of overlap temperature prior to injection.
44 World Pipelines / MAY 2023
trial usually faced using injection moulded polypropylene
(IMPP) in offshore environments is navigating the
equipment into what can be very cramped working spaces
which necessitates a tailored approach for each vessel,
working closely with customer-side engineers to deliver a
bespoke design package and manage barge integration to
support the project. No stranger to technical challenges,
CRC Evans successfully delivered the largest ever coated
field joint, in ultra-deep waters ranging 1400 - 1950 m, off
the coast of Angola. This required a selection of bespoke
IMPP technologies customised to meet specific project
challenges. IMPP is the most advanced coating type for
field joints, offering excellent operating temperature
and impact performance, and is applied in thicknesses
10 - 100 mm. The project required field joint coating during
onshore spool fabrication utilising the patented IMPP
and flamespray polypropylene (FSPP) coating systems. To
overcome the restrictive conditions onboard the vessel
and facilitate a smooth offshore process, CRC Evans
designed and manufactured custom blasting equipment
including the automated SABRE consisting of up to six
blasting nozzles, two bespoke RAPTOR heat coat machines
and five sets of IMPP spreads capable of casting field
joints in multiple planes. CRC Evans was able to support
the demands of the project, providing QHSE management
and logistical and operational support. The company’s
local entity in Angola worked alongside international
technicians, providing a 14-strong skilled, local workforce
that contributed over 100 000 site hours with zero loss
time incidents (LTI).
Tier 1 contractor in Australia
CRC Evans has delivered the largest ever reeled field
joint, completed at a high production rate to a high
standard, with zero repairs needed, leading to time and
cost savings for the customer.
In 2020, CRC Evans was engaged by a Tier 1 subsea
contractor to carry out field joint coating operations
for 22 km of pipeline 200 km off the northwest coast
of Australia. The coating works would take place at
BOMC Spoolbase in Bintan, Indonesia on an 18 in. dia.
corrosion-resistant alloy pipeline.
In an industry first, the operation would require
the reel-lay installation of 23 in. dia. pipe, including
insulation thickness, adding complexity to the
workscope.
As this project commenced at the height of the
pandemic, there were significant logistical challenges in
mobilising personnel to Indonesia and compliance with
country access and quarantine requirements. To avoid
travel-related disruption, our team spent additional
weeks onsite, helping to ensure that the project was
completed successfully and on time.
Solution
CRC Evans would treat 22 km of 18 in. pipeline with
65 mm of 5-layer polypropylene insulation. Standard
spoolbase equipment would require an uprating to
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Figure 3. Custom coating conducted by the CRC Evans coating team in Angola.
Figure 4. The CRC Evans coating team worked on a project located
offshore Western Australia.
handle the height of the pipeline. The coated pipeline
would total 23 in. dia. overall, the largest IMPP pipe
spooled to date.
Delivery
Preparatory site works commenced in December 2020 and
pre-qualification testing took place at CRC Evans’ coating
46 World Pipelines / MAY 2023
facility in Lancashire, UK. Investment
in remote technology enabled live
viewing of testing operations by our
customers, who could access the feed
from any location in the world.
To achieve the required results,
CRC Evans proposed a combined
solution utilising its RAPTOR,
SOLARIS, IMPP and enclosed
HYDRATM quench equipment. The
RAPTOR was mobilised to handle the
large pipe OD and thickness. Its high
frequency heating input combined
with the ability to heat and apply
powder simultaneously helped to
reduce cycle times. This reduced
the amount of heat going under the
factory coating, helping minimise the
risk of cracking during spooling. This was critical given
the overall size of the pipe.
SOLARIS was deployed to ensure precise and
consistent control of the overlap temperatures prior
to injection and to decrease the risk of cracking or
disbondment during spooling. Our IMPP system could
support the high production rates whilst helping
to withstand the high bending stresses normally
associated with coating large pipe OD. Using the
enclosed HYDRA, the entire field joint was fully
quenched, with air blades to reduce the risk of sagging
and deformation post injection.
CRC Evans’ operations and HR teams worked
tirelessly throughout to ensure the welfare, health
and safety of our people whilst adapting to evolving
worldwide travel restrictions. This allowed our onsite
projects team to keep the job running smoothly.
With difficulties related to leaving the country, our
people spent many months away from home to ensure
that this project was completed on time and within
customer requirements. This combination of equipment
proved highly successful in delivering the expected
quality of work.
Meeting challenges
Technically challenging projects such as these have
helped to cement CRC Evans’ reputation as a solutions-
oriented partner, leveraging the company’s 90 year
track record and wide expertise to overcome unique
challenges that can meet and exceed customers’
expectations. With its newly expanded capability
and reach, CRC Evans’ high standard of delivery is set
to expand over new geographies. The global energy
transition depends upon the efficient delivery of new
clean energy infrastructure. This will drive innovation
and investment throughout the CRC Evans’ business as
the company responds to new technical and logistical
challenges spanning renewables activities including
hydrogen pipelines, offshore and floating wind, carbon
capture, and storage and nuclear.
 Darran Pledger, STATS Group, UK, discusses techniques that allow operators to
perform necessary maintenance, repairs, and modifications without interrupting the
flow of the product, while reducing downtime and increasing efficiency.

H
ydrocarbon pipelines are essential to ensure
energy security for many countries around
the world. Pipelines play a critical role in
meeting the energy needs of households,
businesses, and industries by providing a reliable,
efficient, and cost-effective means of transporting
hydrocarbons.
One of the primary advantages of pipelines is their
ability to transport large volumes of hydrocarbons
efficiently and safely over long distances. Pipelines offer
a more cost-effective way to transport hydrocarbons
than other modes of transportation, such as trucks or
tankers, which can be more expensive and have higher
environmental risks.

Figure 1. SureTap ST410-90 12 in. hot tap, Canada.

47
 To maintain the integrity of these pipelines, regular
inspection and maintenance is crucial for ensuring the safe
and efficient transportation of oil, gas, and other products.
Regular inspections help identify potential issues before
they become major issues, preventing integrity threats, and
reducing the risk of incidents or environmental damage.
Hot tapping and line stopping
Pipeline hot tapping and line stopping are two critical
techniques used for maintenance, repair, and modification
of pipelines without interrupting the flow of the product,
reducing downtime and increasing efficiency.
Pipeline hot tapping involves cutting a hole into a
pressurised pipeline to create a new branch connection
without disrupting the flow of the product. The hot
tapping process requires specialised equipment and highly
skilled technicians to perform the procedure safely and
efficiently. Firstly, a split tee is welded onto the pipe (or
a mechanical tee is fitted if welding is not possible) and a
pressure test is conducted against the parent pipe. A valve
is then added, and a drilling machine mounted which has
a pressure competent boundary to ensure no unplanned
release of pipeline contents during the cut. The cutter is
Figure 2. 24 in. BISEP with integrated bypass, Belfast, Northern Ireland.
48 World Pipelines / MAY 2023
normally a hole cutter with centre pilot drill which acts
both as a guide and to retain the pipe coupon.
Line stopping, however, involves stopping the flow of
product through a pipeline temporarily. This technique
is used to perform maintenance on a short section of
the pipeline without depressurising the entire line when
incumbent valves are not available or not providing
the required level of isolation. During line stopping, a
temporary plug is inserted into the pipeline to prevent
the flow of product. This allows operators to work on the
pipeline in a controlled environment, with the isolated
section of pipeline vented and purged, reducing the risk
of leaks or other safety concerns. If pipeline flow must
be maintained, a standalone bypass or line stopping tools
with integrated bypass can be deployed.
Both pipeline hot tapping and line stopping are critical
techniques used by operators to ensure the safety and
reliability of pipelines. One of the primary benefits of
pipeline hot tapping and line stopping is the ability to
minimise downtime and maintain product flow. Shutting
down a pipeline for maintenance or repair can be a costly
and time-consuming process, and it can result in significant
product losses, adverse effects to the environment,
integrity threats and increased risk. By using these
techniques, operators can perform necessary work
on the pipeline while the product is still flowing,
reducing the requirement to depressurise, vent and
purge large sections of pipeline.
Double block and bleed
The term double block and bleed (DBB) is mostly
used to define a level of isolation provided by
valves in a pipeline or process system. The term is
used to describe a safe method of isolation from
a pressurised or hazardous medium to facilitate
breaking of containment. This terminology is
also utilised to identify the relative integrity of
temporary isolation systems. However, although
DBB is a universally used term to specify a level
of isolation, the definition of the term is by no
means universal.
The UK Health and Safety Executive guidance
document, ‘The Safe Isolation of Plant and
Equipment’, defines DBB as “an isolation method
consisting of an arrangement of two block valves
with a bleed valve located in between.”1
Testing and monitoring the effectiveness of
the isolation is specified in the guidance document
which states (Ref. Article 165), not must but should:
• “Prove the integrity of all isolation points of an
isolation scheme before proceeding with intrusive
work (unless your risk assessment has indicated that
the use of non-proved isolation is acceptable).
• Each part of the isolation should be proved
separately, e.g. prove each valve in a double block
and bleed scheme.
• Each part should be proved to the highest pressure
which can be expected within the system during
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 Figure 3. Seal test sequence.

• the work activity. Particular care is required when

there is a low differential pressure across valves
where sealing mechanism is activated by pressure.
• Where possible, each part of the isolation should
be proved in the direction of the expected
pressure differential.”
Many global operators have developed
their own guidance with regards to DBB which
is typically derived from the HSE guidance
document HSG 253.

Hot tap installed line plugging

STATS BISEP® offers pipeline operators a solution
using industry-leading technology for temporary
line plugging and is available from 3 - 56 in.
and pressures up to 153 bar. Achieved using
patented and DNV Type Approved technology,
the BISEP provides a fail-safe DBB isolation
deployed through a single hot tap penetration,
without the need for additional hot tapped
bleed or vent ports. The BISEP offers significant
safety advantages over traditional line stop
technologies, with the hydraulically activated
dual seals providing leak-tight isolation.
The dual seal isolation barrier is confirmed
once each seal is independently tested with
full pipeline pressure in the correct direction;
and the pressure between the seals is vented,
creating a zero-energy zone. The zero-energy
zone between the seals is monitored throughout
the workscope, confirming the isolation integrity
with zero leakage which increases worksite
safety.

Seal verification sequence

Once deployed into the pipeline, the BISEP is
hydraulically activated, compressing the plugging
Figure 4. 36 in. BISEP, fuel gas line decommissioning, Abu Dhabi, UAE. head which energises dual elastomer seals,

50 World Pipelines / MAY 2023

causing them to radially expand against the pipe wall. The hydraulic activation
allows the seals to be manipulated to improve performance when sealing in
pipes with issues such as pitting, ovality or weld seams, ensuring a leak-tight OUR BALL VALVES
seal.
As the seals are energised, the trapped pipeline content in the annulus GO BEYOND THIS
between the seals is compressed due to the seal compression reducing the
annulus volume. This increases the annulus pressure to higher than pipeline
DISPLAY
pressure, monitoring this pressure to prove no pressure loss is an initial
indication that the seals are isolating. The annulus pressure is continually

AND YOUR
monitored and the pipeline pressure inboard (section of the pipeline to be
isolated) is vented, generating a differential pressure across the plugging head.
Once inboard pressure is fully vented, the BISEP secondary seal is tested
in-situ to above the pipeline pressure in the correct direction. This proves
the integrity of the secondary seal. The annulus is then vented to a safe area EXPECTA-
and locked-in. This allows the primary seal to be tested to the full differential
pressure and in the direction of the pressure threat. The isolation is then
monitored for an extended period prior to issuing the isolation certificate and
TIONS!
allowing safe breaking of containment.

Fail-safe isolation
The BISEP provides a fail-safe isolation as the seals are activated and
maintained by two independent mechanisms; hydraulic activation and pressure
1/8’’ - 56 ‘‘
differential across the seals provided by the pipeline pressure. The differential
pressure maintains self-energisation of the seals, ensuring isolation integrity
independent of the hydraulic control circuit.
The BISEP launcher (housing) features integrated flanged ports to allow safe
depressurisation of the isolated pipeline. Flushing and purging of the isolated
section can be efficiently conducted without welding any extra fittings onto CLASS 2500
AND HIGHER
the line. In addition, once maintenance activities have been completed, the
BISEP seals can be used as a pressure boundary to perform a reinstatement
test of the newly repaired or replaced pipe section as the seals are designed
to resist back pressure.
The BISEP is the only hot tap installed isolation tool that satisfies the OIL, GAS,
design criteria for DNV Type Approval for Pipeline Isolation Plugs. The design HYDROGEN,
criteria satisfies the requirements for Pipeline Isolation Plugs to provide DISTRICT ENERGY
& VARIOUS
dual seal and isolation in accordance with Offshore Standards: DNV-OS-F101 APPLICATIONS
(Submarine Pipeline Systems) and recommended Practices: DNV-RP-F113
(Subsea Pipeline Repair) and is code compliant with ASME BPVC Section VIII,
Division 2.

Integrated bypass: maintaining production

The BISEP can be configured with an integrated bypass through the launcher,
which ensures no interruption to flow, maintaining production throughout the
maintenance activities. The BISEP is installed into the pipeline unset, allowing
deployment into a flowing pipeline, resulting in no interruption to production
and saving time onsite. This configuration includes many of the benefits of
the standard BISEP, however the addition of an integrated bypass reduces the
worksite area and number of fittings required, significantly reducing project
costs and timescales.
Pipeline hot tapping and line stopping are critical techniques used by
operators to ensure the safety and reliability of pipelines in the energy
industry. These techniques allow operators to perform necessary maintenance,
repairs, and modifications without interrupting the flow of the product,
minimising downtime and reducing environmental risks. However, these
techniques require highly skilled technicians and specialised equipment to
perform safely and efficiently, and failure to follow proper procedures or to
use appropriate equipment can result in accidents, injuries, or environmental
damage.

www.boehmer.de
 Energy transition
As the oil and gas industry transitions to more sustainable
energy, and investment in carbon capture and storage
(CCS) and hydrogen accelerates, there is a growing focus
on how existing pipeline infrastructure can be repurposed
for CO2 and hydrogen transportation. Therefore, the
requirement for isolation and intervention technology
to isolate these pipelines safely and efficiently for
maintenance or modification is increasingly important.
STATS DBB isolation tools can provide high integrity
isolation in traditional hydrocarbons as well as hydrogen
and high-pressure liquid CO2 pipelines.
STATS is the only company in the world with an
extensive track record of providing hot tapped isolation
of high-pressure CO2 pipelines, operating at up to 138 bar.
Isolating liquid CO2 pipelines has many challenges and
project success required the careful control of CO2 phase-
change during venting, and the appropriate selection
of steel and elastomer materials to accommodate CO2
service.

Reducing venting and

flaring
Pipeline operators face challenges
associated with eliminating
greenhouse gas (GHG) emissions
during intervention activities such
as hot tapping and line isolation
for mainline replacement and
facility upgrades. STATS’s inline
(Remote Tecno Plug®) and hot tap
installed isolation (BISEP) tools are
contributing to reducing carbon
emissions for their customers.
Using leak-tight, DBB pipeline
isolation technologies, localised
repair and maintenance worksites
can be safely isolated without the
need to depressurise large sections
of the pipeline, thereby avoiding
the need to discharge significant
quantities of GHGs into the
atmosphere. In the case of large
diameter gas pipelines, this can
prevent the potential discharge of
thousands or tens of thousands
of tons of methane emissions into
the atmosphere.

Innovation
STATS are committed to
incorporating sustainability into its
core activities to assess and measure
its social and environmental impact.
As the company strives to support
the industry move to a lower carbon
future, it will continue to innovate
FOR 40 YEARS, WE’VE BUILT and develop new technologies
FOR 40 YEARS, WE’VE BUILT to enable energy transition and
THEM RUGGED SO YOU CAN
support net-zero targets. Ultimately,
THEM RUGGED SO YOU CAN providing a scalable and sustainable
RELY ON THEM TO PERFORM
business with purpose, for the
RELY ON THEM TO PERFORM benefit of people and the planet.
Dairyland Electrical Industries is the world’s leading manufacturer of
solid-state decoupling
Dairyland Electrical products
Industries is for
thethe corrosion
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manufacturer of References
We’ve been making rugged and reliable products since 1983.
solid-state decoupling products for the corrosion protection industry. 1. The Safe Isolation of Plant and Equipment,
After
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Health & Safety Executive (2006).

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Learn more about our Always Rugged Promise:
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Girish Babu Nounchi and Jayaraj
Padayachiyar Govindan, Wood Plc,
and Shankar Mohan, Worley, explore
governing factors in the efficient
selection of pipeline material.

aterial selection plays a vital role for any industry, and there is no
exception for the oil and gas sector. In onshore pipelines
projects, pipeline material and its welding accounts for the
majority of the cost, whilst in natural gas pipelines it is usually
60% of the project allocated budget (CAPEX). Choosing the right pipeline
material with optimised grade therefore leads to enormous savings in project
capital cost. However, it’s very technically challenging, interesting, and sensitive
to select the pipeline material in view of techno commercial aspects; factors
such as fluid type, fluid composition, fluid velocity, sour or corrosive, presence
of solid particles, pipe size, design conditions, operating parameters, design
life, material properties, fabricability, severe environment conditions, material
availability, performance and their combination will have a significant
influence. While selecting materials, consideration should be given to their
safe design and reliable performance under the anticipated in-service
conditions over the lifetime of the component.

Process environment
Hydrocarbon fluids are majorly classified as crude oil, natural gas, gas
condensate, multiphase, liquid hydrocarbons, produced water, etc. Material
deterioration is quite common in its lifecycle due to direct contact between the
fluid and internal wall of the pipe in various conditions such as uninterrupted
fluid flow, fluid composition, improper periodical maintenance, differential
pressure, and velocity. The basic principles to avoid material deterioration are
creating a barrier between the internal wall of the pipe to fluid contact, or using
better resistant material against the fluid composition and/or injecting corrosion
inhibition in the fluid. Higher percentage of CO2, H2S, chlorides, sulphur, water
cut, organic acids, solid suspended particles and oxygen will cause damage, loss
of the material and ultimately reduces the material life.

53
 When CO2 in the fluid mixes with water it forms carbonic
acid, resulting in iron carbide scales at an elevated temperature.
The metal begins to corrode and will be enhanced when
oxygen and organic acids dissolve the protective iron carbide,
preventing further scale formation. Presence of bicarbonates
increases the alkalinity of the fluid and reduces the corrosivity.
Corrosion resistance alloys (CRAs) are considered immune to
this in most conditions, but some of the lower grade stainless
steel (SS) type 13Cr may suffer at higher temperatures and low
pH. The materials resistance to CO2 corrosion in the order
CS < CS with lining < SS 300 series < 22 Cr < 6Mo < GRP.
The primary concern with hydrogen sulphide (H2S) is
hydrogen attack on the metal which causes it to become
brittle. Fluids with high levels of H2S are termed ‘sour’ and
NACE defines the H2S levels above 0.05 psi of partial pressure
as a sour condition for gas phases. In aqueous phases,
above 10 ppm mass is considered sour. The hydrogen attack
mechanism is complex and caused by the absorption of atomic
hydrogen in steel, depending on certain conditions such as
pressure, temperature, and the pH value of the fluid.
Chlorides in the fluid attack the material through
de-passivation effect caused by chlorides ions, and is aggressive
on 300 series of austenitic steel. This chloride stress corrosion
is prompted by the temperature, chloride stress concentration
and residual stresses in the metal. It will be enhanced by the
presence of O2 and low pH. The chloride content shall not
exceed 50 ppm in water at any case during the hydrotesting.
High nickel alloys, nickel-iron (Inconel), nickel-iron-chromium
alloys are highly immune and resist this corrosion. The order of
resistance is 25Cr > 22 Cr > 6 Mo > SS 300 series.
Elemental sulphur is an extremely strong oxidant, and when
mixed with water forms sulphuric acid, reacting with carbon
and low alloy steels (CRA) to form sulphides. However, highly
alloyed nickel CRA’s such as Inconel (High PREN) are resistant to
sulphur attack.
Presence of solid suspended particles or sand in the fluid
will remove the metal layer based on the fluid flowrate, the
density and morphology of solids. Velocity range shall be
maintained to avoid deposits at the bottom of the pipe, and
at the same time flow rate shall not cause erosion to break
the corrosion inhibitor film in case of it’s injection in the fluid.
In general comparison the velocity range based on the pipe
material is non-metallic materials < CS < CRA. In certain fluids,
however, the velocity may be similar in CS and CRA materials
pipe.
The dissolved oxygen in the fluid (produced water)
oxidises the metal very quickly. HDPE lined CS can be used for
produced water, oil, multiphase, H2S (max 3 mol%), chlorides,
CO2 excepts wet and dry gas, aromatics, and acid services by
considering limitations of pressure and temperature. However,
the GRE pipe can be used even in dry gas and allows higher
limitation of H2S (max 7 mol%). For both materials, special
flow assurance studies recommend in case of solid deposits
> 10 g/m3 in the fluid to confirm no erosion effect. RTP have
similar robust advantages but limitations in size availability.
Internal coatings or linings are not an acceptable method to
mitigate cracking in sour service such as HIC and SSC, however
they may be used to mitigate general or localised corrosion.
54 World Pipelines / MAY 2023
Design conditions and operating parameters
The MAOP, MDMT, maximum and minimum operating
temperatures, tie-in temperature, and installation temperature
(soil temperature at 1 m burial depth of cover) are a few
parameters that greatly influence the pipeline size and material.
Flow assurance specialists provide the pipeline size options
based on volume flowrate, transient and hydraulics studies with
respect to the destination pressure requirement. However, the
selection of pipeline materials such as carbon steel (CS) API 5L
with optimised grade, non-metallic materials (RTP, RTRP, GRE,
HDPE), lined CS, CRA cladded steel, SS and DSS alloys are mainly
from the studies of corrosion management plans. In general,
CS API 5L, PSL-2 pipes up to grade X70 are used for non-sour
applications, and in case of sour services the grade is limited
to X65. For the required MAOP, installation and operating
temperatures, the minimum pipe wall thickness will significantly
reduce with respect to increase in the grade of material due to
higher SMYS, resulting in less tonnage cost. RTP and RTRP are
replacing the usage of CS flowlines (< 8 in.) for higher pressure
(3000 psi) and temperature (-33 to 82˚C) of multiphase lines
(untreated fluid) due to flexibility in installation and easily
operable – despite high initial investment and less design life
compared to CS (20 vs 25 years).
Material properties
The properties of material will vary with respect to the chemical
composition. The susceptibility of the material depends on the
temperature, loads, internal and external environment until it
reaches its threshold value. For CS PSL-2 pipes with thickness
≤ 25 mm, specification API-5L restricts maximum carbon
equivalent percentage (CEIIW = 0.43) for most of the grades with
a suggested percentage of each material element and pipe
forming. The mechanical tests such as tensile, CVN, DWT, bend,
guided bend, hardness and flattening with respect to seamless or
welded pipe are covered in API-5L specification and test pieces
are in accordance with ASTM A370.
For gas, two-phase gas/condensate lines and the liquids
which will convert to gas at near atmospheric temperature
require the pipe material to have sufficient inherent toughness
to resist fracture propagation. Two possible modes of fracture
exist i.e. brittle (cleavage) and ductile (shear). The CVN impact
test helps to know the resistance in the pipe body to ductile
fracture propagation. Even with fully ductile material it is
possible to have long propagating fractures which are due
to high pressure, low temperature (< -29˚C), decompression
character, SMYS, pipe size, wall thickness, pipe design factor,
backfill conditions, etc. Several empirical relationships have
been derived from full scale test with methane to predict
the propagation behaviour. For rich gas or two-phase lines
operating at higher pressures, those relationships are not
valid and may not be conservative. In certain cases, it may be
impossible to arrest a fracture by pipeline material selection
alone and an alternatively dedicated crack arrestor may be
required. Brittle fracture propagation can be avoided by
specifying a drop weight tear test (DWT) at a temperature
lower than the minimum design temperature, and selecting
a pipe material which will fail in a ductile manner. If the
manufacturer meets the minimum average absorbed value and
Untitled-5 1 27/11/2019 15:39
 shear area requirements, then no additional assessment tests
are required.
The hardness value for CS is restricted to 22 HRC by NACE
MR-0175. For the welded CS pipes in API 5L, hardness is limited
to 22 HRC for the internal surface of the pipe and 27 HRC
for the external surface of the pipe. PWHT method involves
tempering at temperatures high enough to reduce hardness
and relive residual welding stresses via high temperature stress
relaxation. ASME B31.8 recommends the PWHT if the thickness
is > 32 mm. The use of special chemistry controls allows the
company/contractors to perform welding without PWHT and be
reasonably sure that weld heat affect zones will be soft enough
to resist cracking which will be very useful for pipe where it is
often difficult to perform PWHT. Steels above a certain hardness
are susceptible to hydrogen induced cracking (HIC) and sulphide
stress cracking (SSC) belongs to hydrogen embrittlement, a
condition of low ductility in metals resulting from the absorption
of hydrogen. HIC occurs without influence of stress and SSC will
be influenced by stressed and strained conditions. Polythionic
acids (sulphur acids) will crack when stressed and sensitised
by the austenitic SS even at ambient temperatures. It causes
problems in steels with ultimate tensile strength > 90 ksi, and is
usually manifested by delayed, catastrophic, and brittle fractures
at tensile stresses well below the ultimate tensile strength of
material. Rolled products such as plates and welded pipe made
from plate or coil are at major risk of HIC due to the flattened
nature of sulphide inclusions, whilst seamless pipes and CRAs
are not susceptible to HIC. Austenitic SS and nickel-based alloys
are mostly susceptible to stress corrosion cracking (SCC) in the
presence of chlorides and H2S.
Non-metallic pipes (such as GRE, GRP, RTR, RTP, HDPE,
etc.) are limited mainly by pressure and not by SMYS like steel
pipe. This allows them to overcome high built-up pressures
sometimes during overflow or surge. The main properties,
such as resistance to creep, hydrostatic design basis, yield/
ultimate (burst) strengths, stress relaxation properties, modulus
of elasticity, compression strength, impact strength, density,
notch sensitivity, thermal properties (brittleness temperature and
melting point), permeation characteristics (fluid permeability and
blistering resistance), compatibility and aging (fluid compatibility,
aging tests, and weather resistance) shall be considered. Lesser
diameter of pipe can withstand the more pressure at established
temperature, and the pressure rating will be decreased by
increase in line size. If the maximum operating temperature of
the fluid is increased for a prolonged time, then the nominal
ultimate burst pressure, nominal ultimate tensile load and
nominal ultimate compressive load will decrease and there
will not be any change in nominal ultimate collapse pressure.
Aromatic content in hydrocarbon applications shall be limited to
maximum 50%.
External environment
The pipelines are affected by the external environment
such as buried or partially buried, culverts, water bodies,
sabkha, wadi, road crossings due to soil type/composition,
soil resistivity, continuous or intermediate wetting, external
surface temperature, seashore areas, arctic environments,
etc. The suitable external coating shall be preferred based
56 World Pipelines / MAY 2023
on the fluid temperature, soil type, and additionally cathodic
protection (CP) shall be provided for normal terrain conditions.
For special terrains, other precautionary measurements should
be implemented such as trench design, bedding, and cover
material. In arctic environments, insulation for the pipeline is a
requirement even if a tough material is used. UV protection is
required for non-metallic lines in above ground applications. CP
systems shall be provided for all metallic buried lines including
SS, even though it is externally coated.
Cost
Proper selection of materials will ensure operational reliability
and integrity throughout the design life of the pipeline
whilst keeping in mind the health and safety of personnel,
environmental protection, repairability, product/process
contamination (impact of corrosion rates), and optimised cost.
The use of corrosion resistant alloys and internally cladded
piping systems shall only be considered when other corrosion
mitigations, such as internal coating and corrosion inhibition,
cannot withstand the harsh service conditions. The use of solid
alloys instead of cladding may not be the most cost-effective
option, however, it is worthwhile to think in terms of lifecycle
costing, which may show a longer life and lower maintenance
cost despite high initial cost. The initial cost comparison with
respect to the CS is, CS < LTCS (1.15 times) < CS + epoxy/
PTFE line (1.5 times) < non metallics GRE & RTP (4 times) < SS
(4.2 times) < CRA (6 - 8 times) < DSS (13 times) < Cu Ni alloys
(> 15 times). The operating companies already have the history
of used material performance that helps to conduct detailed
studies of process and operating conditions before selection
of a new material. Such use shall be economically justified with
consideration to potential damage mechanisms. Detailed study
of flow conditions, corrosion mechanisms involved, and the
expected life of material is important before selecting a specific
metal for the application.
Conclusion
Historically, no single material has survived all types of problems
caused by various types of corrosion, since the material suitable
for SSC may fail due to fatigue. Another material which can resist
high temperature corrosion may fail due to pitting. Selecting a
suitable grade of SS, such as a low carbon variety or stabilised
grade, will avert intergranular corrosion or weld decays if welding
operations are involved. There is continuous development in
the materials by metallurgists to tackle the corrosion in the
hydrocarbon industry, but the primary consideration shall be
given to economically superior material with respect to the
design requirements and design life.
References:
1. API RP 5L: Specification for Line Pipe.
2. API SPEC 15HR: High-pressure Fiberglass Line Pipe.
3. API SPEC 15S: Spoolable Reinforced Plastic Line Pipe.
4. ASME B31.8: Gas Transmission and Distributing Piping Systems.
5. ASTM A 370: Mechanical Testing of Steel Products.
6. ISO-13623: Petroleum and Natural Gas Industries - Pipeline Transportation Systems.
7. ISO-15663: Petroleum and Natural Gas Industries - Lifecycle Costing.
8. NACE MR-0175 / ISO 15156: Petroleum and Natural Gas Industries - Materials for
Use in H2S-Containing Environments in Oil and Gas Production.
9. NOUNCHI, G. B., BAHUBALI C., ‘Many layers to RTP’, World Pipelines, (November
2021), pp. 51 - 55.
I
mproving competitiveness and environmental footprint as well
as keeping everyone safe during construction activities are the
main challenges for the oil and gas industry. With this in mind,
Sicim is continuing to invest in research and development
(R&D) in order to innovate its equipment and practices of
constructing onshore pipelines and plants.
Sicim’s continuous strive for excellence has been recognised
with different awards by IPLOCA. During the last three years, the
company was awarded a total of six prizes in different domains
such as health and safety, environmental, new technologies,
and excellence in project execution. The following is a brief
description of the main solutions implemented.
Flying washing basket
To ensure a perfect cleaning of all heavy equipment in safe
conditions, Sicim developed the flying washing basket. This
system is composed of a suitable crane with remote control and a
dedicated basket to host the washing operator. The flying washing
basket allows the operator to perform a 360° flight all around the
equipment, cleaning every part with ease.
Leonardo Gravina, General Manager, SICIM, Italy, introduces machinery that
minimises cost, machine downtime, and manual handling.
Figure 1. Sur de Texas
(onshore) pipeline project
landfall platform.
The main advantages are the elimination of manual handling
hazards, the mitigation of the hazards associated with working
at height, the elimination of slip and trip hazards, and the
improvement of housekeeping.
Oil and lubricant saving distribution system
Engine and hydraulic system oil and lubricants change
operations are part of standard maintenance procedures.
With the aim to improve this process, Sicim implemented a
controlled oil and lubricants distribution system in its Mexican
facilities.
This system consists of refilling tanks located in a separate
area to minimise HSE risks. Through pumps, the oil and
lubricants are then distributed to different workstations via
a system of pipes. Single service points are equipped with
flow meters to monitor and measure the quantity of oil and
lubricants used in real-time. This allows for the optimisation
of consumption as well as minimised cost, machine downtime,
and manual handling. This also avoids leaks during refuelling,
thus keeps workstations clean.
57
 Sur de Texas pipeline project
Between 2017 and 2018, Sicim executed the Sur de Texas (onshore)
pipeline project in the region of Altamira, Mexico. The scope
of work entailed three components: landfall execution, landfall
support and pipeline. The project was executed on an EPC basis,
including permit application. The pipeline diameter was 42 in., X70
with wall thickness from 23.7 - 45.52 mm.
The execution plan was largely based on unconventional
construction techniques: temporary platforms to support the
landfall construction (north), 4 double line HDD crossings, tunnel
crossing (landfall north), 56 in. direct pipe installation (landfall
south), docks and river crossings, and very little conventional pipe
laying works. Pipes were installed in flooded areas and across the
lagoons and coastal wetlands.
Landfalls required the design and construction of solid
embankments importing soil from an existing quarry located
7 km from the project area. To minimise the impact on the
local community, a specific traffic management plan had to be
implemented. From an environmental point of view, Sicim had to
re-engineer a crossing solution (HDD and direct pipe) to consider
problematic geological conditions and restriction of the working
strips to preserve the unique flora and fauna richness of the area –
the mangroves.
The main project achievements were: timely completion
of all project milestones, 1 million worked manhours, 0 LTIs,
and a stunning ‘below zero’ impact on the mangroves – 100%
preservation of existing forest and +33% new mangrove
reforestation.
Airborne and self-assembly excavator
The services connected with the operation and maintenance
of the Camisea Pipeline in Peru require proper solutions for
their critical challenges, and namely the capability to mobilise
emergency crews in a very short timeframe to extremely remote
areas that require equipment able to be transported by helicopter
and assembled onsite without the assistance of auxiliary systems.
To cope with these challenges, Sicim developed a self-
assembling excavator with the following features:
) Capability to be disassembled in elements not heavier than
3.9 t (max-lifting-capacity of the helicopter).
Figure 2. Containerisable multi-purpose tracked transporters
(EPE smartcarriers).
58 World Pipelines / MAY 2023
) Reassembling to be manually performed using specific devices
already attached to the excavator.
) Rapidity of assembling/disassembling (less than 2 hours and
30 minutes).
The airborne and self-assembling excavator meets all safety
requirements and the latest engine emission applicable standards.
Safe choker belt
The choker belt is a special lifting gear designed to lift a single
pipe. During the years, Sicim experienced several accidents related
to hand or finger crushes. In order to reduce the risk of injuries
during pipe lifting operations, Sicim implemented a specific
modification of the ‘industry standard’ choker belt based on the
following:
) Installation of a carter that covers all the rotating parts,
avoiding any shearing.
) Application of removable handles to allow the slinger to
secure the lower part to its holder without putting fingers
between the belt and pipe.
Sicim initially started to use the new ‘safe choker belt’ on a
56 in. pipeline project to gradually extend its use to all pipe sizes
up to 60 in.
When it comes to the dramatic improvement in safety in
relation to entrapments/shears, with zero accidents recorded after
implementation, it was also noticed a drastic reduction in the time
connected with the overall pipe handling operations.
Personnel detection tool
The safety of workers operating on the ground near live heavy
machinery is vital. Sicim decided to equip its heavy equipment
(pipelayers and excavators) with a proximity visual/audible
detection warning and alert system to reduce the risk of impacting
pedestrian workers when working in proximity.
The selected proximity warning system is called personnel
detection tool (PDT) and is designed for personnel and object
detection. Frequency modulated continuous wave (FMCW) radar
detects moving and stationary objects, providing the operators
with a suitable time frame to avoid collisions. The sensors
provide active object detection in heavy equipment blind spots,
minimising false alarms.
The strive for continuous excellency
The continuous strive for better and safer equipment has
allowed Sicim to design its types of machinery with quick-
detachable parts to allow easier transportation in containers
(containerisation method). Among the types of equipment that
were redesigned in accordance with this concept, there are
pipelayers, multipurpose transporters, pipe carriers, pipe welders,
and bending machines.
Finally, to keep control of this fleet, Sicim has introduced the
use of the MasterLog System which, through web server software,
has the purpose of ensuring the acquisition and telemetry of
functional parameters and other data generated by vehicles,
machinery, and equipment that are operating remotely.
Keep updated

Keep up-to-date
with us to hear the
latest pipeline news

For more news visit:

www.worldpipelines.com
60
 The recipients of the 2023 John Tiratsoo Award for Young
Achievement are Cassandra K. Moody and Sarah Newton.
Senior Editor, Elizabeth Corner, gets to know the winners.

Cassandra K. Moody, M.S., P.E, President and
Principal Engineer, Time For Change, LLC.
Elizabeth Corner: Congraulations Cassandra! What are your
thoughts upon winning the award?
Cassandra K. Moody: I’m very honoured to receive the 2023
John Tratsoo Award for Young Achievement at PPIM 2023.
There are so many people in the pipeline industry to thank for
guidance and encouragement along the way. I am excited to
continue encouraging the next generation of pipeline thought
leaders as they are entrusted with the duty of care for this great
industry transporting safe and reliable energy to the world!
EC: What would you say has been your career highlight so far?
CK: During my career thus far, I’ve gained a broad perspective
of experience on projects spanning the lifecycle of pipeline
projects, including many deep-dives in pipeline and facility
integrity management initiatives as an operator, independent
consultant, and expert witness. The highlight of my career
has been noticing the changes in the industry since I’ve been
working, namely being active in the National Academies
of Science sponsored committee to study and make
recommendations for valve automation to the National
Transportation Research Board for PHMSA and Congress.

61

Figure 1. Cassandra K. Moody.
EC: How would you describe your career path?
KC: It’s definitely been non-linear. I actually thought I wanted
to be in the alternative energy space when I started (I originally
wanted to be a doctor). And then when I made my way to
engineering I was thinking alternative energy, but at the time
the Obama incentives ran out, so I found myself in Houston,
and oil and gas is prevalent here. I got my job on a golf course
actually! I was talking to the President of a pipeline company,
he’s a very good golfer, we were at the tee box at the 18th hole
and our drives were very even. We went up to the approach
shot, and I had a hybrid and he had an iron (so he wasn’t going
for the green), and he looked at me and asked “you’re going
for it?” and I said “absolutely, if you don’t go for it you’re never
going to make it”, and he said “you need to come in on Monday
for an interview”. So it all just serendipitously happened after
that. Since then, I worked for a corporate oil and gas company
for eight and a half years and then decided I wanted to help
more than one pipeline operator so I started my own pipeline
consultancy. This is not what I thought I would be doing when
I would grow up, but I wouldn’t have it any other way, and it’s
really neat to have the opportunity to help young engineers and
female engineers kind of make their own way and their own
career paths in the industry.
EC: Who are your mentors or role models in the pipeline industry?
CK: Pat Veith, Shawn Laughlin, Chris Yoxall, Michael Lopez, Rusty
Belflower, Chris Alexander, and Tara Podnar McMahan.
EC: What is your message to other young pipeline professionals?
What makes this industry rewarding and attractive?
KC: The pipeline industry has been personally rewarding to me
in terms of opportunities to gain experience and expand my
responsibilities. I was selected to be ‘Miss Piggy’, the person
responsible for cleaning and inspection pigging at my company
because I was ‘young and good with technology’. Being willing
to leverage technology to improve analysis and work process
efficiencies has benefited me during my career. Additionally,
many opportunities to better the industry are present to attract
62 World Pipelines / MAY 2023
other young professionals to develop and seek out better ways
to safely operate pipelines.
EC: Do you feel like you make a difference in your job?
KC: I hope so. If not for my girls/children inspiring them to be
whoever they want to be, then hopefully to make opportunities
for others in the industry, and to give those who might not have
the loudest voice in the room a seat at the table.
EC: Are there any expectations you had about this career path
that you have found differed from reality, in both a good or bad
way?
KC: It depends. I mentioned I was really interested in alternatives
when I started, and coincidentally I was at a conference
yesterday where they were talking about alternative fuels and
renewables, and so it’s kind of coming full circle. But I do still
think there’s definitely a place for traditional oil and gas, and
those people who have been in the industry for a long time
have lots of knowledge. I really think that’s where the key is:
it’s getting that knowledge exchange from those with lots
of experience. Not just in terms of years of experience, but
experience with unique projects and different perspectives,
and really capitalising on that information and sharing it across
the industry. I do think the industry as a whole is collaborative
and does do well with sharing lessons learned. Because really,
when there’s an incident from one pipeline operator, it affects
everybody, with public perception. So I really like to see the
collaboration and working together and that knowledge sharing
and knowledge transfer, not just from the young or from the old
generations to the young generations, but in terms of complex
projects and experiences.
EC: What skills are the most crucial to succeeding in this career?
What type of person do you need to be?
KC: I think you need to be a very nimble and flexible person
who is very adaptable to change. That’s actually what my
company, Time For Change, is named after: it’s the ability to
adapt, whatever challenges you face. And as engineers, I think
most of us are really good problem solvers. But some engineers
seem to be solving the same problem over and over and not
looking outside of the box for new solutions to the problems
that that we all face.
EC: What the best bit of advice you have for someone looking
to move into this area?
KC: I would find a mentor. I am a huge proponent of mentors
to help with knowledge sharing and transfer. Having a formal
relationship where you can have a safe space to share your
experiences, ask for feedback, accept constructive criticism
and have have somebody support you in driving change and
progressing your career is invaluable.
EC: And your hopes for the future?
KC: In the future, I aim to personally grow my company, Time For
Change Engineering Consulting, to serve the pipeline industry in
finding ways to safely optimise ROI (Return on Integrity), while
creating opportunities for young persons and women in science,
technology, engineering, and mathematics through my company’s
internship programme and other industry initiatives.
 Sarah Newton, CambioTM Product Lead and
Senior Geological Engineer, BGC Engineering
Inc.
Elizabeth Corner: Congraulations Sarah! What are your thoughts
upon winning the award?
Sarah Newton: I’m grateful to have been nominated and pleased
to have been awarded. Grateful to have been able to work
with such incredible teammates on this work (BGC engineers,
software developers, client partners) and pleased to have been
able to contribute to risk reduction in the pipeline industry.

EC: What would you say has been your career highlight so far?
SN: By far the highlight of my career has been to realise that
our work has had measurable impacts on pipeline geohazard
failure rates. We estimate that our methods have reduced our
clients’ pipeline geohazard failures by 80% compared to industry
average failure rates. This is a statistic that we’ve been tracking
for the past seven years on nearly 500 000 km of pipelines. I’ve
also enjoyed partnering with client pipeline integrity teams and Figure 2. Sarah Newton.
working with a great, diverse team at BGC. Not to mention
the opportunity to conduct field work in remote and beautiful the road map for the product. I work with the designers, product
landscapes (including the Peruvian Amazon, Alaska, Australian owners and software developers to bring the vision into reality.
Pilbara, and much of Canada).
EC: What does a typical day in the role look like? Is there a typical
EC: Could you briefly describe your current role? day?
SN: Right now I’m the Cambio Product Lead. Cambio is the SN: I spend a lot of time connecting with different people. I
geohazard risk management software that we’ve developed for the talk to our pipeline clients to understand what their needs are
pipeline industry and other industries, and in that role I establish for the software. I meet our internal team, improve our designs

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 and build out new features, and work through geotechnical and

ADVERTISERS’ geohazard type problems. I also still do a decent amount of

technical consulting work as well. It’s a very connected role – it’s

DIRECTORY
a lot of fun in that respect!

EC: And what qualities do you think you need to succeed in the
Advertiser Page
role? What do you think makes you good at it?
ABC 55 SN: I think curiosity is the cornerstone; being interested in
other people’s problems and challenges, and trying to help
AGRU 33 them figure out how best to address them. Working to try to
overcome what it is that they’re struggling with, either in the
more mundane workflows or if they’re really trying to come at
AMPP 19
something that hasn’t been tackled in the science yet. So we
spent a lot of time doing research and development, thinking
Böhmer GmbH 51
about how to improve the state of the practice and how to
share what we learn with others. There’s a big push to get our
CRC-Evans 4, bound insert
research out there in the world and to publish what we uncover
so others can benefit from the work that we do.
Curtiss-Wright EST Group OBC
EC: Can you tell me something that the readers might not know
Dairyland 52 about your company, or about the product?
SN: The main thing is just how effective it’s been. We’ve been
DeFelsko 21 targeting this goal of a global reduction of geohazard failure risk
in the pipeline sector. Our target has been to to take that down
DENSO GmbH 49 by 10% from 2015 rates by 2025 and I’m pretty confident we’re
going to meet this goal.
Denso Inc. 7
EC: Who are your mentors or role models in the pipeline industry?
Girard Industries 45
SN: My main two role models in the pipeline industry have been
Gerry Ferris and Michael Porter – both are exceptional leaders,
mentors, and innovators in the field of pipeline geohazard risk
Global Hydrogen Review IBC
management at BGC Engineering Inc. who have supported me
throughout my career.
Horizontal Drilling International 11

EC: What is your message to other young pipeline professionals?

Laurini 41 What makes this industry rewarding and attractive?
SN: There are lots of real-world problems to work on, with the
Maats 39 potential to make a measurable impact. There is the opportunity
to use new technologies – especially in the field of remote
Midwestern 45 sensing – giving us the ability to scale assessment across vast
geographies and to bring novel solutions to longstanding
Palladian Energy Podcast 2 problems. And the importance of solving of the problems
is compelling – people and the environment can be badly
Pigs Unlimited International LLC 19 impacted, so it’s imperative we do this right.

Pipeline Inspection Company 55 EC: What are your hopes for the future?
SN: Expand our methods to further operations globally,
incorporate new datasets and technologies, build something
Propipe 12
useful, used by many people. Use what we’ve learned supporting
pipeline operators and apply the methods in other sectors to
ROSEN IFC
improve overall climate change resiliency for infrastructure and
communities. And maybe do some field work in Italy!
Seal For Life Industries bound insert, 25

EC: Do you feel like you make a difference in your job?

Stark Solutions 15 SN: Totally. I mean it’s incredibly motivating to be part of
something that feels like it has real-world impact and actually
STATS Group OFC, 26 move the needle on something like this.

WeldFit 29

World Pipelines 59, 63

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