Pipeline news and updates from Germany, Italy, Gulf of Mexico, and USA.
KEYNOTE: UK AND EUROPE REPORT
10. Europe's shaken midstream sector
World Pipelines Contributing Editor Gordon Cope analyses midstream developments throughout Europe, with a particular focus on the uncertain future of Europe's hydrogen economy.
PIPELINE CONSTRUCTION
16. Fit for the future
Jonny Thorns, Construction Project Director, National Gas, and Henry Lewis, Contracts Manager, United Living Infrastructure Services.
23. The future of pipeline installation
John Barbera, Barbco.
CATHODIC PROTECTION
27. Optimising cathodic protection
Article courtesy of Dairyland Electrical Industries.
DAMAGE AND DEFECT ASSESSMENT
33. Catalysts for innovation and sustainability
Chris Cantrell, Senior Managing Director, Standards and Engineering Services, ASME.
PIPELINE SERVICES AND MAINTENANCE
37. Pushing lifespan limits
Adrian Gamman, Norclamp.
PIPELAYING AND VESSELS
42. Pipelay reimagined Andrew Wallace, VP Offshore Solutions, Miros.
49. Perfect pre-commissioning for subsea umbilicals Article courtesy of EnerMech.
55. A critical contingency for offshore pipelines Geronimo Rodriguez, Oil States.
INTEGRITY AND INSPECTION
57. Sealing success with advanced metallic enclosures Emanuelle Mayor, Petroseal.
EMISSIONS
61. Fuelling innovation in methane detection Mark Naples, Managing Director, Umicore Coating Services.
The Best Liquid Epoxy Solutions For Pipelines
Combining industry-leading abrasion resistance with unmatched flexibility, our range of epoxy solutions are built tough, easy to apply and designed to last.
Whether its HDD or field joint coatings, we’ve got the solution.
The Toughest HDD Coating on the Market HBE - The Best Performing Field Joint Coating
EDITOR’S COMMENT
CONTACT INFORMATION
MANAGING EDITOR
James Little james.little@worldpipelines.com
EDITORIAL ASSISTANT
Alfred Hamer alfred.hamer@worldpipelines.com
SALES DIRECTOR
Rod Hardy rod.hardy@worldpipelines.com
SALES MANAGER
Chris Lethbridge chris.lethbridge@worldpipelines.com
Annual subscription £60 UK including postage/£75 overseas (postage airmail). Special two year discounted rate: £96 UK including postage/£120 overseas (postage airmail). Claims for non receipt of issues must be made within three months of publication of the issue or they will not be honoured without charge.
Applicable only to USA & Canada: World Pipelines (ISSN No: 1472-7390, USPS No: 020-988) is published monthly by Palladian Publications Ltd, GBR and distributed in the USA by Asendia USA, 701C Ashland Avenue, Folcroft, PA 19032. Periodicals postage paid at Philadelphia, PA & additional mailing offices. POSTMASTER: send address changes to World Pipelines, 701C Ashland Avenue, Folcroft, PA 19032.
In US President Donald Trump’s lengthy first address to Congress since returning to the White House, he championed American energy independence, and made a point of mentioning an Alaskan energy project that has been on the drafting table for some time.
Alaska LNG is a US$44 billion project, proposed by the Alaska Gasline Development Corporation (AGDC), and designed to send natural gas from the North Slope 800 miles south to Nikiski, where it would be cooled to a liquid state and exported, most likely to America’s Pacific allies.
Trump signed an executive order on his first day back in office to “unleash Alaska’s extraordinary resource potential”, and his Congress address signalled full support from the new administration, but the non-contiguous state proves to be a challenging place in which to develop new oil and gas projects. High operational costs, combined with regulatory uncertainty and the lingering threat of litigation from environmental groups, has historically deterred investment. Trump’s renewed support for developing oil and gas in the state is a move forwards, but it’s not enough.
Representatives for the project have been seeking support from international investors: most recently, Alaska Governor Mike Dunleavy and energy officials visited South Korea to discuss energy cooperation. The delegation included officials from the Glenfarne Group, a partner in the project. Trump has named Japan, South Korea and other nations as potential investors in the pipeline project, citing trillions of dollars up for grabs. In February, Trump announced a JV for the project with Japanese Prime Minister Shigeru Ishiba, and similar preliminary agreements exist with China and Taiwan.
A gas sales precedent exists with Great Bear Pantheon (an Alaska-based exploration company and wholly owned subsidiary of Pantheon Resources Plc) to buy up to 500 million ft3/d of gas from the project, but no binding agreements are in place.
Late in 2024, the project secured a US$50 million pledge from state developers, which will go some way towards lowering the risk for any investing party coming onboard to develop and build. America’s Asian allies may currently be more amenable to investing in getting the project built – despite a Pacific-wide shift towards renewable energy – as a way of fending off potential tariff threats from the US.
In our upcoming Americas issue, published in July, David Hobbs and Pat Galvin from Pantheon Resources Plc discuss efforts to unlock North Slope gas, and why the recent discovery of low-CO2 natural gas is now seen as a game changer for the Alaska LNG Project. The article describes how phasing the project will be the key to getting it built: “The full Alaska LNG export project plan includes three major infrastructure components: the 800 mile 42 in. pipeline across Alaska, a large gas conditioning plant on the North Slope to remove the relatively large amounts of CO2 contained in the gas produced at Prudhoe Bay, and the 20 million tpy tidewater liquefaction plant in Nikiski, Alaska [...]The value in constructing Phase 1 of the Alaska LNG project first is that the part of the project considered the riskiest to outside investors, the pipeline, is seen by in-state stakeholders looking to avoid an energy shortfall as the most valuable part of the project. This phase satisfies Alaska’s long-term energy security and lowers the risk profiles for the conditioning plant and liquefaction facility.”
Perhaps the best approach is to align the project’s phasing with both market appetite and in-state energy needs; delivering early value while building momentum and investor confidence for the full buildout. This strategy could prove pivotal in turning long-standing ambitions into reality.
SENIOR EDITOR Elizabeth Corner elizabeth.corner@worldpipelines.com
Still pioneers.
WORLD NEWS
Germany: GASCADE announces 400 km of natural gas pipelines to be converted for hydrogen in 2025
GASCADE Gastransport GmbH has announced that the initial filling of the first pipeline section within the ‘Flow – making hydrogen happen’ programme has been successfully started.
As part of this project, approximately 400 km of an existing natural gas pipeline with a diameter of 1.4 m will be gradually converted to transport hydrogen by the end of 2025.
This is the first project of its kind in the world. It will create a substantial part of a north-south highway for hydrogen transportation. “With this conversion, GASCADE is not only demonstrating its technological expertise and innovative knowhow but also sending a strong signal for the hydrogen economy. We are proud to be starting the commissioning of the first large-scale hydrogen pipelines in Germany now. This provides planning certainty for the market ramp-up of the value chain worldwide,” said Managing Director Christoph von dem Bussche. “The ‘Flow – making hydrogen happen’
programme is a central component of GASCADE’s strategy of making existing infrastructure available for the transport of hydrogen quickly and cost-effectively. Converting the pipelines creates the basis for a safe and efficient hydrogen supply in Germany,” explained Managing Director Ulrich Benterbusch.
By initially filling the first section of ‘Flow – making hydrogen happen’, GASCADE says it is doing pioneering work in the hydrogen sector and making energy history. The pipeline conversion aims to contribute to reducing CO2 emissions and promoting renewable energies.
“Our vision is to create a sustainable and climate-friendly energy future. We are setting a new standard in the industry and showing that we are successfully taking the necessary steps. I would like to express my particular gratitude to all colleagues involved for their great commitment,” added Flow Programme Manager Dirk Flandrich.
Italy: H2SITE and SNAM collaborate on hydrogen separation project promoted by ARERA
H2SITE has announced its collaboration with SNAM, one of Europe’s key energy infrastructure operators, to develop a project focused on the separation of hydrogen and natural gas mixtures.
As part of this initiative, H2SITE has designed a Pd-alloy membrane separator, capable of extracting hydrogen from 2% to 10% concentrations. Once built, this unit will represent the largest installation of its kind, capable of separating hydrogen at low concentrations while achieving high recovery rates.
The Pd-alloy membrane separator allows the recovered hydrogen to be used directly in fuel cells, hydrogen-to-power solutions such as gas turbines and engines, and hightemperature ovens. At the same time, it minimises the hydrogen content in the remaining natural gas, preventing unwanted alterations in its composition. This is particularly important for industrial consumers whose processes cannot tolerate significant hydrogen concentrations and ensures compliance with local regulations in the gas grid. H2SITE membranes will operate at pressures above 50 bar, an
industrial scale proof point relevant for large-scale hydrogen storage applications, such as salt caverns or depleted reservoirs. H2SITE’s hydrogen separation technology has already been successfully validated with gas distribution grid operators, demonstrating the compatibility of existing distribution infrastructures with the transport of hydrogennatural gas mixtures. It has also proven the efficient separation of hydrogen from the natural gas stream, enabling both the production of high-purity hydrogen and the removal of hydrogen from natural gas while maintaining to clean streams.
This initiative marks a significant step towards decarbonising the energy sector, leveraging existing infrastructure, such as pipelines, and integrating new ones, such as salt caverns etc. to facilitate hydrogen integration as a clean and renewable energy source. Through advanced separation solutions, H2SITE and SNAM are contributing to making hydrogen a key resource for the future of sustainable energy.
EU proposes gas storage regulation extension until 2027
The European Commission has proposed to extend the current gas storage regulation until the end of 2027, aiming to secure energy supplies and stabilise the European gas market amidst geopolitical tensions and market volatility.
The extension of the regulation (COM/2025/99) is seen as a crucial step in preparing the EU for upcoming winter seasons in a coordinated manner.
Adopted in June 2022 during the energy crisis, the gas storage regulation has been instrumental in ensuring sufficient gas supplies for EU homes and businesses.
A recent report highlights the effectiveness of gas storage regulation (COM/2025/98) in securing supply and mitigating the risk of disruptions, contributing to the EU’s efforts to reduce energy dependence on Russia.
With a 90% filling target established, the EU has consistently exceeded this goal before each heating season. The EU gas storage facilities, which provide 30% of the winter supply, have enabled companies to purchase and store gas at lower prices during the summer, making energy more affordable for EU citizens.
The new proposal is accompanied by a recommendation by the European Commission for countries to consider market conditions and introduce flexible measures for refilling storage facilities this summer, ensuring optimal purchase conditions and avoiding market distortions.
The proposal will now be reviewed by the European Parliament and Council.
WORLD NEWS
IN BRIEF
BRAZIL
Baker Hughes has announced a joint technology development programme with Petrobras to provide a definitive solution for stress corrosion cracking due to CO2 (SCC-CO2) in flexible pipe systems.
GULF OF MEXICO
McDermott has announced the safe and successful completion of engineering, procurement, construction, installation, and commissioning (EPCIC) activities in the Gulf of Mexico for Shell Offshore Inc. (Shell), a subsidiary of Shell plc., to begin oil production at its Whale development.
USA
Miller Electric Mfg. LLC, global manufacturer of arc welding products, and Novarc Technologies, a fullstack AI robotics company specialising in the design and manufacturing of automated welding solutions, announced a strategic partnership aimed at transforming the welding industry with artificial intelligence (AI).
INDIA
GlobalData, citing Bloomberg, reported that India’s staterun refiners are nearing the completion of the world’s longest liquefied petroleum gas (LPG) pipeline, which is expected to start operations by June and enhance supply chain efficiency.
USA
Oxford Flow has secured its largest order to date, valued at nearly US$1 million, for its ES stemless axial flow valves. The order from bp is a significant milestone in Oxford Flow’s expansion in the US market.
Apollo to partner with bp on TANAP gas pipeline
bp and Apollo have announced that they have reached agreements for Apollomanaged funds to purchase a 25% noncontrolling stake in BP Pipelines (TANAP) Ltd – bp TANAP – the bp subsidiary that holds bp’s 12% interest in TANAP, owner and operator of the pipeline that carries natural gas from Azerbaijan across Türkiye.
Under the agreement, Apollo funds will purchase the non-controlling shareholding in bp TANAP for a consideration of approximately US$1 billion. Proceeds arising from this transaction will contribute towards bp’s programme for US$20 billion in divestment and other proceeds.
While the deal enables bp to monetise its interest in TANAP, bp will remain the controlling shareholder of bp TANAP and retain a long-term commercial and strategic interest, including governance rights, in the pipeline – a vital part of the gas value chain for the bp-operated Shah Deniz gas field in Azerbaijan.
The transaction is anticipated to close in 2Q25, subject to regulatory and TANAP shareholders approvals.
TANAP, running for approximately 1800 km across Türkiye, is the central section of the SGC pipeline system. The SGC transports gas from the bp-operated Shah Deniz gas field in the Azerbaijan sector of the Caspian Sea to markets in Europe, including Italy and Greece. In November 2024 Apollo and bp completed their previous agreement for Apollo to partner with bp on TAP – the final leg of the SGC.
William Lin, bp Executive Vice President, Gas & Low Carbon Energy said: “We are pleased to extend our partnership with Apollo and to deepen our partnership in this key piece of energy infrastructure for Europe. This unlocks capital from our global portfolio while retaining our role in this strategic asset for bringing Azerbaijan gas to Europe.”
Penspen to deliver feasibility study revalidation for Trans-Saharan Gas Pipeline project
Penspen has been awarded a contract to provide a feasibility study update for the Trans-Saharan Gas Pipeline (TSGP), a landmark infrastructure project with the potential to transform African energy dynamics, enhance economic integration, and bolster global energy security.
Spanning more than 4000 km from Nigeria to Algeria, the pipeline, the TSGP Project is jointly sponsored by the Nigerian National Petroleum Company (NNPC) Ltd (Nigeria), SONATRACH (Algeria) and SONIDEP SA (Niger), and would facilitate the transportation of up to 30 billion m3 of natural gas across West and North Africa annually, ultimately linking to European markets. This ambitious initiative is poised to unlock new economic opportunities for transit countries, foster regional cooperation, and support Africa’s growing energy demand.
Arun Behl, Penspen’s Sales & Marketing Director (Middle East & Africa) commented: “The award of the feasibility study of this high-impact project underscores Penspen’s expertise in large-scale energy infrastructure development and our commitment to advancing strategic initiatives that drive economic growth and regional stability.”
The TSGP Project was initiated by the collaborative efforts of Nigeria and Algeria in 2002, with Niger admitted in 2008 as a co-sponsor. In 2006, Penspen delivered the original feasibility study for the project, finding the pipeline to be technically and economically feasible and reliable.
Penspen has been engaged to re-validate and update the feasibility study of the pipeline, considering earlier route options. Delivered from Penspen’s offices in the UK and Middle East, and with support from fellow Sidara brand Dar, which is established and active in the three countries, the study will cover analysis of the regional gas market, environmental and social evaluation, economic and financial analysis including cost estimation, legislation and consultation reviews, risk analysis, and development of scope of work for the Front-End Engineering Design (FEED).
By harnessing the vast gas reserves of Nigeria and neighbouring producers, the TSGP aims to significantly contribute to Africa’s energy independence while also serving as a critical supply route for European nations seeking to diversify their energy sources.
PROTECTIVE OUTERWRAPS
BUTYL TAPE WRAP SYSTEMS
LIQUID EPOXY COATINGS
PETROLATUM TAPE WRAP SYSTEMS
SOIL-TO-AIR INTERFACE
HEAT SHRINKABLE SLEEVES
INTERNAL PIPE LININGS
BITUMEN TAPE WRAP SYSTEMS
6 - 10 April 2025
AMPP 2025
Nashville, USA
https://ace.ampp.org/home
5 - 8 May 2025
CONTRACT NEWS
McDermott completes EPCIC project in Gulf of Mexico
McDermott has announced the safe and successful completion of engineering, procurement, construction, installation, and commissioning (EPCIC) activities in the Gulf of Mexico for Shell Offshore Inc. (Shell), a subsidiary of Shell plc., to begin oil production at its Whale development.
Awarded in 2021 and completed in February, the project leveraged McDermott’s marine assets, including its North Ocean 102 vessel and the newly upgraded Amazon, to execute complex pipelay operations, reaching water depths of nearly 2800 m (9100 ft). This included installing approximately 50 km (30 miles) of pipeline and 15 km (9 miles) of umbilicals connecting five subsea drill centres to the new Whale floating production platform. Seamless collaboration across multiple offices, plus skilled engineering and
Northwind Midstream Partners expands off-spec gas treating, gathering, compression and carbon sequestration system
Northwind Midstream Partners LLC has announced that it has constructed and put into service 150 million ft3/d of highcirculation amine treating capacity, two acidgas disposal and carbon sequestration wells, over 200 miles of large-diameter pipelines and 41 750 hp of compression across five compressor stations.
Northwind is building one of the industry’s leading off-spec, NACE standard, natural gas infrastructure systems in Lea County, New Mexico (USA), designed to manage produced natural gas with high levels of carbon dioxide and hydrogen sulfide.
Northwind’s Phase 1 buildout, to be completed by mid-year 2025, is anchored by its Titan Treating Complex, where the Company recently added 100 million ft3/d of high-circulation amine treating capacity and an additional deep acid-gas injection and carbon sequestration well. The Titan Complex now operates total amine treating capacity of 150 million ft3/d and two acid gas injection wells. The completion of Phase 1 will increase total treating capacity to 200 million ft3/d and Northwind has also reached FID and customer support to further expand total treating capacity to 400 million ft3/d by 2026.
procurement guided by rigorous safety protocols, ensured the project’s success. Designed for complex offshore operations, the Amazon delivered an advanced ultra-deepwater pipelay system with a high-level of automation. In a Gulf of Mexico first, it installed five 3350 m (approximately 11000 ft), steel catenary risers, showcasing the vessel’s high top tension capacity, and marking a significant milestone for subsea infrastructure projects.
The Shell Whale development, located about 200 miles southwest of Houston, features a semi-submersible production platform, with capability for remote operations and monitoring of almost every aspect of the facility – representing a significant advancement in sustainable, high-efficiency energy production.
ON OUR WEBSITE
• EIA updates forecast for 2025 US natural gas prices, expects oil prices to decrease later in the year
• Summit Midstream announces US$90 million acquisition of Moonrise Midstream
• EACOP announces closing of its first financing tranche
• Tallgrass announces open season for the Pony Express pipeline
Follow us on LinkedIn to read more about the articles linkedin.com/showcase/worldpipelines
World Pipelines Contributing Editor Gordon Cope analyses midstream developments throughout Europe, with a particular focus on the uncertain future of Europe’s hydrogen economy.
urope’s energy sector is facing its most taxing challenges in many decades; the war in Ukraine could spill into the EU, the shift to a low-carbon economy could cost trillions of Euros, and pipelines are being blown up willy-nilly. While problems abound, they also present significant opportunities for the midstream sector.
The destruction of major pipelines has caused a seismic shift in Europe’s energy network. In September 2022, saboteurs attacked the 100 billion m 3 /y Nord Stream pipeline network that runs under the Baltic Sea from Russia to Germany. In October 2023, the 10 billion m 3 /y Balticconnector pipeline between Estonia and Finland was breached by a suspiciously errant anchor. As a result of sanctions and sabotage, the EU has had to replace approximately one-third of the 500 billion m 3 of gas that it consumed annually.
Germany’s Uniper utility quickly built facilities on the North Sea ports of Brunsbuettel, Stade and Wilhelmshaven where floating LNG (FLNG) ships could discharge cargoes into the regional pipeline network. In addition, the EU introduced measures to reduce consumption. Their efforts were successful; as of the official start of winter season on 1 November 2024, storage levels were at 95%; DET, the operator of the Wilhelmshaven facility, announced that it would be suspending operations between 5 January and 1 April 2025.
Algeria is looking to cash in on Europe’s need for alternate gas. The country’s gas production, pegged at 101 billion m 3 in 2023, has risen by over 15% as major projects in various existing fields come on-stream. Most of Algeria’s exports of 52 billion m 3 are delivered through major gas lines to Europe, including the 575 km MedGaz line from Algeria to Spain and the 2475 km TransMed line running from Algeria via Tunisia to Sicily and mainland Italy. But major fields are ageing, and are not being replaced at sufficient pace to keep up production. Algeria, which has traditionally limited foreign participation through high taxation and contract rules that favour state-owned Sonatrach, is starting to court international oil companies (IOCs). In November 2024, the country launched a series of new gas licensing rounds, hoping that the likes of ExxonMobil and Chevron can find new reserves and boost production by 20 billion m 3 over the next decade, allowing it to further increase exports to Europe.
Greece, Israel and Cyprus are promoting the Eastern Mediterranean (EastMed) project, an 1800 km gas pipeline. The ROW will start in Cyprus and connect to Greece, and then through a second offshore line to Italy, running roughly 1200 km offshore and 600 km onshore. Italy’s Edison, along with a subsidiary of France’s EDF and Greece’s DEPA International Projects, are promoting the project through their joint venture IGI Poseidon. The US$6.7 billion line will have a capacity of 10 billion m 3/y in the first phase, with the potential to double capacity in the second phase.
Green pipes
The prospect of a green hydrogen economy has two great advantages; it helps achieve net-zero carbon emissions by 2050, and it reduces the potential geopolitical threat from belligerent suppliers. The EU has earmarked over €13 billion for improving hydrogen technology, production and demand. Analysts calculate that over US$23 billion is needed to build offshore wind farms to generate an estimated 300 terawatt hours (TWh) of power, enough to create up to 15% of the estimated hydrogen consumption in 2050. In the Netherlands, up to 700 MW of generation has been slated for the Ten noorden van de Waddeneilanden site in Dutch waters. In late 2023, Dutch gas network operator Gasunie began pipeline construction near the port of Rotterdam, with the intention of connecting four regional hydrogen hubs by 2030 (although the company recently announced permitting issues and staffing problems have pushed that deadline out to 2033).
Germany’s core hydrogen production and distribution network has been estimated to cost US$21.6 billion and extend for 9700 km. Germany’s gas transmission association FNB Gas announced that the first 525 km of the hydrogen core grid would be built in 2025 by converting 507 km of existing gas pipe and building 18 km of new pipe. They estimate that the entire system would be completed by 2032.
Ireland is exploring a subsea pipeline to deliver hydrogen to Scotland, which would augment the plans that the Net Zero Technology Centre in Aberdeen has regarding converting the country’s abundant wind energy into exports. The Centre estimates that a new-build hydrogen pipeline capable of meeting 10% on mainland Europe’s needs would cost £2.7 billion and be online by the mid-2030s.
Belgium’s gas transmission operator Fluxys plans to spend US$2.19 billion on hydrogen pipelines up to 2033. The pipeline system would connect Dunkirk, Zeebrugge, Ghent, Antwerp, Liege, Cherlero, Mons and Brussels.
UK-based HyNet is planning an 85 km dedicatedhydrogen pipeline network that will be the backbone of its plan to supply the industrial region of Liverpool with low carbon energy. In phase 1, blue hydrogen will be produced and consumed at the Stanlow Manufacturing Complex and nearby off-takers. Phase 2 will see up to 270 km of new pipe extended throughout the region to serve regional utilities. In addition, salt caverns will be converted to hydrogen storage in order to smooth supply and demand profiles.
Algeria is keen to leverage its abundant solar and wind power to deliver low-carbon hydrogen to the EU. State-owned energy firms Sonatrach and partners have signed a memorandum of understanding with Italian grid operator Snam, VNG of Germany, and Austria’s Verbund to launch feasibility studies for large-scale green hydrogen production and a pipeline network across the Mediterranean.
Tunis is also eager to participate. Germany and Italy are planning a hydrogen-ready pipeline, dubbed SoutH2, that would receive gas from Tunisia and deliver it to northern Europe. In January 2025, Algeria, Austria, Italy, Germany, and Tunisia signed a joint letter of intent to advance the 3500 km project.
Challenges
Much of Europe’s LNG regasification infrastructure is far from major consuming regions in the north, and the continent lacks much of the pipeline interconnectivity that is essential for gas to be transported with efficiency and flexibility. Fortunately, that is slowly being addressed. The Baltic Pipe was officially commissioned in late 2022. The 275 km line connects Norway’s North Sea natural gas network through a series of underwater and surface segments to Poland, and is capable of delivering up to 10 billion m 3 annually, helping to reduce Poland’s dependence on coal for its electricity needs. The new, 182 km Interconnector Greece Bulgaria (IGB) line will deliver up to 5 billion m 3/y from the Southern Gas Corridor system that transports Azeri gas to Europe.
When it comes to rolling the EU’s hydrogen network out, significant technological and economic challenges exist. For instance, transmission of alternating current (AC) electricity from offshore wind farms faces unacceptable power losses as distances exceed 100 km. One way to avoid losses is Power to Gas (P2G), in which seawater is desalinated as feedstock in order to create hydrogen through electrolysis on-site, then transporting the gas to shore via repurposed natural gas pipelines. In September 2024, Siemens and Germany’s Fraunhofer Institute successfully linked a wind turbine with two electrolysers in a pilot project in Denmark. The purpose of the onshore H2Mare project was to demonstrate how the fluctuating nature of wind can be efficiently harvested to make hydrogen, but the researchers found the process to be quite complex; transferring such a mass of new technology to industrial scale at an offshore site will be fraught with difficulties.
Hydrogen causes embrittlement in traditional steel pipelines, creating the potential for catastrophic failure. Experts in Holland have challenged Gasunie’s assertion that existing gas networks are safe, which is causing delays. German utility giant Uniper, which is part of Gasunie’s plan to build the Delta Rhine Corridor (DRC) to connect the Port of Rotterdam to Germany, has spoken publicly about its concerns over the delays that are pushing commissioning from 2030 to 2034.
The lack of demand is forcing producers to rethink projects. In September 2024, Shell cancelled plans to build a low-carbon hydrogen plant on Norway’s west coast. Equinor also announced that it would not build a pipeline designed to carry up to 10 GW of blue hydrogen from Norway to Germany. In October 2024, Spain’s Repsol announced that it would pause 350 MW of electrolysis capacity in its home country, due to tax policy and demand concerns.
In 2023, Denmark and Germany agreed to build a transborder hydrogen pipeline by 2028 to leverage Denmark’s abundant offshore wind and Germany’s industrial demand for decarbonising steel and cement industries. In late 2024, however, Denmark’s gas transmission operator Energinet postponed the project deadline by three years, citing technical, economic and regulatory complications.
A very large caveat looms over the future of the hydrogen economy; the discovery of white, or natural hydrogen deposits. The US Geological Survey (USGS) estimates that there could be as much as 5 trillion t beneath the ground. Geologists are piecing together where it is being produced (where water comes in contact with bedrock basalts), and coalescing into reservoirs (similar to gas traps). Currently, there are over 40 companies searching worldwide for economic deposits, including Canadian, Australian, American and European firms; recently, explorers announced they had discovered up to 46 million t of pure hydrogen in the Lorraine region of France.
All is not gloom and doom
In February 2025, France-based Verso Energy signed a cooperation agreement with the Finnish city of Oulu to
build an 80 000 tpy facility that will process green hydrogen into synthetic aviation fuels (eSAF). Finland currently has no eSAF production; the €1.4 billion plant is necessary for the country to meet the EU requirement of a 2% blend of sustainable fuel at the continent’s major airports.
Also in February 2025, 17 major European green hydrogen stakeholders, including Ammonia Europe, Hydrogen Europe and the Gas Infrastructure Europe, signed a declaration calling for greater clarity between strategic and political vision and market reality. They noted that swift action is necessary to develop electrolyser capacity, infrastructure and a cohesive market place.
Shortly thereafter, Reuters reported that the AggregateEU platform used to joint purchase natural gas would be repurposed to line up buyers with producers. 1 The original purpose of the platform, which was set up during the energy crisis of 2022, was to pool buying orders to give participants more pricing leverage. Starting in September 2025, the platform will now be used for both green hydrogen and critical minerals.
While the spectre of stranding expensive electrolysis plants hangs over the sector, natural hydrogen may turn out to be a blessing in disguise for the midstream sector. In the space of the next decade, the cost of green hydrogen is expected to approach the magic US$1/kg range through advances in technology. At the same time, discoveries of cheap natural hydrogen reservoirs will gain traction. Green hydrogen plants can be built anywhere (normally near refineries), while hydrogen reservoirs will require extensive pipeline networks to deliver to other consumption markets.
Future
Wood Mackenzie, a consultancy, estimated that EU gas demand shrank from just under 500 billion m 3 in 2021 to 399 billion m 3 in 2023. A cold snap in the beginning of 2024, combined with lower prices, saw a rise of 9 billion m 3 through the year, with modest increases expected for 2025 as the EU economy gains steam. It is unlikely that the continental demand will recover to pre-war levels as increases in renewable energy sources eats into gas demand.
The rollout of the hydrogen economy in Europe is expected to proceed in a piecemeal manner as governments, energy producers and industrial consumers sort out mandates, markets and demand. The EU will continue to regulate its development, spurred by both netzero legislation and energy security concerns. Producers will seek assurances that they will not be left holding the bag if investments become stranded. Consumers will have to be assured that hydrogen can be delivered in a safe manner. Regardless, pipeline companies will play an integral part in those projects that succeed, facing significant risks as well as substantial rewards.
• Extend your background to fill the full ‘bleed area’ - it’ll make sure you don’t end up with white edges round your advert when it is printed.
Trim area: 210mm x 297mm
• This is the size your advert appear
Safe area: 190mm x 277mm
• Keep all important bits of your design - text, logo, icons - inside this area. (Not your background - that still needs to run to the edges of the bleed.)
Art work specifications / our preferred form
• PDF-x/1a.
• PDFs generated using Press Settings. In addition, please note the following:
• PDFs should be compatible with Acrobat 4 0 or highe
• Please ensure all fonts are embedded.
• All original graphics must be saved as CMYK at 300 dpi they are to be used.
• Please ensure all PDFs are higher than 144 resolution
• Images should not be tagged with any ICC profiles.
We operate a preflight system prior to printing to check that all advertisement material complies with the above specifications. Any advertisement that does not comply with these specifications may need to be resupplied.
Jonny Thorns, Construction Project Director, National Gas, UK, and Henry Lewis, Contracts Manager, United Living Infrastructure Services, highlight the pipeline construction work ensuring the future safety and sustainability of Britain’s natural gas network.
ational Gas owns and operates the high-pressure National Transmission System (NTS) that transports gas safely to wherever it’s needed in Britain. It has a key role in Great Britain’s transition to a clean energy future.
A crucial part of the management of the NTS pipelines is ongoing construction work to ensure that the transmission system is sustained as a safe gas delivery system, and fugitive methane emissions are minimised to reduce any environmental harm. This is the ongoing and essential process of maintaining the NTS; whilst significant, ambitious decarbonisation projects – that seek to help
Figure 1. Chignall St. James pipethrough.
us enable the transition to cleaner energy and achieve net zero by 2050 – are in planning and development.
Over the decades of gas transmission in the UK, the management and maintenance of the NTS has continually innovated to allow the teams that deliver the construction, commissioning and decommissioning work to improve. There are significant challenges to the execution of construction works, including maintaining energy resilience and security of supply, particularly during colder weather conditions, when demand for gas is greater.
Feeder 5 focus – Jonny Thorns, Construction Project Director, National Gas
Feeder 5 is a key pipeline that runs from Bacton Gas Terminal in Norfolk for National Gas, through East Anglia into the south of London, and through to Kent. It is a significant section of pipeline that serves a huge area with power generation, industry and homes and businesses dependent on its supply for power and heat. During 2024, National Gas scheduled the largest body of work the region had ever experienced, and possibly the largest in the company’s recent history for pipeline improvement works with a target of getting it completed before the end of 2024.
The works involved an exceptionally detailed non-routine operation (NRO) outlining how to safely isolate Feeder 5, which spans over 132 km (82 miles) of pipeline. The safe isolation of this pipeline and the resulting outage was successfully delivered by a huge team effort from a range of National Gas departments along with our principal contractor, United Living Infrastructure Services. There were long days, weekends, and night shifts to deliver key milestones such 24 hour operation at Chelmsford compressor station to ensure a safe and timely network isolation.
Maintaining a safe and reliable NTS is a vital part of the work National Gas does every single day. Some of the NTS
pipes are more than 60 years old; this means an ever-increasing task of maintaining and replacement to secure Britain’s energy.
National Gas’ construction teams manage programmes that involve the replacement of above ground installation (AGI) assets such as valves, insulation joint (IJ), and pipe supports, and they use specialist flow stop techniques to achieve outages.
The Feeder 5 project was enormous: it is National Gas’ biggest single feeder outage to date and the core construction works were completed within a six week period with significant work either side to safely isolate the system, well ahead of schedule. This meant that the gas system could be restored by mid-November 2024, before the cold weather arrived. The key construction project outputs from the outage allowed for completion of eight IJ replacements, one pipe-through and a grand total of 20 golden welds. These works were completed ahead of schedule and with demonstrable collaborative working. The completion of these complex and challenging projects is a step change in how National Gas is doing work, maximising outages to complete more.
In real terms, this meant that roughly five golden welds were being completed a week, across multiple sites. There were many challenges to overcome, including managing pipe spring and misalignment that required specialist analysis, in addition to the careful management of naturally occurring radioactive material (NORM) gases. Beyond the scale of the project, the implications of delays or serious issues were huge, and months of careful planning preceded mobilisation to site. Any setbacks could have jeopardised the return to service of Feeder 5 ahead of winter, a critical period for energy security in the Southeast, particularly London. This is a tangible example of how National Gas will deliver more largescale pipeline improvement works, alongside commissioning hydrogen and carbon capture and storage (CCS) projects for the clean energy future.
Working in partnership to deliver critical infrastructure – Henry Lewis, Contracts Manager, United Living Infrastructure Services United Living Infrastructure Services (ULIS) has a longstanding, collaborative relationship with National Gas. Its engineerled expertise spans the full spectrum of asset lifecycle management, from maintenance and refurbishment to design and construction, delivering complex projects successfully and safely across the UK and ensuring the reliability and safety of the NTS and supporting the transition towards a low-carbon gas network.
Working in close partnership with National Gas, ULIS played a central role in delivering this project, managing various complex construction activities across multiple locations. Its expertise in complex engineering, project management, and operational execution was instrumental in overcoming major challenges and ensuring the project’s success.
Project scope and execution
Roxwell
Mobilisation at Roxwell was initiated promptly following contract award, enabling early Q10 surveys. These surveys
Figure 2. Chignall St. James pipethrough welding.
Since 1948, Tinker & Rasor has been a trusted name in holiday detection, relied upon by pipeline professionals worldwide. For over 76 years, our holiday detectors have set the benchmark for performance and reliability, ensuring the integrity of protective coatings by detecting coating flaws with precision. With a legacy of innovation and toughness, Tinker & Rasor continues to lead the industry, delivering cutting-edge solutions to safeguard pipeline coatings and maintain quality standards across the globe.
helped in the swift development of welding procedures, effectively mitigating scheduling risks. The works involved the removal of all existing mainline concrete plinths and mechanical jack pipe supports to facilitate pipeline corrosion investigations. Additionally, ULIS replaced three large-bore IJs (24 in. and 36 in.) and carried out a deep, sheet-piled excavation to address a leaking buried valve. Roxwell also served as a central fabrication hub, supporting installations at Chignal St James, Braintree, and Horndon.
Chignal St James
At this site, ULIS undertook the removal of a below-ground block valve arrangement, which included 900NB off-take valves and bypass pipework. Over 35 t of redundant material were removed, with access track stabilisation completed to ensure smooth equipment access. Collaborating with National Gas, the test pressure was reduced from 172 bar to 150 bar to enhance safety.
Braintree
Above-ground works were executed without requiring major civil interventions. Temporary supports were installed beneath the pipework, enabling the replacement of IJs while maintaining system integrity.
Horndon
At Horndon, the replacement of a free-issue IJ was successfully completed, incorporating a bagging point and conducting pre-testing to meet system requirements. The test pressure was adjusted from 172 bar to a more practical level, and wire rope cutting techniques were used for the removal of existing concrete plinths to minimise disruption.
Abridge and Luxborough Lane
Works included large-bore IJ replacements, pretesting, and adjustments to test pressures. Additional pipe support replacements were undertaken, with welding procedures expedited to meet tight deadlines.
ULIS also delivered two additional opportunity projects, involving IJ replacements, corrosion inspections, and rapid mobilisation within a week. These were successfully facilitated by the central hub at Roxwell, ensuring efficient delivery.
Achievements and best practices
Despite the original nine week outage being reduced to just five weeks, ULIS successfully achieved programme sign-off on 25 October 2024. Several key factors contributed to this success:
) Strategic planning: establishing Roxwell as a central hub enabled efficient logistics management and minimised downtime.
) Collaborative success: strong collaboration between ULIS, National Gas, and subcontractors ensured timely completion of works.
) Flexible resource mobilisation: the ability to rapidly mobilise teams and adjust resources as needed played a critical role in meeting the project deadlines.
Figure 3. Roxwell lifting in new IJ(3).
Figure 4. Roxwell IJ(3) cutting.
Figure 5. Roxwell site compound.
) Positive client feedback: National Gas recognised the team’s professionalism and resource management as essential to the smooth execution of works.
Overcoming challenges
Executing a project of this scale within such a condensed timeframe came with significant challenges. At Braintree, substantial movement in one of the IJs required immediate response, leading to a continuous 26 hour shift to resolve the issue. Similarly, at Abridge and Luxborough Lane, design adaptations were required to address future ground settlement risks, which ULIS successfully implemented in collaboration with National Gas.
At Horndon, managing the interface between Cadent and National Gas operations on a shared site required proactive planning and clear work area segregation to ensure efficient progress. Chignal St James presented difficulties due to belowground pipework encased in concrete, necessitating a revised sequencing plan to mitigate potential delays.
Lessons learnt and future applications
The successful execution of this project demonstrates National Gas’ evolving approach to large-scale pipeline improvements, where maximising outages to complete multiple projects at once is becoming the new standard. ULIS’ experience in delivering complex mechanical outages within tight deadlines highlights the importance of detailed planning, collaborative execution, and adaptability in overcoming challenges.
ULIS Contracts Manager, Henry Lewis, said: “With over 85 ULIS personnel working alongside National Gas teams and subcontractors, the collective effort ensured the successful delivery of these outage works. The lessons learnt from this project will shape future large-scale improvement initiatives, helping to further refine processes, reduce risks, and enhance efficiency across the NTS”.
National Gas Construction Project Director Jonny Thorns said: “It’s fantastic to see this collaborative and extensive project come to completion. I am immensely proud that our teams have worked together to make these massive pipeline improvement works possible. This project is a step change in how we work by maximising outages to deliver more.
“As we move into delivering bigger and more ambitious pipeline projects, Feeder 5 is a great example of how we will deliver a bigger workbook, which in the future will see the addition of hydrogen and CCS projects.”
The Feeder 5 project stands as a significant milestone in National Gas’ ongoing efforts to maintain and enhance the NTS. Through meticulous planning, expert execution, and a strong commitment to collaboration, this project not only achieved its immediate objectives but also set a benchmark for future infrastructure improvements.
As National Gas continues to prepare for a cleaner energy future, projects like Feeder 5 demonstrate the critical role of innovation and efficiency in ensuring a resilient and sustainable gas transmission system for Great Britain.
John Barbera, Barbco, discusses the ways contractors can improve their operations by choosing simple, reliable, and durable horizontal directional drilling (HDD) rigs.
orizontal Directional Drilling (HDD) has proven to be a revolutionary technique for the installation of pipelines, especially within the oil and gas sector. This method provides precision, minimal disruption to the environment, and cost-efficiency that traditional trenching methods simply cannot offer. As global energy demands grow, HDD becomes crucial in evolving energy infrastructure while maintaining environmental compliance and reducing risks associated with pipeline construction. But, in an industry where downtime equals lost revenue, contractors are increasingly seeking machinery that prioritises reliability.
Understanding HDD
HDD is a trenchless technique used for underground pipeline installation, minimising the surface disturbance typical of traditional excavation. The process begins with drilling a small pilot hole, which is then widened using reaming tools, allowing the pipeline to be pulled back through the bore. This efficient method ensures the pipeline can be installed beneath obstacles such as rivers, roads, or environmentally sensitive areas, without disturbing the surrounding landscape.
The ability to reduce surface disruption is especially valuable in environmentally sensitive zones. By using HDD, pipelines can be installed without disturbing wildlife habitats, water bodies, or plant life, protecting these ecosystems from the long-lasting effects of traditional construction methods. For contractors and project managers, minimising environmental impact is critical in meeting regulatory requirements and managing the growing demands for infrastructure development in such areas.
The advantages of HDD in pipeline installation
Minimal environmental disruption
Traditional trenching methods can devastate ecosystems, requiring large-scale land clearing, which increases soil erosion, harms local wildlife, and often pollutes water sources. HDD mitigates these concerns by drilling underground, preserving the surface and maintaining the integrity of the natural environment. This advantage makes HDD particularly effective for pipeline installations in rivers, lakes, wetlands, and other protected areas.
Cost-effectiveness
While HDD equipment may initially come at a higher cost, the long-term savings are substantial. Trenching methods often demand extensive road-building, excavation, and backfilling, which are time-consuming and costly. HDD reduces the need for such operations and minimises the requirement for land restoration, making it more affordable in the long run. The simplicity of HDD also reduces the need for expensive, specialised repair services.
Faster installation
HDD allows contractors to complete pipeline installations quickly, especially in challenging terrain. The minimal surface disruption, coupled with the precision drilling technology, accelerates the process, allowing for faster job completion.
This efficiency significantly reduces downtime and limits the disruption to local communities or businesses, which is vital in urban environments or high-traffic areas.
Enhanced safety
Safety is paramount when dealing with oil and gas pipelines. HDD enhances safety by reducing the need for on-site personnel during high-risk operations. Since much of the work is conducted underground, operators and workers are shielded from potential hazards such as explosions, fires, or accidents involving heavy equipment.
Additionally, advanced tracking systems ensure precision drilling, preventing accidents and errors that could lead to environmental disasters.
Flexibility
HDD is incredibly versatile and adaptable to various soil conditions, from soft clay to hard rock. Whether the pipeline needs to cross urban areas, highways, or remote regions, HDD provides an efficient solution that meets the demands of the specific environment. For manufacturers, this means the continued need for HDD rigs capable of adapting to different pipeline sizes and soil conditions.
A new line of HDD drills
While many manufacturers continue to develop complex systems with sophisticated electronic controls for their HDD rigs, Barbco is taking a different route. By focusing on simplicity, reliability, and durability, Barbco aims to meet the real-world demands faced by contractors in the field. In an industry where downtime results in lost revenue, Barbco’s new line of HDD rigs is designed to reduce service calls, simplify maintenance, and keep projects on track.
The new 60 000 lb model from Barbco marks a departure from traditional HDD technology, which often relies on complex systems like the Controller Area Network Bus (CAN Bus) to communicate with various electronic control units. These systems, while effective in theory, often lead to increased downtime due to technical failures and the need for specialised service. This approach eliminates the CAN Bus and replaces it with a simplified 12 VDC wiring system, removing the potential for costly and timeconsuming repairs in the field.
Key features
Simplicity and reliability
Barbco’s new drill design focuses on what matters most for contractors – reliability. By removing complex electronics, circuit boards, and programmable controls, rigs are less prone to breakdowns that require specialised technicians. This streamlined approach means that most issues can be addressed locally by any qualified mechanic or service shop, reducing downtime and ensuring faster repairs.
Figure 1. Barbco BD60 Solidworks view.
This emphasis on reliability is especially critical when considering the challenges contractors face when their equipment goes down. With Barbco’s drill, contractors no longer need to worry about waiting for proprietary parts or a technician’s availability. Instead, they can continue their work without the added cost and stress of extended service delays.
Durability and longevity
Barbco’s commitment to durability extends beyond its simplified electronics. The new drill models are designed with a heavy-duty frame, built to withstand the rigours of tough pipeline projects. With proper maintenance, these machines can last 15 – 20 years, ensuring a better return on investment compared to other rigs that may need costly repairs or replacements much sooner.
Cost-effectiveness
In addition to reducing downtime, Barbco’s drills are cost-effective over the long term. By stripping away unnecessary technological upgrades and focusing on durable, easyto-repair components, Barbco delivers a machine that offers value without sacrificing performance. Contractors can invest in a rig that will work day in and day out, without the hidden costs associated with complex systems and expensive repairs.
Simplified repairs
For contractors, the ability to service equipment locally is a major advantage. With Barbco’s 12 VDC wiring system and focus on simplicity, common issues can often be addressed without waiting for specialised technicians. This ability to conduct repairs locally translates into less downtime, fewer expensive service calls, and an overall more efficient operation for contractors.
The future of HDD
The rise of Horizontal Directional Drilling has transformed pipeline construction, offering numerous benefits in terms of environmental protection, cost-efficiency, speed, and safety. As the oil and gas industry continues to grow and evolve, HDD will play an even more prominent role in pipeline installation, helping to meet global energy demands while minimising environmental disruption. For manufacturers, the focus is on creating equipment that meets these growing demands. Barbco’s approach, centred on simplicity, reliability, and durability, ensures that contractors have the tools they need to keep their projects on track, reduce downtime, and improve profitability. As more contractors recognise the value of reliable, easy-to-repair HDD rigs, Barbco’s new line is set to become
an industry standard for those who want dependable performance in challenging conditions.
Conclusion
As the oil and gas sector continues to face increasing demands for pipeline infrastructure, Horizontal Directional Drilling will remain a key solution for efficient, environmentally conscious pipeline installation. With Barbco’s new line of HDD rigs, contractors can count on reliable, durable, and cost-effective equipment that reduces downtime and provides long-term value. In an industry where every minute counts, contractors need an HDD solution that prioritises dependability over complexity, ensuring that they can stay focused on the job at hand, not on fixing their equipment.
High voltage Holiday Detector
Detects holidays, pinholes, and other discontinuities using continuous DC
n Lightweight, one-piece ergonomic design provides comfortable all-day use
n One wand covers the entire voltage range from 0.5 to 30 kV
n Up to 16 hours of battery life—powerful Li-ion batteries fit neatly within the compact wand handle eliminating the need for a separate battery box
n Built-in Certified Voltmeter and Voltage Calculator feature
n Industry standard connectors and adaptors provide compatibility with nearly all existing electrodes
EXHIBITION & CONFERENCE
9-12 SEPTEMBER 2025
FIERA MILANO - MILAN
Powering a sustainable energy future
Join the world’s largest event for natural gas, LNG, hydrogen, climate technologies and AI.
50,000 Attendees
1,000 Exhibitors
1,000 Speakers 7,000 Delegates
BOOK YOUR STAND
150 Countries represented
Join 1,000 exhibitors and connect directly with global procurement teams from major energy companies driving energy projects worldwide.
This article, courtesy of Dairyland Electrical Industries, analyses the role of DC decouplers in corrosion prevention and safety.
athodic protection (CP), when properly applied, is an effective technique to minimise the natural corrosion process that occurs on pipelines, tanks, and other buried metallic structures. To maintain effective CP coverage with minimal current demand, the structure must be well-isolated from earth for DC current flow.
However, these structures require electrical earthing for both personnel safety and protection of the structure from damage due to over-voltage conditions. These earthing bonds require the CP system to protect significantly more material surface area for which it was likely not designed. As a result, it is often difficult to maintain adequate CP potentials on the structure that is to be protected.
A practical and widely accepted solution is to install DC decoupling devices in series with the bonding connections between the cathodicallyprotected structure and the earthing system. Decouplers are designed to block CP current while allowing steady state AC, AC faults, and lightning to pass freely. This prevents CP current from passing to the earthing system and so minimises the amount of CP current required to protect the pipeline.
This article will examine the basic function of DC decouplers and over-voltage protection devices and explain how they should be used in conjunction with cathodic protection systems to obtain optimal corrosion and safety protection.
The challenges with cathodic protection and earthing systems
CP systems, and external corrosion protection in general, require that the protected structure be electrically well-isolated from earth. Since CP systems are designed to protect only relatively small defects in the coating of the protected asset, the degree of isolation determines the efficiency and effectiveness of the CP system in protecting the structure. Certainly, the less surface area of the structure that is directly in contact with earth, the less CP current is required for protection. This is the basic function of high resistance pipeline coatings. Additionally, every surface on the structure that interfaces other earthed structures must be insulated to minimise CP current flow through the other structures. This is accomplished using flange isolation kits and monolithic joints at piping connections, dielectric fittings for smaller piping connections, conduit and sensor connections and isolation pads for above-ground pipe supports.
In addition to these mechanical interfaces, there are electrical connections between the structure and earth for which continuity must be maintained to protect the structure and personnel from potential over-voltage conditions. These connections include earthing bonds for AC interference mitigation, AC faults and lightning protection and earthing bonds for electrical equipment that is electrically bonded to the structure.
AC mitigation earthing paths
The main intent of AC mitigation systems is to dissipate unwanted voltage along the pipeline resulting from induced AC from nearby power transmission lines and AC faults and lightning. The general technique for mitigating induced AC pipeline voltage is to connect the pipeline at appropriate locations to a suitably low impedance earthing system in order to collapse the voltage to a safe value. The earthing system is commonly bare zinc ribbon or copper wire run in parallel with the pipeline.
The design process typically begins with software modelling by specialised consultants, inputting various factors such as soil resistivity, lateral separation distance and power system characteristics (voltage and amperage) to arrive at an induced AC voltage map at all points along the pipeline. Then, by applying low impedance earthing points at various locations along the affected area, the AC effects under steady-state and fault conditions can be modelled, and the earthing system design can be optimised to address worker touch and step voltage safety, coating stress voltage, and AC current density issues. Depending on many variables – such as the separation distance and geometry between the pipeline and power lines, power levels, soil resistivity, pipeline coating, etc. – spacing of earthing connections may vary between a few hundred metres to several kilometres.
These mitigation bonds between the pipeline and the earthing system provide a low impedance path for AC interference to dissipate, but they also introduce additional material surface area for the CP system to protect as illustrated in Figure 1. As a result, the rectifier often cannot support the increased current load and CP potentials can become compromised, leaving the structure inadequately protected.
Figure 1. CP Protection of AC mitigation systems without DC isolation.
Figure 3. CP Protection with DC isolation using decouplers.
Figure 2. CP Protection of electrical equipment earthing without DC isolation.
EFFICIENT - HIGHER TEMPERATURES
KEEPING YOU PUMPING & PRODUCING LONGER
PERMANENT MAGNETS
RECOMA®
Samarium Cobalt Grades 18-35E
NdFeB
Neodymium Iron Boron Grades N28 - G57 YEARS
STATORS, ROTORS & MOTORS
AC Induction
DC Brushless
MFL & NMR Assemblies
ESP s & Mud Motors
LWD & MWD Assemblies
Magnet ic Coupl ings
Position Sens ors
PRECISION THIN METALS
Moly Permalloy
Arnokrome™
Non-Grain Oriented Silicon Steel Arnon™
Other Alloys as thin as 2 microns
Widths: 0.030” to 17.5”
Gauges: 0.062” to
Electrical equipment earthing
It is common for electrical equipment, such as motor operated valves, to be electrically bonded to pipelines
through the power supply system and therefore the earthing system of the power supply. Consequently, the equipment, its earthing system, and everything to which it is bonded, including the utility earthing system, is bonded to the pipeline. These earthing systems then become additional paths that pickup CP current and so present additional material to be protected by the CP system as shown in Figure 2. This can have a dramatic negative impact on CP system performance.
Electrical earthing conductors are needed to conduct AC fault current and prevent over-voltage conditions and must be left in place. National electrical codes require equipment earthing conductors to be 1) permanent and continuous, 2) rated to handle the anticipated AC fault current from the source, and 3) of low impedance to allow AC fault current to flow, permitting a clearing device (circuit breaker or fuse) to clear the fault. These define what is an “effective groundfault current path” for safety, per the US National Electrical Code.1 To remove the offending conductor for convenience on the CP system is to allow an unacceptable shock hazard at the site during any over-voltage condition and would violate electrical codes.
DC isolation using decouplers
When faced with insufficient CP potentials due to such required earthing bonds, CP designers might be inclined to add more cathodic protection (i.e. rectifiers and anode beds) and tolerate high CP current demand. However, this is likely a prohibitively expensive option and may ultimately not provide sufficient protection.
A practical and widely accepted solution is to install DC decoupling devices in series with the bonding connections between the cathodically-protected structure and the earthing systems as shown in Figure 3. Decouplers are designed to block CP current while allowing steady state AC, AC faults and lightning to pass freely. This prevents CP current from passing through the earthing systems and so minimises the amount of CP current required to protect the pipeline. Note that when used in series with electrical equipment earthing systems, the decoupling device must be specifically approved for such use.
Solid-state over-voltage protectors use high power solidstate electronic switching components to maintain DC and AC isolation between structures. Under normal conditions, this switch remains open, maintaining DC and AC isolation between the structures. When the differential voltage across the terminals exceeds a prescribed voltage threshold (which is often in the single digits), which would occur during a fault or lightning event, the switch closes virtually instantaneously, collapsing the voltage across the terminals and electrically bonding the structures. Immediately following the overvoltage event, the device then automatically switches back into the OFF state to maintain DC isolation.
Solid-state decouplers, in addition to bonding structures during AC faults and lightning, provide a continuous conduction path for steady state AC to pass through the device at all times. With this low impedance conduction path for steady state induced AC current, a solid-state decoupler
Figure 6. Dairyland’s OVP is a solid-state Zone 1 over-voltage protector.
Figure 5. A Dairyland PCR decoupler installed to DC isolate a motor-operated valve from earth.
Figure 4. A Dairyland PCR decoupler installed as part of an AC mitigation system.
SPACERS CASING MICROTUNNEL
We design and manufacture casing spacers, in different sizes and features, suitable for inserting pipelines in microtunnels, providing calculation reports and stress analyses to predict the loads at every point of the line and carrying out destructive tests on wheels, in order to certify the maximum load capacity. We also take care of packing and shipping to destination.
reduces AC potentials on the pipeline and prevents the AC voltage from triggering the solid-state switch. An example of a solid state decoupler installed as part of an AC mitigation system is shown in Figure 4. In Figure 5, a decoupler is shown installed to DC isolate a motor-operated valve from electrical earthing.
Several industry standards suggest and/or recommend the use of DC decouplers in earthing circuits to maintain effective cathodic protection.2,3,4,5
Isolation joint protection using decouplers
Isolation joints are very effective at isolating cathodically protected piping from earthing or other CP systems. As a result, CP designers, who are primarily concerned with isolation, can often overlook the need to protect isolation joints from AC faults or lighting using decouplers or overvoltage protection devices. But without proper over-voltage protection, AC fault and/or lightning current on the pipeline can arc across the isolation joint material, damage the joint and/or expose personnel to over-voltage hazards. Even when pipelines are grounded for AC mitigation, without protection across the isolation joint itself, there is no guarantee that fault and lighting current will not arc across the isolation joint material. In fact, several industry standards recommend or require installation of over-voltage protection devices across isolation joints.6,7,8,9,10
DC decouplers and over-voltage protection devices provide a conduction path for faults and lightning around the
joint and thus limit the voltage across the joint to safe levels. This protects the isolation joint while maintaining electrical isolation at lower voltages. In addition to protecting the joint from damage, appropriate over-voltage protection devices ensure safe touch potential across the joint in the event of an AC fault so that personnel are protected.
Pipelines that share a common corridor with high voltage transmission lines can be exposed to thousands of amps of current during a phase-to-ground fault. Many solid-state devices are designed to operate reliably and continuously under such conditions without the need for replacement. However, spark gap devices, which are commonly used to protect isolation joints from lightning, are typically not rated for AC currents above 500A at 0.2 sec. As a result, spark gaps often fail when exposed to typical AC faults.
Examples of an over-voltage protector and a decoupler installed on bolted flange isolation joints are shown in Figures 6 and 7.
Summary
To minimise corrosion, pipelines and storage tanks rely on expensive coatings, isolation joints and cathodic protection systems to electrochemically isolate the structure from the earth. However, to mitigate the damaging and hazardous effects from AC interference, AC faults and lightning, these structures require intentional earthing systems. These conflicting requirements are successfully addressed, in general, by the use of solid-state DC decouplers and overvoltage protectors. These devices, when installed in electrical connections between CP-protected structures and earth, provide both DC isolation and bonding for AC and lightning.
Solid state DC decouplers and over-voltage protectors are also highly reliable for preventing arcing and minimising touch potentials across isolation joints during AC fault or lightning events.
References
1. US National Electrical Code, NFPA 70, Article 250.4(A)(5).
2. US National Electrical Code, NFPA 70, Article 250.6(E).
3. NACE SP0177, Section 4.10.1
4. EN 15280:2013, Section 9.3.1.3
5. ISO 15589-1, Section 7.3.6
6. US Code of Federal Regulations for Natural Gas Transportation – 49 CFR 192.467 (e) and (f).
7. US Code of Federal Regulations for Transportation of Hazardous Liquids by Pipeline – 49 CFR 195.575 (d) and (e).
8. NACE SP0177. Section 4.9
9. ISO 15589-1. Section 7.3.3
10. BS EN 50433. Section D.2.2
Dairyland Electrical Industries will be hosting a webinar on this topic – Introduction to Decouplers – with World Pipelines on 29 May 2025. Learn more and register at www.worldpipelines.com/events
Figure 7. Dairyland’s SSD is a solid-state Zone 2 decoupler.
Chris Cantrell, Senior Managing Director, Standards and Engineering Services, ASME, explores how standardisation and certification can lead to innovation and sustainability in oil and gas pipelines.
he global oil and gas industry stands at the intersection of tradition and transformation. As it navigates the complexities of meeting growing energy demands while transitioning to more sustainable practices, standardisation and certification emerge as pivotal tools to harmonise processes, enhance safety, and drive innovation. Applying and adopting standards in the construction and operation of oil and gas pipelines can yield significant benefits and certification provides even more confidence for manufacturers, operators, insurers, and end-users alike.
The case for standardisation in oil and gas pipelines
Oil and gas pipelines are critical infrastructure that transcend borders, transporting energy resources across continents. However, when products and components used in these pipelines are manufactured in different regions, such as the Americas, Asia, and Europe, inconsistencies in size, style, and performance measures can arise. These discrepancies can lead to operational inefficiencies, increased costs, and safety concerns.
Standardisation can mitigate these challenges. Standards and certifications essentially act as a common language and help to ensure that all components conform to a uniform set of specifications and performance criteria. For example, standards including those produced by The American Society of Mechanical Engineers (ASME) provide a uniform framework for manufacturers and operators, fostering interoperability and compatibility. This commonality not only reduces the risk of mismatched components but also simplifies procurement and maintenance processes.
Enhancing
safety and reducing public health risks
Pipeline failures can have catastrophic consequences, including environmental damage and risks to public health. Adopting standardised practices for design, construction, installation, inspection, maintenance, and repair helps to ensure that products meet stringent safety and quality benchmarks, minimising the likelihood of failures. Standards evolve to meet current industry and societal needs, too. For instance, the recent update to the ASME B31.12 Hydrogen Pipelines Standard demonstrates how standards are revised to address emerging technologies and sustainability initiatives. By including a comprehensive exception chapter for hydrogen pipelines, this standard supports fit-for-purpose projects while helping to maintain pipeline safety.
Moreover, standardisation facilitates better risk management. Operators can rely on proven methodologies and practices, reducing uncertainties associated with deploying new technologies or materials. This is particularly critical in regions with varying regulatory requirements, as standards offer a consistent and proven baseline for compliance.
An example of standardisation’s benefits can be seen in ASME’s B31Q Standard for Pipeline Personnel Qualification. ASME B31Q establishes the requirements for developing and implementing an effective Pipeline Personnel Qualification Program. It specifies the requirements for identifying tasks that impact the safety or integrity of pipelines, for qualifying individuals to perform those tasks, and for managing the qualifications of pipeline personnel at a company or site. ASME B31Q was established and developed with industry partners and subject matter experts utilising a combination of technically based data, accepted industry practices, and consensus-based decisions. The B31Q standard also offers guidance and examples of a variety of methods that may be used to meet selected requirements.
Driving innovation and market growth
Standardisation does not stifle innovation; instead, it provides a foundation upon which new technologies can thrive. By
establishing clear parameters developed by subject matter experts from many stakeholder groups, standards encourage manufacturers to innovate within defined boundaries, leading to more efficient and effective solutions. For example, standardisation in pipeline construction materials has spurred the development of advanced composites and corrosionresistant alloys, enhancing pipeline longevity and performance.
In the context of global markets, standardisation facilitates trade by removing technical barriers. Manufacturers adhering to internationally recognised standards – particularly those who have also earned internationally recognised conformity assessment certification – can access a broader customer base, while operators benefit from a wider range of compatible products. This interconnectedness fuels market growth and strengthens the global supply chain.
In most cases related to pipeline design, procurement, and fabrication, having a certified Quality Program is essential. ASME’s Quality Program for Suppliers (QPS) certification can be a key to unlocking doors to international markets. This unique quality program was developed using Subject Matter Experts (SMEs) and uses the best quality practices from across industries. This certification demonstrates a company’s commitment to understanding and meeting national regulations, industry specifications, customer requirements, and standards.
Advancing sustainability goals
Sustainability is a pressing priority for the oil and gas sector. Standardisation plays a crucial role in helping companies adapt to evolving environmental expectations and regulatory requirements. By re-engineering processes and revising product portfolios, companies can achieve scalability while reducing their environmental footprint.
For instance, standardised practices can enable the efficient integration of renewable energy sources into existing pipeline networks. Companies can repurpose infrastructure to transport hydrogen or other alternative fuels, supporting the transition to cleaner energy systems. Additionally, standards promote resource efficiency by providing a methodology for optimising material usage and minimising waste during manufacturing and construction.
A collaborative effort
The benefits of standardisation are magnified through collaboration. Organisations like ASME and the Pipeline Research Council International (PRCI) exemplify the power of partnership in developing and refining standards. Joint efforts to update the ASME B31 suite of piping standards with the hydrogen service requirements found in the ASME B31.12 Hydrogen Pipelines Standard highlight the importance of pooling expertise to address industry challenges.
Collaboration extends beyond industry bodies to include governments, academia, and other stakeholders. By fostering a culture of shared responsibility, the oil and gas sector can leverage collective knowledge to enhance standardisation efforts. This holistic approach ensures that standards remain relevant and responsive to technological advancements and societal needs.
Standardisation is foundational, certification is next level
In an era of globalisation and sustainability, standardisation is more than a technical requirement; it is a strategic enabler. For the oil and gas industry, adopting and applying standards harmonises operations, helps to enhance safety, and drives innovation. Moreover, it positions companies to meet the dual imperatives of economic growth and environmental stewardship.
As the industry continues to evolve, the role of standardisation will only grow in importance. By leaning into standards even more during times of transition, oil and gas companies can build a resilient and sustainable future, ensuring
that energy continues to flow reliably and safely to meet the world’s needs.
But standardisation is just the first step. Product and personnel certification also make a huge difference to pipeline operators, constructors, inspectors, and regulators. When pipeline systems are built, regulators look for certifications that show the pipeline was designed, constructed, and inspected to accepted standards and regulations. When pipelines are operated, companies use certified systems to verify the continued integrity of the pipeline components and controls. When the time comes for repairs and replacements to pipelines and their components, operators tend to look for companies that have a proven track record, have certified inspection and examination personnel, and that use certified equipment and processes in their repair and replacement work to ensure that the original design parameters and regulatory requirements have been maintained. ASME’s piping standards, personnel certification in design and geometric dimensioning and tolerancing (GD&T), and pipeline personnel qualification requirements include recognising other organisations’ certifications that meet requirements or even mandating these requirements for safety-critical work.
ASME’s PRT (Parts Fabrication) Certification is a high demand certification as well. Intended for parts and component manufacturers without design capability, PRT certification opens doors to suppliers. The program allows certification to be extended to parts suppliers who fabricate parts from the design(s) provided by a BPV Certificate Holder.
ASME recognises that not all parts manufacturers are involved in fabrication activities that require them to design (including developing stress calculations and analysis required by the BPV Code) and therefore ASME created a time and resource-saving alternative for their suppliers with PRT Certification. The PRT Certificate is applicable to manufacturers and suppliers in the piping value chain but also opens other avenues for suppliers to provide services in other industrial markets.
Whether your customers currently require certification or may in the future, conformity assessment certification adds value, can help differentiate your company from competitors, and opens doors to more proposal opportunities.
Adrian Gamman, Norclamp, discusses extending the life of ageing pipelines, focusing on risks, solutions and sustainability.
n the global energy infrastructure, it’s no secret that pipelines serve as the arteries of industry. Stretching across continents and beneath oceans, these networks transport billions of barrels of oil and gas annually, connecting production sites to refineries, power plants, and consumers. The oil and gas industry relies heavily on this infrastructure to meet the world’s insatiable demand for energy. In recent years, the stakes have grown even higher with public scrutiny over environmental performance, coupled with stricter regulatory requirements.
Pipelines are, by design, built to withstand immense pressure, hostile environments, and decades of continuous operation. However, many of these structures are now ageing, pushing the limits of their intended lifespans. Most of these structures, laid down in the late 1900s, were designed to function for 20 to 40 years, which means pipelines worldwide are facing their twilight years. This presents mounting challenges for operators tasked with maintaining their safety and functionality. We all know that failures in pipeline integrity can lead to catastrophic consequences: oil spills, leaks and economic disruptions that would severely affect global markets.
For an industry navigating the transition to cleaner energy while ensuring the uninterrupted flow of resources, innovation and smart solutions are key.
The risks of ageing pipelines
As pipelines age, they face a convergence of risks. Corrosion is one of the most pervasive issues, caused by a combination of environmental exposure, the chemical composition of transported materials, and physical wear. Corrosion not only weakens pipelines but also increases the likelihood of leaks and ruptures – events that can devastate ecosystems and contaminate water supplies, while emissions from compromised infrastructure
undermine global decarbonisation goals. For operators, the financial impact is also significant, as repairs, regulatory penalties, and the risk of reputational damage all add up. Mechanical stress and material fatigue also threaten pipeline integrity. Dents, cracks, and deformations accumulate over time, often exacerbated by substandard construction practices or insufficient maintenance. The risk of these structural failures grows with each passing year. Yet despite these challenges, pipelines remain indispensable. Global energy demand continues to grow in parallel with population increases and industrial expansion. Meeting this demand while managing the risks of ageing infrastructure requires a dual focus on new solutions and sustainability. One such innovation, Norclamp’s Infinity Clamp, represents a breakthrough in how operators can maintain and repair ageing pipelines efficiently and sustainably.
A transformative solution
The Infinity Clamp is a revolutionary repair and maintenance tool designed to address the most pressing issues of ageing subsea pipelines. Unlike traditional clamps, which are limited in their ability to cover extended pipeline sections, the Infinity Clamp offers a modular design that allows operators to scale repairs seamlessly. This is a key feature as corrosion will almost always spread, and the need for a larger – or more –clamps will often be needed down the line. The Infinity Clamp makes this easy because it uses an interlocking system to form a continuous seal over damaged sections of pipeline, regardless of length. Each clamp integrates seamlessly with the next, creating a reliable, 360° seal that restores the pipeline’s integrity. It is therefore well suited in situations where corrosion and other defects extend beyond typical clamp lengths. This patented compression packer technology ensures that even the most compromised pipelines can be repaired without the need for costly replacements.
Beyond its technical capabilities, the Infinity Clamp stands out for its efficiency. It is designed for rapid, diver or ROV-installed deployment, minimising downtime and operational disruption. This ease of installation is critical in subsea environments, where time and resources are often limited. ROV installation also means installation is possible in deeper water fields with clamp setting fully automated for ease of deployment.
Economic and environmental benefits
The Infinity Clamp is more than just a practical tool. By enabling targeted repairs, it reduces the need for full-scale replacements, saving operators millions in capital expenditures. Its rapid deployment minimises production downtime, ensuring that pipelines can return to service quickly and efficiently.
Norclamp’s commitment to sustainability further enhances the clamp’s value. In collaboration with the
Figure 1. An ageing pipeline with a leak that needs immediate repair work.
Figure 2. The Infinity Clamp being positioned over the damaged area of the pipe. It is designed for rapid, diver or ROV installed deployment, minimising downtime and operational disruption.
Dairyland decouplers are critical to cathodic protection systems. They keep workers and valuable assets safe from AC faults, lightning, and induced AC voltage, all while optimizing your CP systems. We hold ourselves to a very high Always Rugged standard to ensure Dairyland products meet all critical performance requirements, provide fail-safe operation, and address hazardous location needs to guarantee longevity and safety. We build them rugged so you can rely on them to perform.
Learn more about our Always Rugged promise: Dairyland.com/AlwaysRugged
Terravera Foundation, they collected and verified specific data and built a digital model for value chain analysis, which provided a detailed overview of the environmental impact across each stage of production and simulates potential improvements. The key finding from the research was that 81% of total emissions identified came from steel production, which spurred a shift in supplier strategy and production methods by Norclamp. The results of the changes are impressive: a 27% reduction in emissions per clamp and a 33% reduction in steel consumption compared to traditional repair methods.
These savings are critical in an industry under pressure to align with global net zero goals. Preserving existing infrastructure is far more sustainable than building new pipelines, which require significant energy and materials. The Infinity Clamp not only extends the life of pipelines but also reduces the environmental footprint of their operation.
Supporting the energy transition
The global shift to cleaner energy is transforming the oil and gas industry in several ways, one being a prompt to find innovative uses for existing infrastructure. Pipelines,
traditionally used to transport fossil fuels, are now being repurposed to carry alternative energy resources. Examples of this include:
) The West Gwinville Pipeline in the US, purchased in 2007 as a natural gas pipeline, was converted to carry CO 2 for enhanced oil recovery.
) The Organic Carbon Dioxide for Assimilation of Plants (OCAP) Pipeline in the Netherlands was an oil pipeline converted to carry CO 2 and has operated since 2004.
For instance, hydrogen – an essential element of the energy transition – requires pipelines equipped to handle its unique stresses. Similarly, Carbon Capture, Utilisation, and Storage (CCUS) projects depend on pipelines to transport captured carbon dioxide to storage sites, also needing robust infrastructure with enhanced integrity and leak prevention.
The Infinity Clamp is uniquely designed to meet these demands. By enabling the adaptation of existing pipelines, it helps operators minimise the environmental and financial costs of constructing new infrastructure. Its modular design addresses new defects as they emerge, making it particularly valuable for pipelines transitioning to transport hydrogen, carbon dioxide, or other sustainable fuels. Maximising the use of existing infrastructure often proves more advantageous than starting from scratch. It reduces costs, saves time, and minimises environmental impacts, all while aligning with sustainability goals. By converting pipelines to handle hydrogen, captured carbon, and biofuels, we can accelerate the energy transition, lower emissions, and maximise the utility of these assets. This approach ensures pipelines remain a vital component of the future energy network, transporting resources safely, efficiently, and sustainably across long distances. The future of pipeline management will also demand more from operators. Companies must prepare for stricter environmental regulations by investing in solutions that reduce emissions and enhance sustainability.
Future directions for pipeline management
As pipelines continue to age, the industry must embrace sustainable strategies that prioritise safety, efficiency, and environmental responsibility. Advanced materials and technologies, such as corrosion-resistant alloys and real-time monitoring systems, will play a critical role in addressing pipeline degradation.
Collaboration between private enterprises, governments, and research
Figure 3. The Infinity Clamp is secured in place with a reliable 360° seal that restores the pipeline’s integrity.
Figure 4. The Infinity Clamp uses an interlocking system to form a continuous seal over damaged sections of pipeline, regardless of length.
institutions will also be essential. Funding for innovation and regulatory reforms that incentivise sustainability are necessary to accelerate progress and ensure the safety and reliability of critical infrastructure in the face of ageing pipeline challenges. 1
Furthermore, with the rapid development of new technologies, the industry – particularly pipeline projects – is increasingly embracing innovations and advanced practices. This shift leverages extensive R&D efforts in the last couple of decades and aligns with the broader trend toward digitalisation and automation. The shift has also enabled remarkable progress, from the adoption of alternative pipe materials and welding techniques to enhanced inspection methods and integrity checks. It’s an exciting time to be a part of the pipeline industry and see the difference innovations like the Infinity Clamp can make to both resilience and longitude of existing pipeline infrastructure.
Conclusion
The challenges posed by ageing pipelines are complex, but they are not insurmountable. Through technological innovation and a commitment to sustainability, the energy industry can extend the life of its infrastructure while supporting the transition to a greener future. The Infinity
Clamp exemplifies this approach, offering a scalable, cost-effective, and environmentally friendly solution for pipeline repair and maintenance. By reducing emissions, preserving resources, and enabling the repurposing of infrastructure, it provides operators with the tools they need to meet the demands of the present and the opportunities of the future. Lastly, as the energy landscape continues to evolve, solutions like the Infinity Clamp will play a vital role in shaping a more agile and resilient industry and ensure that pipelines remain a critical infrastructure and a foundation for progress in a rapidly changing world.
About Norclamp AS
Norclamp, a subsidiary of the IK Group, delivers highquality, standardised clamp solutions designed to extend the life of pipelines and production systems. As a new player in the market, Norclamp draws on over 30 years of expertise from IK Group, a global engineering powerhouse known for leveraging its innovative DNA to create effective, groundbreaking solutions and products driving the energy transition.
References
1. Sharma, Ivanova, and Hassan (2024).
As the premier portable two-in-one Hydrostatic Testing Units in the pipeline industry, Midwestern’s HTU-350/500 automatically fill and test pipelines in one step. These units offer the fastest fill rate based on horsepower input with automatic switchover for filling pipe, pushing pigs and pressure testing.
That’s how Midwestern stands up to the pressure.
s a company that has spent over four decades in the offshore industry, Miros has seen firsthand how the success of offshore operations hinges on accurate planning and cutting-edge maritime technology. Pipelay and flexlay are a great example of this. Laying subsea pipelines isn’t just about deploying heavy machinery and skilled crews; it’s a finely tuned dance where nature’s unpredictable forces play a starring role. Among the many factors influencing operations, weather and wave conditions are perhaps the most critical.
Andrew Wallace,
VP Offshore Solutions at Miros,
on enhancing pipelay operations through real-time and predictive intelligence.
For instance, a sudden rise in wave height can cause vessel instability, increasing stress on product and equipment and risking damage to the subsea infrastructure. This makes precise in-operation monitoring and forecasting essential to maintaining operational safety and efficiency. That’s where the integration of operation-critical, real-time measurements and predictive insights has transformed how our clients approach these challenges. In addition, leveraging cutting-edge technologies like AI-powered wave and vessel motion prediction can be a game-changer for maritime safety and operational efficiency.
Understanding the impact of sea state on pipelay and flexlay operations
Pipelay and flexlay operations involve deploying rigid or flexible pipelines on the seabed, often in challenging environments where water depths, currents, and seabed conditions vary significantly. The method we use depends largely on the project’s requirements:
) S-lay: the pipe forms an ‘S’ shape from the vessel to the seabed, typically used in shallow to moderate depths.
) J-lay: the pipe descends almost vertically, suitable for deepwater applications.
) Reel-lay: pipes are prefabricated and spooled onto large reels, enabling rapid deployment for shorter pipelines.
) Flexlay: similar to reel-lay but focused on deploying flexible pipes for dynamic applications.
Regardless of the method, each operation is highly sensitive to environmental conditions, particularly waves. For instance, high wave heights can increase the stress on
the stinger and the pipeline, while long wave periods can amplify vessel motion, making precise pipe deployment more challenging. In J-lay operations, excessive vessel movement can compromise the vertical alignment required for deep-water installations, whereas in S-lay, lateral wave forces can disrupt the pipe’s smooth descent to the seabed. A slight miscalculation can jeopardise the pipeline’s integrity, damage equipment, or put the crew at risk. This is why having accurate weather forecasts and real-time wave measurements is non-negotiable.
The role of weather forecasts in offshore operations
Before any pipelay operation begins, our clients spend weeks, sometimes months, analysing weather forecasts to identify the safest and most efficient operational windows. Waves, wind, and currents directly impact vessel stability, pipeline tension, and the precision required for subsea deployment. High seas can cause the vessel to pitch and roll, increasing stress on the pipeline and the stinger, a curved structure guiding the pipe to the seabed.
For our customers and, by extension, Miros, one of the most critical lessons has been to thoroughly understand the interplay between forecasted and real-time data. While long-term forecasts give us a broad operational timeline, they lack the granularity needed for day-to-day decisionmaking. A forecast might predict calm seas for the week, but real-time data could reveal a sudden change in conditions, requiring immediate adjustments by the minute or even second. This is where the Miros WaveSystem has been invaluable. Committed to aligning with our customers’ needs we work closely together with our users to ensure the solutions deliver measurable value and continuously evolve to meet operational demands.
Driving efficiency in pipelay operations
The WaveSystem provides highaccuracy, real-time wave and sea-state data. Unlike traditional wave buoys, which can be limited by deployment constraints and maintenance challenges, the Miros system uses radar technology to deliver immediate and precise measurements directly from the vessel. This eliminates delays in data availability and enhances operational responsiveness, making it a clear upgrade over conventional methods. Wave buoys can be cumbersome to position and uphold, whereas the WaveSystem is dry-mounted and uses radar technology to measure wave height, period, and direction
Figure 1. With PredictifAI wave and vessel motion prediction, you are not just reacting to current conditions; you are anticipating coming scenarios. This foresight allows you to promptly reschedule operations, allocate resources, or implement mitigation strategies in advance.
Source: Miros PredictifAI.
directly from the vessel, all delivered through secure and reliable cyber services. The benefits of this are profound:
) Immediate insights: having real-time wave data to hand allows for up-to-the-second monitoring of sea conditions as they evolve, ensuring instant and accurate decisions to adapt operations.
) Improved safety: by continuously tracking wave heights and directions, conditions that might compromise vessel stability or pipeline integrity can be avoided.
) Operational efficiency: real-time measurements help optimise tensioner settings and stinger angles, ensuring the pipeline is laid smoothly and safely.
For instance, during a recent project in the North Sea, the crew detected an unexpected secondary wave system that wasn’t reflected in the initial weather forecast. Because they could measure this occurrence in real-time, our client was able to adjust the vessel’s positioning and delay certain high-risk tasks until conditions stabilised. This proactive approach prevented potential equipment damage and safeguarded the integrity of the project.
The power of prediction
While real-time data is essential, the ability to predict upcoming waves and vessel motion conditions takes planning to the next level. This is where Miros PredictifAI comes into play.
Using artificial intelligence, advanced algorithms and machine learning, PredictifAI pairs AI with X-band radar and DNV alpha-factor approved real-time measurements with weather forecasts and historical data to deterministically predict wave and vessel motion conditions up to a couple of minutes in advance.
Addressing the critical challenges posed by unpredictable marine environments offers a transformative approach to offshore planning and execution. With wave and vessel motion prediction, it isn’t simply a case of just reacting to current conditions but rather anticipating upcoming scenarios. This foresight allows for the prompt rescheduling of operations, reallocation of resources, or the implementation of mitigation strategies in advance.
With vessel charter and crew costs running into hundreds of thousands of dollars per day, wave and vessel motion prediction can assist in minimising downtime by identifying optimal windows for pipelay activities.
Moreover, predictive insights can help to better handle sudden changes in sea state that could endanger the crew or compromise the pipeline.
During a project off the coast of Norway, PredictifAI proved invaluable. The system provided a two-minute prediction and an alert to a sharp increase in wave height, giving the crew time to react, secure equipment, reposition
Figure 2. WaveSystem provides actionable insights allowing the operator to adjust the vessel’s positioning until conditions stabilise. Source: Miros WaveSystem.
Figure 3. Miros WaveSystem provides high-accuracy, real-time wave and sea-state data. WaveSystem is dry-mounted and uses radar technology to measure wave height, period, and direction directly from the vessel. Source: Miros WaveSystem.
AGRULINE XXL PIPES
•
• FAST AND EASY INSTALLATION
•
• HIGH-QUALITY MATERIALS
• EXPERTISE IN PLASTICS PROCESSING
the vessel, and communicate adjustments to the rest of the vessel.
Integrating real-time and predictive insights
The combination of artificial intelligence, X-band radar, and advanced IoT-enabled sensor technology to provide real-time monitoring of sea conditions creates a powerful synergy. Real-time measurements ensure vessels are always aware of current conditions, while predictive insights allow them to look into the future. This innovation is more than just a product; it’s a platform designed to transform maritime safety and operational efficiency, built as an add-on to the growing suite of applications in our WaveSystem portfolio. Together, they form a comprehensive decision-making framework that can revolutionise the approach to pipelay and flexlay installations.
Beyond operations: the broader benefits
If you are looking to enhance operational efficiency, while also significantly improving safety and costeffectiveness, tools like the Miros WaveSystem and PredictifAI can be beneficial. They not only assist by minimising downtime and preventing equipment damage, but they can also reduce project expenses while creating a safer environment for crews. Additionally, these
technologies offer broader advantages, such as boosting environmental compliance, and they also contribute to environmental compliance with accurate wave data and predictions helping to avoid unnecessary delays, reducing fuel consumption and emissions from idling vessels.
Looking ahead
As the pipelay industry continues to evolve, the integration of real-time measurement and predictive technologies will become standard practice. The shift towards data-driven decision-making has been one of the most exciting developments so far. It’s not just about laying pipelines; it’s about doing so with precision, safety, and efficiency, even in the face of nature’s uncertainties.
At Miros we have set a new benchmark for what’s possible in offshore operations. By combining real-time accuracy with predictive intelligence, we have transformed how operators’ approach pipelay and flexlay installations, making them safer, more capable, and more resilient to the challenges of the sea. Empowering offshore operators with real-time insights and predictive capabilities will inevitably enhance operational safety and efficiency, supporting the sector’s overall journey toward sustainability and resilience. With intelligent AI-powered products, we can challenge the status quo and turn challenges into opportunities, shaping the future of the offshore industry.
TRIDENT 400 SUBSEA
ACOUSTIC RECEIVER
The Trident 400 receiver system is a digital receiver designed to detect all frequencies from 8kHz to 50kHz. It has been developed to meet the harsh operating conditions associated with offshore marine environments.
Digital Filtering allows to isolate individual pigs (within 1kHz) and increased distance detection due to reduced background noise.
Data from the receiver can be viewed in real time using the PigView Software included
The specialist subsea umbilical team at EnerMech discuss advanced techniques for subsea umbilical pre-commissioning in deepwater oil and gas expansions.
s the oil and gas industry ventures into increasingly complex and deepwater environments, the expansion of subsea production systems has become more prevalent. These expansions typically involve the addition of new wells, flowlines, and umbilicals, which must seamlessly integrate with existing infrastructure. In
deepwater projects – often beyond depths of 2000 m – this integration presents unique challenges, particularly during the pre-commissioning phase of subsea umbilicals.
To address these challenges, EnerMech has developed and commercialised innovative subsea umbilical testing techniques that cater to the demanding conditions of such environments.
Understanding umbilicals
Subsea umbilicals are vital for transporting fluids, electrical power, and communication signals between surface facilities and the subsea production systems. Typically, these umbilicals are complex assemblies containing multiple fluid cores, electrical cables, and fibre optic lines. The fluid cores are designed to transfer various critical substances, including:
) Hydraulic fluids for operating subsea equipment.
) MEG (mono-ethylene glycol) or MEG/water blends, often used for hydrate inhibition.
) Production chemicals like corrosion inhibitors or kinetic hydrate inhibitors, essential for maintaining the integrity of subsea wells.
In the initial installation phase of a subsea production system, these fluid cores are pressure tested and connections verified from the surface using portable test units. However, in the case of brownfield expansions – where new infrastructure is added to an existing field – both ends of the umbilical are terminated subsea, making surface-based testing impossible. This necessitates a new approach to ensure the integrity of subsea connections, particularly in deepwater environments where water depths can range from 900 - 2200 m.
A dual approach to umbilical testing
EnerMech has responded to the growing demand for reliable subsea testing solutions by developing two distinct techniques tailored to different project requirements. These techniques are specifically designed to address the unique challenges of deepwater umbilical testing, including high pressures, the need for ultra-clean fluid delivery, and the logistical complexities of operating at extreme depths.
Subsea Test Pump (STP) powered by ROV
The first technique involves the use of a self-contained, ROV-powered Umbilical Subsea Test Pump (USTP). This system, configurable with up to three pumps and three fluid reservoirs, is ideal for testing shorter umbilicals or flying leads where the volume to pressurise (VTP) is relatively
small. The USTP system is deployed to the seabed, where the customer’s ROV connects the testing equipment to the umbilical via a hot stab connection. The same ROV simultaneously provides hydraulic power to the USTP. The entire testing process is controlled remotely, allowing for realtime monitoring of pressure and leak integrity. This method is particularly effective when the fluid volume required for testing is manageable, making it a preferred choice for smaller-scale applications.
There are two parallel systems on-board the USTP to allow testing of both umbilical hydraulic and chemical lines. Each system has an independent pump, which is powered by the ROV hydraulics, via a custom hot stab – options exist to run the pumps either separately or both at the same time. One stream is used to inject typically MEG, and the other for hydraulic fluids.
All parts of the system are flushed to the required cleanliness levels before use – for critical hydraulic fluids this includes flushing to the stringent ISO. The USTP is then flow tested and sampled on deck to show compliance, prior to deployment.
The USTP has the umbilical test fluids located onboard the frame in two pressure-compensated barrels. Each barrel holds approximately 170 l of umbilical fluid. The umbilical fluids are filtered to the required cleanliness value before being pumped into liner bags fitted in the compensated barrels. Where more than two different fluids are required or if the higher subsea storage capacity is needed, the STP can be connected to a separate subsea storage chemical basket.
Each system is protected from over pressurisation with on-board pressure reducing valves (PRVs). The tests pressures are recorded on dedicated data loggers for each system that can be viewed in real time and downloaded when required through the optical uplink system. A subsea Keller gauge is also fitted to each system as a back-up data logger that provides a visual display of the pressure in each system in real time.
The optical Uplink system consists of a sender unit located on-board the STP and a receiver unit located on-board the ROV. The ROV Optical Link unit sends real time information, through the ROV umbilical, to a system laptop situated in the ROV control room. This allows for the ROV operators to instruct on stopping/starting/varying pressurisation rates.
The ROV operator controls the rate of pressurisation by increasing or decreasing the hydraulic flow to the on-board pump. On completion of the test, the data can be uploaded to the laptop for client acceptance, without the need to recover the unit to the surface. Once the test has been accepted, the STP can be reconfigured to conduct the controlled depressurisation of the tubes on test to the specified abandonment pressures before disconnection of the test flying lead and recovery of the STP to the surface.
On-board the STP, the controlled depressurisation is conducted through a flow control device/orifice plate. The flow control device is sized for each umbilical system, and calculated based on actual requirements, volume/bar and pressure, and prevents excessive depressurisation rates of the umbilical tubes.
Figure 1. EnerMech Twin-Pump Umbilical STP Unit front and rear view (showing twin fluids).
Twin single-section composite downlines
The second technique, for projects involving larger umbilicals or when significant volumes of testing fluid are required, EnerMech utilises twin single-section, self-supporting composite downlines. These downlines are deployed from the surface to the subsea end and are specifically designed to handle different types of fluids – one line for hydraulic fluids and the other for MEG-based fluids. The composite construction and smooth-bore ensure that the downlines maintain the required cleanliness standards and structural integrity under high-pressure conditions. This approach is not only suitable for testing umbilicals but can also be used to test flowlines flooded with potable water or a MEG/water mix.
For the downline option, the fluids and pumping system are located on the marine vessel (PSV/LCV etc) meaning there is no restriction on volumes and types of fluids that can be provided.
The twin composite downlines have some unique benefits including:
) Suitable for most applications: each downline is 1500 m long x 0.75 in. ID. Larger/longer composite lines can be provided for custom projects.
Key benefit Umbilical STP Composite downline
Large fluid volumes
Multiple subsea tests
Fluid change-over whilst deployed
Ability to handle nitrogen injection
System can remain in place subsea between operations
Remain mobilised during weather events
Independent of ROV hydraulic water supply
) High pressure: 10 000 psi (690 barg) MAWP.
) Single-section and self-supporting: custom umbilical sheathing increases longitudinal load capacity to 7000 kg.
) Collapse resistant: external collapse pressure of 100 bar/1000 m with option to use EnerMech EFPS surplusvalve system for deeper operations.
The downline system has been successfully deployed over 20 times, with typical deployment and recovery times of around 1 hour to WD of up to 1350 m.
Strategic advantages and industry impact
The choice between these two techniques depends on various factors, including the volume of fluid required for testing, the specific project needs, and the customer’s operational preferences. The ROV-powered STP system is favoured for smaller operations where mobility and ease of deployment are critical, while the composite downline technique is better suited for extensive systems requiring larger fluid volumes.
EnerMech’s ability to offer these specialised testing solutions has allowed the company to carve out a niche in the subsea testing market. By strategically investing in the necessary equipment – such as the composite downlines, which represent a significant financial commitment –EnerMech has ensured they can meet the demands of this specialised field.
Meeting evolving client needs with operational expertise
EnerMech’s success in subsea umbilical testing has been driven by a motivation to adapt to client needs in real-time, rather than through traditional R&D methods. Operational teams have responded to client demands by repurposing existing technology, such as adapting subsea testing units initially used for pipeline pressure testing to accommodate fluid reservoirs and clean pumps for umbilical testing. This pragmatic approach has allowed EnerMech to quickly bring effective solutions to market, meeting the evolving demands of the industry.
This is a strategy replicated on a global scale with the ability to tailor services to specific client requirements, whether for projects in West Africa or Australia, highlighting a commitment to operational excellence and customer satisfaction.
In the coming years, as deeper and more challenging environments are tackled by the oil and gas sector, the need for reliable subsea umbilical pre-commissioning solutions will grow.
EnerMech’s innovative approaches to subsea testing offer a proven method for ensuring the integrity of critical subsea infrastructure. By having two different methods which can be applied to different scenarios, both new developments and brownfield expansions are completed with the highest standards of safety and reliability.
In this episode, we look at the work of the Pipeline Industries Guild, in facilitating connections and learning for pipeliners of all kinds in the UK. Featured guests: Kate Lazenby, Executive Director, Pipeline Industries Guild, and Barry Hayward, Pipeline Industries Guild Chair, and Chief Commercial Officer at South Staffordshire Plc.
This episode of the podcast covers:
• How the Guild engages with professionals across a range of pipeline sectors in the UK.
• How the Guild works with regulatory bodies to influence policies and standards for the UK pipeline industry.
• The ways in which the Guild contributes to skills development, particularly as the UK pipeline sector faces evolving needs in technology and sustainability.
• How the Guild maintains a global perspective, as well as a UK focus.
LISTEN NOW
CATCH UP ON THE SEASON SO FAR
Episode One: PLCA
Episode Two: PLCA
Kate Lazenby
Barry Hayward
Elizabeth Corner
Geronimo Rodriguez, Oil States, explains why an emergency pipeline repair system (EPRS) is a necessary, fail-safe solution to secure the reliability and integrity of subsea infrastructure.
s subsea infrastructure is as vital to global economies as offshore pipelines, failure is not an option. These assets must operate reliably while moving essential production miles to shore from water depths ranging from 1000 – 10 000 ft. This can be challenging, as such assets are susceptible to corrosion defects as well as external forces including impact damage from ship anchor-chain drag as well as dropped objects from platforms – all of which can render assets inoperable. Disruption to pipeline operations due to mechanical failures or external damage can lead to serious consequences that encompass environmental impact as well as substantial production and financial losses.
When a pipeline is compromised by a defect or sustains damage, operators must respond rapidly to contain the damage and
complete repairs or risk extended downtime. To react swiftly, asset owners must prioritise investments in incident planning. Ideally, the plan that is put in place must be comprehensive, straightforward and easily executable, and the best way to achieve those objectives is to implement a permanent solution – one that reduces complexity during a high-pressure scenario and allows for carefully orchestrated, efficient and safe repair.
Building a resilient network
Integrating resilience factors into pipeline engineering, procurement, construction and installation (EPCI) programs and installing an emergency pipeline repair system (EPRS) are crucial measures for minimising operational disruptions over the service life of an offshore pipeline. Combining both technical services and
the latest subsea repair technologies, an EPRS offers a holistic solution that can protect and maintain pipeline mechanical integrity.
Designed as an integrated contingency package containing specialised tools, spare parts and detailed response protocols that facilitate urgent repairs, a typical EPRS includes:
) Fully assembled clamps, connectors, and fittings.
) Gaskets, seals, and spare fasteners.
) Technical and Service team support.
As a first step in building resilience, operators must evaluate existing assets to determine which of the most valuable pipelines cannot be rendered inoperable for an extended period. The next step is to customise and pre-install an EPRS that can be quickly accessed and deployed in the event of an emergency.
Because a breach in pipeline integrity and subsequent repairs can have significant and costly operational and environmental consequences, time is of the essence. Operators must have immediate access to spare components and repair solutions to mitigate damage and reduce downtime. With predefined repair equipment suites that are customised for a pipeline’s specific operating conditions, an EPRS allows operators to shave months off the downtime typically required after an emergency event. The time savings from an integrated solution combined with having immediate access to spare equipment can amount to millions in cost avoidance.
Fast emergency repair
Emergency repair technology providers offer a way to rapidly return pipelines to operation following an integrity issue. When a pipeline sustains damage that takes it out of service, having access to a complete package of field-proven technology solutions to perform repairs is essential.
As an example, Oil States’ robust EPRS capabilities transform pipeline emergency response from reactive to proactive damage control, minimising downtime risk and disruption. The lead time for a new EPRS system is at least 18 months. However, having this hardware already built and properly maintained will reduce the readiness time as the system can be available in two weeks.
Associated proprietary subsea technologies for fast emergency repair include misalignment connectors, swivel
ring flanges, mechanical pipe end connectors and diverless leak repair clamps, all of which support the pre-installed EPRS as a holistic solution for reinforcing offshore pipelines. Each component is customised for a project’s unique needs.
Understanding the unique operating conditions of offshore environments, a team of highly specialised subsea pipeline system experts is essential to deliver design, manufacturing and support for pipeline construction, repair and expansion projects.
Future-proofing mega projects
A recent Middle East project where OSI provided an EPRS package demonstrates its appropriateness for emergency response and field reinforcement. To tap additional gas reserves in part of the world’s largest non-associated natural gas reservoir, an operator desired to expand its operations in the Persian Gulf. The operator desired to add nearly 20 million tpy of LNG production capacity before the end of the decade. With recoverable reserves of more than 900 trillion ft3 of gas, the targeted field holds approximately 10% of the world’s known reserves. Expansion of the operator’s project includes EPCI of nearly 250 km of offshore and onshore gas pipelines, connecting facilities that would supply feed gas for two additional LNG trains.
Oil States manufactured the first EPRS for 38 in. diameter pipelines in 2015 to help the operator manage the integrity of its vast pipeline network. System hardware was designed as a permanent fixture for preventative maintenance to help optimise uptime reliability for the operator’s mature gas wells and ensure the necessary level of readiness to respond to an emergency repair in real time. The package was designed specifically for the project, meeting the required wall thickness parameters and fluid compatibility checks. Although the EPRS has fortunately not been necessary to date for incident resolution, having the system available as a contingency solution helps future-proof asset integrity and provides foundational support for new construction.
Reinforcing pipeline longevity and reliability
A company’s license to operate is predicated on safety, which is why emergency readiness is absolutely imperative. Emergency solutions like the EPRS are essential to preserving the integrity of the world’s pipeline network and the safe, reliable transportation of energy to shore.
Reinforcing operations with emergency repair tooling and technical support promotes pipeline integrity and safety – and in a worst-case scenario, helps circumvent severe damage to the asset, environment and community.
With major EPCI developments set to expand subsea pipeline networks globally, an EPRS is an indispensable asset for sustained operations and emergency response for offshore pipelines.
About the author
Geronimo Rodriguez is a regional operations and pipeline product development manager with more than 18 years of experience in deepwater and onshore drilling and subsea pipeline solutions.
Figure 1. Oil States provided 16 - 38 in. Mechanical End Connectors as part of an EPRS package in 2012 for a client in the Middle East, and OSI continues to maintain the hardware to this date.
Emmanuelle Mayor, Petroseal, discusses how advanced metallic enclosures provide the definitive solution for high-pressure, high-temperature, online leak sealing.
very year, millions of tons of industrial gases and liquids escape due to unsealed leaks, causing financial losses, safety risks, and environmental damage. In high-pressure and high-temperature environments, conventional sealing methods such as composite wrapping quickly reach their operational limits. This is where metallic enclosures prove superior. Designed to encapsulate leaks and facilitate the injection of highperformance sealing compounds, they ensure a safe, long-lasting, and efficient online repair without requiring production shutdowns. Why is this technology critical? It meets the most stringent safety and environmental standards while offering unmatched adaptability to operational constraints.
A growing need in industry
Industrial leaks are not only a maintenance issue; they represent a critical environmental and financial challenge. According to the International Energy Agency (IEA), methane emissions from oil and gas infrastructure reach approximately 75 million tpy. Beyond methane, leaks of steam, hydrocarbons, and aggressive chemicals pose severe safety hazards and impact facility profitability.
Metallic enclosures provide a direct and effective response to these challenges. They enable rapid and efficient intervention under extreme conditions, preventing costly shutdowns while avoiding environmental impacts. Their application spans multiple industries, including refining, petrochemicals, power generation, and nuclear sectors.
Why wrapping is insufficient
Composite wrapping has gained popularity as a quick-fix repair solution, but it presents several significant limitations:
) Temperature and pressure resistance: most composite wraps degrade beyond 150°C and 20 bar, making them unsuitable for high-energy systems.
) Chemical compatibility: aggressive media such as acids and hydrocarbons can break down composite materials over time.
) Durability concerns: wrapping solutions often require frequent monitoring and may fail under cyclic thermal or pressure conditions.
In contrast, metallic enclosures can withstand pressures exceeding 200 bar and temperatures beyond 700°C, making
them the preferred choice for high-risk applications where safety and longevity are paramount.
The engineering behind metallic enclosures
At Petroseal, metallic enclosures are engineered within 24 hours to fully encapsulate the leaking area of a pipeline or pressurised equipment. Its installation follows a rigorous process:
) Custom design and manufacturing: the enclosure is tailored to the leak’s geometry and service parameters or selected from standard designs for common applications.
) Mechanical fixation: the enclosure is clamped securely around the leak site, ensuring structural integrity.
) High-performance sealing compound injection: a specialised sealing compound, formulated to match the fluid type and operating conditions, is injected under controlled pressure to achieve immediate sealing.
Sealing compounds used in metallic enclosures must comply with stringent industrial standards to ensure reliability. For instance, Petroseal’s high-performance sealants conform to ISO 9001 quality management systems, guaranteeing consistent material performance. Furthermore, compounds designed for nuclear applications meet products and materials used in nuclear sites (PMUC) certification to minimise halogen and sulfur content, preventing corrosion risks in power plants.
Industry compliance and standards
The use of metallic enclosures for leak sealing must adhere to multiple industry regulations and engineering standards. Key guidelines include:
) ASME PCC-2 (Repair of pressure equipment and piping): Provides best practices for in-service repair techniques, including mechanical enclosures.
) API 570 (Piping inspection code): Governs the inspection, rating, and repair of piping systems in the oil and gas industry.
) EN 13480 (Industrial piping): Establishes European standards for metallic piping design and integrity management.
) CODAP (French pressure vessel code): Offers design criteria for pressure equipment in critical environments.
Figure 1. In this case, after two days of round-the-clock manufacturing, these designs were successfully installed with clamps (left: before, right: after).
Industry standards provide the technical foundation for designing and applying enclosures that withstand pressure, temperature, and operational stresses. By complying with these rigorous standards, metallic enclosures ensure both safety and regulatory acceptance in highly controlled industries.
Real-world applications and case studies
A maintenance engineer from a European refinery shares his experience:
“We faced critical hydrocarbon leaks at 390°C and 35 bar on our heat exchanger. Wrapping was not an option due to the configuration and the extreme conditions. The metallic enclosure allowed us to isolate the leaks safely and maintain production without costly downtime.”
Planning
) Day 1 – 11am: urgent online leak sealing request received from maintenance engineer (data received: pressure, temperature, media, pictures and videos).
) Day 1 – 1pm: leak analysis done. Sketch and scope of work sent by Petroseal for measurement steps by the refinery contractor.
) Day 1 – 3pm: measurements received. Engineering department working on it.
) Day 1 – 6pm: both designs sent to refinery.
When an urgent leak sealing request is received, every minute counts. Effective planning and responsiveness ensure a fast intervention. Within hours, Petroseal transforms a critical situation into a structured solution: from receiving the request to delivering precise designs, each step is executed with efficiency. By quickly assessing the situation, gathering key measurements, and providing customised solutions, we help industries minimise downtime and maintain safe, continuous operations.
A key tool for emission reduction
As environmental regulations become increasingly stringent, industries face mounting pressure to reduce fugitive emissions and enhance sustainability. One key solution lies in the use of metallic enclosures for leak sealing, which play a crucial role in limiting harmful emissions and ensuring operational safety.
Containing methane and industrial vapours: many industrial sites experience leaks not only of methane (a potent greenhouse gas) but also of various volatile organic compounds (VOCs) and process vapours. These emissions contribute to air pollution, regulatory non-compliance, and potential health hazards. By effectively sealing leaks at their source, metallic enclosures help industries control atmospheric releases, ensuring compliance with environmental standards while reducing their overall impact on air quality.
Enhancing safety for workers and the environment: toxic and hazardous leaks pose significant health and safety risks, not only to personnel working in industrial plants but also to surrounding ecosystems. By containing leaks at their source, metallic enclosures prevent the spread of dangerous substances, reducing exposure risks and improving workplace safety standards.
Preserving asset integrity and minimising economic losses: uncontrolled leaks can lead to costly downtime, equipment damage, and product losses. By deploying metallic enclosures, industries can maintain the integrity of their piping and pressure systems without the need for costly shutdowns or extensive repairs. This ensures continuous production, optimises maintenance costs, decrease energy costs and extends the lifespan of critical assets.
In addition, initiatives such as the Oil & Gas Methane Partnership (OGMP 2.0) emphasise the need for advanced leak detection and repair (LDAR) programs. Integrating metallic enclosures into these programs enhances compliance and reinforces corporate sustainability commitments.
Incorporating metallic enclosures as part of a proactive leak management strategy is not just a regulatory necessity, it is a smart investment in sustainability, safety, and operational efficiency.
The future of metallic online leak sealing
The demand for high-reliability leak sealing solutions continues to grow, driven by safety, environmental, and economic factors. Industries worldwide face increasing regulatory pressures to minimise emissions and prevent unplanned shutdowns, making efficient and durable leak sealing technologies more critical than ever. Advanced materials and designs, combined with digital monitoring and predictive maintenance technologies, are shaping the next generation of metallic enclosures.
Petroseal, by continuously innovating and adapting to these new solutions, positions itself as a leader in online leak sealing, setting new standards for operational excellence and sustainability. Our commitment to research and development ensures that our enclosures not only meet but exceed industry expectations, providing customers with customised, high-performance solutions.
Investing in metallic enclosures is not just about extending asset life, it is about ensuring a safer, more efficient, and environmentally responsible future for industrial operations. By integrating online leak sealing best practices, companies can improve reliability, reduce longterm costs, and contribute to a more sustainable industrial landscape. With Petroseal as a trusted partner, industries can confidently meet today’s challenges while preparing for the future.
June 10-12, 2025
he Global Methane Pledge (GMP) laid out ambitious targets for tackling global methane emissions over the next decade. The initiative represents humanity’s first major concerted effort to tackle this growing environmental threat, committing governments worldwide to reduce atmospheric methane levels by at least 30% by 2030.
Achieving the GMP’s vision will be crucial for meeting international climate goals of limiting global warming to just 1.5°C. However, this target is growing further out of reach. Data released in the Global Methane Budget 2024 shows that methane levels have not fallen in the years since the GMP, and without immediate action the world could be on track for 3°C temperature increase by 2100.1
The fossil fuel sector bears much of the responsibility for methane emissions and as a result it has a duty to act. Thankfully,
Mark Naples, Managing Director, Umicore Coating Services, explores how advances in regulation and technology are furthering the oil and gas sector’s progress in methane detection to meet its targets for tackling emissions.
since its launch in 2021 the GMP has catalysed significant advancements in the technologies and regulations that the industry will need. By spurring innovation and investment in cutting-edge strategies for detecting and mitigating leaks, this pledge is supporting businesses in identifying and quantifying methane emissions more accurately than was previously thought possible. Combined with an evolving regulatory framework that further encourages data collection, the industry is quickly acquiring the necessary tools to make a real difference on methane.
A call to action
The GMP is a voluntary framework that supports signatories to collectively reduce methane emissions from human-caused sources. Launched at COP26 in 2021, it has since been signed by more than 150 countries representing more than half of all the world’s human-caused methane sources.
Achieving the GMP’s goal is critical to minimising the impact of climate change and protecting human life. Reducing methane levels by 30% over the next six years would reduce global warming by 0.2°C by 2050,2 preventing the equivalent of more than 200 000 premature deaths and hundreds of thousands more medical conditions.3 This is due to methane’s significant global warming potential – methane is a potent greenhouse gas that has become a particular focus in the fight against climate change due to its heat-trapping characteristics. The gas is the second most prominent contributor to global warming after carbon dioxide, heating the atmosphere almost 90 times faster than carbon dioxide in the first 20 years after its release. However, its relatively short atmospheric lifespan means that reducing emissions today would have a significant impact in just a few years.
The particularly large impact of fossil fuel companies in this regard means they are a prime area of focus for reducing overall emissions. Oil and gas producers are the second largest contributor to anthropogenic methane emissions after agriculture, with the International Energy Agency (IEA) estimating that they account for more than a third of total methane emissions from human activity.4 Leaking pipeline or storage infrastructure and incomplete fossil fuel combustion are both major sources of methane emissions, with this problem made worse by the relatively poor standard of data collection in this area. Improving data quality must become a priority for the energy sector if the GMP’s target is to be realised.
An evolving landscape
Since the GMP was launched, significant progress has been made in the legislative landscape to support reduction efforts. This culminated at last year’s COP28 climate summit which saw several major methane producers commit to regulations to start bringing a 30% reduction within reach. Since then, the USA has finalised rules to tighten requirements on oil and gas facilities as well as establishing a Super-Emitter programme to identify the facilities making the biggest emissions contributions. Canada has announced plans to eliminate flaring and venting activity, and in the EU, the first ever regulation to reduce energy sector methane emissions was introduced this year, obliging the fossil fuel industry to measure, monitor, report, and verify
emissions.5 This same stringency will also be applied to imported fuel, encouraging international exporters to introduce the same monitoring standards.
This regulatory action mirrors a growing commitment from the industry to improve emissions detection since 2021. COP28 prompted launch of the Oil and Gas Decarbonisation Charter (OGDC), which asks companies to lead the way for the entire industry on bringing down methane emissions.
Through the OGDC, companies are asked to demonstrate detailed implementation plans for achieving their targets and showing the progress being made. Gauging this progress will require a detailed baseline of emissions levels of the kind only made possible by advanced gas detection technologies.
Building a data profile
In 2023, the Environmental Investigation Agency identified that the GMP’s success relies on three key pillars. These are: monitoring, reporting and verification; mitigation; and capacity building.6
The need for more accurate monitoring is underscored by the fact that atmospheric methane concentrations could be up to 95% higher than the figures provided by oil and gas companies.7 Inaccuracy of this scale prevents targeted maintenance and means that any policy and regulation is working from an incomplete picture. Ad hoc gas detection will no longer be sufficient – in the new landscape, businesses must prioritise uplifting the quality and accuracy of their emissions data, and this will only be unlocked by investing in connected detection networks.
The need to meet the GMP’s targets has encouraged a shift towards more sophisticated gas detection technologies. Satellite technology has seen particular advancements in recent years with the launch of the UN Environment Programme’s Methane Alert and Response System (MARS) exemplifying this progress. MARS coordinates observations from multiple satellites to identify large-scale emission sources, and during its pilot phase in 2023 it detected more than 1000 energy-sector linked plumes around the world – with 400 matched to specific facilities.
Drones are also providing operators with a bird’s eye view over their infrastructure, helping them to rapidly identify potential leaks to facilitate immediate maintenance. These proactive systems can be combined with groundbased networks of fixed and portable devices to provide a comprehensive overview of pipelines and storage tanks. Such technology provides continuous monitoring that enables energy operators to scan facilities around the clock, offering a substantial improvement over traditional periodic inspections.
Innovation in sensing
Some of the most significant advancements in methane detection have been in sensors based on advanced spectroscopy techniques that use infrared light to facilitate accurate gas detection in the range of ppb. This technology, known as laser absorption spectroscopy (LAS), has gained prominence in the industry in recent years due to the high sensitivity and selectivity it provides.
LAS systems pass an infrared beam through an optical filter that only allows a specific wavelength into a sampling before
DIAMOND SPONSOR PLATINUM SPONSORS
GOLDEN
ADVERTISERS’ DIRECTORY
passing through to a detector. The optical filter will only transmit the IR wavelength that the target gas, e.g. methane, will absorb. This results in high-resolution spectral information that can be used to quickly and precisely determine any presence of the gas.
This technology has numerous applications in the oil and gas sector, with fixed and portable devices granting comprehensive oversight of where leaks occur. Such sensors facilitate on-site measurements of emissions from well heads or storage tanks, and can be integrated into processing facilities to monitor methane levels in real-time, or used to measure concentrations in flare gases to help optimise combustion efficiency.
The effectiveness of LAS technology heavily depends on the optical components involved, particularly the filters that isolate the wavelength of interest. As a result, a great deal of work has gone into improving optical filter technology in recent years to provide the oil and gas sector with the highperformance equipment it needs.
Recent advancements in thin film coating technology have resulted in infrared filters that can significantly enhance the sensitivity and selectivity of LAS equipment. In particular, improvements in narrowband filters that precisely match methane absorption lines are helping sensor manufacturers to maximise signal-to-noise ratios, resulting in greater accuracy. Greater environmental stability has resulted in filters that can maintain performance in a wide range of conditions to better support field deployments, while the increasing adoption of this technology means it is more important than ever to tailor filter specifications for specific detection requirements. This helps to optimise the sensor’s performance in various applications and environments.
Progress into action
The advancements being made in regulation and technology since the GMP was launched represent a real opportunity for the oil and gas sector. Armed with these tools, the industry has the chance to build a more accurate profile of methane emissions to support ongoing reduction activity. Implementing this technology will require industry-wide collaboration of a type never seen before, but failure to act is not an option – delays in reducing emissions now will only result in a bigger problem to overcome in the future and put the 2030 targets further out of reach.
As the world’s understanding of the threat posed by methane improves, detection technology will provide a viable path forward for reducing emissions and bringing progress back in line with GMP goals. By investing in innovation today, businesses have the chance to start building a greener tomorrow.
References
1. Global Carbon Project (2024), Global Methane Budget 2024
2. Global Methane Pledge (2023), Global Methane Pledge
3. European Commission (2021), Launch by the United States, the European Union, and Partners of the Global Methane Pledge to keep 1.5C within reach
4. International Energy Agency (2024), Global Methane Tracker 2024
