World Pipelines - August 2025 by PalladianPublications

Volume 25 Number 8 - August 2025

Unlock the Power of Data

Elevate your asset integrity with unmatched data accuracy and unparalleled expertise

Our unique synergy of advanced inspection systems, cutting-edge analytics and human expertise allows us to transform data into knowledge. Knowledge enables smarter decision-making and delivers a comprehensive understanding of asset safety, lifetime, and performance.

C O NTENTS

25 | NUMBER 08 | AUGUST 2025

03. Guest comment

Antonia Syn, Rystad Energy.

05. Editor's comment

07. Pipeline news

Pipeline news from Argentina, USA, UK, and Egypt.

KEYNOTE: CONSTRUCTION BEST PRACTICES

14. Fuelling the future

Walter Crommelin, Nick Homan, Kalen Jensen, and Sean Keane, four key leaders at the Pipeline Research Council International (PRCI), came together to explore current research priorities, safety standards development, environmental concerns, and workforce development initiatives in order to effectively prepare for the future.

24. Next generation approach to pipeline data management

Vinay Baburao, Director Digital Transformation, CRC Evans, explains how digital technology is delivering next generation pipeline services data management.

ENERGY SECURITY

33. Q&A: a new era of risk and resilience

World Pipelines interviews Raghu Yabaluri, Global Oil and Gas Market Leader, Black & Veatch, on the current state of energy security for pipelines, and the pressure points to which we must pay attention.

HYDROGEN PIPELINES

39. Repurposing: pass or fail?

Ben Cowell, Integrity Engineer, Luke Fahy, Integrity Engineer, and Nigel Curson, EVP of Technical Excellence, Penspen.

EPC CASE STUDIES

45. High-voltage, high-velocity

Scott Salter, Director of Power and Utilities, Audubon Co.

51. CCS success

Andrea Bombardi, Executive Vice President, RINA.

PIPELINE CONSTRUCTION

55. The rise of multi-pipe handling systems

Alyson Cram, Vacuworx, USA.

59. Overcoming the impossible

Patrick Koch, General Manager, LCS Cable Cranes.

61. Cutting through complexity

Giacomo Betti and Marco Paris, Tesmec, Italy.

65. Evolving excavators

Margherita Laurini, Chief Financial Officer, Laurini Officine Meccaniche, Italy.

67. Powering the future

Jimmy Herring, Chief Executive Officer, Infra Pipe Solutions.

MANAGING PIPELINES

71. Staying ahead of pipeline thieves

Harry Smith, Sales and Senior Research Engineer, Atmos International.

77. Relieving insurance costs with AI geospatial technology

Sean Donegan, President and CEO, Satelytics.

OFFSHORE AND SUBSEA

81. Achieving certified accuracy

Patricia Sestari, Voyis.

CORROSION CONTROL & CONDITION ASSESSMENT

87. Extending pipeline longevity Kristopher Kemper, AMPP, USA.

DECOMMISSIONING

93. Managing benzene risks in pipeline decommissioning Mark Burrup, Dräger.

PIPELINE INSPECTION

97. Long-term integrity with baseline inspections

Jim Costain, Craig Hall, Thomas Mrugala, and Ron James, NDT Global.

101. Going above and beyond

Jeff Taylor, Founder and President, Event 38 Unmanned Systems.

107. Transforming oil and gas inspections

Enzo Wälchli, Chief Commercial Officer, ANYbotics.

PIPELINE MONITORING

111. The wireless fight against methane emissions Sandro Esposito, SignalFire Telemetry Inc., USA.

121. A new compass for inspection

Dr. Mario Paniccia, CEO, ANELLO Photonics, USA.

125. Digital control at the edge of the world

Ajitkumar Sreekumar, Vice President of Sales, IMI.

Winn & Coales International Ltd has specialised in the manufacture and supply of corrosion prevention and sealing products for over 90 years. The well-known brands of Denso and Premier offer cost-effective, long-term corrosion prevention solutions. The front cover features their Viscotaq ViscoWrap™ HT system being applied to 350 km of 10 in. and 56 in. diameter field joints on the Master Gas System Expansion Phase III Project in Saudi Arabia.

GUEST COMMENT

Antonia Syn Analyst, Commodity Markets Research – Gas & LNG, Rystad Energy

Egypt is rapidly expanding its LNG import capacity – but pipelines will play a critical role in meeting its gas security requirements. The country’s gas balance still hinges on affordable pipeline flows from Israel even amid a flurry of new floating storage and regasification units (FSRUs).

The 12 day shutdown of Israel’s Leviathan field in June 2025 proved the point. When Israel halted exports, 16 million m 3/d – the equivalent of 4 million tpy – stopped flowing through the East Mediterranean Gas (EMG) pipeline. With only one LNG import terminal – the Hoegh Galleon FSRU at Ain Sokhna – already operating at maximum capacity, Egypt could not offset the lost supply. The impact was immediate: fertilizer, petrochemical, and urea plants were cut off within a day, diverting gas toward power generation. Jordan – which relies on Israeli volumes for 60% of its power – rushed to reverse the Arab Gas Pipeline (AGP) to draw emergency flows from Egypt. The disruption exposed how brittle and interdependent the region’s gas grid remains. Even as Egypt races to install more FSRUs, it cannot simply swap the pipelines for LNG.

Falling domestic production since mid 2024 has flipped Egypt from being a net LNG exporter to a net importer. Egypt scrambled to secure new FSRUs to meet peak summer cooling demand. The Hoegh Galleon FSRU arrived in June 2024, followed by the sub chartered Energos Eskimo , which received its first cargo on 15 July 2025. The Energos Power came online on 19 July, with two more – Energos Winter and Energos Force – scheduled for August. With the Hoegh Gandria joining in 4Q26, Egypt’s regasification capacity is set to vastly exceed current pipeline imports. Even so, pipeline flows into Egypt will remain indispensable for two reasons.

Firstly, LNG imports are financially unsustainable for Egypt. Dollar denominated cargoes force Egypt to burn scarce foreign exchange reserves or negotiate deferred payments, deepening its fragile balance of payments. The country remains under a US$8 billion IMF programme, now on its fifth review to unlock another tranche. Yet summer 2025 alone will cost over US$9 billion in LNG imports, plus another US$600 - 700 million for fuel oil. This steep energy bill is expected to strain the country’s foreign exchange reserves further and put downward pressure on the Egyptian pound. New LNG purchases could fuel inflation, increase the cost of other critical imports, and deepen Egypt’s fiscal hole. By contrast, pipeline gas under longer term contracts is cheaper and insulated from volatile LNG spot prices. It is not just affordable – it is financially essential.

PIPELINE FLOWS INTO EGYPT WILL REMAIN INDISPENSABLE

Secondly, Israel’s growing gas surplus next door is expected to become ever more accessible to Egypt through planned pipeline upgrades. Leviathan alone already supplies over half of Egypt’s imported gas, at around 14 billion m 3 in 2024. The field’s phased expansion will lift Israeli output from 28 billion m 3 to more than 40 billion m 3 by 2030. Expansion projects at the Tamar field, also exporting to Egypt and Jordan, will further create additional volume Egypt has every incentive to secure. Alternative export options are limited: Israel’s proposed FLNG project was shelved on cost grounds, meaning its surplus gas remains captive to regional pipelines.

Planned pipeline expansions could channel these extra volumes to Egypt. The EMG pipeline connection between Ashkelon and Arish (currently at a capacity of 6 billion m 3) is slated for an additional 2 billion m 3 expansion, while the proposed Nitzana pipeline would add another 6 billion m 3. Meanwhile, the AGP – once designed to export Egyptian gas – can flow in reverse, pulling additional gas from Jordan into Egypt.

Avoid safety risks and project delays

when you switch to PipePillo® engineered pipeline supports, the trusted quick and easy replacement for cribbing, foam, sandbags, and pad dirt to keep crews working faster and safer away from the trench.

Whether in or out-of-trench, PipePillos® support your team and your pipe, so your team can stay focused on the job, and not worry about their safety. Contact PipeSak Inc. for engineered pipeline supports, impact protection, saddle bag weights, and all around protection.

Fast, safe & easily stacked

Reliable, versatile, permanent

Won’t float & supports fully loaded pipelines

Proven long-term ovality prevention

Eliminates the need for cribbing, foam, sandbags, and pad dirt

Reduces labor & speeds up your project

PipePillo® Pipeline Supports:

EDITOR’S COMMENT

CONTACT INFORMATION

MANAGING EDITOR

James Little james.little@worldpipelines.com

EDITORIAL ASSISTANT

Alfred Hamer alfred.hamer@worldpipelines.com

EDITORIAL ASSISTANT

Emilie Grant emilie.grant@worldpipelines.com

SALES DIRECTOR

Rod Hardy rod.hardy@worldpipelines.com

SALES MANAGER

Chris Lethbridge chris.lethbridge@worldpipelines.com

SALES EXECUTIVE

Daniel Farr daniel.farr@worldpipelines.com

PRODUCTION DESIGNER

Siroun Dokmejian siroun.dokmejian@worldpipelines.com

HEAD OF EVENTS

Louise Cameron louise.cameron@worldpipelines.com

DIGITAL EVENTS COORDINATOR

Merili Jurivete merili.jurivete@palladianpublications.com

EVENTS COORDINATOR

Chloe Lelliott chloe.lelliott@worldpipelines.com

DIGITAL CONTENT COORDINATOR

Kristian Ilasko kristian.ilasko@worldpipelines.com

JUNIOR VIDEO ASSISTANT

Amélie Meury-Cashman amelie.meury-cashman@worldpipelines.com

DIGITAL ADMINISTRATOR

Nicole Harman-Smith nicole.harman-smith@worldpipelines.com

ADMINISTRATION MANAGER

Laura White

laura.white@worldpipelines.com

Palladian Publications Ltd, 15 South Street, Farnham, Surrey, GU9 7QU, UK Tel: +44 (0) 1252 718 999 Website: www.worldpipelines.com Email: enquiries@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.

SENIOR EDITOR Elizabeth Corner elizabeth.corner@worldpipelines.com

Reduced flow has been noted on several US-bound Canadian pipelines following the introduction of US tariffs in March: “Since the announcement, Wood Mackenzie’s real-time pipeline monitoring has detected flow reductions along three major crude systems that deliver Canadian crude to US markets: Southbow’s 590 000 bpd Keystone - Hardisty to Steele City pipeline, TransMountain’s 890 000 bpd TransMountain system, and Enbridge’s 307 000 bpd Express pipeline.”1

Canada is the world’s fourth largest oil exporter, but it sends some 75% of its exports to the US. There is major political momentum towards new pipeline projects and the majority of Canadians support building new oil infrastructure in order to patch this vulnerability, according to a poll conducted by The Globe and Mail.2

Much is happening towards the goal this summer. “Now the real work starts” said Carney as he marked the passage of Bill C-5 on 26 June, which grants powers to the cabinet to fast-track infrastructure projects. At the Calgary Stampede on 5 July, Prime Minister Mark Carney said that a new oil pipeline to Canada’s Pacific coast is set to make it onto the federal government’s list of projects of national interest. “I would think, given the scale of the economic opportunity, the resources we have, the expertise we have, that it is highly, highly likely that we will have an oil pipeline that is a proposal for one of these projects of national interest.”3 Carney added that he also supports a proposed CAN$16.5 billion carbon capture system for Alberta’s oilsands.

The day after Carney’s comments, Alberta and Ontario signed a deal to work together to help fast track investments in energy infrastructure. The two provinces want Ottawa to amend or repeal the Impact Assessment Act, and repeal the Oil Tanker Moratorium Act, Clean Electricity Regulations, the Oil and Gas Sector Greenhouse Gas Emissions Cap, and other federal initiatives that “discriminately impact the energy sector”, said a statement from the Alberta government.

On 22 July, Ontario, Alberta, and Saskatchewan announced a new MoU to construct new pipelines using Ontario steel, and build new rail lines to transport critical minerals from Ontario to Western Canada.

So is a revived Northern Gateway project on the cards? This much debated (and long since cancelled) project remains contentious. Enbridge’s proposed pipeline would have transported oil from Alberta to Kitimat, B.C., for export via tanker. In 2016, the Federal Court of Appeal overturned the Canadian government’s approval of the project, citing inadequate consultation with Indigenous peoples. The new Bill has caused concern among Indigenous communities, who are worried that the government could speed up approvals for infrastructure and energy projects and override legitimate protest.

Reflecting on the cancelled Northern Gateway and Energy East pipeline projects, an article in The Conversation about the case for building new pipelines argues: “On the one hand, any progress that mitigates the significant cost of US tariffs are likely dollars well spent. Building new pipelines strengthens the bargaining power of Canadian producers [...] On the other hand, if the US never follows through on tariffs on energy exports – or if future administrations do not share Trump’s affinity for chaotic trade policy – Canada could end up right back where it started when these projects were cancelled”.4

In this issue of World Pipelines, we focus on construction best practice. Canada almost certainly needs to lay new pipe as part of its quest to lay down its future direction. As the nation seeks its own form of energy independence, it should make a deliberate effort to value legal due process, Indigenous sovereignty, economic foresight, and global climate alignment. Good infrastructure is sometimes built fast, but it is always fair, future-proof, and built well.

1. https://www.woodmac.com/news/opinion/reduced-flow-on-several-us-bound-canadian-pipelines-following-introduction-of-tariffs/

2. https://www.theglobeandmail.com/business/article-canadians-support-building-new-oil-pipeline-poll/

3. https://www.reuters.com/sustainability/climate-energy/carney-says-new-oil-pipeline-proposal-canada-is-highly-likely-2025-07-06/

4. https://theconversation.com/could-new-pipelines-shield-canada-from-u-s-tariffs-the-answer-is-complicated-259660

Still pioneers.

Across energy and critical infrastructure, we bring expertise where complexity is highest, partnering with globally local teams and leveraging unrivalled proprietary technologies. Like the M-500 Single Torch External Welding System, seamlessly integrated with Data 360 our cloud-based digital platform that analyses, and visualises your project performance data in real time. We move projects forward, no matter the challenge.

We’re here to partner on how our specialist welding and coating solutions can help you power tomorrow.

WORLD NEWS

Sulzer expands operations in Argentina with third facility opening

As part of its ongoing strategy to grow across Latin America and enhance its service offerings, Sulzer has expanded its footprint in Argentina with the opening of a third facility. In addition to a field service hub in La Plata and a main office in the heart of Buenos Aires, Sulzer has recently opened a new rotating equipment service centre in Ezeiza to serve its clients in key industries including oil and gas, pulp and paper, power generation, and food and beverage. This milestone strengthens the company’s local presence and underscores its commitment to supporting customers across the region with greater reach and capabilities.

Sulzer’s new facilities will support essential industries in the region, such as oil and gas, pulp and paper, power generation and food and beverage. The expansion underlines Sulzer’s global

strategy of establishing full-service, in-region capabilities to meet the needs of its industrial customers.

The facility provides a more advanced setup by creating a safer and higher-capacity production facility for customers. In addition, Sulzer is expanding its engineering capabilities to offer pump operators innovative energy efficiency upgrades that reduce emissions by lowering their assets’ power consumption.

Gabriel Skazon, General Manager of Sulzer Argentina said: “The opening of three new facilities in Argentina is a testament to our ongoing commitment to providing our customers in the region with critical manufacturing and industrial solutions and unparalleled service offerings. We are excited about this progress and our growth in Argentina and the broader Latin America region.”

CF Industries announces start-up of Donaldsonville complex CO2 dehydration and compression unit, permanent CO2 sequestration

CF Industries Holdings, Inc. has announced the start-up of the CO2 dehydration and compression facility at its Donaldsonville Complex in Louisiana. The facility will enable the transportation and permanent geological sequestration of up to 2 million tpy of CO2 that would otherwise have been emitted into the atmosphere. ExxonMobil, the company’s carbon capture and sequestration (CCS) partner for this project, will be transporting and permanently storing the CO2

On an interim basis, ExxonMobil is storing CO2 from the Donaldsonville Complex in permanent geologic sites through enhanced oil recovery. Upon receiving its applicable permits, ExxonMobil plans to transition to dedicated permanent storage, starting with its Rose CCS project. Rose is one of many

dedicated permanent storage sites ExxonMobil is developing along the Gulf Coast to expand its integrated CCS network. The US Environmental Protection Agency issued a draft Class VI permit for Rose in July, and final permits are expected later this year.

“The start-up of the Donaldsonville carbon dioxide dehydration and compression facility and initiation of sequestration by ExxonMobil is a historic milestone in our Company’s decarbonisation journey,” said Tony Will, President and Chief Executive Officer, CF Industries Holdings, Inc. “By starting permanent sequestration now, we reduce our emissions, accelerate the availability of low-carbon ammonia for our customers and begin generating valuable 45Q tax credits.”

Sumitomo announces investment in CO2 transportation pipeline project

Sumitomo Corp., through its wholly-owned subsidiary in the UK, Summit Energy Evolution Ltd. (SEEL), has agreed new funding for the development of a CO2 transport pipeline, to support Peak Cluster Carbon Capture project (Peak Cluster). Peak Cluster will capture CO2 from four plants in and around the Peak District, which currently produce 40% of the UK’s domestic cement and lime production, vital for key sectors of the economy including construction, manufacturing and environmental protection. CO2 transported by new-build pipeline will contribute to the industry’s decarbonisation as part of the CCS value chain. Through this investment, Sumitomo Corp. will further promote Energy Transformation, one of the growth areas in its current Medium-Term Management Plan.

SEEL, through its joint venture vehicle Progressive Energy Peak Ltd. (PEPL), has agreed to make equity investment into Peak Cluster Ltd. (PCL), the project company for the CO2 transport pipeline development. National Wealth Fund, the UK government’s principal investor and policy bank, is also making a new investment in PCL.

The planned total investment of £59.6 million will be used to further develop the CO2 transport pipeline project through to a

final investment decision (FID) as early as 2028. This includes the successful completion of FEED and other studies that underpin the regulatory approval and consenting process. Cement and lime are two of the hardest industrial sectors to decarbonise due to the high levels of process emissions which cannot be mitigated through a transition to low carbon fuels. CCS is therefore essential to the decarbonisation of the sector.

The UK is a leading country in the global CCS sector, with the government aiming to capture 50 million tpy of CO2 by 2035. Peak Cluster will decarbonise the UK’s largest group of cement and lime plants, and transport 3 million tpy of CO2, contributing to the realisation of UK Government’s target.

The new build buried onshore pipeline will become part of a full value chain CCS network, which will transport the CO2 emissions captured on industry sites to the coast, to be stored permanently deep under the seabed of the East Irish Sea within Morecambe Net Zero (MNZ) project being developed by Spirit Energy, a UK energy company. Peak Cluster CCS network will help decarbonise hard-to-abate industries and secure the future of this critical industry and safeguard and create 13 000 jobs including the Spirit Energy’s storage.

WORLD NEWS

IN BRIEF

BRAZIL

Strohm has completed successful field trials with Petrobras for its TCP pipe design offshore Brazil, at water depths of approximately 1500 m.

NETHERLANDS

Fugro has announced a partnership with DTACT, a high-tech software company, and Ubotica, a leader in AI-powered satellite intelligence, to develop a unique data fusion and intelligence platform.

CANADA

NDT Group Inc., a provider of pipeline inspection and integrity services, has adopted the PLXPortable from mechanical testing provider Plastometrex, becoming the first company in Canada to deploy this in-field material verification system.

SERBIA

The Serbian Minister of Mining and Energy attended the signing of a document defining the technical specifications of the Serbia-Hungary oil pipeline.

USA

Intensity Infrastructure Partners, LLC and Rainbow Energy Center, LLC have announced they will jointly develop a natural gas pipeline in North Dakota.

MEXICO

TC Energy has announced that it has commenced the collection of tolls from the Comisión Federal de Electricidad (CFE) for the Southeast Gateway pipeline.

SWITZERLAND

ANYbotics, provider of AI-driven robotic inspection solutions, has launched a new gas leak and presence detection solution for its ANYmal robot, aimed at changing how industrial sites identify and manage costly and hazardous gas leaks.

Tallgrass announces commencement of open season for new natural gas pipeline from the Permian Basin to multiple markets

Tallgrass has announced the launch of a binding open season, commencing 21 July 2025, to solicit commitments for firm transportation service on its previously announced pipeline project from multiple points of receipt in the Permian Basin to Rockies Express Pipeline markets and points of delivery specified in accordance with the

open season terms.

The new pipeline project is unique in that it will enable natural gas to access markets broadly across the US, including multiple major markets that are key hubs of activity for industrial, agricultural, and data centre development.

France’s NaTran and Teréga and Spain’s Enagás launch hydrogen pipeline joint venture for H2med project

Spain’s Enagás – through its affiliate Enagás Infraestructuras de Hidrógeno (EIH) –alongside France’s NaTran and Teréga have announced the signing of a Shareholders’ Agreement, which establishes the creation of a joint venture dedicated to the development of the BarMar, Project of Common Interest (PCI), the renewable hydrogen pipeline that will connect Barcelona, Spain, to Marseille, France - a key part of the H2med project, alongside the CelZa project. This major new step, coming one year after the signing of a Joint Development Agreement in June 2024, provides a clear structure and accelerates the implementation of this essential component of the EU’s first clean hydrogen corridor, which aims to cover 10% of Europe’s hydrogen consumption by approximately 2030.

The new company, which will be based in the South of France, in Région

Provence-Alpes-Côte d’Azur, defines the project’s governance structure. The shareholding is distributed as follows: EIHEnagás with 50%, NaTran with 33.3%, and Teréga with 16.7%. This split reflects the overall balance of the H2med project, which is shared 50% by Spain and 50% by France. Mr. Francisco Pablo de la Flor, from Enagás, has been appointed as the new entity’s Chief Executive Officer (CEO). This was announced eight days after European support was reconfirmed during a high-level meeting between the leaders of the five companies involved in the H2med project and the Executive Vice-President of the European Commission, Ms. Teresa Ribera, who oversees the Green, Just, and Competitive Transition.

The project’s momentum is further solidified by the recent signing of Grant Agreements with the European Climate,

Infrastructure and Environment Executive Agency (CINEA) for the BarMar and CelZa (Celorico–Zamora) projects. The funding secured represents 100% of the funds requested under the Connecting Europe Facility (CEF) and covers 50% of the development costs.

Arturo Gonzalo, CEO of Enagás, commented: “The creation of this joint company embodies our collective commitment and determination to deliver this vital energy infrastructure for Europe. This marks the beginning of a new operational phase that will allow us to tackle the technical and regulatory challenges with an integrated team and a common goal: making H2med a reality.”

Sandrine Meunier, CEO of NaTran, said: “This new joint company provides the necessary framework for the longterm development of the BarMar hydrogen pipeline, a key component of the H2med project. It also gives concrete form to cross-border cooperation in developing strategic energy infrastructure to decarbonise our industries. Based in France, the BarMar company is now a place where all partners’ expertise in hydrogen transport will converge to foster a new phase of Europe’s energy.”

Carolle Foissaud, CEO of Teréga, commented: “The announcement of the BarMar company anchors H2med at the heart of Europe’s energy sovereignty and enables the achievement of carbon neutrality goals. The European funding testifies to the confidence placed in our joint expertise. Along its partners, Teréga is fully mobilised to make this European clean hydrogen corridor a success for the decarbonisation of our industries and regions.”

Induction Heating Generators & Coils

STOPAQ®: Visco-elastic systems

COVALENCE®: Heat shrinkable multi-layer sleeves

BORE-WRAPTM: sacrificial Abrasion Resistant Outerwrap (ARO)

9 - 13 September 2025

CONTRACT NEWS

McDermott awarded offshore contract by Brazil’s BRAVA Energia

Gastech Exhibition & Conference

Milan, Italy

https://gastechevent.com/

23 - 24 September 2025

Subsea Pipeline Technology Congress

London, UK

https://sptcongress.com/

8 - 10 October 2025

Carbon Capture, Utilization and Storage (CCUS) Conference

Houston, USA

https://www.woodmac.com/events/carboncapture-utilization-storage-conference/

21 - 23 October 2025

Carbon Capture Technology Expo

Europe

Hamburg, Germany

https://www.carboncapture-expo.com/

3 - 6 November 2025

ADIPEC

Abu Dhabi, UAE

https://www.adipec.com/

19 - 23 January 2026

PPIM 2026

Houston, USA

https://ppimconference.com/

15 - 19 March 2026

AMPP Annual Conference + Expo

Houston, USA

https://ace.ampp.org/home

27 - 30 April 2026

Pipeline Technology Conference (PTC)

Berlin, Germany

https://www.pipeline-conference.com/

4 - 7 May 2026

Offshore Technology Conference

Houston, USA

https://2026.otcnet.org/

McDermott has been awarded an offshore transportation and installation contract by Brazil’s BRAVA Energia for the Papa-Terra field in the Campos Basin and the Atlanta field in Block BS-4 within the Santos Basin, both offshore Brazil.

Under the contract scope, McDermott will execute the transportation and installation of flexible pipelines, umbilicals, and associated subsea equipment for two new wells at the Papa-Terra field and two new wells for the Atlanta Phase 2 development. The scope also includes

pre-commissioning and onshore base support services.

“This award highlights the vital role of subsea infrastructure in enabling long-term production and asset value for deepwater developments,” said Mahesh Swaminathan, McDermott’s Senior Vice President, Subsea and Floating Facilities. “We will leverage our proven integrated delivery model, marine capabilities and expertise in delivering brownfield deepwater solutions to support Brazil and the broader South American offshore market.”

Bridger Photonics announces methane leak detection contract with Pacific Gas & Electric

Bridger Photonics Inc. has announced it is working with Pacific Gas and Electric Company (PG&E). Bridger’s technology will help PG&E to detect and repair system leaks and reduce methane emissions across its natural gas distribution pipeline system.

“PG&E’s utilisation of Bridger’s advanced aerial leak detection technology represents a significant step forward in reducing risk on

our natural gas system and in lowering methane emissions,” said Jeff Janvier, Lead of Gas Distribution Operations at PG&E.

“This sensor enables us to accurately pinpoint leaks on our system from an aerial platform, including precise measurement of flow rates, thus mitigating safety risk and reducing methane emissions in a prioritised manner.”

Tekmar Group plc awarded contract for Middle East energy infrastructure project

Tekmar Group plc has announced the award of a contract to supply bespoke subsea infrastructure technology for a pipeline project via a major offshore EPC contractor operating in the Middle East. The base case scope is valued at approximately £2 million, the full amount of which will be recognised in the current financial year. This covers the design and manufacture of specialist reinforced concrete support structures for a large-diameter gas pipeline. There is also potential for additional scope supporting

the broader requirements of the project. Delivery is scheduled to be completed by September 2025.

Richard Turner, CEO of Tekmar Group, commented: “We are delighted to have been selected for this significant project in the Middle East, which remains a key market for the Group. As an existing customer of Tekmar, it underscores the trust our customers have in our technical expertise and our ability to deliver high-value infrastructure solutions worldwide.”

Subsea7 awarded contract offshore Egypt

Subsea7 has announced the award of sizeable contract offshore Egypt. Subsea7 will be responsible for the engineering, procurement, commissioning, and installation of flexible pipelines, umbilicals, and associated subsea components for a tie back to existing infrastructures. Project management and engineering work will begin immediately at Subsea7’s offices in France, Portugal, and Egypt. Offshore activity is expected to start in 2026.

David Bertin, Subsea7’s Senior Vice President GPC East, said: “Our early engagement has been instrumental in shaping a shared vision and delivering innovative, efficient solutions. This award is a testament to the strength of our collaboration, our proven track record, and our commitment to safe, high-quality execution. We are pleased to be able to support our client in enabling and executing such a strategically important project in Egypt.”

CONTRACT NEWS

THE MIDSTREAM UPDATE

• Two-thirds of pumps run inefficiently, Sulzer reveals – with millions in energy savings left untapped by industrial operators

• Wabtec finalises acquisition of Evident’s Inspection Technologies division

• DNV advances JIP to enable safe CO2 pipelines for CCS

• Connected by pipeline: Marathon and Osage Nation find success

• FET to provide UAE-based offshore construction firm with two work class remotely operated vehicles

• Qapqa has signed a contract for the supply of automatic welding equipment and services

• John Crane launches new dry gas sealing solution

• Joseph Gallagher to deliver trenchless crossings on Liverpool Bay CCS project

Ntorya to Madimba pipeline contract awarded

Aminex has announced that the Tanzania Petroleum Development Corp. (TPDC) has awarded an EPC contract for the construction of the gas pipeline from the Ntorya gas field to the Madimba gas processing plant to China Petroleum Pipeline and China Petroleum Technology & Development Corp.

Charles Santos, Executive Chairman of Aminex commented: “We are delighted to receive confirmation of the award of the EPC contract for the construction of the Ntorya to Madimba Pipeline. This is a major milestone, reflecting the commitment of the Tanzanian government to progress the project, and follows the signing of a Gas Sales Agreement, the award of the

Development Licence that locks the project in for 25 years, and the update of a Field Development Plan with upgraded production figures – all in the past 18 months.

“The signing of the contract demonstrates the Tanzanian government’s conviction of Ntorya’s enormous value to Tanzania as a world class gas resource that will help alleviate energy poverty, boost industrial development and improve the lives of ordinary people. A conviction that we share at Aminex.

“We thank the TPDC and all Tanzanian agencies for working together to reach this major milestone and look forward to providing a more detailed update to the market as soon as we can.”

SLB OneSubsea secures EPC contract for Northern Lights CO2 transport and storage project expansion

SLB has announced the award of an engineering, procurement and construction (EPC) contract by Equinor (Technical Service Provider) to its OneSubsea™ joint venture for a CO2 subsea injection system for the Northern Lights phase two project offshore Norway.

The final investment decision for phase two was made by the Northern Lights’ owners TotalEnergies, Shell and Equinor following a commercial agreement with an end-use customer, marking a decisive milestone for the adoption of carbon capture and storage (CCS) at scale. The SLB OneSubsea scope includes two new satellite subsea CO2 injection systems with associated tie-in equipment. Work

has already commenced, with first deliveries expected in 2026.

“Equinor’s enduring commitment to subsea standardisation is now yielding substantial benefits across new offshore value chains, including CO2 storage. By utilising standardised components, we achieve reduced risk and economies of scale, which enhance both traditional and innovative subsea projects,” said Mads Hjelmeland, CEO, SLB OneSubsea. “The Northern Lights project is pivotal for Europe’s path toward net-zero emissions, and it is well aligned with our own strategy to expand the frontiers of subsea for a sustainable energy future.”

ROSEN (UK) Ltd secures key contract for UK carbon capture project

ROSEN (UK) Ltd has secured a major contract to provide design verification and subsea engineering support for one of the UK’s most significant carbon capture projects.

As part of this contract, ROSEN will conduct comprehensive design verification of the project’s CO2 transportation pipelines, ensuring they meet the highest safety, reliability, and performance standards. ROSEN’s engineering expertise will support the client to reengineer and repurpose pipelines for carbon storage. This collaboration, which began in

early 2025, marks the start of a two-year partnership, with potential for further projects as the UK accelerates its transition to net-zero emissions.

Gordon Blair, Business Development Manager, commented: “We are proud to be part of a project that is shaping the future of the UK’s energy sector. Our deep expertise in pipeline verification and subsea engineering ensures the infrastructure supporting carbon capture is both safe and efficient.”

With ageing infrastructure requiring enhanced safety management and new energy commodities demanding innovative transport solutions, the need for coordinated research and knowledge transfer has never been greater. The Pipeline Research Council International (PRCI) has emerged as a collaborative platform, bringing together operators, service providers, and technical experts to address these complex challenges through seven decades of practical, science-based research.

The collective perspectives of PRCI’s current Executive Board illuminate how it is driving innovation while maintaining its commitment to safety, reliability, and environmental stewardship. This roundtable discussion features insights from Walter Crommelin, PRCI Chair (Gasunie); Nick Homan, PRCI Vice Chair (Marathon Pipeline); Kalen Jensen, PRCI Research Steering Committee Chair (ATCO); and Sean Keane, PRCI Research Steering Committee Vice Chair (Enbridge).

With evolving technologies, changing regulatory landscapes, and increasing environmental concerns, organisations like PRCI are at the forefront of addressing these challenges to help shape the future of the pipeline industry – what are the current priorities for pipeline research at PRCI?

Walter Crommelin (Gasunie)

The pipeline industry is navigating a range of complex challenges, which directly shape PRCI’s research priorities. Operators must deal with aging pipelines and ancillary systems under increased public scrutiny while considering their role in the energy transition toward a carbon neutral society. These challenges are interconnected – pipeline operators can only participate in the energy transition if they demonstrate capability in managing current infrastructure safely and reliably.

Kalen Jensen

Nick Homan Sean Keane

Walter Crommelin

enhances problem-solving, and

leading to more creative and effective solutions. Working together allows teams to combine strengths and tackle challenges more effectively. Ultimately, it is a powerful tool for achieving goals that would be difficult to attain alone.

Figure 2. Researchers and graduate students work together on an experimental setup to enhance natural gas soil aeration systems, improving safety and reducing methane emissions. This hands-on collaboration supports PRCI’s mission to develop the next generation of skilled pipeline professionals.

Kalen Jensen (ATCO)

Walter raises an excellent point about that interconnection. What we’re seeing at PRCI is research portfolios increasingly targeted at addressing gaps that will have the largest impact across member jurisdictions. We focus on practical research that furthers knowledge, reliability, safety, and operating efficiency precisely because we can’t separate current operations from future needs.

Sean Keane (Enbridge)

That’s right, Kalen. The research within PRCI is diverse, spanning the full pipeline lifecycle, but it’s all focused on closing gaps related to safe, reliable, environmentally sound, and cost-effective pipeline transportation of energy. Our current priority areas – emerging fuels, efficient and effective crack management, greenhouse gas (GHG) emissions reduction, and optimising the detection and mitigation of mechanical damage – reflect that dual focus Walter mentioned.

Nick Homan (Marathon Pipeline)

Building on what Sean outlined, PRCI’s mission centres on producing research to promote safe, reliable, sustainable pipeline systems. What is particularly exciting is how those research priorities now encompass both traditional hydrocarbon energy-based pipeline transmission and future energy commodities like hydrogen and CO2 through the Emerging Fuels Institute (EFI). Our technical committees execute research projects that evaluate technology and techniques to address asset integrity threats, reduce emissions, and improve equipment performance – addressing both sides of Walter’s equation.

Ensuring the safe and reliable transportation of energy resources depends on maintaining pipeline safety and integrity. What role does PRCI play in advancing standards and best practices to uphold these critical priorities?

Crommelin

PRCI represents a collaboration of many different companies, both operators and service providers. Our research results are validated by these groups, ensuring high quality and reliability – exactly what standardisation needs to be effective. The results aren’t based on the opinions of a few but on the substantiated results supported by many.

Jensen

That collaborative validation is crucial. PRCI focuses on practical, scientifically robust solutions to tangible industry problems. What makes this approach unique is that the projects and solutions are vetted by operators, service providers, and industry associations – the same parties that develop consensus-based standards supporting safe and reliable pipeline operation worldwide.

Figure 1. Collaboration fosters innovation,

drives collective success

Stop Pipeline Defects in Their Tracks

PETROSLEEVE

Installation in less than an hour.

PETROSLEEVE® is a steel compression repair sleeve that neutralizes threats faster, safer and more cost-effective than traditional methods.

Keane

Kalen’s point about practical solutions really resonates with our experience. As an operating company, much of our PRCI-funded research relates to improving safety and integrity practices across design, construction, operation, and abandonment. The research engages industry experts to set scope and provide feedback through completion, but crucially, independent experts design and conduct the research to protect against biased outcomes.

Homan

Sean touches on something important about independence leading to credible outcomes. PRCI research has become the basis for numerous American Petroleum Institute Recommended Practices (API RP). For example, our research on mechanical damage contributed to API RP 1183: Assessment and Management of Pipeline Dents. What Walter said about the council’s structure is key – any member can seek reevaluation or enhancement of results, which continuously improves industry standards. Our research also forms the basis for pipeline engineering software solutions and the PRCI Pipeline Repair manual, making the knowledge practically accessible.

Figure 3. An aerial methane detector surveys a refinery, showcasing advancements in GHG detection. Ongoing PRCI research aims to help natural gas operators reduce emissions from compressor stations and pipeline maintenance, minimising environmental impact.

Figure 4. The installation of a gas pipeline in Gilroy, California, equipped with advanced fibre optic sensors for real-time monitoring of strain and temperature to ensure safety and integrity. New solutions like this reflect PRCI’s and the industry’s focus on sustainability, efficiency, and innovation.

With the global shift toward cleaner, more sustainable energy solutions, organisations in the energy sector are under growing pressure to tackle critical environmental and safety challenges. How is PRCI rising to meet these demands, particularly in reducing GHG emissions and improving pipeline safety as part of the energy transition?

Keane

The energy transition has focused attention on reducing GHG emissions and risks associated with potential leaks. What’s encouraging is that this focus aligns well with ongoing and planned research portfolio.

Jensen

Sean’s right about that alignment, and I think it also demonstrates PRCI’s adaptability. We’ve shown flexibility in responding to changing industry needs through establishing Strategic Research Priorities (SRP) and the EFI. This pivot in research execution mechanisms and targeted research portfolio creation has enabled rapid, holistic execution of project portfolios addressing challenges facing our members and the industry.

Crommelin

The EFI has been transformative over the past four years by initiating substantial projects that address major issues with emerging fuels. PRCI research now examines existing oil and gas pipeline systems along with hydrogen, biogas, and CO2 systems associated with the energy transition. For existing systems, there’s ongoing research into preventing and detecting GHG emissions, helping operators reduce environmental impact while keeping more commodity in the pipeline.

Homan

Walter’s point about the dual focus is exactly what we’ve implemented. PRCI recently completed an SRP focused on GHG emission reduction, providing options for natural gas transmission pipeline operators to identify and reduce emissions from compressor stations and pipeline maintenance activities. Simultaneously, the EFI has completed research on asset integrity improvements required to introduce hydrogen and CO2 into existing pipeline transmission systems. It’s that comprehensive approach Kalen described in action.

With growing emphasis on renewable energy sources, carbon capture technologies, and reducing environmental impact, organisations must adapt to remain relevant. How is PRCI preparing for the future energy transition, including the shift towards renewable energy sources and carbon capture technologies?

Jensen

The EFI’s creation and successful promotion has enabled systematic execution of alternative fuels projects at an unmatched pace. Its thoughtful structure and governance has enabled rapid transitions from shifting to alternative fuels to the transport and storage of captured carbon, helping the pipeline industry meet energy transition demands across all member organisation jurisdictions.

Keane

Kalen’s right about the pace. To tackle the challenges from the shifts toward ammonia, biofuels, carbon capture and sequestration, hydrogen, and renewable natural gas, PRCI created the EFI specifically because no single organisation could address these challenges alone. It brings together global expertise to strengthen research collaborations, transfer knowledge, and enable partnerships to fund and prioritise research, leading to key knowledge updates, standards development, and training creation.

Crommelin

That is exactly why the EFI model works so well. It allows members interested in energy transition to pool resources and collaboratively push research in areas where they see greatest value while the existing PRCI structure provides all members the optionality to continue improving upon existing systems. This dual approach allows PRCI to flexibly respond to industry changes while bringing like-minded operators together and preventing unnecessary research duplication.

Homan

The consortium approach Walter and Sean describe is essential. PRCI created the EFI as a research consortium allowing interested pipeline operators to pool resources and complete research projects needed to ensure safe pipeline operations when transporting new energy sources in pipeline infrastructure. What Kalen mentioned about the systematic execution – that’s only possible because of the collaborative structure and shared investment model.

Figure 5. A natural gas pipeline stretches across the Bow River on its own dedicated bridge downstream of the Seebe Dam in Alberta, Canada, and highlights a critical piece of energy infrastructure that plays a key role in transporting natural gas safely and efficiently. PRCI addresses the challenges on advancing pipeline research to ensure energy transportation remains safe, reliable, environmentally responsible, and cost-effective across the entire pipeline lifecycle.

catgroup.net

As the energy industry evolves, pipeline infrastructure faces increasing demands to adapt to new technologies, stricter environmental regulations, and shifts in energy sources. With renewable energy and hydrogen gaining traction alongside traditional oil and gas, what are the anticipated challenges and opportunities for pipeline infrastructure over the next 25 years?

Jensen

Repurposing existing aged infrastructure to meet decarbonising economy needs while meeting growing population energy demands presents a generational challenge. This requires creative, robust technical solutions that uphold the reliability customers depend on, all while maintaining an unwavering commitment to safety.

Keane

Kalen touches on the infrastructure challenge, but I’d add that digital innovation opportunities are evolving just as quickly. Artificial intelligence (AI) for interrogating massive, complex data is already reshaping the toolset for managing infrastructure through all lifecycle phases. With these opportunities come new challenges in cybersecurity, data privacy, and workforce training needed for digital adoption.

Crommelin

Both Kalen and Sean bring attention to key challenges in the evolving fuel landscape. Significant progress is still needed to develop efficient transportation methods for various energy carriers. The future envisions a diverse mix of energy sources –both molecular and electrical – tailored for different applications. Achieving this vision will require substantial infrastructure development to ensure users have access to the most suitable energy options for their needs. This task becomes even more complex in densely urbanised areas, where safety and practicality are of utmost importance.

Homan

Walter’s description of a mosaic perfectly illustrates the complexity we’re navigating. Achieving zero pipeline safety incidents remains our ultimate goal, but research must keep advancing to address emerging threats and anticipate the unknown. As asset integrity challenges evolve – whether from external factors like geohazards or the integration of new energy sources such as hydrogen –pipeline research must adapt accordingly. Sean’s emphasis on digital tools highlights their critical role, but as Kalen pointed out, we also need innovative, resilient technical solutions that uphold reliability while tackling the decarbonisation challenges.

The pipeline industry requires a skilled workforce to ensure safety, efficiency, and innovation. As the industry evolves with new technologies and regulations, what initiatives are in place to support workforce development and training in the pipeline industry?

Jensen

Cultivating new talent and preserving domain expertise throughout the careers of pipeline professionals are essential to the industry’s long-term success. Recognising this, organisations like PRCI have

introduced comprehensive engagement initiatives designed to support the growth and development of as many operators as possible.

Crommelin

Kalen’s point about career-long development is especially critical now. The workforce is changing because many of the talented individuals who ‘grew up’ alongside developing pipeline systems have retired. A younger generation must now maintain existing and build future pipeline systems with fewer opportunities to learn from experience and mistakes. PRCI is uniquely positioned to support workforce development through applied research by providing guidelines, best practices, and technical evaluations that are applicable to dayto-day pipeline system operations.

With the development of the PRCI Academy, we’re making research more accessible as part of a larger framework for helping individuals understand prerequisites and follow-ups needed to become subject matter experts. This leverages years of research for anyone entering the industry and contributing to keeping society running smoothly, safely, and sustainably.

Homan

Walter’s mention of the PRCI Academy is an exciting development that builds on our existing achievements. At PRCI, knowledge transfer is a strategic priority. We’ve established in-person and online training programs covering a range of pipeline research topics such as pipeline repair fundamentals, managing geotechnical hazards, and nondestructive examination training for long seam evaluation, providing foundational knowledge for engineers and technicians.

The Academy framework takes this effort to the next level, offering a more systematic and comprehensive approach to training. It directly addresses the need for career-long professional development, as highlighted by Kalen, ensuring industry professionals have access to the tools and knowledge they need to succeed at every stage of their careers.

Final thoughts

The insights shared by PRCI’s leadership highlight its role as a driving force in transforming the pipeline industry. PRCI’s Emerging Fuels Institute (EFI) reflects its commitment to strategic research, workforce development, and industry standards during a transformative era in energy. Aligned with its Strategic Resource Priorities (SRP), PRCI focuses on sustainability, efficiency, safety, and innovation. Through initiatives like the PRCI Academy and specialised training programmes, PRCI drives research and equips the next generation of pipeline professionals to meet the industry’s evolving needs.

Striking a balance between addressing the immediate challenges of aging infrastructure and fulfilling the longterm demands of the energy transition, PRCI continues to solidify its reputation as the pipeline sector’s leading research collaborative. The future of pipeline infrastructure hinges on the kind of coordinated, science-driven approach PRCI has championed throughout its history.

PIPELINER

The S SETTANTA PIPELINER combines Laurini’s legacy of equipment innovation with a modular boom and stick design for unmatched versatility across multiple industries. Featuring a compact footprint with massive lifting power, a hydraulic high-rise cab, and full integration with the D DECKHAND® pipe handling system by LaValley Industries, the S SETTANTA is purpose-built to handle pipe with precision.

• H Hydraulically actuated variable gauge undercarriage gives you 360° full reach for superior maneuverability and stability

• H Hydraulic high-rise cab enhances visibility for stockpiling, loading/unloading trucks and rail cars

• I Integrated DECKHAND® pipe handling system increases safety, control and productivity in any condition

• H Heavy lifting on a smaller chassis allows for 2 25% more lift capacity than a similarly-sized excavator

• M Modular front-end design features quick disconnect boom and stick system with fully automatic electronic and hydraulic connections for any application

In the left pictures: 2 PIECES DIGGING BOOM

3 PIECES DIGGING BOOM

CRANE BOOM

Vinay Baburao, Director Digital Transformation, CRC Evans, explains how digital technology is delivering next generation pipeline services data management.

Digital technologies are set to play a transformative role in the sectors in which we operate. While historically slower to adopt new technologies, the industry is now undergoing a rapid shift – driven by the growing influence of cloud computing, artificial intelligence, Internet of Things (IoT), and automation. These advancements are empowering organisations to predict, adapt, and optimise in ways that were unimaginable just a decade ago.

One of the key benefits being achieved across all areas of activity is the greatly enhanced access to data – how it is collected, collated, the way in which it can deliver realtime information and results, and how this in turn is bringing significant benefits to the industry.

In the pipeline welding, technology, and coating services field for example, data management across the pipeline lifecycle has tended to be fragmented and reactive. Critical information from stakeholders such as pipe mills, welding crews, coating teams, and non-destructive testing (NDT) providers are often siloed – if collected at all. In many cases, data is only compiled after project completion, severely limiting its value for real-time decision-making or quality assurance.

Field teams typically have had to rely on spreadsheets, paper logs, and lengthy email chains, creating a patchwork of disconnected records. These traditional methods led to significant inefficiencies, data loss, and reporting delays, especially across geographically distributed projects. The absence of integrated, real-time data not only hindered operational transparency, it also made it difficult to anticipate issues or drive continuous improvement.

While partial digital solutions are available on the market, they have not yet achieved cutting edge advancement. Typically, they focus on digitising inspection data through manual entry or document uploads at various stages of production. In most cases, users input information into mobile or web platforms after the fact, which still introduces delays, inconsistencies, and missed opportunities for real-time insights.

Taking the various shortcomings into account, it was clear there was a need for a system of data management that would make a transformative shift from retrospective data gathering to a system that would engender proactive, connected decision-making.

End-to end integration of digital management platform

Initially conceived in response to meet a specific project requirement off the coast of Guyana during 2023 - 2024, where the need to capture weld data from our equipment became a critical operational priority, CRC Evans developed the DATA 360 data management platform.

Engaging in deeper conversations with clients and industry stakeholders confirmed this was not an isolated need. There was a significant gap in the market for a truly integrated, domain-specific platform capable of digitising and connecting every stage of the production lifecycle – from welding to NDT.

A next generation solution, the platform is fundamentally different from the partially digital solutions available on the market, delivering true end-to-end integration, consolidating

material traceability, welding, coating, and NDT into one unified platform.

Rather than relying on fragmented tools, it provides a purpose-built digital ecosystem tailored to the complex demands of pipeline and fabrication projects, automatically capturing data directly from welding and coating machines as production occurs.

This real-time data flow replaces manual logging and ensures immediate visibility, accuracy, and operational intelligence. In comparison to other systems that digitise after the fact, DATA 360 digitises in the moment – transforming how data is collected, connected, and used to drive smarter, faster project execution.

Cutting-edge digital technologies

It leverages a suite of cutting-edge digital technologies designed to transform how energy infrastructure is planned, executed, and analysed. These technologies don’t just digitise data, they enable a more intelligent, connected, and predictive approach to project execution:

) Cloud computing ensures secure, scalable access to project data from anywhere in the world, enabling collaboration across global teams.

) AI and optimisation algorithms power PipeFitter, a solution for pipe stalk configuration, dramatically improving fitment efficiency and material usage.

) AI-based geospatial clustering is used to intelligently assign unique joint IDs by analysing GPS data, reducing errors, and enabling automatic traceability.

) IoT integrations connect directly to welding and coating machines, capturing production data in real time, eliminating manual entry and unlocking live operational insights.

) A mobile-first architecture empowers field teams to report and access critical information instantly, streamlining workflows and improving responsiveness

At the heart of the platform is a vision to create a digital twin of the energy infrastructure as it’s being built – a living, evolving model that mirrors the physical asset and unlocks powerful capabilities in traceability, quality assurance, and lifecycle management. In short, it doesn’t just collect data, it builds intelligence into the infrastructure itself.

It is now being deployed across multiple global on- and offshore projects, with feedback confirming it is delivering a wide range of benefits, helping clients improve operational efficiency, ensure compliance, and reduce project risk.

Core advantages for clients

Its application is relevant across various sectors where production complexity and traceability are critical to success, particularly for industries that operate under strict regulatory standards and demand end-to-end visibility across the asset lifecycle. This includes oil and gas pipeline construction, offshore wind and renewable energy projects, and process plants and fabrication yards – places where high-volume, high-precision welding and material tracking are essential, and infrastructure projects involving pressure piping or regulated welds.

Some of the core advantages include:

) Improved productivity through faster data reporting and reduced rework.

) Complete material and weld traceability to meet stringent regulatory standards.

) Real-time monitoring of production and asset performance.

) Elimination of delays caused by manual paperwork or miscommunication.

) Data-driven decision-making for better planning and resource allocation.

) Increased transparency across all project stakeholders.

Figure 1. Automated welding system enabled with DATA 360. Capturing real-time operational data to drive compliance, quality, and performance insights.

Figure 2. Field teams reviewing weld data on a tablet via DATA 360. Enabling immediate and mobile data access.

Figure 3. Live monitoring screen powered by DATA 360. Providing instant visibility into system performance and compliance status.

No difficult-to-inspect pipeline should be left behind.

Whether you're dealing with short or extremely long pipelines, or you require ultra-high resolution, or high inspection speed.

Our Surveyor UT ILI family is designed to handle it all.

Explore what our ILI technologies can do for you.

Helix

Phasix Matrix

Case study: welding

In a welding project, the ability to swiftly identify the root cause of defects and minimise downtime is of utmost importance. The vast amount of data generated during welding poses a challenge, as it requires significant time to collect and analyse data from every station and welding system.

This process becomes even more complex when welds are not tagged, making problem identification more difficult. Therefore, a solution that can streamline this data analysis process is crucial for reducing downtime and improving efficiency in welding projects.

DATA 360 revolutionises how welding data is handled. By wirelessly collecting and hierarchically collating data it presents a comprehensive overview to the user. This system’s ability to indicate if data falls within the set limits of welding parameters could be a game changer in identifying and resolving issues in a few minutes.

Identifying the issues during production is only one of the benefits; the data collected is helpful in the extracting operational insights about the project. Furthermore, the welding data and defect data can be fed into a machine learning model, which can predict the defect before it happens and control the parameters with which we weld.

Incorporating cutting-edge digital technologies provides expedited access to production data, improved analytical capabilities, and precise data tagging.

This reduces downtime and minimises the number of inspection personnel required to extract, transform, and analyse data. Additionally, the platform serves as a data repository of as-built documentation for customer infrastructure, with data curated and ready to use for compliance needs.

The DATA 360 platform enables real-time monitoring of production activities during welding, coating, and inspection. It utilises long-range Wi-Fi communication, which allows for the wireless downloading of logs from all stations and evaluates the status of joints based on the parameters established during the qualification process.

Delivering real-world impacts

At a time when clients are under growing pressure to improve compliance, efficiency, traceability, and sustainability, platforms such as DATA 360 respond to those needs – not just as a product, but as a transformation tool for how projects are executed and managed in the digital age.

Some real-world examples include:

) Reducing downtime through real-time weld verification: in a recent offshore project, compliance required validating weld parameters after each pass before moving to the next station. Traditionally, this would have meant a technician had to manually download data from each welding machine, analyse it on-site, and confirm compliance – a process that could take 15 - 20 minutes per joint. The welding module in DATA 360 provides automatic verification in under 30 seconds, eliminating delays and human error.

) Accelerating regulatory compliance reporting: compiling final documentation can be a significant burden for projects with strict regulatory oversight. The platform can reduce the timescale from months to weeks.

) Reducing manpower and exposure on the firing line – traditionally, field teams would need to physically monitor the production line, manually collecting data on each joint. Integrated IoT-enabled systems capture this information automatically in real time, reducing the number of personnel required, minimising exposure to hazardous environments.

The advent of digital transformation is not just crucial for end-users, it is increasingly imperative for businesses to reinvent how they work to ensure they remain relevant, current and fit for the purpose of servicing modern day requirements.

As we look to the future as an industry, there is immense potential to build intelligent tools that can provide real-time guidance, automate analysis, and support decision-making in the field.

CRC Evans is also exploring how Physical AI can be embedded into core equipment, making machines not just connected, but context-aware and self-optimising.

This convergence of operational data and intelligent systems will mark a new era for the industry – one where digital technology doesn’t just support the work, but actively enhance it. The future is not about replacing human expertise, it is about amplifying it with the right data, at the right time, in the right way as, we lay the foundation for that future today.

About the author

Vinay Baburao, Director of Digital Transformation, CRC Evans, leads enterprise-wide innovation initiatives through the development and deployment of transformative digital platforms. He has more than 17 years of cross-industry experience spanning industrial products, elevators, and medical devices. His work focuses on harnessing data-driven tools, automation, and connected technologies to modernise field operations, enhance traceability, and deliver measurable efficiency gains.

Figure 4. DATA 360 provides real-time data collection and cloud enablement at every stage of pipeline construction.

MITIGATE

AC

INTERFERENCE AND OPTIMIZE YOUR CP SYSTEM

When your pipeline shares a right of way with high-voltage power lines, the electromagnetic field on the power lines can induce unwanted voltage onto the pipeline, creating a safety hazard for personnel and contributing to AC corrosion problems. Dairyland decouplers provide an effective grounding path that mitigates induced AC, while simultaneously maintaining DC isolation to optimize your CP system. With a Dairyland decoupler, your CP system will continue to work efficiently, and the pipeline and personnel will be safe from AC interference.

Let us help you find the right solution for your AC Mitigation problems.

Above. Beyond. Below.

Mainline Pipeline

Direct Pipe®

Horizontal

Directional Drilling

Gas Distribution

Facilities Construction

Pipe Fabrication

Maintenance & Emergency Repairs

How do we best approach protecting complex oil and gas pipeline infrastructure? What do we need to take into account as we survey the magnitude of the task at hand?

Raghu Yabaluri: We need to take a more holistic approach and evaluate various threats from a physical, digital, legal, and societal lens.

Let’s start by looking at physical operational threats that can lead to significant safety and environmental issues. Leaks, for instance, can create major issues – financial and reputational – for companies. There are also physical threats: bad actors scheming to interfere with pipelines and their systems, as well as natural disasters that create major disturbances to the infrastructure itself.

Another dimension to consider is how we protect both existing and new infrastructure in a digital world. Many companies are modernising their systems via AI, automation, and other technologies. As they do, they must make sure that they modernise in terms

of both value and security. If I can easily operate my machine remotely, then a bad actor can easily operate my machine remotely, too.

Cybersecurity threats have increased recently, and will only increase further. When we were all offline, we didn’t have as many risks. As we started integrating online, we saw hacks, such as the Colonial Pipeline issue, where bad actors broke into an IT system. Colonial had to shut down the entire pipeline, the lifeline for the Northeastern US. As we continue integrating OT with IT systems, threats will increase even more.

Thirdly, the concept of right-of-way (ROW) is critical. Virtually everywhere we build pipelines, we get a ROW, or lease, for a particular amount of time from the landowners or the government. There is always a possibility that they revoke a lease and cease our ability to operate. So we must be mindful of several factors, including how to interact with communities, to maintain these privileges.

We recommend a ‘big tent’ approach: engage the communities and landowners at the earliest stages of development. Consider how those communities are going to react to having a pipeline on or near their land, not just today but in 10 - 20 years. For instance, the community may require a financial stake in the pipeline. In Canada, 23 First Nations communities brokered such an arrangement with the Enbridge West Coast Pipeline project.

Given the complexity of global energy supply chains, how can pipeline infrastructure be more resilient to disruptions (natural and manmade)?

RY: Resilience starts with comprehensive, accurate, and continuous evaluation of the man-made and natural risks to the infrastructure and overall markets, as well as the creation of dynamic risk management. Many projects fail because operators conduct a risk management exercise that is static, not dynamic, in nature. When you don’t know the unknowns, or don’t plan for them, they eventually will reveal themselves with disastrous consequences. Keep your evaluation process dynamic by actively looking for signals that make you better informed about future risks.

Consider the Russia to Europe pipeline [Nord Stream I and II], an asset taken for granted worldwide for decades. In reality, there were plenty of risk signals for years. With dynamic evaluation, mitigating actions could have been implemented a few years ago and saved untold consequences.

With cybersecurity, new and different types of attacks emerge virtually every day. You might not always be able to predict a particular attack. But one should continuously learn from the developments and attacks in other industries, too –and adapt quickly. If you are breached, it’s important to react quickly to minimise any impact. Change your risk management accordingly. For this, you may need to make your infrastructure resilient to new cyber threats and make necessary investments.

What are the most pressing vulnerabilities in energy supply chains?

RY: We have witnessed several pressing vulnerabilities in the past decade. First, we’ve seen a shift in global political environments and markets (e.g. Russian gas to Europe).

We’ve also seen a shift in energy demand from fossil fuels to cleaner energy and now back to gas in some parts of the world. Cyberterrorism has shut down critical international infrastructure operations and forced some to pay significant ransoms. Ignoring asset integrity and ineffective network control have resulted in high-consequence incidents, such as a spill some years ago that led to 1 million gal. of bitumen leaking into an American river.

Expanding on a couple of issues, the shift in energy demand was widely misread. Five years back when people started talking about energy transition, some said “let’s not invest in any more oil and gas infrastructure”. That led to a misconception that oil and gas demand was going to disappear or drop massively within 10 - 15 years. Many investments were paused.

Today, gas is an important transition fuel, as well as a means for providing energy security. Gas is one of the cleanest ways to meet some of our key energy requirements, especially base load, while we transition. In other words, conventional wisdom swung from demand dying down to demand increasing. That kind of avoidable volatility puts pressure on prices.

To combat ineffective network control, asset integrity is more critical than ever. Continuous monitoring is essential. While uncommon in the US and EU, in some regions, bad actors will punch a hole into a pipeline to steal the oil, which starts a leak. It’s critical to quickly identify when that happens. Now, rather than depending on human monitoring, AI and other technologies can be used to remotely monitor what’s coming in, what’s going out, and where changes are happening in near-real time.

What strategies can pipeline operators use to mitigate the risks of geopolitical instability and ensure continuity of energy supply?

RY: We already covered dynamic portfolio management and scenario modelling that enable you to react quickly to emerging situations. There are a few other strategies.

First, diversify suppliers. Create multiple supply sources to secure oil, gas, or product in order to mitigate disruption from any one player. Second, create redundancies – multiple transportation routes through additional pipelines and other modes. If you add an FLNG to your network or build another pipeline, then, if you get blocked on one end, you can still get supply from another place.

Third, adjust your operations in high-risk areas. If it’s dangerous to do physical monitoring, implement automated monitoring. Or build new pipelines that are not easily accessible, such as underground lines. In addition, implement greater security.

Finally, utilisation of longer-term contracts, financial hedging and other economic instruments can help mitigate financial losses.

What role do pipelines play in supporting a sustainable and diversified energy portfolio in the long term?

RY: Pipelines remain the safest, lowest-carbon and most cost-effective mode for the transport of molecules. They are

essential to the reduction of environmental and operational risks to the supply of energy, domestically and internationally.

Natural gas is now widely recognised as the dominant energy transition fuel, and gas pipeline infrastructure is key for companies, states, and nations to manage energy demand, especially the base load. Further, pipeline infrastructure will be critical to ensuring the commerciality and scalability of hydrogen and carbon capture, utilisation, and storage (CCUS). Existing rights of way can help accelerate these pipelines, as will the increase in incentives for CO2-enhanced oil recovery (EOR) that were passed in the recent US budget act.

Can you discuss any specific cybersecurity measures that are being implemented to protect pipeline systems from cyberattacks?

RY: As internationally important critical infrastructure, pipelines will be points of attack, whether in a political conflict or a cyber conflict. It’s not about when they get attacked, it is about how many times they are attacked – and whether operators will be able to keep the attackers from achieving their goals. That is why we need to have multiple cyber programmes set up to defend pipeline systems.

Operators need to know three things. What assets do they have end-to-end (every single asset, because any asset can be attacked)? Second, if the system is breached, how can it be exploited? Third, once you know the answers to the first and second questions, how do you monitor, defend and respond in case of attack?

Regulators are increasingly mandating cyber requirements – which is where the TSA (Transportation Security Administration) comes into play in the US.

But operators also need to have the right architecture and technology. For instance, companies are adopting cyber frameworks such as Zero Trust Architecture to combat and minimise impacts of any disruptions. These architectures segment the networks that operate pipeline assets (OT) from information systems that monitor those assets (IT). This separation reduces a bad actor’s access to critical systems.

Finally, companies need to implement access control and train their workforce. Only the right people should have access to some of these very critical systems and people with access must be thoroughly trained on security processes.

How do you assess the risk of sabotage or other malicious activities that could target pipeline infrastructure?

RY: Let’s talk about the two types of sabotages – cyber and physical. The hard truth is that cyber risks are always expanding and changing. Pipelines are becoming more connected, remote controlled and automated, all of which makes them more vulnerable to new kinds of attacks. Attackers are taking advantage of the same new techniques and technologies, including AI, to disrupt and sabotage operations. That means you can’t simply look at past old attack techniques when assessing risk. If you do, you’ll get blindsided by the next new attack type. You have to plan for the unknown, and that means going back to basics.

Companies can decrease the probability of a successful attack by strengthening their defences via asset management, training and segmentation as well as deploying robust monitoring and response programmes. When possible, build those defenses in while building or modifying new assets. Don’t bolt in on, build it in.

Physical risks – typically correlated to the geopolitical environment, societal impact, and physical location, terrain and right-of-way of the asset – are also still a major hazard. Assets in high-risk environments have to be actively monitored and protected for sabotage and physical damage. Similarly, assets in urban/suburban contexts may warrant higher consequence ratings than those in exurban/rural contexts.

It’s also critical to gauge and actively manage changing societal sentiment, whether it opposition to CO2 pipelines or disagreements regarding First Nation access.

What are the main risks associated with operating ageing pipeline assets, and how can they be addressed?

RY: Most pipelines are 50 plus years old. That presents a lot more risk to operations and integrity. What’s more, investing in upgrades to old equipment doesn’t always make sense financially. So those upgrades get deferred, which can lead to issues such as physical leaks, unplanned downtime or non-compliance. Regulations change over time. And you need to comply with them, even if you have older equipment.

Finally, stakeholder groups are changing, too. When we built pipelines 50 years ago, we didn’t typically have stakeholders from the activist and environmental community.

In light of increasing demands for energy security, how can pipeline systems be designed to provide long-term reliability without compromising on sustainability or environmental goals?

RY: For new projects and the modernisation of existing assets, operators should account for five things. First, consider lifecycle assessment – including economics, operations, and carbon intensity. Understand the impact of your assets from initial construction (materials, transportation) to operation and end-of-life (disposal, recycling). Complement that understanding with relevant environmental impact analyses. And be sure to conduct these assessments prior to making any investment decisions on whether to build or replace an asset.

Second, leverage sustainable materials. New materials such as high-density polyethylene (HDPE) and composite pipes offer lower carbon footprints than traditional steel and can serve as offsets to an operators’ global footprint of materials.

Third, leverage lower intervention installation methods. Capabilities such as boring technologies and horizontal drilling (HDD) can reduce the surface intervention required for installation. It also translates to less equipment, smaller workforces, and less carbon.

Fourth, implement waste, water and emission reduction strategies during construction and operations.

And fifth, plan for reuse and/or decommissioning. For example, reuse old pipelines for CO2 or hydrogen transportation.

Ben Cowell, Integrity Engineer, Luke Fahy, Integrity Engineer, and Nigel Curson, EVP of Technical Excellence, Penspen, introduce a structured screening assessment to evaluate the feasibility of repurposing pipelines to transport hydrogen, using two different aged pipelines to illustrate the approach.

The UK government, through the Climate Change Act of 2008,1 has committed to achieving net zero by 2050, with a key milestone of decarbonising the energy sector by 2035. Globally, energy production accounts for over 75% of emissions, making the transition to low-carbon alternatives essential. Hydrogen has emerged as a promising energy vector due to its high specific energy density and low emissions.

A critical aspect of scaling hydrogen deployment is the development of efficient transportation infrastructure. Repurposing existing natural gas pipelines for hydrogen has gained significant attention as a potentially cost-effective and highly expedient solution. However, the suitability of these pipelines varies.

Given the scale of planned hydrogen infrastructure projects, such as the European Hydrogen Backbone (EHB)2 –which envisions approximately 53 000 km of hydrogen pipelines across Europe by 2040, there is an urgent need for an efficient

Table 1. Assumed cost and subsequent weighting per parameter

Parameter

method to determine which pipelines are viable candidates for conversion.

This article introduces a method designed to expedite the process of evaluating pipelines for hydrogen transport, using two aged pipelines to illustrate the approach.

Methodology in play

Coating condition 15 000 8

Pipeline condition 50 000 4

Material data availability 12 000 9

Capacity 55 000 4

Welding records 18 000 8

Encroachments 24 000 6

Depth of burial 20 000 7

Valve suitability 70 000 1

Environment 10 000 10

Table 2. Case A pipeline details

Construction

Justification

New coatings: costs cover removal, surface prep, and reapplication

Based on integrity assessments for defects, ILI runs and potential repairs

Systems may lack records, requiring extensive material sampling and lab testing

Higher pressures may necessitate pipe reinforcement or testing. New compressors are a necessity

Missing records mean comprehensive assessment of weld metal

Risk assessments, potential rerouting and slabbing

Additional cover or protective measures to prevent damage

Valve upgrades or complete replacement

Additional monitoring, advanced leak detection, and regulatory approvals

This model is designed as a high-level screening assessment to evaluate hydrogen feasibility, considering several key parameters. The methodology utilises a 1 - 10 rating and cost-based weighting system to determine the suitability of the pipeline based on the Kepner Tregoe method.3

Each parameter is assigned a rating and weighting that reflects the typical costs of addressing that parameter. In isolation, each parameter does not significantly influence the decision to repurpose. However, the multiplication of the associated rating and weighting indicates how well the pipeline meets the required criteria for repurposing.

Based on the parameters, an assumed cost and cost-based weighting based upon engineering judgment and research conducted by MARCONA,4 implementing a maximum total cost of adapting a pipeline commissioned before 1984 of €274 000/km for 100% hydrogen service has been proposed. These cost-based weightings remain a constant throughout the screening process, to be multiplied with the changing variables – the Engineering Ratings.

Key parameters in pipeline repurposing

Material grade

Specified minimum yield strength (SMYS) (MPa) 299/358/348

Specified minimum tensile strength (SMTS) (MPa) Unknown

Charpy (V-Notch) toughness (J) 76.8 and 40.7/101.2/44.7

Internal coating type N/A

External coating type

Cathodic protection system

Fibreglass reinforced bitumen

Impressed current (target protection criterion of 850 mV)

Welding method Unknown

Welding records

Depth of

) Coating condition: hydrogen repurposing typically extends a pipeline’s service life. External coatings are the first line of defence against corrosion, so their condition is critical. Legacy coatings such as coal tar enamel or tape may have degraded significantly, whereas modern fusion-bonded epoxy coatings offer better longevity. Poor coatings increase reliance on cathodic protection systems and pose shielding risks that complicate corrosion control.

) Pipeline integrity: cracks, dents, and other defects are especially problematic in hydrogen service due to hydrogen embrittlement and accelerated fatigue crack growth. In-line inspections (ILI) using advanced tools like EMAT or MFL-T are essential but costly. Anomalies acceptable in methane service may require remediation due to hydrogen’s reduced ductility thresholds.

) Material records: reliable material certificates are essential. Properties like yield strength, ductility, and chemical composition (especially carbon and phosphorus content) inform hydrogen compatibility. Without records, destructive or non-destructive testing must be performed – an expensive and time-consuming process. Pipelines with high-strength steels (e.g., X70+) may be more prone to embrittlement than lower-grade steels.

)

Capacity and flow: hydrogen has only about one-third the energy density of methane by volume, so flow rates and pressures must be significantly increased to deliver the same energy output. This stresses systems that already operate near maximum allowable operating pressures (MAOP) and may require compressor upgrades.

) Welding records: welds are common failure points in hydrogen service. Historical welding practices may not meet today’s compatibility standards. Absence of documentation necessitates additional testing, particularly where welds have been repaired or replaced. Post-weld heat treatment (PWHT) history also plays a role in determining residual stress levels.

) Depth of burial: a shallow pipeline is more vulnerable to third-party interference especially in farmland or urban environments. Hydrogen’s effect on steel ductility means even minor impacts can be more dangerous. Options include

Construction year 1997

Pipeline length 106

Outer diameter (mm) 711

Wall thickness (mm) 8.7/11.1/12.7/15.1

Material grade X70

Specified minimum yield strength (SMYS) (MPa) 482

Specified minimum tensile strength (SMTS) (MPa) 565

Charpy (V-Notch) toughness (J) 27

Internal coating type N/A

External coating type Factory extruded polyethylene

Cathodic protection system Impressed current (target protection current of 850 mV)

Welding method Longitudinal seam weld

Welding records Yes

Depth of burial Yes

Maximum allowable operating pressure 84

installing concrete slabs or physically lowering the pipeline, although the latter is often impractical over long distances.

) Right-of-way encroachments: development over time may have brought buildings or infrastructure closer to pipeline corridors. Hydrogen’s higher diffusivity and explosiveness compared to methane mean greater blast impact zones. Where encroachments are too severe, rerouting may be necessary – an expensive and logistically complex process.

) Valve suitability: valves must be compatible with hydrogen and spaced appropriately to isolate pipeline segments during emergencies. ASME B31.12 mandates tighter valve spacing in highdensity areas. Older valves may need replacement, especially if material compatibility cannot be confirmed.

) Environmental and regulatory constraints: in sensitive environments, repurposing may be preferred over new construction due to regulatory hurdles. Operators must weigh the relative cost, time, and ecological impact of replacement against rehabilitation.

Applying the methodology

Case A: assessing a legacy pipeline

Case A examines an older natural gas pipeline. This pipeline was originally designed and operated under standards and material specifications that may not align with modern hydrogen service requirements. As a result, there are inherent challenges, some of which are considered below.

To systematically evaluate the feasibility of repurposing this pipeline, a high-level screening assessment was conducted based on the aforementioned methodology. The distinct lack of missing material and data records related to a derivation of a new MAOP for Case A from ASME B31.12 and related material and design factors based on location class.

Case

B: evaluating a contemporary pipeline with improved records

Case B examines a newer natural gas pipeline with the aforementioned methodology. This pipeline was designed and operated under modern standards and material specifications. However, some aspects may not align with modern hydrogen service requirements. As a result, there are inherent challenges, some of which are considered below.

Screening

results: case study comparison

For Case A, the Engineering Ratings are based on the condition of the asset. In the minimal available data, it was determined that significant remedial repairs and ILI surveys must be undertaken to allow hydrogen service. This was based on the number of significant defects reported along the pipeline, alongside insufficient material and pressure data to perform crack analysis and dent assessment.

Case B is more promising. The insight onto the current condition of the pipeline was much clearer due to improved data records and recent ILI data, which provided a comprehensive assessment of its integrity, unlike Case A. Additionally, the pipeline in Case B was in far better condition, with fewer signs of corrosion, mechanical damage, or other degradation concerns.

The total feasibility scores were 29% for Case A and 52% for Case B. Using an arbitrary 40% benchmark for repurposing versus replacement, Case B shows greater viability based on cost and

Table 3. Case B pipeline details

Table 4. Cost impact weighted scores for Case A

Table 5. Cost impact weighted scores for Case B

practicability. Pipelines below this threshold may still be suitable for lower hydrogen blends or with targeted remediation.

The screening assessments highlight a clear contrast in repurposing feasibility between older and newer assets. Case A, an older pipeline, presented challenges such as degraded coatings, incomplete material and welding records, and uncertainty around valve compatibility. These issues raise the likelihood of added costs, material testing, recoating, mitigation, valve replacement, re-routing, and inspection, before hydrogen suitability could be achieved.

By contrast, Case B, a newer pipeline, featured modern coatings, comprehensive records, and better material properties, making it more feasible for repurposing with fewer modifications and simpler defect assessments. Nonetheless, even in the newer system, considerations such as environmental exposure and third-party encroachments remain critical factors.

Supporting the hydrogen transition at scale

This comparison highlights the value of structured high-level screening in assessing the feasibility of repurposing natural gas pipelines for hydrogen service. With initiatives like EHB2 targeting 60% of the proposed pipeline network to be repurposed from existing natural gas infrastructure and the remaining 40% to be newly built – operators face growing pressure to evaluate the suitability of their assets efficiently.

A robust qualitative screening process enables operators to triage their networks, prioritising pipelines based on key criteria before committing to detailed engineering assessments. This

directs investment where it’s most impactful. As the hydrogen transition accelerates, such proactive methods will be critical to safely and effectively scaling repurposed infrastructure for the emerging hydrogen economy.

References

1. IEA, Global Energy Review. International Energy Agency, 2022.

2. European Hydrogen Backbone (EHB), The European Hydrogen Backbone (EHB) initiative | EHB European Hydrogen Backbone, 2025.

3. HALL, W., A Case Study of the Use of the Kepner-Tregoe Method of Problem Solving and Decision Making, June 1996.

4. Marcogaz, Study: Cost estimation of hydrogen admission in the gas system, MARCOGAZ Tech Forum on Cost Estimation of Hydrogen Admission into Existing

LEADING THE WAY IN TRENCHING SOLUTIONS

Tesmec trenchers replace multiple traditional machines. Even in the hardest conditions they deliver consistent depth, vertical walls and smooth trench bottoms. Tesmec trenchers improve safety, cut fuel use and emissions, and simplify site logistics, ultimately reducing costs and boosting productivity. Contact us to optimise your next pipeline project.

aced with an unexpected loss of planned power supply and a tight energisation deadline at its new pumping station in South Texas, US, a natural gas infrastructure company turned to Audubon Co. for a full-scale engineering, procurement, and construction (EPC) solution. The greenfield project, executed in two distinct phases, turned the power on for pumping natural gas liquids (NGLs) within five months. The company delivered a 138 kV/4160 V, 7.5 MVA mobile substation; 1200 ft, 138 kV transmission to - permanent transition strategy while navigating complex stakeholder negotiations and overcoming lead time challenges.

Gap in the grid: seeking an alternative power

In mid-2024, as a natural gas infrastructure owner advanced construction on its newest pumping station in South Texas along a cross-regional pipeline, a major gap emerged – the expected 4160 V service from a neighbouring site was no longer viable. With a March 2025 energisation deadline looming, the asset faced a make-or-break moment. Reliable high-voltage power was essential to begin pumping y-grade NGLs through this vital leg of the pipeline system.

“NGL startup wasn’t scheduled for another nine months, but suddenly the pumping station was without a plan for power,” said Scott Salter. “This kind of gap creates serious downstream risk, not just for the project schedule, but for commissioning and operations all the way to product delivery to the consumer. Situations like

Scott Salter, Director of Power and Utilities, Audubon Co., comments on how the firm energised an NGL hub in only five months with an agile, full-scale EPC solution.

this are becoming more common as grid stress increases and utilities face tighter resource constraints. We’re seeing more operators needing self-contained, fast-track power solutions, and it’s changing how we think about project execution. You can’t just wait for a utility window anymore. You have to engineer around the delay.”

The midstream firm reached out to EPC service provider Audubon, seeking urgent support after its power plan in South Texas fell through. Recognising the time-sensitive nature of the request and the critical role of power in keeping pipeline construction on

track, mobilisation was quick. What began as a series of fast-paced consultations and technical reviews evolved into a full-scale solution. The EPC contract was formally awarded in August 2024 – with concept work, stakeholder engagement, and material strategy already underway in parallel to meet the aggressive schedule. In September 2024, engineering and design kicked off, officially starting the clock on the project timeline.

Power sequence: prioritising energisation in phases

Audubon planned a tight, focused strategy to keep the project on schedule, key to which was a temporary, mobile substation. Electrical infrastructure carries long lead times, especially substation elements. Even if a substation was designed overnight, its equipment would still not arrive by March 2025. So, the team pivoted –and engineered the site’s permanent substation around a modular substation that would be rented as an interim power solution.

“The only way to meet the deadline was to split the workstreams,” remarked Salter. “Speed was the overarching goal, but it was really about smart strategy. The temporary substation wasn’t a stopgap – it was a launchpad. We intentionally designed it to carry forward into the permanent configuration so that every piece of work counted toward the long-term solution. That’s how we stayed ahead of the schedule without sacrificing quality.”

Unlike a conventional mobile substation, the temporary system needed to support a future cutover to permanent infrastructure. That meant more than powering up; it meant planning ahead. Audubon engineers integrated permanent A-frame and high/low bus structure into the temporary layout, allowing for a smooth switchover to permanent in phase two. Temporary equipment included the transformer, 138 kV breaker, and disconnect switch.

Behind the scenes, the procurement team expedited materials for the temporary substation and orchestrated long-lead packages for the permanent substation. By issuing early packages and pre-qualifying vendors, the supply chain was kept aligned with the project’s needs, despite volatility in material availability across the power market.

Audubon Project Manager Jules Marks commented: “The quick design-build on this project meant a lot had to happen at the same time. Every procurement decision had to map back to field placement, constructability, and project sequence. There was no room for handoffs or delays, either. We were constantly aligning materials, vendors, and field crews with evolving design realities. It wasn’t just fast-track; it was full immersion at every step.”

Balancing act: negotiating transmission line placement

Transmission line design also began in September 2024, with what looked like a straight path for placement.

Figure 1. Engineered, procured, constructed in five months: temporary, mobile substation for new NGL pumping station in South Texas, US.

Figure 2. 1200 ft, 138 kV transmission line utilising previously abandoned, retrofitted poles to save time and cost without sacrificing quality.

Expect A Higher Standard

Substation EPC by the numbers

) 1200 ft, 138 kV transmission line.

) 138 kV/4160 V, 7.5 MVA temporary, mobile substation.

) 138 kV/4160 V permanent substation.

) Eight dedicated engineers, designers, and project managers.

) Five months from kickoff to completion.

) Six months from kickoff to energisation.

) 18 months from kickoff to permanent substation.

The site’s western border already had existing pole infrastructure, as well as a parallel neighbouring power line that set the routing precedent. Routing proved to be another unexpected challenge, however. Requirements from adjacent landowners competed, resulting in a very narrow corridor to fit the transmission line.

“The routing demands did threaten the schedule at that point,” Salter noted. “We dug in with the design, though, and worked with all the stakeholders to better understand their concerns and expectations. We backed the routing revisions with hard data to meet all safety and clearance standards.”

Audubon’s reputation for collaboration and flexibility was put to the test – and held up. Thanks to skilled cooperation and strategic design, the 1200 ft, 138 kV transmission line was successfully routed through a narrow, 40 ft wide corridor adjacent to utility-owned and private midstream property. And rather than starting from scratch, the site’s previously abandoned transmission poles were utilised and retrofitted to meet current design standards. After full inspection, structural integrity verification, and modification, construction proceeded without the time or cost associated with new fabrication and delivery. It was a resourceful solution that balanced safety, schedule, and cost.

By the end of December 2024, the transmission line was fully installed – despite the route negotiations that nearly stalled the project. The midstream asset’s startup schedule remained intact, underscoring the value of practical problem-solving in a high-stakes environment.

Meter pressure: problem-solving at the 11th hour

Even with engineering, procurement, and field execution aligned, the project encountered another challenge that nearly derailed the schedule for energisation and startup – this time over a single component: the energy meter. From the beginning of the South Texas pumping station project, the site’s 5 kV power meter was committed by the regional utility provider. This detail often goes unnoticed in a typical power project schedule, but when several parts for the meter became unavailable in the autumn of 2024, it became a huge problem. For Audubon, the challenge became almost iconic – a marker of the larger project’s importance and the team’s ingenuity in execution.

Marks reflected on the moment they learned the meter would be delayed: “Without a meter the station wouldn’t have power. So, at that point the whole team was all in, from Pittsburgh to New Orleans. There wasn’t time or use for finger-pointing, just rolling up our sleeves. We were going to do whatever it took.”

Understanding the meter as nonnegotiable, the power group took over its scope and re-engineered it to use available current transformers (CTs) and potential transformers (PTs) without sacrificing quality, compliance, or performance. The solution shipped and installed in early 2025 and was successfully field-inspected and -tested by the utility company.

This adaptive, crossfunctional, hands-on approach showed itself repeatedly.

Whether negotiating clearances, configuring design for two different phases of energisation, or building equipment outside

Figure 3. Map view of transmission line placement within a narrow, 40 ft wide window between competing stakeholders.

Figure 4. Electric substation design allowing for seamless transition from temporary to permanent infrastructure.

of scope, the EPC team constantly responded to changing conditions with superior technical performance.

EPC agility for the win: meeting the timeline and exceeding expectations

Construction began on the site’s high-voltage substation on 1 January 2025 – four months after project kickoff. Substation installation wrapped up in late February – tested, inspected, and cleared – five months after project kickoff. By the time commissioning was done, power was set and ready for pumping operation. Site energisation happened at the six month mark, with NGL pump startup quickly following two weeks after that.

With the pumping station energised and operating, the Audubon power group has shifted focus to phase two: EPC on the 138 kV/4160 V permanent substation alongside engineering, fabrication, and installation of the site’s relay panels and power distribution centre (PDC) building. The team’s efforts on the temporary substation went beyond filling a power gap; they built momentum – the permanent substation is scheduled for cutover in early 2026. Thanks to the foresight in the original design and sequencing, the foundational steel, grounding, and bus configuration are already in place. Though complex, the transition is expected to occur with minimal service interruption.

What began as a fast-track challenge with fractured plans became a model for adaptive EPC execution. The delivery for the natural gas client in South Texas showcases what’s possible when engineering precision and project dedication meet execution urgency for critical energy supply. With a compressed schedule, multiparty constraints, and unpredictable obstacles jeopardising success, technical fluency, stakeholder collaboration, and creative problem-solving were exhibited.

“Projects like this don’t happen accidentally,” said John Pierce, Senior Vice President of Manufacturing and Infrastructure for Audubon. “They happen because talented people make fast, wise decisions based on experience. They own the challenges and refuse to let momentum stall. We are incredibly proud of our work on this project. With reliable power, our client will surely bring critical energy resources to end users for the long term.”

For the midstream infrastructure company, the pumping station now stands as a key asset in the broader expansion of its natural gas portfolio. It is an example of

how integrated, dedicated EPC services can deliver certainty –especially when the power has to be on.

About Audubon

Audubon Companies LLC provides EPC, consulting, fabrication, and field services to energy and industrial operators across the globe. The company’s expertise spans the midstream sector, supporting 6+ billion ft3/d of gas treatment, 1+ million hp of gas compression, and 9+ million bbls of NGL handling since 1997. The company bring agile, collaborative project solutions, dedicated in every phase to safety, quality, and results. For clients’ most important assets and most challenging problems, Audubon delivers.

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

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

The urgency of the energy transition is no longer in question. With global CO2 emissions reaching an estimated 41.6 billion t in 2024, including increases from both fossil fuel use and land-use change, the pace and scale of action must accelerate. Among the tools available to address this challenge, carbon capture and storage (CCS) stands out as an essential solution, particularly for sectors that cannot yet decarbonise through electrification.

Heavy industries such as steel, cement, refining, and petrochemicals remain among the most difficult to decarbonise. Even under the most ambitious energy scenarios, fossil fuels are expected to play a role in the global energy mix for decades. CCS therefore serves not only as a transitional technology, but as a permanent feature of the industrial decarbonisation landscape. However, realising its potential depends on our ability to deploy infrastructure at scale, especially in CO2 transport and storage.

For CCS to be effective, capture is only one part of the equation. Transport and storage must also be engineered for commercial and operational success. Building pipelines and injection facilities that are safe, durable, and cost-effective is a significant task. Yet it is one that must be addressed with urgency, given that many capture projects are already reaching technical maturity.

Repurposing infrastructure for CO2 transport

While capture technologies have advanced rapidly, CO2 transport infrastructure has not kept pace. According to the International Energy Agency, more than 65 000 miles of dedicated CO2 pipelines will be needed globally by 2050 to support net-zero ambitions. At present, only a small fraction of that capacity exists.

Constructing new pipelines on this scale faces significant constraints. Regulatory complexity, permitting delays, environmental assessments, and public opposition all contribute to lengthy project timelines and high capital costs. As a result, repurposing existing gas pipelines offers an efficient and economically viable alternative. These networks already connect

Andrea Bombardi, Executive Vice President, RINA,

explores how robust data, modelling, and integrated planning can help CCS infrastructure move from concept to reality.

industrial areas with potential storage zones, making them an ideal foundation for CCS deployment.

Existing corridors, including rights-of-way and established environmental clearances, reduce the need for fresh negotiations with stakeholders and shorten project development timelines. In many cases, the steel, route, and supporting infrastructure can be retained, provided that rigorous requalification is performed.

However, repurposing is not as straightforward as reversing flow or rerouting content. CO2, particularly in its dense or supercritical phase, behaves quite differently from natural gas. Its thermodynamic properties impose new engineering demands, necessitating careful requalification of materials, coatings, welds, and seals.

The risks associated with dense-phase CO2 transport include rapid decompression, extreme cooling, and high energy release in the event of leaks. These conditions can lead to long-running ductile fractures and accelerated corrosion, particularly when water or contaminants like hydrogen sulfide and oxygen are present. Pipelines originally built for hydrocarbons were not designed to manage these stresses.

To mitigate these risks, technical due diligence is essential. Laboratory analyses alone are not sufficient. Full-scale dynamic testing under realistic pressure and temperature conditions, including the use of cut-out pipeline segments, provides the data required to assess integrity and performance. These tests simulate real-world operations, including long-term pressure cycling, rapid decompression, and exposure to impurity-laden CO2

RINA has played a leading role in these efforts, contributing to five of the 15 active full-scale CO2 transport trials globally. These trials examine fracture propagation, corrosion mechanisms, and coating performance, generating critical data that informs safe pipeline conversion and regulatory acceptance. The results not only support specific reuse projects, but also feed into industry-wide learning for standards development and future asset assessments.

Economic viability and lifecycle costs

The technical feasibility of pipeline reuse must be matched by economic viability. In many cases, repurposing infrastructure can reduce capital expenditure by 50 - 70% compared to greenfield construction. This is particularly true where existing pipelines already serve industrial clusters or are located near proposed storage sites. However, headline savings must be evaluated in the context of full project economics.

Pipeline reuse often entails upgrades to compression and dehydration systems, which may be underspecified for densephase CO2. Monitoring equipment, including sensors and inline inspection tools, may also need to be replaced or recalibrated. Additionally, components such as valves, gaskets, and elastomers must be requalified for compatibility with CO2 and its potential impurities.

Beyond hardware, there are cost implications for operational monitoring, maintenance scheduling, and integrity management. Unlike conventional hydrocarbon systems, CO2 pipelines may require more frequent inspection, especially if there is a risk of phase changes or impurity-induced corrosion. The operational profile of CO2 transport is also different, as pipelines may be

operated intermittently in early phases of deployment, which introduces new stress cycles and challenges for flow assurance.

Operating expenses require equal attention. CO2 is more energy-intensive to compress and transport than methane. If impurity removal is not performed upstream, corrosion risk increases, raising the cost of inspection and maintenance. These operational risks, if unaddressed, can erode the financial case for reuse.

Therefore, cost-effective deployment depends on early and rigorous feasibility assessment. Preliminary front-end engineering and design (pre-FEED) and FEED studies should incorporate detailed techno-economic modelling, assessing capital costs, operational variables, regulatory compliance, and financing options. Sensitivity analyses are useful in understanding how different parameters, such as CO2 purity or pressure regimes, affect cost and performance.

Well-structured modelling not only informs engineering decisions but also improves investor confidence. As CCS projects scale, securing financing will increasingly depend on a demonstrable understanding of technical risk and cost certainty. Projects that can present a coherent, data-backed risk mitigation strategy are more likely to achieve financial close and attract long-term partners.

In some jurisdictions, financial incentives or carbon pricing may further shape project economics. Where government subsidies or regulatory frameworks support early CCS investment, developers must be able to prove that infrastructure reuse is aligned with funding eligibility, particularly where performance benchmarks are linked to emissions avoided or permanence of storage.

Lessons from deployment and the path forward Real-world CCS projects around the world provide valuable insights into the challenges and solutions associated with infrastructure deployment. In Italy, the Ravenna CCS project is repurposing offshore and onshore pipelines to transport captured CO2 to a depleted gas reservoir in the Adriatic Sea. The project began injection in 2024 and is expected to scale up significantly by 2027. RINA’s work on the project has included pipeline integrity assessments, certification, and long-term monitoring strategies.

In Malaysia, a pre-FEED study commissioned by Petronas is evaluating the infrastructure needed to connect CO2 capture sites to offshore storage. The study considers a hybrid approach of repurposing existing gas infrastructure alongside new pipeline construction. Similar studies are underway in the UK, Switzerland, and India, where industrial corridors and ageing hydrocarbon infrastructure create opportunities for strategic reuse.

These projects also highlight the urgent need for consistent international standards. While codes such as ASME B31.12 provide a framework in North America, many jurisdictions lack detailed technical guidelines for CO2 pipeline conversion. Fragmented regulatory landscapes create uncertainty for developers and delay project approvals.

To address these gaps, collaborative efforts are growing. RINA recently led a study for the International Pipeline Research Council, mapping global knowledge gaps in CO2 transport and proposing a roadmap for coordinated research. The study’s

We are running out of space...

Our inventory in sales & rental in pipeline equipment is out of this world. We have a huge amount of machines from all the big brands that are ready for worldwide delivery, or even further if you want...

You can build on BAUMA!

findings emphasise the importance of fracture control, corrosion behaviour, and system monitoring under varied operational conditions. These areas must become focal points for standard development and shared research across borders.

Moreover, the regulatory environment must evolve to support long-term investment. Clear rules on liability, monitoring, and post-closure stewardship are essential for de-risking storage and transport assets. Government incentives, such as tax credits or carbon pricing mechanisms, can also play a role in enhancing project viability and investor returns.

Public engagement is another vital component. Many pipelines pass through or near populated areas, and public confidence is critical. Transparent communication, combined with demonstrable safety records and environmental performance, can help build the trust needed for project approvals. Data from full-scale tests, third-party certifications, and continuous monitoring systems provide the evidence base for this dialogue.

In parallel, the emergence of CO2 utilisation markets, including synthetic fuels, carbonated materials, and green chemicals, is beginning to create new commercial incentives for transport infrastructure. While these markets are still developing, they signal a shift toward circular carbon systems where transport is not only a conduit to storage but an enabler of low-carbon production.

CCS is also increasingly linked to hydrogen strategies, particularly where blue hydrogen production generates concentrated CO2 streams. In such cases, shared pipeline

corridors and coordinated infrastructure planning can create economies of scale and improve return on investment.

The broader lesson is clear. Technical and economic feasibility must be considered together. A pipeline that is structurally sound but economically uncompetitive will not attract investment. Likewise, a financially attractive route that lacks integrity assurance will not pass regulatory scrutiny. Success depends on integrating engineering discipline, financial modelling, policy awareness, and social responsibility into a single, cohesive strategy.

Conclusion

CCS has evolved from an experimental idea to a viable component of global decarbonisation. Its role in reducing emissions from essential industrial sectors is no longer theoretical, and the need for scaled infrastructure is increasingly urgent.

Repurposing existing pipelines offers a practical and efficient way to accelerate CO2 transport deployment. But doing so requires more than engineering ingenuity. With the right combination of technical capability and financial foresight, CCS infrastructure can be delivered reliably, safely and at scale. As projects move from concept to construction, the focus must remain on the foundational pillars of feasibility: robust data, proven performance, and integrated planning.

The path to net zero is challenging, but it is navigable. When backed by a robust infrastructure strategy, CCS offers a credible and forward-looking solution – particularly as technology continues to drive progress toward a circular economy.

MULTI-DIAMETER

Multi-Diameter pigs or Dual-Diameter pigs are used for lines with definite changes in outer diameter (i.e. 8” x 10”), but also lines of one diameter that contain several large internal diameter changes (i.e. valves, connectors, tee’s etc.)

Propipe produces all styles of pigs, backed up with engineering drawings and studies, plus prototype development and in-house testing.

Alyson Cram, Vacuworx, USA, describes the evolution of vacuum lifting.

TThe global material handling industry – particularly in the energy sector – is in the middle of a technological shift. As efficiency and safety remain a top priority in lifting operations, vacuum lifting continues to play a vital role in getting the job done effectively. Vacuworx is at the forefront of the evolution, delivering equipment designed to meet the demands of real-world applications with greater efficiency than ever before.

For more than 25 years, lifting one joint of pipe at a time has been standard practice. But as the demand to do more with fewer resources – fewer people and tighter timelines – continues to grow, Vacuworx recognised a way to help customers work more efficiently. By listening to the needs of industry, Vacuworx adapted the concept behind its multi-pipe

Figure 1. Custom lifter in Southeast Asia lifting two joints of pipe at once.

lifter, which lifts up to nine joints of pipe at once, and is now being applied to smaller vacuum lifting systems.

Multi-pipe lifting

The Vacuworx Computer Controlled Multi-Pipe (CC-MP) lifter was originally a one-off, custom-designed solution for streamlining high-volume unloading at Port Geraldton in Australia, where more than 33 000 pipes were handled over a nine month project.

Traditional offloading methods had proven to be slow and labour-intensive, requiring crews to manually engage with each pipe. This not only reduced overall throughput but introduced safety risks as well. Vacuworx was contacted to find a better solution, resulting in the CC-MP.

The CC-MP system uses multiple vacuum pads to lift up to nine joints of pipe at once. Because each pad operates independently, it introduced a completely new way to lift and release loads via a wireless control pad. This gave the operator more control over individual joints being lifted. This design also allowed for more precise vacuum pressure monitoring across each pad, helping ensure safer and more consistent handling, even when conditions vary.

Safety measures

The programmable logic controller (PLC) used in the CC-MP is an intelligent control platform that actively manages safety, detects abnormalities, and responds in real time. Whether it is regulating vacuum levels or halting operations to prevent a dangerous lift, the PLC ensures everything functions within tightly controlled parameters.

“In any lifting operation, particularly those involving multiple heavy and potentially unevenly distributed objects, the ability to maintain total control over the load is absolutely critical,” said Keith Sparks, Engineering Manager at Vacuworx.

“That’s where our focus on fail-safe design really comes into play. Any unsafe action is automatically identified and rejected by the system’s logic. The operator is alerted immediately, and either the lift is halted, or the system adjusts based on built-in safety protocols,” Sparks said.

That level of protection goes well beyond the software. The CC-MP also includes physical redundancies. If one part of the system fails, a backup is already in place to maintain control. For example, if vacuum is lost on a single pipe, the system can isolate that section while continuing to safely hold the rest of the load. This not only protects the materials and equipment involved but also prevents costly delays.

“Partial failure isolation is one of the most valuable features of our multi-pipe lifter system. Instead of shutting down an entire operation over one issue, we maintain control of the load and keep everything moving,” Sparks continued.

Further development

The success of the CC-MP’s concept, design, and execution opened the door for further development, and its core ideas are being applied to smaller job sites through the RC Series and other custom-built lifters.

These modified variations of the RC Series have taken the foundational ideas of the CC-MP and adapted them into a

more compact, mobile format better suited for construction environments or laydown yards. Instead of nine vacuum pads, these scaled-down versions typically use two, but still retain the ability to operate with a single vacuum pad, just as crews have been doing for over 25 years. While these units are operating on a smaller scale, they still have the same emphasis on precision, control, and real-time operator feedback.

“The strength of the smaller equipment lies in its modular architecture. Operators can deploy the system with as little as a single vacuum pad or as many as the spreader rail will accommodate, depending on the job’s requirements. This scalability gives crews the freedom to quickly adapt the lifter to new tasks without needing to replace core equipment,” Sparks said.

This approach is now being adopted internationally, with successful applications across a range of job sites. In Kansas, US, a multi-pipe variation of the RC Series vacuum system was deployed to improve efficiency on a domestic project involving pipe ranging from 6 - 10 in. in diameter. On a separate project in Southeast Asia, a custom vacuum lifter took advantage of Vacuworx’s modular capabilities to handle two 20 in. pipes simultaneously, as well as a single 36 in. pipe weighing 12.5 t –demonstrating the system’s ability to manage large-diameter and heavy loads with precision and control. These real-world examples highlight how the core principles behind the CC-MP are being adapted around the globe to solve complex material handling challenges, especially in applications where efficiency and tight project timelines are critical.

Job sites often demand flexible equipment that can work in tight quarters. By integrating key CC-MP features into Vacuworx’s standard equipment offerings, such as the RC Series, crews’ get the agility they need while maintaining the safety and efficiency benefits that made the CC-MP stand out.

“By giving operators the tools to adapt quickly and confidently, this system helps minimise downtime, reduce manual intervention, and improve overall jobsite safety,” Sparks said.

Industry transformation

Focus on control, safety, and responsiveness is what continues to drive innovation at Vacuworx. “From day one, we’ve focused on building systems that don’t just work – they work intelligently,” Sparks said. “We want operators to feel confident in the equipment, knowing it will give them feedback when something’s off and respond accordingly.”

The ongoing development of multi-pipe vacuum lifting technology continues to push the boundaries of what’s possible in material handling. At Vacuworx, research and development efforts are focused on refining the technology itself by optimising controls, improving modularity, and enhancing overall system integration. These advancements aim to broaden the types of materials and environments vacuum lifting can support.

A major area of innovation lies in the integration of digital monitoring and predictive maintenance capabilities. By embedding sensors and data analytics into multi-pipe systems, operators gain real-time insights into equipment performance. This allows for smarter decision-making in the field, reduces unexpected downtime, and helps protect people

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.

and materials. When combined with remote control operation and independent pad control, the result is a smarter, more responsive lifter that works with the operator – not just for them.

The success of the CC-MP system at Port Geraldton was a turning point. What began as a highly specialised solution for unloading nine joints of pipe at once quickly proved the broader potential of the concept. Its precision, flexibility, and safety benefits caught the attention of companies beyond port logistics, prompting Vacuworx to scale the technology into more mobile formats, including the RC Series and other small custom lifters.

These scaled-down systems retain the core benefits of the original CC-MP design, like independent pad control, configurable setups, and real-time vacuum monitoring, but are compact enough for use in construction environments, laydown yards, and infrastructure projects. That means crews working in tighter, more complex spaces can still take advantage of the same safety and efficiency gains.

What was once considered a niche solution is now proving to be a versatile tool for solving everyday material handling challenges. The multi-pipe lifting approach proves that gamechanging technology doesn’t have to be complicated – it just has to be built for the realities of the job. Through intelligent design, robust engineering, and close collaboration with end users, Vacuworx is not only solving today’s toughest handling challenges, but helping shape what comes next for the industry as a whole.

Figure 2. Vacuworx CC-MP working at Port Geraldton in Australia.

Figure 3. Multi-lift control panel monitoring multiple pads at once.

Patrick Koch, General Manager, LCS

Cable Cranes, discusses how cable crane systems transform pipeline construction in challenging terrain.

When pipeline construction reaches the limits of accessibility – across deep valleys, steep slopes, or ecologically sensitive zones –traditional logistics come to a halt. But where wheels stop, cables take over. Cable crane systems have emerged as a transformative solution for the transport, placement, and installation of materials in even the most remote and rugged regions of Europe and beyond.

Used extensively in hydroelectric infrastructure and high-altitude pipeline corridors, these systems provide something that’s often missing in extreme

construction environments: direct, reliable, and low-impact access from above.

High-performance logistics in the air

The process begins far from the trenchline. Pipes, equipment, and fill material are delivered to a base station, typically accessible by road. From there, the cable crane system – spanning hundreds or even thousands of meters – lifts and transports loads directly to the job site via an airborne carriage.

Each pipe section is secured with two reinforced nylon straps and suspended in the air. What follows is a smooth aerial transfer, avoiding all terrain-related obstacles and delivering the load precisely where it’s needed – no bulldozers, no temporary roads, no ecological disruption.

This airborne delivery system not only boosts logistical efficiency but also protects landscapes that are often fragile or regulated. It’s a solution that makes engineering sense –and environmental sense.

Precision installation without touching the ground

One of the most impressive aspects of the system lies in its precision. Using two independently controlled lifting devices, operators can adjust the tilt of the pipe mid-air during lowering. This fine control allows perfect alignment with already installed sections, even in inclined or winding terrain.

Once in position, the pipe remains suspended and stable for welding. An external line-up clamp secures it for the jointing process, ensuring consistency and safety without the need for scaffolding or extra supports. The result: high-quality welds in locations where human access alone would be near impossible.

Coating, backfilling, and more by crane

After welding, the next challenge is coating the joints and protecting the pipeline. Here too, the crane system proves its versatility. It deploys a specially designed work platform directly above the pipe, giving coating and sandblasting crews a stable and elevated workspace – free from uneven ground or time-consuming scaffolding.

Beyond installation, the system continues to support the construction process with trench protection and backfilling. Sandbags and padding material are transported via bulk baskets into difficult terrain, enabling rapid construction of trench barriers without manual hauling. And where native backfill isn’t available, material can be loaded at the base and flown in by crane. The dual-hoist setup allows for precise and remote-controlled unloading into the trench, ensuring even compaction and fill quality.

Minimising footprint and maximising impact

In an era where infrastructure is expected to coexist with nature, cable crane systems represent a smarter approach. By eliminating the need for road construction and minimising ground intervention, they drastically reduce environmental disturbance and post-project restoration costs. Flora and fauna remain largely untouched – and project timelines are accelerated by streamlined access.

Whether used for penstock installation on alpine hydropower plants or long-distance pipeline projects through national parks and reserves, the advantages are clear: minimal ground impact, high-precision operation, and adaptability to the harshest conditions.

Sustainable logistics solutions

With growing investment in sustainable energy, highland water management, and remote grid connectivity, the need for resilient and low-impact construction technologies is greater than ever. Cable crane systems meet this demand with proven efficiency, especially when integrated early in the planning phase.

For engineers, project developers, and EPC contractors operating at the edges of feasibility, cable cranes unlock the full potential of complex topographies – allowing infrastructure to move forward where it otherwise wouldn’t.

Figure 1. Pipeline installation in an open trench.

Figure 2. Cable crane in use for pipeline construction.

Figure 3. Transporting a section of pipe using cable cranes.

Giacomo Betti and Marco Paris, Tesmec, Italy, outline Tesmec’s role in landmark pipeline construction projects.

As the global demand for reliable and sustainable energy networks grows, the construction of new pipelines has never been more critical or complex. From the shale-rich basins of Argentina to the deserts of Saudi Arabia, delivering different diameter

Figure 1. Tesmec 1875XL EVO working in Master Gas Phase 3 project in Saudi Arabia.

pipelines safely, quickly, and cost-effectively requires innovative solutions. Tesmec, a provider of advanced trenching technology, is proving indispensable to this new era of pipeline construction, setting benchmarks in performance, efficiency, and sustainability.

Tesmec’s cutting-edge trenchers are reshaping the pipeline industry and playing a key role in major projects around the world including the Master Gas Phase 3 project in Saudi Arabia.

A project in Argentina

Tesmec equipment is currently been used by Techint E&C in a major pipeline project in Vaca Muerta, Neuquén, Argentina. This ambitious 437 km pipeline, with a 30 in. (76.2 mm) diameter, is designed to boost oil transport capacity, strengthening Argentina’s domestic distribution and export capabilities.

To tackle the region’s demanding terrain and tight project timelines, two Tesmec 1675EVO chainsaw trenchers were deployed. Weighing 150 t and powered by a formidable 760 HP (567 kW) engine, the 1675EVO is engineered specifically for large-diameter pipelines and utilities in hard rock conditions. With the flexibility of three boom configurations, it can excavate trenches up to 732 cm (24 ft) deep and 183 cm (72 in.) wide, ideal for Vaca Muerta’s varied geology.

The deployment of these trenchers has been instrumental in keeping the project on schedule. Their ability to maintain consistent trench profiles in rocky subsoils has minimised rework and improved safety. Moreover, the efficiency of the 1675EVO has enabled the project to progress with fewer machines and less manpower, underscoring Tesmec’s value in megaproject environments.

The Master Gas Phase 3 project in Saudi Arabia

In Saudi Arabia, Tesmec has taken on an equally formidable challenge with the Master Gas Phase 3 project, a cornerstone of the kingdom’s strategy to convert power plants from oil to natural gas, supporting its commitment to a cleaner energy mix and net-zero emissions. This project requires excavation of two parallel trenches, each stretching 150 km, at depths of 2 m and widths exceeding 2.1 m. To meet these demanding specifications, Tesmec provided the 1875XL EVO Chainsaw Trencher, a 160 t class trencher and the most powerful in Tesmec’s products portfolio. Equipped with a 950 HP (709 kW) engine, the 1875XL EVO is built for large diameter pipelines in hard rock and the toughest excavating conditions. It can excavate trenches up to 732 cm (24 ft) deep and 213 cm (84 in.) wide, making it ideal for projects where precision and productivity are critical.

Before excavation began, Tesmec conducted comprehensive terrain

Figure 3. Tesmec 1675EVO working in Argentina.

Figure 2. Tesmec 1675EVO digging a trench to accommodate a 30 in. pipeline.

assessments using ground-penetrating radar (GPR) and drones to detect underground obstacles and validate feasibility. Alongside the equipment, Tesmec’s dedicated team delivered technical and operational support, optimising machine performance and ensuring smooth project execution.

The combination of the 1875XL EVO’s unmatched trenching capacity and advanced planning tools enabled a safer, faster, and more predictable installation process. This project highlights not only the machine’s raw capabilities but also Tesmec’s holistic approach to complex infrastructure development.

Advantages in pipeline projects

One of the most compelling advantages is exceptional efficiency: a single Tesmec trencher can outperform entire fleets of traditional excavators, reducing the number of machines required on-site. This efficiency translates into reduced fuel consumption and fewer personnel, delivering substantial cost savings over the life of a project.

Reliability is another critical benefit. Tesmec trenchers are designed to maintain consistent performance in the harshest conditions, whether cutting through solid rock, asphalt, or mixed soils. This proven dependability ensures that excavation progresses without interruption, helping projects stay on schedule and within budget.

These trenchers are engineered to operate effectively in diverse environments, from remote rural landscapes to congested urban corridors, with minimal disruption to surrounding communities and ecosystems. Lower noise levels

and smaller site footprints support more sustainable and socially responsible construction practices.

Precision is a defining characteristic of Tesmec technology. Advanced systems such as TrenchTronic enable operators to achieve consistent trench depth and width, with smooth bottoms and vertical walls that meet stringent project specifications. Excavated material can be transferred directly onto trucks via integrated conveyors, streamlining logistics and reducing the need for further handling.

Smart project management is further enhanced by features like remote monitoring, GPS guidance, and selfdiagnosis. These capabilities allow project teams to track progress in real time, anticipate issues before they arise, and ensure every stage of excavation is recorded and managed accurately.

Safety remains at the forefront of Tesmec’s approach. Fewer machines and less manpower translate into a reduced risk of accidents. In addition, pre-construction surveys and continuous performance monitoring help maintain the highest safety standards on site.

Finally, sustainability is embedded in every aspect of Tesmec’s equipment and processes. Lower fuel consumption and emissions help reduce the carbon footprint of pipeline construction. Noise reduction technologies and efficient operations protect local communities and wildlife from unnecessary disruption, supporting broader environmental goals.

Driving the future of the pipeline industry

From the Vaca Muerta basin to the Saudi Arabian desert, Tesmec’s trenching solutions are proving essential to the world’s most ambitious pipeline projects. By combining state-of-the-art technology, operational excellence, and a commitment to sustainable practices, Tesmec is not only supporting the energy transition but also redefining what is possible in modern pipeline construction.

As energy infrastructure expands to meet new demands, the importance of reliable, efficient, and environmentally responsible trenching technology will only grow.

Figure 4. Tesmec 1875XL EVO working in Master Gas Phase 3 project in Saudi Arabia.

Margherita Laurini, Chief Financial Officer, Laurini Officine Meccaniche, Italy, discusses a new excavator operating at the frontier of pipelaying.

In 2025, Laurini Officine Meccaniche reached a remarkable milestone: 70 years of history, innovation, and continuous growth.

Founded in 1955 in Busseto (Italy), the company has evolved from a small artisanal workshop into an international benchmark in heavy machinery for the pipeline, demolition, and tunnelling sectors.

To commemorate this important anniversary, Laurini unveiled its most ambitious product to date: ‘Settanta’ an excavator fully designed

and built in-house, not only for demolition but also for handling and laying pipes.

On 30 May 2025, Laurini opened the doors of its headquarters to share a memorable day with employees, partners, clients, and suppliers. The event featured the official presentation of the Settanta, followed by a celebratory dinner honouring 70 years of success and innovation – with music, entertainment, and the unmistakable family spirit that has distinguished Laurini for three generations.

A high-versatility multifunction excavator

Settanta is a multifunction excavator built for versatility, designed with a modular approach and tailored to meet the demands of various sectors: demolition, lifting, pipe handling, excavation, and sheet piling.

At the heart of the project is the Hydraulic Quick Coupling System (HQCS) – an automatic system that enables operators to switch arms and tools directly from the cab, with fully automated hydraulic and electrical connections.

For demolition purposes, the cabin can tilt up to 30˚. The Settanta Pipeliner instead has a cabin that rises up to 5 ft.

The machine can be configured with a variety of easily interchangeable arms, including:

) Pipeliner configuration with modular quick coupler for LaValley Industries’ Deckhand® system.

) Excavation arm (monoboom or triple boom) with a reach of up to 14.5 m and a capacity of up to 5000 kg.

) Sheet piling arm.

) Crane arm with lattice and integrated winch for lifting and pipe laying.

) Demolition arm with an operating height of 24.5 m and tool capacity up to 3000 kg.

) Telescopic arm from 25 - 30 m for high-altitude operations, with a capacity of up to 2000 kg.

A new frontier in pipelaying

A revolutionary extension of the platform is the Settanta Pipeliner version, combining Laurini’s tradition of innovation with a modular boom and stick design, offering superior performance in pipe handling operations. Key features include:

) Hydraulic variable-width undercarriage: allows for full 360° rotation, delivering exceptional maneuverability and stability.

) Hydraulically elevated cab: enhances visibility during pipe yard operations and loading/unloading of trucks and trains.

) Deckhand® system integration: ensures greater safety, control, and productivity under any working condition.

) Compact chassis, high power: offers up to 25% more lifting capacity compared to similarly sized excavators.

) Modular front system: boom and stick with fully automatic electronic and hydraulic quick coupler system.

With an operating weight of 33 t, Settanta delivers performance comparable to that of a 45 t excavator. It is powered by a 350 HP SCANIA DC09 engine, paired with a cutting-edge hydraulic system.

The frame has a transport width of just 2.5 m, which extends to 3.7 m during operation, making the machine easy to transport without the need for special permits.

The tiltable or elevating cab (up to 30°), is airconditioned, FOPS certified, equipped with advanced displays and customisable operating modes, ensuring maximum operator comfort and safety under any condition.

With Settanta and its Pipeliner evolution, Laurini Officine Meccaniche not only celebrates its past but also powerfully projects its vision into the future of mechanisation on construction sites.

A machine that represents the perfect blend of tradition, innovation, and Italian passion.

“The SETTANTA was engineered from the ground up to lift with unmatched power and control. LaValley Industries collaborated with Laurini to develop the SETTANTA Pipeliner, fully integrating the DECKHAND pipe handling system. Together, we designed a purpose-built machine for pipeline construction,” commented Jason LaValley, CEO/Founder of LaValley Industries.

Figure 1. The same lifting capacity over 360˚.

Figure 2. Lifting capacity equal to a machine 25% heavier.

Jimmy Herring, Chief Executive Officer, Infra Pipe Solutions, explores the rapid growth and evolving challenges of the global pipeline construction and natural gas distribution market, highlighting the critical role of infrastructure modernisation, regulatory compliance, and supplier reliability in meeting rising energy demands.

The global pipeline construction market, which encompasses the design, engineering, and construction of pipelines that transport oil, gas, and water across various global regions, is forecast

to increase from US$45.12 billion in value in 2024 to US$538.80 billion by 2030. This explosion in growth is primarily driven by the relentless demand for energy infrastructure due to expanding oil and gas exploration worldwide. As a result, the entire pipeline supply chain – from raw materials to manufacturers to equipment suppliers to distributors to pipeline construction companies to the contractors they work with – face a myriad of technological, regulatory, environmental, and economic challenges to keep pace with expansion.

The rising demand

Within this broader market, global natural gas distribution is expected to grow to US$1.3 trillion in value by 2029, at a stunning compound annual growth rate (CAGR) of 6.9%. As the world’s top producer, the US produces ~13 million bbls of crude oil and ~100 billion ft 3 of natural gas daily, accounting for one-fifth of the global market supply. However, the market is at a critical inflection point: many existing pipelines are nearing or exceeding their design life, leading to increasing maintenance costs and potential disruptions. In fact, as of today, 75% of North American utility companies are in the process of replacing ageing cast iron and steel pipes with High Density Polyethylene (HDPE) or Medium Density Polyethylene (MDPE) installations, representing >100 000 miles in North America alone. HDPE and MDPE pipes, which Infra Pipe – a North American polyethylene pipe manufacturer – produces, are more resistant to corrosion, leaks, and ground movement, contributing to fewer disruptions and enhancing service reliability. And materials matter, given that this market is highly regulated on federal, state, and local levels, as well as by ‘social’ pressures to ensure that pipes put in the ground are environmentally safe and constructed securely. Thus, it is vital for natural gas distribution companies to purchase products from suppliers who are producing to the regulatory standards for quality assurance.

Pipeline construction: a regulated, multi-stage process

Construction of oil and gas pipelines is a multi-stage process involving specialised teams working sequentially along the pipeline route. While standardised, it is extremely detailed and subject to strict regulations and ongoing inspection. Safety is a top priority throughout the construction process, as is limiting environmental impact as much as possible.

Before the first barrel of oil or cubic foot of natural gas can be transported, pipeline companies analyse the most efficient routes for the new pipelines, avoiding populated areas whenever possible. Then they must acquire the right-of-way (ROW) to build, operate and maintain the pipelines, which requires extensive inspections. While that is underway, engineers design the system. Each of these steps is rigorously reviewed by regulatory officials and construction can only begin

after the route selection receives approval, the ROW is obtained, and the system design is completed. Once approved, the route is surveyed and staked out, any vegetation is cleared, and the ground is graded and prepared for installation. Once installed, connections are rigorously inspected, using qualified testing methods. Pressure testing is conducted to ensure performance to the designed application. After the site is cleaned up, markers are placed along the route to indicate the presence of a pipeline. To ensure their integrity, pipelines are inspected regularly and are equipped with safety features to prevent leaks and explosions. Given these extensive requirements and processes, it is no surprise that pipeline construction projects are an expensive undertaking several years in the making.

Meeting utility standards: the supplier’s crucial role

Once a pipeline is in place, a natural gas distribution company delivers pressurised natural gas from a main transmission line to smaller pipelines for further, more targeted distribution within a region. It is responsible for managing the entire process of natural gas delivery, from the maintenance and inspection of pipelines to the regular meter readings, and the installation of new customer connections, and repair and replacement of pipelines. It also provides emergency and other technical services when needed. These gas utilities require suppliers to meet or exceed all the regulatory requirements for producing their products, often creating dedicated materials and engineering committees to monitor all facets of sourcing and operation. For suppliers, this is the most intense part of the process, but it is the first, and arguably most important prerequisite for supplying a utility.

Once a supplier is approved by a utility, the supply channel, which includes direct utility, integrators, and distributors, is determined by the utility. The sales process then varies by the determined channel and could include requests for quotation (RFQs), negotiated integrated supply contracts, partnership selling, pricing agreements, and open market quoting. Utilities also test new supplier products, and audit facilities and procedures, requiring all supply channel partners to be qualified to supply natural gas products.

At Infra Pipe, we find that utilities prefer to work with a limited number of qualified suppliers who provide consistency in service and quality and meet or exceed all the regulatory requirements. To be a top tier, preferred polyethylene pipe manufacturer in North America, it is necessary to abide by the industry’s strict regulatory requirements, including raw materials, dimensional tolerances, print line requirements, bar coding, and product identifiers such as striping.

Corrosion protection with outstanding strength and abrasion resistance

FORTIDE®-HT For very high temperatures up to +150 °C

FORTIDE®-ST For standard temperatures up to +95 °C

FORTIDE®-TL For chemical-resistant tank & pipe lining

FORTIDE®-WS For application on wet surfaces

The new FORTIDE® Epoxy coatings guarantee the 100 % Made in Germany quality from industry leader DENSO. All FORTIDE® products are free of VOC & isocyanates and fully comply with ISO 21809-3. Beneﬁt from a unique range of corrosion protection solutions: DENSO® Petrolatum tapes, DENSOLEN® PE/Butyl tapes, DENSOLID ® Polyurethane coatings, DEKOTEC ® Shrink sleeves, SEALID ® All-in-1 – and now FORTIDE ® Epoxy coatings. denso-group.com

The future of North American natural gas distribution

Gas distribution systems are integral to modern infrastructure, and companies like Infra Pipe manufacture products that ensure that gas is moved safely and efficiently with minimal environmental impact. Given today’s complex and evolving landscape, we see two areas as having particular impact on the future of the North American natural gas distribution market:

Safety and infrastructure modernisation

Many natural gas distribution systems have ageing

In addition, environmental concerns and increasingly stringent regulations call for the reduction of methane emissions from leaks, and regulatory bodies like PHMSA are proposing stricter safety regulations to prevent incidents like over pressurisation and improve emergency response planning. Taken together, this is a critical area of focus for Infra Pipe as we look to extend our reach in North America.

Workforce development

Just as areas of pipeline are ageing, so is our workforce. The industry faces challenges related to an emerging skills gap and attracting new talent. The future of our industry depends on investing in training programmes to equip workers with the necessary skills for the digital age and address safety and energy transition needs.

The need for ever-expanding oil and natural gas pipelines continues as the demand for energy skyrockets. This growth, combined with increased regulatory requirements for pipeline construction, have put pressure on the gas distribution market to provide material and equipment that ensures pipeline integrity and reliability. In light of the federal government’s mandated distribution integrity management programmes (DIMPs), pipeline companies need trustworthy suppliers to both replace and build new products that meet current guidelines and quality standards. Infra Pipe’s investments in wall monitors, advanced resins, and bar code print lines to track and trace pipelines exceed industry requirements for pipeline integrity and safety. We are doing our part to support the industry with the highest quality manufacturing processes and training the next generation of leaders to power the future of the industry throughout North America.

References

1. Research and Markets 2025 report: https:// uk.finance.yahoo.com/news/pipelineconstruction-industry-report-2025-145500527. html

2. https://www.thebusinessresearchcompany. com/report/natural-gas-distribution-globalmarket-report

3. https://www.aranca.com/knowledge-library/ special-reports/investment-research/ growing-consolidation-in-the-us-oil-gassector

Harry Smith, Sales and Senior Research Engineer, Atmos International, argues that theft detection hardware matters more than ever for pipeline operators.

Pipeline theft remains a serious global issue, with an estimated US$133 billion in crude oil and refined products lost annually to theft or adulteration worldwide. 1 While attention should be given to advanced software, the foundation of any effective detection system still lies in its hardware. Without high - resolution, real-time pressure and flow monitoring, particularly in hard to reach locations, many thefts will go unnoticed or unverified.

From ‘slash and grab’ to concealed tapping points

In some regions, particularly Latin America and Sub - Saharan Africa, theft remains crude and opportunistic. The ‘slash and grab’ method involves using tools such as metal spikes or grinders to breach a pipeline (Figure 1), often causing immediate leaks and posing significant safety risks. These are typically carried out to access small amounts of product quickly, sometimes for domestic use, and often result in poor sealing and structural damage. 2

More refined techniques involve clamps and welded tapping points. These are frequently found on pipelines up to 20 in. in diameter and are associated with organised criminal groups seeking to remain undetected. Thieves’ hardware can often be designed to allow slow valve openings and controlled withdrawals that stay below metering thresholds, reducing pressure transients and avoiding alarms. In Italy, a tapping point was detected by Atmos’ technology only 147 m from its actual location (Figure 2), confirming the precision now achievable with modern theft detection systems. 2

The rise of remote valves, tunnels, and night-time operations

Thieves are also becoming more technologically advanced. In Costa Rica for example, tapping points have been connected to relays powered by motorcycle batteries and remotely operated (Figure 3), significantly reducing the risk of on-site detection. 2 These methods blur the lines between physical and digital intrusion, with electronics enabling fast, low-profile product removal from pipelines.

Tunnel-based theft has also emerged in regions such as India and Costa Rica. In one case, a 40 m tunnel was used to extract fuel covertly, with the product routed to a private facility 300 m from the tapping point (Figure 4). 3 Despite the complexity, Atmos’ detection systems identified the event with a sensitivity level of 0.2%, demonstrating how properly calibrated hardware can detect even long-distance, low-rate thefts.

Night-time theft is an increasingly common strategy, often involving skilled engineers, thermal imaging, and professional-grade welding kits. In one case in the Democratic Republic of Congo, battery-operated pressure sensors detected a theft event at approximately 00:30 with a +/- 150 m location error. 3 In the UK, repeated alarms triggered over five nights led to the discovery of a tapping point and confirmed the importance of continuous overnight monitoring, even during shut-in conditions.

The role of high-resolution detection hardware

Effective detection depends on more than simply having sensors in the right places. It requires sensors that can capture high frequency signals and detect subtle anomalies in real time. Atmos Eclipse is a non-intrusive device capable of acquiring flow, pressure, and temperature data even in environments without power or telecom infrastructure. It is designed for high-consequence areas where quick detection is critical.

Figure 1. Metal spike embedded in a pipeline wall. These methods pose a high risk of leakage and environmental damage.

Figure 2. A tapping point discovered in Italy.

Figure 3. Motorcycle battery powering the circuit.

ENHANCE YOUR PIPELINE PROJECTS WITH

DELTA PIPELINE MACHINERY

Delta Pipeline Machinery o ers a robust modern eet of over 300 pieces of pipeline and associated equipment ready for dry rental, ensuring swift deployment for your pipeline infrastructure projects worldwide.

OUR EQUIPTMENT INVENTORY INCLUDES:

• Sideboom Pipelayers: 40 - 105 ton capacity

• Excavator Pipelayers: 30 - 90 ton capacity

• Tracked Padding Machines: Xrok Granite Range

• Welding Tractors: 8 - 12 ton capacity

• Tracked Carriers: 8 - 12 ton capacity

• Pipe Bending Machines: 18 - 48” towed

• Pipe Carriers: D7, D8 models

Delta Pipeline Machinery Voltstraat 19, 5753 RL Deurne, the Netherlands

Contact Delta Pipeline Machinery today to secure the equipment you need for your next project. Our expert team is ready to support your success with reliable, high-quality machinery.

• Hydraulic Excavators: 20 - 65 ton capacity

• Dozers: D6, D7, D8, D9 with various blades, rippers and winches

• Motor Graders: 12, 14, 16 ft with a selection of accessories

• Rough Terrain Cranes: 40 - 120 ton capacity

• Road Trucks & Pickup Trucks: Available in large quantities upon request to selected markets

• In-house mechanical, fabrication and engineering services available for bespoke projects or alterations on short notice

Atmos Odin complements this by offering a portable, battery-powered pressure logging solution capable of collecting data at 60 Hz for up to 40 days. Its lowprofile design makes it difficult for thieves to detect and tamper with. Both systems have been instrumental in theft detection on legacy networks in Africa, where limited SCADA coverage made conventional monitoring impractical. Using these tools, engineers were able to locate multiple theft points with exceptional accuracy, even in remote or heavily forested terrain. 4

Smart software for layered detection

Hardware provides the raw visibility, but software enables interpretation. Atmos combines negative pressure wave (NPW) and intelligent flow balance methods to identify a broad spectrum of theft scenarios. The NPW technique identifies the characteristic pressure drops caused by valve openings or closings at tapping points and offers near real - time detection with location triangulation. This method is especially effective in high-pressure, dynamic conditions and offers dual opportunities to detect both the start and stop of a theft event.

Intelligent flow balance, on the other hand, looks for discrepancies in volume across a pipeline segment. It accounts for operational conditions such as transients and packing/unpacking, providing an effective method for identifying slow withdrawals that fall below NPW sensitivity. Enhanced algorithms recently introduced by Atmos allow the system to detect changes between historical flow difference and real-time patterns, making it possible to identify theft rates as low as 0.1% of nominal flow. 2

Human insight: offline analysis for low-flow and legacy systems

Not all thefts trigger automated alarms. In pipelines where flow variance is minimal or instrumentation has drifted, offline analysis by experienced engineers remains essential.

This forensic-style review allows operators to review high-resolution datasets from both portable and fixed sensors, overlay algorithms, and compare historical operating conditions.

In Costa Rica, engineers used analog pressure data and three comprehensive algorithms to map a suspected theft event in 3D. This resulted in a confirmed theft alarm and law enforcement intercepting 12 containers of stolen fuel before they were moved. 5 In Belgium, engineers detected over a dozen thefts by analysing data that wasn’t visible to the SCADA system. In one instance, the tapping point was located with an accuracy of 40 m across a 100 km network, negating the need for an expensive pig run. 2

Integrated strategies for better outcomes

Atmos recommends a multilayered approach to theft detection. High quality hardware ensures high frequency, high resolution data acquisition. Smart software applies pressure wave detection, flow balance modelling and algorithmic filtering. Finally, human analysis bridges the gap, particularly in complex, low flow or legacy environments.

Atmos’ experience across the world shows that theft detection cannot be solved with a single method. Different pipelines, different terrains and different criminal tactics require a modular but integrated strategy. In all cases, the combination of hardware, software and people has proven to be the most effective way to detect and respond to theft events.

Detect fast, locate precisely, adapt continuously

Theft techniques are becoming more organised, better concealed and technologically enabled. Operators need to match that evolution with theft detection systems that combine speed, precision and adaptability. Whether it’s tunnel theft in Latin America or small-volume overnight siphoning in the UK, the solution begins with sensitive, real-time hardware, and supported by smart algorithms and expert review.

Investing in a high-resolution, multimodal detection system isn’t just a defensive move, it’s an operational necessity. With the right strategy, pipeline operators can reduce false positives, respond quickly and protect infrastructure and public safety in an increasingly uncertain world.

References

1. https://oilmanmagazine.com/article/oil-theft-a-frighteninginternational-perspective

2. https://www.atmosi.com/en/resources/technical-papers/ongoingpipeline-theft-challenges-and-the-importance-of-hardware-for-theftdetection/

3. https://timesofindia.indiatimes.com/city/delhi/40-metre-tunnel-leadspolice-to-underground-oil-theft-nexus/articleshow/104229398.cms

4. https://www.atmosi.com/en/resources/case-studies/sep-congo-optfor-atmos-theft-net-as-an-effective-theft-detection-solution-for-itslegacy-pipelines

5. https://insightcrime.org/news/brief/costa-rica-oil-theft-record-high/

Figure 4. The tunnel used by thieves in Costa Rica (top left) for their tapping point route (bottom left) which led to storage containers at a private property 300 m from the tapping point (right).

WORLD LEADERS IN PADDING TECHNOLOGY

XROK GRANITE 400 DOUBLE SCREEN DECK

Over the last eight years Xrok Granite 400 pipe padding machines have worked on many major and some of the most challenging pipeline projects around the world. Having gained invaluable working experience in the eld and listened to valuable customer feedback, our design team has made cutting edge improvements and upgrades to the current model with some innovative advances to further improve production, versatility and reliability. One of the major advancements is the redesigned screen box, which is the heart of any padding machine. The new, stepped double-deck technology signicantly boosts both e ciency and performance, placing the Granite 400 in a class of its own. Whether deployed to the driest of deserts or to the wettest and harshest environments in the world, the new improved Xrok Granite 400's superior performance will outperform and pad more pipe per day than any other machine currently on the market which equals huge cost savings to the customer. xrok.com

PAT ENTED

Sean Donegan, President and CEO, Satelytics, discusses how to lower energy sector premiums by adopting proactive risk reduction methods.

For decades, the energy sector has accepted rising insurance premiums as the cost of doing business. They have done this even though this cost is steep: into the hundreds of millions for some larger companies. Insurance, in other words, is one of the energy sector’s largest costs and only growing larger.

The size of these premiums makes sense: energy producers are at risk for major challenges that can easily escalate into disasters if proactive steps are not taken. Leaks, spills, and equipment failures are endemic to the industry and can cost businesses untold millions in regulatory fines and legal payouts.

What doesn’t make sense is that so many energy companies have accepted that their premiums will only

continue to grow, year after year. As it turns out, steep insurance premiums don’t have to be a fact of life. Emerging technology is rapidly changing the nature of this situation for energy companies – and they’d be wise to pay attention. Insurers are willing to negotiate discounts on premiums when the insured company demonstrates the application of advanced technology to limit potential future insurance claims. In fact, some of these insurers have expressed incredulity that this benefit is not pursued more often.

A relatively new technology, AI-powered geospatial analytics, is being recognised for its operational benefits, as well as its ability to cut insurance costs. For organisations managing assets like pipelines or power grids, these savings can add up to tens of thousands or even millions of dollars annually.

AI-powered geospatial analytics can lower premiums

AI-powered geospatial analytics is receiving significant attention among oil and gas companies. Geospatial

analytics empowers businesses to control their risk profiles. By using analysis of spectral fingerprints, and the power of cloud computing driven by AI-based algorithms to quickly identify and prevent issues, it allows companies to manage their assets more effectively while showcasing responsible practices to insurers. Geospatial analytics companies utilise algorithms to monitor vast infrastructures like pipelines, power grids, and waterways. The technology delivers alerts within hours of obtaining the data and imagery from satellites.

The process begins with high-resolution satellite imagery, which takes in the full sweep of an oil and gas producer’s pipeline operations. This imagery – which is both multispectral and hyperspectral – is then fed into algorithms that can analyse it and provide oil and gas providers with indispensable insights. Critical problem points like methane emissions, crude oil leaks, produced water leaks, or right-of-way encroachments can be effortlessly identified and quantified; micro-disruptions can be traced at the component level while still in their infancy before they’ve spiralled out of control.

This latter point is crucial, as – when it comes to leak detection – time is of the essence. A business can lose millions of dollars in remediation costs, regulatory fines, and PR repair when encountering a two-week delay in leak identification. AI-powered geospatial analytics companies are detecting leaks like this now, and saving businesses millions of dollars in the process. One oil and gas producer with operations in North Dakota (USA) is on record saying that geospatial analytics identified a produced leak at least 13 days before their traditional methods would have identified the leak. In that two-week delay, the impact of the leak may have tripled or quadrupled.

Oil and gas companies are facing steep risks

Part of the reason the energy sector would be wise to pay attention to newer technologies that can lower premiums is owed to one simple, unalterable fact: without technological intervention, insurance premiums are only going to climb. However, on the flip side, certain technologies can be an insurance premium ‘discount’ windfall. The rationale for this is manifold and is worth discussing.

To begin with, ageing energy infrastructure is a global issue. In the US alone there are approximately 2.5 million miles of pipelines – roughly 100 times the Earth’s circumference. A significant portion of this infrastructure is outdated; for instance, 54% of gas transmission lines were installed before 1970, creating the perfect storm for potential leaks and other challenges. The problem of oil leaking is nonetheless pervasive and is in no small part responsible for the high insurance premiums paid by oil and gas companies.

Let’s take a look at the Tesoro leak in North Dakota in 2013 when 840 000 gal. of oil seeped from a broken pipeline. This was a slow leak that went on for months before it was discovered, only because the landowner saw oil-soaked farmland appear. The leak was so slow - going

Figure 1. AI-powered geospatial analytics can detect produced water and liquid hydrocarbon leaks in densely-packed rights-of-way.

that Tesoro’s internal leak detection systems failed to pick it up, but once discovered, according to reports, the Tesoro leak took place on a 6 in. diameter pipeline that was not easy to locate. This incident highlights how geospatial analytics could have identified such a hard-todetect leak much earlier.

Likewise, in October 2019, a leak occurred on the Keystone Pipeline near Edinburg, North Dakota, resulting in the release of approximately 383 000 gal. (9120 bbls) of crude oil. The pipeline was shut down following a leak detection alarm, and TC Energy, the pipeline’s operator, dispatched an emergency response team to contain the spill – after the leak had been detected. The leak affected an area of roughly half an acre, primarily in a low-lying area where water naturally accumulates. No doubt that the right technology in place might have meant the energy producer could have been alerted to the issues much earlier in the process.

It is not necessarily negligence that is to blame here. No energy-producing company has the resources to patrol every inch of its ageing and widely distributed pipeline infrastructure 24/7. And even if they did have those resources, many early-stage leaks – ranging from methane (gas) leaks to liquid hydrocarbon (crude oil) leaks to produced water (brine) leaks – would remain undetectable by conventional instruments.

The result, of course, is that premiums continue their upward climb. Right now, many companies are seeing their insurance rates rise by as much as 50% annually, a trajectory that is unsustainable. Clearly, something needs to change.

Organisational silos are hindering evolution

The question then becomes: why have so many oil and gas producers neglected this technology and the potential savings on insurance premiums? The fact is that many oil and gas companies as well as utilities are generally unaware of the insurance industry’s interest in incentivising the use of new tech to decrease claims filed.

Part of it comes down to organisational fragmentation. In the world of oil and gas, everything is bigger – not merely the pipelines, but the internal bureaucracy as well. Entire departments working on similar but adjacent issues may rarely – if ever – come into contact.

Think of it this way. On the one side, you have executives who are responsible for developments in technology – focused on productivity: technological tools that will enhance the day-to-day operations of the business. On the other side, you have those working with insurance companies. The problem? Organisational silos are separating these two departments and while the executives on the risk management side may be looking at ways to reduce premiums, they may not realise that certain technologies, such as geospatial analytics, can, in fact, help with these costs.

But it is important to break down the silos as insurers are being pressed by regulators and investors to only insure responsible companies. The same applies to the

investment sector, where companies face increasing pressure to prioritise environmental protection.

Geospatial analytics – a fusion of science and software – helps energy producers mitigate risk. By enabling proactive decision-making, this technology creates opportunities for mutual benefit between industry players and their insurance providers and ultimately offers premium reductions to oil and gas, pipeline, and electric and gas utility customers employing proven and effective geospatial analytics to avoid risks that result in insurance claims.

Here are examples of how AI-powered geospatial analytics can help an energy producer:

Benefits to the insured

) Reduce insurance and reinsurance premiums.

) Monitor assets for a wide range of potential threats and premiums are reduced – a net-zero cost effect.

) Early detection reduces loss of product and revenue, remediation costs, regulatory fines, and the hidden costs of PR repair.

Benefits to the insurer

) Fewer claims to process equals money saved.

) Clients mitigate risk, looking for methods, techniques, and solutions for being on guard.

) Reduce claim liability through early detection and subsequent reduced magnitude.

) Reduce the number of events, which translates to reduced claims.

) A proactive approach yields reputational and share price benefits with the insurer’s corporate investors.

No matter one’s role within an oil and gas company, it is paramount to understand that certain technologies, such as geospatial analytics, can help with insurance discounts, especially for priority concerns (like produced water, one of the highest insurance claims payout).

This awareness needs to spread, and fast. It is beyond dispute that, by demonstrating proactive efforts to reduce risk, oil and gas companies can meaningfully reduce their yearly insurance costs. When assets are carefully monitored for potential issues –leaks, equipment failures, etc. – premiums inevitably go down. It’s as simple as that.

About the author

Sean Donegan is the President and CEO of Satelytics. He brings over 30 years of technology and software development experience to the company. A dynamic leader, Sean’s career has been focused on building companies through creativity and innovation, recruiting highly effective teams to solve customers’ toughest challenges. Sean founded or owned four successful software companies, most recently Sean Allen LLC, which was focused on predictive analytics in the oil and gas marketplace.

ENGINEERED TO ENDURE

When the environment pushes the limits, rely on solutions designed to last — above and below the surface

Ensuring accuracy in underwater inspections is critical for subsea operations, where measurement errors can lead to costly rework, safety risks, and operational inefficiencies.

To establish a validated standard of precision, Voyis’ Discovery Stereo Vision System underwent third-party certification by Bureau Veritas (BV), a globally recognised authority in testing and inspection. This certification confirms that the system meets stringent accuracy requirements, reinforcing its reliability for critical underwater inspections across offshore energy, ocean sciences, and civil infrastructure.

Achieving certified accuracy

Patricia Sestari, Voyis, highlights the importance of Bureau Veritas certification for underwater stereo vision systems.

The importance of accuracy in subsea inspections

High-accuracy optical measurement systems are essential for underwater inspections, where traditional survey techniques such as sonar may not provide the required level of detail.

The Discovery Stereo Vision System, now BV-certified, enables engineers to conduct precise assessments of subsea structures, reducing uncertainties and improving decision-making across various industries.

In offshore oil and gas, accurate measurements are crucial for monitoring the integrity of subsea pipelines, wellheads, and risers. Over time, corrosion, mechanical stress, and marine growth can compromise these structures,

leading to costly failures or environmental hazards. The Discovery Stereo system enables engineers to detect early signs of damage, conduct precise metrological assessments, and verify structural integrity without requiring costly and time-consuming dry-docking or manual intervention by divers.

For offshore wind farms, precision in subsea inspections ensures the stability and longevity of turbine foundations, mooring systems, and cable routes. Harsh oceanic conditions can lead to scouring around monopiles and jacket foundations, while mechanical wear can degrade critical mooring points. With high-accuracy 3D modelling and change detection capabilities, operators can track degradation trends over time, proactively planning maintenance to prevent failures and extend asset lifespan.

Hydroelectric dams and reservoirs also benefit from high-resolution optical inspections, particularly for assessing

concrete structures, intake grates, and penstocks. Over time, cavitation, sediment accumulation, and structural fatigue can impact dam efficiency and safety. The Discovery Stereo system allows operators to conduct thorough visual assessments, identify stress fractures or debris obstructions, and ensure that critical components remain operational without requiring costly dewatering or manual inspections.

In marine biology and environmental monitoring, optical accuracy plays a pivotal role in studying habitats and assessing the impact of human activity on underwater ecosystems. Researchers rely on precise 3D reconstructions to monitor coral reef health, seagrass growth, and the stability of artificial reef structures. The Discovery Stereo Vision System enables the collection of repeatable, high-accuracy data to track ecological changes over time, supporting conservation efforts and habitat restoration initiatives.

By obtaining BV certification, the Discovery Stereo system provides assurance that collected data meets the highest accuracy standards, eliminating potential risks associated with imprecise measurements. This level of confidence is critical for industries that depend on reliable, high-resolution optical data for predictive maintenance, regulatory compliance, and environmental stewardship. Seamless data integration ensures that accurate optical measurements align with existing survey and asset management workflows, facilitating efficient data processing and decision-making.

The BV certification process

Bureau Veritas’s certification process involved two primary accuracy tests: Linear Accuracy (Drift Ratio) and Local Accuracy. Each test was designed to validate the system’s measurement precision under different conditions.

Linear accuracy: beam metrology test

Long-range measurement accuracy is crucial for applications such as subsea metrology, where errors can propagate over extended distances. To validate this capability, the Discovery Stereo Vision system underwent a Beam Metrology Test, designed to measure drift across a fixed length.

A 6 m rigid beam was selected as the test platform. Markers were affixed along its length, and their exact positions were measured using a Coordinate Measurement Machine (CMM) to establish a precise reference. The Discovery Stereo Vision System was mounted on a controlled gantry system and traversed along the beam while capturing stereo image data.

By analysing deviations in marker positioning, the test confirmed that the Discovery Stereo met the required specifications for linear accuracy, exceeding the operational accuracies defined in IMCA S 019, an industry guidance document for subsea metrology. This verification establishes the system as a dependable tool for large-scale metrology, including

Figure 1. Local Accuracy assessment conducted by Bureau Veritas.

Figure 2. Linear Accuracy assessment conducted by Bureau Veritas.

• The ability to achieve precise fit-up alignment is a vital stage in the construction of pipelines because it creates the foundation for stronger welds that last longer, can support more weight and are capable of withstanding higher levels of fatigue.

• The Red Ram Clamp ensures that your welding systems operate at peak performance by delivering precise alignment from the start—reducing downtime and ensuring fewer weld repairs and cut-outs.

Take control and master every light or heavy wall out of round pipe fit-up, first time right within Hilo tollerance.

On and Offshore Red Ram Clamps, diameter ranges: 24” to 32”, 36” to 44”, 48” to 56”

SUSTAINABILITY INNOVATION

pipeline measurement, subsea infrastructure mapping, and component dimension verification.

Local accuracy: chain inspection test

While large-scale measurement accuracy is essential, high-resolution local inspection is equally important for assessing critical assets such as mooring chains, pipelines, and weld joints. The Local Accuracy test evaluated the Discovery Stereo’s ability to capture fine details at close range.

A mooring chain section was used as the test object, with small, high-contrast markers affixed to its links. These reference points were precisely measured using a vernier caliper to establish a ground-truth dataset. The Discovery Stereo was deployed on an ROV, manoeuvred around the chain to capture high-resolution images from multiple angles, ensuring complete coverage.

The captured data was processed to extract precise measurements, validating the system’s capability for detailed asset inspection. The results confirmed that the Discovery Stereo achieved the necessary level of accuracy, reinforcing its suitability for applications such as corrosion assessment, structural integrity monitoring, and maintenance planning.

Beyond certification: rigorous accuracy verification

While BV certification validates the performance of a single reference unit, it does not account for potential variability across production models. To address this, Voyis implements a stringent verification process to ensure every Discovery Stereo Vision System meets the same high standards before shipment.

Linear accuracy verification on every unit

Unlike industry practices where only select units undergo validation, Voyis performs the same Beam Metrology Test described in the BV certification on every Discovery Stereo Vision System. Following production and calibration, each unit is subjected to the 6 m beam test to confirm that its measurements align with the datasheet specifications.

This process is meticulously documented, with a Calibration Report provided to customers for full transparency. By ensuring that every unit achieves certified accuracy levels, Voyis provides confidence in the system’s reliability for high-precision subsea operations.

Industry-leading calibration process

Achieving consistently high accuracy requires more than just certification – it demands a rigorous calibration process tailored to the challenges of underwater imaging. Voyis has developed an industry-leading calibration approach to ensure optimal system performance across all units. ) Image sharpness optimisation: high-quality imagery is critical for accurate photogrammetry. Each Discovery Stereo camera undergoes a validation process to optimise image sharpness, ensuring clarity across both close-up and distant targets. Standardised focus charts

Figure 3. Chain inspection results from the local accuracy assessment.

at nominal range are used to confirm precise focus calibration.

) Precision alignment: the optical components must be precisely aligned to avoid distortions that could compromise measurement accuracy. Voyis employs specialised fixtures and procedures to maintain tight tolerances, ensuring consistent optical performance across all units.

) Intrinsic calibration: each unit undergoes intrinsic calibration in Voyis’ proprietary underwater test fixture to account for lens characteristics and internal optical parameters. This step ensures accurate interpretation of image data, crucial for generating scaled 3D reconstructions.

) Stereo calibration: to enable accurate 3D modelling, the relative position and orientation of the two stereo cameras are precisely measured and modelled. This extrinsic calibration process ensures proper image rectification, allowing for accurate depth and distance measurements.

) IMU calibration: the system’s Inertial Measurement Unit (IMU) plays a key role in real-time 3D modelling and navigation. Each Discovery Stereo undergoes IMU calibration to precisely model its position relative to the cameras, enhancing the accuracy of its motion-tracking capabilities.

Achieving and maintaining accuracy in underwater inspections is vital for reliable data collection and operational efficiency. The BV certification of the Discovery Stereo Vision system validates its performance against industry standards, but Voyis goes further by implementing comprehensive verification on every unit. By combining rigorous calibration with independent certification, Voyis ensures that customers receive a consistently high-performance system capable of meeting the most demanding subsea inspection requirements.

Mothball, Commonising and Pipeline Preservation

Microbial Control and H2S Suppression

The oil and gas industry frequently requires mothball commissioning, seawater hydrotesting, and long-term lay-up strategies to preserve pipelines and associated assets. These processes present challenges related to microbiologically influenced corrosion (MIC), biofilm formation, and hydrogen sulphide (H2S) generation. Effective microbial control is essential to maintaining the integrity of pipework, reducing fouling, and ensuring flow assurance. Vink Chemicals provides high-performance biocide solutions, including integrated surfactants and oxygen scavenger combination chemistry, to suppress H2S, control biofilms, and mitigate asset degradation risks.

Integrated Microbial Control for Mitigating Corrosion, H2S, and Iron Sulphide Risks

Microbiologically influenced corrosionduring pipeline lay-up and hydrotesting, driven by sulphide- and iron-reducing bacteria, leads to pitting, iron sulphide deposition, and hazardous H2S generation. Biofilm formation protects microbes from conventional treatments, accelerating damage and posing safety and operational risks. Effective control of microbial activity, H2S, and FeS is essential to maintain integrity, ensure fluid quality, and prevent costly downtime. High-Performance Biocides and Combination Chemistry for Effective Control.

Vink Chemicals oﬀers a range of advanced solutions for pipeline control and preservation, incorporating biocides, integrated surfactants, and oxygen scavengers to achieve long-term microbial suppression. Our product line includes:

• Broad-spectrum biocides to target SRB, IRB, and other bioﬁlm-forming microorganisms.

• Synergistic biocide formulations with integrated surfactants to enhance bioﬁlm penetration and disruption.

• Oxygen scavenger combinations to reduce microbial activity and prevent oxidative corrosion.

• Environmentally compliant solutions meeting industry regulations while ensuring high eﬃcacy.

Vink Chemicals GmbH & Co. KG

Eichenhöhe 29, 21255 Kakenstorf, Germany

Oil & Gas

Phone: +49 4186 – 88 797 0

E-mail: oilgas@vink-chemicals.com www.vink-chemicals.com

grotan®

Kristopher Kemper, AMPP, USA, describes how new coating technology reduces energy usage, cuts carbon footprints, and protects pipelines.

Rescue Pipeline Services has completed an internal pipeline project with a trusted flow coating in Italy, using an eco-friendly metal decontamination chemical. This represents a significant advancement in internal pipeline coatings for existing pipelines. Coval Technologies, provider of coating solutions, developed MC-400, a single-component, nano-engineered flow coating that leaves a smooth surface that resists hydrocarbons while delivering durability. Nanocomposite coatings are engineered with nanoparticles that interact with the substrate on a molecular level. This interaction can occur through chemical bonding rather than just mechanical interlocking. The small size of these particles allows them to penetrate microscopic pores and irregularities on the surface, forming a uniform crosslink contact with the substrate. The high surface energy of the nanoparticles promotes strong adhesion. As the coating cures, the crosslinking between the polymer chains and nanoparticles creates a tough, durable, and highly resistant surface.

Energy efficiency and environmental benefits

This flow coating enhances pipeline performance by reducing internal wall roughness and friction. The result is that less energy is required to transport gas and liquids. This decrease in energy translates directly into carbon footprint reduction.

“In large-diameter gas pipelines, the energy savings can reach up to 45%,” said Ryan Crowe, President of Coval Technologies. “These are impressive figures, representing both large cost savings and substantial environmental benefits.”

The MC-400 is a single-component formulation designed for internal pipeline coating applications, exhibiting remarkable

hardness with superior protection against abrasion, wear, and corrosion. The covalent bonding ensures a strong and permanent connection to the metal substrate. The combined results are turbulence reduction leading to increased efficiency, reduced energy consumption, increased flow, and reduced fouling to reduce iron oxide scale (black powder) and wax deposits from forming on the pipeline walls.

Application process: preparing the pipeline for coating

The application of MC-400 was made possible by Rescue Pipeline Services’ customised coating system, which first cleans out the pipeline with surfactants, water, and a series of cleaning pigs in accordance with SSPC-SP11 Power-Tool Cleaning to Bare Metal. This Association for Materials Protection and Performance (AMPP) standard requires the surface to be free from all visible oil, grease, dirt, dust, rust, coating, oxides, corrosion products, and other foreign matter when viewed without magnification. SSPC VIS Guide 3 is a great resource for confirming the SP11 visually. However, some rust remaining at the bottom of the pits is acceptable if the surface was pitted initially. This is integrated with CleanWrx Solutions 207® metal decontamination chemical specifically designed to decontaminate the metal of iron chlorides, microbiological induced corrosion (MIC), sulfates, and sulfides providing an optimal surface for MC-400 to chemically bond to the inside of the pipeline as it is propelled between the pigs down controlled by compressed air in the pipeline.

Standards for surface decontamination and preparation

Chlorides, salts, sulfates, and nitrates are common substances found on surfaces that can affect the performance and durability of protective coatings and the corrosion resistance of steel. Each of these substances can have different effects on the integrity of the coating and the underlying steel substrate. Rescue Pipeline and Coval Technologies were able to confirm the proper surface decontamination by using AMPP standards, like ‘NACE 6G186-2010-SG Surface Preparation of Soluble Salt Contaminated Steel Substrates Prior to Coating,’ ‘NACE SP0716-2016 Soluble Salt Testing Frequency and Locations on Previously Coated Surfaces,’ ‘SSPC GUIDE 24-2018 Soluble Salt Testing Frequency and Locations on New Steel Surfaces,’ and ‘SSPC GUIDE 15-2020 Field Methods for Extraction and Analysis of Soluble Salts on Steel and Other Nonporous Substrates.’

Performance benefits

CleanWrx Solutions 207 provides a healthy, safe, and environmentally conscious metal surface preparation solution to exceed the highest standards for corrosion elimination, even in the most challenging heavy-industrial environments. The chemical addresses this phenomenon on contact and, as a result, will form an amorphous oxide layer (Lewis acid), creating a uniform receptive on the entire surface; this would be the passivation state or layer measured in nanometers. This amorphous oxidation phase would be considered an adduct/electron receptive, which explains the extraordinary adhesion values achieved with this technology.

Figure 1. Test spool removed for coating adhesion test and thickness readings.

Figure 2. Pig receiver on offshore platform.

Figure 3. Pipe launching setup with minimal footprint onsite.

In the many adhesion tests done, the tendency is to break the coatings cohesively rather than adhesively.

In addition to adhesion properties, CleanWrx Solutions 207’s features enhance its performance in metal surface preparation, including:

) Prevents flash rust.

) Can be used in all types of equipment including ultra-high pressure (UHP), wet abrasive blast equipment, and highpower water wash.

) Will not foul lines, filters, or pumps of equipment.

) One-step process.

) Creates a true chemical bond at the coating to substrate interface.

) Cleans substrate of all contaminants, including biofilm, MIC, sulfides, iron chlorides, sulfates, nitrates, and others at the molecular level.

) No need to control the environment after surface preparation.

) Enhances traditional surface preparation standards, eliminating the corrosion mechanism.

Challenges in pipeline contamination and corrosion control

Aggregated iron sulfide (FeS) and ionically bonded FeCl2 (iron chloride) are pervasive, difficult, and high-liability issues for pipeline, petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical, seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect or near-perfect metal cleanliness, thus reducing expected coating life by 30 - 75%. Because conventional surface preparation processes have historically been unable to adequately relieve micro-contamination of metal surfaces, organisations have settled for an uneasy balance between economic and physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes and rely more heavily upon barrier coatings to supply needed corrosion control.

Pig receiver on offshore platform

However, coatings cannot fill the gap; no matter how advanced the coating, surface-tolerance does not extend to application over chloride or sulfate-contaminated steel, as coating performance is highly dependent upon unimpeded bonding with the surface it is meant to protect. Consistent coating adhesion is impaired by microcontaminants present in metal surfaces during fabrication and those potentially embedded during surface preparation blast processes in field maintenance.

A one-step chemical additive application process decontaminates surfaces at the molecular level, eliminating visually undetectable levels of highly corrosive substances, providing a uniform receptive surface before coatings application.

Historically, the focus has been on the adverse anions (chlorides, sulfates, and nitrates), with little attention paid to the high aggregation of FeS on a substrate of today’s metal assets.

This one-step chemical additive application process reacts and solubilises FeS with an oxidation process to

reduce the microbial preference areas and solubilises the ionically bonded FeCl2 aggregated on the metal substrate. In addition, it reacts and solubilises FeCl2, sulfate (SO42-), and nitrate (NO3-) over the general surface area to be decontaminated.

The chemical additive addresses the cations and insoluble sulfides. It chemically breaks the ionic attraction between the anions and cations and eliminates the cathode-anode reaction (corrosion reaction).

Typically, a coating system designed for the intended service environment will rarely fail. Substrates fail and coatings lose adhesion because of unaddressed microscopic cationic and anionic contaminants such as sulfides, chlorides, sulfates, nitrates, or other non-reacted contaminants.

The primary focus has been on adverse anions (chlorides, sulfates, and nitrates), not addressing the high aggregation of cations and insoluble sulfides (FeS) at the oxide metal interface, and ignoring ionic attraction between anions/cations.

Conclusion

The following summarises the combined results of the CleanWrx Solutions 207, the Coval Technologies MC-400, and Rescue Pipeline Services’ customised coating system.

) Improved pipeline efficiency by reducing surface friction of the pipe wall.

) Increased pipeline capacity.

) Lower fuel consumption and reduced emissions at the same flow.

) Increased flow capacity at decreased pressures for de-rated pipelines.

) Protection against internal corrosion and black powder formation.

) Reduced build-up of contaminates on pipe walls.

) Faster pigging and less frequent scrapping.

) Rescue Pipeline technical support services and proven application techniques allow application to very long pipeline lengths of varying diameters by accessing only the ends of the pipeline segment.

The successful completion of this project demonstrates the potential of advanced coating technologies and surface preparation solutions in extending pipeline longevity and optimising operational efficiency. By integrating Coval Technologies’ MC-400 with CleanWrx Solutions 207 and Rescue Pipeline Services’ expertise, this innovative approach sets a new standard for internal pipeline protection. As industry continues prioritising sustainability, energy efficiency, and asset integrity, these cutting-edge solutions pave the way for safer, more reliable, and costeffective pipeline operations worldwide.

About the author

Kristopher Kemper has nearly 20 years of experience with pipeline coatings technology and is an auditor in the AMPP QP quality audit programme for industrial coating contractors across many industries.

Mark Burrup, Dräger, highlights the importance in managing the risk of benzene exposure in the decommissioning of pipelines, and discusses ways to minimise these risks.

As the global energy sector continues its transition, and legacy assets reach the end of the road, many operators are facing up to the complex and costly challenge of decommissioning ageing pipeline infrastructure. In the UK alone, more than £24 billion is expected to be spent on shutting down the North Sea by 2033, according to the latest figures from Offshore Energies UK, with similar investment patterns emerging worldwide. This work encompasses the safe removal, cleaning, and disposal of vast networks of pipeline systems, storage tanks, and auxiliary equipment. Against the backdrop of an industry drive for cost

efficient decommissioning, underpinned by environmental responsibility, safety continues to demand absolute attention. Key to that is the issue of benzene exposure. Highly toxic, often invisible, and widely present in pipeline residues and vapours, benzene poses serious safety and compliance challenges during every stage of decommissioning.

An invisible yet potent hazard

Benzene is a volatile hydrocarbon found in crude oil, natural gas condensate, and many petroleum products. It is colourless, flammable, and recognised by the International Agency for Research on Cancer (IARC) as a Group 1 carcinogen. Within pipeline networks, benzene can remain trapped in residual product films, scale, sludge, or vapour pockets – particularly in low-flow sections, dead legs, and sealed systems.

When pipeline segments are opened, cut, flushed, or cleaned, benzene can be released as vapour or aerosolised droplets. It is absorbed through inhalation and skin contact, and even minimal exposures over time have been linked to serious health consequences, including blood disorders and several forms of leukaemia.

In the UK, the legal workplace exposure limit (WEL) for benzene is set at 1 part per million (ppm) over an eight hour time-weighted average (TWA). Exceeding this limit carries not only health risks, but also regulatory consequences, including fines, reputational damage, and potential project shutdowns.

Why benzene matters to the pipeline sector

Pipeline decommissioning comes with inherent challenges and presents a specific set of benzene-related risks, which differ from other parts of the hydrocarbon supply chain.

Health and safety hazards top the list. Workers involved in pipeline segment removal, hot-tapping, pigging, or tank farm cleaning are frequently exposed to confined spaces with poor ventilation: ideal conditions for benzene vapour accumulation. Short-term exposure to concentrations of 100 - 500 ppm can cause dizziness, nausea, and respiratory distress, while chronic low-level exposure has a cumulative effect, increasing the risk of leukaemia and bone marrow suppression.

Operational risks are also heightened. Cutting into a contaminated line without proper gas testing can expose personnel to flammable atmospheres or toxic vapours. Even after flushing, residual sludge in bends or low spots may retain benzene concentrations high enough to exceed safe exposure limits. In some cases, vapours can flash off unexpectedly due to temperature changes or pressure drops, endangering workers and delaying progress.

Environmental compliance is a growing concern as benzene is moderately water-soluble and mobile in the subsurface, making it a potential groundwater contaminant if residues are released during dismantling or transport. Under anaerobic conditions, such as marine sediments or buried infrastructure, benzene biodegrades slowly, increasing its persistence in the environment.

As such regulatory scrutiny is intensifying worldwide and, in addition to the UK’s 1 ppm limit, agencies such as Occupational Safety and Health Administration (OSHA), National Institute for Occupational Safety and Health (NIOSH), and the EU set strict thresholds for both long- and short-term exposure. Many decommissioning contracts now require third-party verification of atmospheric testing and formal documentation of benzene management strategies.

As well as being a real health issue, it is a substance that requires a multi-dimensional operational, environmental, and regulatory approach. This must be systematically addressed in any decommissioning plan.

Tools for safe pipeline operations

Managing benzene exposure requires accurate detection and monitoring throughout the decommissioning lifecycle. What is required is a tiered suite of gas detection solutions tailored to the specific conditions of pipeline work.

Dräger-Tube® colorimetric detection tubes provide spot checks for benzene using chemically reactive glass tubes. When used with a manual pump, these tubes give an immediate, visual indication of benzene concentration. Because they filter out other Volatile Organic Compounds (VOCs) through a pre-layer, they offer reliable, benzenespecific readings, which is ideal for verifying safe entry or confirming suspected contamination.

For ongoing work in dynamic or confined environments, portable multi-gas detectors, such as the Dräger X-am® 8000, are used as standard. These instruments can be fitted with photoionisation detection (PID) sensors to monitor VOCs in real time. While PID is not inherently benzene-selective, high VOC readings can act as an early warning, prompting further testing. When used with benzene-specific pre-tubes, these detectors can deliver both general screening and targeted measurements, balancing speed with specificity.

For tasks requiring higher precision, the Dräger X-act® 7000 combines tube-based chemistry with digital accuracy. It reads pre-calibrated MicroTubes electronically, eliminating human interpretation errors and delivering lab-grade benzene measurements in the field. This is especially useful for verifying Workplace Exposure Limits (WEL) compliance before extended work begins in enclosed spaces or during tank farm cleanouts.

At the most advanced level, the Dräger X-pid® 9500 provides selective real-time benzene readings through a hybrid system that combines PID and gas chromatography (GC). The device can differentiate benzene from similar compounds like toluene or xylene, delivering accurate results in under a minute. Controlled via an intrinsically safe smartphone interface, it is particularly valuable for contractors or operators conducting high-frequency benzene testing across multiple sites.

Integrating benzene control into pipeline decommissioning

A robust benzene control strategy integrates detection, prevention, and training into routine pipeline

decommissioning workflows. Pre-work risk assessment is essential. This includes reviewing line history, pigging records, flushing effectiveness, and past incidents to identify likely benzene accumulation points. Based on these factors, a tailored monitoring strategy can be developed.

Fixed monitors or portable devices with data logging capability (such as the X-am 8000) should be deployed at known risk zones, including valve pits, sump areas, and enclosed valve stations.

This should be taken in tandem with ventilation and purging protocols, which must be enforced. Lines should be flushed with inert gas or air, and vented until VOC levels are consistently below exposure thresholds. For buried or partially accessible infrastructure, strategic venting and air movers may be required.

As always, worker’s personal protective equipment (PPE) must be appropriate to both the task and the risk. In many cases, this will include benzene-resistant gloves, splash protection, and respiratory protection, ranging from half-mask respirators with organic vapour cartridges, to full Self-Contained Breathing Apparatus (SCBA) systems. Hot work controls, meanwhile, should include continuous gas monitoring and permitting procedures. Intrinsically safe tools and thermal imaging can be used to reduce ignition risk during cutting or welding.

Waste handling protocols must ensure that benzenecontaminated liquids, sludges, or cuttings are properly

contained, labelled and disposed of as hazardous waste. Documentation should align with local environmental and hazardous materials regulations.

This must always be underpinned by worker training. All personnel involved in pipeline decommissioning should be trained to recognise benzene hazards, understand detection readings, and respond appropriately to alarm conditions.

Turning insight into action

Pipeline decommissioning is a uniquely complex process, one that combines technical challenges, environmental responsibility, and worker safety. Benzene detection, monitoring, and disposal cuts across all three dimensions. For operators and contractors, understanding where and how it appears in pipeline systems is the first step toward controlling it.

But with modern detection technologies and a risk- based approach, benzene no longer needs to be the hidden threat in decommissioning operations. Instead, it can become a known factor, one that is measurable, manageable, and ultimately, preventable.

For the pipeline industry – where reliability, integrity, and safety are foundational – the message is clear: detect early, act decisively, and protect your teams. With the right tools, benzene risk doesn’t have to compromise progress.

Jim Costain, Craig Hall, Thomas Mrugala, and Ron James, NDT Global, answer key questions about baseline inspections, re-inspections, and the evolving needs of pipeline operators.

In today’s critical pipeline landscape, where energy infrastructure is expanding into deeper waters, more geologically complex regions, and increasingly harsh environments, ensuring the integrity of assets from the outset should not be viewed as a luxury, but a necessity.

Baseline inspections, often conducted before a pipeline enters service, deliver vital data that becomes the foundation for lifetime asset integrity management.

At NDT Global, we believe that what you don’t know at the start of a pipeline’s lifecycle can and often does cost you down the line. That’s why our baseline inspection programmes are built around high-resolution ultrasonic and acoustic resonance technologies that provide the clearest, most actionable picture of pipeline condition from day one.

What is a baseline inspection, and why does it matter?

A baseline inspection provides a pipeline’s ‘as-laid’ fingerprint. It documents any anomalies resulting from mill defects, construction damage, handling errors, or environmental stress during installation, before the pipeline is placed into service.

“It’s about integrity before operation,” explains Jim Costain. “Baseline data allows operators to detect quality control issues, such as sloping laminations or welding flaws, that could evolve into critical failures if undetected.”

According to Craig Hall, “Commonly used hydrotesting only confirms strength, it cannot detect features like small girth weld cracks or mid-wall defects that may leak but go unnoticed. Baseline ILI provides that detailed, holistic picture.”

For operators, this means a reliable reference point to compare future inspection data against. Any anomalies observed later can be analysed in terms of growth rate, cause, and risk, allowing for smarter intervention strategies.

When is the best time to inspect?

Planning baseline inspections during the construction or pre-commissioning phase enables cost-effective and technically superior results.

“Early engagement, ideally at the Front-End Engineering and Design (FEED) stage lets us design around piggability and avoid the need for expensive workarounds,” says Ron James. “Temporary launch and receiver traps can be used before production starts, leveraging existing infrastructure already onsite for hydrotests.”

And there’s another major advantage: water. It’s the safest and cheapest pumping medium available, and it supports the use of ultrasonic tools that can’t be run in gas lines until later modifications.

Figure 1. Ensuring precise data capture for the baseline survey.

Figure 2. Turning insights into actionable integrity decisions.

Figure 3. Inspection tool preparation to meet the unique challenges of the pipeline.

Equipment that works as hard as you do.

Whatever the job requires, the Vacuworx RC Series is built to handle it all. From pipe to concrete and beyond, it’s engineered for the variety your work demands—so you can keep moving forward.

You bring the hustle.The RC Series handles the heavystuff.

Advanced technology: from insight to advantage

One of the biggest advances in baseline inspections is the shift from traditional magnetic flux leakage (MFL) tools to high-resolution ultrasonic (UT) and acoustic resonance technologies (ART).

“UT tools can measure with ±0.4 mm accuracy in thickwalled pipelines. MFL tools only reach ± 10% of nominal wall thickness,” says Thomas Mrugala. “That level of accuracy is critical for identifying and sizing crack-like features, especially in offshore or hydrogen pipelines.”

Craig Hall agrees: “If you’re dealing with crack threats, UT is the only option. EMAT isn’t typically used for baselines, and MFL can’t reliably detect cracks.”

Adapting

to environmental and operational realities

Modern pipelines face increasingly extreme conditions; deepwater pressures, seismic zones, corrosive products, and aggressive terrain.

“Geohazards and environmental loads are often underestimated,” notes Jim Costain. “A strong baseline allows us to detect deformations caused by seabed shifts or fault lines before they evolve into integrity risks.”

ART Scan tools are particularly effective for these environments, especially where hydrogen embrittlement or CO2 service introduces new failure modes.

Additionally, CRA-lined pipelines, dual-diameter segments, and high-pressure transmission lines are all well within the capabilities of NDT Global’s customisable inspection solutions.

It’s not just for new pipelines

One of the most common misconceptions about baseline inspections is that they’re only for new pipelines. That couldn’t be further from the truth.

“Any pipeline undergoing a change – like switching from oil to hydrogen, or from wet gas to dry gas – needs a new baseline,” explains Thomas. “You’re introducing new operational risks that weren’t part of the original design basis.”

Operators looking to repurpose pipelines must understand their true condition. Issues like legacy corrosion, metal fatigue, or mill anomalies can become safety-critical when the product or pressure regime changes.

“Our data teams can use baseline inspections to determine fitness-for-service, inform regulatory approvals, and guide necessary upgrades,” adds Ron James.

Regulatory

and commercial drivers for re-inspections

Baseline inspections are only the beginning. Operators must also prepare for re-inspection planning, particularly in jurisdictions governed by PHMSA or CSA Z662 regulations.

“You don’t want to scramble five years down the road when your inspection interval expires,” says Craig. “Having a clear, high-quality baseline allows risk-based interval planning, especially when facing new threats like SCC or fatigue cracking.”

Re-inspections not only satisfy compliance but also saves money. Baseline comparisons enable anomaly trending and helps to determine whether a feature is growing and how fast.

“We’ve helped operators avoid costly excavations by showing a feature hasn’t changed since the baseline,” adds Thomas. “That kind of decision-making is only possible with accurate, repeatable baseline data.”

Real-world success: technology that saves

time

In a recent offshore project, NDT Global was asked to inspect a flowline with a CRA liner and a diameter mismatch between the flowline and riser. The original plan called for a permanent subsea receiver – an expensive proposition.

Instead, NDT Global designed a custom tool that adapted to both diameters and eliminated the need for new subsea infrastructure. The operator saved millions in capital and construction costs while still achieving a complete, highresolution baseline inspection.

These types of tailored solutions, made possible by early engagement and flexible tool design, underscore the value of working with an experienced inspection partner.

From reactive to proactive: a shift in mindset

Operators are beginning to understand that pipeline integrity is not just about avoiding failures, it’s about building a proactive, data-driven integrity programme from day one.

“You can’t manage what you can’t measure,” says Jim. “High-quality baseline data lets you quantify growth rates, assess strain accumulation, and respond to threats before they impact production.”

NDT Global’s commitment to quality, innovation, and client support ensures that every inspection adds value not just for compliance, but for smarter, safer, and more sustainable pipeline operations.

Baseline inspections are not optional, they’re foundational

As the global energy transition accelerates and the demand for safe, reliable pipelines continues to grow, the role of baseline inspections becomes even more vital. From enabling regulatory compliance to reducing long-term OPEX, baseline inspections offer a powerful return on investment.

Using advanced ultrasonic and acoustic resonance tools, NDT Global helps operators gain clarity, reduce risk, and unlock the full potential of their pipeline assets starting from ‘hour zero’.

Jeff Taylor, Founder and President, Event 38 Unmanned Systems, discusses how drones capable of Beyond Visual Line of Sight (BVLOS) pipeline inspection enable new possibilities in routine asset inspection.

IIn 2024, drone manufacturer Event 38 Unmanned Systems was introduced to Phoenix Air Unmanned (PAU), an aerial inspection service provider, by Shell Pipeline Corp. PAU was looking for the right drone for a proof-of-concept demo of a BVLOS pipeline inspection for Shell’s assets in Louisiana. The goal of the demo was to field-test the possibilities of using drones, rather than manned aircraft, for routine pipeline inspections.

In late 2023, Event 38 had launched the E455, its largest fixed-wing vertical takeoff and landing (VTOL) drone. The E455 offered several key features critical to PAU’s mission:

) BVLOS compatibility: thanks to its robust payload capacity, the E455 could easily carry the multiple cameras required for the drone to be added to PAU’s BVLOS waiver.

) VTOL capability: while some drones require groomed runways, the E455 can take off and land from virtually any space, giving PAU more flexibility in the field.

Another factor in PAU’s decision to adopt the E455 was the agility of the Event 38 team. Event 38’s size, structure, and hands-on culture meant they could quickly deploy key team members to work side-by-side with PAU to integrate the E455 into PAU’s existing systems.

Mission planning and gear specifications

Ohio-based Event 38 traveled to PAU’s facilities in Georgia for a week of training and integration. After just three days of classroom and field training, six PAU pilots were flying the E455 independently.

The E455 flies with a custom version of ArduPlane, and ground control stations use a custom version of QGroundControl. Both platforms were developed in-house by Event 38, led by Mathew Wright, Event 38’s VP of Engineering and Operations. After training was completed, Wright spent two more days in Georgia, integrating the E455 into PAU’s existing infrastructure himself.

While training and integration were seamless, there were still potential challenges to prepare for, including the risk of connectivity loss. The inspection route ran through a few stretches of land with potentially spotty coverage. To ensure

a consistent connection between the drone and the ground crew, Event 38 developed a double-bonded radio solution.

The E455 was fitted with:

) An Elsight Halo 4G LTE cellular radio. This radio can maintain a strong connection as long as it is within range of a cell tower.

) Silvus 2.4 GHz radios for point-to-point connection.

The system was programmed to automatically default to the strongest connection.

To maintain compliance with PAU’s BVLOS waiver, the E455 was also outfitted with an Iris Casia three-camera system. This included:

) A pair of forward-facing cameras, with overlapping fields of view. The cameras were mounted on the right and left sides of the E455, creating a 170° field of view.

) A rear-facing camera with a 90° field of view.

The final piece of equipment fitted to the E455 was a NextVision DragonEye EO/IR camera. The DragonEye was recommended by Event 38, who has a long history of success integrating the DragonEye with its drones for other customers. The DragonEye is more than capable of spotting and capturing imagery of the targets most relevant to this particular mission. The DragonEye was the only piece of equipment carried by the E455’s payload bay. The radios and the Iris Casia camera system were mounted elsewhere in the drone.

The sheer scale of the mission posted some of the most significant challenges for PAU during the planning process. Flying the E455 through airspace classes where BVLOS is not authorised was unavoidable, so the team had to figure out how to maintain visual line of site (VLOS) in these areas. This required strategic vehicle placement to keep ground control crews close to the aircraft without sacrificing efficiency.

The scale of the mission also forced some creative thinking in terms of basic logistics. The demo required 700 miles of driving, all the way across the state of Louisiana (USA). PAU had to develop a plan for keeping ground crews housed and fed and routing their mobile ground infrastructure as efficiently as possible.

Mission report

The goal of the mission was to fly 300 miles in a single day. Unexpected fog on the day of the mission led to a short delay, but after just two hours, the skies had cleared, and the E455 was launched for its first mission flight. The mission was completed by noon the next day.

The E455 flew 330 miles in just 7.6 flight hours over two days. Had the fog delay not occurred, completing the entire mission in a single day would have been possible.

Thanks to the bonded radio solution, ground crews never lost connection with the E455. A single hand-off of controls was completed during each leg of the flight. The quality of the live video feed stayed consistent with customer requirements for the duration of the

Figure 1. A PAU crew member inspects the E455 before takeoff.

Figure 3. With its robust VTOL capabilities, the E455 can take off from virtually anywhere.

Be the FBE Expert Everyone Trusts.

Fusion Bonded Epoxy (FBE): Application and Inspection

• Learn the critical checkpoints that determine coating success

When it comes to pipeline integrity, coatings aren’t just a layer—they’re the last line of defense. One ﬂaw in a Fusion Bonded Epoxy (FBE) coating can shut down an entire operation. That’s where you come in.

AMPP’s new hands-on training and Level 1 certification is built for applicators and inspectors, by experts who know the real-world demands of the field. From surface prep to final inspection, this program teaches you how to spot what others miss—and prevent failures before they happen.

You know what’s at stake. This is how you lead.

Scan the QR code to get started.

Train with AMPP. Inspect with authority.

• Gain conﬁdence with hands-on inspection and testing during the application process

• Stand out with a certiﬁcation that proves you’re ready for the toughest jobs

mission, and the point-to-point radio connection achieved a five mile range. Even with the fog delay, the demo was considered a success.

Spotlight on the E455: why it worked

As previously mentioned, the E455’s VTOL capabilities and BVLOS compatibility were both contributing factors to PAU’s decision to work with Event 38. But the E455’s construction offered several additional advantages that lend themselves well to the needs of the pipeline industry.

Many fixed-wing drones currently on the market are made from foam. But Event 38 took a different approach with the E455, which is made from carbon fibre. Carbon fibre is lightweight, which allows for relatively slow flight speeds even at maximum weight. This allows for the long endurance and accurate data collection needed for surveying and inspection flights. Operators can take their time flying over sensitive areas that require a closer look. Additionally, carbon fibre is stiff and strong enough to withstand higher air loads at high speed. The E455 can travel at a wide envelope of flight speeds, from 39 - 62 mph.

Plus, the E455 is hollow. Its carbon fibre skin is roughly one millimeter thick, leaving a tremendous amount of usable internal volume. This is especially valuable for BVLOS and other flights that require a lot of equipment: radios for redundant connections, cameras and computers for detection and avoidance (D&A), sensors, and more. The carrying volume of the E455 allows operators to be more efficient with every mission.

Moreover, the E455 is manufactured entirely in-house at Event 38’s manufacturing centre in the American Midwest. As a result, Event 38’s aircraft are not limited by the constraints of aircraft purchased off-the-shelf from third-party sources. Event 38’s manufacturing team can create space for additional radios, support specialty sensors, and modify virtually ever specification of the aircraft to accommodate the specialised needs of a given customer or mission.

Drones: the next generation of utility inspection?

While the E455 is hardly the first drone to complete a successful pipeline inspection, the scale of this particular mission – 300 miles in a single day’s worth of flying – represents tremendous possibility for the future. But using drones for aerial inspection may also lead to greater efficiency on the ground.

Traditionally, aerial utility inspections have been conducted with helicopters and other manned aircraft. The pilot inspects the area with the naked eye through the window of the aircraft and takes photos of potential issues that need boots-on-theground investigation.

The primary drawback to this method is limited accuracy. A pilot can keep careful notes on where they observe any anomalies worth investigating, but the speed of the aircraft makes it difficult to record the exact location. Pipeline technicians can spend several hours searching for the site in question.

The E455 eliminates time spent searching by tagging any noteworthy sites with exact latitudinal and longitudinal data. With precision coordinates from the E455, technicians can travel directly to each work site as quickly as possible. This leads to increased efficiency and eliminates unnecessary delays when crews are deployed to address a time-sensitive problem. After the completion of the demo, Shell Pipeline Corp. remarked directly on the value of this exact location data.

Event 38 has already leveraged several key takeaways from the success of the project. “This demo was an excellent opportunity for us to learn more about how the E455 operates in real-world scenarios,” said Wright. “We were able to make some other modifications that will translate to a better user experience going forward.”

From advancements in scale to better operational efficiency, the success of this demo represents significant potential for deploying drones in the utility industry.

Figure 4. The E455 flew a total of 18 flights for this mission.

Figure 5. Event 38’s Mathew Wright trains PAU crew members to fly the E455.

INTRODUCING THE

Better Cleaning with the Pit Hog

Galaxy Brushes is proud to unveil the Pit Hog, a cutting-edge innovation designed to take your pipeline cleaning to stellar heights, blasting through grime, one pipe at a time. With a powerful strip brush technique, this brush outshines traditional flat wire and pencil brushes, ensuring unparalleled cleaning efficiency.

Out-of-this-World Features:

Superior Cleaning Power: The Pit Hogʼs strip brush design maximizes wire contact with the pipe, delivering superior results in clearing out debris.

Custom Fit for Any Mission: Choose your wire diameter (ranging from 0.010" to 0.020") and tailor cleaning effectiveness to your needs.

Durable Materials for Any Terrain: Available in both carbon and stainless steel, the Pit Hog is built to withstand even the toughest pipelines.

Galaxy-Grade Quality: Backed by the legendary service and craftsmanship that make Galaxy Brushes the star of the industry.

Take your pipeline maintenance to the next level with the Pit Hog.

The oil and gas industry faces significant challenges: a shrinking workforce, ageing infrastructure and assets, rising costs, and achieving net zero targets. The integration of autonomous robots into critical inspection routines is yielding promising results. ANYmal, a highly robust four - legged robot developed by ANYbotics, is specifically designed for harsh industrial environments. It helps address these strategic objectives by automating inspections in complex facilities such as refineries, petrochemical plants,

Enzo Wälchli, Chief Commercial Officer, ANYbotics, underlines the potential of autonomous robotics to transform safety, efficiency, and sustainability in oil and gas inspections.

offshore platforms, floating production storage and offloading (FPSO) units, and onshore gas storage sites.

The oil and gas sector is undergoing a significant transformation through the integration of advanced robotic systems. ANYbotics’ autonomous legged robots –

Figure 1. ANYmal waterproof inspection robot.

the IP67-rated ANYmal D and the world’s only ATEX/IECEx (Zone 1 IIB) certified ANYmal X – are demonstrating their ability to revolutionise safety, efficiency, and sustainability in hazardous industrial environments. Designed for

complex terrains and explosive atmospheres, these robots are rigorously tested and have already proven their value in critical autonomous inspections.

Operational facilities, like gas processing plants, provide realistic testing environments. The strict safety protocols within ATEX/IECEx zones make robots like ANYmal X essential for minimising human exposure to hazardous conditions, a key concern in oil and gas operations.

The core function of both ANYmal D and ANYmal X robots is autonomous inspection. They perform visual and thermal measurements of equipment, providing vital condition monitoring data. In oil and gas facility inspections, their real-time data gathering and transmission are crucial for leak prevention and structural integrity. Companies such as Shell, SLB, Petrobras, Petronas, SEFE, DSM-Firmenich, and W. R. Grace and Co. are already recognising the transformative ability of these technologies.

Deployments begin with digitally mapping the facility. The robots create detailed 3D point clouds for navigation and localisation, which is crucial for autonomously managing extensive sites. The robots navigate obstacles, ensuring access to hard-to-reach locations for thorough inspections.

Once mapping is completed, repeatable inspections are conducted autonomously, with remote operation via LTE and VPN. This remote capability is essential for monitoring assets in remote locations, enabling continuous oversight without constant human presence. The robots’ performance in challenging conditions demonstrates their robustness and adaptability. They maintain operational stability in harsh, dirty, and dangerous environments, ensuring continuous monitoring regardless of external factors.

ANYbotics prioritises user experience and field support. Its intuitive interfaces facilitate rapid mission setup. Simulation models and on-site support enable field engineer adaptation and independent robot operation. This user-friendly approach is vital for widespread adoption. Data integration is also critical. Inspection data is seamlessly integrated into plant management software via ANYbotics’ Data Navigator, which is essential for efficient monitoring and analysis.

Robotic inspection offers maximum value when data is readily available and actionable, Data Navigator transforms robot data into actionable insights for preventive maintenance. Providing seamless access to asset health and empowering teams to optimise maintenance and ensure plant uptime. By centralising asset condition data it enables failure prediction

Figure 2. ANYmal inspection.

Figure 3. ANYmal autonomous robot inspection plant.

Figure 4. ANYmal X climbing stairs at Ex proof environment.

and resource savings. Its intuitive interface and flexible deployment options also ensure accessibility and security.

Data Navigator features include an asset-centric approach, an easy-to-use interface, historical data analysis, improved data access, and increased operational efficiency. Operational deployments demonstrated its capabilities, analysing thousands of inspections rapidly. Its intuitive design allowed maintenance teams to use it immediately. Test reports highlight the robots’ ability to reduce human involvement in hazardous tasks, enhancing safety and reducing risks.

ANYbotics’ robots also contribute to plant integrity through continuous monitoring, which is crucial for

anomaly detection and failure prevention. Their realtime data ensures prompt issue resolution, minimising downtime. Integrating these robots into plant inspection operations enhances safety, efficiency, and sustainability through reduced manual inspections and improved data integration. They support emergency response, leak detection, and structural integrity assessments.

ANYbotics’ collaborative development of tailored robotic solutions marks a milestone in transforming plant inspections and enhancing safety in hazardous environments. Remote industrial facilities present significant operational hurdles, primarily stemming from the need for frequent on-site personnel. This results in increased costs, operational delays, and heightened safety risks. Furthermore, false alarms necessitate manual verification, leading to inefficient resource allocation and potential downtime.

In the energy sector, these challenges are exacerbated, demanding robust, realtime monitoring to prevent leaks and ensure structural integrity. To mitigate these issues, operators require solutions that enable remote infrastructure monitoring, minimise on-site visits, and enhance personnel safety.

ANYbotics’ robots offer a practical solution. Following rigorous testing, these robots are deployed in demanding operational environments. Integrating seamlessly with existing plant management platforms, ANYmal facilitates automated data collection and remote monitoring. Their ability to navigate complex terrains makes them well-suited for asset inspections and other critical infrastructure assessments.

The deployment of ANYmal yields measurable benefits, including reduced operational costs through fewer on-site inspections, improved safety by minimising human exposure to hazardous environments, faster response times due to real-time anomaly detection, and enhanced operational resilience through automated inspections. Many customers are expanding the use of ANYmal across various sites following the success of their initial deployments and are integrating robotic inspections into their standard operating procedures (SOPs), including training personnel in robotic operations and data analysis.

The increasing adoption of ANYmal underscores the transformative potential of autonomous robotics in driving efficiency, safety, and innovation across critical industrial sectors.

Sandro Esposito, SignalFire Telemetry Inc., USA, elaborates on the challenges in monitoring gas distribution pipelines for leaks and failures.

Gas distribution pipelines – stretching millions of miles globally – deliver natural gas to homes, industries, and power generators, forming the backbone of modern energy infrastructure. However, leaks and failures in these pipelines pose significant safety risks, contribute to climate change due to methane (CH4) emissions, and challenge regulatory compliance for operators. Addressing these challenges requires a thorough understanding of the failure mechanisms, statistics on leak sources, and the integration of advanced monitoring technologies, including wireless telemetry, to ensure safety and environmental sustainability.

Statistics on gas leak sources in distribution networks

Studies reveal that gas leaks within distribution networks are primarily caused by the following:

) Corrosion and material degradation (30%): this occurs when pipelines, particularly those made of older steel and cast iron, degrade due to environmental exposure.

) Third-party damage (20%): excavation and construction activities often result in accidental damage to pipelines.

) Equipment failures (15%): valves, joints, and fittings can fail due to wear, poor maintenance, or manufacturing defects.

) Natural forces (10%): soil movement, flooding, and frost heave can stress pipelines.

) Operational errors (5%): human errors during operations can lead to leaks.

) Other/unknown causes (20%): encompasses less common or undetermined reasons.

Potential failure points in gas distribution systems

Failure can occur at various points in gas distribution systems:

) Pipeline walls: erosion and corrosion can lead to thinning and cracks.

) Joints and fittings: degradation of seals or physical damage can lead to leaks.

) Valves: can become stuck or leak due to mechanical failures.

) Service connections: points where the main connects to customer premises may fail due to material fatigue.

) Pressure control devices: failures may lead to over-pressurisation and potential ruptures.

) Meters and regulators: ageing or damaged infrastructure can develop leaks.

Factors impacting pipeline integrity

Several factors affect the long-term integrity of gas pipelines:

) Corrosion: chemical reactions with the environment degrade metal pipelines.

) Erosion: particulate matter within the gas can erode the interior of the pipeline.

) Stress corrosion cracking: combination of stress and environmental conditions creates cracks.

) Mechanical damage: damage from vehicles, heavy equipment, or natural disasters.

) Ground movement: seismic activity, soil subsidence, and frost heave.

) Pressure cycling: repeated pressure fluctuations can lead to fatigue.

) Material defects: manufacturing flaws may reduce pipeline durability.

) Temperature variations: expansion and contraction cycles create stress.

) Ageing infrastructure: older systems are inherently more prone to failure.

The environmental and safety impacts of leaks

Methane, the primary component of natural gas, is a potent greenhouse gas (GHG), with 84 times the warming potential of

Figure 1. Gas pipeline. (Source: US Department of Energy.)

Figure 2. Neighbourhood gas regulator station with pressure telemetry. (Source: SignalFire Telemetry Inc.)

Figure 3. Annual emissions (million t CH4) for the top 10 country emitters.

Trenton's Wax-Tape® Anticorrosion System is uniquely qualiﬁed to protect assets in corrosive offshore environments.

Critical Beneﬁts for Offshore Applications:

■ Quick and easy to apply, with minimal equipment requirements

■ Readily conforms to irregularly shaped surface

■ Requires minimal surface preparation (SSPC SP2 or ISO St2)

■ Can be applied over wet surfaces at “in-service” temperatures

European Ofﬁce: +33 (0) 1 70 62 94 74 europe@trentoncorp.com www.trentoncorp.com

carbon dioxide (CO2) over a 20 year period. Leaks contribute to climate change while creating safety hazards, including explosion risks in populated areas. According to the US Environmental Protection Agency (EPA), methane emissions from natural gas systems account for nearly 30% of total US methane emissions, emphasising the need for stringent monitoring and rapid leak mitigation.

Estimated annual methane emissions from gas distribution pipelines

According to the EPA’s Inventory of US GHG Emissions and Sinks, methane emissions from US natural gas distribution pipelines are estimated at approximately 6 - 7 million tpy of CO2, translating to approximately 350 000 tpy of methane emitted from the distribution segment alone.

This represents around 1 - 2% of total US methane emissions from the natural gas system, highlighting distribution pipelines as a significant yet actionable contributor to methane emissions reduction efforts.

Figure 3 shows estimated annual emissions (million t CH4) from gas distributed pipelines for the top 10 country emitters. Additional data for well-maintained infrastructure in importing regions includes:

) Italy: 0.16 million t.

) France: 0.10 million t.

) UK: 0.08 million t.

) Germany: 0.02 million t.

China, not listed in the chart in Figure 3 due to study constraints, still contributes significantly with ~0.85 million t from pipelines and LNG, per IEA Methane Tracker.

Why these numbers matter

When combined, the displacement of 18 million t of CH4 annually marks significant GHG emissions – considering methane’s high global warming potential.

The US alone accounts for approximately 5.6 million t, more than a quarter of the global pipeline emission total.

And high-ranking producers like Russia, Pakistan, Iran, and Canada also reflect legacy infrastructure and larger networks.

Wireless telemetry: a solution for modern pipeline monitoring

Wireless telemetry technology enables real-time monitoring of pipelines, allowing operators to promptly detect leaks, track pressure and flow anomalies, and respond swiftly to potential failures. These systems integrate sensors, data acquisition devices, and wireless communication protocols to create a robust monitoring framework.

Benefits of wireless telemetry in leak monitoring include:

) Continuous real-time data: enables early detection of leaks and unusual pressure or flow patterns.

) Remote accessibility: operators can monitor pipeline integrity without being physically present.

) Data-driven maintenance: historical and live data facilitate targeted maintenance.

) Cost efficiency: reduces the need for manual inspections while increasing detection accuracy.

Figure 4. Example of low powered methane sensor. (Source: Nevada Nano.)

Figure 5. MQTT and TLS data flow and encryption from sensor to SCADA.

Figure 6. Battery powered wireless transmitter with methane sensor. (Source: SignalFire Telemetry Inc.)

) Improved safety: faster detection and response reduce the risks of explosions and service interruptions.

) Emission reduction: helps utilities actively monitor and reduce methane emissions.

Supporting regulatory compliance with Quad O and Quad Oa

The EPA’s regulations, Quad O (40 CFR Part 60 Subpart OOOO) and Quad Oa (Subpart OOOOa), mandate leak detection and repair, regular monitoring, and reporting of methane emissions from oil and gas facilities. Wireless telemetry helps operators meet these requirements by:

) Automating data collection: providing accurate, timestamped data for regulatory reports.

) Reducing manual survey gaps: continuous monitoring ensures intermittent leaks are detected.

) Prompt repair interventions: automatic alerts trigger faster maintenance actions.

) Supporting Environmental, Social, and Governance (ESG) reporting: demonstrating proactive environmental management to regulators and stakeholders.

Challenges in implementing wireless monitoring systems

Despite its advantages, deploying wireless telemetry systems comes with challenges:

) Data overload: high volumes of data require robust analytics for actionable insights.

) Integration with legacy systems: older SCADA systems may require upgrades for compatibility.

) Power management: ensuring long-term battery life in remote sensors.

) Signal interference: urban environments may require network optimisation.

) Cybersecurity: protecting infrastructure from cyber threats is essential.

) Initial capital investment: cost-effective long-term, upfront costs can be high.

New solutions on the market address the challenges in implementing wireless monitoring systems by leveraging multiple technologies. Technologies such as LoRaWAN, NB-IoT, and LTE-M are commonly used in wireless telemetry for pipelines due to their low power consumption and reliable long-range data transmission capabilities, allowing sensors to operate for years without replacement. The main advantage of cellular technologies like NB-IoT and LTE-M is that users don’t need to invest in telemetry infrastructure. The cellular towers and their communication network are already widely available. In addition, these cellular technologies provide for low power consumption while simultaneously offering on-demand bi-directional communications and report by exception when measurements exceed a critical threshold. Furthermore, overthe-air (OTA) field device upgrades are possible with such technologies. This is crucial for operators with hundreds or thousands of scattered sensors, as it ensures the sensors are equipped with the most up-to-date firmware.

Figure 7. Class 1 Div 1 wireless pressure sensor using LTE-M.

(Source: SignalFire Telemetry Inc.)

Figure 8. Corrosion sensor coupled with LTE-M wireless transmitter.

(Source: Axess Corrosion.)

iCoaTek, an independent anti-corrosion research and testing centre in Shanghai, provides certiﬁed inspection, material testing, and expert analysis for pipeline coatings.

Serving the global petroleum industry, we help ensure long-term asset integrity and safety by identifying and mitigating corrosion risks.

iCoaTek’s certiﬁed experts deliver independent, reliable inspection and testing for pipeline coatings and cathodic With 10+ years’ experience and international credentials, we ensure anti-corrosion quality, project safety, and compliance at every stage.

Communication protocols are also a key component for efficient, reliable, and secure data exchange. Many devices now utilise the protocol Message Queuing Telemetry Transport (MQTT) invented in 1999. This technology was originally designed to monitor pipelines using satellite communications, where power in remote areas is a constraint, as is the high cost of data transmission over satellites. This technology only sends data when needed. It automatically buffers temporary data when communication isn’t possible and provides the receiving host (subscriber) with a list of all possible data to subscribe to.

While MQTT is a protocol for transferring data, another essential component is the formatting of that data. The Open SparkPlug standard, maintained by the Eclipse Foundation uses compressed binary for data efficiency. It also standardises the structure of the data, which makes its plug-and-play for the receiving subscriber to parse the message. Most modern monitoring and SCADA systems have adopted this language, allowing users to easily, reliably, securely, and quickly integrate data from wireless devices into their systems – systems like AVEVA Wonderware, PI, Inductive Automation’s Ignition, SignalFire Cloud, VTSCADA, GeoScada, Integration Objects SIOTH, etc.

Another challenge in measuring gas leaks or pressure leaks along pipeline networks using wireless technologies is the power requirements of sensors and the need for devices that are suitable for use in hazardous locations where power is unavailable or too costly to install.

Finally, in terms of challenges in deploying wireless monitoring systems, the issue has been, for a long time, the high power requirement of gas measurement sensors. These have typically been using tunable laser diodes or pellistors. Both technologies require a lot of power, therefore making it challenging to have a battery-powered device with long battery life. If using solar-powered systems, these technologies would require a costly solar power array.

Today, there are new low-power gas detection sensors that use molecular property spectrometer (MPS) integrated in micro electro-mechanical sensors (MEMS) form factor (Figure 4).

Cybersecurity in using wireless IoT devices

Transport Layer Security (TLS) is like a secure, private tunnel for your data on the internet (Figure 5). When you conduct online banking, shop on Amazon, or make any online purchase, TLS keeps your credit card numbers, passwords, and personal data hidden from hackers as they travel between your device and the website, ensuring that no one can steal or tamper with it.

TLS addresses cybersecurity concerns in MQTT data transmission by encrypting data in transit, ensuring confidentiality so attackers cannot read the payload. It provides authentication, verifying that clients and brokers are who they claim to be, preventing impersonation attacks. TLS also ensures data integrity, using checksums to detect any tampering during transmission. When combined with MQTT, which lacks built-in encryption, TLS protects IoT data against eavesdropping and man-in-the-middle attacks while maintaining low overhead suitable for resource-constrained devices. This combination enables secure, reliable messaging

for IoT and industrial systems, aligning with modern cybersecurity requirements for data protection.

How modern wireless sensors open new possibilities

Newer wireless sensors have opened the possibility of deploying measurements in gas distribution networks at the lowest overall cost by combining in a small form factor all these technologies: LTE-M/NB-IoT for over-the-air communications, MQTT for efficient and reliable data exchange, SparkPlug for standardise language using less bytes of data and MEMS sensors with low power consumption for longer battery life.

Case studies: wireless telemetry in action

Cities like Boston and Los Angeles have implemented wireless telemetry programmes that have significantly reduced methane response times for leaks. In some pilot programmes, methane emissions reductions of up to 80% were achieved compared to traditional manual survey methods, proving the effectiveness of continuous monitoring.

In gas distribution, several operators are starting to deploy wireless transmitters to monitor pressure (Figure 7) and methane emissions (Figure 6) throughout their network of pipelines. Many are also adding corrosion sensors to monitor the thickness of the pipe walls, as well as track the injection of corrosion inhibitors into the pipeline system (Figure 8).

Pipelines are also equipped with cathodic protection (CP) systems to extend the life of the pipes by injecting microcurrents on the surface of the pipe. These systems can fail and are often in remote areas. Adding cost-effective wireless transmitters to these systems enables operators to monitor their CP system’s operations. If they stop working, they can quickly remediate the situation, avoiding corrosion from setting in before it’s too late.

Future trends in pipeline monitoring

Emerging technologies are poised to further revolutionise pipeline monitoring:

) AI and machine learning: for predictive maintenance and leak forecasting.

) RedCap 5G: next generation of LTE-M Cat M1 for IoT devices, leveraging 5G networks.

) Low orbit satellite communications: to deploy sensors where cellular communication isn’t available.

) Integration with digital twins: for comprehensive system modelling and risk analysis.

Conclusion

Monitoring gas distribution pipelines for leaks and failures is a critical component of maintaining safety, operational integrity, and environmental responsibility. Understanding leak statistics and failure points helps operators prioritise monitoring efforts, while factors such as corrosion, erosion, and material ageing necessitate continuous assessment. Wireless telemetry provides a scalable and efficient solution for monitoring pipeline networks, reducing methane emissions, and complying with regulations such as Quad O. By investing in advanced monitoring technologies, utilities can ensure a safer, cleaner, and more reliable energy future while aligning with global sustainability goals.

We can tailor to your requirements, produce 1 - 12 page formats, print colour or mono and more

+44 (0)1252 718999 reprints@worldpipelines.com

Dr. Mario Paniccia, CEO, ANELLO Photonics, USA, describes how to enable safer and more predictable pipeline inspection using integrated photonics.

Pipelines are the unseen lifelines of modern civilisation – transporting oil, gas, water, and other essential resources across thousands of miles of terrain, both above and below ground as well as underwater. Yet, these vital arteries are under constant threat. The majority of pipeline incidents are caused by either corrosion or mechanical damage, both of which can result in catastrophic failures, environmental disasters, and costly economic fallout. From burst pipelines spilling oil into oceans, to gas leaks under urban centres triggering fires or evacuations, the stakes are high when it comes to ensuring that these assets are maintained and inspected regularly.

Early detection of such issues is essential, but also incredibly challenging. Pipeline networks span remote regions, rugged landscapes, dense cities, and deep seafloors. Many of these

zones are what engineers call GPS-denied environments – areas where satellite signals are obstructed, unreliable, or non-existent. In these conditions, traditional navigation systems fail and the ability of inspection tools like robotic pigs, remotely operated vehicles (ROVs), and autonomous underwater vehicles (AUVs) to accurately track position vastly deteriorates.

As a result, the integrity of the inspection data is compromised. Pinpointing the location of cracks, corrosion or joint weaknesses becomes unreliable, making it difficult to direct repair crews where to look or to prioritise safety interventions. This navigation blind spot has long been a weak link in the infrastructure monitoring chain. However, recent advancements in optical gyroscope technology may finally provide the missing piece.

The challenge: precision navigation in the dark

Imagine inspecting a metal pipeline that runs 50 miles under a forested mountain range. There is no GPS signal and magnetic compasses are distorted by the surrounding steel. The pipeline may twist, curve, narrow, or expand along the way. Robotic inspectors (smart pigs) must traverse this complex environment quickly and efficiently, all while collecting precise data on wall thickness, structural integrity, and signs of corrosion. But what happens if the robot loses track of its position?

Even a small navigational drift (say, a few cm/m), adds up quickly. Over a multi-hour inspection run, it could amount to several metres of positional error. That means the data collected from one location may be wrongly attributed to another. Worse, if anomalies are detected, like pitting corrosion or a stress crack, it becomes difficult to accurately locate them again for repair, especially if the system can’t reliably recreate the original conditions.

Underwater and offshore inspections pose even more challenges. Ocean currents, pressure changes, tether dynamics, and interference from massive steel oil platforms make navigation even harder. ROVs and AUVs often must navigate blind once they drop below the surface. In such environments, precise, drift-resistant, and self-contained navigation systems are no longer just ‘nice to have’ – they are mission-critical. That’s where optical gyroscope-based inertial navigation systems (INS) enter the picture, offering a resilient alternative to traditional GPS or magnetic-based solutions.

The silicon photonics revolution

ANELLO Photonics, a company specialising in silicon photonics and sensory technology, has introduced a new technology: the SiPhOGTM, or Silicon Photonics Optical Gyroscope. Built using semiconductor manufacturing techniques, this chipscale optical gyro is redefining what’s possible in navigation for industrial inspection systems.

Traditional inertial sensors come in two categories:

) Micro-electro-mechanical systems (MEMS) gyroscopes, which are small and cheap but suffer from low accuracy and high drift and are sensitive to temperature and vibration.

) Fibre optic gyroscopes (FOGs) and ring laser gyros (RLGs), which are far more precise but are big, bulky, and expensive.

SiPhOG bridges this gap by miniaturising high-precision optical sensing into a solid-state semiconductor chip, enabling military-grade navigation performance at a fraction of the size, weight, power, and cost. The innovation lies in its use of integrated photonics, which bends and routes laser light through microscopic waveguides etched directly into silicon. As the system rotates, the laser’s phase shift is measured using the same Sagnac effect as in fibre optic gyros – by measuring an interference pattern that is sensitive to angular velocity.

What makes this revolutionary?

) Bias drift <0.5°/h – previously only achieved by large, expensive FOGs.

) Nanoradian-scale sensitivity – crucial for long-duration inspections.

) Coin-sized form factor – small enough for small, mobile, embedded robots.

) Temperature and vibration resistance – perfect for harsh environments.

By integrating these SiPhOGs with accelerometers, magnetometers, GPS (if available), and onboard software into a system, ANELLO creates full-stack inertial navigation systems (INS). These systems use advanced sensor fusion algorithms to cross-check inputs, validate data in real time and reject erroneous or spoofed signals, and can track very accurately position in real time.

Real-world deployment: smart pigs, drones, and undersea robots

When integrated into smart pigging systems, ANELLO’s solutions ensure that data about pipeline anomalies is tied to accurate, repeatable positions. This is a game-changer. Previously, data points from long pipeline runs were vulnerable to cumulative drift. A sensor might detect a problem, but good luck finding it again 15 km later. Now, operators can confidently send repair teams to the exact location of a defect, reducing downtime and increasing repair success rates.

In the offshore world, where inspection is typically carried out by AUVs or ROVs, the need is even more urgent. Ocean environments present variable buoyancy, currents, and magnetic distortions due to large metal structures. A misaligned inspection can result in missed weld defects, leaking flanges, or incomplete coverage. But with ANELLO’s SiPhOG-based inertial navigation solutions, drones can maintain consistent heading and depth control, even when GPS is unavailable.

Moreover, the georeferencing of inspection data becomes more powerful. Because the system maintains orientation and velocity tracking even during GPS dropouts, the entire inspection mission can be logged and tied to physical infrastructure – valves, joints, T-junctions, or flanges. This level of traceability transforms maintenance, audit trails and operational planning.

Safety, compliance and environmental resilience

Beyond operational benefits, there are growing regulatory drivers for better inspection traceability. In many regions, oil and gas pipeline operators are required to maintain detailed inspection logs, validate inspection integrity, and produce auditable records. Fines for non-compliance can stretch into millions of dollars.

By embedding high-precision solutions into inspection platforms, operators can meet or exceed these standards. Every mission becomes a verifiable dataset, not just a report. With redundant positioning from inertial and GPS sources, and onboard spoofing and jamming detection capability, the risk of false data is minimised.

This also translates to environmental protection. Consider the 2015 Santa Barbara oil spill in California, where a corroded pipeline ruptured and released over 140 000 gal. of crude oil, contaminating sensitive coastal areas. Although prior inspections had detected corrosion, the pipeline’s condition

was underestimated and critical maintenance was delayed. This underscores the importance not only of high-fidelity sensing, but also of accurate, repeatable localisation – ensuring that inspection data is actionable and defect sites are unmistakably mapped for timely intervention.

With technologies like the SiPhOG, such disasters become less likely and inspection platforms become smarter, more autonomous, and vastly more dependable.

Economic impact and future roadmap

The cost savings from improved inspection fidelity are tangible. Every hour saved on vessel time in offshore operations can result in tens of thousands of dollars or more in savings. Avoiding unnecessary pipeline shutdowns or repeated pigging runs can save hundreds of thousands in downtime, labour, and logistics. More importantly, early defect detection prevents environmental cleanups that can cost millions and tarnish public trust.

From a manufacturing perspective, ANELLO also provides supply chain assurance. The firm fabricates its chips domestically in the US, ensuring that critical infrastructure – especially defense or national security applications – are not reliant on foreign technology. That’s a strategic advantage in an era where tech sovereignty is becoming more important than ever.

Looking ahead, ANELLO plans to further miniaturise its sensors, aiming for sub-inch form factors that can be embedded into a wider variety of devices, from autonomous robots to handheld inspection tools. AI-driven sensor fusion will evolve, allowing systems to self-calibrate, self-diagnose, and even adapt to changing conditions in real time.

Conclusion

As pipeline networks expand and age, the challenge of inspecting them safely, accurately, and efficiently becomes more pressing. The risk of failures due to corrosion, mechanical damage, or natural wear is too high to ignore. Yet traditional inspection tools often fall short – not because of sensor limitations, but because of navigation failures in complex environments.

Technology offers a compelling solution. By introducing high-precision, GPS-independent, and environmentally resilient navigation to inspection systems, it revolutionises how we monitor and maintain critical infrastructure.

From smart pigs in steel pipelines, to underwater drones patrolling offshore rigs – these tiny optical gyroscopes are making the invisible visible, and turning inspection from a guessing game into a science.

In doing so, the ANELLO gyroscopes aren’t just protecting assets. They’re protecting the environments around them, the people who depend on them, and the trust that underpins modern energy and utility networks.

Figure 1. ANELLO Maritime INS.

Figure 2. ANELLO SiPhOGTM – Silicon Photonics Optical Gyroscope.

Figure 3. ANELLO X3 IMU.

Ajitkumar Sreekumar,

Vice President of Sales at IMI,

explores how flow control experts are helping operators solve today’s toughest pipeline challenges, from North America to Brazil.

As energy infrastructure faces mounting pressure from regulators and investors to operate more safely, efficiently, and reliably, pipeline operators are rethinking how they manage control systems in extreme environments. In Alaska, one of the world’s largest oil pipelines is undergoing a digital transformation project with the deployment of digital valve control systems. Far from being a simple upgrade to existing practices, the adoption of these technologies represents a case study in how engineering expertise, collaboration, and regional investment are reshaping flow control applications.

Operating one of the world’s largest oil pipelines spanning nearly 800 miles across Alaska’s rugged and remote terrain requires more than just robust infrastructure. It demands an approach to flow control that prioritises safety, reliability, and adaptability in the face of extreme environmental and operational conditions. In such a context, IMI’s delivery of 15 QuickTrak TM digital valve control systems and positioners represents a strategic response to the evolving needs of critical energy infrastructure.

Engineering for harsh environments

The Alaskan pipeline operates in one of the most demanding environments on the planet. Temperatures can plunge to -40°C and access to remote sites is often limited for pipeline personnel. In such conditions,

traditional valve control systems can struggle to maintain performance, leading to increased maintenance requirements, reduced efficiency, and elevated safety risks.

IMI’s QuickTrak Digital Valve Control System and Positioner was developed with these considerations in mind, blending a microprocessor-based control system with an integrated valve positioner. Combining this digital controller with a high-performance actuator, it delivers the precision of a hydraulic system without the associated environmental and logistical burdens. Its closed-loop system, based on the valve and spool position to control the stepper motor, ensures that actuator pressure is continuously adjusted based on real-time feedback. This enables the valve to be accurately put into desired positions even under fluctuating temperature, flow, and pressure conditions.

This level of control is a necessity in demanding conditions such as those found in Alaska, where even minor deviations in valve performance can have significant consequences. Indeed, pipeline operators face multiple persistent challenges to maintain continuity, including ensuring safety, minimising downtime, and managing maintenance costs. These issues are interconnected and solving them requires operators to adjust their perspective from a narrow view of upgrading individual components to taking a more holistic, system-level approach.

QuickTrak addresses these challenges through a combination of design innovation and diagnostic intelligence. Magneto strictive linear position transducers located within its actuator stem can provide fast and highly accurate control feedback, enabling rapid response to control inputs. This not only improves process stability but also reduces mechanical stress on the valve, improving component reliability.

The system’s built-in diagnostic analysis capability also allows operators to monitor valve performance in real time and analyse historical data to identify trends and predict failures before they occur. This proactive approach to maintenance is essential in remote environments, where unplanned interventions are costly and logistically complex.

Moreover, QuickTrak’s modular design streamlines the number of components required for installation. By eliminating the need for external volume boosters, simplifying the control system and lowering the number of components mounted on the actuator, IMI has reduced the probability of unplanned downtime and made the system easier to maintain. This is a direct response to the operational realities faced by pipeline operators, and it reflects how flow control suppliers should commit to engineering solutions that are both effective and practical even in the most hazardous environments.

Built-in safety and compliance

In critical infrastructure, safety is non-negotiable. The QuickTrak Digital Valve Control System and Positioner incorporates multiple layers of protection – software, firmware, and mechanical – to ensure fail-safe operation under all conditions. In the event of a fault or loss of air supply, the system’s solenoid and three-way valves isolate the servo-valve and initiate a controlled shutdown, preventing uncontrolled movement and maintaining system integrity.

The system is also certified to ATEX, IECEx, CSA, and UL standards, confirming its suitability for use in potentially explosive environments. Though these certifications go beyond regulatory requirements, pipeline operators should use them as a baseline when specifying components. Products that meet these standards reflect the supplier’s rigorous approach to quality and their understanding of the environments in which their products operate.

A strategic deployment in Alaska

The decision to deploy QuickTrak across the Alaskan pipeline is both a technical upgrade and a strategic investment in the future of the asset. By replacing legacy systems with intelligent digital controllers, pipeline operators can benefit from enhanced visibility, faster response times, and improved safety margins these systems provide.

The deployment of such solutions also reflects a broader industry trend toward digitalisation. As operators seek to modernise their infrastructure, they are increasingly looking for partners who can deliver not just products, but complete solutions thanks to a portfolio approach. Flow control solutions suppliers should be able to integrate advanced control systems into existing infrastructure while also providing the engineering support needed to ensure successful implementation. Companies with the ability to do so can offer a key differentiator to stakeholders involved in component specification.

Collaboration, customisation, and commitment

Yet, what truly sets these equipment suppliers apart is not just the performance of their products, but how they engage with customers throughout the installation process. For example, from the earliest stages of the Alaskan project, IMI worked closely with the pipeline operator to understand the specific challenges associated with the

Figure 1. IMI’s new facility in Brazil.

application. This collaborative approach ensured that the solution delivered was not only technically sound, but also aligned with the operator’s operational goals and constraints.

Similarly, any engaged supplier should be able to provide well-informed engineering teams that can work closely with site operators to address the specific technical demands of each site. This includes supporting long-term performance, reliability and regulatory compliance through steps such as adapting control technologies and actuator configurations to suit environmental and operational constraints.

This commitment does not end with installation alone. Timely service and dependable support should be a given for pipeline operators working in remote or high-risk environments. It is essential that any partner organisation has the global infrastructure to respond quickly and provide access to the resources needed to maintain operational continuity. In locations where downtime is more difficult to manage, that responsiveness becomes even more critical to ensuring long-term reliability and minimising disruption.

Supporting regional growth

While the Alaskan deployment highlights IMI’s capabilities in extreme environments, the company’s recent investment in South America demonstrates its commitment to supporting customers worldwide. The opening of a new state-of-the-art facility in Sorocaba, Brazil, marks a significant expansion of IMI’s operations in the region, and is particularly important to help further support a continent where the company’s business has grown by 3.7 times since 2019.

This facility consolidates engineering, manufacturing, service, and logistics operations under one roof, enabling IMI to facilitate faster support for customers in the region and respond quicker and more effectively to customer needs. This includes providing technical support for the more than 1900 valves IMI has installed throughout Brazil.

Indeed, the opening of the new Sorocaba site represents the strengthening of IMI’s commitment to the South American process automation market. Over the past five years, IMI has invested more than R$3.5 million (£464 100) in tools for Brazil alone, with more than R$116 million (£15 381 600) invested in suppliers.

Now with a new facility combining the company’s distribution, field service, and valve repair operations, IMI will be able to better deliver customised solutions – including QuickTrak Digital Valve Control System and Positioners – with shorter lead times and greater flexibility. For new and existing customers, this also means faster access to the technologies and support they need to succeed in increasingly competitive markets.

The future of pipeline control

The integration of the system into the Alaskan pipeline, alongside the company’s expanded presence in Brazil, reflects how the role of flow control in critical

infrastructure is being redefined. In the pipeline sector, where failures can quickly add up to millions of dollars in lost revenues and repair costs, the shift from reactive maintenance to proactive asset management is becoming increasingly essential.

IMI supports this transition by combining advanced control technologies with deep engineering expertise and a commitment to long-term service beyond project completion. This approach can help operators to best meet the core requirements of modern pipeline management, including improving safety, minimising downtime, and enhancing operational efficiency.

It is increasingly important that any organisation within process industry supply chains understands the pressures facing the sector and can deliver engineering solutions that provide measurable, lasting improvements. These include – but are not limited to – extending asset life, ensuring regulatory compliance, or optimising performance in demanding environments. If so, they are well-placed to help the industry further thrive.

Figure 3. QuickTrak pipeline monitor

Figure 2. The new facility in Brazil.