World Pipelines - February 2025 by PalladianPublications

C O NTENTS

03. Editor's comment

05. Pipeline news

Contract news and updates from Kinder Morgan, USDOT, Penspen and more.

KEYNOTE: DIGITALISATION

08. Securing the midstream Ian Bramson, Black & Veatch, outlines how to confront cybersecurity challenges in pipeline operations.

CONSTRUCTION

15. Navigating the African-Atlantic Gas Pipeline project Andreas Hausmann, ILF Consulting Engineers.

21. Pipeline construction: more complex than plant construction?

Dr Awadh O. Al-Oadah, Director Projects, Saudi Aramco.

FLOW: MEASUREMENT

25. Upgrading the UAE's pipeline management Marek Lukaszczyk, WEG.

28. Meeting methane regulations with leak detection Doug Baer, ABB.

INLINE INSPECTION Q&A

33. Inline inspection Q&A With responses from 3P Services, Onstream Pipeline Inspection, and NDT Global.

WELD INSPECTION TECHNOLOGY

39. The future of pipe spool welding Alexandre Nadeau, CEO, Tecnar, and Agha Umer, Head Quality-Welding Department, Bin Quraya.

43. Getting across advanced imaging Paul Hillman, Eddyfi Technologies, Canada.

REMOTE OPERATION

47. The need for remote monitoring technology Jamey Hilleary, Lindsay Corporation.

SYSTEMS AND SOFTWARE

51. Optimising burst pressure rates François Lachance, Creaform, Canada.

PIPELINE MACHINERY FOCUS

55. Pipeline machinery focus Featuring Pettibone, USA.

EDITOR’S COMMENT

CONTACT INFORMATION

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According to the latest ‘Energy Cyber Priority’ report from DNV Cyber, published in January, energy companies are increasingly recognising cybersecurity as a critical priority, with 65% of energy professionals identifying it as the greatest risk to their business. 1

The sector is boosting investment in cyber defences, with 71% of professionals expecting increased spending in this area. Notable progress includes stronger leadership awareness, enhanced employee training, and growing investment in operational technology (OT) cybersecurity, as the new digital technologies that underpin the energy transition also create new vulnerabilities.

The energy transition is broadening the industry’s exposure to cyber risks, with threats from state actors, cybercriminal gangs, and malicious insiders on the rise. Supply chains present a particular vulnerability, as many companies lack full visibility into the cybersecurity practices of their suppliers. Meanwhile, generative AI is enabling more sophisticated cyberattacks, prompting calls for greater innovation in training and skills development to counter evolving threats.

The report emphasises the need for the energy sector to double its cybersecurity efforts to safeguard physical infrastructure, secure supply chains, adapt to advanced threats, and leverage AI responsibly. Companies must prioritise OT security, enhance workforce skills, and innovate in training to remain resilient amidst growing geopolitical tensions and increasingly sophisticated adversaries.

In the keynote article for this issue of World Pipelines, Ian Bramson, Vice President of Global Industrial Cybersecurity, Black & Veatch, discusses how to confront cybersecurity challenges in pipeline operations (p.8). Ian outlines how “the midstream industry remains plagued by fragmented regulations, legacy systems and an expanding attack surface. With the increasing convergence of OT and information technology (IT) and the proliferation of new digital tools, operators face challenges that are technical, logistical and cultural.”

It’s worth highlighting the broader implications of failing to address cybersecurity threats to midstream assets. The potential for cyberattacks to cause physical harm to infrastructure, disrupt energy supplies, and endanger public safety underscores the urgency for action. The interconnectedness of the global energy sector means that a breach in one region could have ripple effects worldwide, and this makes clear the importance of collective effort. Governments and industry must work together not only to safeguard oil and gas supply, and the work of the energy transition, but also to build trust with stakeholders and the public. The most secure version of our future will heavily rely on collaboration, regulation, and innovation.

Read Black & Veatch’s article for an understanding of the types of threats facing the pipeline sector, and the ways in which they are evolving. The piece paints a vivid picture of the realities of safeguarding pipeline infrastructure in 2025: “This isn’t just bureaucratic box-checking. It’s a wake-up call for an industry increasingly in the crosshairs of sophisticated threat actors”.

1. https://www.dnv.com/cyber/insights/publications/energy-cyber-priority-2025/

SENIOR EDITOR Elizabeth Corner elizabeth.corner@palladianpublications.com

Still pioneers.

WORLD NEWS

Allseas announces completion of Southeast Gateway pipeline

Allseas has completed a 700 km 36 in. pipeline for the Southeast Gateway pipelines project in southeast Mexico for client TC Energy.

Allseas pipeline vessels, onshore and offshore teams delivered the pipeline in 11 months including nearshore scope and pre-commissioning. Solitaire laid most of the pipeline, with Lorelay and Tog Mor providing support. Pioneering Spirit installed the nearshore section at Coatzacoalcos, without a stinger. Instead, the hanging stinger transition frame served as a ‘mini’ stinger, a solution tailored to the shallow water depth.

Project Manager Johan Paauwe said: “Thanks to the great

collaboration between the Allseas and TC Energy teams, we successfully navigated this dynamic project. The trust placed in us by our client fuelled our drive to deliver this ambitious pipeline, and once again demonstrate Allseas’ leadership in delivering complex, large-scale infrastructure projects efficiently, on time, and on budget.”

“The Southeast Gateway Pipeline Project, with much credit due to the performance of the collective Allseas/TC Energy team, is a classic example of how large scale offshore pipelay ventures are delivered safely, environmentally compliant, and on plan”, said Mike Bagale, TC Energy’s VP of Mexico Projects.

Kinder Morgan announces acquisition of Bakken gas gathering, processing system from Outrigger Kinder Morgan, Inc. has announced that its subsidiary, Hiland Partners Holdings LLC, has agreed to purchase a natural gas gathering and processing system in North Dakota from Outrigger Energy II LLC for US$640 million.

The acquisition includes a 270 million ft3/d processing facility and a 104 mile, large-diameter, high-pressure rich gas gathering header pipeline with 350 million ft3/d of capacity connecting supplies from the Williston Basin area to highdemand markets. The gathering and processing system is backed by long-term contracts with commitments from

major customers in the basin.

“We’re pleased to be integrating this complementary system with our existing Hiland gas assets to aggregate additional supplies from the Bakken,” said KMI Natural Gas Midstream President Tom Dender. “This strategic acquisition allows us to efficiently expand our footprint and provide incremental transportation and processing services to meet the growing needs of our customers.”

The transaction requires clearance under Hart-ScottRodino and is expected to close in 1Q25.

USDOT proposes new rule to strengthen safety requirements for carbon dioxide pipelines

The US Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (PHMSA) has announced new comprehensive proposed requirements for carbon dioxide (CO2) and hazardous liquid pipelines.

The Notice of Proposed Rulemaking (NPRM) will strengthen existing standards for hazardous liquid and CO2 pipelines (including CO2 that is transported in a supercritical fluid state), and for the first-time, establish new standards for transporting carbon dioxide in a gaseous state via pipeline. The proposal also specifically addresses lessons learned from PHMSA’s multi-year investigation into a CO2 pipeline failure in Satartia, Mississippi, in 2020 as well as input from the public in what has been PHMSA’s largest public outreach campaign on record.

“America is leading the way in the race to safely capture, transport, and store carbon dioxide underground, with all of the associated economic and environmental benefits,” said former US Transportation Secretary Pete Buttigieg. “As this technology grows rapidly across the country, we are proud to propose comprehensive new rules to ensure that carbon dioxide pipelines are safe.”

“I have learned first-hand from affected communities in Mississippi and across America why we need stronger CO2 pipeline safety standards,” said PHMSA Deputy Administrator Tristan Brown. “These new requirements will be the strongest, most comprehensive standards for carbon dioxide transportation in the world and will set our nation on a safer path as we continue to address climate challenges.”

This NPRM responds to a significant anticipated need corresponding with expansion of carbon capture and storage (CCS) infrastructure resulting from billions of dollars in new incentives in former President Biden’s Bipartisan Infrastructure Law and Inflation Reduction Act.

If adopted as-is, the rule would establish a set of new requirements, including:

) Establishing for the first-time design, installation, operation, maintenance, and reporting requirements for carbon dioxide gas pipelines.

) Establishing new requirements that pipeline operators must adhere to when converting existing pipelines to transport carbon dioxide in different phases.

) Requiring all carbon dioxide pipeline operators to provide training to emergency responders and ensure carbon dioxide detection and other equipment is available for local first responders to use and efficiently respond during an emergency.

) Implementing more robust requirements for communicating with the public during an emergency.

) Requiring more detailed vapour dispersion analyses to better protect the public and the environment in the case of pipeline failure.

The Department of Energy has forecasted a significant expansion of the US carbon dioxide pipeline network as part of a new global effort to capture and sequester excess heattrapping carbon dioxide pollution.

5 - 9 February 2025

CONTRACT NEWS

TAP selects Penspen for hydrogen repurposing assessment

77th Annual PLCA Convention 2025 Marco Island, Florida, USA

https://www.plca.org/annual-convention-events

11 - 13 February 2025

AMI Pipeline Coating 2025 Vienna, Austria

https://www.ami-events.com/event/c52c6186cbe4-4db1-b7bf-35e6f2e28614

6 - 10 April 2025

AMPP 2025

Nashville, USA

https://ace.ampp.org/home

5 - 8 May 2025

20th Pipeline Technology Conference

Berlin, Germany

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

5 - 8 May 2025

Offshore Technology Conference 2025 Houston, USA

https://2025.otcnet.org/

19 - 23 May 2025

29th World Gas Conference (WGC2025) Beijing, China

https://www.wgc2025.com/eng/home

25 - 29 May 2025

Annual Pipe Line Contractors Association of Canada (PLCAC) Convention Banff, Canada

https://pipeline.ca/

10 - 12 June 2025

Global Energy Show 2025

Calgary, Canada

https://www.globalenergyshow.com/

Penspen has been awarded a contract by Trans Adriatic Pipeline AG (TAP) to provide hydrogen gap analysis services on one of the most strategic energy infrastructure projects in Europe.

Under the contract, Penspen’s UK-based engineering team will perform a comprehensive desktop and field assessment review of TAP’s above ground installations (AGIs), block valves (BVs) and compressor stations (CSs) to assess the feasibility of introducing hydrogen blends to the existing gas pipeline, supporting TAP’s strategy of capacity expansion for new volumes of hydrogen and other renewable gases to foster long-term sustainability and decarbonisation in the region.

The 877 km TAP natural gas pipeline connects to the Trans Anatolian Pipeline (TANAP) at the Greek-Turkish border,

Perma-Pipe secures Middle East contract

Perma-Pipe International Holdings, Inc. has announced it has received a formal letter of award for a development project located in the GCC region. Perma-Pipe will provide thermal insulation, anti-corrosion coatings, and other services from its Abu Dhabi facility. Project commencement is expected to begin in the third quarter of 2025. The value of this project is estimated to exceed US$43 million.

This project will utilise Perma-Pipe’s anticorrosion coatings capabilities, fabrication, and the TRACE-THERM® insulation system, a spray-applied polyurethane foam jacketed with a high-density polyethylene casing.

Saleh Sagr, Sr. Vice President for Perma-Pipe’s MENA region, commented, “This award follows the successful execution of numerous development projects in the region. Our differentiated coating solutions have proven to be well-suited for technically challenging projects. We would like to thank our customers for this significant award.”

David Mansfield, President and CEO, commented, “This award provides evidence that our technologies are well-positioned to meet the complex requirements in virtually all geographies as we continue our focus on highly active oil & gas markets worldwide. This project continues an increase in large-scale project activity we are seeing globally and, when coupled with other recently announced project awards, further strengthens our record backlog position heading into 2025.”

crossing Albania and the Adriatic Sea to connect to the gas network in southern Italy. Operational since the end of 2020, TAP is a key part of the Southern Gas Corridor and plays a significant role in boosting Europe’s energy security and supply diversification.

Darren Bartlett, Energy Transition Director at Penspen, commented: “Using our considerable in-house infrastructure repurposing experience, Penspen supports energy operators worldwide by enhancing access to lower-carbon fuels. By assessing the suitability of existing infrastructure, like the TAP pipeline, for hydrogen blends, we continue to support the delivery of cleaner energy to the communities we work in.”

The contract from TAP is the latest in a string of hydrogen services awards for the company in the UK and Europe.

ON OUR WEBSITE

• Reuters: Enbridge defeats lawsuit over crude oil transport

• Mayer Brown advises Chevron on US$3 billion Argentina oil pipeline

• Wabtec to acquire Evident’s Inspection Technologies division

• Howard Energy Partners acquires ethylene pipeline from EPIC Midstream Holdings

• Phillips 66 to grow Permian midstream business with EPIC NGL acquisition

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Ian Bramson, Vice President of Global Industrial Cybersecurity, Black & Veatch, explores ways to confront cybersecurity challenges in pipeline operations.

il pipelines are a prime target for cyberattacks, with vulnerabilities that threaten not only operational integrity but also national security, economic stability and environmental safety.

Despite growing awareness of these threats, the midstream industry remains plagued by fragmented regulations, legacy systems and an expanding attack surface. With the increasing convergence of operational technology (OT) and information technology (IT) and the proliferation of new digital tools, operators face challenges that are technical, logistical and cultural.

The question isn’t whether pipeline systems will be attacked, but whether the sector is adequately prepared to defend against and recover from those attacks.

The state of cybersecurity in midstream operations

When assessing the cybersecurity posture of midstream operators, the picture is decidedly mixed. The companies responsible for transporting oil and gas range from large multinationals with vast resources to small, budget-constrained operators.

As a result, the sector’s security practices vary widely, creating a patchwork of strengths and vulnerabilities.

While high-profile incidents like the Colonial Pipeline attack of 2021 have shone a spotlight on the risks, progress across the industry has been uneven. The incident, which disrupted fuel supplies across the US East Coast for days, demonstrated just how exposed midstream systems are. It also revealed the catastrophic ripple effects that can occur when these systems are compromised.

Yet, even as the attack prompted governmental agencies like the Transportation Security Administration (TSA) to issue directives for pipeline security, the lack of a unified regulatory framework has left many operators to fend for themselves.

Unlike the power grid, which is governed by the NERC Critical Infrastructure Protection (CIP) standards, pipelines fall under TSA jurisdiction, where guidelines lack enforceable teeth. While TSA’s directives encourage operators to address vulnerabilities, the absence of rigorous compliance requirements means that implementation is inconsistent.

Adding to the challenge is the sector’s resistance to more stringent oversight. Many operators prefer voluntary measures to avoid the costs and operational disruptions that more prescriptive regulations might entail. This dynamic leaves the sector vulnerable to evolving threats, even as attacks grow more sophisticated and damaging.

A sector under siege

The cyber threats facing midstream operators have evolved from nuisance-level incidents to attacks capable of inflicting widespread economic and societal harm. What was once a primarily IT-focused issue has expanded into a crisis encompassing both IT and OT domains.

Ransomware attacks continue to dominate the threat landscape. The Colonial Pipeline attack was a reminder of the sector’s vulnerability to such campaigns, where attackers encrypt critical IT systems and demand payment for their release. While the attack did not directly target the pipeline’s OT systems, the operational shutdown that followed highlighted the interconnectedness – and fragility – of midstream operations.

Beyond ransomware, advanced persistent threats orchestrated by nation-states represent an even more insidious risk. These sophisticated attacks often infiltrate OT systems, where they gather intelligence or manipulate processes over long periods without detection. The consequences of such breaches can be catastrophic, ranging from pipeline failures to large-scale environmental disasters.

Insider threats, whether intentional sabotage or unintentional errors, add another layer of complexity. A careless click on a phishing email or a failure to follow proper security protocols can expose critical systems to attackers. This risk is compounded by the industry’s reliance on third-party vendors, whose own vulnerabilities can become entry points for cyber adversaries.

The sector’s increasing reliance on IIoT devices, remote sensors and automation has also broadened the attack surface. While these technologies enhance operational efficiency and visibility, they often lack robust security measures, making them an attractive target for attackers seeking to exploit weak points.

Challenges unique to midstream operations

What sets the midstream sector apart from other parts of the energy industry is its operational complexity. The nature of pipeline operations introduces cybersecurity challenges that are distinct and difficult to overcome.

One of the most significant challenges is the sector’s vast geographic footprint. Pipelines stretch across thousands of miles, often traversing state and national borders. This sprawling infrastructure creates an expansive attack surface that is difficult to monitor and secure comprehensively. Securing a pipeline is not like securing a refinery; we’re not just talking about a single location. You’re dealing with remote assets spread across entire regions.

Adding to this complexity is the prevalence of ageing infrastructure and legacy systems.

Many pipeline systems were designed decades ago, long before cybersecurity was a concern. These older systems often lack the computational capacity to support modern security tools, making retrofits expensive and technically challenging.

The convergence of IT and OT systems further complicates matters. IT systems like billing and scheduling are now increasingly integrated with OT systems that control the physical operations of pipelines. While this integration offers efficiency gains, it also creates new vulnerabilities. A breach in an IT system can cascade into the OT environment, disrupting operations and potentially causing physical harm.

Applying lessons learned

All this underscores the need for a more proactive and consequence-driven approach to cybersecurity in the midstream sector. Operators cannot afford to wait for the next crisis to act.

One critical lesson is the importance of prioritising high-impact assets. Instead of trying to secure every component equally, operators should focus on systems and assets that, if compromised, would have the greatest impact on safety, uptime and revenue. This approach requires detailed risk assessments and a deep understanding of operational interdependencies.

Another lesson is the value of early detection and rapid response. Many attacks succeed because anomalies –such as failed commands or unauthorised access attempts – are not recognised or addressed in time. Implementing real-time monitoring systems and investing in advanced analytics tools can help operators detect and respond to threats before they escalate.

Collaboration is also essential. The midstream sector involves multiple stakeholders, including operators,

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regulators and third-party vendors. Effective cybersecurity depends on close communication and shared intelligence among these parties. The seams in this system – whether between companies, states, or nations – are where attackers are most likely to strike.

Securing the future: strategies for resilience

If it’s going to strengthen its defences, the midstream sector must embrace a multi-faceted approach to cybersecurity that combines technology, governance and culture.

First, operators must improve visibility and monitoring. Real-time data collection and analytics tools, powered by artificial intelligence and machine learning, can help identify anomalies across IT and OT systems. These tools not only enhance threat detection but also support better decisionmaking during incidents.

Next, segmentation between IT and OT systems is critical. By maintaining clear boundaries between these environments, operators can prevent breaches in one domain from spreading to the other. At the same time, robust communication protocols must ensure that operational efficiency is not compromised.

Addressing the challenge of legacy infrastructure requires targeted investments. While wholesale replacement of ageing systems may be impractical, incremental upgrades – such as adding intrusion detection systems, secure communication protocols and firewalls – can significantly reduce risk.

Finally, operators must manage third-party risks. This includes conducting regular audits of vendors, ensuring compliance with stringent security requirements, and monitoring for vulnerabilities in equipment and software provided by third parties.

Cultivating a cybersecurity culture

But technology alone is not enough to secure midstream operations; a cultural shift is also required. Employees at all levels, from executives to frontline workers, must understand the role they play in maintaining cybersecurity.

Training programmes tailored to pipeline operations are essential. Workers must be equipped to recognise threats such as phishing attempts and follow secure protocols for accessing systems.

Meanwhile, leadership must demonstrate a commitment to cybersecurity by integrating it into organisational priorities and decision-making processes.

The road ahead

The midstream sector stands at a pivotal moment. As threats grow more sophisticated and the stakes get higher than ever, operators have no choice but to accelerate their efforts to secure critical infrastructure. The path forward requires not just technological upgrades but also regulatory clarity, collaborative partnerships and a commitment to fostering a cybersecurity-aware workforce.

The industry is also going to face outside pressure to speed things up.

The TSA recently unveiled a sweeping proposal to tighten cybersecurity standards across pipelines and

other public transportation systems. Building on the cybersecurity frameworks crafted by the National Institute of Standards and Technology (NIST) and the Cybersecurity and Infrastructure Security Agency (CISA), the proposed regulations aim to fortify critical infrastructure against a rising tide of cyber threats.

If enacted, these rules would require transportation operators to develop comprehensive cyber-risk management programmes, report cyber incidents to CISA and appoint a physical security coordinator tasked with addressing security concerns. The approach leans heavily on proactive measures, mandating annual cybersecurity assessments, systematic identification of vulnerabilities, and operational plans identifying officials in charge of cyberattacks and detailing how to protect critical systems, detect cyberattacks and recover from incidents.

This isn’t just bureaucratic box-checking. It’s a wake-up call for an industry increasingly in the crosshairs of sophisticated threat actors. Pipelines form the lifeblood of the nation’s economy, and their interconnected networks make them especially vulnerable. The proposed regulations recognise this reality, aiming to drive accountability while offering a framework to strengthen resilience.

Ultimately, the initiative underscores a simple but critical truth: in an era where digital threats can disrupt entire supply chains, safeguarding vital infrastructure isn’t optional – it’s existential.

For operators, this presents an opportunity to build cyber defences that match the stakes. Whether they seize it is the question that remains. Midstream operators are the gold standard of targets. It’s time they became the gold standard of cybersecurity.

For updates and breaking news on cyber security for pipeline assets, visit www.worldpipelines.com

) Global Risks Report 2025: top threats are conflict, environment and disinformation

) DNV Cyber research reveals energy companies boosting investment in cybersecurity arms race, to manage the ‘greatest risk’ to the industry today

) Cybersecurity threats in the pipeline industry: strategies for protection and mitigation

) GlobalData: cyberattacks a growing threat for oil and gas

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Andreas Hausmann, ILF Consulting Engineers, outlines the details of the African-Atlantic Gas Pipeline project, one of the most ambitious and transformative infrastructure projects in Africa.

y completing the FEED Phase II in May 2024, the project sponsors, Nigerian National Petroleum Company Ltd (NNPC) of Nigeria and Office National des Hydrocarbures et des Mines (ONHYM) of Morocco, as well as other stakeholders, including the Economic Community of West African States (ECOWAS), National Oil Companies (NOCs) of

ECOWAS member countries, and SMH (Société Mauritanienne des Hydrocarbures) of Mauritania, made a tremendous step forward in the development of this strategic mega-project, the African-Atlantic Gas Pipeline (AAGP), also known as the NigeriaMorocco Gas Pipeline (NMGP).

This project is one of the most ambitious and transformative infrastructure projects in Africa, with the potential to reshape the continent’s energy landscape.

It falls in line with the “Decade of Gas Master Plan” that the former Nigeria’s President Muhammadu Buhari launched in 2020. On the Moroccan side, this landmark project is part of the South-South cooperation upheld by King Mohammed VI. In 2024, His Royal Majesty King Mohammed VI of Morocco and His Excellency, Nigeria’s President Bola Ahmed Tinubu reiterated their commitment for the actualisation of the project, with the support of ECOWAS, its member countries and Mauritania.

The AAGP project, an onshore/offshore gas pipeline crossing the land/waters of 16 countries, shall bring Nigerian, Mauritanian, and Senegalese gas to the West and North African markets and also extend to the European market via Spain.

By traversing 16 countries, the pipeline shall not only supply the local markets with a sustainable and reliable source of energy, it will also support industrial and economic development and create a competitive regional power market.

This is particularly important in a region where energy access remains a significant challenge, hindering growth and development.

The pipeline will provide a new avenue for the countries along the route to export/import gas to/from their neighbouring countries and Europe.

The objectives in detail:

) Electrification and energy self-sufficiency in the region.

) Improved living conditions of neighbouring populations.

) Boost regional economy, develop industry, and create jobs and wealth.

) Economic integration of countries crossed.

) Unlock Africa’s vast untapped natural resources.

) Reduction of gas-flaring and use of reliable and sustainable energy.

) Energy security and autonomy for underserved West African nations.

Potential gains from the project

Significant new hydrocarbon accumulations of natural gas were discovered offshore Mauritania and Senegal in 2015. Nigeria, an OPEC member, has the largest gas reserves in Africa and the seventh-largest in the world.

Morocco stands to gain immensely from the pipeline. By securing a steady supply of natural gas, Morocco can reduce its energy imports, lower costs, and support its ambitious renewable energy goals. Moreover, the pipeline will position Morocco as a key energy hub between Africa and Europe, enhancing its strategic importance on the global stage.

The project also enhances Africa’s role in the global energy market. By connecting African gas resources directly to Europe, the AAGP offers an alternative to Russian gas, which has dominated the European market for decades. This diversification of supply is particularly relevant in the context of the ongoing energy transition and the European Union’s efforts to reduce its reliance on fossil fuels from politically unstable regions.

This pipeline will become a symbol of pan-African cooperation, economic development, and geopolitical strategy.

Seen from today’s perspective, this more than 6000 km long gas pipeline, when completed, will be the longest offshore pipeline in the world and the second longest pipeline over all.

Figure 1. Project map.

Expect A Higher Standard

Project specifics

The pipeline starts at Brass Island in Nigeria, goes offshore from Nigeria to Southern Morocco with intermittent onshore returns for compression and offtake in Ghana, Cote d’Ivoire, Liberia, Guinea, Senegal and Mauritania. It proceeds to onshore Morocco with several compressor stations and offtake points and finally connects to the existing MaghrebEurope Pipeline, also known as Gazoduc Maghreb Europe (GME), close to the Strait of Gibraltar, where it extends to its end point in Spain.

Landfalls in Ghana and Nigeria have been located to best synergise with the existing West African Gas Pipeline (WAGP) for gas injection so that AAGP gas can be accessed by WAGP offtakers in Ghana, Togo and Benin.

Land-locked ECOWAS countries of Burkina Faso, Mali and Niger will be fed from the AAGP by onshore spur lines. Coastal ECOWAS countries without compressor stations, like Sierra-Leone, the Gambia and Guinea-Bissau will be connected to the AAGP by offshore spur lines and standalone offtake facilities.

Intakes to the AAGP may be provided in Nigeria, Mauritania and Senegal for gas coming from the following sources: Brass Island (including Escravos/Badagry), Nigeria; Yakaar-Teranga, Senegal; Greater Tortue Ahmeyim, Senegal/ Mauritania; and Bir Allah, Mauritania.

The technical details of the AAGP project are as follows:

) Pipeline length: 5110 km offshore, 1830 km onshore.

) Diameter: 32 - 46 in. offshore; 48 in. onshore.

) Pressure class: 1500 lb offshore, 600 lb onshore.

) Throughput (Design): 15 billion m3/y (initial), 30 billion m3/y (final).

) Number of compressor stations: 12 (+5).

) Number of receiving stations: 2.

) Number of (standalone) offtake stations: 6.

) Number of (standalone) intake stations: 1.

) Number of block valve stations: 61.

The locations of the above ground installations (AGIs) have prudently been chosen not only out of flow assurance reasons but also by considering potential gas intakes and offtakes and the vicinity to large cities.

The design of the AGIs has consistently been following the approach ‘design one – build many’. For that a standardised, repeatable concept broke the design down into standard blocks, like: pigging, compression, metering, gas offtake, gas intake, and utilities.

These blocks allowed for addition/deletion from the particular stations as required. Design capacities of the AGIs are as follows:

) Design life: 40 years.

) 1500 lb rated compressor station.

) Compressor station design capacity: 30 billion m3/y.

) 48 in. inlet and 48 in. outlet.

) Gas intake area design capacity: 10 billion m3/y.

) Gas offtake area design capacity: 5 billion m3/y.

) Standalone gas intake station design capacity: 10 billion m3/y.

) Typical block valve station rated at 600 lb with design capacity of 30 billion m3/y.

Offshore pipeline design

The following parameters were used for the offshore pipeline design:

) Standard: DNV-ST-F101.

) Design life: 40 years.

) Design pressure: 220 bara.

) Design flowrate: max. 30 billion m3/y, varying per section.

) Material specification grade: DNVGL 450.

) External coating: 3LPE.

) Internal coating: high solid liquid epoxy coating (solvent-free).

) Thickness of concrete weight coating: 50 - 95 mm.

) Cathodic protection: sacrificial anodes (offshore), impressed current (shore/onshore).

Preliminary flow assurance calculations determined the approximate distance between offshore compressor stations and the design pressure.

The offshore routing sections were developed by considering constraints such as environmentally protected areas, existing infrastructure (pipelines, cables, platforms, etc), fishing areas, ammunition dumping grounds, exploration areas, local bathymetry (e.g. canyons), etc.

Onshore pipeline design

The following parameters were used for the onshore pipeline design:

) Design life: 40 years.

) OD - nominal pipe size: 48 in. (1219 mm).

Figure 2. Simplified offshore pressure profile phase 4.

Dairyland’s PCRX is a solid-state, maintenance-free device designed to simultaneously provide DC decoupling and AC continuity/grounding when used with cathodically protected structures. Unlike traditional decouplers, PCRX’s capacitance compensation technology renders it virtually invisible to interrupted survey testing, making it easier than ever for you to protect and maintain your CP system. Commonly used to decouple electrical equipment from grounding systems, for AC mitigation projects, or other isolation and grounding applications, the PCRX is the most sophisticated decoupler in the world.

Scan to watch a short video. For more product information, visit Dairyland.com / PCRX

) Maximum design temperature (°C): 75.

) Minimum design temperature (°C): -10.

) Design pressure (barg): 103.

) Maximum allowable operating pressure (barg): 93.

) Material specification grade: API 5L X70 PSL 2.

) Specified minimum yield Strength (MPa): 485.

) Cathodic protection: impressed current.

The onshore pipeline sizing has been based on a preliminary steady state flow assurance calculation. The onshore routing sections were developed by considering existing infrastructure corridors, use of relatively flat terrain/avoidance of steps, optimum number of crossings, avoidance of populated areas, avoidance of environmentally sensitive areas, consideration of other projects/developments in the area. The onshore route is crossing the Atlas mountains, and the route selection was challenging in that region.

Construction phases

The project construction has been segregated into the following phases:

) Phase 1A: Installation of AAGP Takoradi to San Pedro segment; with the main objective to bring gas from the WAGP to Côte d’Ivoire.

) Phase 1B: Installation of AAGP Dakar to GME (North of Morocco) segment; the main objective is to connect sources of gas in Mauritania and Senegal to Morocco/ Spain.

) Phase 2: Installation of AAGP Brass Island to Takoradi segment; the main objective is to increase the gas supply from Nigeria to Ghana and Côte d’Ivoire.

) Phase 3: Installation of AAGP San Pedro to Dakar segment; main objective is to complete the AAGP, deliver gas to all intermediate consumers, increase the export to Morocco and Spain/Europe with gas from Nigeria.

) Phase 4: Upgrade of the capacity in case of business needs (adding compressors and intermediate compressor stations).

Contracts

For the contracting strategy, multiple drivers have been taken into account, including: project structure, CAPEX distribution, project schedule, main project risks/ opportunities, market environment/feedback, contractors core competence, logistics and financial considerations, and potential commercial opportunities.

Focus has finally been laid on traditional lump sum turnkey EPC contracts. The chosen contracting strategy has been based on: regional PMCs, line pipe supply, marshalling yard/concrete weight coating, EPC for offshore and/or onshore pipeline, and EPC for AGIs.

The project implementation will require several Financial Investment Decisions (FIDs) for a first gas of the first phases by 2029. Total estimated CAPEX of this project are in the range around US$25 billion.

Conclusion

The African-Atlantic Gas Pipeline is a landmark project with the potential to transform Africa’s energy sector and enhance the continent’s role in the global energy market. By fostering economic growth, promoting regional integration, and providing an alternative energy supply to Europe, the AAGP will have far-reaching impacts that extend well beyond the immediate regions it serves.

ILF Consulting Engineers (ILF) with its office in Munich, Germany, together with its Joint Venture partner DORIS Engineering (DORIS) located in Paris, France, were commissioned to carry out the Project Management Consultancy (PMC) services for the FEED Phase II of this project, including the quality management, project control, design vetting and CAPEX/OPEX review, which will support ONHYM & NNPC in the delivery of this strategically important project.

The overall project services managed by ILF and DORIS comprise the onshore and offshore pipeline and above ground installations (AGIs), the engineering surveys, the environmental and social impact assessment (ESIA), the land acquisition studies (LAS), and the project implementation framework.

The Joint Venture excelled in supporting ONHYM & NNPC in the delivery of this strategically important project by combining the expertise of ILF and DORIS in their special fields of competence.

Figure 3. Simplified onshore pressure profile phase 3.

Dr. Awadh O. Al-Oadah, Director Projects, Saudi Aramco questions the assumption in the construction industry that plant construction is more complex than pipeline construction, detailing how demands on scale, logistics, and compliance complicate the picture.

n the construction industry, infrastructure development encompasses two critical domains: pipelines and plants, where no two projects are identical. However, pipeline construction is often misunderstood as being less complex than plant construction, primarily due to its linear design and seemingly repetitive process. However, a deeper analysis reveals that cross-country pipeline construction involves a multifaceted set of challenges that surpass those encountered in plant construction in many ways.

This article aims to dispel the misconception that pipeline construction is straightforward and highlights the technical, environmental, and geopolitical complexities that make it a uniquely demanding endeavor. It also examines how advanced technologies are leveraged to overcome these challenges, ensuring the safety, efficiency, and sustainability of pipeline projects.

Unmatched scope and scale

Pipeline construction projects span vast distances, often traversing hundreds or even thousands of miles or kilometres. These projects must adapt to varying terrains and climates, requiring meticulous planning and coordination. Whether pipelines cross deserts, mountains, forests, or urban landscapes, they demand a comprehensive understanding of geographic, environmental, and logistical factors to ensure seamless execution.

Unlike plant construction, which is confined to a single location and involves developing facilities within predefined boundaries, pipelines must navigate through diverse terrains and environments. This expansive scope brings about numerous logistical challenges, from transporting materials to coordinating teams over long distances. Each kilometre introduces new challenges, requiring complex planning and execution. The controlled environment of greenfield plant projects can simplify and help in managing the logistics and reduce unexpected challenges. This fundamental difference in scale underscores the complexities unique to pipeline construction, where each segment presents distinct technical and logistical hurdles.

) Variable terrain: pipelines traverse mountains, deserts, forests, rivers, and urban areas, each demanding different construction techniques, equipment, and environmental measures. This dynamic nature complicates engineering and construction compared to a plant’s static location.

) Route optimisation: unlike a plant with a defined boundary, selecting a pipeline route involves balancing environmental conservation, land acquisition disputes, and geopolitical considerations, often leading to extensive feasibility studies and negotiations.

This scale and variability present unique challenges that are rarely encountered in plant construction, which benefits from a defined and controlled location.

Technical complexity

Pipeline construction involves unique technical challenges that surpass those encountered in plant construction:

) Dynamic forces and durability requirements:

• Pipelines are exposed to dynamic forces such as soil erosion, seismic activity, and temperature variations, necessitating complex engineering to ensure long-term stability.

• Corrosion-resistant materials and advanced coatings are essential, significantly increasing the technical requirements compared to plants.

) Construction techniques and logistics:

• Cross-country pipelines require specialised machinery, such as horizontal directional drilling (HDD) for major and long crossings and automated welding systems for largescale pipe joining.

• The logistics of coordinating construction across vast, remote regions often involve deploying teams and resources to isolated and remote locations, a challenge not typically faced by plant construction.

While plant construction demands precision and sophisticated technology, it typically operates within a controlled environment, offering more predictability in logistics and engineering execution.

Nature of construction

The nature of construction for pipelines is fundamentally different from that of plants. It requires adaptability to local conditions, and involves extensive trenching, welding, and laying of pipes over varying terrains. Each segment of the pipeline requires precise engineering to accommodate the specific geographical and geological conditions. Weather conditions can also play a significant role, with adverse weather potentially causing delays and requiring adaptive construction methods.

For instance, desert pipelines must contend with extreme heat and shifting sands, necessitating specialised coatings and trench stabilisation techniques. In cold climates, pipelines are designed with insulation to prevent permafrost thawing, which could destabilise the ground. Urban pipelines face unique challenges as they must navigate dense and existing pipelines and utility networks, roads, and populated areas, often relying on technologies like Ground Penetrating Radar (GPR) and HDD.

Plant construction, by contrast, typically takes place on greenfield sites with controlled conditions that provide a clean slate for development. Although plant projects involve significant equipment integration and engineering, they benefit from a more predictable and controlled construction environment compared to the diverse and often unpredictable conditions faced by pipeline projects.

Logistics and accessibility

Unlike building a plant involving a single, accessible and fenced site, logistical challenges in pipeline construction are amplified by the remote and diverse terrains encountered. Pipeline projects must deal with remote and often inaccessible terrains. From mountains to rocky, sandy and wet area, every obstacle requires specialised equipment and techniques, significantly increasing the logistical complexity.

Pipeline construction in regions characterised by deserts and rocky terrains demands a segmented approach, where each segment must adapt to the specific geographical and environmental challenges it encounters. Unlike plants, which are built on cleared and levelled land, pipelines must be laid across varied terrains, from shifting sand dunes to hard rocky outcrops. In arid areas, the loose sand requires specialised trenching techniques to stabilise the pipeline. Techniques such as geotextiles and trench barriers are often deployed to prevent sand erosion around the pipeline. Rocky terrains, common in mountainous regions, require blasting and drilling to create trenches, while ensuring minimal disruption to the surrounding environment.

To address these challenges related to pipeline construction, modern technologies like drones and geographic information

systems (GIS) are used for route planning and real-time monitoring. These tools enhance efficiency and enable project teams to adapt quickly to unforeseen obstacles, ensuring timely delivery and resource allocation.

Environmental impact

One of the most significant differences between plant construction and pipeline projects is the environmental impact. Pipelines cross various ecosystems, each requiring thorough environmental assessments and mitigation strategies. The need to protect natural resources adds layers of complexity to the planning and execution phases.

Environmental considerations are a critical aspect of pipeline construction, particularly in sensitive ecosystems. Wetlands often require elevated pipelines to maintain natural water flow, while forested areas demand selective clearing and reforestation to minimise environmental impact. Long-term monitoring is essential to ensure pipelines do not disrupt local habitats or water supplies.

Risk analysis and compliance

A comprehensive risk analysis must be conducted to identify and mitigate potential pipeline construction related issues, which is often more complicated than the risks faced during plant construction.

Ensuring safety during pipeline construction involves addressing risks unique to remote and harsh environments. Extreme temperatures and sandstorms pose challenges to

worker safety and equipment durability. Personal protective equipment and cooling systems are essential to maintain safe working conditions.

Surveillance cameras play a crucial role in monitoring safety and construction activities, ensuring compliance with safety protocols, and identifying potential hazards. Advanced systems equipped with AI and IoT capabilities provide real-time insights, enabling swift responses to emergencies. Wearable technologies are increasingly used to monitor worker health and safety, particularly in extreme environments. By integrating these technologies, pipeline construction projects can achieve higher safety standards while maintaining effective project delivery and efficiency.

Summary

Pipeline construction is a complex and dynamic process that demands a combination of engineering expertise, innovative technologies, and environmental stewardship. Unlike plant construction, which typically occurs in controlled environments, pipeline construction spans vast and often unpredictable terrains, requiring multidisciplinary skills, robust planning, adaptive construction techniques, and advanced tools to address inherent challenges and ensure successful execution.

Recognising and addressing these complexities is essential for effective project management, leading to improved outcomes, sustainable practices, and higher industry standards. By better preparing and allocating resources, the industry can achieve more efficient and sustainable pipeline development.

Marek Lukaszczyk, WEG, discusses how advanced motor technologies and variable speed drives (VSDs) are enhancing efficiency, reducing costs and improving sustainability in energy-intensive infrastructure projects.

lobal energy demand is projected to grow at 1.3% annually by 2030, according to Deloitte’s 2025 Oil and Gas Industry Outlook, prompting increased investments in low-carbon technologies. As the sector grows, challenges like pipeline integrity, flow reliability and environmental risks remain.

In the fast-paced energy sector, ensuring the seamless operation of pipelines and flow systems is critical to maintaining efficiency and sustainability. Deloitte reports that, “Some companies are engaging in increased investments in lowcarbon technology projects to help balance the risks associated with the traditional oil and gas market. These investments will likely help companies position themselves as key players in the future energy landscape.”

Nevertheless, these investments must offset the challenges of managing pipelines – whether for oil, gas, or water injection systems – that are growing more complex. Chief among these challenges is ensuring the continuous and safe operation of equipment under extreme environmental conditions, in addition to maintaining optimal flow rates and reducing energy consumption while increasing operational efficiency.

Older technologies are energy-hungry

In pipeline systems, energy efficiency is a critical concern, particularly for water injection systems in oilfields. Water injection, essential for pressure maintenance and boosting oil production, is highly energy-intensive. According to the International Energy Agency (IEA), water injection systems can account for up to 30% of total energy consumption in upstream oil and gas operations.

This challenge is exacerbated by the increasing need to enhance productivity while reducing environmental footprints. Traditional water injection systems, often relying on older, inefficient

technologies, are ill-suited to meet the demands of modern energy infrastructure. Consequently, industries are seeking more energy-efficient solutions that lower operational costs while improving performance.

At the same time, pipeline operators must manage harsh conditions, such as extreme heat, humidity and the need for explosion-proof solutions in hazardous zones. These environments demand equipment that is both durable and reliable, capable of functioning effectively despite fluctuating temperatures and corrosive elements. This complexity not only drives up operational costs but also heightens the need for stringent safety standards to ensure the longevity of infrastructure and protect personnel.

The energy sector is under increasing pressure to reduce its environmental impact. As Deloitte reports, “Oil and gas companies are focusing on increasing operational efficiency and maintaining safe, reliable operations while navigating growing environmental and regulatory pressures.” Investments in new technologies must not only enhance performance but also align with global sustainability goals, such as the United Nations’ Sustainable Development Goal 7, which aims to ensure access to affordable, reliable, sustainable, and modern energy for all, and the IEA’s target of net-zero emissions by 2050.

Sustainable practices – such as transitioning to renewable energy and integrating smart technologies into energy systems – are no longer optional; they are essential for maintaining a competitive edge.

Fortunately, WEG’s integrated drive solutions play a key role in boosting sustainability by reducing energy waste. Through the use of high-efficiency motors and VSDs, WEG optimises power consumption and minimises operational costs. By enhancing system performance and implementing energy-efficient technologies, WEG’s VSDs and high-efficiency motors significantly reduce energy consumption in demanding pipeline systems, directly contributing to both cost savings and sustainability.

Better control over energy consumption

To address these barriers, industry is increasingly turning to technology that improves efficiency and safety. One such solution is the integration of VSDs, which allow for better control over energy consumption by adjusting motor speed to match operational demand. By integrating VSDs, the energy usage can be optimised to only what is necessary at any given time, reducing waste and increasing overall energy efficiency.

Additionally, advancements in motor technologies, such as WEG’s W22Xdb explosion-proof motors and the high-efficiency WEG W22 motor series, help ensure that equipment can withstand the extreme environments of oilfields and marine applications. With greater attention paid to energy efficiency, motors now deliver higher outputs with reduced energy input, helping companies address their energy consumption challenges while ensuring high reliability. These motor solutions are designed to work seamlessly in industries that rely heavily on high-volume, continuous processes –such as those in the oil, gas and water treatment sectors.

There is also a strong focus on smart infrastructure. For example, the incorporation of remote operation technologies enables operators to monitor systems from afar, ensuring the continuous flow of oil and gas while minimising downtime. Digital technologies such as predictive maintenance systems and remote diagnostics help identify potential issues before they escalate, reducing unplanned

Figure 2. WEG’s W51Xdb is a compact, flameproof motor with the highest power density in its class, boosting pipeline efficiency and safety in explosive environments.

Figure 1. In the United Arab Emirates (UAE)’s oil and gas sector, WEG’s motor technologies help reduce energy consumption and enhance the sustainability of critical pipeline systems.

maintenance and enhancing the lifetime of critical assets. However, achieving the right balance of energy efficiency, safety and operational effectiveness in critical systems remains a key challenge.

Peak efficiency under intense desert heat WEG is at the forefront of providing solutions that address these complex challenges, particularly in the UAE’s key energy infrastructure projects. A notable example is WEG’s involvement in a US$2.4 billion water injection project designed to increase oil production while reducing energy consumption. The project, which will replace an outdated high – salinity water system, is expected to reduce energy usage by up to 30% and be powered entirely by renewable energy.

WEG’s integrated drive solutions are central to driving the water injection pumps that form the backbone of this innovative infrastructure. The company will provide 21 integrated drive packages, featuring WEG M-Line (Master Line) 6.6 kV medium voltage motors with power ratings ranging from 6.63 MW to 11.97 MW, along with MVW01 medium voltage VSDs and oil-type phase-shifting transformers.

This sophisticated system will treat seawater and deliver over 110 million imperial gallons of nano-filtered seawater per day, utilising a vast transportation network spanning 75 km of pipelines. The integration of WEG’s systems in this high-performance environment ensures that the pumps operate at peak efficiency, even under the intense desert heat of the UAE.

In addition, WEG is also supporting the Abu Dhabi National Oil Company (ADNOC) in a crucial oil pipeline project. This US$3 billion infrastructure, spanning over 300 km, will transport up to 1.5 million bbls of crude oil daily from Abu Dhabi to Fujairah.

WEG will supply 20 medium-voltage flameproof motors to drive multiple horizontal centrifugal pumps. This includes nine W22Xdb 3.3 kV, 50 Hz units (850 kW – 990 kW) and eleven 6.6 kV M-Line motors (6710 kW–6980 kW), all designed to withstand the harsh Arabian desert heat (up to 55°C) and are IP55-certified for dust and water protection.

To optimise energy efficiency and safety, the solution features integrated arc-resistant VSDs, which are capable of absorbing any explosions caused by sudden electric arcs, protecting pump operators and maintenance personnel working on site.

This combination of WEG motors, VSDs and transformers ensures the pipeline’s horizontal pumps perform reliably in extreme desert conditions while maximising safety and efficiency. The ability of WEG to provide an integrated, customisable solution for such complex systems speaks to the company’s extensive experience in the oil and gas industry.

As the UAE continues to invest in advanced energy infrastructure, WEG’s innovations in motor technology, VSDs and digital solutions are helping the energy sector transform and adapt to modern challenges. As the energy sector continues to evolve, WEG’s commitment to innovation and sustainability will remain a cornerstone of its contribution to the UAE’s key energy projects.

Coating Thickness Gauges

PosiTector 6000 FS3

ased on quantity, carbon dioxide (CO2) is, by far, the largest source of global greenhouse gas emissions (GHG). Carbon dioxide emissions have thus long been the focus of efforts to reduce the impact of industrial activities on the environment and ensure that society remains on track to meet climate change and net zero goals.

However, CO2 is not the only GHG source. The second largest source of greenhouse gas emissions is methane. Although some distance behind CO2 in terms of volumetric emissions, methane is significantly more potent than CO2 and remains in the atmosphere for about 10 years before dissipating. Indeed, 1 kg of methane in the atmosphere has 84 times the global warming potential of CO2 over a 20 year period. Methane is thought to be responsible for around a third of the historical increase in global temperatures that have occurred since pre-industrial times.

Methane is the primary component in natural gas, the use of which accounts for over 30% of global methane emissions. Natural

gas is and will continue to be an important part of the energy mix even as we transition away from traditional fossil fuels. However, while natural gas is significantly cleaner than coal, it still produces emissions that contribute to climate change. Worryingly, methane emissions continue to increase each year.

The energy sector is responsible for nearly 40% of all methane emissions related to human activity. Coal, oil, and natural gas operations are each responsible for around 40 million t of annual methane emissions. According to the International Energy Agency (IEA), this amount is far too high to meet the world’s climate goals within the required timeframes. More than 5 million t of methane emissions originate from leaks and are thus preventable. Clearly urgent action is required to reduce methane emissions rapidly.

The solution for this problem requires both regulatory and technological change. On the regulatory side, progress has historically been slow, although recent years have seen some major breakthroughs. For instance, in November 2023 the EU announced

its intention to create its first law aimed at restricting methane emissions both in EU countries and globally. The EU Methane Regulation will impose limits on methane emissions from the energy sector both directly in European countries, and throughout the global supply chains that deliver natural gas to the EU. Although the EU contributes only 5% of global methane emissions directly, it is the largest global importer of fossil fuels, and so this legislation has the potential to have a significant impact.

Furthermore, the EU has set a target of reducing methane emissions within the region by at least 55% by 2030. This will obligate suppliers of coal, oil and gas to both measure and report their methane emissions, as well as taking action to reduce them. The EU’s Methane Strategy also imposes mandatory leak detection and repair (LDAR) obligations on energy industries across Europe.

Meanwhile, in the US, the Methane Emissions Reduction Program forms part of the Clean Air Act. It provides US$1.36 billion in financial and technical assistance through multiple funding

Doug Baer, ABB, explains how laserbased and IoT technologies are opening new possibilities for mitigating leaks –and even preventing them before they happen – as regulations are tightening across the energy sector.

mechanisms and establishes a Waste Emissions Charge for methane emissions specifically.

There is of course only so much that regulations alone can achieve. They must also be enforced and provide the technological and cultural environment to allow businesses to mitigate emissions as rapidly and on as wide a scale as possible. It must also provide measures for transparency to encourage widespread compliance and provide accountability. With leaks comprising a significant proportion of overall emissions, eliminating them could help to make significant progress in wider efforts to tackle global warming generally.

To encourage companies to conform to this and other similar legislation which may appear in the future, an effective, efficient and rapid method of detecting leaks is required. The benefits of achieving a significant reduction in methane emissions are not just environmental. Methane gas leaks are also extremely expensive for industry, with some studies indicating that fugitive emissions cost

billions in lost revenue each year, while also creating serious safety issues for industrial facilities and their surrounding areas. To that end, reduction of methane emissions represents a compelling business case too.

To reduce methane emissions, one must first be able to measure and quantify them. However, measuring methane presents technological challenges. Methane is invisible, does not leave a smoke trail, and is generally not easy to detect. Traditional methods used to detect gas leaks have typically lacked the accuracy, speed and sensitivity required, particularly for small or hidden leaks.

Advances in digitally enabled technologies have helped to transform natural gas leak detection practices in recent years, enabling exponential improvements in sensitivity, accuracy, speed, and cost. For example, ABB’s gas leak detection system is based on a high sensitivity gas analyser capable of measuring and reporting methane and ethane concentrations several times per second. Ready for operating within three minutes without any additional warm-up time, the analyser’s vibration-proof design enables it to be used in vehicles, aircraft, and carried around on foot. The analyser uses the Off-Axis Integrated Cavity Output Spectroscopy (OA-ICOS) principle, which utilises tuneable laser sources that produce light at selected wavelengths to interact with the gases being analysed.

Each laser beam enters a highly reflective mirrored cavity, where it is reflected thousands of times before exiting onto a photodetector. This creates a very long optical path many kilometres in length, which allows the use of telecommunicationsgrade near-infrared diode lasers, which are widely considered the most reliable, rugged and longest lifetime lasers available. They also yield extremely strong absorption signals. As a result, the measurements of the target gases are recorded quickly and with extremely high sensitivity, precision and accuracy.

This method offers a sensitivity over 1000 times greater than conventional leak detection technologies, allowing the analyser to rapidly detect single parts per billion (ppb) variations of the target gases over ambient levels. This enables quick detection of methane emissions and natural gas leaks, even when measured from long distances.

Preventing large leaks before they occur is vastly preferable to attempting to mitigate them after they escalate. Real-time monitoring has been a major focus for manufacturers of leak detection solutions in recent years. Having the ability to identify potential issues before they escalate can significantly reduce downtime and repair costs, as well as reducing the likelihood of methane leaking into the atmosphere.

Flow monitoring devices can be used to measure the rate of change of pressure or the mass flow at different sections of a pipeline. Significant differences in mass flow or pressure could indicate a potential leak, although it cannot pinpoint its precise location. This is where software-based, IoT-enabled dynamic modelling comes in. This monitors various flow parameters at different locations along the pipeline, which are then included in a model to determine the presence of leaks in the gas pipeline and allow the location to be narrowed down.

Once the approximate location has been determined, more localized technologies can be used. ABB’s mobile gas leak detection solutions leverage advanced laser-based sensors, GPS technology and analytical software to dramatically improve both the speed

Figure 2. ABB’s HoverGuard airborne gas analyser provides a highly effective solution for long distances and difficult-to-reach locations.

Figure 3. ABB’s mobile gas leak detection solutions leverage advanced laser-based sensors, GPS technology and analytical software to deliver fast and accurate gas leak identification and location.

Figure 1. ABB’s gas leak detection system is based on a high sensitivity gas analyser which uses the Off-Axis Integrated Cavity Output Spectroscopy (OA-ICOS) principle.

and accuracy of gas leak identification and location. The difference in precision and accuracy between this technology and previous approaches is greater than 1000 to 1. That is analogous to the difference between today’s high-definition TV and the black and white sets of old.

Combined with a GPS module, an onboard ultrasonic anemometer to measure wind velocity, and advanced proprietary analytics, ABB’s MobileGuard™ can detect, precisely locate, and accurately estimate the size of natural gas leaks at a rate that covers 10 - 25 times more land area per hour than traditional methods. Importantly, it eliminates false positives associated with biogenic sources of methane like sewage and animal waste by also detecting ethane, found only in thermogenic pipeline gas, along with methane.

It combines an OA-ICOS analyser with an ultrasonic anemometer for measuring wind speed, and a GNSS (Global Navigation Satellite System) antenna for measuring location. The system uses advanced algorithms to combine this data with gas concentration measurements, enabling it to locate, map and quantify the size of pipeline leaks from a moving vehicle far from the emission source. The system analyses data locally and presents geospatial maps of all measured parameters in real-time. Data and detailed analysis of it can be securely relayed to cloud storage for easy sharing and further study or historical trend analyses.

The technology can detect methane from leaks from over 300 ft away in a vehicle moving at speeds up to 88 kph. In practice,

this allows surveyors to cover 10 - 25 times more land area per minute than with traditional detection methods.

ABB’s HoverGuardTM provides a solution for difficult-to-reach locations. An airborne analyser mounted on a drone is passed through the diffused methane plume, allowing fast and safe identification of potential leakage points, at a fraction of the cost of aircraft or satellite-based systems. MicroGuardTM offers a solution for conducting surveys on foot. This utilises the same technology, comprising an OA-ICOS gas analyser, backpack, ruggedised tablet with GNNS and a custom-designed sample wand, combined with enhanced analytical software.

Using technologies available today, it is estimated 80% of oil and gas methane abatement measures, and up to 98% of coal measures, could be implemented immediately and cost-effectively. Methane detection has undergone a remarkable shift, propelled not only by advancements in hardware like the laser-based OA-ICOS technology but also by the sophisticated integration of computer analytics and refined algorithms. By leveraging data analyses and advanced fluid-flow models, OA-ICOS analysers can now be embedded in versatile mobile solutions. These integrations empower organisations with the capability to detect methane leaks with unprecedented precision, reliability, and efficiency. As the regulatory environment continues to shift to reflect a more stringent approach towards methane emissions, so too do the technological capabilities that allow companies to measure and ultimately mitigate leaks.

Inline inspection

World Pipelines quizzes some inline inspection experts on ILI solutions and recent inspection projects.

with...

Johannes Keuter, 3P Services

Johannes studied Mechanical Engineering and Business Administration and holds a Master of Science (MSc) degree from the University of Paderborn, Germany. Over the last 12 years he has worked in several onshore and offshore pipeline inspection projects around the globe in which he gathered oil and gas industry experience in management positions and various technical positions, from research and development, operations, and business development. From 2012 to 2018 he worked as a Global Product Manager for metal loss inline inspection (ILI) services and later for crack detection services at the ROSEN Technology and Research Center in Germany. In 2018, he took over a technical lead role for global challenging pipeline projects within ROSEN Germany for more than three years. In 2022 he joined 3P Services as a Sales & Project Manager. Since 2024, his responsibilities have included the Area Manager position and the Vice President role for 3P Services North America’s business units.

McKenzie Kissel, Onstream Pipeline Inspection

McKenzie is a Product Manager at Onstream Pipeline Inspection. He has over 15 years in the ILI industry with a focus on MFL tool design, development and commercialisation, ranging from NPS 3 to 48. He has led multifaceted design teams and development for MFL platforms as well as application-specific ILI projects to successfully inspect unique pipelines. McKenzie is a professional engineer with an MBA. He graduated with a BSc in Mechanical Engineering from the University of Alberta and an MBA from the Haskayne School of Business at the University of Calgary.

Willem Vos, NDT Global

Willem, Senior Technical Specialist at NDT Global, is an electrical engineer with an MSc in Measurement Technology, bringing over 25 years of expertise in pipeline integrity. Since joining the inline inspection industry in 2001, he has advanced cutting-edge solutions, including acoustic resonance technology (ART) for precise pipeline inspections.

Briefly discuss a recent project where inline inspection was used.

Johannes Keuter, 3P Services: Two 10 in. heavy wall offshore pipelines running parallel from platform to platform required a metal loss inspection. There are heavy wall riser sections with 0.719 in. (18.2 mm) wall thickness at the foot of the platforms. The pipelines are located offshore California, USA.

With common magnetic flux leakage (MFL) tool designs, the wall thickness of 0.719 in. (18.2 mm) cannot be sufficiently magnetised in a 10 in. pipeline. Therefore, an MFL inspection seemed not feasible. In addition, a previous third party MFL inspection wasn’t successful because of this. Ultrasonic inspection (UT) tools failed to get good data because of debris issues. The high cleanliness requirements for UT technology could not be met.

3P Services has extensive experiences with heavy wall MFL inspections. Consequently, an existing MFL magnetiser design was used and optimised to magnetise the riser wall thickness. In addition, pull-through tests were performed prior to mobilisation to verify a sufficient magnetisation under the given circumstances.

The MFL tool recovered complete inspection data that allowed an interpretation over the entire length of both pipelines. One pipeline has shown significant internal metal loss but almost no external metal loss. However, the second water injection pipeline has shown predominantly external metal loss, partially deeper than 50%. The operator’s targets were achieved, budget and time schedule were met.

Q A

McKenzie Kissel, Onstream Pipeline Inspection: Last summer, Onstream performed the first commercial pipeline inspection with the new 4 in., 1.5D TriStream MFLTM technology. This NPS 4 pipeline, a natural gas gathering line, had previously been inspected by Onstream in 2017 via a bi-directional MFL combo tool tether application, where the line was accessed through a riser on the line. In 2017, a tethered application was chosen to inspect this line due to natural gas pipeline product having inadequate flows and the launch and receiver risers containing 1.5D 45° bends. In this initial inspection, the majority of the line was able to be inspected via the tethered system; only the sections containing the 1.5D bends were not able to be inspected as the technology could not transverse the fittings.

2024 was the re-inspection interval for this line and the client was informed that Onstream now had a technology able to navigate the 1.5D 45° bends. The challenge of the inadequate gas flows remained. To overcome this challenge, the operator brought in a pump truck with fluid and prepared the line to pump the tool. Ultimately, Onstream was able to perform a successful ILI, achieving 100% coverage of the entire line with less downtime and simplified project planning and preparation as compared to the previous inspection seven years ago.

Willem Vos, NDT Global: NDT Global recently carried out an ILI scope of work in Qatar, which entailed the baseline inspection of newly laid subsea pipelines. The client selected ultrasound technology due to its ability to inspect corrosion resistant alloy (CRA) and detect any injurious integrity threats in heavy wall pipes prior to service.

Can you talk about how ILI solutions can help to inspect pipelines that are transporting hydrogen or carbon dioxide?

Johannes Keuter, 3P Services: Generally speaking, ILI is an essential part of maintaining and monitoring a wide range of potential risks for pipelines, especially those transporting critical fluids such as hydrogen and carbon dioxide. ILI allows for detection of potential issues like corrosion, cracks, or other structural weaknesses, that could lead to catastrophic pipeline failures, which normally results in loss of products and possible harm to environment and humankind.

Specific risks such as hydrogen embrittlement or CO 2 corrosion can be avoided by using ILI tools to detects such risks in early stages prior being untreatable.

ILI systems (GEO, MFL, UT, etc.) therefore increase the safety, efficiency and longevity of pipelines and are thus an important component of energy efficiency in our everyday lives.

3P Services has also been working in critical media such as hydrogen for many years. In 2015, 3P Services carried out an intelligent inspection in Texas, in which the inspection tools were propelled by the hydrogen medium and measured reliably in the pipeline despite being exposed to this product. Other reference projects have been successfully carried out in media such as supercritical ethylene, cumene and naphtha.

Willem Vos, NDT Global: Crack diagnostic technologies play a large role in managing hydrogen transportation systems. Hydrogen introduces the risk of accelerated fatigue crack growth, as the pipeline steels become more brittle when hydrogen molecules dissociate, and the atoms get absorbed into the steel microstructure. To date, we have supported several operators with crack detection technology specifically to enable them convert to a hydrogen service.

When we look at CO2, it’s attractive to compress it to dense phase for transportation capacity, which results in relatively high pipe wall thickness, making ultrasound an attractive solution for metal loss measurements, especially for detection of early, low-level corrosion activities. Fortunately, we know that dense phase CO2 can be used as a coupling medium, so the design of the lines will not be restricted by the wall thickness limitations of MFL.

Discuss inline inspection methods (MFL and UT) and their different advantages.

Willem Vos, NDT Global: MFL uses magnets to measure changes in magnetic fields to detect metal loss in pipelines, making it suitable for a wide range of media, both gas and liquids. MFL tools have been around for decades and are available from a wide range of suppliers.

3P Services: 4 in. MFL 1.5D ILI tool

3P Services: Detected pinholes in ultra-high-resolution NEO data.

Ultrasonic metal loss is available for liquid (UT) and gas (ART) pipelines and offers the benefit of direct measurement which allows for better assessment of complex corrosion features.

By utilising direct measurement technology, UT and ART can detect and size laminations, CRA defects and accurately measure corrosion including features under pipeline supports. Unlike MFL, UT sizing accuracy is not affected by pipeline wall thickness, making it highly suitable for heavy wall pipelines such as those seen offshore.

Johannes Keuter, 3P Services: UT and MFL are commonly used in the pipeline ILI industry since decades. MFL tools magnetise the pipeline wall thickness to a predefined level which is needed to achieve the performance specifications published from the ILI vendor. The upper and lower limit of the magnetisation determines the upper and lower wall thickness for which the MFL tool can be used. Hence, the wall thickness in a specific pipeline must fit to the wall thickness range of the MFL tool. This range is typically narrower than the wall thickness range for which UT tools can be used.

Furthermore, the performance specifications for MFL tools, in particular the probability of detection (POD) and the absolute depth sizing tolerances are wall thickness dependent. Hence, the absolute tolerances increase with increasing wall thickness because they are in percentages of the wall thickness. In contrast, the POD and depth sizing tolerances for UT tools are independent from the wall thickness. That leads to the fact that in high wall thicknesses, the UT performance specifications are typically more accurate as the MFL performance specifications.

However, the UT measurement principle’s cleanliness requirements are higher than for MFL. Hence, it is important to have a clean pipeline. Otherwise, the UT data could be influenced and limited by debris. Although a clean pipeline is also recommended for MFL inspections, MFL is in general more robust against debris. For pipelines with cleaning issues, MFL is often the better choice.

The strength of MFL to detect the deepest point of very small anomalies is a weakness of UT technology. A small deepest point below the POD of a UT tool could be missed by UT whereby MFL may detect it. On the other hand, it is difficult to detect lamination with MFL but easily possible with UT. However, the laminations reflect the UT signal and the pipe wall ‘behind’ a lamination cannot be inspected with UT but with MFL.

There are several more examples of strengths and weaknesses of both technologies. To overcome this, 3P Services provides both technologies either as stand-alone or as combined inspection tools.

McKenzie Kissel, Onstream Pipeline Inspection: The ILI inspection methods of MFL and UT are used to identify and size integrity threats in pipelines. MFL is an indirect measurement method, while UT is a direct measurement method. UT utilises sound waves that propagate through the pipeline media and measures response times to identify and size features. MFL uses permanent magnets and Hall sensors

Q A

Pipeline Inspection: NPS 4 Test flow loop at Onstream’s facility in Calgary, AB, Canada

capturing changes in the flux to identify and predict the geometry of the features.

UT technology is suitable for use in liquid pipelines, where the liquid media can transmit the UT wave from the sensor through to the pipe wall and back. The technology is particularly good for identifying and sizing long features in the pipe body. Additionally, it is suitable for identifying and sizing cracks and crack-like features. The technology has limitations outside of liquid pipeline media as the UT wave cannot be transmitted.

MFL technology is a cost-effective solution to managing corrosion-based metal loss threats in pipelines. The technology can be deployed in liquid or natural gas pipelines. The indirect method is very effective at identifying and sizing metal loss features inside or outside the pipe in various shapes and sizes. Advances in artificial intelligence, the volumes of data

Onstream Pipeline Inspection: Pipeline riser navigated by new 1. 5D 4 in. TriStream MFL TM ILI tool.

Onstream

Q A

collected by the ILI tool, and the feedback from in-ditch findings from operators have resulted in Onstream being able to achieve high accuracy detection and sizing specifications for their Triaxial TriStream MFL platform.

How do you ensure the accuracy and reliability of your inspection results with pipelines in challenging terrains/environments?

Johannes Keuter, 3P Services: For over 30 years, 3P Services has been driven by the idea that we must ‘Protect People

and Planet’. Our ILI services are designed and engineered to ensure the safety and protection of our planet and its inhabitants. Our general inspection concept is to adapt our inspection tools to the pipeline’s existing configuration rather than insisting on pipeline modifications until standard ILI equipment can be applied, which generally leads to solutions that are more cost effective for the client, where challenging pipelines exist.

This core competence has allowed 3P Services to execute countless challenging pipelines in the last 30 years. A team with outstanding experience in handling challenging pipelines, either with regards to the terrains, the environment, the pipeline route or layout or with regards to the operating conditions during the ILI run, does assess every upcoming pipeline inspection in detail. This approach ensures finding the ideal solution for every single pipeline inspection.

McKenzie Kissel, Onstream Pipeline Inspection: Free swim conventional ILI tools are designed to accommodate most pipeline environments such as operating pressure, temperature, wall thickness (WT) compliance, bend compliance, products encountered, etc. For example, at Onstream, all tools are designed for the harshest of environments such as sour H2S gas with water, any other products will be less harsh. The main design parameters include:

• 13.8 MPa (2000 psi) pipeline operating pressure.

• 1.5D bend capability.

• Inspect 90% of the WT found in onshore pipelines.

• Line temperatures up to 70°C (150°F).

• Tool travel speeds up to 4 m/sec.

In the scenarios where the pipeline is operating outside of these conditions, special tools can be designed to address an ILI tool limitation. Onstream has developed a tool for operating in 20.7 MPa (3000 psi) salt water, or tools to inspect pipelines with operating temperatures at 150°C (300°F).

In some cases, a pipeline may not be able to be inspected by a free swim conventional ILI tool, but rather through an unpiggable tether application. This may be due to inconsistent flows, tight bends, or lack of launch or receive facilities. In cases like this, Onstream can inspect these lines via a wireline tether bi-directional ILI tool. With the pipeline out of service, the pipeline can be accessed with one cut location in the line, may be a planned dig site, or through a mid-point riser, the line will then be inspected with a bi-directional ILI attached to the wireline tether truck, providing the same inspection coverage and deliverable as a free swim conventional ILI.

Willem Vos, NDT Global: We’re constantly pushing the limits on accuracy and reliability of our tools, one example is the launch of our Eclipse tools, the first application of pitchand-catch technology on a crack detection ILI tool. Pitchand-catch signals allow for more accurate sizing of tilted cracks (e.g. hook cracks). Other tools, like the ART Scan fleet, use non-contact sensors and run entirely on wheels. We see those tools have negligible wear, even in runs exceeding 900 km, thereby eliminating the issues around pipeline length.

NDT Global: Engineering Excellence: NDT Global’s largest 56 in. ultrasonic inline inspection tool, setting new standards in pipeline diagnostics.

NDT Global: ART Scan delivers unparalleled accuracy in detecting and diagnosing pipeline anomalies, ensuring safety and reliability for critical energy infrastructure.

What considerations need to be made prior to pipeline inspection?

Willem Vos, NDT Global: I think a well-engineered cleaning programme is a good investment towards getting the most out of your ILI programme. Whether it’s the assessment of the optimised cleaning pig setup, or a full progressive cleaning campaign, the data is always better if the pipeline is cleaner.

Johannes Keuter, 3P Services: A good data base is a key to a successful and value adding pipeline inspection. For pipelines which have never been inspected, a step-by-step approach is necessary. The accessibility for inline tools must be discussed and normally soft-to-hard tools are used one after the other. In a nutshell, soft foam pigs, hard foam pigs, cleaning and gauging tools. That ensures that intelligent tools can negotiate the pipeline. In certain circumstances, a specific cleaning program must be designed.

However, in case the integrity threats for a specific pipeline are known, the proper inspection technologies must be chosen. 3P Services is happy to support operators in this assessment. If these threats aren’t known, it is reasonable to perform a geometry inspection first. Close cooperation between the operator and the ILI vendor and an exchange of information enables us to design the ideal tool. Next to mechanical pipeline parameters, operating parameters, access possibilities and the split of responsibilities must be discussed. A meeting prior to the pipeline inspection to agree on the onsite procedure is recommended. The available data, the agreed procedures and the defined deliverables allow complete preparation of the pipeline inspection.

McKenzie Kissel, Onstream Pipeline Inspection: Regardless of the ILI technology to be used to inspect a pipeline, the pipeline considerations are the same. Ideally, the considerations for ILI should be made at the design or construction phase of a pipeline, rather than after the pipeline is built. The fittings, bends, pipeline diameter, constant or same diameter (not dual diameters), WT, and launch and receive facilities all impact the ability of an ILI tool to successfully navigate the pipeline. Beyond the pipeline design, the pipeline’s operating parameters such as product, temperature, cleanliness, pressure, and flowrates are additional considerations that impact an ILI.

The ideal pipeline for ILI purposes has launch and receive barrels sufficiently long enough for the ILI technology to be used, limited bends that are very large sweeping radii, constant pipe diameter, a WT that is close to standard for a given NPS with minimal changes between the nominal WT, and all the fittings in the line. For natural gas pipelines, the operating pressure, flowrates, bends, and fittings play a significant role in whether a pipeline can be successfully inspected. For a crude oil line, the flowrates, or run time, are the main drivers for success.

What are the latest developments in inline inspection technology?

Johannes Keuter, 3P Services: Recently, a Canadian pipeline operator was supporting 3P Services’ NEO’s commercial inspection and technology development. This was accomplished

by introducing the NEO demo video to the operator team during an introductory meeting. 3P Services was invited to bring it to the field to test it on 36 in. pipe pieces (before pipelaying) that were susceptible to flood damage. Prior to a field demo test, the live NEO demo kit was presented at a pipeline workshop which 3P Services and the operator attended and where NEO and its capabilities were demonstrated. This allowed some of the operator integrity teams to see for themselves what it could do – such as detect pinholes and internal complex corrosion. This new technology is ideal to detect internal pinholes and complex corrosion, even in challenging pipeline conditions such as high speed, low pressure or heavy wall.

Another late development addresses the often neglected Glass Fiber Reinforced Plastic (GFRP) pipelines. Damage and defects in GFRP pipelines are not uncommon. Various pipe samples provided by the GFRP industry prove that they exist. Damage can be caused by mechanical influences, by heat (e.g. lightning strike) or by fatigue of material. 3P Services’ approach to develop an ILI technology for GFRP lines aims to enhance pipelines’ safety. Our prototype is based on analysis and tests in laboratory and test field environment to reliably detection internal and external defects and consequences of cracks and changes in wall thickness or other mechanical damages with a precise location. We are always looking for engaged industry partners with whom we can work together to push forward our technical developments and to test them in the field. With an operator as partner, we can increase the amount of runs, data and third party verification.

McKenzie Kissel, Onstream Pipeline Inspection: The most recent ILI development at Onstream is the commercial release of the NPS 4 1.5D ultra-high resolution TriStream MFL tool equipped with Triaxial sensors, geometry caliper, and inertial mapping unit. This latest development is capable of navigating tight 1.5D 90° bends at wall thickness up to schedule 80, inspecting pipelines previously thought to be uninspectable with a conventional free swim ILI tool.

Significant development and testing were completed on this platform before the release. The design was tested against an inhouse flow loop with tight schedule 80 bends in various configurations. The use of the latest advancements in additive manufacturing provided Onstream designers the ability to optimise and iterate the tool design concurrently, not only providing a timely development solution, but one that is fully capable of inspecting unexpected pipeline routings, collecting ultra-high-resolution data, providing operators industry-leading performance specifications.

Willem Vos, NDT Global: I think the last major breakthrough was the introduction of ultrasonic inline inspection for gas pipelines: ART Scan uses pressurised gas as a coupling medium, pushing the boundaries on wall thickness and accuracy for gas pipeline design.

Meanwhile, there’s a strong drive to deliver more accurate crack diagnostics for gas pipelines, to manage issues like stress corrosion cracking (SCC), and an increased focus on geohazards. We’re working hard to support pipeline operators on these urgent issues.

LISTEN NOW

In this episode, Elizabeth Corner speaks to Kevin O’Donnell, Executive Director of the PLCAC, about how membership organisations benefit the pipeline sector and those who work in it, discussing events, networking, resources, training, skills development, and learning.

This episode of the podcast covers:

• The PLCAC’s primary aims as an association.

• The part community plays in fostering business connections.

• How to define success as a membership organisation.

• How events are evolving to meet the needs of pipeliners.

• How the PLCAC uses data from its members to advance the industry.

• And more!

Kevin O’Donnell Elizabeth Corner

Alexandre Nadeau, CEO, Tecnar, and Agha Umer, Head Quality-Welding Department, Bin Quraya, consider how industry resistance, technological progress, and potential gains in productivity and workforce efficiency are shaping the future prospects of automated pipe spool welding.

he pipeline industry is the backbone of energy and resource transportation, requiring high precision and reliability to meet stringent safety and durability standards. Pipelines, both onshore and offshore, involve complex assemblies, long project timelines, and a demand for highly skilled labour. Traditionally, welding – one of the most critical stages in pipeline construction – has relied heavily on manual skill, especially when fabricating pipe spools that involve intricate connections and specific geometries.

Companies are increasingly turning to automation as the industry faces pressure to reduce project timelines and costs, along with a shortage of skilled welders. Orbital welding machines, widely adopted for the main pipeline welds, have been instrumental in improving weld quality and consistency. Now, a new wave of automation is focusing on pipe spool welding. One example is Bin Quraya, a construction firm in Saudi Arabia, which has expanded its automation efforts beyond pipeline welding to embrace the benefits of automated pipe spool welding with Tecnar’s Rotoweld 3.0 and its welding intelligence technology, PerfectPass-iQ.

Challenges in pipe spool welding

Unlike the long, uniform sections of pipelines, pipe spools require custom configurations and precise fittings to connect various pipeline segments. These connections often involve complex joints with fitting and pipes that often differ slightly in geometry. Furthermore, the fit-up always needs to respect a strict finished dimension, and the welding joints are usually where there is room to

adapt, making each joint unique. Skilled welders must maintain high-quality welds while contending with potential misalignment, ovality, gap variations, and the need for consistent root penetration. Given these demands, maintaining productivity and quality is a challenge, and any errors result in costly rework and project delays.

In response to these challenges, pipeline projects have increasingly turned to automation for mainline pipeline welding. Orbital welding machines have become a mainstay, ensuring precision and efficiency by automating the welding process along the continuous lengths of pipelines. Although pipe spool prefabrication in the construction and industrial sectors has embraced automation for more than 15 years, this sector of activity of pipeline fabrication has mostly still relied on manual welding, especially in Asia. However, companies like Bin Quraya are leading the way by recognising the advantages of automation for pipe spool welding.

Automation in pipeline welding and orbital welding

Bin Quraya’s journey in welding automation began with a focus on the mainline pipeline welding process. Partnering with an established provider of orbital welding services and equipment, they introduced orbital welding machines for pipeline construction. The switch to automated welding for pipeline segments streamlined their operations, reduced weld defects, and improved overall productivity.

Having successfully implemented automation for pipeline welding, Bin Quraya then turned its attention to pipe spool fabrication. This shift required a solution tailored to the unique challenges of spool welding, and they found the answer in Tecnar’s Rotoweld 3.0.

Enter automated spool welding

The Rotoweld is a pipe spool welding station that was pioneered in the 80s by Tecnar founder François Nadeau. The product became famous for being the first to deploy four-dimensional synergic welding to control the root pass with Lincoln Electric’s STT process. In 2016, Tecnar launched the third generation of the product, the Rotoweld 3.0, which truly democratised pipe spool welding automation in North America with its highly mature semi-automated welding process and extremely rugged design. Furthermore, the notion of maximised arc-on-time was put forward with the twin bay design that allows the welding robot to weld almost all the time on the active welding bay while the unactive welding bay is getting loaded with the next spool.

Nowadays, Tecnar makes the Rotoweld 3.0-iQ. This new model, introduced in 4Q23, is now a fully automatic welding station incorporating

Figure 1. Rotoweld 3.0-iQ at Bin Quraya fabrication shop.

Figure 2. Rotoweld 3.0-iQ welding a production part at Bin Quraya.

Figure 3. Rotoweld 3.0 PerfectPass-iQ user interface during welding.

Tecnar’s welding intelligence technology, PerfectPass-iQ. This solution was designed with the specific requirements of pipe spool welding in mind, providing unparalleled consistency and speed. With PerfectPass-iQ, the welding process is fully automated, including real-time monitoring and adjustment to ensure optimal weld parameters are maintained at every step.

After acquiring the Rotoweld 3.0-iQ, Bin Quraya managed to qualify their welding procedures with Saudi Aramco, one of the world’s leading energy companies, in just a few weeks. The streamlined qualification process and rapid onboarding enabled Bin Quraya to go into production less than a month after receiving the machine. In just a few months, over 800 welded joints were completed, with a remarkably low reject rate of less than 1.6%, with only minor issues arising as operators adjusted to making fully penetrated Gas Tungsten Arc Welding (GTAW) root tacks at the fit-up stations. As operators become more adept with the system, Bin Quraya aims to further reduce the reject rate to below 1%.

Overcoming resistance to automated short arc welding

A notable aspect of the Rotoweld is its use of the short arc welding process, which, while efficient, is sometimes met with resistance in the industry. Short arc welding offers greater control and minimal spatter, making it ideal for spool welding. However, the perception of short arc welding as less robust compared to other methods has posed an adoption barrier. Bin Quraya’s success, however, has demonstrated that, with the right equipment and procedures, short arc welding can achieve high-quality welds with exceptional reliability.

The PerfectPass-iQ technology embedded in the Rotoweld 3.0 has played a pivotal role in overcoming this resistance, especially for Asian countries that were still heavily reliant on manual GTAW welding. By continuously monitoring and adjusting parameters, PerfectPass-iQ delivers consistent quality, countering any skepticism about the short arc process’s ability to meet industry standards. This consistency has allowed Bin Quraya to meet Aramco’s rigorous quality requirements and paves the way for

broader acceptance of automated short arc welding in pipe spool fabrication.

Productivity gains and workforce efficiency

One of the most striking outcomes of Bin Quraya’s adoption of the Rotoweld 3.0-iQ has been the boost in productivity. The PerfectPass-iQ technology enables the operator to step away from the machine to perform other tasks while the weld is in progress, drastically improving workflow efficiency. According to Bin Quraya, the productivity achieved with the Rotoweld 3.0 is so high that it effectively replaces up to 20 manual welders. The return on investment calculated by Bin

Quraya is far less than a year, around seven to eight months based on their recent experience, and the net present value over the life expectancy of a single unit has been evaluated at around US$8 million, assuming the machine is feed at its nominal daily productivity during its entire life span.

The significant reduction in required labour addresses the industry’s skilled labour shortage, allowing companies like Bin Quraya to allocate their workforce more effectively and meet project demands without compromising quality. This level of productivity also translates into cost savings and shorter project timelines, providing a competitive edge in an industry where efficiency is paramount.

Another significant aspect of moving towards automation is the culture change that is enabled in the fabrication shop. Installing such a piece of equipment requires a mentality change because everybody now relies on one single KPI, the total diameter in. per shift. And a team needs to be built around this goal. At Bin Quraya, a team was put together which included one Rotoweld operator, one spool sequencer that loads the next piece on the non-active welding bay, one fitter that fits the next piece to be welded and one inspection specialist that performed the PAUT testing that was the method of choice for Bin Quraya on their first project.

Future prospects for automated welding

Buoyed by the success of the Rotoweld 3.0, Bin Quraya is now exploring additional applications for the technology.

The company plans to qualify more welding procedures with the Rotoweld 3.0, potentially expanding its use across various project types and configurations. With more machines expected to be integrated into their facilities in the near future, Bin Quraya is setting a new standard for efficiency and quality in pipeline spool welding, showing the broader industry what is possible with fully automated solutions.

Conclusion

The pipeline industry’s gradual shift toward automation, especially in areas like pipe spool fabrication, is reshaping how projects are executed. With the success of companies like Bin Quraya, the benefits of automated welding are becoming increasingly clear: higher productivity, lower reject rates, and the ability to address labour shortages. The Rotoweld 3.0 and its PerfectPass-iQ technology exemplify the potential of automation in tackling the challenges unique to pipe spool welding, setting new benchmarks for quality and efficiency.

As more companies adopt advanced welding automation solutions, the pipeline industry is poised for a transformative era. The success story of Bin Quraya demonstrates that with the right technology and vision, even the most challenging aspects of pipeline construction can be streamlined, ultimately delivering safer, more reliable, and cost-effective projects for the energy sector.

Paul Hillman, Eddyfi Technologies, Canada, outlines how next generation automated ultrasonic testing improves efficiency and reliability in pipeline girth weld inspection.

ipeline girth weld (PGW) inspection at the point of installation is a time and quality critical operation, requiring highly trained operators and reliable equipment. Over the past two decades, automated ultrasonic testing (AUT) has played an ever more significant role in verifying weld integrity versus traditional radiography methods, thanks to its speed and sensitivity to a wide range of weld defects, as well as to reducing the risk of radiation exposure to pipeline personnel.

The first ultrasonic systems for this specialised application consisted of many conventional single crystal ultrasonic testing (UT) probes, each targeting a specific zone of the weld independently, or in tandem, on both the upstream (US) and downstream (DS) sides of the weld. Such systems required large scanner setups and specialised readout displays. In the following years, multiple-element phased array ultrasonic testing (PAUT) probes and electronics began to be deployed, allowing creation of many and varied ultrasonic beams from a single transducer. Specialised software enabled precise calculation of how each beam should form and propagate from the PAUT probe to specific weld zones. This process, known as focal law calculation, and a composite strip chart display of all target zones are now common practices in zonal discrimination analysis.

Advanced imaging

Recent years have seen the increasing deployment of advanced imaging techniques in PAUT in the form of various implementations of the total focusing method (TFM), thanks to the rapid improvements in computing power that inspection

instrumentation can leverage. This creates highly focused imaging of the weld under test by simultaneously calculating the response from multiple beam paths constructed from each individual element contribution of the PAUT probe. For successful weld exam, several images will need to be calculated each assuming a different path of propagation to region of interest, these images can be combined or viewed separately to aid in review.

A new AUT platform

WeldXprtTM is a new AUT platform from Eddyfi Technologies, combining standard and advanced ultrasonic methods in a single platform with cutting-edge software tools, dedicated to PGW inspection. This turnkey system embeds end-to-end capability inside a single package, enabling the full workflow from inspection technique design and validation through to calibration, acquisition and analysis, whatever UT inspection approach is required.

Ultimately, efficiency, speed and reliability are paramount in this application where every second can count, and this is where advanced software integration can bring significant benefits.

Inspection design

One of the first tasks of an inspection campaign is designing and validating the inspection technique, which includes the calibration blocks that will be used during the campaign to verify the sensitivity of the equipment. The calibration blocks are designed such that they contain representative reflectors, from which the ultrasonic response can be correlated when an indication is found in a weld under examination. For the zonal discrimination technique, the weld is divided into discrete zones and a reflector is machined into the calibration block with the correct angle and dimensions to match the weld profile or postulated reflector at each position.

The capability to design the calibration block is built within WeldXprt, the output of which being mechanical drawings to fabricate the physical block and the software having knowledge of all positions and essential parameters of the calibration block reflectors. This in turn gives the software the information for creation of the focal laws and is the foundation for automated verification of correct calibration when running in the field.

Calibrated performance

During inspection it is critical to ensure that the equipment is performing as it should be and that all ultrasound channels have the correct sensitivity for the flaws they are looking for. This is why dedicated

Figure 1. Multi-screen support gives enhanced productivity with all relevant information displayed live.

Figure 2. Automated calibration verification shown with a typical zonal discrimination display.

Propipe

PIG HANDLING EQUIPMENT

calibration blocks move with the inspection equipment with the requirement to run the inspection scanner over them at set intervals. When the calibration scan takes place, each reflector present in the block should be seen in the data at the correct position and with consistent sensitivity.

To support this, the software can verify all of these essential parameters automatically, checking for each reflector simultaneously and giving a go/no-go result to the calibration file and storing it alongside the relevant inspections files.

This approach gives recorded traceability of the calibration files and ease of linking with inspection results when analysing production welds or for later review.

TFM at high speed

TFM based techniques for PGW applications in lieu of zonal discrimination have been growing in recent years. This technique utilises similar multi-element phased array probes but differ in how the data is collected and represented. The first implementations of TFM utilised the collection of full matrix capture (FMC) raw data which was then processed into a high quality imaging of the weld. FMC is the process by which UT beams from individual elements of the PAUT probe are fired one at a time, each time waiting for the reflections to be received and storing a response for all individual elements before moving up the array until the last element is pulsed and the reflections stored. This gives the software a lot of raw data from which to create high-resolution images of the weld, but the drawback being the increased time needed to collect the data means slower scanning speeds.

Enter plane wave imaging (PWI)

PWI is an alternative method to create high-resolution TFM imaging of welds, but now at high scanning speeds. It relies on a different way to gather the raw data that is used to form the images, where, instead of firing individual elements, a large aperture of elements is fired simultaneously, steered to cover the region of interest. As a result, much less time is needed to complete the acquisition and therefore scanning speeds can be much quicker. Typically, this can be more than four times faster than FMC based methods, with similar results and faster even than classical sectorial phased array.

Software assisted analysis

Being able to rapidly assess AUT data following the physical scanning of the weld is a honed skill of analysts. There can be numerous underlying channels to review including those for each zone of the weld and complementary techniques like volumetric phased array and time of flight diffraction (TOFD) and even TFM based channels. This leads to a lot of information to crunch in a short time window. Data displays have adapted to support this – such as the strip chart layout and merged data views, where data from multiple channels or beams may be combined in a single view. These have helped the analyst to report indications which must then be assessed according to the relevant code being used for the campaign. WeldXprt brings powerful new tools for software assisted analysis to the data reviewer, enabling capabilities to support

in screening of data, highlighting and measuring indications that meet a set of criteria which can be pre-configured by the quality team. This ‘rule-based’ method of deploying software assisted analysis leverages predefined rules which can be configured for each type of channel or group of channels, meaning that rules for detection and sizing can be specific to each region of the weld, processing the data in a matter of seconds, whilst highlighting indications and displaying their measurements in the analyst’s view. This form of operation can mimic the criteria defined by codes for reportable indications making it strictly predictable and a valuable aid to operators to flag indications whilst also speeding up their measurements. Being analyst controlled, it allows intervention and approval of the skilled engineer to quickly review and confirm the results.

Applying the code

Once relevant indications have been found, marked, and measured by the analyst the next task is to determine how these should be assessed by the relevant code case and whether each is acceptable or rejectable and ultimately whether any need intervention by the repair crews. As many industry professionals will know, these codes can be complex, with indication criteria which can change based on specific region and position in the weld, as well as type and proximity to other indications and accumulation over given lengths. Certainly, it takes a highly skilled and knowledgeable analyst to apply these rules at pace.

Here is where software can assist as well, by reviewing the relevant indications that have been found, manually or through assisted analysis and applying the code case to them through branch like assessment of the various sections of the code which could apply. This includes interaction (where close indications are grouped) and accumulation (assessing over set lengths) criteria as well as relevant position and classification. This type of advanced software use, overseen by the analyst, can ensure that code cases can be applied efficiently and consistently across the inspection campaign and gives the quality team additional capabilities in management and review of the large cohort of data that is collected during a pipeline installation.

Conclusion

AUT continues to be the method of choice for girth welds during many inspection campaigns at pipeline installation thanks to the reliability, sensitivity, and speed of results. Newly industrialised advanced software tools such as those present in WeldXprt add significant benefits to productivity and reliability of inspection results, opening insight to trending and putting power in the hands of the operator.

WeldXprt supports a complete set of ultrasonic techniques, giving flexibility for campaign deployment whether based on zonal discrimination or TFM, capable to perform these techniques simultaneously alongside conventional, PAUT and TOFD methods in multi-group configuration. With the embedding of tools needed for inspection technique design through to reporting, this turnkey system takes care of end-toend inspection support.

Jamey Hilleary, Lindsay Corporation, reviews the multiple efficiencies offered to pipelines by remote monitoring technology.

ipeline integrity in the oil and gas industry encompasses a set of complex challenges. For project managers, it’s an increasingly difficult job to maintain operations with ageing infrastructure, corrosion, harsh environmental conditions and expansive pipeline systems that can stretch across thousands of miles and diverse terrains. The addition of a global technician shortage only complicates matters. These lengthy pipelines are critical to the world’s energy supply chain, making leak detection and response an increasingly large issue.

Oil and gas pipeline systems worldwide are expanding in scope and complexity at a time when the pool of qualified technicians is actually shrinking. Adequate supervisory control over critical systems is necessary for maintaining safe and efficient operation of these vast pipeline networks.

As the industry continues to prioritise sustainability and safety, adopting innovative technologies will be critical to ensuring the reliability and longevity of pipeline networks. Remote monitoring solutions can address many of the pipeline industry’s issues:

Real-time data collection

Continuous real-time operations tracking on key pipeline parameters such as pressure, temperature, flowrate and vibration. This immediate visibility enables operators to identify anomalies or irregularities swiftly, allowing for quick corrective actions before they can escalate into major issues.

Enhanced leak detection

Advanced monitoring systems improve leak or rupture detection capabilities through highly sensitive sensors to minimise environmental damage and safety hazards. These tools can also pinpoint the location of pipeline leaks with greater accuracy, minimising response times and reducing environmental impact to meet sustainability goals, rather than an analytic application.

Cost efficiency

Traditional inspection methods, like manual checks or pigging operations, are labour-intensive and expensive, causing additional downtime on the line. Remote monitoring reduces the need for frequent manual interventions, lowering operational costs while maintaining high safety standards. Quick identification may also reduce losses of valuable inventory.

Improved safety

With continuous oversight, remote monitoring solutions can enhance pipeline safety for operators and the surrounding property. Early warning alerts, triggered by defecting abnormal line conditions, can allow for swift preventive actions to reduce the risk of catastrophic failures – protecting personnel and infrastructure.

Access to remote locations

Remote monitoring solutions and similar technologies are particularly beneficial for pipelines in uninviting or inaccessible areas. Advances in IoT and cloud technologies can provide flexibility with wireless systems operating independently, ensuring uninterrupted monitoring from any location – even in the harshest environments.

Regulatory compliance

Remote monitoring systems help operators comply with stringent regulations by maintaining detailed records of pipeline conditions and operational parameters. Automated reporting features simplify compliance processes and reduce administrative burdens.

Predictive maintenance

By leveraging data analytics and machine learning, remote monitoring solutions enable predictive maintenance. Operators can anticipate potential failures and schedule maintenance proactively, reducing downtime and extending pipeline lifespan.

Field-proven remote monitoring solution

Lindsay Corporation introduces the new Watchdog Scout XP – the most advanced and reliable solution for rectifier monitoring and GPS synchronised current interruption. Rigorously tested for the oil, gas, power and infrastructure industries, the Watchdog Scout XP sets a new standard for dependable remote monitoring able to withstand high voltage surges – even in high lightning strike areas. Field-proven remote monitoring solutions like Watchdog Scout XP offer innovative approaches to address today’s pipeline challenges.

The Watchdog Scout XP gives engineers and technicians the freedom to remotely monitor operations even those pipelines in the harshest of settings. This solution will improve response time and system integrity, making it much easier for them to efficiently and effectively identify issues in a number of different industries.

The benefits of remote pipeline monitoring with Watchdog Scout XP include:

) Available in a variety of configurations.

) Monitor more with two additional potential or current measurements compared to the Watchdog Scout.

) Instant visibility to field asset status and automatic compliance report generation.

) Simple and faster to install with the ability to programme over the web or onsite using the onboard LCD display and navigation buttons.

Figure 1. Lindsay Corporation Watchdog Scout XP.

) Programme either in the field or on the web with Elecsys Connect.

) Schedule interruptions anytime and anywhere – available 24/7/365.

) On-demand communication from anywhere in the world with 2-way cellular or satellite or optional Modbus/SCADA.

) Surge-protection tested per IEC 61000-4-5 specifications.

) Additional analogue channels enable monitoring of up to four voltage potential and current measurements.

) Offers ‘fail-safe’ dual relay current interruption capability.

) Advanced self-testing circuitry automatically verifies channel calibration.

) Extreme reliability in harsh settings – high voltage electrical and lighting surges.

Cathodic protection

As remote monitoring has become a key tool in pipeline integrity management, impressed current cathodic protection (ICCP) systems are essential for corrosion prevention and pipeline integrity management.

The electrochemical process, applying a controlled electrical current to the metal with an external power source to apply an electrical current to the metal structure, effectively creates a cathode to reduce the corrosion rate of the metal.

The Watchdog Scout XP has more useful features than any other rectifier monitor system on the market, translating into more benefits for industry cathodic protection programmes.

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Positive impact on labour

Traditional inspection methods, such as manual checks or pigging operations, are labour-intensive and expensive. Remote monitoring reduces the need for frequent manual interventions, lowering operational costs while maintaining high safety standards.

By providing technicians visibility to the cathodic protections systems, we’re also enabling them to verify regulatory compliance from anywhere using web-based monitoring tools that offer immediate alarm notifications in the event of any system failures.

Integrated Watchdog Scout XP with the Elecsys Connect web portal, engineers and technicians will have 24/7/365 access to key data and detecting trends. The combination will help improve response time and system integrity, making it much easier for technicians to efficiently and effectively identify issues in a number of different industries.

Industrial-strength remote monitoring

Coupling the industry’s most advanced and reliable solution for rectifier monitoring and GPS synchronised current interruption with the industry leading web-based remote monitoring interface will be a game changer for many pipeline engineers.

A powerful software application, Elecsys Connect gives users access to all of their remote monitoring units (RMUs) in one easy-to-use application. Viewable on a smart phone, tablet or computer – anywhere you have web access –

Elecsys Connect lets you keep up to date on what’s happening out in the field.

Some features of Elecsys Connect include:

) Technicians can access and analyse remote monitor data, utilising any web-enabled devices.

) Users can schedule regularly emailed data reports and files or obtain on-demand data reports.

) Configure alarms and reporting schedules over the air, with the ability to remotely change alarm parameters and monitoring frequency.

) The ability to use GPS function for pinpointing locations.

) Offers both file and data transfer capabilities.

) Tool offers the options of both graphical and tabular data display.

) Seamless web-based integration with other Elecsys products.

) Serving up users with 24/7/365 real-time data.

) Provides users with the flexibility of being anywhere while they monitor pipelines with mobile optimisation.

) The software empowers users with enhanced monitoring and control functions.

With Elecsys Connect, users can set alerts for out-of-the norm readings, as well as receive regularly scheduled reports. Technicians can select individual RMUs, or group them together into zones. With accurate GPS maps providing precise locations for units in the field, users know exactly where the data is

coming from. They see the most recent information for each remote monitoring unit and call up historical data in tabs or graphs to generate reports. With Elecsys Connect, they can quickly analyse data for trends in individual units or across an entire site.

Elecsys Connect offers a variety of configuration options to customise the system to the user and their needs. The solution also allows you to change the configuration at any time. Additionally, new software settings are automatically transmitted to the unit.

Applications in the field

Pipeline operators using the Watchdog Scout XP and Elecsys Connect have reported significant improvements in operational efficiency, safety and regulatory compliance.

In remote oilfields, the system’s solar-powered sensors have enabled 24/7/365 monitoring, reducing the need for on-site personnel. And in high-risk areas, its rapid alert system has helped prevent potential environmental disasters by detecting leaks early.

As remote monitoring capabilities continue to evolve and solutions like Watchdog Scout XP and Elecsys Connect are adopted by industries utilising pipelines, they will see line-specific challenges decrease and increase efficiencies for technicians and engineers working in today’s pipeline industries.

François Lachance, Creaform, Canada, outlines accurate FEA simulation methods for achieving less conservative burst pressure rates.

sset owners often rely on conservative methods for integrity evaluations due to their simplicity and familiarity, even though they involve excessive safety factors.

However, in the context of ageing infrastructure, asset owners face more pipelines requiring inspection and repair than their available human and financial resources can manage. To cope, they must prioritise and address only necessary repairs, while avoiding unnecessary work.

Figure 1. Creaform scanners can

Level I, II, and III assessments

Asset owners decide to comply with Levels I, II, or III based on the complexity and accuracy required to assess the asset’s condition and the associated costs and time constraints.

Level I analysis for burst pressure is for simplified and conservative assessments. Requiring minimal data, it is primarily used for early-stage assessments or for straightforward pipeline defects. Level II provides more detailed analysis with refined estimates, typically used for complex defects requiring a moderately conservative

approach. This level allows the owner to reduce some of the excessive conservatism present in Level I, resulting in more accurate pressure estimate for more complex or critical defects.

Level III, on the other hand, uses advanced tools like FEA for precise calculations in high-risk pipelines, offering the most accurate burst pressure estimates. This level is chosen for complex, high-risk pipelines where precision is critical, and failure could have significant safety, environmental, or financial consequences.

Comparison of burst pressure calculation: FEA simulation (Level III) vs. analytic method (Level II)

Creaform tested four pipeline samples to compare burst pressures using different methods. The maximum operating pressures of these pipeline samples were then calculated using five techniques:

) B31.G Standard.

) B31.G Modified Standard.

) B31.G Standard – Effective Area.

) PSQR.

) FEA Simulation.

Results are shown in Table 1.

Method for burst pressure analysis

B31.G standard

The B31.G standard focuses on evaluating the severity of metal loss due to corrosion and other defects and helps determine whether a pipeline can continue to operate safely or if repairs or replacements are necessary. It provides guidelines for calculating the remaining strength and safe operating pressure of corroded pipelines.

The B31.G method calculates a “safe operating pressure” based on factors such as:

) Size and depth of the corrosion defect.

) Original wall thickness and diameter of the pipeline.

) Material properties of the pipe.

The B31.G standard is integrated into VXintegrity’s Pipeline module.

The results obtained with the B31.G standard show very conservative burst pressures, between 3.17 x and 5.19 MPa, for the four samples.

B31.G modified standard

The B31.G modified standard is an enhancement of the original B31.G method for assessing the remaining strength of corroded pipelines. The modified version refines the original approach by providing a more accurate and less conservative estimate of the pipeline’s remaining strength, particularly when dealing with deeper or more extensive corrosion.

It allows for more precise calculations by:

) Considering the actual profile and dimensions of the corrosion defect in greater detail.

Table 1. Burst Pressures with analytic methods compared to FEA simulation

Table 2. Burst pressure with FEA simulation compared with experimental tests

Figure 2. VXintegrity now offers the most precise burst pressure assessment available on the market.

) Reducing the level of conservatism in calculating the safe operating pressure of a corroded pipeline, leading to less unnecessary downtime or repairs.

One key improvement in the B31.G modified method is the use of the actual measured dimensions of the corroded area instead of idealised defect shapes. It also better accounts for longer, shallower corrosion profiles, which are less critical than deeper, smaller defects.

The B31.G modified standard is also integrated into VXintegrity’s Pipeline module.

The results obtained with the B31.G modified standard show slightly less conservative burst pressures, between 4.22 MPa and 6.68 MPa, for the four samples.

B31.G standard – effective area

While B31.G and its modified version focus on relatively simple and conservative assessments, B31.G Effective Area is an iterative method that adds a layer of sophistication. It provides a more accurate evaluation of corroded areas and a less conservative estimate of the corrosion profile by using a more detailed representation of the defect geometry.

By using different lengths to approximate the corrosion profile and assessing more data points at high resolution, VXintegrity produces a more reliable and consistent assessment.

The data obtained with B31.G – Effective Area shows slightly more permissive burst pressures, between 5.11 MPa and 7.98 MPa, for the four samples.

PSQR

VXintegrity now offers a streamlined path to FEA simulation, determining residual burst pressure through nonlinear elastoplastic analysis. Customers can simply export the 3D model of a damaged pipeline with a single click and receive a simulation analysis compatible with VXintegrity. With this tool, Creaform obtained the most accurate estimation of burst pressure, between 10.17 and 15.35.

Burst pressure result analysis

As shown above, burst pressures obtained with FEA simulation are up to 2.5x higher than with the more conservative B31.G and PSQR approaches.

The Pipeline Stress and Qualification Review (PSQR) method is an approximation technique developed by TransCanada for calculating the burst pressure of pipelines, especially those with complexities not adequately addressed by other methods. It is designed to provide a more accurate and less conservative approach than traditional methods like B31.G. PSQR incorporates more nuanced considerations, allowing for a better balance between safety and efficiency.

The PSQR method is also integrated into VXintegrity’s Pipeline module. The results obtained with PSQR show less conservative and more accurate burst pressures, between 5.57 MPa and 8.85 MPa, for the four samples.

FEA simulation

The FEA simulation is an advanced computational technique used to predict the pressure at which a pipeline will rupture due to internal stress. This method provides a highly detailed analysis of the pipeline’s structural integrity, particularly under internal pressure conditions, material defects, or metal loss due to corrosion.

The FEA simulation accurately calculates the burst pressure by analysing the pipeline’s mechanical response to the internal pressure at the critical failure point.

Because FEA simulation provides deeper insights by using more accurate models and factoring in complex geometries, material non-linearities, and precise load conditions, results obtained with FEA simulation align more closely with the pipeline’s real burst pressures under real-world conditions.

Asset owners can then avoid unnecessary repairs and save on maintenance costs, leading to more efficient use of resources and reducing unnecessary downtime.

In short, with FEA simulation, pipeline owners can make strategic decisions, leading to optimised operations, reduced costs, and better risk management.

Proof of rigour and accuracy of FEA simulations

When developing its model, Creaform Engineering compared its FEA simulation to numerous real cases and actual burst pressures.

Validation with real burst pressure values

Creaform Engineering aimed to validate the implementation of the triaxiality criterion outlined in the API 579 standard. To achieve this, the team compared the burst pressure values simulated with FEA to actual burst pressure data. They used a thesis from the University of Malaysia, 1 which includes a pipeline damage model and real explosion data obtained from experimental tests.

Figure 3. VXintegrity and Creaform engineering provides a complete solution for Level III FEA assesment for burst pressure.

The results showed that, in all cases, the burst pressures obtained through FEA simulation were 15 - 20% more conservative than the experimental values. This indicates that the simulation values maintain a 15 - 20% safety margin compared to the actual burst pressures observed in testing.

3D scanning technology

Creaform’s FEA simulation model is created by leveraging advanced 3D scanning technology, which offers unique benefits, such as traceability over time, metrology-grade accuracy, and human-independent results.

Internal pressure constraints, boundary conditions, and material properties automatically applied to FEA simulation model

Creaform automatically applies internal pressure constraints, boundary conditions, and material properties to the FEA simulation model.

By applying these constraints at key locations and running a non-linear FEA simulation, Creaform can accurately predict rupture points and the combined effect of these forces on the pipeline’s integrity. In VXintegrity, these constraints and combinations of forces are applied through advanced material models and boundary conditions, ensuring a comprehensive burst pressure analysis.

Triaxiality used to find the pipeline burst pressure

Based on API 579, Creaform uses the triaxiality criterion for assessing the pipeline burst pressure, especially in regions where stress concentration or defects affect material behaviour. Triaxiality is a measure of the ratio of hydrostatic stress (mean stress) to equivalent von Mises stress, and it helps determine how ductile or brittle the material behaves under complex loading conditions. Lower triaxiality indicates more ductile behavior, meaning the material can undergo significant plastic deformation before failure.

Engineers validate simulation analysis

The simulation results obtained by Creaform Engineering make FEA simulation for burst pressure analysis easily accessible for routine inspections. Customers simply export a precise 3D model of their damaged pipeline, accessible on-site with VXintegrity. The data transfer, feasible with one click, is safe through cloud services. Then, Creaform Engineering’s team runs its FEA simulation models. Using the triaxial strain criteria of API-579, they calculate stress and strain and evaluate the burst pressures and their locations. They generate 3D visual reports of the digitised surface to enable asset owners and service companies to clearly visualise the constraints and limits on their operating pipelines, reducing the time and effort needed to comply with Level III assessment requirements.

FEA simulation models so close to reality

With Creaform’s accurate and reliable burst pressure analysis, asset owners get a true representation of the pipeline’s performance under pressure, helping them to identify potential failure points before they occur. This proactive

approach enhances the overall safety of operations while saving costs associated with unnecessary maintenance, repairs, and inspections.

In summary, Creaform’s new FEA simulation results allow for more informed decision-making regarding pipeline operations because engineers and management can now base their decisions on reliable predictions rather than cautious estimates.

Case studies

Sasol – enhancing pipeline integrity in South Africa

Sasol, a global leader in chemicals and energy, faced challenges in maintaining the integrity of their pipeline network, which spans large geographical areas. Traditional methods of inspection were time-consuming and lacked the precision needed to identify potential failures. Sasol adopted advanced 3D scanning and NDT technologies, and by integrating FEA simulations could enhance the accuracy of their integrity assessments.

By using the VXintegrity Pipeline Module, Sasol was able to conduct inspections of pipeline sections in a fraction of the time previously required. By integrating real-world 3D scan data with FEA simulations, Sasol could potentially predict burst pressures more accurately, enabling more efficient maintenance scheduling and extending the lifespan of their pipelines.

Tilt Inspection & Consulting – pipeline inspections in Canada

Tilt Inspection & Consulting, a Cwanadian pipeline inspection company, was tasked with evaluating pipelines in remote areas where traditional inspection methods were impractical. The company adopted advanced 3D scanning and NDT technologies to streamline their inspection process.

Using the VXintegrity Pipeline Module, Tilt was able to conduct comprehensive integrity assessments quickly and efficiently. By integrating 3D scanning data with FEA simulations in the future, Tilt Inspection & Consulting could identify areas of concern, such as corrosion and dents, that traditional methods might overlook. This would allow them to provide more accurate, actionable data while potentially reducing inspection time and costs.

The future of pipeline integrity assessments

The integration of FEA simulations and advanced 3D scanning technologies represents a significant leap forward in pipeline integrity management. By improving the accuracy of assessments and enabling operators to make more informed decisions, these technologies help reduce the risk of pipeline failures and optimise maintenance strategies.

As the industry continues to embrace these advanced technologies, pipeline operators will be better equipped to ensure the safety, efficiency, and longevity of their infrastructure, ultimately driving greater value and sustainability in their operations.

References

1. ALANG, N.A., RAZAK, N.A., SHAFIE, K.A., and SULAIMAN, A., ‘Finite Element Analysis on Burst Pressure of Steel Pipe with Corrosion Defects’, Corrosion & Fracture Focus Group, Faculty of Mechanical Engineering, University of Malaysia.

PIPELINE MACHINERY FOCUS

World Pipelines’ quarterly pipeline machinery focus.

Pettibone introduces the Extendo 1536X telehandler to its X-Series product lineup: in addition to providing heavy-duty material handling performance on construction jobsites, the 1536X is designed to operate with a baler attachment for industries that routinely move pipe or poles.

The Extendo 1536X features a 2-section boom compromised of formed boom plates that offer greater strength while reducing weight. The boom design gives the telehandler an impressive maximum load capacity of 16 000 lb with standard fork frames. Even when extended to its maximum lift height of 36 ft, the machine can lift up to 13 000 lb.

The 1536X is powered by a 120 hp Deutz TCD 3.6 Tier 4 Final diesel engine. Mounted onto a side pod, the engine offers easy accessibility to components and daily service checks, while still allowing for exceptional curbside visibility and a ground clearance of 20 in. The telehandler has a 30 gal. fuel tank and comes standard with foam-filled tires.

For operators in the oil and gas market and utility industry, the 1536X offers a baler attachment, also commonly known as a pipe and pole grapple. The implement is designed specifically for stockyards and other pipe and pole handling applications. The machine delivers a maximum load capacity of 14 700 lb when equipped with the baler.

The Extendo 1536X comes standard with X-Command®, a Pettibone telematics program that offers real-time access to machine data, saving time and money for equipment owners and service technicians.

Built on Pettibone’s next-gen X-Series platform, the 1536X features an advanced boom design. Boom deflection is minimised for better control and accuracy when placing loads. Significant boom overlap provides smoother operation and reduces the contact forces on wear pads, thereby extending service life.

An external, bottom-mounted extend cylinder further reduces the load on wear pads by up to 50%. The cylinder location provides improved service access to

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internal boom components. Fastener-less wear pads also simplify service, and heavy-duty extension chains help to ensure stable boom functions.

Pettibone’s tried-and-true hydraulic circuit delivers exceptional controllability and operating feel, while enhancing efficiency and cycle speeds. Cylinder cushioning dampens the end of strokes – both extending and retracting – to avoid the wear and tear of hard, jarring stops, while also helping to prevent the potential spilling of a load. The 1536X uses a single lift cylinder that improves operator sight lines and has twin hydraulic lines for tilt and auxiliary plumbing.

The drivetrain and axles are optimised to provide greater tractive effort with minimal tradeoff on top-end speed. A pintle-hitch mount adds versatility for towing. Built for use on rough terrain, the machine offers full-time 4-wheel-drive with a limited-slip front-axle differential. Tight-steer-angle capability provides an efficient turning radius. The Dana VDT12000 Powershift transmission offers three speeds, forward and reverse.

The Extendo operator cab maintains Pettibone’s ergonomic seat, pedal, joystick and steering wheel positions, while optimising line of sight in all directions. An analogue/LCD gauge cluster comes standard, and an optional 7 in. digital display with an integrated backup camera is also available. The cab also offers enhanced climate control, flat bolt-in glass, a split-door design, an openable rear window, lockable storage under the seat, and water-resistant components for easy interior washdown.

All-steel fuel and hydraulic tanks are built to resist damage, and the lockable fuel-fill is in a clean, accessible location. Options include solid tires, a sling hook for additional load security, a high-output LED lighting package, and a variety of attachments.

Pettibone/Traverse Lift, LLC is part of the Industrial Technologies Group, an affiliate of The Heico Companies. Founded in 1881, Pettibone has been recognised as the industry leader in material handling equipment since the company revolutionised the industry with the first forward-reaching, rough-terrain machines in the 1940s.

The Pettibone Extendo 1536X.

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:

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