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GP 43-32 - Pipe Handling Logistics For Pipelines
GP 43-32 - Pipe Handling Logistics For Pipelines
GP 43-32
Applicability Group
Date 30 March 2004
GP 43-32
BP GROUP
ENGINEERING TECHNICAL PRACTICES
30 March 2004 GP 43-32
Guidance on Practice for Pipe Handling Logistics for Pipelines
Foreword
This is the first issue of BP Engineering Technical Practice (ETP) GP 43-32. This document will be
updated on a periodic basis to include new BP experiences and any additional pipe handling
logistics’ mandatory requirements. This is not a standalone document; it must be used in
accordance with the requirements of ETP document PR 43: Status of ETP Pipeline Documents. In
addition to the requirements for this document, those of relevant BP group standards also have to
be fulfilled.
Copyright © 2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
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Table of Contents
Page
Foreword .............................................................................................................................................. 2
Introduction .......................................................................................................................................... 4
1. Scope.......................................................................................................................................... 5
2. Normative references ................................................................................................................. 5
3. General guidance ....................................................................................................................... 5
3.1. General............................................................................................................................ 5
3.2. The pipe supply chain ..................................................................................................... 6
3.3. Pipe tracking.................................................................................................................... 6
3.4. Supply chain simulation modelling.................................................................................. 7
3.5. Examples of simulation modelling .................................................................................. 7
3.6. Pipe handling and lifting .................................................................................................. 7
3.7. Pipe transportation .......................................................................................................... 9
3.8. Pipe storage .................................................................................................................. 11
Bibliography ....................................................................................................................................... 13
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Introduction
This document provides access to the repository of BP experience in pipe handling logistics for
pipelines. This includes items such as specifications, examples, lessons learnt, success stories, and
failures. Mandatory pipe handling logistics requirements are contained in the body of this document.
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1. Scope
a. This Guidance on Practice is concerned with the supply of pipe, including induction bends,
from the pipe mill to the pipeline construction site. It covers the following activities
associated with pipeline construction:
1. Modelling and optimisation of the pipe supply chain from pipe mill to pipeline work
site.
2. Pipe handling using cranes and other lifting devices at each stage in the supply chain.
3. Pipe transportation by road, rail and sea.
4. Pipe storage.
b. The supply, handling, transportation, and storage of linepipe and other materials required
for pipeline construction operations present considerable risks to pipeline projects. The
movement of very large numbers of pipe joints from mill to coating yard, pipe dump and
pipeline right-of-way or laybarge, is a very significant challenge in terms of logistics,
safety, and security. The pipeline construction industry is obviously highly experienced in
these areas, but there are still opportunities for improvement, particularly as pipelines are
being constructed in ever more remote locations.
c. This document is included in the ETP document set as a link to the repository of BP
experience as well as internal BP and external reference documents on the issues outlined
above.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. The latest edition of the normative document
referred to shall apply.
BP
GP 43-31 Guidance on Practice for Linepipe Procurement.
3. General guidance
3.1. General
This Guidance on Practice shall be applied to all BP projects. It shall be read by the Project
Management Team during the Select or Define stage of a project and applied during the writing
of invitations to tender for construction contracts and the supply of linepipe.
Clause 3.2 below describes the activities involved in the pipeline supply chain.
Clauses 3.4 and 3.5 below describe how the supply chain operation can be
optimised using a simulation model.
Clauses 3.6, 3.7, and 3.8 below give an outline of the requirements for pipe
handling, transportation, and storage. References to the standards and practices are
given in Clause 3 below.
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1. Ensure that all activities are properly controlled and that an audit trail is in place from
steel making through to pipe forming, coating/bending, transportation, storage and on
through all construction activities.
2. Be capable of identifying and tracking unique pipe numbers and should ideally be
part of a pipe tracking data base that will continue to track pipe through construction
and testing activities.
b. A logistics expert with experience in the country or area of construction should join the
Project at an early stage.
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These identify the associated risks and management controls to be applied in order
to avoid injury to personnel and damage to the pipe and coating.
e. Lifting plans shall be generated for lifts.
f. Persons employed in the handling of pipe, whether by manual or mechanical means, shall
be instructed in the relevant lifting plans and procedures and shall be trained in the use of
the lifting equipment employed.
g. If personnel, in addition to the lifting equipment operator, are required to assist with the
lifting operation, lift plans and procedures shall be put in place such that no personnel are
present in the lifting area when pipe is being lifted.
h. Pipe of different diameters shall not be lifted together.
Information including pipe diameter, weight per metre (foot), length to be lifted and
whether coated or non-coated is required for correct selection of the lifting
equipment. (This information would also be included in the task risk assessment
procedure)
i. Pipe of 150 mm (6 inch) diameter and greater shall be handled with lifting devices such as
fixed or mobile cranes, using vacuum lifting equipment or slinging methods agreed in the
job specific lifting plan.
j. If hooks are used these shall be padded on the lifting face to avoid damage to the pipe
ends.
Pipe handling at intermediate shipment locations such as ports and temporary
storage sites poses real HSSE and pipe damage risk issues. Such exposure warrants
extra attention.
Vacuum lifting is the preferred method of lifting pipe and is suitable for use with
cranes, side booms or excavators. Vacuum lifting is very effective in combination
with an appropriate excavator and the combination of vacuum unit with hydraulic
rotator mounted on an excavator allows the unit operator to handle pipe without the
need for additional personnel in areas around the pipe, thus reducing risk and cost.
Vacuum lifting was successfully used on construction of the AGT pipelines and the
In Salah Gas pipeline. This linked photograph shows a side boom crane with
vacuum unit attached, lifting a double joint of 48 in pipe. The photograph also
shows some key advantages of vacuum lifting such as personnel positioned well
away from the pipe and the pipe being lifted centrally.
Although vacuum lifting is suitable for handling pipe at all stages between the pipe
mill and the pipeline right-of-way, either as single or double joints, it is not
currently suitable for lowering a welded pipe string into the trench.
k. Safety devices shall be used with vacuum lifting equipment to reduce the risk of release of
the vacuum while the equipment is under load.
l. If the vacuum pump fails, warnings shall be activated and vacuum maintained at the lifting
head for sufficient time for the operator to safely lower the pipe.
m. For a pipe with a rough external surface such as some concrete coatings, a special vacuum
seal or an alternative lifting system should be used. In such cases trials shall be performed
to prove the system’s effectiveness.
The performance of vacuum lifting systems depends on the condition of the pipe
surface and the type of seal used.
Three failures occurred on AGT Pipelines Project when using vacuum lifting.
• Bolts over-tightened while attaching hydraulic rotator.
• Wood chips from dunnage accumulated on pipe resulting in vacuum release.
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• Vacuum skirts became worn due to crane operator placing/ sliding unit onto
pipe without using hydraulic rotator.
Another incident involving a crane lifting pipe with a vacuum unit resulted in pipe
being dropped due to operator error. This incident is described in an IPLOCA safety
alert.
3.7.1. General
a. Pipe may be transported by road, rail, or sea depending on the pipe mill and project
locations.
All methods of transport present a safety risk to personnel as well as a risk of
damage to the pipe and coating or even loss of the pipe.
b. Pipe shall be transported such that there is no harm to people and no damage to the pipe.
c. Pipe shall be secured during transportation so the load does not move and the pipes packed
with separators/dunnage so that they cannot impact each other or any other hard surface.
Damage to pipe can be caused in several ways, including:
• Pipe ends damaged during loading and unloading.
• Pipe ends damaged by longitudinal movement.
• Abrasion caused by rubbing against adjacent pipes or a protrusion such as a
weld.
• Longitudinal fatigue cracks caused by static and cyclic stresses due to
combinations of vertical movement, vertical loads and abrasion damage.
For future reference, studies are currently underway into the viability of alternative
means of transporting pipeline materials, including hovercraft and airships.
d. Dunnage should not include sawdust-filled bags if pipes are to be lifted with vacuum units.
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In Salah Gas Project also had to consider the effects of static electricity, generated
by wind blown sand and by pipe being stored close to overhead power lines. It was
found difficult to earth (ground) the pipe stack with the coating systems used, so they
had to rely on warning signs.
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Bibliography
The follow reference documents are available for use in planning logistics for pipe handling:
BP
[1] GP 43-03 Guidance on Practice for Pipeline Project Execution.
[3] Paper on Pipeline Delivery and Construction Logistics Modelling by Lanner Group.
[6] BP Bombax Pipeline Project Specification SS 029: Line Pipe, Material Handling and Transportation.
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