World Pipelines - May 2025

®

Volume 25 Number 5 - May 2025

Oman, Middle East

dual leak-tight seals double block & Bleed Isolation

48” SureTap® & BISEP® Hot Tapping & Plugging

When it comes to Fusion Bonded Epoxy (FBE) coatings, precision isn’t optional.

It’s critical.

Fusion Bonded Epoxy coatings are essential to long-term pipeline integrity. But only when applied and inspected correctly. Failure isn’t just costly. It’s avoidable.

That’s why AMPP, the global authority in materials protection and performance, offers targeted training and certification built by the industry, for the industry: • Fusion Bonded Epoxy (FBE): Application and Inspection Course Master the full lifecycle of single and dual-layer external FBE coatings—from application to testing.

Demonstrate your commitment to safety, sustainability, and operational excellence while building the skills needed to drive higher performance and lower risk across the industry.

• Fusion Bonded Epoxy (FBE): Application and Inspection Level 1 Certification This new certification is designed to complement the FBE course and provide industry-recognized credentials worthy of project specification.

Stay ahead of the curve by earning the credentials that will set the industry standard.

Learn more at ampp.org/fbe

25 ??

??

42

35 ??

CONTENTS WORLD PIPELINES | VOLUME 25 | NUMBER 05 | MAY 2025

03. Editor's comment 05. Pipeline news

PIPELINE GASES 38. Mapping Europe's CCUS future

Pipeline news from Alaska, Alabama, Brazil and the Middle East.

Olivier Mette, Global Advisory Director, Xodus.

KEYNOTE: NORTH AMERICA 10. The future of North America's midstream sector

Under pressure from the White House, Canada and Mexico and taking a long hard look at the continent's energy infrastructure, writes World Pipelines Contributing Editor, Gordon Cope.

of rica’s sector

ver the better part of a century, North America has benefited from the integration of both crude, natural gas and refined fuels between Canada, the US and Mexico.

Producers, pipeline companies, refineries and petrochemical plants can choose the most efficient and cost-effective way of delivering energy irrespective of international borders.

In practice, this has meant billions of dollars in savings.

Since the election of President Trump in 2024, however, things have changed. In February 2025, the White House signalled it would issue energy tariffs against Mexico, Canada and other nations. The mere threat has forced both neighbouring jurisdictions to take a cold, hard look at a relationship founded on trust. While the situation remains very much in flux, several major changes are

Author, Xodus, examines the prospects of Europe’s carbon capture, utilisation and storage industry, the progress that has been made and the challenges ahead. fter the best part of three decades worth of promise, carbon capture, utilisation and storage (CCUS) in Europe is taking off. More progress has been made since the turn of the decade than in the 10 years preceding, with numerous industrial clusters across the continent having taken shape and mapped out their plans.

We have never been closer to having a functioning CCUS project in Europe.

In the UK, bp, Equinor and TotalEnergies reached final investment close on the Northern Endurance Partnership (NEP) and Net Zero Teesside Power (NZT Power) projects, key cogs in the East Coast Cluster, at the end of last year. It’s a monumental achievement and the first time that a large-scale CCUS project in the UK has progressed to this stage.

Work on the CO2 receiving and storage facilities of Norway’s Northern Lights project concluded last year, meaning it is now primed and ready to receive and permanently store emissions from European industries, with first injection expected this year.

PAGE 38 Under pressure from the White House, Canada and Mexico are taking a long, hard look at the continent’s energy infrastructure, writes World Pipelines Contributing Editor, Gordon Cope.

39

38

42. Measurement instrumentation for carbon sequestration

The future of North America’s midstream sector

PAGE

10

11

10

Laura Chemler, Emerson.

46. The methane challenge Dr Neil Bird, Fluenta.

PIPELINE MANAGEMENT 15. Unlocking the energy value chain

Carlos Garcia Alvarado and Vicki Knott, CruxOCM.

ENVIRONMENTS 17. Strengthening pipeline security

Dr Neil Bird, Chief Scientist, Fluenta, UK, discusses how to transform pipeline emissions monitoring.

John Cusimano, Armexa.

21. Combining cybersecurity and open automation Hany Fouda, Schneider Electric.

ethane is pivotal to today’s environmental challenges. Whilst there’s limited scope for direct intervention with CO2, the management of methane is altogether more realistic – and in many instances can become cost-neutral.

Mitigating the loss of methane and, especially the productive use of methane rather than venting, flaring or even leaking is low-hanging fruit for regulators and governments seeking to achieve ambitious targets.

Methane, as a greenhouse gas with a global warming potential over 80 times greater than carbon dioxide over a 20 year period, has become an urgent priority. For the pipeline sector, the focus has shifted from basic compliance to proactive emissions monitoring and reduction, driven by a mix of regulatory changes, technological advancements, and growing public scrutiny.

25. Triumphing over temperature extremes

Neil Wilds and Dr Jeffrey David Rogozinski, Sherwin-Williams.

MIDSTREAM OPERATOR FOCUS 30. Fuelling the future Hua Feng, PhD, Black & Veatch.

COVER STORY 35. Seamless gas segregation Razal Kabeer, STATS Group.

PAGE 46

47

46

CONSTRUCTION 50. Supporting the British pipeline industry Clive Zanker, UKOPA.

LEAK DETECTION 53. In the balance

Joe Kelly, Atmos International

®

Volume 25 Number 5 - May 2025

ON THIS MONTH'S COVER

CBP019982

Drone footage of a hot tapping and plugging operation on a 48 in. gas transmission line in the Sultanate of Oman. STATS Group successfully performed 48 in. hot tapping using the SureTap® ST1530-90, enabling the deployment of dual BISEP® line stop tools for leak-tight double block and bleed isolation. Uninterrupted gas flow was maintained through an integrated bypass operating at 75 bar pressure, ensuring the tie-in of two gas processing plants. This critical operation avoided a shutdown while also significantly reducing greenhouse gas emissions by preventing the need to vent the entire pipeline.

Oman, Middle East

dual leak-tight seals double block & Bleed Isolation

Copyright© Palladian Publications Ltd 2025. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in the articles or the advertisements. Printed in the UK.

48” SureTap® & BISEP® Hot Tapping & Plugging

ISSN 1472-7390

Reader enquiries [www.worldpipelines.com]

Delivering future-focused intelligent flow control

Correctly specified flow control can provide a safe working environment, increase process efficiency, reduce emissions and increase your profitability.

We are experts in the movement, storage and transportation of liquids and gases, delivering flow control solutions with the highest levels of safety and reliability.

Contact us to find out more or speak to one of our expert advisors.

+44 (0)1225 733200

| mail@rotork.com | rotork.com

EDITOR’S COMMENT CONTACT INFORMATION MANAGING EDITOR

James Little

james.little@worldpipelines.com

EDITORIAL ASSISTANT

Alfred Hamer

alfred.hamer@worldpipelines.com

SALES DIRECTOR

Rod Hardy

rod.hardy@worldpipelines.com

SALES MANAGER

Chris Lethbridge

chris.lethbridge@worldpipelines.com

SALES EXECUTIVE

Daniel Farr

daniel.farr@worldpipelines.com

PRODUCTION DESIGNER

Amy Babington

amy.babington@worldpipelines.com

HEAD OF EVENTS

Louise Cameron

louise.cameron@worldpipelines.com

EVENTS COORDINATOR

Chloe Lelliott

chloe.lelliott@worldpipelines.com

DIGITAL EVENTS COORDINATOR

Merili Jurivete

merili.jurivete@palladianpublications.com

DIGITAL CONTENT COORDINATOR

Kristian Ilasko

kristian.ilasko@worldpipelines.com

JUNIOR VIDEO ASSISTANT

Amélie Meury-Cashman

amelie.meury-cashman@worldpipelines.com

DIGITAL ADMINISTRATOR

Nicole Harman-Smith

nicole.harman-smith@worldpipelines.com

ADMINISTRATION MANAGER

Laura White

laura.white@worldpipelines.com

Palladian Publications Ltd,

15 South Street, Farnham, Surrey, GU9 7QU, UK Tel: +44 (0) 1252 718 999 Website: www.worldpipelines.com Email: enquiries@worldpipelines.com Annual subscription £60 UK including postage/£75 overseas (postage airmail). Special two year discounted rate: £96 UK including postage/£120 overseas (postage airmail). Claims for non receipt of issues must be made within three months of publication of the issue or they will not be honoured without charge.

Applicable only to USA & Canada: World Pipelines (ISSN No: 1472-7390, USPS No: 020-988) is published monthly by Palladian Publications Ltd, GBR and distributed in the USA by Asendia USA, 701C Ashland Avenue, Folcroft, PA 19032. Periodicals postage paid at Philadelphia, PA & additional mailing offices. POSTMASTER: send address changes to World Pipelines, 701C Ashland Avenue, Folcroft, PA 19032.

I

recently took some speech classes, to prepare for a public speaking role at a conference hosted by my lovely friends over at World Cement magazine.

Through a handful of one-to-one lessons I learned how to get into a speaker state, and the following nuggets of wisdom have stuck in my mind: ) When you care about the topic you’re speaking about, it will show. ) Trust that the right word will fall into place when you take your time with delivery. ) Hand gestures help us enunciate and be expressive. ) The most important thing is that your audience receives what you are saying. You are responsible SENIOR EDITOR Elizabeth Corner elizabeth.corner@worldpipelines.com for handing them a spoonful of knowledge each time you speak.

These learnings proved helpful when I was called to be on stage at the conference; they are also proving just as valuable now, as I prepare to host a new series of webinars for the World Pipelines and Oilfield Technology communities this spring and summer.

We have a brilliant run of sessions lined up throughout May and June, featuring experts from STATS Group, Dairyland Electrical Industries, Denso Inc., Proserv, and Luna. Each webinar will tackle a different challenge: including subsea pipeline modifications, offshore pipelay, cathodic protection, and sensing technology for a gas condensate producing well.

Webinars have come a long way since the Zoom fatigue of the early 2020s, when we couldn’t work out why we were always on mute. They have grown to become essential tools: places we learn, network, and gather insight, all without leaving our desks (home or office). The ability to access real-time expertise, and interact with the webinar presenters, can be invaluable.

Of course, we’ve all seen the memes about webinars that turn out to be glorified sales pitches. That’s not what we offer here. Our goal is to create curated conversations, giving attendees what they need in a way that’s clear, engaging, and respectful of their time and existing knowledge of the subject at hand. So, join us! Listen and learn, ask questions, challenge your assumptions, and connect with a global community of pipeliners.

And if you’re thinking about hosting a webinar yourself, why not book with us? You’ll get professional reach, niche expertise, a warm, well-paced discussion, and a unique bit of communion with your dialled-in audience.

In this month’s issue of World Pipelines, we bring you articles on the future of North America’s midstream sector (there’s a lot to cover here); how natural gas midstream operators are helping to power AI’s energy revolution; the use of autonomous robotics to transform pipeline inspections; pipeline control room transformation; and lots more.

We’re also running a special feature on operating pipelines in extreme environments, which includes: a guide for OT professionals on TSA pipeline security directives; the challenge of combining cybersecurity and open automation in remote and vulnerable assets; and tackling pipeline corrosion in extreme temperatures.

The medium might change (a conference, a webinar, an article) but the mission remains the same: to communicate ideas that move the industry forward. Good communication – from the control room, to the field, and back to the boardroom – is critical for safe and efficient operations.

Together, 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.

crcevans.com

WORLD NEWS EQT Corp. acquires Olympus Energy upstream and midstream assets for US$1.8 billion EQT Corp. has entered into an agreement to acquire upstream and midstream assets from Olympus Energy for US$1.8 billion.

The announcement comes as EQT increases its 2025 production guidance by 25 billion ft3e following the acquisition of gathering, transmission and storage assets from Equitrans Midstream Corp.

President and CEO Toby Z. Rice commented: “EQT is off to an exceptional start in 2025, with the first quarter generating the strongest financial results in recent company history. Seamless coordination across our integrated midstream and upstream assets resulted in volumes at the high end of guidance, and our tactical production response opening chokes into peak winter prices drove higher realisations. Along with lower-than-expected capital spending, EQT generated more than US$1 billion of free cash flow in the first quarter alone.

“We are raising 2025 production guidance by 25 billion ft3e

while reducing the mid-point of 2025 capital spending by US$25 million due to strong well performance, ongoing efficiency gains and additional Equitrans Midstream synergy capture. This underscores the tremendous momentum we’re experiencing at EQT and we see no signs of slowing down as we look ahead.

“We are also announcing that we have entered into an agreement for the accretive bolt-on acquisition of the upstream and midstream assets of Olympus Energy, which has a vertically integrated asset base and an unlevered free cash flow breakeven price comparable to EQT’s peer leading position at the low end of the cost curve.

The purchase price equates to an approximately 15% unlevered free cash flow yield, highlighting attractive value for EQT shareholders. Additionally, the assets are positioned adjacent to several proposed power generation projects, providing potential strategic value upside.”

Glenfarne becomes lead developer for the Alaska LNG project Glenfarne Alaska LNG, LLC, an affiliate of Glenfarne Group, LLC, and the Alaska Gasline Development Corporation (AGDC) signed definitive agreements for Glenfarne to become majority owner of Alaska LNG, the sole federally permitted LNG export project on the US Pacific Coast, and lead its development to construction and operations of the entire project. Alaska LNG is designed to deliver North Slope natural gas to Alaskans and Alaska utilities and export up to 20 million tpy of LNG .

Under the agreement, AGDC is divesting 75% of 8 Star Alaska, a subsidiary AGDC created to hold and manage all Alaska LNG project assets, to Glenfarne. Glenfarne assumes the role of Alaska LNG’s lead developer and will lead all remaining development work of Alaska LNG from front-end engineering and design (FEED) through to a final investment decision (FID).

AGDC remains a 25% owner of 8 Star Alaska and a key partner to Glenfarne on the project.

Alaska LNG’s three subprojects are an 807 mile 42 in. pipeline, the 20 million tpy LNG export terminal in Nikiski,

Alaska, and a North Slope-based carbon capture plant to remove and safely store 7 million tpy of carbon dioxide. In light of steadily declining gas production from Cook Inlet, which has historically been Alaska’s primary in-state natural gas basin, phase one of the project will kick off immediately, prioritising the development and final investment decision of the pipeline infrastructure needed to deliver North Slope gas to Alaskans as rapidly as possible.

Following a successful final investment decision, the State of Alaska will retain a 25% share in 8 Star Alaska and have the option to invest up to 25% in any or all of the three 8 Star Alaska subprojects.

AGDC and Glenfarne executed a letter of intent in June 2024 and an exclusive term sheet in December 2024 in advance of this binding agreement. Glenfarne is the owner of Texas LNG, which has recently announced that its capacity is fully sold out and Kiewit has joined the project as its EPC contractor with a final investment decision later this year.

Williams commissions two Transco projects to meet growing energy demand Williams has announced the successful commissioning of the Southeast Energy Connector in Alabama, and the Texas to Louisiana Energy Pathway along the Gulf Coast. These fully contracted expansions of the existing Transco pipeline were strategically designed and built to reduce land use and minimise community and environmental impact while delivering additional natural gas volumes to the region.

“I congratulate our team for the efficient completion of these projects, demonstrating our ability to execute largescale expansions in a safe and environmentally responsible manner,” said Alan Armstrong, President and Chief Executive Officer for Williams. “Demand for affordable, reliable and clean natural gas continues to grow across US markets, driven by increasing electric power generation, reshoring of energy-

intensive manufacturing, data centre load growth and LNG exports. Williams is committed to meeting this demand with 12 high-return transmission projects currently in execution, which will add more than 3.25 billion ft3/d to our transmission systems over the next several years.”

The Texas to Louisiana Energy Pathway project expands Transco’s capacity in Texas and Louisiana by 364 million ft3/d to support reliability and diversification of energy infrastructure along the Gulf Coast, a growing demand centre for domestic needs and LNG export activity.

The Southeast Energy Connector supports the conversion of electric power generation in Alabama from coal to natural gas and provides 150 million ft3/d of natural gas to meet the area’s clean energy needs.

MAY 2025 / World Pipelines

5

WORLD NEWS IN BRIEF

US Transportation Secretary advocates for enhancing pipeline safety

USA

US Transportation Secretary Sean P. Duffy has announced that Pipeline and Hazardous Materials Safety Administration (PHMSA) will be encouraging all regulated pipeline owners and operators to voluntarily adopt new safety management systems (SMS). The utilisation of SMS will enhance pipeline safety and is supported by the National Transportation Safety Board (NTSB).

“We are committed to carrying out

The EIA has reported that in 2024, pipeline companies completed five pipeline projects to transport petroleum liquids in the USA, according to its recently updated Liquids Pipeline Projects Database.

INDIA GAIL (India) Limited has completed laying of over 97.6% of the integrated JagdishpurHaldia-Bokaro-Dhamra Pipeline (JHBDPL), popularly known as ‘Pradhan Mantri Urja Ganga’, carrying Natural Gas to Eastern and North-Eastern part of India.

USA Energy Transfer LP and MidOcean Energy have announced that Energy Transfer’s subsidiary, Energy Transfer LNG Export, LLC, has entered into a Heads of Agreement (HOA) related to its Lake Charles LNG project with MidOcean, an LNG company.

UK Energy consultancy Penspen has announced it is launching its first training courses in Aberdeen, focused on repurposing pipelines for hydrogen and CO2 capture and transmission.

USA Vaquero Midstream, a natural gas gathering and processing midstream company operating in the Delaware Basin, closed on an expanded US$400 million credit facility led by BOK Financial®.

USA PHMSA has issued a Corrective Action Order to South Bow, which directs the operator to take specific actions to improve the safety of the Keystone Pipeline after a crude oil release was discovered on 8 April 2025, in Ransom County, North Dakota.

6 World Pipelines / MAY 2025

President Trump’s agenda to unleash American energy in all ways – big and small.

Here at the Department of Transportation, that mission includes ensuring our natural resources can efficiently and securely reach consumers. Enhancing pipeline safety through innovative management systems is just one way we can boost our energy security and lower costs for the American people,” said Duffy.

Phillips 66 completes acquisition of EPIC NGL Phillips 66 has announced the completion of its previously announced acquisition of EPIC Y-Grade GP, LLC and EPIC Y-Grade, LP, which own various subsidiaries and long-haul natural gas liquids pipelines, fractionation facilities and distribution systems (EPIC NGL) for total cash consideration of approximately US$2.2 billion.

The EPIC NGL business consists of two fractionators (170 000 bpd) near Corpus Christi, Texas, approximately 350 miles of purity distribution pipelines and an

approximately 885 mile NGL pipeline (175 000 bpd) linking production supplies in the Delaware, Midland and Eagle Ford basins to fractionation complexes and the Phillips 66 Sweeny Hub. The expansion project from 175 000 bpd to 225 000 bpd for the NGL pipeline is expected to be completed in 2Q25. A second expansion to increase capacity to 350 000 bpd has already been sanctioned with completion expected in the 4Q26.

Traverse Pipeline reaches FID to transport natural gas between Agua Dulce and the Katy area WhiteWater has announced that WhiteWater, MPLX LP, and Enbridge Inc., through the WPC joint venture, have partnered with an affiliate of Targa Resources Corp. and have reached FID to move forward with the construction of the Traverse Pipeline.

The bi-directional Traverse Pipeline is designed to transport up to 1.75 billion ft3/d of natural gas through approximately 160 miles of 36 in. pipeline along the Gulf Coast between Agua Dulce in South Texas and the Katy area.

Supply for the Traverse Pipeline will be sourced from multiple connections, including

the Whistler, Blackcomb, and Matterhorn Express Pipelines. The Traverse Pipeline enhances optionality for shippers to access multiple premium markets.

The pipeline will be wholly owned by the Blackcomb Pipeline joint venture, which is owned 70.0% by WPC, 17.5% by Targa, and 12.5% by MPLX, which is incremental to MPLX’s ownership interest in WPC. The pipeline will be constructed and operated by WhiteWater and is expected to be in service in 2027, pending receipt of regulatory and other approvals.

Vallourec in exclusive negotiations to sell Serimax for €79 million Vallourec has entered into exclusive negotiations with Aldebaran, a French investment company, for the sale of Serimax, Vallourec’s subsidiary specialising in mechanised welding solutions, for an enterprise value of €79 million, of which €7 million will be paid via an earn-out. The completion of the sale is expected in the next few months, subject to consultation of the

employee representative bodies and satisfaction of customary conditions precedent, including obtaining the necessary regulatory approvals.

This transaction is part of the New Vallourec’s initiatives to rationalise its invested capital and focus the Group on its core business as a premium seamless tubular solutions provider.

PETROLATUM TAPE WRAP SYSTEMS

PROTECTIVE OUTERWRAPS

LIQUID EPOXY COATINGS

BUTYL TAPE WRAP SYSTEMS

SOIL-TO-AIR INTERFACE

HEAT SHRINKABLE SLEEVES

BITUMEN TAPE WRAP SYSTEMS

INTERNAL PIPE LININGS

CONTRACT NEWS EVENTS DIARY

Vallourec wins a new major line pipe contract offshore Brazil

5 - 8 May 2025

Vallourec has secured a major contract with Allseas to supply line pipes for Búzios 10 offshore project located at the Búzios field, operated by Petrobras. This contract represents nearly 18 000 t of subsea seamless premium carbon steel line pipes, for the risers and flowlines. The contract includes an optional scope of almost 5000 t.

Located off the coast of Rio de Janeiro, Búzios is one of the world’s largest deepwater fields. This field represents a significant part of the Brazilian oil company’s operations. The field’s production is expected to substantially increase as five additional units are set to commence operations by 2028.

The contract also includes Vallourec’s Pipe Navigator solution, a centralised digital portal that offers instant access to

20th Pipeline Technology Conference Berlin, Germany https://www.pipeline-conference.com/

5 - 8 May 2025

Offshore Technology Conference 2025 Houston, USA https://2025.otcnet.org/

19 - 23 May 2025

29th World Gas Conference (WGC2025) Beijing, China https://www.wgc2025.com/eng/home

up-to-date contractual documentation, data and analysis covering every aspect of its line pipe projects. The entire production will be carried out at our cutting-edge facility in Jeceaba (Minas Gerais, Brazil) to ensure high local content and a reduced carbon footprint.

Philippe Guillemot, Group’s Chairman and CEO declared: “This contract reinforces our strategic positioning in Brazil, one of our key markets for complex offshore projects. It also serves as legacy to our ability to deliver premium tubular solutions, fully manufactured in Brazil. This contract also validates the investment strategy implemented over the past three years to enhance our industrial performance and meet the most demanding requirements of our customers.”

25 - 29 May 2025

Annual Pipe Line Contractors Association of Canada (PLCAC) Convention Banff, Canada https://pipeline.ca/

10 - 12 June 2025

Global Energy Show 2025 Calgary, Canada https://www.globalenergyshow.com/

25 - 26 June 2025

Carbon Capture Technology Expo North America 2025 Houston, USA https://www.ccus-expo.com/about/registrationnorth-america

9 - 12 September 2025

Gastech Exhibition & Conference Milan, Italy https://www.gastechevent.com/visit/visitorregistration/

23 - 24 September 2025

Subsea Pipeline Technology Congress (SPT 2025) London, UK https://sptcongress.com/registration

8 World Pipelines / MAY 2025

Saipem awarded US$720 million of new offshore contracts The first contract encompasses the engineering, procurement, construction and installation (EPCI) activities for the repair of damaged subsea pipelines for a major client in Middle East. The duration of the project is expected to last three years and it emphasises the growing importance of the maintenance of existing offshore fields, which is an integral part of Saipem portfolio complementing the EPCIC (Engineering, Procurement, Construction, Installation & Commissioning) and EPRD (Engineering, Preparatory works, Removal and Disposal) business.

The second contract is a Limited Notice To Proceed (LNTP) by ExxonMobil Guyana Limited, pending necessary government and regulatory approvals, and involves the engineering, procurement, construction, and installation (EPCI) of subsea structures, umbilicals, risers and flowlines (SURF) for the production facility and gas export system of the proposed Hammerhead oil field development project, located in the Stabroek block offshore Guyana at a water depth of around 1000 m.

Saipem will use a variety of construction and support vessels, including Saipem FDS2.

Logistics will be executed and managed in Guyana through the Vreed-en-Hoop Shorebase Inc. (VEHSI) yard, generating employment and local content opportunities. The project is expected to last four years.

ON OUR WEBSITE • STATS Group wins Malaysian

pipeline isolation contract • Perma-Pipe International

Holdings, Inc., announces new project awards in the Americas and MENA region • Energy Industries Council

appoints three experienced energy leaders to its Board of Directors • Global Underwater Hub and

Subsea Innovation Cluster Australia join forces to boost subsea sector Follow us on LinkedIn to read more about the articles linkedin.com/showcase/worldpipelines

Under pressure from the White House, Canada and Mexico are taking a long, hard look at the continent’s energy infrastructure, writes World Pipelines Contributing Editor, Gordon Cope.

The future of North America’s midstream sector 10

ver the better part of a century, North America has benefited from the integration of both crude, natural gas and refined fuels between Canada, the US and Mexico.

Producers, pipeline companies, refineries and petrochemical plants can choose the most efficient and cost-effective way of delivering energy irrespective of international borders.

In practice, this has meant billions of dollars in savings.

Since the election of President Trump in 2024, however, things have changed. In February 2025, the White House signalled it would issue energy tariffs against Mexico, Canada and other nations. The mere threat has forced both neighbouring jurisdictions to take a cold, hard look at a relationship founded on trust. While the situation remains very much in flux, several major changes are

11

likely to emerge over the next few years, especially in the midstream sector. In this article, we will first discuss the status quo, then examine how things may evolve.

Good neighbours In 2024, Canada exported approximately 4.4 million bpd of crude and 8 billion ft3/d of natural gas, primarily to the US West Coast, Midwest, and the USGC. The US, in turn, supplied 300 000 bpd and 2.8 billion ft3/d of gas to eastern Canada. In addition, the US supplies about 7 billion ft3/d of gas and 1.2 million bpd of diesel and gasoline to Mexico. The movement of all this energy is primarily based on economic factors, such as the cost of transportation, energy needs, and other market forces.

The drawback to Canada’s over-reliance on one single large customer became evidently clear when Trump threatened a 25% (reduced to 10%) tariff on Canadian crude.

For the last decade, the ruling Liberal party in Ottawa has run a virtue-signalling vendetta against the Canadian oilpatch, trying to throttle the sector for the sake of the environment.

Trump’s tactics caused a seismic shift in political posturing when federal politicians realised that almost 20% of the country’s exports were in jeopardy. Suddenly, diversification of the marketplace became topic number one in Canada, and that brought pipelines to the fore.

In mid-2024, the expansion of the Trans Mountain pipeline (TMX) finally entered service. When the TMX project was originally announced by Kinder Morgan in 2012, expansion of the 300 000 bpd line that ran over 1000 km from Alberta to tidewater in British Columbia (BC) would cost CAN$5 billion and add almost 600 000 bpd capacity. It was generally considered a sound investment that would open up new markets in Asia. But TMX quickly ran into the ditch when a succession of BC governments demonised the project on environmental grounds. Kinder Morgan eventually walked away, obliging the federal government to purchase the line.

COVID-19, flooding, and Indigenous opposition caused the cost to balloon to CAN$34 billion.

In the end, the project turned into a success; Trans Mountain is already loading 24 tankers per month, and expects that to expand to 30 once Vancouver harbour improvements to allow night-time movement of ships is completed. The operator is also looking at further boosting capacity by as much as 300 000 bpd through drag-reducing agents and new pumps.

Almost two decades ago, Enbridge proposed Northern Gateway, a 525 000 bpd pipeline that would transport diluted bitumen from Alberta to the Pacific port of Kitimat, BC. In 2017, the Trudeau government cancelled it, citing the dangers of marine shipments to west coast waters. While pundits have recently proposed renewing the project, Enbridge has expressed little interest, citing a horde of restrictive federal regulations that would have to be repealed in order to justify the investments needed to revitalise the line.

Other projects are now being seen in a new light. In 2013, TC Energy proposed re-purposing the natural gas mainline that ran from Alberta eastwards to Ontario, creating the 4000 km Energy East network to deliver up to 1.1 million bpd

12 World Pipelines / MAY 2025

of crude all the way to tidewater in New Brunswick. The project quickly met stiff opposition from environmental groups, First Nations and the province of Quebec, resulting in the company shelving the plan in 2017. Likewise, TC Energy has expressed no interest in renewing the proposal, having spun off its oil transportation business in order to concentrate on natural gas opportunities in the US and Mexico.

A more viable option may be a long-discarded plan to run a northern leg of the Trans Mountain pipeline to Kitimat, BC. The company’s original expansion plans called for a 400 000 bpd branch line starting in BC, that would then run several hundred kilometres northwest. The plan was subsequently dropped while Trans Mountain concentrated on the main expansion, but the company added sufficient capacity while building TMX to make the branch line project feasible. Trans Mountain says it has no current plans to revisit the option, however.

LNG New natural gas lines for LNG face better prospects.

After lagging behind the US in the development of LNG export plants, Canada is belatedly realising their value; because Pacific-coast projects are situated thousands of kilometres closer to Asian markets than those in the USGC, transportation costs are far lower, and thus more competitive.

LNG Canada, Shell’s massive, 14 million tpy complex in the Pacific port of Kitimat, BC, will begin delivering LNG in 2025.

It is being followed by nearby Cedar LNG, which will use a floating liquefaction plant to produce 4 million tpy by 2028.

The BC government, a long-time opponent to fossil fuel development, is now onboard after feeling the pinch from Trump’s antics; it is promoting the fast-track development of several other projects, including the 12 million tpy Ksi Lisims LNG, the 3 million tpy FortisBC plant, and the 2.1 million tpy Woodfibre LNG project. Feedstock for the plants will come from the massive unconventional gas reserves in northern BC and Alberta. Owners of the Ksi Lisims LNG facility have plans to build a CAN$6 billion gas line that will run from northern BC to a tidewater terminal 100 km north of Prince Rupert, BC. Canada also has LNG potential on its Atlantic coast.

Europe, which entered crisis mode when natural gas from Russia was cut off after the invasion of Ukraine, is developing a hydrogen economy in order to ensure security of energy supply and to meet environmental goals of net-zero emissions by 2050. But it will also need new sources of LNG. When German Chancellor Olaf Scholz approached Prime Minister Justin Trudeau in 2022 seeking Canadian energy, the latter infamously responded; “There has never been a strong business case,” for Atlantic LNG. Now that Trudeau is gone, proponents of LNG and hydrogen production on the east coast of Canada are dusting off plans and examining extensions to existing gas pipeline networks.

Mexico Mexico has had previous experience with the White House interfering in energy matters; when the Biden administration announced a pause in LNG approvals in order to assess

The Smart Way to Isolate.

SmartPlug® Isolation System

Two Independent Plugging Modules. Zero Compromise.

The SmartPlug® Isolation System delivers true Double Independent Isolate and Monitor (DiiM) isolation—with independently anchored plugging modules that eliminate single points of failure. Rated up to 350 bar, it ensures safe, efficient, and high-integrity pipeline repairs with onboard control, bi-directional piggability, and remote pressure monitoring.

See the SmartPlug® in Action

their environmental impact, the move side-swiped LNG projects in Mexico. While Trump cancelled the pause upon his inauguration, the subsequent imposition of tariffs on Mexican food and vehicle exports highlighted his predilection for strong-arm tactics to win trade concessions. The Mexican government has little doubt that the administration could take a page from Russia’s playbook and leverage their dependency on US energy imports for geopolitical gain. In order to reduce the threat, Mexico has supercharged the search for new domestic sources.

Historically, most of its domestic gas has come from gas associated with oilfields. But giant fields like Cantarell are rapidly declining, and the country needs to develop nonassociated fields. Grupo Carso, owned by Mexican billionaire Carlos Slim, has been in discussions with Pemex to develop the Lakach field in the deep-water Gulf of Mexico. Located 70 km offshore from the state of Veracruz, the field holds an estimated 1.1 trillion ft of gas. First discovered in 2007, Pemex has long delayed investment due to high costs.

Now that energy security has entered the calculus, Grupo Carso, which has invested in numerous offshore ventures in Mexico, is optimistic that technological advances can make the project viable. In February, 2025, Mexico’s President Sheinbaum also announced plans for Pemex to increase its current domestic production from 3.3 billion ft3/d to 5 billion ft3/d by 2030 through a multi-billion dollar exploration and drilling programme.

In order to reduce its dependency on US gasoline and diesel, Pemex is belatedly spending funds to rejuvenate its existing six refineries and increase output. Theoretically, the state-owned company has enough capacity to meet all domestic needs for diesel and gasoline, but a combination of theft, mismanagement and neglect has seen utilisation rates drop below 50%. To help ween Mexico off of imports, former President Andrés Manuel López Obrador (AMLO) championed a new refinery, the 340 000 bpd Dos Bocas facility in the state of Tabasco. The project, which is also known as Olmeca, has been beset by delays and price inflation, from the original estimate of US$8 billion to over US$20 billion. In addition, the company used plans that had been drawn up several years ago, and the specs are antiquated and not suited to the coastal site. So far, output has been around 50 000 bpd, but the uncertainty generated by Trump will, no doubt, incentivise the current administration of President Sheinbaum to iron out production bottlenecks.

The future The US will continue to use Canadian crude. Of the 4.4 million bpd of Canadian crude shipped to the US, the majority is in the form of diluted bitumen, where the viscous output from the oilsands is thinned with a diluent to make it transportable by pipeline. Once it reaches its destination at refineries in the US Midwest (PADD 2), it is separated from the diluent and processed through distillation columns to separate lighter fractions. The residue tar is then run through cokers to milk every molecule of energy. Because of the vast capital expenditures needed

14 World Pipelines / MAY 2025

to make the process efficient, the refineries are reliant on heavy crude, and alternate sources in Mexico or Venezuela are incapable of making up the difference; trying to swap out lighter shale crude from Texas would result in the uneconomic optimisation of assets. It is therefore very unlikely that PADD 2 refineries, which account for over 20% of refining in the US, would abandon Canadian crude; in fact, Enbridge announced plans in March 2025, to expand its mainline network into the US, spending CAN$2 billion to add up to 300 000 bpd capacity by 2027.

Mexico will continue to buy US gas. For the last decade, Mexico has been building up its network of natural gas mainlines in order to import inexpensive gas from Texas.

Currently, the 7 billion ft3/d of imported gas is mainly used in gas-fired electric utilities. The country also has half a dozen LNG plants in various stages of design and construction that are expected to add several billion ft3/d more over the coming decade, and it is unlikely that domestic production will expand sufficiently to meet new demand.

Other nations further afield are glancing nervously at their potential exposure to Trump’s ire, and taking palliative steps. In January 2025, Trump’s cabinet officially backed the development of LNG in Alaska. The Alaska Gasline Development Corporation (AGDC) is a state-promoted enterprise that seeks to commoditise up to 34 trillion ft3 of gas that is stranded on the North Slope adjacent to the Prudhoe Bay field. The US$44 billion project would see an 800 mile mainline capable of delivering up to 3.3 billion ft3/d to the Pacific port of Nikiski, where a liquefaction plant would produce up to 22 million tpy of LNG for export to Asia. Japan, which is eager to avoid potential tariffs, is urging Tokyo-based Mitsui to invest; the massive conglomerate would bring LNG technology and marketing skills to the project, as well as deep pockets.

In the US, the Trump administration is busy trying to deregulate the energy sector and ramp up pipeline construction. While some midstream companies are greeting the moves with cautious optimism, others are reacting with alarm. Elon Musk’s Department of Government Efficiency (DOGE), has been placing pressure on the Pipeline and Hazardous Materials and Safety Administration (PHMSA) to reduce staff. In March 2025, seven of the top officials accepted buyouts or resigned, placing the agency in charge of pipeline safety in jeopardy. Critics are concerned that the gutting of the PHMSA comes at a time when expert guidance over the regulation of new classes of pipeline networks, including CO2 and hydrogen, is urgently needed.

In conclusion, while Trump will eventually leave the White House, the integrated energy network that was the envy of the world will be a thing of the past. In the coming years, Canada will endeavour to restructure its midstream sector to reduce the over-whelming reliance on the US as a customer, seeking out new markets in Asia and Europe.

Mexico can’t easily wean itself off Texas gas, but it can seek out new domestic sources and build renewable solar and wind farms to diversify its sources of electricity. Regardless, the midstream sector will seek ingenious ways to adapt and prosper for the coming decade.

Carlos Garcia Alvarado, CTO and Vicki Knott, CEO, CruxOCM, discuss how to optimise midstream operations to enhance efficiency and unlock value across the supply chain.

he energy industry, particularly the integrated midstream sector, stands at a pivotal moment. While pipeline control room operations have traditionally been viewed as a necessary expense, a new perspective is emerging: these operations represent a significant opportunity to drive efficiency, enhance profitability, and unlock substantial value across the supply chain. After all, pipelines are the vital arteries connecting production to processing and distribution, playing a crucial role in delivering both liquid and gaseous energy resources to the world.

A new era of operational excellence Forward-thinking organisations are recognising the power of strategic investment in agility and operational excellence.

This approach moves beyond short-term cost reduction to embrace the potential for significant value creation. By viewing control room operations as a strategic hub for data-driven

15

decision-making and optimisation, companies can gain a competitive edge in a rapidly evolving energy landscape.

It’s important to acknowledge the industry’s existing strengths. The pipeline sector has a long history of innovation and operational excellence. We’re not suggesting a radical overhaul, but rather a strategic enhancement, leveraging modern software development practices to build upon these strengths and unlock new levels of efficiency and performance.

Empowering pipeline operations CruxOCM is at the forefront of this transformation, providing innovative solutions that empower pipeline control rooms to become strategic assets. Our approach is deeply rooted in modern software product development principles, which this section details.

Pipeline abstraction and standardisation enable unified and efficient management. We streamline pipeline complexities, enabling standardised, automated software solutions that enhance agility, maintainability, and safety. This standardisation, built upon microservices and API-first architectures, facilitates real-time responses to asset fluctuations and optimises throughput, ensuring consistent and reliable delivery of both liquid and gaseous resources. This allows for a more unified and efficient approach to managing diverse pipeline networks.

Real-time active monitoring is the foundation for informed decisions with advanced data analytics, enhancing existing expertise. We believe that real-time monitoring is essential for value generation and operational excellence. CruxOCM delivers the right information to each stakeholder quickly, enabling fast business and operational decision-making. Utilising modern data analytics and machine learning, we provide predictive insights, not just reactive alerts, empowering operators and managers to make proactive adjustments and optimise performance in real time.

We build upon the existing expertise of control room operators, providing them with enhanced tools to make informed decisions.

Enhanced software interoperability is a result of breaking down data silos with open APIs, fostering seamless integration. CruxOCM prioritises seamless communication between software systems, enabling real-time data exchange and command execution. We provide the foundation for software automation, going beyond traditional SCADA communications to create a more integrated and responsive operational environment. This is achieved through open APIs and standardised data formats, allowing for easy integration with existing systems.

Open and portable data means empowering innovation with cloud-native architecture, enabling data-driven decisions. We champion an open data model, eliminating vendor lock-in and providing secure access to operational data. This empowers executives to make informed decisions and optimise production schedules, fostering a culture of data-driven innovation and collaboration. Built on cloud-native architecture, our solutions offer scalability and flexibility.

Continuous software deployment allows us to stay ahead of the curve with Devops practices, ensuring continuous improvement. Our solutions are designed for continuous deployment, ensuring your organisation always benefits from the latest features and updates, maximising the value of your software investment and adapting to the evolving demands of the industry.

16 World Pipelines / MAY 2025

Leveraging DevOps practices, we ensure rapid iteration and deployment of new features, enabling continuous improvement.

Robust zero-trust cybersecurity can protect critical infrastructure with advanced security protocols, building trust and resilience. We implement a zero-trust cybersecurity architecture, ensuring continuous authentication and monitoring, and adhering to industry best practices. This proactive approach safeguards operational data and enhances system resilience, protecting critical infrastructure from evolving cyber threats. Our security protocols are designed to meet the highest industry standards.

Value-driven partnerships are crucial for aligning mutual success with agile development, fostering collaborative innovation. CruxOCM’s success is aligned with our clients’ success.

We focus on building strong partnerships and delivering solutions that generate tangible, measurable benefits, driving continuous improvement and maximising return on investment. Through agile development methodologies, we ensure that our solutions are tailored to meet the specific needs of our clients.

Realising the potential Enhancing existing strengths with modern software solutions The potential for transformation in the energy sector is significant and immediate. Human-centred industrial autonomy initiatives, powered by modern software solutions, are driving substantial improvements in operational efficiency and profitability for integrated midstream companies.

While the industry has made significant strides in optimising production and processing, pipelines remain a vital link with untapped potential. These dynamic systems, currently managed with manual processes and offline optimisation, represent a significant opportunity for improvement.

By embracing agility, standardisation, and automation, companies can transform their pipeline control rooms into strategic assets, creating a genuine competitive advantage and contributing to a more sustainable and efficient energy future.

Innovation and collaboration driven by modern software The time for action is now. Companies that prioritise valuedriven partnerships and invest in transformative technologies like CruxOCM will be better positioned to: ) Drive sustainable operational efficiency and profitability. ) Navigate the evolving energy landscape with greater agility and resilience. ) Solidify their market position in a dynamic and competitive environment. ) Contribute to a more sustainable and efficient energy future.

As industry leaders, we must recognise this fundamental shift in how we approach pipeline operations. Those who act decisively will reap significant rewards, leading the way in a dynamic and evolving energy sector. By embracing innovation and collaboration, particularly in the realm of modern software development, we can unlock the full potential of our pipeline infrastructure and build a more resilient and sustainable energy future together.

®

ENGINEERED TO ENDURE

Protect your assets for a lifetime with our everlasting and cost effective solution.

Self Healing Corrosion Prevention & Sealant Technology

Self Healing Corrosion Prevention & Sealant Technology

John Cusimano, Vice President OT Cybersecurity, Armexa, outlines a guide for OT professionals on TSA pipeline security directives and the 2024 proposed rules.

ipeline operations are essential to the global transportation of oil, gas, and other resources, and the security of these operations is increasingly under the microscope. As cybersecurity threats grow more sophisticated, securing Operational Technology (OT) systems, which control the physical infrastructure of pipelines, has become paramount. In light of these evolving challenges,

17

the TSA Pipeline Security Directives and the 2024 Proposed Rules are critical for OT professionals in the pipeline sector.

The TSA Pipeline Security Directives, particularly the 2021-01D and 2021-02E directives, focus on enhancing the cybersecurity posture of pipeline operators through basic security measures and risk management practices.

However, the 2024 proposed rules take this a step further, placing a stronger emphasis on OT systems and recognising their integral role in the safety and reliability of pipeline operations. This article explores what OT professionals need to know about the TSA’s directives and the new proposed rules, as well as how these changes will affect the pipeline industry’s approach to cybersecurity.

Understanding TSA’s pipeline security directives The TSA Pipeline Security Directives, initially issued in 2021 and updated annually, outlined critical measures to secure pipeline operations from cyberattacks, particularly in light of high-profile incidents like the Colonial Pipeline attack.

These directives mandated pipeline operators to implement certain cybersecurity practices, including: ) Risk assessments of critical IT and OT systems. ) The implementation of local and remote access controls, network segmentation, patch management, monitoring and detection, and incident response plans. ) Cybersecurity training for personnel involved in pipeline control and operations.

These measures were essential for addressing vulnerabilities in pipeline control systems, especially those dependent on OT systems.

The 2024 proposed rules: a shift toward OT-centric cybersecurity The 2024 proposed rules from the TSA represent a significant shift in regulatory focus. The updated rules explicitly recognise that OT systems are a primary target for cyberattacks and need enhanced protection. Some key changes include: ) Stronger focus on OT systems: the 2024 rules expand on previous directives by specifically addressing the cybersecurity of OT systems, which are often more vulnerable due to their long lifecycle, legacy systems, and lack of frequent updates. The rules call for comprehensive Cybersecurity Risk Management Programmes (CRMPs) that integrate IT and OT cybersecurity efforts to provide a more holistic security approach. ) Risk-based cybersecurity: the TSA’s 2024 rules emphasise risk-based assessments for OT systems, requiring operators to assess threats and vulnerabilities in their critical control systems and consider the consequences of compromise. This aligns with established standards such as ISA/IEC 62443 and NIST 800-82, which focus on the cybersecurity of industrial control systems (ICS) and industrial networks. ) Continuous monitoring and reporting: the 2024 proposed rules mandate continuous monitoring of OT systems for real-time threat detection. This will help operators quickly

18 World Pipelines / MAY 2025

identify and respond to cyber threats before they can compromise pipeline operations. Additionally, operators are required to report cybersecurity incidents to the TSA and other agencies within a set time frame (e.g. 24 hours). ) Supply chain security: recognising that cyberattacks often come through third-party vendors, the new rules require pipeline operators to implement supply chain security measures to reduce the risk posed by external partners and vendors.

Broader scope of covered pipeline operators in the 2024 proposed rules One of the most significant differences between the 2021 TSA directives and the 2024 proposed rules is the broadened scope of covered pipeline operators.

Under the 2021 directives, the TSA focused primarily on critical pipeline systems, particularly those considered high-risk due to their impact on national security or public safety. This included major operators that control large pipeline systems and networks transporting vital resources across long distances. The 2021 directives had a more limited focus, applying to a relatively smaller group of high-priority operators.

In contrast, the 2024 proposed rules are expected to expand the coverage to include more smaller operators and those operating less critical pipeline systems. This broader inclusion is intended to ensure that cybersecurity standards are applied more uniformly across the industry, regardless of the size or perceived importance of the pipeline system. Smaller operators, who may have fewer resources or cybersecurity expertise, will now be required to follow similar risk management practices, continuous monitoring, and incident reporting procedures.

This expanded scope means that a wider range of pipeline operators – whether large or small – will need to upgrade their cybersecurity practices to meet the new regulatory requirements. For OT professionals working in these smaller or less critical systems, the 2024 rules will bring new compliance responsibilities, including developing and implementing robust cybersecurity measures for their OT environments.

What does this mean for OT professionals?

For OT professionals working in the pipeline industry, the TSA’s 2021 directives and the 2024 proposed rules signify a shift toward a more proactive cybersecurity posture. Here are the key takeaways for OT professionals: ) Increased focus on OT systems: the 2024 proposed rules place OT systems at the heart of pipeline cybersecurity efforts. OT professionals must ensure their control systems are secure from cyber threats through regular risk assessments, patch management, and system updates. ) Broader applicability: with the expanded scope of covered pipeline operators, OT professionals in smaller organisations and those managing less critical systems will now need to implement the same cybersecurity standards as large operators, ensuring more consistent security across the industry.

) Collaboration with IT teams: the 2024 rules emphasise

the integration of IT and OT cybersecurity efforts. OT professionals should work closely with IT teams to ensure that the full pipeline infrastructure is protected against cyber threats. ) Training and awareness: continuous training for OT personnel on recognising and responding to cyber threats is a key component of the proposed rules. OT professionals should ensure their teams are well-versed in cybersecurity best practices and prepared to handle potential security incidents.

Conclusion: a collaborative effort for stronger security As cybersecurity threats to OT systems grow more sophisticated, pipeline operators and OT professionals must take proactive measures to secure their critical infrastructure. The 2024 TSA proposed rules provide a roadmap for achieving stronger cybersecurity defences, with a particular emphasis on OT systems. By integrating cybersecurity best practices, collaborating across teams, and following regulatory guidance, OT professionals can play a crucial role in safeguarding the integrity and reliability of pipeline operations.

For pipeline operators, the road ahead requires a more strategic, risk-based approach to cybersecurity – one that

PRODUCTS

FOAM PIGS

SOLID CAST PIGS STEEL PIGS

TRACKING EQUIPMENT

addresses the vulnerabilities inherent in OT systems and ensures pipeline safety and resilience in the face of evolving threats. With the expanded scope of covered pipeline operators, the entire industry must work together to meet these challenges and build a more secure future for pipeline operations.

About the author John Cusimano, Vice President, OT Cybersecurity at Armexa is an accomplished business and thought leader with more than 30 years of experience in process control, functional safety, operational technology (OT) and industrial control systems (ICS) cybersecurity.

John has performed and led hundreds of OT cybersecurity vulnerability and risk assessments and helped dozens of companies establish OT cybersecurity programs.

He is a voting member of the ISA 99 cybersecurity standards committee. As part of that committee, he chaired the subcommittee that authored the ISA/IEC 62443-3-2:2020 standard ‘IACS Security Risk Assessment & Design.’ He is the developer and primary instructor of multiple training courses on OT cybersecurity.

John is a Certified Functional Safety Expert (CFSE), a Certified Information Systems Security Professional (CISSP), Global Industrial Cyber Security Professional (GICSP), and ISA 62443 Expert.

Pigs Unlimited International, LLC

SERVICES

CUSTOM PIG DESIGN INTERACTIVE WEBSITE PIGGING RESOURCES PIGGING FORMULAS

Making the World a Cleaner Place, One Pipeline at a Time...

15719 Treichel Rd. Tomball, TX 77377

www.pigsunlimited.com

(800) 578-7436 sales@pigsunlimited.com

integrated bypass maintains production during isolation

Dual Leak-Tight Seals Double Block & Bleed Isolation Isolated Pipeline

The BISEP® has an extensive track record and provides pioneering double block and bleed isolation while

Monitored Zero-Energy Zone

dual seals provide tested, proven and fully monitored leak-tight isolation, every time, any pressure.

e are in an era marked by geopolitical tensions, economic volatility, and rapid technological change. It’s therefore no surprise that oil and gas operators are juggling multiple challenges, including, and by far not the least, how to embrace digital transformation amid rising cybersecurity risks.

Driven by geopolitical turmoil, hostile nation states and easier access to increasingly sophisticated AI technology, meaning even amateur hackers can become perpetrators, cybersecurity risks are palpable.

Hany Fouda, SVP, Process Automation, Industrial Automation Business, Schneider Electric, goes over the challenges of cybersecurity in Remote Terminal Units (RTU) in oil and gas, highlighting new and existing solutions.

Combining cybersecurity and open automation

21

Between 2022 and 2024, reported incidents in critical infrastructure rose by 668%, according to data from the European Repository of Cyber Incidents.1 In oil and gas, one of the most high-profile ransomware attacks was Colonial Pipeline, which brought one of the largest and most vital pipelines in the US to a standstill, causing disruptions of Gasoline supplies and panic buying.

National cyber agencies are also raising the alarm. In March, the UK’s cyber chief warned the threat to the nation’s most critical infrastructure is ‘enduring and significant’,2 following a similar warning by the US government.3 No wonder oil and gas operators are nervous about forging ahead with digital transformation. On the one hand they know that in the current complex landscape they need the agility, cost savings and operational efficiency that digitisation delivers. But, on the other, they must walk the tightrope of safety, security and compliance with national cybersecurity regulations alongside this innovation.

Modern technology, new threats Modern Remote Terminal Unit (RTU) technology, for example, offers, among other things, enhanced operational efficiency, considerable time and monetary savings, and smarter and safer monitoring and control of remote operations. Replacing 30 year old legacy technology with modern RTUs means security and regulatory compliance can be managed remotely, mitigating the need to send engineers on expensive round trips to remote locations to manually update passwords. Money is saved and security is more quickly maintained. But it must also be acknowledged that if these devices lack robust security measures, they themselves create new threat vectors for hostile actors.

This raises the question; how to undergo digital transformation faster to harness operational efficiencies and innovation, while maintaining security, tight oversight, and control over processes?

Figure 1. Schneider Electric SCADAPack 470i.

22 World Pipelines / MAY 2025

Solutions and technologies are needed to effectively bridge this gap between these two imperatives. This is what we at Schneider Electric are focused on. We have built our pipeline process automation solutions with cutting edge technologies and open innovation, backed by integrated security and the trust and resilience of technology proven over many years. One need does not require a compromise over the other.

RTUs now and for the future Central to this is building RTU technology that simplifies cybersecurity management and provision without hindering future technological adoption. This can be achieved with inbuilt cybersecurity provisions that include integrated firewall and DNP3 Protocol secure authentication support to deliver a secure, end to end, technology stack. Furthermore, Operational Technology (OT) systems can leverage Information Technology (IT) tools to help secure infrastructure like pipelines.

This way, operators don’t need to purchase and apply thirdparty, external firewalls and layers of security to wrap around the RTU, which can be complex. Instead, the RTU technology is cost effective, easy to roll out, and requires less training and overall management.

But, as well as making technology for today, it’s crucial to future proof these assets that historically are only upgraded in decade-long life cycles. Companies should have access to cutting-edge applications when they are ready for them, rather than waiting for the next upgrade cycle.

This kind of flexibility and security can be found in the newest release of our flagship rugged RTU technology, the SCADAPack 470i and 474i, which offers Edge computing, AI, analytics, flexible data logging and processing for remote operations. It’s cost effective, easy to roll out, and requires minimal training and overall device management by users; our answer to future proofing Schneider RTUs purchased today.

It can be used with directory services, such as Active Directory, and incorporates the ability to restrict access to users with OT network accounts using role-based access control (RBAC). A key extension to this ability is the restriction of user access within the RTU itself. This way, only the functions required by a user to do their job are made available when they are interacting with the SCADAPack 470i and 474i. For example, a technician could be authorised to view the status of the RTU’s flow calculations, but not to modify the logic application being used by the RTU. Using RBAC to manage accounts at an OT network level has major advantages over managing accounts on a device-by-device basis. Changing access credentials creates significant risk.

Updating a password or account device-by-device cannot be sustained at scale.

Using Privileged Access Management (PAM) tools, such as CyberArk, with the SCADAPack 470i and 474i allow OT network administrators to control access on a device-bydevice and service-by-service basis using centrally managed device accounts. In this case, an operator could request access to a specific site and receive temporary credentials to the RTU specific to the site. When the work is complete, the PAM updates the credentials on the specific device restricting access until a future request is submitted.

INNOVATIVE SOLUTIONS FOR YOUR TOUGHEST PROBLEMS Dairyland decouplers are critical to cathodic protection systems — keeping workers and valuable assets safe from AC faults, lightning, and induced AC voltage — all while optimizing your CP systems.

We were the first company to introduce solid-state decoupling products to the industry, replacing the unreliable and dangerous polarization cells that exposed workers to shock hazards and highly caustic chemicals.

In the decades that have followed, our solution-focused team has continued to deliver innovative decoupling products, solving critical problems across numerous applications and industries.

For more than forty years, Dairyland has pioneered new technologies and set new standards in the market. And we’re not done yet. If a solution to your problem does not yet exist, we’ll work to find one.

Let us help you find the right solution to your problem.

WWW.DAIRYLAND.COM

Syslog, supported by the SCADAPack 470i and 474i, is a standard approach used to log events on a computing device, like failed login attempts. This enables an OT network administrator to quickly detect anomalies such as unexpected configuration changes or potential security breaches, allowing for a timely response. Syslog also provides a comprehensive audit trail of activities; essential for forensic analysis, compliance with regulations, and understanding the sequence of events leading up to a security incident.

Innovation at the edge That said, for oil and gas pipeline operators, Edge computing offers faster processing and a much lower latency than the Cloud, bridging the gap between remote pipeline infrastructure and centralised operations. It enables real-time computing in locations where it would not normally be feasible. For process automation of critical infrastructure this provides reliability by enabling continuous operation, processing and analytics of real time data even when network connectivity is limited or unreliable.

Operators can analyse vast datasets from pipelines, oil rigs, and refineries in real time without the delay of sending the information to central servers. This enables faster leak detection, predictive maintenance and overall real-time actionable insights and continuous learning capabilities for more efficient asset management.

Schneider Electric’s updated SCADAPack 47xi, with its support for Python, the language of analytics, can be considered the bridge to future innovation, ready to be incorporated into our existing RTU technology when operators are ready. For example, some of our customers are upgrading to SCADAPack and purchasing the 470i and 474i, not with the intention to utilise it right away, but as a capability they know they can adopt in the near future.

An open innovation device Nowadays it is not enough to only offer traditional function securely alongside cutting-edge capabilities. Innovation and technology are fast moving fields, and one OEM does not have the monopoly on all future capabilities. Likewise, no one understands a customer’s needs better than themselves.

Therefore, as part of their digital transformation, oil and gas pipeline operators must be free to innovate and adopt other technology outside of one single OEM, including Schneider, if they want.

For example, if a company wants to have a docker container specific sub software from another technology provider, even an innovative startup, they should be able to do this completely independently without the propriety OEM’s approval or intervention. Or adopt an algorithm to automate valves to isolate pipeline leaks they should be able to.

An open approach to technology adoption and integration can foster innovation and enhance the customer experience, removing all barriers to improving operations in response to the volatile times.

This is why the SCADAPack 47xi is designed as open automation technology; where operators can incorporate commercial off the shelf applications, even if not made specifically for RTUs or oil and gas. And with core functionality separated from the innovation part, security is never compromised.

24 World Pipelines / MAY 2025

Company wide capabilities That’s not to say that Schneider Electric and its sister companies don’t have innovative applications on offer. We are working with companies that are using SCADAPack along with our sister company AVEVA’s Pipeline Integrity Monitor rupture detection algorithms that can be run at the Edge. This technology drastically improves the location, speed, sensitivity and accuracy of leak detection within a pipeline system with the use of the negative pressure wave (NPW) leak detection method, enabling faster response to abnormal situations, ultimately avoiding loss of containment, better protecting people and the environment, and ultimately increasing the safety of pipeline operators.

In addition, Schneider Electric’s Ecostruxure Automation Expert (EAE) integrated with Geo SCADA, is an open, softwaredefined platform, that can be integrated at the edge. It ensures interoperability and portability, enabling industries to swiftly adapt to market changes and integrate digital technologies, including AI, for real time data analysis and faster decision making and responses based on real system dynamics and optimisation.

The integration and cohesion of Schneider Electric’s systems offers efficiencies which our customers, including a major USA and UK gas network supplier, have highlighted as game changing.

For example, all functionality for SCADAPack and Geo SCADA is mastered in the latter, meaning if the RTU is damaged in anyway, such as by lightning strike, reconfiguration is seamless as everything is mastered and templated in Geo SCADA will can be downloaded to the new SCADAPack RTU. What’s more, parameters can be changed from the control room, instead of sending out engineers, saving significant “wind shield” time and money through central management and control. Another benefit is that being able to store information continuously for regulatory purposes provides a major advantage over other systems where data storage is limited.

Better operations today and tomorrow Digital transformation in oil and gas is inevitable and will no doubt be a competitive differentiator in an increasingly dynamic world.

But organisations must be allowed to go at their own pace and not be dictated to by inflexible technology that doesn’t enable incremental and flexible upgrades, while ensuring cybersecurity compliance and high standards.

Schneider Electric is committed to supporting customers in advancing digitalisation as and when they are ready by providing the complete package for their journey; edge compute, analytics, ruggedised RTU and AI, plus the ability to integrate cutting edge technology from other vendors. This, along with robust cybersecurity infrastructure and hard breaks to ensure operations are always protected and risk mitigated.

Cybersecurity isn’t a threat that will ever disappear, but it mustn’t hinder digital innovation that can enable operators to be adaptable and agile in an ever-changing world – the gap between the two must be bridged.

References 1.

2.

3.

https://www.forescout.com/resources/2024-global-threat-roundup-report/ https://www.ncsc.gov.uk/pdfs/news/ncsc-warns-enduring-significant-threat-touks-critical-infrastructure.pdf https://homeland.house.gov/2024/11/12/new-house-homeland-releases-cyberthreat-snapshot-highlighting-rising-threats-to-us-networks-critical-infrastructure/

Neil Wilds, Global Product Director – CUI, and Dr. Jeffrey David Rogozinski, Global Product Director – Fusion-Bonded Epoxy/Pipe, Sherwin-Williams Protective & Marine, USA, explain how considering different coatings can help you make the most of pipeline infrastructure repairs. any energy pipeline infrastructure assets face harsh operating conditions related to temperature extremes. For example, buried and aboveground pipelines pumping heated contents face extreme cold in northern climates and sometimes drastic temperature differentials where pipes transition from buried to exposed. Compressor stations also experience dramatic temperature fluctuations at compression points, leading to condensation forming on affected assets.

These temperature differentials create conditions that can encourage corrosion.

In fact, they’re partly responsible for the repairs that are eventually required on many pipeline and compression station assets.

Condensation and other moisture on the exteriors of affected equipment can deteriorate protective coatings as it works its way down to the metal substrate, where pitting corrosion can develop. This moisture can also drip onto surrounding equipment and promote corrosion there. In addition, moisture can become trapped under the traditional insulation systems that are applied to assets for thermal protection. There, it can create the potentially dangerous condition of corrosion under insulation (CUI). In addition, thermal stresses and the associated material fatigue can deteriorate protective coatings.

While corrosion is certainly expected on coated assets over time, it does not have to happen rapidly. When it does, pipeline operators should take the time to investigate alternatives so they can avoid having to perform premature maintenance in the future. For pipelines, that could mean choosing different materials or adding layers of protection. On compressor station assets, it may mean removing insulation in favour of coatings that offer a similar level of thermal retention to retain process heat and mitigate condensation potential, while also eliminating CUI. Each decision offers the opportunity to extend asset service lives and thereby decrease long-term operational and environmental costs in the process.

25

Enhancing pipeline corrosion resistance

Figure 1. A dual-layer FBE coating system features a base anti-corrosion FBE layer to prevent pipeline corrosion with an abrasion- and moisture-resistant overcoat (ARO/MRO) applied on top that protects the base layer from wear.

Figure 2. A dual-layer ARO/MRO FBE coating system like Pipeclad® HOT 150 Flex MRO Abrasion-Resistant Overcoat can be used to improve moisture, gouge and impact resistance on buried and exposed pipelines.

Figure 3. Using a thermal insulative coating on various assets such as process piping allows pipeline operators to remove physical insulation systems, while maintaining process heat, minimizing condensation and eliminating CUI in the process.

Pipeline repair needs typically become evident via line monitoring and various inspection methods. Technicians will likely observe cathodic protection (CP) systems for early warning signs of corrosion in buried pipelines. In addition, they’ll perform periodic testing using ultrasonic devices, magnetic particle inspections and/or internal inspections with remote-operated devices. Direct visual inspection of buried pipes is not possible, but technicians can observe the exterior condition of non-insulated exposed pipes.

When such inspections reveal corrosion or the potential for it to develop, pipeline operators have a unique opportunity to improve future performance. The field history of how the coatings performed in service can serve as a baseline for decision making. If that baseline falls short of performance expectations for an asset and its operating environment, operators may want to explore other coating options.

Evidence of abrasions that cut through the fusionbonded epoxy (FBE) coatings typically applied to pipe exteriors is a helpful example for considering alternative coatings. Such FBEs are designed to mitigate corrosion. But when the continuous coating layer is breached, exposing the metal substrate below, corrosion can run rampant – especially considering how the elevated operating temperatures of pipelines contribute to increased corrosion potential.

In this case, the pipeline operator could add additional layers of protection to provide a stratification of properties from the outermost layer to the metal substrate below (Figure 1). For example, in especially rocky soil conditions, the pipeline owner could add a durable abrasion-resistant overcoat (ARO) on top of the FBE layer that’s applied directly to the pipe surface. The resulting dual-layer FBE coating system features the base anti-corrosion FBE layer to prevent pipeline corrosion and the top abrasion-resistant layer that protects the base layer from wear (Figure 2).

Perhaps the environment the pipeline is buried in is wetter than originally anticipated and is causing premature corrosion: in this case, a moisture-resistant overcoat (MRO) could be a suitable alternative to the original single-layer FBE system used. Such MROs reduce the rate of moisture ingress into the coatings, minimising the potential for moisture to work its way down to the pipe substrate and increase the potential for coating delamination due to fundamental adhesion loss and/or cathodic disbondment.

Sometimes operators can realise both abrasion and moisture resistance in the same coating system. As an example, Pipeclad® HOT 150 Flex MRO Abrasion-Resistant Overcoat provides excellent protection against moisture, as well as corrosive and abrasive elements in the environment.

It’s also rated for use on assets running at high operating temperatures.

Eliminating CUI by default Figure 4. Condensation and ice can form on the exterior of assets experiencing significant temperature differentials between their interior contents and the ambient air.

26 World Pipelines / MAY 2025

Corrosion can also be a difficult issue on numerous assets associated with compressor stations. Atmospheric corrosion is one animal to corral, but CUI is a completely different one

systems. With no physical system mounted on top of a to manage due to it being hidden below insulation systems valve, for example, there is nothing under which corrosion – with potentially no visible signs of its existence. could form. The corrosion zone that would otherwise exist CUI is common, and nearly inevitable, on pipeline between the insulation and the substrate is gone, and CUI infrastructure assets that are covered by traditional potential is simply eliminated by default. The only thing left insulation systems consisting of thick mineral-based to worry about is atmospheric corrosion, which is much insulation wrapped around assets with metal cladding slower to form and easier to identify compared to corrosion installed on top. The systems protect personnel from burns, hidden underneath insulation systems. while also helping materials inside pipes, valves, vessels and other equipment maintain elevated temperatures.

They’re also used to minimise the temperature differential Retaining process heat with TICs between the inside and outside of heated assets to The potential to even consider using a TIC instead of mitigate the development of condensation, which could a traditional insulation system can be attributed to the become a source of exacerbated corrosion potential.

While highly effective at these tasks, traditional physical insulation systems are particularly prone to troublesome CUI because moisture and contaminants very often infiltrate cladded insulation systems.

Once there, the moisture will never dry out, leaving it and electrolytes in constant contact with the insulated Ideal for measuring the remaining wall asset’s metal substrate. With the thickness and the effects of corrosion or elevated heat from the covered asset present in this moist, warm erosion on tanks, pipes, or any structure environment, corrosion potential is n 6 Models available including Corrosion, Xtreme, very high. However, asset owners can help to minimise the potential Multiple-Echo, Low Frequency, and Precision for CUI by using an effective CUIn All models include Min Scan mode, memory, mitigation primer, such as Heat-Flex® statistics, and USB ACE or other similar coatings with n Advanced models include: A-Scan, B-Scan, superior proven performance.

Bluetooth, and WiFi When CUI – or the conditions n Weatherproof, dustproof, and waterfor it – is present, pipeline operators resistant—IP65-rated enclosure have a somewhat surprising option to eliminate it. They can instead UTG C3 opt for using a thermal insulative Scan here Advanced model in coating (TIC) system featuring an A-Scan mode to learn effective CUI-mitigation primer more underneath the TIC. Such a system can deliver comparable levels of thermal performance as traditional insulation systems, with just the coating acting as a thermal barrier.

With this high level of insulating capacity possible in coatings, pipeline operators can, in many cases, remove physical insulation systems in favour of applying a few layers of the coating material. In doing so, they can maintain the necessary thermal PosiTector UTG M features Thru-Paint capability to performance while also eliminating quickly and accurately measure the metal thickness of a CUI (Figure 3). painted structure without removing the coating.

The potential for CUI to disappear when using TICs is realised Award Winning Probe Interchangeability because the coatings take the PosiTector gauge body accepts ALL ultrasonic wall thickness, coating thickness, place of physical exterior insulation surface profile, environmental, soluble salt, gloss, and hardness probes manufactured since 2012.

Ultrasonic Thickness Gauges

+1-315-393-4450 n 1-800-448-3835

techsale@defelsko.com n www.defelsko.com

coating’s ability to retain a great deal of process heat within an asset. When using a TIC like Heat-Flex® Advanced Energy Barrier (AEB) from Sherwin-Williams Protective & Marine, a coating layer applied at just a half- to threequarters-inch thick can help assets maintain operating

temperatures up to 350°F (177°C), with excursions to 400°F (204°C). The coating can retain process heat at levels comparable to traditional in-service mineral-based insulation systems, while eliminating the threat of CUI and reducing the need for additional resources.

A high insulation particle content within its dried coating film provides Heat-Flex AEB with this level of insulating capability. The insulation particles couple with entrapped air present in the coating’s film, acting as an effective insulator that slows the transfer of heat energy through the coating. More heat then stays within the coated asset, meaning owners don’t need to expend as much energy to heat the contents.

Owners can also reduce their heating expenditures due to the consistent thermal performance TICs offer compared to traditional insulation systems over time. As moisture finds its way beneath the cladding in a traditional system, mineral wool insulation loses some effectiveness – up to 85% of its R-value when 10% water by volume is present in the mineral wool. As the insulation’s thermal performance diminishes, pipeline operators will need to increase heating for the affected asset.

TICs don’t face the same moisture-related issues. Their closed-cell coating film structure minimises the amount of moisture the coating can absorb. In addition, that moisture can dissipate from the coating through heating and evaporation within 24 hours. Therefore, TICs are able to maintain thermal consistency and will remain at that same level of insulating capacity throughout their service lives. That means pipeline operators can maintain assets at their required operating temperatures without needing to increase process heat over time.

Given the surprising thermal performance TICs offer, pipeline operators may be able to replace most of their traditional insulation systems with TICs during repair and maintenance cycles. That includes insulation on compressors, process piping, coolant lines and an array of other assets (Figure 5). In addition, operators can consider using TICs on sections of aboveground pipelines, depending on the thermal performance needs and ambient temperatures. Such pipeline sections are present in remote areas or regions with extreme permafrost where burying pipe underground is less feasible.

Mitigating condensation with TICs

Figure 5. While not part of pipeline infrastructure, this heater treater is a representative example of how TICs can replace traditional insulation systems. The unit was first primed with Heat-Flex® ACE for corrosion protection (top) and then covered with the TIC Heat-Flex® Advanced Energy Barrier (middle) to lock in process heat with no physical insulation system needed.

Finally, applicators topcoated the unit (bottom) for aesthetic and durability purposes.

28 World Pipelines / MAY 2025

TICs like Heat-Flex AEB can help to minimise the development of condensation on the exterior of assets that face extreme temperature differentials between their internal contents and the ambient air. Such temperature gaps are particularly common at compression transition points, as a gases’ temperature increases drastically when compressed and decreases rapidly as it decompresses.

Moisture forming on the surface of assets due to condensation can become a source for corrosion on the affected assets themselves, as well as any surrounding equipment. It can also lead to the formation of thick ice that completely covers valves and other components, leaving them unable to be operated (Figure 4). The

insulating capabilities of a TIC help to minimise the difference between the surface temperature of an asset and the ambient air, keeping condensation and freezing to a minimum. For example, a TIC added to the exterior of aboveground pipes can help to minimise the formation of condensation on pipes where they emerge from or enter the ground. These soil-to-air interfaces are notorious for creating condensation in cold weather due to the pipe contents being much warmer than the ambient air.

Using a TIC for condensation mitigation also removes a notable contributor to CUI. When condensation occurs underneath insulation systems, it adds even more moisture to the mineral wool, diminishing the effectiveness of the insulation system and raising the potential for CUI because more moisture will be in contact with the substrate.

Using a TIC instead literally removes the CUI potential while also reducing condensation.

alternative options when performance is poor is critical for extending service life and reducing maintenance costs.

Extreme temperature differentials can accelerate corrosion, but by using an ideal coating system for the application, operators can mitigate this risk. Advanced TICs offer a solution for insulated applications by retaining process heat and minimising condensation while eliminating the potential for CUI. By replacing traditional insulation with TICs, operators can achieve significant cost savings, environmental benefits and enhanced asset longevity, ultimately leading to more efficient and sustainable pipeline operations.

Realising cost and environmental savings Notable cost and environmental savings are possible when replacing traditional insulation systems with TICs. The biggest savings come from eliminating the thick mineral-based insulation, wiring, pins, banding and exterior metal cladding. All these materials add to the cost and environmental footprint of insulating hot assets. Switching to a coating as the insulator eliminates those physical materials and the hard and environmental costs of manufacturing, shipping and storing them. Additional savings are evident by eliminating CUI and therefore minimising the amount of steel that will corrode and need to be replaced on assets over time.

Pipeline operators can also save money by eliminating complex CUI inspection protocols when switching to TICs. Technicians will no longer need to remove portions of cladding and insulation to visibly inspect the metal substrate below. Operators can then extend their inspection and maintenance intervals.

Reducing CUI risk and improving asset lives Addressing corrosion on pipeline infrastructure assets and considering

Visit our website:

Follow us on

:

30

Hua Fang, PhD, Managing Director, Black & Veatch, explores how natural gas midstream operators are helping power AI’s energy revolution. he rise of artificial intelligence (AI) and high-performance computing is fuelling an unprecedented surge in energy demand, notably among hyperscale data centres.

These facilities require vast, uninterrupted power supply to sustain AI workloads, which are significantly more energy-intensive than traditional computing tasks.

With some data centres already consuming upwards of 200 MW – and projections pointing to gigawatt-scale demands soon – the strain on the energy sector is growing.

Natural gas, delivered through 2.7 million miles of underground pipeline systems – including local utility distribution pipelines and interstate transmission pipelines that stretch across the country, is emerging as a crucial solution, offering a reliable, scalable and cost-effective fuel source to power generators.

31

To explore natural gas’s role in supporting AI infrastructure, it’s essential to first examine the surging energy needs of AI-driven data centres, which are consuming record levels of power, making energy reliability a pressing concern.

AI data centres: the energy demand challenge The rapid adoption of AI across industries – from cloud computing and autonomous systems to scientific research and generative AI applications – has led to unprecedented energy requirements. AI-driven infrastructure demands continuous processing, high-density server clusters and large-scale cooling systems. Some AI training models require prodigious amounts of energy, further underscoring increasing need for robust, uninterrupted power supplies.

Moreover, hyperscale AI data centres operate under stringent reliability thresholds, often targeting ‘five nines’ (99.999%) availability, meaning downtime must be minimised to mere minutes per year. These reliability standards make energy sourcing a critical challenge.

Historically, data centres have procured power through utilities that integrate a mix of energy sources, including renewables, nuclear and fossil fuels. However, as AI data centre construction scales, utilities are struggling to keep up.

Many developers now face multi-year delays, learning they must wait three to four years before utilities can allocate power capacity due to grid constraints.

This backlog has prompted AI data centres to explore alternative energy solutions and procurement mechanisms, with natural gas emerging as a primary candidate due to its stability, reliability and scalability.

Natural gas in the data centre energy mix Natural gas remains a cornerstone of US energy infrastructure, accounting for a substantial portion of the nation’s power generation. Its dispatchable nature – meaning it can ramp up or down as needed – makes it a crucial resource to maintain grid reliability and supply mission-critical applications such as AI data centres.

While power grids increasingly integrate renewable energy sources such as solar and wind, these sources present inherent challenges due to their intermittency. The current generation of battery storage solutions remains challenged to provide power for durations longer than four to six hours, making it an insufficient solution to complement solar and wind resources independently powering the data centre facilities.

Natural gas, by contrast, provides several distinct advantages: ) Reliability: unlike renewables, natural gas power generation is available 24/7 and can scale to meet demand in real time. ) Scalability: gas-powered generation facilities can expand to accommodate increasing loads, either through increasing generating capacity on existing assets or by constructing additional generation assets. ) Lower emissions: many data centres rely on diesel generators for backup power, but natural gas offers a

32 World Pipelines / MAY 2025

comparatively cleaner and more sustainable alternative with significantly lower emissions. ) Geographic flexibility: the USA has a vast natural gas pipeline infrastructure, allowing data centres to locate near abundant energy sources rather than being constrained by utility grid limitations.

Additionally, natural gas infrastructure benefits from decades of technological advancements in pipeline integrity, leak detection and efficiency. AI-driven predictive maintenance is helping midstream operators improve pipeline monitoring, ensuring secure and stable gas delivery in response to fluctuating demand.

New procurement strategies With utilities struggling to keep pace with data centre growth, many operators are adopting new procurement models. Rather than solely relying on grid connections, hyperscale data centres increasingly are securing dedicated energy sources.

Many AI data centre operators are signing agreements with natural gas power plants to ensure dedicated energy supplies over extended periods. Others are exploring so-called behind-the-meter generation, where natural gas turbines or fuel cells produce power directly on-site. What’s more, collaborations between data centre developers and midstream operators are creating tailored energy solutions such as microgrids and direct pipeline connections.

The shift toward direct procurement highlights concerns about grid reliability, regulatory hurdles, and the need for energy security in AI-driven operations. From a technology perspective, companies are increasingly exploring behind-themeter combined-cycle gas turbines, which offer enhanced efficiency and lower emissions compared to the reciprocating internal combustion engines (RICE) that traditionally serve data centres as bridging and backup power.

The role of midstream natural gas operators Midstream operators are crucial players in this evolving energy landscape. Their ability to transport, store and manage natural gas supplies directly impacts how effectively AI data centres can access and deploy gas-powered energy solutions.

With increasing demand, midstream operators are expanding pipeline networks to accommodate data centre clusters. Expedited permitting for new pipeline projects, along with the integration of AI-based optimisation in pipeline routing, is helping streamline gas distribution for dataintensive industries.

Additionally, midstream operators are leveraging underground gas storage to ensure a steady supply, mitigating the risks of seasonal demand fluctuations.

At the same time, recent advancements in natural gas compression and liquefaction technologies are improving energy efficiency. By utilising AI-driven optimisation techniques, operators can forecast gas demand, enhance pipeline throughput and detect leaks faster, making the entire supply chain more resilient.

From DESIGN to TEST to MANUFACTURE to PROJECT

Propipe Limited - www.piggingsmarter.com For Global Sales Tel: +44 1429 872927 Email: groupsales@propipe.co.uk

For North American Sales Tel: +1 902 417 5075 Email: sales@propipenorthamerica.com

Innovations such as high-efficiency turbines, hybrid gasrenewable microgrids and fuel cell-based distributed power generation are gaining traction, offering flexible and scalable solutions for AI-driven workloads.

Regulatory considerations Natural gas is a heavily regulated industry, and the intersection of AI infrastructure development and midstream energy expansion will require close coordination between energy providers, regulators and data centre operators.

But as AI computing scales, operators will need to navigate a myriad of environmental and policy changes, given the imposition of stricter emissions requirements on natural gas power generation. This has led to increased investment in carbon capture, utilisation and storage solutions for gas-fired power plants.

Additionally, regulatory agencies are implementing policies that encourage midstream operators to minimise methane leaks and improve operational transparency. Regulatory frameworks that support cleaner gas-fired generation while ensuring reliable energy supply will be critical to the longterm viability of natural gas in AI power solutions.

Federal and state governments also are exploring incentive programs for lower-emission natural gas technologies. As data centres continue to demand large-scale power, balancing energy security with environmental commitments will be a priority.

Industry collaboration for long-term energy solutions Strategic partnerships between AI infrastructure developers, midstream operators and renewable energy interests are essential for creating hybrid energy ecosystems. For example, natural gas integrated with solar and wind generation can create baseload power solutions that balance sustainability with reliability.

Collaborations between energy companies and AI technology developers also are driving innovation in energy efficiency. Machine learning algorithms now predict and optimise gas consumption, cutting waste and maximising the performance of gas-powered plants.

By adopting joint regulatory frameworks and collaborative permitting processes, stakeholders can ensure that AI-driven energy expansion is both efficient and compliant with environmental standards.

The future of AI and natural gas infrastructure While the intersection of AI and energy infrastructure is still evolving, several trends indicate that natural gas will continue to play a critical role in powering AI workloads.

One trend to watch is the expansion of on-site power generation. Many hyperscale data centres are moving toward localised power generation, leveraging natural gas-powered microgrids or fuel cell technology. These solutions provide long-term energy resilience by reducing dependence on centralised grids while maintaining cost efficiency.

On-site power solutions also are emerging as solutions for colocation and edge computing centres. Natural gas generators,

34 World Pipelines / MAY 2025

paired with battery storage, can ensure that AI workloads remain uninterrupted in remote or underserved locations.

Another is the rise of hybrid energy models. Rather than relying solely on one energy source, data centres increasingly are adopting hybrid energy models. Some facilities are pairing natural gas with renewables and battery storage, allowing for lower emissions while maintaining high reliability levels.

Natural gas serves as a bridge fuel, providing stability while the renewable energy sector scales up storage capabilities.

Flexible gas plants, designed to integrate with solar and wind, are expected to be a key component of AI-driven energy strategies.

Finally, keep close watch on the growing role of AI in optimising energy efficiency. AI is revolutionising energy efficiency within the natural gas sector with advanced machine learning algorithms helping optimise pipeline operations, enhance leak detection and improve energy consumption forecasting.

By using predictive analytics, natural gas suppliers can reduce inefficiencies and ensure power delivery exactly when and where it is needed. These advancements will help position natural gas as a more sustainable option in the AI-driven energy landscape.

The backbone of the digital revolution As AI-driven computing accelerates, the energy sector must evolve to support its immense power demands. Natural gas midstream operators are uniquely positioned to provide scalable, reliable and cost-effective energy solutions that address the challenges faced by hyperscale data centres.

Their existing infrastructure, coupled with advancements in efficiency and emissions reduction, positions natural gas as a vital component of AI’s energy future.

The growing need for uninterrupted, high-density power requires strategic investments in infrastructure, regulatory collaboration and technological innovation. By integrating natural gas with hybrid energy models, deploying AI-driven efficiency optimisations and advancing cleaner gas technologies, midstream operators can ensure a sustainable and resilient energy supply for AI workloads. These efforts will not only enhance energy reliability but also contribute to a balanced approach between sustainability and industrial growth.

While renewables and battery storage will continue to evolve, natural gas remains the most viable and immediate solution for meeting AI’s reliability and scalability requirements.

And that means midstream operators will play a defining role in shaping the next era of AI-powered energy solutions.

About the author Hua Fang, PhD, is a Managing Director of Black & Veatch, where she leads the sustainable fuels practice and Black & Veatch’s Energy Market Perspective (EMP), a proprietary 25 year forecast of the electric and fuel markets in North America. Fang is an economist who for more than 20 years has provided economic, commercial and regulatory advisory expertise in natural gas, electricity, carbon, hydrogen/ammonia, renewable diesel and other sustainable fuels markets.

Razal Kabeer, Project Engineer, STATS Group, Abu Dhabi, UAE, discusses how precision pipeline intervention has enabled seamless gas segregation in a project in Oman.

S

TATS Group was contracted to perform hot tapping and line stopping operations for OQ Gas Networks (OQGN) on its 48 in. gas pipeline in Sur, Sultanate of Oman. This complex project involved deploying dual STATS BISEP® line stop tools to achieve a leak-tight double block and bleed isolation of a 150 m pipeline section, ensuring the safe and efficient integration of a new extension of Sur gas supply station. Gas flow was maintained

continuously through an integrated bypass operating at 75 bar, the operation eliminated the need to shutdown and purge the entire 65 km pipeline, significantly reducing greenhouse gas emissions by preventing largescale venting and flaring.

Figure 1. BISEPs deployed, isolating the 48 in. pipeline allowing section to be removed and gas supply maintained through integrated bypass (80 bar).

35

The integration of the extended gas supply station into the existing 48 in. pipeline was successfully completed without disrupting service to OQGN customers. By isolating the pipeline section and employing advanced hot tap and BISEP isolation technologies, the project team enabled safe, controlled modifications on a live system – ensuring

Figure 2. Dual BISEP deployment with integrated bypass.

Figure 3. 48 in. SureTap Hot Tapping Operation.

36 World Pipelines / MAY 2025

uninterrupted gas supply and maintaining consistent pressure throughout the operation.

To support the project, STATS provided two 48 in. BISEPs each with a slab valve, split tee fitting and completion plug, rated to class 600. In addition, STATS supplied SureTap® hot tap machines and personnel for 48 in. and 2 in. tapping operations.

STATS BISEP technology provides operators with pioneering hot tap installed line stopping capabilities to enable the safe and effective repair and modification of pressurised pipeline infrastructure. The patented BISEP provides a fail-safe double block and bleed isolation deployed through a single full bore hot tap intervention and is the only DNV Type Approved line stop tool. This verifies that the design criteria satisfy the requirements for Pipeline Isolation Plugs to provide dual seal and isolation in accordance with; DNV-OS-F101 (Submarine Pipeline Systems) and recommended Practices; DNV-RP-F113 (Subsea Pipeline Repair) and in compliance with code ASME BPVC Section VIII, Division 2.

Prior to mobilisation to the worksite, all STATS supplied equipment undertook a client witnessed Factory Acceptance Test (FAT) at STATS operational facility in Abu Dhabi. All equipment was tested at maximum isolation pressure to meet operational requirements and ensure full compliance with safety and operational standards.

The work scope began with the excavation of a 150 m straight pipe section on the 48 in. pipeline, parallel to the new extension of Sur gas supply station. Once the excavation was completed, two split tee fittings were welded onto the 48 in. pipeline, one at each tie-in location and hydrotested to verify the integrity of the welded joints. Following successful testing of the fittings, STATS 48 in. slab valves and SureTap hot tap machine were installed. Hot tapping was performed at each location and the pipe coupon recovered, allowing the hot tap machine to be removed providing full bore access for the BISEP isolation tool. With access points created the 48 in.

BISEPs were installed to the slab valves and a 50 m temporary bypass line was constructed and attached to the BISEP deployment launcher, ensuring continued gas flow once the BISEPs were deployed into the flowing pipeline.

The BISEPs were hydraulically deployed into the pipeline and activated, each plugging head features dual elastomer seals that are compressed to radially expand against the inside of the pipe wall. Hydraulic activation allows for high integrity sealing, even in pipelines with internal corrosion, pitting or ovality issues.

The BISEP offers significant safety advantages over lip seal technologies, with the hydraulically activated dual seals providing leak-tight isolation of pressurised pipelines.

Once deployed each BISEP is subject to a test regime to independently test both the primary and secondary seals with full pipeline pressure (80 bar). Each seal is tested in the correct direction and the pressure between the seals is vented, creating a zero-energy zone. The zero-energy zone between the seals is monitored throughout the workscope, confirming the isolation integrity with zero leakage, a crucial factor in the energy industry where any compromise in integrity can have severe consequences. In addition, the line pressure acting against the BISEP pressure head offers a fail-safe feature by

providing actuation independent of the hydraulic system. Once the test regime was complete, an Isolation Certificate was issued to notify all parties of the safe isolation of the 50-meter pipe section.

To enable the isolated section to be vented and purged, STATS supplied a mechanical strap clamp with a 2 in. branched off-take. Once installed to the 48 in. pipeline, a hot tap machine and valve were installed and the pipeline drilled to provide a vent point. The isolated pipeline section was then safely flared, and nitrogen-purged to eliminate any residual gas. Once gas-free conditions were confirmed, a cold cutting machine was used to remove short sections of pipe spools, and the redundant pipeline section was safely removed. A tie-in pipeline bend spool was precisely positioned and welded into place to provide connection to the Sur gas supply station.

Upon completing the tie-in at both locations and commissioning the extension of Sur gas supply station by introducing gas, the isolation certificate was withdrawn.

The BISEPs were then gradually unset and retracted into the deployment launcher, and the slab valves were closed, allowing recovery of the BISEPs and temporary bypass. The hot tap machine was then reinstalled onto the slab valves and used to install 48 in. completion plugs into the flanges of the welded split tee fittings, ensuring secure and permanent blinding of the system.

The successful completion of this project highlights the exceptional execution, strong collaboration, and seamless

Figure 4. SureTap machine with 48 in. Completion Plug.

communication between all stakeholders. By leveraging advanced BISEP isolation technology, STATS ensured a safe and efficient operation without any safety incidents or disruptions to gas supply. The ability to maintain uninterrupted production while preventing large-scale venting significantly reduced greenhouse gas emissions, reinforcing the project’s environmental benefits. This achievement not only underscores the expertise and reliability of STATS technology but also sets a benchmark for safe, sustainable, and innovative pipeline intervention solutions in the industry.

GIRARD INDUSTRIES 6531 N. Eldridge Pkwy Houston, TX 77041-3507, USA sales@girardind.com

Toll Free: 800.231.2861 Phone: 713.466.3100 Fax: 713.466.8050 www.GirardIndustries.com

Unmatched Performance and Proven Results

Olivier Mette, Global Advisory Director, Xodus, examines the prospects of Europe’s carbon capture, utilisation and storage industry, the progress that has been made and the challenges ahead. fter the best part of three decades worth of promise, carbon capture, utilisation and storage (CCUS) in Europe is taking off. More progress has been made since the turn of the decade than in the 10 years preceding, with numerous industrial clusters across the continent having taken shape and mapped out their plans.

We have never been closer to having a functioning CCUS project in Europe.

In the UK, bp, Equinor and TotalEnergies reached final investment close on the Northern Endurance Partnership (NEP) and Net Zero Teesside Power (NZT Power) projects, key cogs in the East Coast Cluster, at the end of last year. It’s a monumental achievement and the first time that a large-scale CCUS project in the UK has progressed to this stage.

Work on the CO2 receiving and storage facilities of Norway’s Northern Lights project concluded last year, meaning it is now primed and ready to receive and permanently store emissions from European industries, with first injection expected this year.

38

39

In the Netherlands, construction work on the Porthos project is ongoing following FID in 2023, with the system expected to be operational in 2026.

And the INEOS-led Greensand Future CCUS initiative confirmed FID in December, paving the way for the storage of CO2 from Danish and European emitters in a depleted oilfield in the Danish North Sea.

Unleashing the Southern North Sea’s CCUS potential

Developing a Europe-wide CO2 storage market could hold the key for the efficient, accessible and cost-effective storage of carbon from industrial emitters.

Recognising this potential, the European Commission has established a technical framework allowing European Union (EU) and European Economic Area (EEA) countries to store captured CO2 within the EEA. In doing so it has provided a route for countries with limited storage capacity to lock away their emissions through CCUS in other countries, allowing those with surplus storage to offer it as a service.

But despite the technical feasibility of transporting CO2 across the EU/EEA and the UK border for permanent storage, policy obstacles currently render it impractical.

One significant challenge is that CO2 captured within the EU/EEA, but stored outside of its jurisdiction, for example in the UK, is not acknowledged under the EU Emissions Trading System (ETS) as being permanently stored.

This means emitters would still be required to forego their emissions allowances, effectively paying twice for the same stored carbon.

As a result, EU/EEA countries are unable to leverage the UK’s substantial CO2 storage capacity in the Southern North Sea, where storage costs are lower than in many other locations.

For many years, the Southern North Sea has been the engine room of the UK’s gas industry and as such it offers extensive, high-quality storage sites capable of accommodating CO2 captured in mainland Europe.

Additionally, the shorter transport distances to UK storage locations compared to other alternatives would further enhance cost-effectiveness and efficiency, with these sites emerging as among the most strategically located and costefficient in Europe.

Unlocking the Southern North Sea sites would allow EU emitters to achieve significant cost reductions compared to current alternatives; simultaneously UK-based emitters would benefit from lower storage costs, thanks to the efficiencies gained from building more resilient carbon networks in the near term.

European CO2 could also be key to making large-scale investment in new CCUS clusters financially viable. By enabling both UK and EU emitters to connect with CCUS infrastructure, industries across the region would have greater opportunities to decarbonise. This, in turn, would encourage investment in CO2 transport and storage projects, particularly in less industrialised parts of the UK, where European CO2 volumes could be instrumental in ensuring projects develop at competitive costs.

Beyond direct cost savings for emitters, countries offering CO2 storage services would see broader economic benefits. In addition to generating revenue from selling storage capacity, expanding the CCUS industry would create new jobs, both directly in project development and indirectly throughout the supply chain, supporting economic growth in emerging industrial hubs.

Forecasting CCUS in the North Sea

Empowering industry with data driven insights

In late 2023, Xodus released ‘Forecasting the North Sea CCUS infrastructure to 2050’, a detailed analysis of 560 potential storage sites, existing North Sea gas pipelines and potential new infrastructure.

The aim was to rank the cost efficiency of different CCUS initiatives with the hope that it will support operators and stakeholders to make better informed investment decisions.

One of the white paper’s key findings was that the volume of CO2 being injected into the North Sea by 2050 is on course to be equivalent to the natural gas currently being extracted from the basin.

If that is to happen, it will require some 100 reservoirs, more than 7500 km of new pipelines and dozens of onshore emissions capturing and gathering sites.

Subsequent research – carried out by Xodus for the Carbon Capture and Storage Association (CCSA) and released at the end of last year by the CCSA in the report ‘Accelerating a Europe-wide CO2 storage market’ – built on this, underscoring the potential advantages for EU Member States and the UK with access to the North Sea storage. But that is only if cross-border CO2 transport and permanent storage are enabled and supported by policymakers.

But while forecasts are useful, the ability to virtually visualise how a cross border CCUS industry will function gives a whole new level of insight for emitters, regulators and storers.

Building on the 2023 research, Xodus worked with the CCSA to create an online interactive dashboard based on economic modelling of the transport and storage of CO2 in Europe (EU-EEA-UK).

For too long, CCUS decision-making has been hindered by a lack of accessible, consolidated data on the economics of CO2 transport and storage. This new dashboard changes that, bridging the gap between modelling and infrastructure.

It allows users to measure the costs of transporting carbon to any region in Europe, shining a light on the economics of the numerous different CCUS clusters that are currently being progressed.

At the same time, storage operators can drill down into where the demand for their services is located.

Policymakers stand to benefit as well, using the dashboard’s insights to craft regulatory frameworks that drive market efficiency and ensure equitable access to storage infrastructure.

Collectively, this free-to-use tool, developed by an integrated team over the course of 18 months, gives us a first

A borderless European CO2 storage market

40 World Pipelines / MAY 2025

look at how Europe’s CCUS market will evolve, where the key clusters will be located and what the most sensible economic options are.

Far from being a static tool, the dashboard is designed to evolve alongside the industry. As CCUS infrastructure develops and costs fluctuate, Xodus are committed to updating the platform and continuing engagement with the CCSA to ensure it remains a relevant, accurate and indispensable resource for the sector.

Seizing the opportunity for a Europe-wide CO2 market The development of a Europe-wide CO2 market is no longer a distant ambition – it is within reach. However, realising this vision requires a concerted effort from policymakers, industry leaders and financial planners.

Economic modelling plays a crucial role in this process, offering valuable insights into feasibility, risk management and financial planning for CCUS projects.

Xodus’ research has clearly shown the substantial benefited that building a well-integrated CO2 storage market can bring. By dismantling policy barriers and enabling crossborder CO2 storage, Europe stands to reduce storage costs by 20% and save billions annually. This not only strengthens economic competitiveness but also accelerates progress toward critical climate targets.

To achieve this, the European Commission and the UK Government must take decisive steps to provide clarity

and confidence to businesses. First, establishing a bilateral agreement under the Trade and Cooperation Agreement (TCA) would enable mutual recognition of each jurisdiction’s CCUS permitting regimes. This alignment would streamline operations and remove regulatory barriers that currently hinder cross-border collaboration.

Additionally, amendments to both the EU and UK Emission Trading Schemes are necessary to allow CO2 storage outside the EU and EEA. This policy shift would create a more flexible and efficient market, ensuring that captured carbon can be stored in the most suitable and cost-effective locations across Europe.

With CCUS projects advancing rapidly across the continent - some set to begin operations this year - there is an urgent need to facilitate cross-border CO2 transport and storage. Doing so will strengthen the resilience of the entire system and maximise the economic and environmental benefits of these projects.

Effective climate action in Europe depends on the future of CCUS, which by extension depends on scaling up deployment across the continent. Swift action is essential.

Without these policy changes, the risk is that higher-cost options will become entrenched and a critical opportunity to build a robust, interconnected CO2 storage network will be lost. But by working together, nations can pave the way for a more efficient, cost-effective and impactful CO2 market, ensuring a sustainable and low-carbon future for generations to come.

Pipeline Industry Website

The home for the latest pipeline news, analysis, comment and events Visit our website today

www.worldpipelines.com

Laura Chemler, Industry Manager for Low Carbon Energy and Sustainability, Emerson, explains how advanced measurement technology helps to ensure accurate billing, operational efficiency and regulatory compliance in CO2 transportation and storage. he oil and gas industry has extensive experience of transporting captured carbon dioxide (CO2), with the first commercial application being as far back as 1972. It has primarily been used to enhance oil recovery, with CO2 injected into underground oil reservoirs to increase oil extraction. Now though, new pipeline networks and transportation routes are being introduced to support dedicated carbon capture and storage (CCS) projects. These pipelines are specifically designed to transport CO2 from industrial facilities to underground storage locations. This makes them critical infrastructure for scaling up CCS efforts and helping industries to meet their net-zero and decarbonisation targets and qualify for government incentives.

These new pipelines can be used to support the emergence of regional CCS hubs, operating with a ‘carbon capture as a service’ business model. When up and running, these hubs will enable multiple major CO2 emitters within a region – such as refineries, gas processing plants, chemical and petrochemical plants, power stations and steel works, for example – to reduce their costs and increase the economic viability of CCS by sharing a pipeline network and infrastructure.

Whether emitters are using their own CO2 pipeline or sharing infrastructure, CCS still involves significant costs, and the transportation and storage of CO2 presents various challenges. These include the need for fiscal monitoring, ensuring that the composition and purity of the CO2 are appropriate, and maintaining pipeline integrity to prevent loss of containment. A broad range of measurement technologies are available to help organisations meet these challenges, optimise CCS efficiency, reduce operational costs and ensure regulatory compliance.

Fiscal monitoring and carbon credits There are several reasons why it is essential to precisely measure CO2 as it is transferred from emitter to pipeline operator and finally to the underground storage facility, and among the most crucial are fiscal monitoring and the allocation of carbon credits. One of the key drivers for carbon capture is that CO2 emitters are increasingly subjected to regional or national government carbon emissions taxes. Organisations that capture CO2 will be remunerated in the form of carbon credits, which are earned by removing CO2 or preventing it from reaching the atmosphere.

Precise measurements are vital to substantiate the amount of CO2 sequestered, which then creates transparency in financial transactions and billing, and enables organisations to receive the appropriate credits. Inaccurate measurements could result in either forfeiting eligible credits or, conversely, claiming credits unjustly, which could lead to legal and financial repercussions. Even minor inaccuracies in measurement can lead to financial discrepancies, potential disputes between parties, and challenges in meeting regulatory requirements.

42

Figure 1. Rosemount Wireless Corrosion and Erosion Transmitters help ensure equipment integrity, preventing failures, leaks or ruptures that could compromise safety and environmental protection.

43

Flow and density measurements Effective fiscal monitoring for custody transfer requires accurate, reliable and traceable measurement of CO2 flow and density.

However, such measurements present several challenges due to the unique properties of CO2 and the complex conditions under which it is transported and stored. For example, CO2 is transported in a supercritical state, where its density resembles that of a liquid but has the viscosity of a gas. This is achieved by holding CO2 above its critical temperature and pressure. Even in the supercritical state, CO2 density will continue to vary based on temperature and pressure.

The instability of the density can pose a challenge in terms of measurement accuracy. Also, CO2 is typically transported through pipelines at high pressures (>100 bar) and moderate temperatures to maintain its supercritical state, and variations in these conditions can affect flow dynamics and measurement accuracy. A further challenge is that captured CO2 often contains impurities (e.g. water, H2S, NOx, SOx) that can alter its density, viscosity and phase behaviour. These impurities can cause corrosion or leaks and affect sensor performance.

A suitable way to overcome these challenges and help ensure accurate and reliable measurements is to implement Coriolis mass flow and density meters. The design of Coriolis meters makes them less susceptible to contamination and deposits caused by CO2 impurities, while a lack of moving parts reduces mechanical wear, improves long-term reliability and increases operational lifespan.

Unlike other flow meters that require conversions from volumetric flow, which can introduce errors, Coriolis meters measure mass flow directly, ensuring accurate CO2 quantification. Also, they simultaneously provide real-time density measurement, which is essential for tracking CO2 phase changes and helping to detect impurities that might affect pipeline integrity and sequestration efficiency.

Ensuring reliable measurements, Coriolis meters remain stable under the high pressures and fluctuating temperatures typically encountered in CCS pipelines, which can affect volumetric meters.

Unlike turbine flow meters or ultrasonic meters, they do not require fully developed flow profiles, which makes them more reliable in dynamic pipeline environments. Supporting proactive maintenance strategies, the Micro Motion™ series of Coriolis meters from Emerson include Smart Meter Verification functionality. This enables operators to check a meter’s calibration in real time without removing it, thereby reducing both downtime and operational costs.

Furthermore, the traceable, verifiable accuracy provided by Coriolis meters helps in ensuring regulatory compliance.

Gas analysis Before CO2 is allowed to enter a pipeline network, its composition must meet specific criteria regarding impurity levels, because the various impurities that may be present in the CO2 stream can increase the risk of corrosion and leaks. It is therefore vital to perform precise analysis of the gas, to establish its composition and purity. Verifying the purity of CO2 composition is also crucial for accurate carbon credit allocation, because it directly impacts the effectiveness and integrity of emissions reduction claims.

To help ensure CO2 quality, advanced automation solutions include conventional continuous gas analysers, which provide realtime, highly accurate assessments of CO2 composition, detecting multiple contaminants even at trace levels. Additionally, gas analysers

44 World Pipelines / MAY 2025

using chromatography or quantum cascade laser technology provide fast, high-resolution spectroscopy for near-live data and trend analysis. This real-time insight enables emitters to effectively monitor and manage gas compositions and respond swiftly if impurity levels exceed permissible thresholds, thereby ensuring the safety, efficiency and compliance.

Pressure and temperature measurements Precise pressure and temperature measurements are essential in CCS projects for several reasons. As previously stated, CO2 is typically transported and stored in a supercritical state, where it exhibits properties of both liquids and gases. Achieving and maintaining this state requires specific pressure and temperature conditions. Accurate measurements ensure that these conditions are consistently met, preventing phase transitions that could compromise system integrity. Fluctuations in pressure and temperature can also lead to material stress, corrosion, or even failure in pipelines and storage facilities. Continuous monitoring helps to detect and mitigate such risks, ensuring pipeline and storage integrity, and therefore safe and reliable operations. In addition, the processes of compressing, transporting and injecting CO2 are energy-intensive. Monitoring pressure and temperature allows for fine-tuning of operations, enhancing energy efficiency and reducing operational costs.

Achieving accurate pressure and temperature measurements can, however, be challenging. CCS environments often involve extreme temperatures, high pressures and corrosive substances, which can degrade sensor performance over time. Prolonged exposure to these challenging conditions can cause sensors to drift, leading to inaccurate readings if they are not regularly calibrated.

Also, the remote or inaccessible locations of pipelines and storage sites can make sensor installation and maintenance difficult, increasing the risk of measurement errors.

It is therefore important for organisations to select pressure and temperature sensors that have been designed to withstand extreme conditions, thus ensuring long-term stability and accuracy.

Modern advanced transmitters come equipped with diagnostics that monitor instrument health, enabling proactive maintenance.

To tackle accessibility challenges, wireless measurement devices simplify installation in hard-to-reach areas and eliminate the need for extensive wiring, thereby reducing both costs and maintenance requirements. Integrated automation systems that continuously monitor pressure and temperature, and provide real-time data and diagnostics facilitate the prompt detection of anomalies, allowing operators to take corrective actions before issues escalate.

Corrosion and erosion monitoring It is vital to ensure that captured CO2 does not reach the atmosphere. Any loss of containment caused by pipeline corrosion and erosion is a significant cause for concern and undermines the purpose of the project. Monitoring for pipeline corrosion and erosion is therefore essential.

When CO2 dissolves in water, it forms carbonic acid, which is corrosive to carbon steel. Impurities such as SOx and NOx can form strong acids upon dissolution, further accelerating corrosion.

Also, solid particles such as sand or debris entrained in the CO2 stream can impinge on pipeline walls, causing wear or erosion.

This process gradually thins the pipeline material, increasing the

risk of failure. Accurate and reliable monitoring of pipelines can be challenging, however. Because pipelines may traverse remote or subsea locations, performing regular manual inspections can prove difficult and hazardous. In addition, the high pressures and varying temperatures under which CCS pipelines operate can affect the performance and longevity of monitoring equipment. Successfully addressing these challenges requires highly sensitive and precise monitoring technologies.

Non-intrusive monitoring systems – such as Rosemount™ Wireless Corrosion and Erosion Monitoring Systems from Emerson, for example – utilise ultrasonic sensors to continuously measure pipe wall thickness without penetrating the pipeline. These sensors are designed to withstand extreme environments and provide real-time data on metal loss due to corrosion or erosion. The integration of WirelessHART® technology enables the transmission of data from sensors to monitoring systems without the need for extensive cabling, reducing installation costs and improving safety by minimising the need for manual inspections. Continuous, highresolution data from the sensors enables operators to detect trends and identify any issues early. This proactive approach enables timely maintenance interventions, enhancing the safety and reliability of CO2 transportation and storage.

Leak monitoring CO2 leaks most commonly occur near pipeline joints and fittings, such as probes penetrating the pipe walls. Leaks can not only enable CO2 to escape into the atmosphere but can also allow water to enter the pipeline, which can lead to corrosion. Having the ability to detect pipeline leaks in real time enables operators to address issues faster. To achieve this, organisations can implement online gas leak monitoring systems that provide actionable information.

Ultrasonic gas leak detectors ‘listen’ for noise generated by gas leaks that occur in the ultrasonic frequency range and then trigger an early warning system. Devices such as the Rosemount Incus Ultrasonic Leak Detectors are ideally suited for monitoring outdoor applications with multiple pieces of equipment like custody transfer points, and are unaffected by inclement weather, wind, leak direction or gas dilution.

It is not cost-effective to implement point detection sensors along the entire pipeline length. An effective pipeline monitoring solution utilising flow metering solutions at suitable points in the pipeline can enable real-time identification of losses that indicate a leak and help pinpoint the location to enable fast remedial actions.

Figure 2. The Rosemount 470XA Gas Chromatograph is designed to simplify gas analysis in fiscal and custody transfer applications.

Turnkey solutions To reduce complexity, automation technology suppliers can provide comprehensive turnkey measurement solutions, specially tailored for addressing the unique challenges of accurately measuring and managing CO2 throughout each project phase.

For example, pre-engineered CO2 integrity stations provide measurement assurance for custody transfer applications in compliance with the European Measuring Instruments Directive (MID) and other international standards. These stations, which are installed at key points in the process integrate various automation solutions to provide measurement and integrity verification. These include Coriolis mass flow and density meters for highly accurate and reliable measurements; analytical systems, incorporating advanced gas analysers, to monitor CO2 purity; a flow computer

Figure 3. Emerson’s turnkey Gas Metering Systems offer accurate, reliable and repeatable flow measurement.

to calculate flow rates and transmit data from the measurement system to a central control point; and sensors to monitor pipeline integrity. Other technologies that can be integrated include leak detection sensors, a remote terminal unit with edge analytics, and emergency shutdown valves.

MAY 2025 / World Pipelines

45

Dr Neil Bird, Chief Scientist, Fluenta, UK, discusses how to transform pipeline emissions monitoring.

M

ethane is pivotal to today’s environmental challenges. Whilst there’s limited scope for direct intervention with CO2, the management of methane is altogether more realistic – and in many instances can become cost-neutral.

Mitigating the loss of methane and, especially the productive use of methane rather than venting, flaring or even leaking is low-hanging fruit for regulators and governments seeking to achieve ambitious targets.

Methane, as a greenhouse gas with a global warming potential over 80 times greater than carbon dioxide over a 20 year period, has become an urgent priority. For the pipeline sector, the focus has shifted from basic compliance to proactive emissions monitoring and reduction, driven by a mix of regulatory changes, technological advancements, and growing public scrutiny.

46

47

Emerging control technologies, such as Fluenta’s FlareSens, and open source projects like MethaneSat and Carbon Mapper, are driving a new narrative. Together, they not only redefine how methane is monitored but also create an expectation for pipeline operators to play a leading role in the energy transition.

Why methane matters Methane accounts for nearly a quarter of the global warming observed today. It is released into the atmosphere through flaring, venting, leaks, and incomplete combustion in flaring operations, including pipelines. The traditional assumption was that flaring would combust around 98% of methane in all circumstances; however, new research and advanced satellite imagery reveal that this ‘combustion efficiency’ is a significant overestimate. Methane ‘slip’ – unburnt methane escaping during flaring – is now recognised as a significant and underreported problem.

The urgency to address methane emissions is particularly acute for the pipeline industry. Pipelines serve as critical infrastructure for natural gas transportation, yet leaks and operational inefficiencies contribute heavily to fugitive methane emissions. In regions like North America, where pipeline networks are vast, regulatory bodies such as the EPA and Canada’s Environment Ministry are policing stricter methane management with increasing efforts. Around the world, various government’s commitments under the Paris Agreement, as well as those operators who are signatories to OGMP 2.0 are under a strict time-line to implement robust emissions reduction measures across all energy sectors.

Revolutionising methane monitoring Fluenta’s newly-released FlareSens technology is leading a new wave of products applying recent advances in technology and the understanding of combustion to the metrology of not just the flare gas itself, but analysis of the processes and transport of gasses generally.

Housed in a 19 in. rack mount unit designed for safe area installation, FlareSens combines accurate volumetric flow data, with dynamic gas composition data to provide continuous emissions monitoring. Calculations for net heating value of both methane and other combustible elements help improve combustion efficiency of the flaring, but also enable precise emissions analysis and reporting for flare gas systems.

FlareSens has the potential throughout the energy industry to go much further and provide accurate analysis of each individual component of the exhaust or flare gas which, when analysed alongside an understanding of what the predicted and expected component gas volumes and masses ‘should be’, can provide an early warning system for fugitive emissions at various process stages.

FlareSens seamlessly integrates with a new generation of measurement instrumentation, enabling more accurate, real-time ‘in situ’ measurements compared to relying solely on calculated emissions values. As satellite data becomes publicly available, the self-regulation facilitated by FlareSens is critical – not just for compliance with tightening regulations, but for eliminating the alarmist ‘Delta’ between measured and

48 World Pipelines / MAY 2025

calculated emissions, and thus maintaining a strong public reputation in an era of intense environmental accountability.

What truly sets FlareSens apart is its potential to transform methane from a costly and environmentally damaging byproduct into a manageable and controllable aspect of pipeline operations. Through the provision of granular, real-time emissions data, FlareSens empowers operators to proactively manage methane emissions, optimise their operations, and contribute meaningfully to global efforts to combat climate change. This innovative technology underscores Fluenta’s role as a leader in emissions measurement and its dedication to advancing sustainability in the energy sector.

The role of satellites in the new era of accountability In case you might think this is alarmist, or an over-reaction to a small problem, MethaneSat, a project spearheaded by the Environmental Defense Fund (EDF), and Carbon Mapper are just two high-profile examples of a whole raft of new satellites measuring methane emissions from space with unprecedented resolution. Of course, there are lots of perfectly natural sources of methane, but the harsh reality of zooming in on a flare stack and seeing it correlate exactly to the presence of high levels of methane is now not just a possibility – it’s extremely real.

MethaneSat has already demonstrated its potential by identifying significant methane leaks and flaring inefficiencies worldwide. In some cases, they are publishing data showing four to five times the amount of measured methane compared with standard calculated values using assumed combustion efficiency.

This transparency is set to reshape the industry, as independent verification of emissions data will place additional pressure on operators to adopt much more rigorous monitoring practices.

For pipeline companies, MethaneSat presents a dual reality – one that combines both significant challenges and exciting opportunities in the evolving landscape of methane emissions management.

On the challenging side, the ability to deliver high-resolution, publicly accessible data on methane emissions creates a new level of transparency. This means that emissions hotspots along pipeline networks, which may have previously gone unnoticed or underreported, will now be visible to regulators, environmental watchdogs, and the public. Such visibility places companies under increased scrutiny, exposing those who fail to adopt proactive measures to monitor and mitigate emissions. This heightened accountability could lead to reputational damage, regulatory penalties, and increased pressure from stakeholders demanding concrete environmental action.

However, for companies willing to embrace innovation and adopt advanced solutions, this also represents a transformative opportunity. The satellite’s precise, independent data can serve as a valuable tool to validate on-the-ground emissions monitoring efforts, reinforcing a company’s commitment to environmental stewardship. By demonstrating measurable progress in reducing methane emissions, operators can not only meet but exceed regulatory requirements, strengthening their position as leaders in sustainability. MethaneSat’s global reach also offers the potential for companies to showcase their

emissions reduction efforts on an international stage, gaining recognition from industry peers, investors, and governments.

This dual role of challenge and opportunity underscores the need for pipeline operators to act decisively. MethaneSat’s data will reshape the expectations placed on companies, making it clear that the era of unverifiable or outdated emissions reporting is over. Those who integrate technologies like FlareSens into their operations will not only mitigate risks but also seize the chance to differentiate themselves in a competitive and environmentally conscious market. In doing so, they can turn transparency into a strategic advantage, using MethaneSat’s insights to build trust and drive positive environmental outcomes.

The integration of these creates a transformative synergy for pipeline operators seeking to address methane emissions with precision and accountability. Combining real-time, ground-based measurements with advanced satellite capabilities, operators gain a comprehensive, multi-dimensional view of their emissions profile, enabling a level of oversight previously unattainable.

This integration empowers operators to monitor methane emissions continuously, detecting leaks or inefficiencies as they occur. With FlareSens, operators can act swiftly to reduce flaring inefficiencies and unintentional methane slip, ensuring that emissions are mitigated in real time and operations are optimised for both environmental and economic outcomes.

As regulatory landscapes evolve globally, operators equipped with these integrated technologies are better prepared to meet or exceed compliance requirements. Governments and industry

Need a reprint?

We can tailor to your requirements, produce 1 - 12 page formats, print colour or mono and more +44 (0)1252 718999 reprints@worldpipelines.com

watchdogs are adopting a more data-driven approach to enforcement, and the availability of accurate, validated emissions data positions operators to stay ahead of the curve. This preparedness not only mitigates the risk of fines or penalties but also demonstrates a proactive commitment to environmental stewardship.

Methane reduction as an industry priority The drive to reduce methane emissions is not just an environmental imperative; it is an economic and reputational necessity for the pipeline sector. With satellites shining a spotlight on emissions from space, the delta between measured and assumed methane emissions is extremely obvious. Technologies like Fluenta’s FlareSens close that gap and provide a wealth of other information to improve both commercial and environmental outcomes. The tools to address this challenge are now readily available. What remains is the will to act.

As World Pipelines readers well know, the pipeline industry has always been at the forefront of innovation.

Embracing these advanced methane measurement technologies can set a new standard for environmental stewardship, operational efficiency, and industry leadership.

Fluenta’s expertise offers a clear pathway for operators to reduce methane emissions, protect the environment, and secure a sustainable future for the pipeline industry. The time to act is now.

he United Kingdom Onshore Pipeline Operators’ Association (UKOPA) is a not for profit organisation that plays a pivotal role in supporting and maintaining the integrity, safety, and sustainability of the UK’s pipeline industry.

As the authoritative voice for the sector, UKOPA facilitates collaboration between pipeline operators, government agencies, and regulatory bodies. The association provides essential guidance, research, and best practice frameworks that ensure the continued safe operation of pipelines, which are crucial to the UK’s energy and industrial infrastructure.

UKOPA is the leading industry association representing the interests of major onshore pipeline operators in the UK. Its members make up more than 96% of pipeline operators in the UK and include key players from various sectors, such as oil, gas, and chemicals.

The association’s primary goal is to ensure the highest standards of pipeline safety and integrity management while promoting operational efficiency and good practice amongst operators.

Established in 1996, UKOPA was created to provide the recognised and authoritative view of UK pipeline operators on strategic issues relating to safety management, operations and integrity management of onshore hydrocarbon pipelines. The association seeks to effectively influence the development and implementation of pipeline-related legislation and standards for the mutual benefit of all stakeholders and promote safety and best practice in the pipeline industry.

The association now also plays a key role in the liaison between pipeline operators and regulatory authorities such as the Health and Safety Executive (HSE) and the Environment Agency (EA). Through its initiatives, UKOPA ensures that the UK’s pipeline infrastructure remains resilient, secure, and compliant with evolving regulations.

Regular member meetings, technical seminars and training sessions provide pipeline operators with a forum for discussion, knowledge sharing and promoting good practice across the industry.

The association also provides a recognised expert industry voice to influence the development of legislation and standards. In doing so, UKOPA helps pipeline operators to develop a comprehensive and consistent view of strategic issues that relate to the safe operation and maintenance of onshore pipelines.

As well as regular meetings, UKOPA members are invited to join voluntary working groups to look in more detail at key aspects of pipeline operations. There are currently six working groups including: ) Emergency planning working group: to provide information and expert opinion on pipeline emergency and resilience planning.

The group also responds to issues on behalf of UKOPA in relation to safety, security of supply and environmental issues, providing advice, information and assistance to Local Authority Emergency Planners ) Fault data and risk assessment working group: provides information and expert opinion with regards to pipeline fault data issues and pipeline risk assessment on behalf of UKOPA in relation to safety, security of supply and environmental issues. ) Infringement working group: provides information, expert opinion and leads activities and initiatives to raise pipeline safety awareness to UKOPA members, industry stakeholders and those working in the vicinity of member’ pipelines. ) Process safety working group: provides information and expert opinion, direction and guidance on process safety issues and matters to members and industry stakeholders on behalf of UKOPA.

50

Clive Zanker, Chairman, UKOPA, explores the role of UKOPA in supporting the British pipeline industry, highlighting its contributions to safety, regulatory compliance, industry collaboration, and future-proofing pipeline infrastructure. ) Pipeline integrity working group: provides information and

expert opinion with regards to pipeline integrity and defect assessment issues on behalf of UKOPA in relation to safety, security of supply and environmental issues. ) Corrosion prevention working group: shares knowledge and guidance to reduce the environmental and financial impact of various corrosion mechanisms. Using the UK’s onshore corrosion experience, UKOPA raises awareness and provides guidance to safeguard assets against corrosion and the associated impacts.

UKOPA is currently developing a seventh Communications Working Group, with a focus on improving communications between the organisation and its membership, as well as exploring ways to further embed the knowledge sharing more widely within member organisations.

All working groups are made up from voluntary representatives from across UKOPA’s membership, with Good Practice Guides and key findings shared with the wider membership organisations for the benefit of the industry.

Enhancing safety in the pipeline industry One of UKOPA’s most critical roles is to promote and enhance safety within the pipeline sector. As pipelines transport hazardous substances over long distances (UKOPA members account for more than 27 000 km of pipelines in the UK), any failure can

Figure 1. The PERO course that UKOPA organises for its members.

51

result in significant risks to public health, the environment, and infrastructure. UKOPA works diligently to prevent incidents through various measures, including: ) Developing industry standards: UKOPA collaborates with regulatory bodies and industry stakeholders to establish comprehensive safety standards and best practices for pipeline operation and maintenance. ) Incident reporting and analysis: the association maintains a database of pipeline incidents, which allows operators to analyse trends and implement preventive measures. ) Risk assessment methodologies: UKOPA provides advanced risk assessment frameworks that help operators identify vulnerabilities and mitigate potential hazards before they escalate. ) Emergency preparedness: the association assists in developing robust emergency response plans to ensure a swift and effective reaction to any pipeline-related incidents. ) Pipeline Emergency Response Officer (PERO): the PERO role ensures a consistent and effective responses to pipeline emergencies in the UK. UKOPA partners with industry experts and The Fire Service College for a comprehensive twoday training course, providing essential skills and real-world scenario-based experience for managing pipeline incidents and coordinating with emergency services. Since its inception, over 2000 individuals have been trained, enhancing the UK’s pipeline emergency response capabilities.

Through these initiatives, UKOPA has contributed to making the UK’s pipeline industry one of the safest in the world.

Regulatory compliance and policy advocacy The pipeline industry is rightfully subject to stringent regulatory requirements to ensure safety, environmental protection, and operational efficiency. To help pipeline operators navigate complex regulatory landscapes UKOPA plays an essential role by: ) Interpreting regulations: UKOPA provides guidance on compliance with national and international regulations, including those set by the HSE, EA, and the Department for Business, Energy & Industrial Strategy (BEIS). ) Engaging with regulators: the association maintains active communication with regulatory bodies to ensure that pipeline operators’ perspectives are considered in policy-making. ) Advocating for industry interests: UKOPA represents the pipeline industry’s interests in legislative discussions, advocating for policies that balance safety, economic viability, and environmental sustainability. ) Promoting good practices: by sharing case studies and lessons learned, UKOPA helps operators stay ahead of regulatory changes and implement proactive compliance strategies.

This proactive approach ensures that UK pipeline operators remain compliant with evolving legal requirements while minimising risks and operational disruptions.

Industry collaboration and knowledge sharing Perhaps the most important element of UKOPA’s membership is how the association serves as a hub for industry collaboration,

52 World Pipelines / MAY 2025

bringing together operators, engineers, policymakers, and safety experts to exchange knowledge and develop innovative solutions. The association facilitates: ) Technical committees and working groups: These groups focus on specific challenges, such as asset integrity, corrosion management, and leak detection. ) Annual conferences and workshops: UKOPA organises industry events where experts discuss emerging trends, regulatory updates, and technological advancements. ) Publication of guidance documents: The association publishes technical documents and guidelines to support pipeline operators in adopting best practices. ) By fostering collaboration and knowledge-sharing, UKOPA enhances industry-wide competencies and promotes continuous improvement in pipeline management. All documents prepared by UKOPA’s working groups are available to members, giving member organisations access to good practice guidelines, shared knowledge and expertise from across the industry.

Future-proofing the UK’s pipeline infrastructure As the energy landscape continues to evolve with pipelines being repurposed, UKOPA plays a crucial role in ensuring the resilience and adaptability of the UK’s pipeline infrastructure.

Some recent initiatives include: ) Integration of renewable energy: UKOPA explores the role of pipelines in transporting hydrogen, biofuels, and other sustainable energy sources. ) Technological innovation: The association supports research into advanced monitoring systems and predictive maintenance technologies ) Sustainability and environmental stewardship: UKOPA promotes practices that minimise the carbon footprint of pipeline operations, such as reducing emissions and improving energy efficiency. ) Workforce development: the association advocates for skills development programmes to equip the next generation of pipeline engineers and technicians.

Through these forward-looking initiatives, UKOPA ensures that the UK’s pipeline network remains safe, efficient, and aligned with the country’s long-term energy and environmental goals.

UKOPA is an indispensable entity in the British pipeline industry, providing leadership, expertise, and advocacy to ensure the safety, compliance, and sustainability of pipeline operations.

By fostering collaboration, promoting best practices, and driving innovation, UKOPA helps maintain the reliability of the UK’s pipeline infrastructure while supporting the transition to a low-carbon economy.

The industry is however facing new challenges and opportunities, UKOPA’s role will continue evolve and play a vital role in shaping the future of the UK’s energy and industrial landscape. The success of UKOPA is however dependent on the continued engagement and involvement of its membership who commit time and energy to ensuring the collective safety and security of the UK’s pipeline network.

Joe Kelly, Principal Engineer, Atmos International, discusses how to optimally balance sensitivity, response time, and reliability with real-time leak detection for offshore pipelines. s the offshore oil and gas industry evolves, the complexity and criticality of its infrastructure demand increasingly sophisticated integrity monitoring systems.

Pipeline leak detection systems are at the forefront of this challenge, particularly for long-distance subsea pipelines transporting hydrocarbons under high pressure.

While individual technologies like statistical volume balance (SVB) and negative pressure wave (NPW) have been used for decades, recent advances in data acquisition, system integration, and algorithmic processing have enabled operators to adopt multimethod leak detection configurations that significantly enhance performance and reliability.

53

Understanding the two core technologies

drop relative to the background noise and the sharpness of the pressure changes are clearly visible, enabling accurate determination of the timing of the pressure drops. These factors are crucial for maximising the precision of leak location estimation.

For an offshore pipeline, high performance data acquisition units sampling pressure at 60 Hz with 20 bit resolution can capture the sharp pressure wavefront even in the presence of transient noise. However, attenuation becomes a limiting factor for long pipelines and the NPW system is most effective when complemented by a volume balance method.

Statistical volume balance (SVB)

Case study 1: wet gas pipeline

The SVB method is based on the principle of conservation of mass. It continuously monitors the volumetric flow rates at the inlet and outlet of a pipeline and applies statistical hypothesis testing to determine whether deviations from expected flow balances indicate a leak.

The sequential probability ratio test (SPRT) is used to distinguish between leak and no-leak probability. This approach allows the system to detect subtle deviations while minimising false positives. SVB’s effectiveness depends on high quality flow data, precise inventory correction to account for pressure and temperature-driven changes and adaptive learning mechanisms to account for instrumentation drift and operational changes.

A wet gas pipeline system operating with a high gas-oil ratio was monitored using SVB. Although significantly shorter than the crude oil pipeline, this system illustrates the adaptability of SVB under different operating conditions.

The pipeline was instrumented with Venturi flow meters at each subsea well and at the topside facility. The SVB system utilised mass flow measurements in tons per hour, benefiting from the high repeatability of the instrumentation. Flow rates at the inlet and outlet were closely matched under stable conditions, with deviations within 0.5%, allowing a minimum detectable leak size of less than 1%.

Transients were occurring during normal pipeline operations, often triggered by changes in field conditions or well cycling. Inventory correction proved highly effective in these situations. During events where flow imbalances arose, the system compensated using pressure data, maintaining the corrected flow difference close to zero. This not only helped preserve sensitivity but also filtered out disturbances caused by operational transients.

One particular advantage of this setup was its ability to identify persistent instrument bias. In one example, the raw flow difference exhibited a consistent offset of around 6 t/hr. The SVB adjusted for this, centring the flow difference around zero and maintaining high leak detection sensitivity. This automatic bias correction was critical in extending operational confidence without requiring immediate instrumentation recalibration.

System validation was supported by recurring well clean-up operations. Every six months, one of the wells was isolated and recirculated, effectively removing its contribution from

Discussing pipeline applications on a crude oil pipeline and wet gas pipeline, this article explores how combining SVB and NPW methods has helped achieve exceptional leak detection performance in offshore operations, including detection thresholds below 1% of reference flow, high location accuracy and minimised false alarm rates. By analysing field results from oil and wet gas pipelines, the engineering trade-offs and integration strategies that define an effective multimethod leak detection system will be examined.

Negative pressure wave (NPW) NPW technology detects leaks by capturing the characteristic pressure drop generated at the onset of a release. This pressure wave propagates bidirectionally from the leak location and is sensed by high-frequency pressure sensors placed at pipeline endpoints or along its length. The time delay between wave detection at each sensor allows for calculation of the leak’s location.

Figure 1 shows two charts, each showing the response to a leak as captured by the same pressure sensor at two locations (inlet and outlet). The chart on the left has a lower resolution (12-bit ADC) and lower scan rate, making it more challenging to distinguish the leak’s signature from the background noise or to determine the timing of pressure changes with accuracy. The chart on the right distinctly highlights the pressure drop caused by the leak at both sensors. The magnitude of the pressure

Figure 1. SCADA sampling (left) versus Atmos’ data acquisition unit (right).

54 World Pipelines / MAY 2025

the overall inlet flow. This created conditions equivalent to a controlled leak test (Figure 2).

The SVB system responded by generating a leak alarm with a sensitivity of approximately 2.3% and a detection time of under 20 minutes. These operations provided an ideal mechanism for verifying the system’s ability to detect real-world leak conditions.

The wet gas pipeline’s performance metrics include detection sensitivity down to 0.73% of nominal flow and response time of under 1 minute for a 13% leak. These results demonstrated not only the versatility of the SVB method in wet gas systems but also its reliability when supported by consistent instrumentation and good maintenance.

Case study 2: oil pipeline with integrated SVB and NPW

Figure 2. The wet gas pipeline leak detection system identifying a controlled leak caused by well clean-up.

A dual method leak detection system was implemented on a crude oil pipeline transporting approximately 120 000 m3/d.

The SVB delivered a high-performance leak detection system achieving sensitivities of 0.5% in 12 minutes and 2% in 3 minutes, with a location accuracy of 3 - 5 km in the pipeline.

Only 6 false alarms were generated in 2024 (on average 0.5 false alarm per month).

57 th Annual Convention

The NPW system achieved a response time of 11 minutes and location accuracy of approximately 200 m in the 283 km pipeline.

Only 4 false alarms were generated in 2024 (on average 0.3 false alarm per month).

This performance was supported by high resolution multipath ultrasonic flow meters with standardised calibration, enabling repeatable measurements and leak detection thresholds

Delivering Sustainable Energy Infrastructure

15-19 September 2025

Save the date : Registration opens May 15, 2025 We look forward to seeing you there!

Find out more at: www.iploca.com/events

ADVERTISERS’ DIRECTORY Advertiser

Page

AMPP

IFC

Dairyland Electrical Industries

23

DeFelsko

27

Denso Inc.

07

Girard Industries

37

IPLOCA

55

Pigs Unlimited International Inc.

19

Pipeline Inspection Company

29

Pipeline Technique Ltd t/a CRC Evans

04

Propipe

33

Qapqa

IBC

Rotork

02

Seal For Life Industries

bound insert

Stark Solutions

09

STATS Group

OFC, 20

T.D. Williamson

13

Tinker & Rasor

OBC

World Pipelines

41, 49

below 1%. Advanced inventory correction accounted for pressure transients such as packing and unpacking, maintaining flow difference stability and minimising false positives. Adaptive tuning based on operational data allowed the system to self correct for drift over time too.

Implementing NPW on the long offshore pipeline introduced specific challenges. Wave attenuation over long distances limited sensitivity near pipeline ends, with sensitivity ranging from 1 4% near the midpoint to approximately 7 - 8% near the inlet or outlet. In the absence of intermediate pressure sensors, leak localisation depended entirely on endpoint readings, making high frequency acquisition essential. Leak validation was accomplished using filtering algorithms and 3D mapping.

The value of a multimethod leak detection system The dual method configuration enhances operational decision making. For example, if a flow meter error triggers a leak alarm in the SVB system but the NPW system shows no corroborating evidence and high frequency pressure data reveals no anomalies, operators can confidently classify the event as a false positive and avoid an unnecessary shutdown.

In the context of a two hour shutdown which would have resulted in a loss of 10 000 m3 of crude oil transport, at US$70/bbl this equates to a financial impact of approximately US$4.4 million. The multimethod leak detection system provides leak detection and risk mitigation through cross verification.

High resolution data acquisition also supports accurate leak localisation, pig tracking and stuck pig detection, pressure surge diagnostics, and real time monitoring of pipeline transients.

Engineering considerations for system integration To deploy effective multimethod leak detection system in offshore environments, several factors must be addressed. For example, high frequency and high resolution data acquisition is essential for NPW. Instrumentation quality is also critical as precision sensors improve detection thresholds.

Reliability is improved through use of virtual servers, mirrored systems and backup instruments. Maintenance is supported through structured framework agreements, which include regular reviews and tuning cycles. Successful deployment also relies on skilled personnel and close collaboration with vendors to manage commissioning, tuning and long term support.

Conclusion It is possible to balance sensitivity, response time and reliability with multimethod leak detection. The implementation of multimethod leak detection systems represents a robust and forward thinking approach to pipeline integrity. By integrating SVB and NPW technologies, supported by high fidelity instrumentation and rigorous operational protocols, operators can achieve a rare balance of sensitivity, speed, and reliability. For those looking to optimise leak detection in complex offshore environments, this case study offers a valuable reference grounded in technical rigour and field tested results.

Since 1948, Tinker & Rasor has been a trusted name in holiday detection, relied upon by pipeline professionals worldwide.

For over 76 years, our holiday detectors have set the benchmark for performance and reliability, ensuring the integrity of protective coatings by detecting coating flaws with precision. With a legacy of innovation and toughness, Tinker & Rasor continues to lead the industry, delivering cutting-edge solutions to safeguard pipeline coatings and maintain quality standards across the globe.

Tinker & Rasor Holiday Detectors – Ensuring Coating Quality, One Spark at a Time!

Model APS

3 Year Warranty

US Toll Free

TOUGH &

INTERNATIONAL

YOU BET!

1 833-332-1010 1 830-253-5621

RELIABLE,

SCAN QR CODE TO SEE PROOF

tinker-rasor.com

info@tinker-rasor.com