World Pipelines - July 2025

C O NTENTS

WORLD PIPELINES | VOLUME 25 | NUMBER 07 | JULY 2025

03. Editor's comment

05. Pipeline news

Pipeline news from TC Energy, SLB OneSubsea, ROSEN, and Joseph Gallagher.

KEYNOTE: SOUTH AMERICA

12. Growing demand in South America

World Pipelines Contributing Editor, Gordon Cope, analyses how administrations across Central and South America are addressing sociopolitical and environmental tensions in their respective midstream sectors, amidst the growing population’s need for energy.

COVER STORY

17. Making DBB look easy

Dave Albertson, Director of Engineering Services, WeldFit.

PIGGING FOCUS

22. Beyond the tool

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

27. Supporting safe operations with ECA

Tom Alexander, Dynamic Risk.

PAGE 27

INTEGRITY & INSPECTION

31. Building on Ireland's energy system

Janet O’Shea, Operations Director, Biodiversity and Environmental Services, DNV, and Catherine Sheridan, Commercial Strategy Director, Biodiversity and Environmental Services, DNV.

OFFSHORE INTEGRITY

35. Controlling localised corrosion

David Celine, Managing Director, Omniflex.

WELDING & MATERIALS

39. Reimagining weld inspection

Norman Stapelberg, Commercial Director, Silveray, UK.

43. Empowering welding excellence

Joachim Böck, Fronius.

HDD Q&A

49. Horizontal directional drilling question and answer World Pipelines reached out to experts in the pipeline installation sector to find out the latest developments in horizontal directional drilling (HDD). With contributions from Michels and Herrenknecht.

SUPPLY CHAIN MONITORING

53. Guardians of the midstream

Tony Fonk, SpotSee President and CEO.

WeldFit makes pipelines more productive – supporting the critical infrastructure that keeps industries and communities moving. From the largest pipeline networks in the US to essential processing facilities around the world, WeldFit delivers performance and reliability wherever pipelines operate. Our latest innovation, the Dually® Double Block and Bleed Line Stop system, has been trusted across America to streamline project timelines and impress operators with its safe, straightforward approach to DBB isolation.

more information contact your SFL representative or email info@sealforlife.com

EDITOR’S COMMENT

CONTACT INFORMATION

MANAGING EDITOR

James Little james.little@worldpipelines.com

EDITORIAL ASSISTANT

Alfred Hamer alfred.hamer@worldpipelines.com

EDITORIAL ASSISTANT

Emilie Grant emilie.grant@worldpipelines.com

SALES DIRECTOR

Rod Hardy rod.hardy@worldpipelines.com

SALES MANAGER

Chris Lethbridge chris.lethbridge@worldpipelines.com

SALES EXECUTIVE

Daniel Farr daniel.farr@worldpipelines.com

PRODUCTION DESIGNER

Siroun Dokmejian siroun.dokmejian@worldpipelines.com

HEAD OF EVENTS

Louise Cameron louise.cameron@worldpipelines.com

DIGITAL EVENTS COORDINATOR

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EVENTS COORDINATOR

Chloe Lelliott chloe.lelliott@worldpipelines.com

DIGITAL CONTENT COORDINATOR

Kristian Ilasko kristian.ilasko@worldpipelines.com

JUNIOR VIDEO ASSISTANT

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

DIGITAL ADMINISTRATOR

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ADMINISTRATION MANAGER

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Carbon offsetting is a global climate strategy that promises to compensate for carbon dioxide emissions by participation in schemes designed to make equivalent reductions of carbon dioxide in the atmosphere. The question is, can you plant your way to net zero?

At its core, carbon offsetting is a balancing act wherein if you emit a ton of carbon dioxide, you pay someone else to remove or avoid that ton elsewhere. It doesn’t erase the original emission, but it compensates for it, at least on paper.

Offsets fall into two broad categories. Avoidance (or reduction) offsets prevent emissions that would otherwise have happened, for example, funding a renewable energy project that replaces a coal-fired plant, or protecting a forest from deforestation. Removal offsets go a step further by actively drawing carbon out of the atmosphere, using nature-based methods such as afforestation or soil carbon sequestration, or technical solutions like direct air capture and carbon mineralisation.

In a recent opinion piece, Wood Mackenzie forecasted that the carbon offset market is heading for a boom, set to become a US$150+ billion industry by 2050.1 Analysis from the ‘Carbon Offset Market Outlook’ forecasts that offsets will play an increasingly important role in a ‘slower-than-hoped energy transition’, and that “rising offset quality [will] support growing offset demand which will exceed supply by the 2040s and surge towards 3 billion t of carbon dioxide equivalent (tCO2e) by 2050”.

The report envisages that offset demand will be fuelled by hard-to-abate sectors such as energy. As these sectors struggle to decarbonise, companies will increase offset purchases as an interim solution. Pipelines sit in the middle of an incredibly emissions-intensive value chain and many operators face significant Scope 3 emissions from upstream suppliers and downstream users of transported hydrocarbons. These are notoriously difficult to reduce directly. Carbon offsets therefore offer a practical and, until relatively recently, affordable way to demonstrate climate ambition, balance out residual emissions, and remain competitive in a world increasingly focused on ESG performance. Offsetting buys time, certainly, but how much time (and how credible the purchase) is up for debate.

Wood Mackenzie argues that the carbon offset market is growing and transforming, because developers and buyers are seeking offsets with greater credibility: demanding tighter methodologies, stronger third-party oversight and more robust environmental integrity. Premium, high-quality credits are increasingly in demand. Better monitoring and new compliance regimes are also playing their part in raising standards.

But let’s imagine trying to erase your carbon footprint with trees, only to discover that you’d need a forest larger that North and Central America combined. That’s the message handed to fossil fuel companies in a new study by ESSEC Business School, that casts doubt on carbon offsetting as a cure-all for emissions.2

For many pipeline operators, offsets can act as a bridge while more substantial decarbonisation measures gain traction, but the era of ‘offset and forget’ is over. The credibility of offset strategies is under rising scrutiny from regulators, investors, and from the public, who are increasingly knowledgeable about what real climate action looks like.

A strong carbon strategy for the pipeline sector must go further than offsets. That includes investing in methane leak detection and repair, electrification of pumping stations, optimised route planning, and support and readiness for lower carbon fuels and infrastructure.

1. www.woodmac.com/news/opinion/forecasting-carbon-offset-use-to-2050-what-you-need-to-know

2. www.newscientist.com/article/2485015-offsetting-global-fossil-fuel-stores-by-planting-trees-is-impossible

SENIOR EDITOR Elizabeth Corner elizabeth.corner@worldpipelines.com

Because we’re pioneers.

Across energy and critical infrastructure, we bring expertise where complexity is highest. With globally local teams and proprietary technologies unmatched in the sector, we move projects forward, no matter the challenge.

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

WORLD NEWS

USDOT rescinds Biden-era guidance

The US Department of Transportation’s (USDOT) Pipeline and Hazardous Materials Safety Administration (PHMSA) has announced it has transmitted a notice to the Federal Register that rescinds an Advisory Bulletin issued by the Biden administration concerning the provisions in Section 114 of the “Protecting our Infrastructure of Pipelines and Enhancing Safety Act of 2020” (2020 PIPES Act).

The rescinded bulletin went beyond the scope of what Congress directed the agency to do in the text of Section 114 and imposed new regulatory requirements and significant costs on the pipeline industry to advance environmental objectives. PHMSA is rescinding this Advisory Bulletin to address Federal overreach and reduce an overbearing and burdensome administrative state as directed by President Trump in Executive Order 14219.

“Eliminating red tape is at the heart of this administration’s plan to maintain energy dominance,” said US Transportation

Secretary Sean Duffy. “President Trump’s aggressive deregulatory agenda is bringing down costs for consumers and unleashing a golden age of American energy.”

“Section 114 provided clear direction to operators and PHMSA,” said PHMSA Acting Administrator Ben Kochman.

“That is why I am rescinding the prior administration’s Advisory Bulletin, which imposed new requirements outside the scope of existing regulations and statute.

The notice rescinding the Advisory Bulletin directs owners and operators of pipeline facilities to adhere to the text of Section 114 of the 2020 PIPES Act and section 60108(a) of the Pipeline Safety Act in developing their inspection and maintenance plans. PHMSA and State pipeline safety enforcement personnel should do the same in reviewing the adequacy of those plans during future audits and inspections.

The rescission is effective immediately upon publication in the Federal Register.

TC Energy commences collection of tolls on Southeast Gateway pipeline

TC Energy has announced that it has commenced the collection of tolls from the Comisión Federal de Electricidad (CFE) for the Southeast Gateway pipeline and has been paid by the CFE for the month of May, on time in accordance with the contract. TC Energy continues to work with the newly constituted Comisión Nacional de Energía (CNE) to obtain the approval of regulated rates as soon as possible, which is required to provide service to potential future interruptible service users on Southeast Gateway other than the CFE.

The Southeast Gateway pipeline, a 1.3 billion ft3/d, 715 km natural gas pipeline, was constructed approximately 13% under the original cost estimate in less than three years from the project’s final investment decision. Southeast Gateway was the first significant energy infrastructure project constructed under

TC Energy’s successful public-private partnership with the CFE.

“The successful completion of the Southeast Gateway pipeline reflects the unwavering commitment of our team, the CFE and the Ministry of Energy (SENER) to support Mexico’s expanding energy demand and future economic development,” said François Poirier, TC Energy’s President and Chief Executive Officer.

To advance Mexico’s economic growth and energy security, the Government of Mexico has announced plans to add approximately 8.5 GW of newly installed capacity from natural gas power plants. The Southeast Gateway pipeline, along with the Company’s other assets in Mexico, is positioned to play a vital role in supporting this initiative and the transition to lower-emission, more reliable energy sources.

East Coast Hydrogen funding kickstarts major clean energy programme

East Coast Hydrogen announced that one of the UK’s most ambitious hydrogen infrastructure programmes has taken a significant step forward with £96 million Ofgem funding confirmed to support its next phase.

East Coast Hydrogen will repurpose and build new gas pipelines to deliver clean hydrogen at scale across the North East, the Humber region, Yorkshire, and the East Midlands – a critical step on the UK’s journey to clean, secure energy.

The company will help power generation and heavy industry across the East Coast transition from natural gas –replacing it with low-carbon hydrogen to protect jobs, keep the lights on, and deliver the infrastructure needed to support the UK’s future hydrogen economy.

Ofgem has now confirmed its support for East Coast Hydrogen – a partnership led by National Gas, Cadent, and Northern Gas Networks – by awarding around £96 million in funding to carry out engineering, planning, and public consultation on proposals. This follows the £500 million

announced by Government for regional hydrogen transport and storage networks as part of the Spending Review.

It will pave the way for delivery of a hydrogen-ready pipeline network which is expected to be delivered over the next decade and make a major contribution to the UK’s decarbonisation efforts.

This latest funding ensures work can continue at pace on the infrastructure needed to deliver that transformation.

Ofgem’s decision signals confidence in the region’s ability to help lead the UK’s hydrogen transition and opens the door to thousands of jobs and future investment in key industrial heartlands.

East Coast Hydrogen is expected to move into the delivery phase later this decade, with the aim of starting hydrogen flows from the early 2030s.

It brings together over 120 organisations across key sectors including hydrogen producers, power generators, industry, energy networks, airports, and hospitals.

WORLD NEWS

SEFE partners with Azerbaijan’s SOCAR to import up to 15 TWh of natural gas per year

IN BRIEF

USA

Intensity Infrastructure Partners, LLC (Intensity) and Rainbow Energy Center, LLC (Rainbow) have announced a partnership to develop a natural gas pipeline from the resource-rich Bakken to eastern North Dakota. This joint effort provides an opportunity for North Dakota to further utilise its natural resources within the state.

UAE

The Forum Energy Technologies (FET) Subsea product line has secured a contract to provide two work class remotely operated vehicles (ROVs) to CCC (Underwater Engineering) S.A.L (CCC (UE)), the UAEbased offshore construction organisation.

UK & USA

DNV advances JIP to enable safe CO2 pipelines for CCS. DNV is advancing Skylark, a joint industry project to enhance our understanding of CO2 pipeline operations ensuring regulators and operators globally have access to the highest quality of information to make their decisions.

GERMANY

In a milestone for European energy security, first gas is flowing through Strohm’s thermoplastic composite pipe (TCP) system at the Wilhelmshaven 2 terminal in Germany, following the successful commissioning of a second floating storage regasification unit (FSRU), Excelsior. This marks the first time gas is being delivered to Europe through this newly installed subsea pipeline infrastructure.

SEFE Securing Energy for Europe and SOCAR, the State Oil Company of Azerbaijan Republic, have announced that they have signed a natural gas purchase contract for the next 10 years. Deliveries from SOCAR to SEFE under this contract will start in 2025.

The annual quantity will gradually increase to 15 TWh, which is approximately 1.5 billion m3. This partnership will support investments in production and infrastructure such as gas compressors, increasing the amount of pipeline gas coming to Europe and thus ensuring the continent’s security of supply.

Dr Egbert Laege, SEFE CEO, said: “This long-term contract is a testament to the strong relationship between Germany

and Azerbaijan. With this partnership, we are establishing a new route for significant gas volumes to reach Europe, thereby diversifying our portfolio and increasing the security of supply of our customers.”

Rovshan Najaf, SOCAR President, said: “This agreement marks another significant milestone in SOCAR’s ongoing commitment to enhancing Europe’s energy security. By supplying reliable and substantial natural gas volumes to SEFE, we are strengthening the partnership between Azerbaijan and Germany, contributing positively to Europe’s energy diversification goals and sustainable growth. SOCAR remains dedicated to investing in infrastructure and production capacities, ensuring secure and uninterrupted energy supplies for our partners.”

Report: Over 50% of top oil and gas firms hit by data breaches over a 30 day period in May

A recent Cybernews analysis found that 94% of the world’s top 400 oil and gas companies have suffered at least one data breach to date. Over 50% of the analysed oil and gas firms were breached in just one 30 day period.

According to the Cybernews Business Digital Index, which grades businesses based on their online security measures, 69% of the companies received a cybersecurity score of D or F, and only 10% achieved an A grade.

The analysed oil and gas companies experienced common systemic vulnerabilities spanning several cybersecurity areas. A significant proportion of companies exhibit unresolved software patching issues – meaning they have not applied important security updates – with 32% vulnerable to general patching gaps and 20% exposed to critical unpatched flaws that could allow attackers to exploit known weaknesses and gain access to their systems.

Email security remains a critical weakness, affecting 48% of organisations. This includes missing protections against phishing, spoofing, and unauthorised access, allowing attackers to trick employees, steal credentials, or spread malware.

Additionally, vulnerabilities in system hosting, found in 74% of companies, point to insecure configurations in the servers or cloud environments that support core

business functions. Issues with SSL/TLS configuration were identified in 91% of organisations, indicating widespread failures in properly encrypting data transmissions –a flaw that can expose sensitive information to interception or tampering.

The data also reveals that corporate credentials have been stolen from over 80% of companies, and 38% of domains are vulnerable to email spoofing. These gaps in security posture indicate that fundamental cybersecurity controls and protocols are either inconsistently implemented or insufficiently maintained across the sector.

Data breaches represent the most prevalent cybersecurity issue across the oil and gas sector. According to the data, 94% of the analysed companies have experienced at least one data breach as of May 2025. Over 50% of companies suffered breaches within the 30 day period in May, and 27.1% experienced breaches during a one week period.

This high frequency of incidents shows not only the scale of the threat but also the ongoing failure to mitigate known risks effectively.

Overall, the data suggests that Asia currently faces the greatest cybersecurity challenges, while Europe shows a more balanced performance. Though heavily represented, North America appears relatively strong in password management and slightly less exposed to high-risk vulnerabilities.

PROTECTIVE OUTERWRAPS

BUTYL TAPE WRAP SYSTEMS

LIQUID EPOXY COATINGS

PETROLATUM TAPE WRAP SYSTEMS

SOIL-TO-AIR INTERFACE

HEAT SHRINKABLE SLEEVES

INTERNAL PIPE LININGS

BITUMEN TAPE WRAP SYSTEMS

9 - 12 September 2025

CONTRACT NEWS

Northern Lights CO2 expansion: SLB OneSubsea secures EPC contract

Gastech Exhibition & Conference

Milan, Italy

https://www.gastechevent.com/visit/visitorregistration/

23 - 24 September 2025

Subsea Pipeline Technology Congress (SPT 2025)

London, United Kingdom

https://sptcongress.com/

21 - 23 October 2025

Carbon Capture Technology Expo Europe 2025

Hamburg, Germany

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

3 - 6 November 2025

ADIPEC 2025

Abu Dhabi, UAE

https://www.adipec.com/

20 - 23 January 2026

PPIM 2026

Houston, USA

https://ppimconference.com/

3 - 7 March 2026

CONEXPO-CON/AGG 2026

Las Vegas, USA

https://www.conexpoconagg.com/conexpo-conagg-construction-trade-show

15 - 19 March 2026

AMPP Annual Conference + Expo

Houston, USA

https://ace.ampp.org/home

27 - 30 April 2026

Pipeline Technology Conference (PTC)

Berlin, Germany

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

4 - 7 May 2026

Offshore Technology Conference

Houston, USA

https://2026.otcnet.org/

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

The final investment decision for phase two was made by the Northern Lights’ owners TotalEnergies, Shell, and Equinor following a commercial agreement with an end-use customer, marking a decisive milestone for the adoption of carbon capture and storage (CCS) at scale. The SLB OneSubsea scope includes two new satellite subsea CO2 injection systems with associated tie-in equipment. Work has already commenced, with first deliveries expected in 2026.

The award follows the successful

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

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

This work is part of an initiative that will play a role in decarbonising North West England and North Wales, helping to cut regional CO2 emissions by 25% starting in the mid-2020s.

The initiative aims to create a lowcarbon future by capturing and securely storing CO2 from heavy industries while also delivering locally produced, low-carbon hydrogen to power businesses, transport, and homes. By developing a carbon capture and hydrogen infrastructure, the project will boost energy security, safeguard jobs, and create new opportunities for skilled workers across the region.

As part of this contract, ROSEN (UK) Ltd will conduct comprehensive design verification of the project’s CO2 transportation pipelines, ensuring they meet the highest safety, reliability, and performance standards. ROSEN’s engineering expertise will support the client to re-engineer and re-purpose pipelines for carbon storage. This collaboration, which began in early 2025, marks the start of a twoyear partnership, with potential for further projects as the UK accelerates its transition to net-zero emissions.

delivery of two subsea injection systems for the first phase of this project in 2023. Northern Lights is part of the world’s first open-source, full-scale value chain for CO2 capture, transport, and storage services. Phase two will increase the current capacity from 1.5 million tpy to a minimum of 5 million tpy of CO2. Northern Lights phase two is also enabled by a grant from the Connecting Europe Facility for Energy (CEF Energy) funding scheme.

In May 2025, Northern Lights received confirmation that all the required permits are in place to start injecting and storing CO2 in the Aurora CCS license in the North Sea. Phase one development of Northern Lights is completed, fully booked and ready to receive CO2 from industrial customers. Operations are scheduled to begin in 2H25.

ON OUR WEBSITE

• Connected by pipeline: Marathon and Osage Nation find success

• APAC on course to become world’s largest CO2 shipping market, forecasts new Xodus CCUS report

• EPIC Crude continues collaboration with Port of Corpus Christi as it finishes Channel Improvement Project

• Charps highlights work on US oil and gas pipeline infrastructure in upcoming TV segment

Follow us on LinkedIn to read more about the articles linkedin.com/showcase/worldpipelines

CONTRACT NEWS

Joseph Gallagher secures contract to deliver trenchless crossings for United Living on Liverpool Bay CCS project UK North West

Joseph Gallagher Ltd (JGL) has announced its appointment by United Living, marking a continuation of the strong working relationship between the two organisations, to deliver a major package of trenchless construction works as part of the transformative HyNet North West project.

With a contract value of circa £50 million, this project reinforces JGL’s expertise in complex underground engineering and its commitment to advancing the UK’s low-carbon energy infrastructure.

HyNet North West is a pioneering initiative at the heart of the UK’s transition to a low-carbon future. Designed to transform the region’s energy landscape, it focuses on:

) Low-carbon hydrogen production combined with CO2 capture.

) Creation of a hydrogen distribution network delivering clean fuel to industrial users.

) Development of underground hydrogen storage in salt caverns.

) Facilities to capture CO2 emissions from new and existing industries.

) Safe CO2 transportation and permanent storage in Liverpool Bay.

This project will significantly decarbonise the North West of England and North Wales, driving inward investment, creating jobs, and contributing to the UK’s net zero targets.

JGL’s scope covers the design and construction of 53 trenchless crossings across a 35 km pipeline route. These crossings ensure safe pipeline installation beneath critical

infrastructure and natural features.

Key elements include crossings under: 34 roads, four railways, eight major oil and gas pipelines, two rivers, one canal, one brook, one woodland, and two tow paths.

Construction on the HyNet project will involve a wide range of trenchless techniques, showcasing Joseph Gallagher Ltd’s technical expertise. Works will include the installation of 24 shafts to facilitate tunnel boring machine (TBM) crossings, alongside two 1200 mm TBM drives in excess of 100 m. In addition, twelve 1500 mm TBM drives will be delivered, spanning lengths of 55 m up to 260 m. The project also incorporates a 20 in. Horizontal Directional Drilling (HDD) crossing and a significant 36 in. crossing beneath the River Dee.

Further installations will comprise two 20 in. auger crossings and thirty-seven 36 in. crossings, ensuring seamless and safe passage beneath existing infrastructure and natural features.

This project showcases JGL’s trenchless technology capabilities and plays a vital role in:

) Supporting the North West’s shift towards a clean hydrogen economy.

) Reducing regional carbon emissions at scale.

) Protecting critical infrastructure through advanced trenchless installation methods.

) Creating approximately 160 roles within JGL’s scope of delivery, accounting for over half of the 300 supply chain jobs projected for the project overall.

) Creating employment and skills development opportunities throughout the region.

) Enabling inward investment into industrial decarbonisation.

Glenfarne: US$115 billion strategic partner interest for Alaska LNG

Glenfarne Alaska LNG, LLC, a subsidiary of Glenfarne Group, LLC and majority owner and lead developer of Alaska LNG, a joint venture with the State of Alaska’s Alaska Gasline Development Corporation, has announced that it has completed the first round of its Strategic Partner selection process, with over 50 companies participating from the US, Japan, Korea, Taiwan, Thailand, India, and the EU.

These potential partners have formally expressed interest for over US$115 billion of contract value for various partnerships with the project, including equipment and material supply, services, investment, and customer agreements.

Alaska LNG’s economic fundamentals allow it to deliver LNG into Asia at prices that are lower than Henry Hub pricing from the US Gulf Coast. Glenfarne launched its Strategic Partner Selection Process in early May to partner with global companies with a desire for a long-term partnership with the Alaska LNG project.

The Alaska LNG project consists of an 807 mile, 42 in. pipeline capable of transporting enough natural gas to meet both Alaska’s domestic needs and supply the full 20 million tpy Alaska LNG export facility.

Further accelerating the project’s execution, the pipeline will be built in two independent, financially viable phases. Phase One will deliver natural gas approximately 765 miles from the North Slope to the Anchorage region.

Phase Two adds compression equipment and approximately 42 miles of pipeline under the Cook Inlet to the Alaska LNG Export Facility in Nikiski, which will be constructed concurrently with the LNG export facility.

Glenfarne anticipates a final investment decision on the domestic portion of the Alaska LNG pipeline in late 4Q25 and recently announced a partnership with Worley to complete the final engineering for the pipeline portion of the project.

Glenfarne Group, LLC is the owner of Texas LNG, which recently announced that its capacity is fully sold out, and a final investment decision is expected later this year. Glenfarne Group, LLC’s other affiliates include the largest importer of LNG into Colombia and Magnolia LNG, a late-stage LNG export project located in Lake Charles, Louisiana. Beyond LNG, Glenfarne Group, LLC owns over 50 operating assets in the energy sector across five countries.

Together with Alaska LNG, its permitted LNG portfolio totals 32.8 million tpy of capacity under development.

World Pipelines Contributing Editor, Gordon Cope,

analyses how administrations across Central and South America are addressing sociopolitical and environmental tensions in their respective midstream sectors, amidst the growing population’s need for energy.

The vast expanses of Central and South America encapsulate some of the largest fossil fuel deposits on earth, as well as an immense population thirsty for energy. The region is also beset by tumultuous geopolitical, social and environmental concerns. The situation has been aggravated by the Trump administration’s volatile tariff gyrations. Various administrations are navigating their way through perilous waters.

Brazil

Petrobras continues to be a significant engine of growth in Brazil. Over the last year, it has increased its proven oil reserves by 500 million bbls, to a total of 11.4 billion bbls. It has earmarked US$111 billion in spending for the next five years, including US$77 billion for exploration and production. In 2024, production surpassed 2.2 million bpd of crude, and 2.7 million boe/d.

In late 2024, Petrobras commissioned the 600 million ft3/d Rota 3 gas pipeline designed to deliver gas from the Santos Basin pre-salt fields to its largest processing unit, the UPGN facility located near Rio de Janeiro. The move is part of the government’s decree to re-inject less of the 13.4 trillion ft3 of reserves in the pre-

salt fields and deliver more to domestic customers. In addition to Rota 1 and Rota 2 pipelines, the system now has the capacity to transport over 1.4 billion ft3/d to onshore facilities. Further proposed expansions to the network could double the capacity.

Most of Brazil’s refining and import infrastructure is located in coastal ports, while consumption occurs throughout the continent-sized country. Because Brazil’s fuel pipeline network amounts to a mere 5800 km (compared to 135 000 km in the US), tens of thousands of trucks are used to deliver gasoline, diesel and jet fuel to market. In order to reduce emissions, increase transportation efficiency and meet growing demand, Brazil’s Energy Research Office (EPE), initiated the Indicative Oil Pipelines Plan that outlines a series of proposed pipelines, including the 1648 km Araucária – Cuiabá project, a 20 in. mainline with a capacity of 200 000 bpd. In all, the EPE calls for an investment of US$6 billion over the decade.

Mexico

Mexico has been wrestling with declining production for the last several decades; output has plunged from 3.4 million bpd in 2004 to 1.6 million bpd in 2024. A lack of investment and corruption at

state-owned Pemex is largely to blame, but the nationalist policies of former President Andrés Manuel López Obrador (AMLO) have also driven away international investment in oil exploration.

LNG holds greater potential. The Pacific coast of Mexico is thousands of kilometres closer than the USGC to markets in Asia and obviates the need for shippers to pass through the Panama Canal. There are six proposed export terminals located on the Pacific and three more on the Gulf coast. Sempra Energy’s Energía Costa Azul (ECA) LNG, located in Baja California, is a former LNG import site. The 3 million tpy train is expected to be commissioned by late 2025, and could ultimately be expanded to 12 million tpy. The Mexico Pacific Limited (MPL) LNG project is located on the Sea of Cortez. The latest plan is to build three trains totaling 14.1 million tpy capacity in Phase 1, and a further three trains in Phase 2, doubling capacity to 28.2 million tpy. While the Biden administration’s suspension on new LNG projects had a chilling, knock-on effect on Mexican plans, President Trump cancelled the pause, allowing proposals to proceed once again.

Colombia

Colombia is South America’s third largest oil producer, with an output of approximately 780 000 bpd (and 1 billion ft3/d of associated gas). It has only eight years of crude and gas reserves left before it runs out, however, so the country’s oil and gas sector was heartened when Ecopetrol announced the discovery of a giant offshore gas field. The Sirius-2 well, located 77 km offshore in the Caribbean Sea, encountered an estimated 6 trillion ft3 of gas, doubling the country’s reserves overnight. Ecopetrol and partner Petrobras estimate that it will cost over US$4 billion to build a pipeline and bring the field online by 2027. Production is expected to approach 500 million ft3/d over a 10 year period.

Attacks on the country’s pipeline infrastructure continue. In April 2025, the Bicentenario crude pipeline was shut down after a guerrilla attack. The 230 km spur line carries over 200 000 bpd of oil from the prolific Llanos basin, connecting up to the larger Ocensa transport system. Members of the National Liberation Army (NLA), were blamed.

The election of Gustavo Petro in 2022 saw a long-standing federal endorsement of fossil fuels reverse as the president announced a shift away from oil, gas, and coal toward renewables. New decrees, including the suspension of new exploration licenses, ensued.

Argentina

The Vaca Muerta unconventional shale play in Neuquén province continues to accelerate. By late 2024, production had risen to 428 000 bpd and 3.8 billion ft3/d from virtually nothing a decade ago; the play has the potential to surge to 1 million bpd and 5 billion ft3/d by 2030.

The rapid growth has necessitated the expansion of the country’s pipeline network in order to deliver energy to domestic and international customers. In late 2024, YPF completed the Vaca Muerta Norte project, a 160 000 bpd line that services both a local refinery and Chile. Approximately 50 000 bpd is delivered to its Lujan de Cuyo refinery in Mendoza, Argentina, 100 km east of the border with Chile. The remaining 110 000 bpd continues west to Chile for processing at the BIO refinery. YPF also plans to build the 440 km Vaca Muerta Oleoducto Sur (VMOS). The US$3 billon line

would run 440 km from Neuquén province to the Atlantic port of Punta Colorada. The line will have 180 000 bpd capacity; when completed in late 2026; further phases will see capacity rise to 550 000 bpd in 2027 and up to 700 000 by the end of the decade. Natural gas networks are also being enlarged. The 800 million ft3/d Nestor Kirchner gas line, completed in 2023, is being expanded by an additional 500 million ft3/d to primarily service growing domestic demand, as well as connect to neighboring countries. In June 2025, the governments of Argentina and Brazil met to coordinate potential shipments of natural gas from the former to the latter using a combination of pipeline reversals and new-build. Currently, it is technically feasible to move approximately 700 million m3/y on existing infrastructure; expansion of interstate networks could allow up to 10 billion m3 by the end of the decade. Preliminary work is underway to delineate the most economical routes. Ambitious plans are also underway to build an immense LNG export project on the Atlantic coast. YPF, Shell and other partners are planning to spend up to US$50 billion to construct Argentina LNG in the coastal province of Rio Negro. The first phase of 10 million tpy will use floating LNG vessels, while future phases envision the construction of onshore LNG facilities in order to boost capacity to 28 million tpy. In June 2025, Pan American Energy, one of the partners in the LNG development, noted that the port would eventually need an additional pipeline with a capacity of over 18 billion m3/y to address liquefaction needs, making it the largest gas pipeline in Argentina.

Venezuela

Venezuela was once the powerhouse of Latin America; with an estimated 304 billion bbls of reserves, the country produced over 3 million bpd, but has seen output plummet to under 1 million bpd. Much of the problem can be attributed to mismanagement, a lack of maintenance, and blatant corruption. The lack of maintenance funds has had a profound impact on the midstream sector. Environmental NGOs estimate that PDVSA suffers over 70 spills every year from its 25 000 km network of pipelines and related infrastructure. The worst contamination in the last 12 months has been the August 2024, discharge of fuel oil from the El Palito refinery, located on the Caribbean coast. Satellite images showed a bloom covering 225 km2. Authorities responded by suspending all fishing and tourism activity in the area.

Guyana

Over the last decade, Guyana has risen to one of the continent’s largest oil exporters. Currently, a consortium led by ExxonMobil produces approximately 650 000 bpd; with the upgrades to its three FPSOs and the arrival of a fourth vessel, production is expected to rise to 940 000 bpd in 2025. With the addition of further commissioned FPSOs, output is expected to reach 1.4 million bpd by the end of the decade.

The government of Guyana is keen to commercialise the associated gas. Under an agreement with ExxonMobil, the latter will deliver up to 130 million ft3/d from the Liza project via a 10 in., 225 km offshore pipeline (costing approximately US$1 billion), to a 300 MW electricity complex near the capital of Georgetown. Over the longer-term, the government is also looking at further pipeline deliveries in order to supply LNG and fertilizer

plants; ExxonMobil and partners have plans to produce up to 1.5 billion ft3/d of gas from its Longtail field when the project comes on-stream later in the decade.

Suriname

The former Dutch colony of Suriname is located due east of Guyana, and shares the same prolific offshore geology. In November 2024, TotalEnergies made a final investment decision on developing its discoveries in Block 58, located 150 km off the coast of the Atlantic nation. The French-based company announced that it would spend up to US$10 billion to develop the GranMorgu project, consisting of the Sapakara and Krabdagu fields, which hold over 750 million barrels of crude. An FPSO capable of producing 220 000 bpd is forecast to begin production in 2028.

Panama

Panama, not normally a country known for its midstream sector, is considering building a 1 million bpd pipeline to transport liquid petroleum gas (LPG). The 100 km line would originate in the north near the port of Colon in the Caribbean Sea, and travel south to the Pacific port of Panama City. The LPG, which would originate from the USGC, would then be transported to the growing market in Asia. Authorities predict that volumes could reach 2 million bpd within the decade.

Problems

Geopolitical challenges beset most producing nations in the region. Such complications have profound impacts on investment and construction plans. For several years, Venezuela has been under pressure from US sanctions to pursue democratic reforms. In March 2025, the Trump administration ordered Chevron to wind down its oil operations in Venezuela, causing PDVSA to curtail shipments to the US amid payment uncertainties. The hardened sanctions have caused Venezuela’s total exports to drop by around 20%, to 700 000 bpd. Currently, Venezuela ships deliver less than 140 000 bpd to the USGC; almost 500 000 bpd is bound for its main customer, China.

In Colombia, the left-leaning President Petro continues to promote environmental policies that undermine investment and maintenance of oil and gas infrastructure. In addition, guerrilla armies continue to blow up pipelines and plunder crude to fuel their drug operations.

Mexico is well aware of the potential for the Trump administration to impede the movement of gas through tariffs or arbitrary curtailment. President Claudia Sheinbaum, AMLO’s chosen successor, announced an ambitious programme in which the state-owned company will drill over 200 exploration wells in an attempt to increase gas output from 3 billion ft3/d to 5 billion ft3/d by the end of her term in 2030.

Pipeline fuel theft in Mexico, which had been suppressed under AMLO’s administration, is also making a comeback. In May 2025, the US Department of the Treasury’s Financial Crimes Enforcement Network (FinCEN) issued an alert focusing on the smuggling of crude oil across the border by Mexican cartels. The cartels obtain the crude through corrupt Pemex officials then export it to Texas using false broker documentation. In addition, cartels tap into fuel lines and steal thousands of barrels a day of diesel and gasoline. The government estimates that Pemex is

once again losing several billion dollars per year from the thefts. FinCen is working with the FBI to identify and arrest cartel member and complicit middlemen.

In Argentina, President Javier Milei (a free-market economist who assumed office in December, 2023), passed legislation designed to encourage investment in major energy projects. The Basis Law calls for significant tax breaks on capital investments, as well as exemption from export taxes up to three years. The move has spurred international investment, but Milei faces pressure from opposition politicians to focus more on domestic issues such as inflation and poverty.

The government of Guyana is building a strong regulatory and fiscal policy to guide the development of the oil and gas sector and the diversification of its economy, but is facing hostilities generated by President Maduro of Venezuela regarding Eswsequibo, a disputed province that borders the offshore fields. In May 2025, mercenaries fired upon Guyanese soldiers patrolling in the region, escalating tensions.

Green energy

Several countries are taking a proactive approach to green energy. Colombia, which is looking to diversify away from fossil fuels, awarded contracts to add almost 4500 MW of solar power by 2028. It has also received interest from nine companies to install up to 3000 MW of offshore wind projects to meet its rapidly growing domestic consumption of electricity. Argentina, blessed with abundant wind, has expanded its network of wind farms to approximately 3300 MW, which represents almost 20% of its energy mix. The government of Brazil’s Ceará state announced it had reached an agreement with Madrid-based FRV to invest US$5 billion to build the H2 Cumbuco plant in Ceará’s Pecém Industrial and Port Complex in northeast Brazil. The first phase of the project will have a capacity of 400 000 tpy of ammonia, eventually rising to 1.6 million tpy.

Like green energy projects in Europe, however, low-carbon initiatives in Latin America are suffering from economic reality. Analysts point to a regional oversupply of electrical energy, a challenging regulatory landscape, and weak growth in demand for renewables. Shell, which had obtained authorisation to build several utility-scale solar farms in central and northeast Brazil, recently approached the country’s energy regulator and requested their permission be revoked, citing market challenges.

The future

In the near term, the expansion of its oil and gas sectors will help both Brazil and Guyana generate much-needed foreign exchange and stimulate their economies. Argentina has a comprehensive economic plan to augment regional pipeline networks to export to Chile, as well as tap into the international demand for LNG and light, sweet crude. Colombia, faced with diminishing reserves, is transitioning to a renewable energy economy. Mexico is hoping its state champion Pemex will reverse declining production and reduce its reliance on the US for natural gas and fuels. Venezuela, unfortunately, will continue to squander its natural resources patrimony. Regardless, over the longer term, a growing population hungry for energy will continue to present significant opportunities to the midstream sector.

Simple and easy aren’t two words usually associated with double block and bleed (DBB) isolation. Though they provide front-line defence against risk during pipeline maintenance, repair, and replacement, traditional DBB tool installations with two separate single seal heads can be a beast.

Depending on pipeline conditions, these heavy, complex tools can also be tricky to deploy or can get stuck in the line, adding steps and stress to the process, and blowing through

Dave Albertson, Director of Engineering Services, WeldFit, discusses how to optimise double block and bleed (DBB) isolation to avoid the difficulties of traditional DBB tool installations.

Figure 1. Early field testing of the Dually DBB Line Stop System, where seals were held for an average of 30 days across 12 job sites.

your budget. All those fittings and bolts mean more hands on deck, more headaches, and more hardware left on the line. And a single failure can trigger a cascade of threats, especially in high consequence areas (HCA).

WeldFit, a provider of pipeline products and services, has attempted to streamline the pipeline intervention process with the Dually® Double Block and Bleed Line Stop System. Since it was introduced in 2023, the Dually system has been installed at more than 60 job sites, performing more than 110 line stops – testimony to the device’s real-world capabilities.

Available for 8 in. through 42 in. pipelines with a maximum operating pressure of 1480 psi (102 bar, 600 class), the Dually system provides a redundant barrier against product leakage with far less setup time. That helps pipeline operators bring assets back online more quickly, reducing revenue loss associated with downtime.

A straightforward take on DBB technology DBB systems typically involve two plugging heads to completely isolate a section of pipe and a bleed valve that ensures the safe venting of residual fluids or gas.

A patented innovation designed for both gas and liquid pipeline intervention, Dually builds on WeldFit’s success with single seal line stops, achieving DBB functionality with a compact, straightforward tool.

Dually utilises a single pivoting-style plugging head with dual seals that isolate pressure, providing an added layer of verifiable safety. The single pivot point design makes it easier to insert, deploy, manoeuvre, and remove. Plus, there are fewer individual pieces to handle, transport, and assemble in the field, and half the taps, fittings, bolts, and welding points as conventional DBB.

The industry has trusted a single stop design for years but wanted double block and bleed for even more crew safety. Other companies have developed double block and bleed solutions that have had operational challenges in the field, which WeldFit believed it could fix, and decided to work with the concept that’s trusted versus developing something entirely new.

It took the traditional plugging head, which has been used in the industry with a standard fitting and a standard single pivot point for some 70 years and found a way through technology to collapse the seals down in such a way where you can fit it all through the same size hole, which is more reliable, simpler to use, and typically provides the quality of seal that customers require.

For any mechanical seal to function optimally, it needs to make uniform contact with a clean surface. Chips or debris left as the result of the tapping process can create gaps in the seal, letting product leak past. Dually’s chip-sweeping capabilities better remove any foreign material that could interfere with a tight seal.

Improving control

WeldFit created a pressure-free Zero Zone between the seals that acts as a reliable indicator of an effective isolation – any leakage past the first seal would cause a detectable pressure spike in the Zero Zone, instantly flagging a problem.

Beyond detection, the Zero Zone allows for the safe release of any lingering product or vapours trapped between the seals once isolation is confirmed via an onboard gauge. Operators can purge the Zero Zone through an internal bleed port to create a fully depressurised space, enabling technicians to work in a zero-energy environment and ensuring maintenance or repairs can proceed with maximum safety.

Gas has to be allowed to move around, but also controlled in where it moves. Even if gas enters the Zero Zone, it is contained within the Zero Zone and its path forward is isolated, preventing it from passing the secondary seal, or leaking out through any connection points on the very front of the tool that might be exposed to the atmosphere, which ensures the integrity of the work area.

The Zero Zone functions as a robust safety mechanism that:

) Verifies the integrity of the upstream seal.

) Provides a controlled means to depressurise the isolated area.

) Allows for the safe removal of hazardous product or vapours.

A matter of gravity

The Dually system is compatible with diverse pipeline products, including natural gas and NGL, and has been effectively implemented above and below ground, in tight trench boxes, and excavations, meaning it’s a practical choice in all common pipeline maintenance scenarios, even in confined spaces.

Dually has also been successful when deployed in difficult geometries where standard solutions might fail, such as precarious angles.

Figure 2. Used in more than 100 pipeline isolations across the US since May 2023, Dually has simplified the line stop process and prioritised safety on the job site.

ACOUSTIC TECHNOLOGY

Propipe are industry leaders in Acoustic technology. Supplying Acoustic pingers and multiple receiver types for tracking and locating pipeline pigs subsea.

Acoustic pingers can also be linked to SMART Gauge systems to detect pipeline defects and anomalies in real time.

When pipelines aren’t horizontal, gravity can work against the process of inserting and setting a heavy DBB tool. If the weight of the tool isn’t distributed evenly, the tool might shift or slip, potentially damaging its sealing mechanisms, not to mention the pipeline itself. An angled pipe might be difficult to seal – the sealing elements might not conform to the walls of the pipe. Working on a pipeline at a precarious angle often means limited and awkward access for technicians

and equipment. This can make the installation, operation, and monitoring of the DBB system more difficult and timeconsuming.

But because of Dually’s compact design it is less susceptible to gravitational forces, meaning it’s equally easy to insert and remove, regardless of the pipe’s angle. Under conditions where other DBB providers were reluctant to go, Dually performed flawlessly, showcasing its versatility.

Real world trials

WeldFit began development of Dually in April 2021, moving into rigorous proof testing that simulated defects under controlled conditions and extensive field trials to validate the system’s reliability under real-world pipeline conditions before its release. Proof testing of the head and components was performed at 1.5 times design pressure (2220 psi for 1480 psi rating, or 151 bar for 102 bar rating); additional testing included deploying the tool in the thinnest and thickest wall pipes to ensure compatibility with every schedule of pipe, and function tests without pressure to check deployment and retraction.

Independent testing is performed at pressures much greater than what will ever occur on a pipeline.

A significant field-testing phase involved working with a major North American operator at 12 US sites along 50 miles of 20 in. and 24 in. diameter pipelines. Testing was conducted over six months, from May to November, under varying weather conditions and pressures. Each deployment lasted approximately 30 days, and the system remained online throughout the test period.

“We had never predicted that some of these heads were going to be in the line for 30 plus days at a time,” Chris Peavy, WeldFit line intervention services coordinator, said. “That longevity alone is incredible. And because we didn’t need to rework, unbolt bypasses, or reattempt seals at any of the 12 job sites, it saved significant time and cost.

“Even if you say we saved two days per site, that’s 24 days of savings on cranes, construction crews, excavators, and labour. That equates to millions of dollars of savings for our client,” he added.

The true test: from the technician’s perspective

Perhaps no one else tests Dually’s simplicity and effectiveness like the technicians who use, monitor, and maintain it.

According to Tim Irelan, a senior technician with 18 years of experience, WeldFit places a strong emphasis on training and certification for technicians using Dually. Senior technicians, with extensive line stop experience,

Figure 3. Verification of the Dually’s no pressure ‘Zero Zone’ functionality on a customer job site.

Figure 4. A WeldFit senior technician adjusts a Dually plugging head.

undergo specific training and auditing to ensure proficiency with the system. For new technicians, WeldFit provides on-the-job training and multiple audits, ensuring only the most competent professionals handle oversight for installations. This rigorous process enhances reliability and safety during field operations.

Technicians’ feedback details Dually’s ease of use, and how units of all sizes perform without failure under diverse, high-stakes field conditions.

Irelan noted that one of Dually’s key advantages is the dual seals, which ensure safety even if there’s a leak in the primary seal.

“The secondary seal holds back vapours, allowing work to continue without having to pull the heads or bypass,” Irelan said. “This is particularly beneficial when servicing customers with stringent no-leak policies.”

Irelan explained that Dually’s seals, which meet industry standards, have been modified slightly in shape to enhance performance. They’ve been tested extensively, he said, including for longevity in a 2500 class vessel where they held 3330 psi (229 bar) for over a month.

Irelan also highlighted the significant reduction in bolting time, a labour-intensive bottleneck for traditional DBB systems. With Dually, the number of fittings is halved, equating to a consistent 50% reduction in setup time. Fewer fittings mean less bolting and welding, which not only accelerates the process but also lowers the risk of human error during assembly. This efficiency translates to significant savings in labour costs and minimises overall project downtime, reducing disruptions to pipeline flow.

“For typical line stop jobs, which can span from three days to a week depending on their size and scope, these time savings can lead to substantial operational cost reductions and improved project timelines,” Irelan said.

Customer feedback has also been overwhelmingly positive: they appreciate the time and cost savings it affords them and value the dual seals for their added safety. What’s more, customers agree that Dually represents a fresh option in the market, expanding service availability.

WeldFit draws inspiration from this feedback to fuel continuing innovations, with ongoing testing and development of new designs and enhancements, including seal styles. This commitment to research and development suggests that the Dually platform will remain at the forefront of pipeline isolation technology and continue to meet evolving industry needs.

Safety, savings, and ESG

Dually may be a relative newcomer to the market, but its performance, along with WeldFit’s reputation for innovation and reliability, has already positioned the technology as a trusted solution for pipeline isolation projects.

) Enhanced safety: the dual seals provide an extra layer of safety, ensuring isolation even if one seal fails. The ability to vent or drain through the isolation port further enhances safety by allowing safe release of trapped fluids or gases.

) Time savings: with fewer fittings, there’s less welding and fewer bolts to align, tighten, and inspect. This can cut setup time by as much as 50%.

) Cost savings: fewer fittings mean lower material and labour costs. The reduced risk of leaks and the ability to continue work if a primary seal fails also contribute to cost savings.

) Versatility: Dually’s design allows it to be used in a wide range of applications, from different installation angles to various pipeline types, making it adaptable to diverse field conditions.

) Environmental benefits: reducing fittings and potential leak points helps minimise emissions, aligning with environmental regulations and sustainability goals. Pairing Dually with WeldFit’s ReCAP® Emissions Recovery system prevents the release of greenhouse gases like methane, protecting not only the immediate work area, but ensuring compliance with regulations and ESG goals.

The Dually Double Block & Bleed Line Stop System by WeldFit has proven itself as an effective alternative to traditional DBB systems. Through its innovative design, rigorous testing, and successful field applications, Dually offers pipeline operators a reliable, efficient, and safe method for isolating sections of their pipelines. It is set to play a crucial role in the future of pipeline maintenance, while making DBB look easier than ever.

Figure 5. 16 in. Dually DBB Line Stop System delivering to a jobsite.

Jim Costain, Ron James, and Craig Hall, NDT Global, share their insights into vendor selection for pipeline inspection.

When it comes to pipeline integrity, selecting the right inspection vendor is critical not only to safeguard assets but to meet regulatory requirements and prevent costly failures. Yet with numerous vendors in the market, how can operators confidently identify a reliable, proven partner?

When it comes to pipeline integrity, few decisions are as consequential as choosing the right inspection

partner. At NDT Global, our approach is shaped by decades of hands-on experience and deep industry knowledge from leaders who understand the high stakes of pipeline inspection. Three of NDT Global’s commercial sales team share their insights into vendor selection.

Their collective experience highlights the importance of selecting a vendor that delivers more

than just a tool, it’s about insight, reliability, and long-term integrity success.

Tool capabilities and resolution

Accurate pipeline inspection hinges on high-resolution tools capable of detecting subtle and early-stage anomalies. Without precise data, defects can go undetected or misclassified, giving operators a false sense of security. This can delay preventive action and increase the likelihood of failure.

Over a three year period, one operator’s inspection programme using NDT Global’s Ultrasonic Inline Inspection Technology identified more than 800 000 features, including over 40 000 laminations and nearly 1000 crack-like anomalies. These insights enabled targeted repairs and proactive integrity planning that wouldn’t have been possible with lower-resolution tools.

A low-resolution inspection approach may not detect corrosion types such as channelling, wall loss under deposits, or crack-like features, issues that can escalate if not properly identified and addressed. Using the wrong technology for a given pipeline condition has led to catastrophic outcomes.

Experience and track record

Experience matters in pipeline inspection. Inspection vendors with extensive field experience bring valuable insights into pipeline behaviour across diverse conditions. Without this knowledge, vendors may deploy inappropriate tools or misinterpret data, resulting in poor decision-making.

For example, in one case, a pipeline failure occurred after years of using the same inspection approach that failed to identify channeling corrosion. The inspection provider persisted with MFL-A despite indications that an alternative technology was better suited. When the pipeline eventually failed, the previously reported features were found to be through-wall defects.

In another case, an operator awarded an inspection contract to a significantly lowercost provider claiming to meet a stringent specification. When the pipeline later failed, it became evident that critical features had been missed entirely. A subsequent reinspection by NDT Global identified extensive through-wall corrosion that had not been reported.

Selecting a vendor solely on price can lead to missed threats and pipeline failures.

Figure 1. Accurate pipeline inspection hinges on high-resolution tools and precise data.

Figure 2. A quality-first approach protects assets.

Figure 3. Experience matters in pipeline inspection.

A quality-first approach not only protects assets but saves costs long-term by reducing rework, downtime, and emergency interventions.

These real-world consequences highlight the risk of relying solely on cost when selecting an ILI vendor.

Compliance with industry standards

Inspection vendors must adhere to recognised industry standards such as API, ASME, and ISO. Non-compliance can result in unreliable inspection results, regulatory penalties, or even forced shutdowns.

NDT Global aligns its processes with global best practices, ensuring all inspections meet or exceed the expectations of industry regulators. This commitment not only enhances data integrity but protects operators from legal, safety, and operational risks.

Credibility

and reliability

Trust in your inspection vendor goes beyond a single run – it’s about consistent delivery of high-quality data and actionable insights. A credible vendor ensures that tool performance, data analysis, and reporting standards are upheld at every step.

Too often, we’ve seen cases where vendors underdeliver, promising high-spec performance at a low price point – only to miss critical threats. In markets where cost becomes the deciding factor, operators may

The cost of a single unplanned repair often exceeds the investment in high-resolution inspection. Choosing the right tool and vendor from the beginning is not just a technical decision – it’s a financial one.

Avoiding the risks of a poor vendor choice

When selecting an ILI partner, consider these key risks of working with an unproven or ill-equipped provider:

) Missed or misclassified defects: risking undetected through-wall corrosion, cracks, or complex threats.

) Regulatory non-compliance: exposing operators to fines or operational shutdowns.

) Higher total cost of ownership: from emergency repairs, re-inspections, and loss of product.

About the authors

) Jim Costain, Director of Commercial Sales, NDT Global, has supported operators worldwide in developing integrity programs built on high-resolution data and trusted analysis.

) Ron James, Director of Commercial Sales - MEAA, NDT Global, brings regional expertise and insight into navigating inspection challenges in diverse operating environments.

) Craig Hall, Commercial Account Executive, NDT Global, partners closely with operators to ensure inspection solutions are aligned with real operational needs and

downtime and rework problems DBB equipment with coupled heads or complicated hydraulics can create.

Dually’s compact design features a single, patent-pending dual seal, pivot-style plugging head with all its movement contained within the line stop fitting. The new design ensures more effective chip sweeping functionality by removing more debris that can interfere with a tight seal.

That means Dually is more maneuverable into and out of the pipeline than other DBB systems, and more reliable when it comes to first-time sealing success.

Tom Alexander, Dynamic Risk, outlines how operators can advance safety, compliance, and cost containment through engineering critical assessment (ECA) as an option for MAOP-reconfirmation.

ipeline safety is a top priority for operators and regulators alike. As part of a continual improvement process, operators are expected to maintain confidence in ongoing reliability by verifying pipeline safety using updated data and validated methods. With the implementation of the Gas Mega Rule, pipeline operators must reconfirm the maximum allowable operating pressure (MAOP) for certain gas transmission pipelines under 49 CFR §192.624.

Traditional methods like hydrostatic testing or pipeline replacement can be costly and disruptive. Engineering critical assessment (ECA) emerged as an efficient, data-driven and compliant solution, but industry-wide guidelines for its execution were lacking.

A collaborative approach to ECA methodology development

Dynamic Risk led a consortium of leading pipeline operators representing a significant portion of the gas transmission mileage in the US to develop a robust ECA methodology through collaboration. The approach aligned with the guidelines of 49 CFR §192.632 and applied established data integration and engineering approaches and principles to meet regulatory objectives through a focused and efficient assessment process.

ECA vs integrity management objectives

Many of the activities developed to support IM objectives are relevant to ECA objectives. Both ECA and IM processes consider factors such as material properties, operational circumstances, threat assessment and defect assessment, and rely on the same data elements to be integrated for analysis. The difference lies in how the information is used. Integrity management considers a wide range of regulations, industry standards and practices to continually manage the integrity of a pipeline over time. Specifically, 49 CFR §192.632 outlines the requirements for an ECA, namely, to provide the equivalence to a hydrostatic pressure test of the pipe, i.e., to be fit to

operate at a test factor appropriate to the class location of the MAOP-R segment. Integrity management is a continual, iterative process, while conversely the ECA is noted to be a one-time event condition snapshot confirming that the pipeline’s design and construction are suitable for operating at the established MAOP. The majority of segments for which the ECA applies (MAOP-R segments) are also subject to 49 CFR §192.710 or Subpart O integrity management and continual evaluation once the ECA has been completed.

How ECA works

To complete an ECA compliant with 49 CFR §192.632, traceable, verifiable and complete (TVC) records for diameter, wall thickness, seam type, and pipe grade are required. Where such values are not available, conservative assumptions can be used for completion of the ECA; however, material properties still must be verified according to 49 CFR §192.607.

The process to determine, acquire and process required data is summarised in Figure 1:

) Phase 1 involves determining feasibility of the ECA, data gathering (existing ILI and other relevant data), records research, data integration and assessment, pre-engineering, and identification of outstanding data needs (data needs may serve to close gaps in TVC material property information and threat assessments).

) Phase 2 involves addressing potential mitigations to outstanding data needs by methods such as (but not limited to) additional ILI, additional excavations, and execution of material verification processes.

) Phase 3 includes the final data integration, engineering analysis, and documentation for the ECA report.

Phases 1 and 2 should be completed at the programme level before beginning work on an ECA to better assess the viability of an ECA and support effective lifecycle planning.

Threats to be considered for ECA

49 CFR §192.632 outlines various threats and conditions that must be assessed to reconfirm a pipeline segment’s MAOP. Since many of these can be addressed using established integrity assessment and integrity management feature analysis methods, it is helpful to organise them within the framework that pipeline operators have relied on for over 25 years as a reference. Figure 2 illustrates ASME B31.8S threat categories mapped against the requirements outlined in 49 CFR §192.632.

Absence of evidence is not evidence of absence. Reliance solely on the historical absence of a threat condition in the assessment path is not sufficient. Segments that require MAOP reconfirmation are evaluated for threat susceptibility using first principles and available data, guided by internal procedures and industry best practices. Threats determined to be nonsusceptible within a pipeline segment requiring MAOP

Figure 1. Data acquisition process.

Figure 2. §192.632 requirements mapped to B31.8S threat categories.

reconfirmation, based on sound justification, are considered to require no further assessment.

Insights from the ECA Consortium initiative

In the autumn of 2023, PHMSA audited ECAs presented by Operator representatives from the Consortium. As this was a new section of the code, the purpose was to validate that the assessment met the requirements of 49 CFR §192.632.

) Data accuracy and completeness are essential: a significant amount of time was spent on records review. The data was subject to a high level of scrutiny and held (appropriately) to a high standard. Even well-documented records can contain errors, making data cross-validation critical.

Supporting records, as well as integration of data using ILI as a baseline to vet against GIS and records can help strengthen confidence in expected data.

Identifying and resolving data issues and gaps early in the process can help make an ECA programme more efficient and effective.

) Engineering analysis strengthens compliance: ECA effectively demonstrates pipeline integrity within regulatory safety margins. Understanding the similarities and differences between ECA and integrity management is critical in ECA completion. The use of a data-driven approach to threat assessment is key to properly assessing threats to the pipeline. As noted, reliance solely on the absence of prior identification of a threat condition within the assessment path is not sufficient. Data integration plays a crucial role in ECA success, with overlaying various types of assessments to determine potential threat interactions being extremely important.

The impact

The successful implementation of ECA proves that this method is not only viable but also scalable for future MAOP reconfirmation projects. Overall, the structure of the ECA utilising integration of ASME B31.8S threats was well received and understood by stakeholders. By leveraging data-driven decisionmaking, pipeline operators can enhance safety, reduce costs, provide

maximum return on investment, and comply with evolving regulations.

Looking ahead

The insights gained through this initiative will help strengthen future pipeline integrity management practices and build increased confidence in the use of ECAs over time. As ECA adoption continues to grow, it is expected to drive innovation and support safe, efficient operations. Dynamic Risk is well positioned to support clients through process and procedure development, gap assessments, and the execution of ECAs.

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Janet O’Shea, Operations Director, Biodiversity and Environmental Services, DNV, and Catherine Sheridan, Commercial Strategy Director, Biodiversity and Environmental Services, DNV, explore how Ireland’s pipeline and energy infrastructure can be repurposed and expanded upon to support the energy transition.

e are at an exciting time for Ireland’s energy sector. As the country accelerates its transition toward a net zero future, its energy infrastructure – from renewable technologies to gas pipelines – must evolve with resilience, agility, and sustainability at its core. Against this backdrop, the recent announcement that DNV had fully integrated the Dublin-based Enviroguide Consulting into its operations, building on its acquisition in 2023, marks a strategic

investment, not only in this key market, but also in the future of a sustainable, resilient energy system for Ireland.

As well as cementing DNV’s commitment to supporting the growth of the Irish market, this expansion reflects the increasing need for deep technical assurance and environmental expertise. As Ireland develops new energy infrastructure and looks to repurpose existing pipelines and assets, this insight will be invaluable. But for this to come to fruition, the country cannot let the opportunity to lead in sustainable and low-carbon framework development and cross-border energy connectivity slip through its fingers.

Ireland’s pipeline energy opportunity

As the energy transition gains momentum, pipeline infrastructure will become an increasingly crucial enabler. However, creating and implementing new systems can be costly and the need for efficient, scalable infrastructure is more critical than ever.

For Ireland, which has €2.8 billion worth of pipeline asset infrastructure across the country, the opportunity lies not only in building new infrastructure to enhance this, but in strategically repurposing the network that already exists to allow it to handle new energies.

DNV’s latest Energy Transition Outlook (ETO) report states that more than 50% of hydrogen pipelines worldwide will be repurposed existing natural gas pipelines, a figure that could increase further in some regions that have significant existing natural gas infrastructure.1

DNV estimates that the cost of repurposing pipelines will only be 10 - 35% of the cost of designing and building new ones, a figure which is supported by other research bodies. This creates a compelling economic argument: considering what existing infrastructure can be repurposed is financially prudent and will often be the best option.

In addition to economics, repurposing offers environmental and social benefits. Reusing existing infrastructure minimises any land disruption, accelerates permitting and helps reduce lifecycle emissions associated with material extraction, construction, and logistics.

The European Hydrogen Backbone initiative, a consortium of 33 energy infrastructure operators, has envisioned a panEuropean hydrogen network, made up of 23 000 km of pipelines by 2040.2 This prediction places emphasis on the repurposing of existing European pipelines, largely due to the cost savings associated with repurposing, and estimates that 75% of a wider hydrogen network will consist of converted natural gas pipelines, which will be connected by 25% of new pipeline stretches.

While repurposing offers compelling benefits, pipeline suitability remains a key technical challenge. DNV’s research indicates that many existing international pipeline standards include hydrogen in their scope but provide no specific integrity or materials requirements for the gas.3

Despite this, DNV has found that such pipelines can still be viable for hydrogen transport if mitigating measures are taken. These include rigorous material testing to confirm adequate fracture resistance and careful evaluation of fluid change impacts, all within the context of local regulatory frameworks. This underlines the need for deep technical knowledge and close collaboration between regulators, operators, and infrastructure experts to ensure repurposing is both safe and feasible.

Expanding Irish operations

DNV’s acquisition and full integration of Dublin-based Enviroguide Consulting is a decisive step in strengthening its presence in Ireland and enhancing its role in the country’s evolving energy ecosystem.

Now operating fully under the DNV brand, Enviroguide Consulting brings with it a wealth of expertise in environmental services, which includes biodiversity, environmental impact assessment (EIA), contaminated land, hydrogeology, flood risk assessments, circular economy principles and sustainability. These capabilities significantly enhance DNV’s ability to offer holistic, locally grounded and future-ready advisory services to energy and infrastructure stakeholders across Ireland.

This integration comes with a substantial commitment to growth. DNV plans to create around 200 new roles in Ireland by 2027, adding capacity across environmental science and engineering, biodiversity net gain and decarbonisation advisory. From its Irish base, DNV will now deliver its full global portfolio, ranging from renewable energy consultancy and risk

Figure 1. Technician operating a manual valve, connected to a hydrogen pipeline at DNV’s Spadeadam Research and Testing facility.

Figure 2. Technician inspecting a reciprocating hydrogen compressor at DNV’s Spadeadam Research and Testing facility.

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management to digital assurance, bringing new technical depth and cross-sectoral insight to support Ireland’s net-zero ambitions.

Crucially, this expansion arrives at a time when Ireland faces both an urgent need and a unique opportunity. It can scale the development of low-carbon infrastructure in tandem with repurposing existing systems, particularly in the pipeline and midstream sectors, to enable the transport of renewable gases.

With the right investment and planning, Ireland has the potential to become a strategic connector between renewable energy generation and industrial demand centres in the UK and mainland Europe. DNV’s bolstered presence in Ireland, now reinforced with environmental intelligence and on-the-ground delivery, will be instrumental in facilitating this transition.

The need for an infrastructure buildout

Ireland’s energy future will be significantly enhanced if we have the connectivity in place to export energy, either traditional gas or low-carbon fuels, to mainland UK or Europe.

However, Ireland’s pipeline availability also creates a stumbling block. Research from the Irish Fiscal Advisory Council (IFAC) found that Ireland ranked 17th out of 67 economies for infrastructure provision, and 38th out of 67 in 2024 in terms of basic infrastructure provision.4 This metric encompasses water infrastructure, the density of road and rail networks, and energy infrastructure.

While Ireland’s electricity infrastructure has expanded in the last 30 years, the IFAC data shows that it remains 26% below the average of high-income European countries.

If Ireland is to support any ambitions of exporting energy in the future, this will necessitate a buildout of infrastructure capacity. But this is not solely a technical exercise – it is a strategic imperative.

It will be a challenge that requires significant coordination between asset owners, regulators, and developers. Early planning and robust risk assessment are essential to ensure that repurposed assets meet safety, performance, and regulatory standards.

This means that if we are to successfully move towards a new integrated energy system, we will need to start planning now.

Supporting energy security

According to the Sustainable Energy Authority of Ireland, more than 80% of the country’s primary energy supply in 2023 was imported from other regions, namely from two gas pipelines and two electricity interconnectors, which are both connected to the UK.5

This high reliance on external supply leaves the country exposed to global price shocks, supply chain disruptions and weather-related vulnerabilities, among other factors. As the energy system decarbonises, building resilience into Ireland’s infrastructure is just as important as the goal of reducing emissions.

Recent events have also underscored the consequences of energy insecurity. Heavily affected by Storm Éowyn, parts of Ireland experienced power outages as high winds and infrastructure strain disrupted supply. Similar disruptions occurred across Spain and Portugal, where surging demand and grid instability during heatwaves led to blackouts affecting thousands of homes and businesses.

DNV’s ETO states that by mid-century, 50% of global energy supply will be in ‘non-fossil’ form, meaning the remaining 50% will be in molecule form. Ireland has the opportunity to scale up the development of renewable gases, including biomethane and hydrogen, which can support in creating resilience with an indigenous supply of energy. Of course, these will need a robust network of pipelines for transportation and potential export to the UK and Europe.

Strengthening Ireland’s pipeline capacity to carry renewable gases can not only improve resilience, but also stimulate investment across the supply chain, from local energy producers to large-scale industrial users. In this way, energy security becomes a driver of economic development, technological innovation and environmental progress.

By reducing dependence on imports and laying the groundwork for self-sustaining, low-carbon systems, Ireland can insulate itself from future disruptions while playing an increasingly active role in Europe’s integrated energy future.

Stepping towards the future

As Ireland works to reshape its energy landscape, the need for coordinated action across infrastructure development, environmental assurance and technical innovation is clear.

From repurposing existing pipeline assets to building new corridors for hydrogen and CO2, the opportunity to transform Ireland into a resilient, connected energy hub is firmly within reach, but it will require foresight, strong levels of investment and trusted guidance.

DNV’s expanded presence in Ireland, backed by global expertise and enriched by the local insight of its newly integrated team, brings technical assurance, environmental acumen and sector-wide collaboration needed to make this transformation possible.

With its Irish office serving as a strategic base, DNV is positioned to provide independent expertise and systems-level thinking to support both public and private sector actors through the complexities of the energy transition. DNV can support in cutting through red tape as we guide you on environmental planning and create opportunities for developers at the site of their projects with our contaminated land and hydrogeology services, ultimately streamlining project delivery and reducing costs.

Whether it’s advising on repurposing infrastructure, navigating regulatory frameworks, or advising developers in building a connected pipeline system, DNV is ready to support and guide the way forward.

Ireland’s energy system is at a turning point. With the right strategy and partners in place, it can not only meet its net-zero goals, but also contribute meaningfully to a secure, sustainable, and interconnected European energy future.

References

1. https://www.dnv.com/energy-transition-outlook/

2. https://natran-deutschland.de/media/nmkerzy1/20200716_european-hydrogen-backboneslide-deck.pdf

3. https://www.dnv.com/focus-areas/hydrogen/repurposing-pipelines-for-hydrogen-guidingoperators-through-the-re-evaluation-process/

4. https://www.fiscalcouncil.ie/wp-content/uploads/2024/10/Irelands-InfrastructureDemands.pdf

5. https://www.seai.ie/sites/default/files/publications/Energy-in-Ireland-2023.pdf

David Celine, Managing Director, Omniflex, explores the problem of localised corrosion control in pipeline applications and explains how a new closed-loop cathodic protection (CP) system could offer the solution the oil and gas industry desperately needs.

n the oil and gas sector, ensuring safety and longevity of pipeline infrastructure is critical. While general corrosion can be effectively managed over time, localised corrosion, such as pitting, crevice corrosion or corrosion under disbonded coatings, poses a more substantial challenge. These localised issues can lead to rapid degradation of pipeline infrastructure and cause catastrophic failures with minimal warning.

Localised corrosion poses significant risks for oil and gas pipelines, especially in buried or subsea environments. It differs from general, uniform corrosion as it focuses damage in small areas. This can lead to unexpected and catastrophic failures even when average corrosion rates for the infrastructure in question appear low.

Typically, this localised corrosion appears in the form of pitting, where small, deep pits penetrate pipeline walls, crevice corrosion, which occurs in shielded areas where stagnant microenvironments form, or microbiologically-influenced corrosion caused by microbial activity, especially under disbonded coatings or in stagnant water.

These forms of corrosion are particularly insidious as they concentrate high amounts of damage in small areas, rapidly reducing mechanical strength and structural integrity as a result.

According to a report by the US Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (PHMSA), which covered January 2010 to January 2021, external corrosion was responsible for nearly 10% of natural gas pipeline incidents in that time. This led to infrastructure damage worth billions of dollars and resulted in the unintentional release of 3000 million ft3 of natural gas.

For operators, the consequences of a corrosion-induced failure don’t end there. For example, following the Prudhoe Bay oil spill in Alaska in 2006 where 267 000 gal. of oil were spilled over 1.9 acres, BP was fined US$20 million. This incident stemmed from a 0.25 in. hole in a 34 in. diameter pipeline and, in the subsequent report, the cause of the hole was put down to localised corrosion.

More recently, the Colonial Pipeline oil spill in North Carolina in 2020 resulted in 2 000 000 gallons of gasoline being spilled as a direct result of localised corrosion issues damaging the pipeline infrastructure. In this case, the clean-up efforts are still ongoing several years later and have already incurred over US$50 million in costs in addition to the US$5 million penalty the operators had to pay to the North Carolina Department of Environmental Quality for environmental damages caused by the spill.

It is clear that localised corrosion represents one of the most pressing challenges facing the oil and gas industry, and that addressing areas of concern before they can cause catastrophic incidents like these will extend infrastructure service lives and potentially save millions in cost down the line.

Limitations of traditional CP systems

While traditional CP systems, both galvanic and impressed current, have been the cornerstone of corrosion control for decades, their efficacy in mitigating localised corrosion is limited. This is even more pronounced under dynamic environmental conditions, such as changes in soil moisture and oxygen levels, where the optimal current required for protection can vary over time.

Normally, ICCP systems operate by maintaining a constant potential to supress the electrochemical reactions responsible for corrosion. While this is effective against uniform corrosion, this is insufficient, and sometimes counterproductive, when it comes to controlling localised corrosion, for three key reasons.

The first problem arises because conventional ICCP systems are typically configured with fixed current outputs. While effective in stabilising the electrochemical potential across large areas, these systems don’t have the agility to detect and respond to localised corrosion incidents. When environmental conditions change, due to varying soil moisture levels or seasonal changes in temperature, these systems continue to

blindly output the same current levels, risking either under- or over-protection occurring.

Next, any efforts to compensate for increasing corrosion levels by increasing CP current indiscriminately can cause hydrogen embrittlement or cathodic disbondment to occur. This creates a dangerous cycle of degradation that increases operational risk as embrittlement will only further compromise pipeline structural integrity and increases the likelihood of structural failure.

Finally, disbonded coatings, crevices and deposits across the pipeline structure can create physical and electrical chemical barriers that effectively shield sections of the pipeline from the CP current. In these areas, the electrochemical potential is insufficient to provide adequate protection, allowing aggressive localised corrosion to set in. Furthermore, because of the lack of protection in these areas, once initiated, localised corrosion can quickly escalate and cause major pipeline damage.

It is clear that to address the challenges posed by localised corrosion both for oil and gas pipelines at present and the hydrogen pipelines of the future, a new approach is needed that can overcome the limitations of current ICCP installations.

A novel approach to localised corrosion control

In response to industry demand for a solution that can adequately tackle localised corrosion, researchers at Deakin University, supported by the Energy Pipelines CRC, Future Fuels CRC, the Australian Economic Accelerator project, Omniflex and specialist pipeline operators, have developed a novel closed-loop CP probe for localised corrosion control.

The novel technology was designed specifically to identify and suppress localised corrosion in complex industrial environments, such as underground or subsea pipelines. Other potential applications include protecting offshore structures, such as wind turbines and oil and gas platforms, and underground infrastructure, like storage tanks.

The technology uses a smart feedback loop where a specially designed electrode array corrosion probe is embedded in or near critical areas of the pipeline. The probe continuously monitors localised electrochemical activity, including real-time corrosion current densities, allowing the system to automatically adjust CP current and potential based on actual corrosion behaviour rather than relying on indirect references alone.

An example of this working in practice is, under fluctuating conditions like heavy rainfall, the system can increase the CP current to raise the local pH and halt active corrosion without overcompensating globally. Once the rain stops and the corrosion threat subsides, current levels are automatically stepped back down to avoid over-protection.

Field tests for the technology established its ability to reduce localised corrosion by roughly 90%. At the baseline test site, average corrosion rate was measured at 0.11 mm/y whereas at the closed-loop CP-controlled test site, corrosion rate was reduced to 0.01 mm/y, which represents a tenfold improvement. When the system detected corrosion spikes, it automatically adjusted outputs and stopped corrosion in 24 - 48 hours.

This level of corrosion reduction can more than double operational lifetimes, making installations more sustainable and cost effective. This capability of closed-loop control of cathodic protection not only mitigates corrosion but also avoids over protection that can cause issues like hydrogen embrittlement and cathodic disbondment of coatings.

Omniflex worked with the Deakin University team to develop the technology’s electronics, integrate sensors and facilitate remote monitoring and control capabilities. The in-built remote monitoring and control capabilities allow ongoing protection to be adjusted in line with ongoing variances caused by factors like stray current and leakage. This means it consistently maintains optimal protection levels unlike traditional ICCP systems that maintain a static output current.

Enhanced ESG reporting with remote monitoring

The in-built remote monitoring capabilities offer the added benefit of facilitating improved environmental, social and governance (ESG) reporting for pipeline operators. This is especially valuable in the sector as ESG is becoming increasingly crucial for driving sustainable and responsible operations while enhancing long-term value.

Strong ESG practices help mitigate environmental risks, such as corrosion and climate change impacts, ensure worker safety and promote transparent, data-driven decision making. Furthermore, ESG initiatives align operations with global

sustainability goals, reinforcing a commitment to preserving resources and fostering resilience in critical infrastructure.

Remote monitoring provides asset owners with access to real-time data on an ongoing basis including total power consumption, anode current outputs, reference electrode test data and anode health condition. By having ongoing access to this live data, engineers can quickly identify abnormalities and address any problems before they escalate, ensuring ongoing asset protection.

Next, they will incur lower maintenance costs on an ongoing basis as the need for site visits and physical inspections is drastically cut. For example, a typical CP installation with no remote monitoring will be inspected twice a year, and significant on-site time is spent taking readings, whereas the same CP system monitored remotely only requires visual inspection once a year, with far less time on site taking readings, reducing operational costs.

Finally, remote monitoring improves ongoing personnel safety. CP protected infrastructure is often located in hazardous and difficult-to-access environments and remote monitoring lessens the need for technicians to physically visit these sites, improving overall safety. By reducing on-site inspections, the risk of accidents and injuries is significantly reduced.

The closed-loop CP technology, which recently won the Corrosion Innovation of the Year Award at this year’s AMPP Annual Conference and Expo, has completed field testing and the project is entering the commercialisation phase, backed by the Australia Economic Accelerator fund.

EPISODE EIGHT

In this episode, Juan Caballero, Chair of the AMPP Board of Directors, talks about AMPP’s global efforts to prevent corrosion and to protect assets, offering insight into how the association listens to its members and serves the pipeline industry.

Juan shares his insights on:

• The merger of NACE with SSPC to form AMPP.

• Materials protection challenges in 2025.

• AMPP’s training programmes, including a sneak peek into the newest offerings.

• Industry trends and how AMPP views sustainability.

• Which certifications are currently in demand.

• Digital learning for pipeliners.

• Regulations that we need to pay attention to now.

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CATCH UP ON RECENT EPISODES

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Juan Caballero Elizabeth Corner

Norman Stapelberg,

Commercial Director, Silveray,

UK, outlines the case for flexible digital X-ray film.

Weld inspection remains one of the most critical components in ensuring the safety and reliability of pipeline infrastructure. For decades, radiographic techniques have provided the high-resolution imaging necessary to detect internal flaws and verify weld integrity. However, as with many other sectors, non-destructive testing (NDT) in the pipeline industry is facing increasing pressure to do more with less: less time, less downtime, fewer consumables, and smaller environmental impact.

Despite remarkable advancements in digital imaging, the dominant radiographic method used in pipeline weld inspection still relies on traditional X-ray film. This has little to do with image quality – film delivers excellent results – and more to do with practicality: it is thin, flexible, easy to wrap around pipes of

various diameters, and familiar to radiographers in the field. But that convenience comes with a cost: chemical processing, image digitisation, physical storage requirements, and significant delays in image access and verification.

This is the context in which Digital X-ray Film (DXF®) emerges, not as a direct competitor to existing rigid digital radiography systems, but as a digital alternative designed to behave like radiographic film while delivering digital images.

The limitations of today’s tools

Whether using single-wall single image (SWSI) techniques with crawlers or double-wall single image (DWSI) setups in less accessible areas, radiographers are working within the physical constraints of the medium.

X-ray film remains popular because it is: flexible enough to wrap around pipes; available in various sizes and even on rolls; and lightweight and field ready.

But film processing is slow, chemically intensive, and creates logistical challenges for storage and traceability. Not to mention the logistical challenges and cost of having mobile film development stations to bring the film development to site. Although this is not strictly necessary, it is often the only way to avoid the high costs of having to return to site to re-shoot any joints that were previously missed, over exposed or under exposed. Alternatives like computed radiography (CR) plates help, but these are in reality analogue solutions that are then digitised afterwards. Similar to scanning in or digitising film, digitising CR plates is an effective and a well-established process, but still prone to loss of resolution or slipping in the scanners to cause blurring. CR plates are typically used in protective cases, to prevent them from being scratched or contaminated, somewhat limiting their flexibility. Flat panel detectors (FPDs) offer excellent image quality and speed, but their rigidity, weight, and cost limit their use, especially in remote pipeline inspection settings where wraparound imaging is ideal. Rotating robotic systems have made FPDs much more useable in pipeline applications but are costly and the process is time consuming.

In short: every current solution has a trade-off, and none truly replicates the convenience of film while delivering the speed and efficiency of digital.

A new approach

DXF seeks to address these challenges head-on. The concept is simple yet powerful: create a digital imaging device that is as thin and flexible as traditional X-ray film, but with integrated electronics that allow for near instant digital capture of radiographic images. Then make its cost low enough to make it semi disposable.

Unlike indirect digital detectors, which rely on scintillators to convert X-rays to light and then light to an electrical signal (introducing loss and blur), DXF uses a direct conversion layer – a proprietary X-ray sensitive semiconductor ink called NPX® –coated onto a flexible pixelated backplane.

This combination:

) Eliminates the need for light conversion and associated image blur.

) Enables ultra-thin, flexible detectors under 1 mm thick.

) Allows for full digital image capture with excellent spatial resolution.

Wrapped in carbon fibre for durability and scratch resistance, DXF can be made in a range of sizes and used in the same way as traditional film: wrapped around welds and exposed using a portable or crawler-mounted gamma or X-ray source.

Benefits in weld inspection

What makes DXF particularly compelling is not just its technical novelty, but its alignment with real-world field practices. The device has been designed for the pipeline environment and not adapted from another industry. Key advantages include the following:

Parallel imaging

Multiple DXF detectors can be wrapped around successive weld joints before crawler insertion. The crawler can then take exposures at each weld in a single pass, dramatically improving

Figure 1. Pipe X-ray inspection in the field.

Figure 2. Pipe X-ray using radiographic film.

Figure 3. DXF detector being wrapped around a pipe.

inspection throughput and reducing the time the pipeline needs to be out of commission.

Immediate digital output

Since images are digitally captured, there is no delay for chemical development or scanning. Radiographers can review images onsite, quickly identify weld flaws, and re-shoot if necessary, all within the same operation window.

Reduced consumables

DXF eliminates the need for film chemistry, darkrooms, image intensifiers, and physical storage. The digital images can be stored, annotated, and transmitted electronically, supporting traceability and compliance requirements with far less effort. Switching from film to digital also significantly reduces the cost of running vehicles with film development labs from project to project.

Cost-effective lifecycle through payper-image

Traditionally, digital radiography systems – particularly flat panel detectors (FPDs) – require significant capital investment. The high up-front cost of each detector often limits how many units inspection companies can deploy, especially in environments where multiple welds must be imaged simultaneously or in parallel. This creates a bottleneck: the technology is available, but access to it is constrained by budget cycles and capital expenditure (CAPEX) limits.

DXF introduces a pay-per-image model that breaks this barrier. Rather than requiring customers to purchase each detector at a prohibitive cost, DXF detectors can be acquired at a low initial price, with users purchasing image credits that activate the device for a set number of exposures.

This model is similar to how many other technologies are now consumed, from cloud computing services like AWS to business software subscriptions. You only pay when you use it.

For inspection service providers, the benefits are immediate and tangible: ) No major upfront expenditure: more detectors can be deployed in the field without waiting for Capex approvals. Every radiographer or team of radiographers can now have their own set of detectors, rather than sharing more expensive FPDs. This massively reduces the cash flow burden of buying expensive detectors, with an extended payback/depreciation period.

) Cost aligns with revenue: credits are consumed only when imaging is performed, so costs track directly with billable fieldwork.

) Scalable operations: companies can scale up or down based on workload, adding more DXF units as needed without overcommitting on their budgets.

) Matches the model of film: today film is bought in batches and consumed as needed. With DXF, pay per click/image replicates the film model, but instead of buying film, the user buys imaging tokens.

Inspection companies often operate teams of radiographers across multiple job sites. A business employing 20 radiographers

would typically struggle to justify buying more than one or two FPD systems – forcing radiographers to share detectors or rotate equipment between sites. With DXF, each radiographer can be issued their own detector at a low initial cost, empowering them to work in parallel and at full speed. This translates into higher throughput, greater flexibility, and a more efficient use of personnel.

Engineering for the field

One of the main concerns for any digital detector in the pipeline industry is ruggedness. CR plates, for instance, often fail prematurely due to scratches, kinks, or sand contamination, which can also damage scanning equipment. DXF, by contrast, is protected by carbon fibre laminates that resist abrasion and allow for field handling and is designed to be semi disposable, so that if a detector is accidentally damaged, it can be replaced at a relatively low cost. Digital flat panel detectors nowadays are built to be very rugged but are still at risk of being damaged. At the high replacement cost of a digital flat panel detector, it needs to capture ~10 000 images to pay back the initial investment cost. Apart from the groundbreaking direct conversion material, called NPX, these DXF detectors are manufactured with wellknown and tested technologies. The backplanes are the same as the a-Si or IGZO backplane technologies used by mainstream flat panel detector manufacturers as well as the technology used in the flexible displays found in phones, televisions and computer monitors. The manufacturing infrastructure is therefore mature and scalable. This means that as adoption grows, DXF production

can scale with demand, driving costs down and enabling broader deployment.

A platform for the future

While DXF’s immediate value lies in its ability to streamline traditional weld inspection workflows, its digital nature opens the door to advanced image processing and AI-based defect detection. Many existing FPD-based systems already support semi-automated flaw detection, and the same software frameworks can be adapted for DXF image formats.

Moreover, as pipeline operators move toward digital recordkeeping and regulatory compliance, the ability to instantly store and tag weld images within digital asset management platforms becomes increasingly valuable.

Conclusion: evolution, not disruption

DXF is not a radical break from current weld inspection practices; it is an evolution. It allows radiographers to use familiar workflows while gaining the speed, accuracy, and convenience of digital imaging. With the ability to wrap around pipes, shoot panoramic exposures, and deliver instant results, DXF offers a way to reduce downtime, cut consumables, and modernise inspection workflows – without a steep learning curve.

While still in development, the trajectory of DXF technology is clear. As the industry continues to balance cost pressures with safety imperatives, tools like digital X-ray film are likely to become the default for pipeline weld inspection in the years ahead.

Joachim Böck, Fronius, details a paradigm shift in how welding is managed, monitored, and optimised.

In industries where safety, precision, and traceability are paramount, such as pipeline construction and oil and gas infrastructure, welding quality is not just a technical requirement – it’s a critical success factor. As a provider of welding technology, Fronius addresses these challenges for both manual and automated welding tasks with a suite of intelligent digital WeldCube solutions: like WeldCube Navigator, WeldCube Air and WeldCube Premium. These tools

are designed to optimise welding processes, ensure compliance, and enhance productivity.

In the age of digital transformation, welding technology is evolving rapidly. With advanced Fronius welding systems like the TPS/i and iWave product lines, modern intelligent welding equipment is capable of capturing and analysing welding data at varying levels of detail. These smart solutions help ensure consistent welding quality and provide full transparency over

the welding fleet, while also actively supporting welders and supervisors in their daily work. From predefined welding parameters to step-by-step visual guides, Fronius welding solutions are redefining efficiency, precision, and user support in the welding process.

Guided

welding for maximum precision

WeldCube Navigator is a powerful tool that combines stepby-step visual guidance with automated parameter control, ensuring that every weld is executed according to plan. For pipeline, and oil and gas companies, where weld integrity is vital, this means fewer errors, reduced rework, and improved safety outcomes.

Key benefits

) Visual sequencing and job control: WeldCube Navigator uses a sequencer to guide welders through each step of the welding process using images and predefined settings. All these instructions are easily digital created in the editor.

) Error prevention and real-time feedback: if the worker deviates from the weld sequencing, the system will immediately flag it. And if it detects a deviation (limit violation) in seams that have been defined as safetyrelevant, welding cannot be continued until released by a welding supervisor. This means that errors are not repeated or duplicated but corrected immediately. This is especially valuable in safety-critical applications.

) Shortened training time: new welders can quickly become productive thanks to intuitive, visual instructions and automatic parameter settings. This is a major advantage in industries facing skilled labour shortages. Using a digital welding sequence plan, companies can pool their expertise and welding skills and transfer them to all employees. This ensures continuous production and helps welders to put full focus on welding.

) Torch-based navigation: welders can operate the system entirely via the torch trigger, allowing them to stay focused on the task without needing to interact with external devices.

By standardising welding procedures and reducing human error, WeldCube Navigator helps companies maintain high quality standards while increasing production.

Easy entry into cloud-based data management

This cloud-based software solution enables centralised data collection and reporting across multiple welding systems. It brings transparency to welding operations and always grants a clear overview of welding certificates and welding procedure specifications (WPS). It is a quick and straightforward way for companies to start benefitting from digitalisation and helps with quality assurance and resource efficiency. For companies it grants visibility and transparency in the welding performance.

The WeldCube Air platform is much more than a digital store for WPS documents, manuals, and spare parts lists. It also enables all intelligent Fronius welding machines to be managed centrally, such as by conveniently rolling out regular updates with a single click.

Key advantages

) No more paperwork and Excel lists: WeldCube Air assists welding supervisors with managing and updating welding certificates. Everything is brought together in one place and managed digitally, allowing supervisors to call up the current qualification status of individual welders at any time. Certifications that are soon to expire are flagged so that they can be renewed in a timely manner.

) WPS-compliant welding – ensuring quality: thanks to its search function, WeldCube Air provides welding supervisors with clarity and an overview of this slew of documents. Standard-compliant parameter sets (jobs) can be prepared with ease and rolled out to the entire welding machine fleet at the click of a button. This allows welders to quickly find the correct settings for the WPS-compliant welding task, reducing the risk of errors. The valuable time saved overall can be invested in activities like optimising processes.

) Easy to install, secure, and available anywhere: the digital solution does not require complex installation and is ready for immediate use. All you need to do is connect the Fronius welding system to WeldCube Air via the internet. No extra software is required. An overview of the welding performance of individual devices or the entire welding machine fleet is created in an instant – on whatever device you prefer, from a PC to a tablet or smartphone. Fronius ensures certified security (ISO/IEC 27001) and protects the stored data in accordance with strict European data protection directives.

) WeldCube Air empowers decision-makers with valuable insights, helping them optimise processes, reduce costs, and ensure regulatory compliance across the entire welding fleet. Minimal effort for full transparency: “We have looked closely at the needs of our customers and focused on what is essential for their day-to-day work. The effort required to go digital should be as low as possible, but the benefits should be all the greater to allow them to fully exploit the potential of our high-end welding machines, without any major investment or risk,” says Joachim Böck, Strategic

Figure 1. WeldCube Navigator guides the welding specialist through the steps required for a component in a clear and comprehensible way. Images show each task in detail, and fixed parameters are pre-set.

Product Manager at Fronius International. Especially welding supervisors, production managers, and quality controllers will benefit from the rapidly available and user-friendly WeldCube Air.

Advanced analytics and process optimisation

WeldCube Premium is the ideal solution for companies that require extensive data management capabilities. It takes data-driven welding to the next level with advanced analytics, custom dashboards, and integration capabilities. It is ideal for companies seeking to implement Industry 4.0 strategies and achieve continuous improvement in welding operations.

As a central data hub, WeldCube Premium provides essential functions for welding supervisors and heads of welding production. Whenever process stability, monitoring of

the process window, or efficient management of all welding systems is required, it is an excellent choice.

Data for each component is collected and aggregated, then made available throughout the welding production process. This also includes upstream and downstream processes and systems, such as neighbouring workstations.

Core features

) Fleet management: enables one-click management of the entire welding fleet and saves time through centralised backups, traceability of installed components within the welding system, and centralised configuration of welding systems.

) Job editor: enhances quality assurance through centralised management of all jobs. In addition to comparing individual parameters, the job history ensures full traceability for maintaining the process window and investigating the root causes of welding quality issues.

) Component documentation: based on traceability data, WeldCube Premium collects all component-related welding data. The documentation can be further enriched via interfaces with additional documents, images of weld seams, or by integrating optical seam inspection systems (e.g., Vitronic). This enables evaluations of production quality, the creation of audit reports, or the transmission of information about irregular seams to a rework station.

) Detailed performance dashboards and statistics: visualise key metrics such as arc time, energy input, wire consumption, and error rates. These dashboards help identify bottlenecks, inefficiencies, or training needs.

) Ready-to-use interface solution: the REST-API web interface in WeldCube Premium enables the analysis and transfer of prepared data, allows access to historical data and provides fixed data packets that include information on components, seams, set values, jobs, and machines.

In addition, the optional Central User Management enables efficient administration of the entire welding fleet. It also makes a significant contribution to quality assurance by ensuring that only authorised personnel can perform specific tasks and that welding systems are always configured with the correct parameters. Furthermore, adjustments to process limits – so-called job changes – are transparently and comprehensively documented as part of approval workflows. With this WeldCube Premium package companies can therefore move beyond reactive quality control and secure quality and embrace proactive process optimisation which is a key differentiator in competitive, high-stakes industries.

Flexibility thanks to open interfaces

And finally, in order that welding data may be documented, analysed, or made available for other software systems, Fronius offers various data interfaces, known as APIs. The customer can use either the ready-to-use solution REST-API or the data that is made available for their own customised data management solutions.

The way that the various functions of the data interfaces from the WeldCube API portfolio combines enable the fully

Figure 2. The WeldCube Air platform enables all intelligent Fronius welding machines to be managed centrally, such as by conveniently rolling out regular updates with one click.

Figure 3. Double-head welding application in container construction.

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customisable and flexible integration of Fronius power sources and WeldCube Premium into a whole system landscape. It can connect with manufacturing execution systems (MES) and enterprise resource planning (ERP) platforms, allows seamless data flow and process automation. There are two possible solutions depending on customer requirements:

) TPS/i and iWave interface solutions: the interface solutions OPC-UA and MQTT enable raw current data and actual states of the welding system to be read out. This makes it possible to transfer data records to third-party systems for independent evaluations, analyses, and visualisations. The welding system parameters can also be set via OPC UA.

) Interface solution for WeldCube Premium: the REST web interface in WeldCube Premium enables the analysis and transfer of prepared data. In contrast to the interface solutions OPC UA and MQTT, historical data can also be accessed here. In addition, this interface solution provides fixed data packets that include information on components, seams, set values, jobs, and machines.

Conclusion

In the oil and gas industry, welding is performed both manually and automatically. Whether for flexible on-site assembly or repair work, serial production of components or large-scale plant construction, welding quality, safety, and traceability are essential. The wide range of the WeldCube portfolio offers the right solution for every challenge and makes the advantages of digitalisation in welding easily accessible.

The most important welding data is recorded, visualised, and analysed, and the clear display on a single screen provides the user with relevant information on all components at a glance. Selected data can also be transferred to higher-level software systems to obtain a central overview of the entire production process.

The data interfaces also offer the option of transferring all available information to the customer’s own documentation and analysis software. All evaluations, visualisations, and reports can thus be individually developed and programmed according to requirements.

Last but not least, customers can implement customised maintenance solutions based on their own data analyses and according to their own specifications. These are displayed on the user’s own systems, for example in apps or desktop views, to support and optimise internal maintenance.

Fronius WeldCube solutions offer a powerful combination of quality assurance, operational efficiency, and digital transformation and represent a paradigm shift in how welding is managed, monitored, and optimised. By integrating WeldCube Navigator, WeldCube Air, and WeldCube Premium into their operations, companies can:

) Reduce rework and downtime.

) Improve safety and compliance.

) Gain transparency into welding performance.

) Efficient work according to standards (with less paperwork).

) Enable data-driven decision-making.

Pipeline Industry Website

World Pipelines reached out to experts in the pipeline installation sector to find out the latest developments in horizontal directional drilling (HDD).

Matt Smith, President, Michels Trenchless

Matt Smith is a leader of trenchless construction disciplines, including horizontal directional drilling (HDD), Direct Pipe and microtunnelling. Since 2022, Matt has served as President of Michels Trenchless, Inc. He oversees all trenchless new installation and rehabilitation operations. Matt has spent almost all his career in trenchless construction. He joined Michels in 2010 as an intern, assisted with many significant tunneling projects, and advanced to become a Project Engineer, Project Manager, Manager of Direct Pipe, General Manager of Contracts and Business Administration for trenchless operations, and Vice President of Trenchless Operations.

Ryan Jackson, HDD Operations Manager, Michels Trenchless

Ryan Jackson began his career with Michels as a skilled equipment operator. Through hard work and on-the-job training, Ryan was promoted in 2012 to a Field Operations Superintendent and to HDD Operations Manager in 2021. He works on some of the largest and most complex HDD projects throughout the world. Ryan is a creative thinker who can quickly adapt to overcome challenges faced in the drilling industry. Whether coordinating mobilisation of equipment to an international destination or simultaneously monitoring production at various field locations, Ryan remains committed to safety and quality.

Simon Herrenknecht, Head of Business Division Pipeline, Herrenknecht

During his studies in automotive and mechanical engineering at the universities of Karlsruhe and Offenburg, Simon worked as a Project Manager in the research department of BMW motorcycles in Munich. In 2014, he joined Herrenknecht, starting as a product manager for HDD equipment in the pipeline business. Since August 2022, he has been Head of the Business Division Pipeline within the Utility Tunnelling Department, where he oversees worldwide Business Development in the pipeline sector.

What are the biggest technological advancements in HDD equipment you’ve seen in recent years, and how are they changing the game for pipeline installation?

Simon Herrenknecht, Head of Business Division Pipeline, Herrenknecht

The biggest trend we see in the HDD market is the electrification of drilling rigs and entire job sites, all in the name of sustainability and efficiency. As the market slowly diversifies into segments beyond oil and gas, such as environmentally conscious areas like new power lines from offshore wind, CO 2, or hydrogen transport, this evolution seems coherent. In this sense, the game with pipeline installation is to change our community’s mindset towards more sustainable jobsites.

Matt Smith, President, Michels Trenchless

As a trenchless contractor performing work on a truly global scale, the advancement of remote monitoring capabilities has a significant, positive impact on Michels and the industry. Our field crews are very knowledgeable about the work we are doing, the equipment we are using and the conditions we are facing. They are adept at working on projects in remote areas. However, the ability for our technical experts to view real-time data and provide informed assistance on challenging situations in North America, Europe, Australia, the Caribbean or anywhere else allows us to collaborate in ways that have not previously been possible. Communication has always been an important part of our business, but adding real-time data to the conversation is a game-changing innovation for us.

Ryan Jackson, HDD Operations Manager, Michels Trenchless

From an equipment perspective, the ability to use a thruster to assist movement on large-diameter and long-distance crossings has allowed us to complete crossings that might not have been possible. Even the most powerful HDD rigs occasionally need help moving an extremely heavy pipe string that has become locked or immobilised. Being able to concentrically fit a thruster around a pipe to advance but not damage provides the power and confidence needed to complete very challenging crossings.

How are you addressing increasingly complex ground conditions or longer bore lengths in HDD projects, especially in challenging oil and gas environments?

Matt Smith, President, Michels Trenchless

We believe constant innovation is necessary to keep advancing the competitive and challenging horizontal directional drilling industry. We have completed some very long and challenging drills, but we are not satisfied with what we have accomplished. Instead, we use the lessons we’ve learned on projects around the world to prepare us for what we will do next.

Ryan Jackson, HDD Operations Manager, Michels Trenchless We think outside the box when we are planning operations. Before we set up our rigs, we explore options for entry and exit angles of large diameter casings to determine the optimal setup for achieving the required depth of cover and the most favourable drilling zones along the alignment.

Simon Herrenknecht, Head of Business Division Pipeline, Herrenknecht

The expertise and knowledge to master such challenging projects exists in the market; the equipment simply needs to keep up with these demands. This means that liability has always been and will continue to be an important factor in the industry. Being able to keep drilling and trust your equipment is a key factor for success, as well as knowing its limits. More and deeper planning, more geotechnical investigations, more ‘theory’ upfront of a project to ensure such risky and complex projects don’t turn into failure. As a manufacturer, we

Michels completed a 15 426 ft horizontal directional drill (HDD) of a 24 in. pipe crossing of Lake Sakakawea on the Missouri River in North Dakota. The crossing is part of new pipeline being constructed from Tioga, North Dakota, to near Watford City, North Dakota. Prior to pullback, the 15 426 ft pipeline was assembled by Michels Pipeline, Inca., into two sections – one of 426 ft and another of 15 000 ft.

must ensure that the equipment can deliver its full power throughout the entire process, maximise the torque and pull forces without altering the rig’s size, and have parts and personnel ready to provide support quickly in case of an emergency. Nowadays, the fastest support is remote support, meaning service personnel can log into the rig system online and access detailed protocols to detect errors and determine solutions. Data needs to be available with a click that ensures the fastest possible fix.

What role is digital technology or automation playing in HDD operations today?

Simon Herrenknecht, Head of Business Division Pipeline, Herrenknecht

Quick support is one of the most important factors for a successful project, so having a digital twin for deep analysing the errors and quickly fixing them remotely will become standard procedure. Automation is linked to that: simple tasks can be taken over by programs to execute them repeatedly almost perfectly – and with the development of the digital technology with AI, those simple tasks can grow into more difficult and complex tasks.

With so many projects lined up for execution, we are asked to find ways to handle the shortage of skilled personnel on our jobsites. Therefore, automating some tasks on site will reduce the workload and help the industry stay on track to fulfil market demands.

Matt Smith, President, Michels Trenchless

Digital technology, such as remote monitoring capabilities, has allowed our technical resources to be centrally located. This has been helpful in an industry facing a shortage of specialised skilled labour because our field crews and technical experts can collaborate without requiring travel to remote locations.

Ryan Jackson, HDD Operations Manager, Michels Trenchless

We are always looking for ways to improve safety on our jobsites. We’ve used automation and advancements in mechanical equipment to increase efficiency and safety. I don’t ever see automation or mechanical equipment replacing our people, but if we can use them to reduce risk or a potential danger, we will aggressively explore ways to do it.

How is the current regulatory or environmental landscape influencing your approach to HDD project planning and execution?

Matt Smith, President, Michels Trenchless

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One of the largest challenges of the current regulatory and permitting situation is that it makes it increasingly difficult to plan the best way to use our resources because project timelines are always shifting to the right. At times, we Listen and

increase our schedules in anticipation of slower-than-desired agency responses.

Simon Herrenknecht, Head of Business Division

Pipeline, Herrenknecht

The current regulatory and environmental landscape significantly influences how we design and support our HDD rigs. With increasingly stringent environmental regulations and permitting requirements, we focus on delivering technologies that minimise frack-out risks and promote environmental protection.

We observe a greater emphasis on early-stage environmental assessments and stakeholder engagement on the side of project owners. Projects are planned with the greatest possible risk mitigation, so implementing real-time monitoring is essential to ensuring safe, environmentally responsible operations.

In response to growing regulatory demands for sustainable and low-emission practices, we are investing in the electrification of rigs and digital tools that streamline

compliance reporting and environmental documentation. These pressures are driving us to innovate and produce robust, efficient, environmentally conscious solutions that help our customers execute their projects safely and successfully while ensuring full compliance.

Looking ahead, what are the key trends or challenges you expect to define the HDD market in the next three to five years, particularly within oil and gas?

Matt Smith, President, Michels Trenchless

Our industry will be affected by a shortage of skilled people. At the same time, we anticipate needing more staff than ever before to manage the tracking and reporting required with the demand for increased regulations and documentation.

Simon Herrenknecht, Head of Business Division Pipeline, Herrenknecht

As previously mentioned, tighter environmental regulations and sustainability demands will be key trends, especially regarding drilling fluid management, frack-out prevention, and habitat protection. To meet sustainability goals and reduce environmental footprints, operators will adopt greener technologies and practices. HDD projects will increasingly factor in climate resilience, adapting to risks like flooding, erosion, and extreme weather events. This includes route planning and equipment designed for harsher environmental conditions. With this increased project complexity, efficient project execution without compromising environmental or safety standards will be critical. These are the reasons to move towards electrification, emission reduction and also digitalisation. The increased integration of digital tools, such as realtime monitoring, AI-driven drill path optimisation, and predictive maintenance, will become standard. These advancements improve operational efficiency, safety, and compliance but require investment in training and upskilling. Automation will help us to address the shortage of skilled labour, on one side, and has the potential to upgrade the attractiveness of jobs, especially in challenging jobsite contexts, on the other side. In summary, the HDD market will progress by balancing stricter regulations, advances in technology, and growing sustainability demands, all while managing cost pressures and workforce shortages.

Ryan Jackson, HDD Operations Manager, Michels Trenchless

Every advancement in our industry is immediately met by the question of ‘what’s next?’ I expect to see more technically challenging projects than ever before, including the completion of HDD projects that would not have been seriously considered a few years ago. The innovations and advancements will continue because the requests for more challenging crossing will not let up.

Digital tools that assist the operator reach new levels of efficiency are becoming more and more the standard on modern HDD rigs.

HK300T hybrid rig for Michels Trenchless in Oedheim, Germany.

Tony Fonk, SpotSee President and CEO, explores how smart monitoring safeguards pipeline integrity before installation.

While pipeline safety standards have grown more sophisticated, from inline inspection tools to advanced coatings, oversight of the logistics chain has lagged behind. This gap becomes more significant as pipeline projects incorporate longer routes, modular components, and fast-track schedules driven by global energy transition goals. Moreover, with mounting pressure for ESG compliance, operators face rising expectation transparency, accountability, and asset traceability across all project phases.

The hidden risk before the pipeline

When most people think about pipeline integrity, they envision weld inspections, corrosion control, and flow assurance. However, some of the costliest failures begin long before any pipe is laid. Between the warehouse and the installation site lies a critical blind spot: the logistics phase.

As energy demand surges and geopolitical pressures reshape global supply chains, pipeline operators are managing tight project margins, increased scrutiny, and shifting tariffs

on high-value infrastructure components. In this environment, any damage sustained during transit – not just to valves, but also to sensors, compressors, and regulators – can spiral into expensive delays, contractual penalties, or environmental risks.

These types of failures are sometimes traced back to undetected internal damage sustained during shipping. Such incidents are increasingly avoidable through better logistics oversight.

Integrity in the midstream pipeline

While traditional quality assurance in pipeline projects emphasises material specifications and correct installation, a critical vulnerability often goes overlooked: transit. Components like valves, compressors, or regulators can pass factory testing and visual inspections, yet still be internally compromised by shock or vibration during transport.

In midstream operations, undetected transit damage is an escalating risk. Sensitive components could experience mechanical stress during shipping that doesn’t manifest until commissioning – causing avoidable delays, rework, or financial penalties. Without proper monitoring between the warehouse and the right-of-way, logistics becomes a blind spot in pipeline integrity.

Although not a midstream example, a related incident in the power sector illustrates the stakes. A 400 t transformer arrived on site with no visible damage, yet failed in the field due to internal impacts sustained during a multi-state shipment. Monitoring data revealed shock events lasting over 50 milliseconds, prompting a complete overhaul of packaging and handling protocols.

The lesson is clear: impact forces don’t need to be visible to be destructive – especially when the component’s performance is critical to system commissioning.

For pipeline projects, these risks extend far beyond hardware. Damaged parts delay commissioning, leave field crews idle, disrupt supply chains, and result in replacement purchases – often subject to tariffs or availability constraints. Transit integrity is no longer a peripheral concern; it’s a foundational one.

Shock events are typically measured in G-force and their duration. For example, an impact of 30 G lasting more than 20 milliseconds can deform internal seals, misalign actuators, or stress calibration-sensitive parts – all without leaving external marks. Such stresses may occur during improper tie-downs, sudden braking, or rough handling across different transport modes. This is especially critical for components like valve regulators and electronic controllers where precision is paramount.

These conditions, though often overlooked in standard QA checklists, represent critical weak points that can compromise performance and reliability if left unmonitored.

Connected shipment monitoring

To address these challenges, operators are turning to connected environmental and impact monitoring devices. Installed at the point of packaging, these systems track shocks, vibrations, and environmental conditions such as

Figure 1. A transformer that failed in the field due to internal impact stress during transit – an issue detected through monitoring.

Figure 2. Monitoring devices installed at packaging detect shock, tilt, and temperature conditions in real time throughout shipment.

Figure 3. ShockLog 298 event data showing shock amplitudes, duration, and thermal profile over a multi-day shipment.

temperature and tilt – capturing a detailed timeline of events during transport.

These purpose-built industrial recorders are tuned to capture precisely the types of mechanical stresses that threaten sensitive components. Data is transmitted via cellular or satellite connections, offering live updates throughout the journey.

It ensures that every high-value asset arrives at the job site ready to perform, rather than waiting to be replaced. Furthermore, it offers something even more valuable: the ability to anticipate problems rather than react to them afterward.

For midstream operators, success depends on predictability, efficiency, and uptime. Pipeline projects often span remote geographies, involve multiple vendors, and face narrow commissioning windows. Unexpected delays – especially those caused by damaged components – can cascade into idle crews, lost revenue, and regulatory setbacks. In this high-stakes environment, having reliable transit visibility is not just a best practice – it’s a strategic imperative. Smart monitoring tools empower operators to pinpoint vulnerabilities in real time, reducing uncertainty and reinforcing confidence across the project lifecycle.

What sets this technology apart is its ability to convert what was once invisible into actionable insights. A shipment that experiences multiple G-force events or a sudden temperature excursion can trigger real-time alerts,

allowing logistics teams to intervene before compromised components are installed.

Case study

In the Permian case, the operator had previously experienced project delays amounting to over US$250 000 due to undiagnosed transit-related valve damage. SpotSee’s ShockLog devices were installed by internal QA teams and calibrated to flag any impact above 25 G. When alerts were triggered from a third-party depot in central Texas, the logistics lead initiated an internal review within 24 hours. Corrective actions, including vendor retraining and tiedown protocol updates, were implemented within a week. Follow-up shipments showed no repeat events, and the maintenance team reported zero commissioning delays in the next two quarters.

In early 2024, a US midstream operator piloted SpotSee’s ShockLog monitoring during the shipment of valves and regulators bound for installation across the Permian Basin. Over a 620 mile transit, three significant impact events exceeding 30 G were detected. ShockLog data pinpointed a recurring issue: improper tie-down procedures at a third-party depot in central Texas.

Armed with this insight, the operator issued new handling protocols and retrained its logistics vendor. Subsequent shipments showed no comparable shock events, and the field team reported zero equipment failures linked to transit for the next two quarters.

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Conventional shipping oversight typically ends at visual inspection and delivery logs. This leaves operators blind to high-impact events that can compromise critical systems. Connected monitoring closes this gap. These systems create a detailed audit trail of the asset’s journey – recording shocks, environmental exposure, and transport anomalies. Logistics teams gain not just traceability, but real-time decision support, transforming reactive damage control into proactive assurance.

Building trust in the supply chain

Modern monitoring systems do more than detect isolated incidents. Transit data becomes a powerful analytic resource when aggregated across fleets and routes. Operators can uncover patterns: are specific lanes more likely to result in shock exposure? Do certain packaging configurations underperform in harsh climates?

For example, SpotSee’s cloud-based analytics platform aggregates shipment data to visualise impact thresholds, G-force trends, and cumulative exposure. These insights support condition-based inventory stocking and allow operators to prioritise components based on their actual handling history, not guesswork.

For pipeline owners, this translates into smarter decisions on routing, packaging, vendor selection, and even spare part procurement – an especially valuable capability when demand is rising and lead times are tight. Pipeline integrity doesn’t begin at the weld; it begins the moment an asset is packed and shipped. Operators who fail to modernise logistics oversight risk schedule delays, regulatory gaps, and spiralling replacement costs, especially in a world where tariffs, inflation, and energy demand are unpredictable.

Conclusion

Connected shipment monitoring isn’t about gadgets for gadgets’ sake – it’s about creating confidence. It ensures that every high-value asset arrives at the job site ready to perform, rather than waiting to be replaced. Furthermore, it offers something even more valuable: the ability to anticipate problems rather than react to them afterward.

As infrastructure builds ramp up to meet renewable transition timelines, adopting predictive monitoring will become a project necessity. Manufacturers, EPCs, and operators that invest in transit visibility can expect improved uptime, reduced commissioning failures, and more accurate spare part forecasting. In a future where precision logistics is the backbone of resilient energy delivery, smart monitoring will be as critical as weld testing or corrosion prevention.

As midstream operators navigate increasingly complex supply chains and project demands, integrated transit visibility will become as essential to integrity as corrosion coating or weld X-rays. It’s no longer a luxury; it’s a competitive edge.

About the author

Tony Fonk is the President and CEO of SpotSee. He brings over 24 years of international experience in developing and executing innovative product, service and channel strategies to his role.

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