World Pipelines January 2022

®

Volume 22 Number 1 - January 2022

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CONTENTS WORLD PIPELINES | VOLUME 22 | NUMBER 1 | JANUARY 2022 03. Editor's comment Max Wedekind, Managing Director of DENSO Group Germany, explores how the company’s new tape solution simplifies the process of corrosion protection.

05. Pipeline news

R

Several acquisitions to report this month. See more news at wwwworldpipelines.com

eliable and permanent protection of pipe sections and weld seams are one of the main challenges in pipeline construction.

A wide range of often time-consuming processes that differ for every application have previously been used. However, DENSO Group Germany’s patented SEALID® All-in-1 provides protection against corrosion as well as mechanical loads in a single step – without additional primer and without the use of other devices.

“The framework conditions in the pipeline business have changed significantly: the challenges in the industry are constantly increasing with shorter project times, higher standard requirements and the complex application of products”, says Thomas Kaiser, Managing Director of DENSO Group Germany. “Besides the permanent protection of pipe sections and weld seams, speed, safety and efficiency are all essential requirements in the construction industry.” SEALID All-in-1 keeps pace with the ever-increasing demands in international pipeline construction by fulfilling the ISO and EN standards: a single wrap is enough to fulfil the requirements of ISO 21809-3 at operating temperatures of up to +70˚C (+158˚F). The requirements of EN 12068 and DIN 30672 for class C50 are also met with a single wrap.

One wrap for corrosion and mechanical protection

KEYNOTE ARTICLE - EUROPE REPORT 09. Solutions for a volatile market

Focussed on the goal of making corrosion protection even more reliable and efficient, after several years of development, DENSO presents a global innovation: SEALID All-in-1, which simplifies the protection of pipes and weld seams.

Alexy Mileev, CEO and founder of Route4Gas, Netherlands, discusses the company’s latest offering designed to reduce post-trade risk.

OPERATOR TECHNOLOGY 15. Dynamic digital twins

PAGE

Figure 1. SEALID® All-in-1 with outstanding cohesive separation pattern.

Kapil Mukati and Brian Sidle, Kongsberg Digital.

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FIBRE OPTICS AND SENSING 22. It's all about perspective

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26-32.indd 26-27

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CONSTRUCTION CHALLENGES 33. Managing better

Eitan Elkin, Prisma Photonics, Israel.

Bonney Hodges, Energy Operations Director at ISN, USA. Eitan Elkin, Prisma Photonics, Israel, discusses the shift in how operators view pipeline monitoring, and what they can do to optimise their solutions.

SUBSEA PIPELINE MAINTENANCE 35. The right combination

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ecently Prisma Photonics had the opportunity to exhibit at one of the industry’s largest oil and gas tradeshows. After a long hiatus, returning to an in-person exhibition was exciting. Several conversations we had with visitors to our booth can be summarised with one visitor’s quote: “the industry is changing. You would not have been here three years ago.

Pipeline monitoring wasn’t that big of an issue.”

Further inquiry has revealed an underlying truth.

Advanced pipeline monitoring and leak detection have shifted to a hard necessity dictated by public perception, environmental impacts, and a regulatory demand in an increasing number of countries. This is, of course, on top of the operator’s own commercial and operational needs. In some cases, regulators are starting to demand redundancy in leak detection systems, using two methods based on different physical principals. So, driven by public image, regulators, and operational needs, the attention paid by pipeline operators to monitoring solutions is growing and will continue to grow, as pressure is not going to subside.

This article will look at the shift in the perception of leak detection and pipeline monitoring solutions, the increasing regulatory demand, and new regulations that appear worldwide. Finally, the article will offer a solution that fits these demands.

Darran Pledger, STATS Group, UK.

OFFSHORE DECOMMISSIONING 41. Preparing for the future

Francis Norman, National Energy Resources Australia.

Leaks in the public eye “I think the environmental impact of this disaster is likely to have been very, very modest.” This is a famous quote by thenChief Executive of BP, Tony Hayward, in an interview following up on the Deepwater Horizon oil spill, which

PIPELINE STEELS 47. Developments in the pipeline

David Evans and Graeme Peacock, Tata Steel, UK.

PAGE 22

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CORROSION: COATINGS AND LININGS 26. A universal solution

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SAFETY 53. The current landscape of pipeline safety Murray Peat, Linewatch, UK.

Max Wedekind, Managing Director of DENSO Group Germany.

JANUARY 2022

®

Volume 22 Number 1 - January 2022

STATS subsea products and services include pressurised pipeline isolation,

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ISSN 1472-7390

Reader enquiries [www.worldpipelines.com]

WORLD PIPELINES

ON THIS MONTH'S COVER

www.statsgroup.com Mechanical Pipe Connector Pipeline Repair. Tie-In or Capping

Copyright© Palladian Publications Ltd 2022. 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.

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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, 17B S Middlesex Ave, Monroe NJ 08831.

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s someone who spends far too much time on the TikTok app, I have a rudimentary grasp on how algorithms work. I’m aware that big tech uses algorithms to direct and refine content, in the hope that we always see something we like and therefore continue to return to the platform in question. I did some research and discovered that Spotify, the digital music service, uses algorithms to tailor its site to its 381 million monthly active users (which includes 172 million paying subscribers… read those figures and weep). An algorithm is a finite sequence of wellSENIOR EDITOR Elizabeth Corner elizabeth.corner@palladianpublications.com defined instructions, typically used to solve a class of specific problems or to perform a computation.

Spotify creates custom listening experiences for each user. It uses three key machine learning (ML) algorithms to study behaviour on the app. Collaborative filtering creates a back end profile based on a user’s personal taste. Natural language processing analyses music by scanning a song’s metadata and mentions across the web, to help group artists into clusters and connect to relevant listeners. Audio models analyse raw data audio and recommend non-popular new songs, identifying similarities in signature, key, mode, tempo, loudness, tone, mood etc to create a sound profile, in order to match a new song to an existing playlist.1 Age, gender and location are also factored in, to ensure no user’s home screen is the same as another’s.

I learned that Spotify’s home screen is governed by an AI system called Bandits for Recommendations as Treatments (BaRT). My Spotify home screen offers me ‘shelves’ that include: playlists I have recently listened to, a new track from one of my favourite artists, and playlist recommendations listed under enticing (to me) headings such as ‘It’s Christmaaaas!!!’, ‘Indie/Alternative’ and ‘Pop a jumper on’. The BaRT system used to curate this home screen combines elements of ‘exploit’ and ‘explore’, as outlined by Spotify Research Director Mounia Lalmas-Roelleke.2 ‘Exploit’ analyses everything a user does on Spotify, including which songs the user likes and which songs they skip, in order to learn about their listening tastes. If you spend less than 30 seconds listening to a song then BaRT thinks you don’t like it, and vice versa.

‘Explore’ compares a user’s activity to that of the rest of the Spotify membership, analysing trends so that the site can suggest playlists or new artists that the user will probably like.

But while the algorithm can learn a user’s behaviour, it won’t necessarily know how or why the user has those preferences. In his article ‘We might need to make our own playlists again. Our lives might depend on it’, Dave Holmes writes: “As well as the algorithm knows my behaviour, it doesn’t know me… It cannot set you up for self-discovery. It just gives you more of what it knows you like… and pushes you to be more of who it knows you are. It can’t change you. You won’t evolve.”3 The message here is enjoy the power of data, utilise it where you can, and understand its limits.

In this issue of World Pipelines, Kongsberg Digital writes about the development of digital twin technology, creating a virtual representation of a real asset and its dynamic performance.

Kapil Mukati and Brian Sidle write: “By combining physics-based models, data science approaches and cloud scalability, the Kognitwin digital twin helps operators streamline and test hypothetical scenarios to maximise performance. This allows for improved prediction of impact options and decision-making, leading to overall enhanced productivity, improved safety levels and more sustainable operations.” Turn to p. 15 to read the article.

A continuously learning digital twin model can provide interpretable ML insights and bring about improved decision-making in the pipeline sector. What you decide to play over your truck’s sound system shouldn’t be such an exact science.

1.

2.

3.

https://analyticsindiamag.com/tech-behind-spotifys-spot-on-recommendations/ https://thewebconf.org/www2019/ https://www.esquire.com/news-politics/a38241127/gut-instincts-vs-sci-ence/?source=nl&utm_source=nl_esq&utm_ medium=email&date=120621&utm_campaign=nl25946471&utm_term=AAA%20--%20High%20Minus%20Dormant%20 and%2090%20Day%20Non%20Openers

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WORLD NEWS STATS UK acquired by SRJ Technologies STATS (UK) Limited has announced that its shareholders have executed a Share Purchase Agreement to sell 100% of the issued share capital of the company to SRJ Technologies Group plc.

The acquisition combines Aberdeenshire-based STATS with SRJ’s portfolio of disruptive technologies that are well positioned to capitalise on global energy market growth and the transition to green energy.

SRJ is a publicly listed company on the Australian Securities Exchange and will undertake an offer of shares to raise AU$142 million to fund the cash component of the purchase price for STATS and to provide working capital for the combined group post-completion. The transaction is subject to customary conditions, including SRJ obtaining the required shareholder approvals, and is expected to close in 1Q22.

The consideration payable by SRJ to STATS shareholders will comprise a combination of SRJ shares (traded on the ASX) and cash. The transaction has an implied value of approximately £73.1 million based on a share price of SRJ of

AU$0.50 per share.

STATS, a market leader in the provision of innovative, technology-led pressurised pipeline integrity solutions, including its BISEP® and Tecno Plug® products, will accelerate SRJ’s strategic priorities in the asset integrity market. SRJ will leverage the global presence of STATS to exploit cross-selling opportunities of SRJ’s disruptive products and technologies, whilst also looking to capture the significant growth opportunities in the energy transition sector with its broader range of asset integrity solutions.

Leigh Howarth will join SRJ’s Board of Directors upon completion of the transaction whilst continuing as CEO of STATS. Pete Duguid, Chairman and founder of STATS, will remain with the business providing strategic direction, particularly in relation to key business development activities in North America. The private equity investor, Business Growth Fund, which has supported STATS since 2012, will realise its investment and exit the business.

Seal For Life Industries acquires Mascoat and Verdia Arsenal Capital Partners, a private equity firm that specialises in investments in industrial growth companies, has announced that its global industrial coatings platform, Seal For Life Industries, has acquired Mascoat Ltd. and Verdia, Inc., both privately owned specialty industrial coatings companies.

Mascoat, based in Houston, Texas, USA, has been a leading manufacturer of thermal insulation coatings, anticondensation, and sound damping coatings since 1995. The company serves a wide variety of industries with its coatings such as industrial, marine, commercial, and automotive applications.

George More, President, CEO, and Founder of Mascoat, said, “We are delighted to become part of the Seal For Life platform. The combination of Mascoat‘s industry-leading insulation and protective coatings with Seal For Life’s extensive coatings portfolio and global footprint will allow us to reach additional markets and customers, and will provide customers even more high-performance solutions to protect

their critical infrastructure assets.”

Tony Crowell, President, CEO, and Founder of Verdia, remarked, “Joining the Seal For Life platform provides Verdia with the critical mass and market access it needs to continue its remarkable growth trajectory. Our customers consider polymeric floor coatings as critical technology for protecting their high-value infrastructure assets, and we look forward to expanding applications of our highly sustainable products around the world.”

Jeff Oravitz, CEO of Seal For Life, remarked, “We are very pleased to welcome the Mascoat and Verdia teams to the Seal For Life family, and look forward to working with them to accomplish our vision of being the leading global provider of protective coating and sealing solutions for infrastructure markets. The incorporation of these highly specialised industrial coatings companies into the Seal For Life platform increases our global scale and the ability to meet the needs of our many global customers.”

Howden confirms acquisition of Compressor Products International Howden, a leading global provider of mission critical air and gas handling products, technologies and services, has completed its acquisition of Compressor Products International (CPI), a leading provider of aftermarket components and services to the global reciprocating compressor market.

Headquartered in Houston, Texas, USA, CPI manufactures precision-engineered, custom aftermarket products which are vital to the longevity, efficiency and safety of reciprocating compressors. This marks Howden’s sixth acquisition of 2021 and is well aligned with Howden’s strategy of expanding its global aftermarket presence in the compressor market. By leveraging CPI’s strategically located service centres, Howden will expand its aftermarket services and coverage across North America and Europe. CPI’s valves and aftermarket products are

complementary and strategically important additions to Howden’s existing aftermarket compressor technology portfolio. As a result of this acquisition, Howden’s addressable markets will increase by US$1 billion.

As part of Howden, CPI will be able to access growth opportunities through additional technology support from Howden and by leveraging Howden’s existing global distribution and services network in China, Asia Pacific and South Africa. With CPI’s predominantly aftermarket revenues, this acquisition will be accretive to both Howden’s aftermarket mix and overall margins. This acquisition also reinforces Howden’s role in supporting the ongoing energy transition towards renewable sources of energy. Howden will leverage CPI’s reciprocating compressor technology to support customers through their energy transition.

JANUARY 2022 / World Pipelines

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WORLD NEWS EVENTS DIARY NEW DATES: 31 January - 2 February 2022

European Gas Conference (EGC) 2022 Vienna, Austria www.energycouncil.com/event-events/ european-gas-conference/

31 January - 4 February 2022 PPIM 2022

Houston, USA https://www.ppimhouston.com/

2 - 4 February 2022

Subsea Pipeline Technology Congress (SPT 2022) London, UK https://sptcongress.com/

8 - 10 February 2022

AMI’s Pipeline Coating 2022

ICR Integrity secures long-term hire contract for Aker Solutions in Angola ICR Integrity (ICR), global provider of specialist maintenance, integrity, and inspection solutions, has been awarded a long-term hire contract with Aker Solutions for the provision of Quickflange™ weldless connections for bp’s offshore assets in Angola.

The award recognises ICR’s commitment to growing the business further in West Africa having appointed Petrowork as its local partner, with offices in Luanda, for repair and integrity services including both Quickflange™ and Technowrap™ engineered composite repairs. This allows the company to hold equipment in-country and have local, trained technicians on-hand to respond quickly to client requests.

Phil Paterson, Business Development Manager at ICR, said: “We are delighted to secure this contract which builds on our existing long-term relationship with Aker

Solutions. ICR is committed to supporting our global clients and we continue to invest in key regions to ensure a dedicated offering is always delivered.

“This contract follows on from the ongoing rental agreement and demonstrates the relationship we have with Aker Solutions as well the internationally recognised quality of the products and services we offer.

QuickflangeTM is qualified and approved to several international type standards and is proven in improving pipeline integrity which is imperative to our clients.”

Fred Nordheim, Supply Chain Manager Aker Solutions, added “We are very active in the region and the Quickflange technology has proven to be a safe and effective solution for us on our brownfield modifications and maintenance project. It’s great to continue working with ICR in Angola.”

Vienna, Austria https://www.ami-events.com/event/

21 - 22 February 2022

Transportation Oil and Gas Congress 2022 (TOGC 2022) Zurich, Switzerland https://togc.events/

7 - 10 March 2022

17th Pipeline Technology Conference Berlin, Germany https://www.pipeline-conference.com/

10 - 12 May 2022

Canada Gas & LNG Exhibition & Conference Vancouver, Canada https://canadagaslng.com/

23 - 27 May 2022

World Gas Conference 2022 Daegu, South Korea https://www.wgc2022.org/

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World Pipelines / JANUARY 2022

McDermott awarded offshore contracts by Saudi Aramco McDermott continues its decades-long partnership with Saudi Aramco with three new awards for engineering, procurement, construction and installation (EPCI) projects.

In total, McDermott will provide EPCI of four drilling jackets and seven oil production deck modules (PDMs) in Saudi Arabia’s Zuluf, Ribyan, Abu Sa’fah and Safaniya fields located offshore in the Arabian Gulf.

“These awards are a direct result of our long track record of successfully delivering shallow water infrastructure for Saudi Aramco and our commitments to the growth of Saudi Arabia’s energy sector as well as In-Kingdom execution in line with Vision 2030,” said Tareq Kawash, McDermott’s Senior Vice President, Europe, Middle East and Africa.

In addition to the seven PDMs and four drilling jackets, the scope of work for the three contract release purchase orders (CRPOs) includes EPCI of more than 28 miles (45 km) of pipelines, more than 62 miles (100 km) of subsea cables and tie-in works to existing facilities. Fabrication is expected to begin in the first quarter of 2022, with offshore installation commencing fourth quarter of 2022 and overall completion expected second quarter of 2023.

THE MIDSTREAM UPDATE •

Snam buys 25% stake in the ‘Peace Gas Pipeline’

•

Wood secures UK North Sea contract wins

•

Producers Midstream II to acquire assets from Midcoast Energy

•

Oil demand back to preCOVID-19 levels outside aviation, says GlobalData

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

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This interview sees Alexy Mileev, CEO and founder of Route4Gas, discuss the company’s latest offering designed to reduce post-trade risk.

E

xtreme volatility continues across European energy markets and gas prices are showing a more than 2000% increase since record lows in May 2020.

As a consequence, major market players had to extend their credit lines significantly to manage higher prices. This comes at the cost of higher margin calls and fewer trade opportunities, adding the problem of reduced liquidity to the gas market.

To help solve these problems, the Amsterdam, Netherlands based company Route4Gas has announced it is now ready to offer post trade risk reduction services.

This will offer to the European gas market a solution that significantly reduces market exposure and is unique, multilateral, fully automated, anonymous and crossmarket. In this discussion, Alexy Mileev, CEO at Route4Gas,

explains the problems he sees and how his company can help resolve them.

How would you describe the problem the European natural gas market is currently facing?

If you look at the TTF price curve recently, it actually looks more like the Burj Khalifa than anything else. While there are still many uncertainties on the exact causes of this, and whether they are supply or demand driven or a combination of both, the results are very clear: a huge increase in prices and volatility.

This in turn brings certain risks into the market. There are extreme margin calls, we don’t talk about millions – we talk about billions at the moment. How can the market

9

participants pay that? Trust in OTC Markets has been lost and from April to October 2021, OTC trades reduced for 80%. The new trades are done almost exclusively via clearing. This is a clear indication that trust in the entire gas market has eroded. Credit risk and counterparty risk are perceived as very high at the moment. And it is not just companies that are in trouble, it is the entire market that is in trouble. And as the reduced trust leads to fewer trades, that leads to an even lower liquidity, which in turn leads to more volatility and higher prices – a vicious circle.

So how do we break this circle and prevent a domino effect impacting the market?

It is here that the Route4Gas post-trade risk reduction service can help by restoring bilateral trust. We have adjusted the

algorithm we already use for our optimisation services and can now use it to enable much more efficient use of credit lines.

We can do this for all market participants, and as we really want to play our part in returning the OTC trading to normal, we will be offering this service free of charge.

Can you give a high-level explanation of how this would work?

The idea is very simple. Customers submit their positions with counterparties they want to reduce. This is done anonymously: no one will see this, not even Route4Gas. That means there is no way of ‘pushing’ volumes into the market. It’s not about adding volumes in the market or to your position, it is about finding offsetting positions that reduce overall exposure and risk. After these positions are submitted, the algorithm in our system looks for the possible cycle trades. But this is not simple triangulation, as the system finds cycles including multiple counterparties.

Also, this will only require a few seconds of calculations, after which traders will receive the resulting trades in their ETRM system. There is only risk reduction, there will never be an additional position that a customer will receive as a result of participating in the Route4Gas PTRR system.

What makes this unique? Is anything like this offered already in the market?

What makes it unique is the simplicity, the speed and automation, the anonymity and the fact that we can involve not only three but many more parties simultaneously. No other service offers this at this speed.

Can you explain more about the company behind this service?

Figure 1. Georg Giokas, CCO at Route4Gas announces PTRR solution.

Figure 2. Route4Gas team in Amsterdam.

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World Pipelines / JANUARY 2022

Route4Gas, a Dutch Startup, currently employs 16 people throughout Europe. It offers the European gas market a solution that is designed for gas traders, operational teams and portfolio managers: and now, also risk managers.

The core of the system is a non-discriminatory algorithm that matches physical and financial gas positions across all participating clients in an automated and fully anonymous way. It unlocks existing opposite trading interests and calculates matching possibilities only on this basis. Through that, it significantly increases the opportunities to get matched and supports liquidity in all markets. Furthermore, the Route4Gas tool couples not only all European marketplaces but also qualified storages, unused transport capacities and existing flows.

It started as my idea in 2016. I looked intensively into the gas market and tried to understand everything about physical flows and bookings. After a while, I realised that there was much potential for optimisation in the European gas industry, and that something had to be done about that.

As the third energy package had been adopted in Europe in 2009 and all the rules for European gas and energy were standardised accordingly in each European country, the market was already transparent. We collected all the data online. Having all this information together with historical data, it was possible to create a unique algorithm.

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As a mathematician, I tried to solve that optimisation issue and came up with an algorithm that would revolutionise the industry. What started with only transport and capacity positions now includes trading storage and post-trade risk reduction too, and will soon be expanded to LNG.

What value do you think you can add in addition to post-trade risk reduction?

Route4Gas has collected data about the whole European gas market from 15 different sources starting from 2015.

Those data consider information about gas transmissions, capacity bookings, tariffs, storages, imports, LNG terminals etc. Analysing this information, we see that the total cost of gas transmission in Europe between different countries is approximately €5.5 billion. When we apply our algorithm to these positions, we see that optimisation in excess of 20% is possible. The main target of our company is to unlock this

Figure 3. Alexey Mileev, CEO and Founder at Route4Gas.

optimisation and help our customers save this €1 billion+ in costs per year.

So the anonymity does not only apply to posttrade risk reduction?

It applies to all the services we offer. The anonymity is embedded in our system and has been underlined through a patent. This is a double win situation: you get access to liquidity and outstanding functionality, and you stay anonymous at any time. The system processes encrypted data (positions and creditworthiness) and discloses the resulting trades only to the respective counterparties.

Security is one of the cornerstones of Route4Gas from the very beginning. We apply best industry practices and standards when developing the product.

What are some of the latest developments around Route4gas?

Early in 2020 VierGas Participation GmbH, the 100% owner of the biggest German TSO Open Grid Europe GmbH (OGE), acquired a 25% stake in Route4Gas B.V., becoming an important strategic partner.

The investment from a major player in the European Market underlines the value and reliability of our services.

Route4Gas went live on 1 September 2020, and customers have achieved a matching rate up to 61% per round. 18 European gas companies have already signed Client Agreements with us, showing their trust in this unique solution.

In June 2021, the company changed its regulatory status, becoming an organised market place (OMP). The evolution of Route4Gas into an OMP is simplifying the use of its services by enabling clients to execute deals directly in the Route4Gas application and ensuring automatic trade reporting to EU Agency for the Cooperation of Energy Regulators (ACER).

Could you explain your regular service in some more detail? How does it compare to post-trade risk reduction?

Figure 4. Route4Gas analytical map.

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World Pipelines / JANUARY 2022

In the Route4Gas system the participants can enter all their mainly physical positions in each

market. A mathematical model then finds the optimal way to match them with positions from other customers.

We are matching physical and financial positions in all different gas hubs in Europe. Just to have an idea what can be submitted: it’s not just simple location swaps, but unused capacities, existing flows, storage positions, etc. can all be submitted as well. Even an LNG product has already been developed in our system. We are planning to launch it in the near future. Imagine, that all market participants submit all their positions on the same place at the same time – fully anonymously. The matching and trading potential is huge!

The whole process from data transfer into the system, price check and matching takes a maximum of 20 minutes and provides various possibilities to trade the fixed prices in the system against the broker market and takes off a lot of risk in view of illiquid markets.

Traders are impressed by the speed at which the system is able to analyse hundreds of positions and come up with complex solutions. It would take a trader days to arrange some of these deals that the system can find in a matter of seconds.

But it’s important to mention that R4G is not a broker.

The so-called ‘matching rounds’ are comparable to single round auctions. The market price spreads are fixed for the round and the customers just submit their positions if they agree with the prices. Such rounds will be run up to 4 times a day.

THE BEST OF CORROSION & COATINGS+

Post Trade Risk Reduction is simply an additional service that’s being offered. From now on Route4Gas clients are also able to submit anonymously their positions on EU gas hubs into regular netting sessions at convenient fixed time. Within seconds of calculation our algorithm generates a number of trade deals, offsetting their exposure and symmetrically reducing risks to each counterpart. There will be no risk at all of ending up with new positions. The Route4Gas post-trade risk reduction services will not create new obligations with third parties, offering only the reduction of initially uploaded positions.

What do your long-term ambitions look like?

Route4Gas will continue to develop its system. It will become a 24/7 system maintaining the single round auctions. Users will be able to add or remove positions at any time. The number of products will increase, but only to an extent that is of interest to customers and while maintaining the simplicity it has right now.

From Route4Gas’ point of view, the further growth will support illiquid markets in their development in the sense of market regulation, small and medium-sized companies will be able to participate in new opportunities in equal measures as well as the large ones. Opportunities will arise for storage operators, which will support the flexibility in the trading market and make it equally accessible.

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Kapil Mukati and Brian Sidle, Kongsberg Digital, discuss the development of digital twin technology for remote monitoring, virtual sensing and operation support.

T

he power of digitalisation initiatives is becoming undeniable. It is impossible to watch television, surf LinkedIn, or attend a tradeshow/ conference without banging headfirst into tangible examples. Computing power improvements, cheaper sensors (real or virtual), and machine learning have all become readily available and companies are folding them into applications designed to improve day-to-day efficiencies.

Even industries that are traditionally

15

resistant to change have begrudgingly accepted that there might be better ways to work.

One tool driving this transformation is digital twins, a virtual representation of an asset and its dynamic performance.

These are being incorporated across industries, including pipeline transmission, to increase visibility and planning while decreasing costs and risks. With the ability to incorporate multiphase flow and dynamic simulations, digital twins can provide real-time monitoring capability for what were previously considered unmeasured or unmeasurable information. Twins are subsequently becoming essential tools for operation optimisation, predictive analysis and maintenance, and training.

In this article, we focus on how dynamic, Kognitwin® digital twins can be used for remote monitoring, virtual sensing, and operational support for pipelines using multiple examples.

Permian-produced water pipeline network

Produced water disposal is becoming more and more crucial due to both the quantity and completion type of oil wells in the Permian Basin. Produced water can be blended with brackish and/or fresh water during recycling operations for hydraulic fracturing purposes or disposed of via water injection wells. As oil production ramps up, insufficient disposal and recycling capacity become a bottleneck to operations. A large oil producer in the Permian Basin had planned to build recycling and injection facilities, including laying pipelines in a staged manner to accommodate increasing production over a five year period.

In reviewing the project, considerations were given to look beyond conventional ways of design. For example, steady state tools, which are sufficient for pump capacity, pipeline size, and boosting station requirements for a given maximum expected flow are unable to provide insight in other areas such as pressure surges, operational control, and ensuring desired flow to correct locations. These are crucial design elements for engineers focused on preventing unintentional shut-ins or diversions.

Independent models were developed for various parts of this large pipe network (>200 miles) to provide timely assistance to engineers for critical design needs. These models were then integrated together to create larger models Figure 1. Dynamic model of produced water pipeline network providing easy scalability. A dynamic process simulation with all sources, sinks and pump stations. Colours show various regions of pipe network installed over time, highlighting modular software was used to model pump stations and process and scalable nature of the digital twin. Pressure, temperature, control in high fidelity, and to integrate various pipe flow flowrates, velocities, fluid properties anywhere in this network can models together. Breaking down a large pipe network into be extracted as a virtual sensor. smaller, modular components provides scalability and faster model speeds without sacrificing accuracy.

These dynamic models were used to perform pressure surge or water hammer analysis, which is a common cause of pipeline failure that happens when highvelocity liquid flow is stopped suddenly, either because of valve closure or pump stoppage. In addition, these dynamic models provide a perfect tool to decide the best control strategy for remote pump stations and create operational procedures, which is difficult, if not impossible, for a large area without considering process transients.

The pipelines are designed for maximum expected flow Figure 2. Santos gas gathering system scope; digital platform HMI example; and simulation vs measurement comparison highlighting model accuracy. capacity, but this flow may

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World Pipelines / JANUARY 2022

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not be reached for years. This means that pipelines may be operating in two-phase flow conditions depending upon pipe size, elevation, and flow conditions. All the expected and even unexpected flow scenarios can be handled by the developed multiphase dynamic models.

Incorporating these models, first in design and then operations, into the digital twin can provide numerous benefits. On the design side, benefits can be derived from sharing and collaborating across the same data sets, visualising their layout with elements of elevation or temperature changes (night/day) and the respective impacts.

Moving into construction, virtual commissioning of the assets can be accomplished to ensure everything works seamlessly from day one. And in operations, the same models can utilise real-time monitoring and virtual sensing to build a decision support system for the network. This Operational Centre, powered by these models, provides the end-users with a remote, centralised decision center to optimise production.

Offshore gas gathering pipeline network The Santos Basin gas pipeline network is a complex network of pipelines collecting gas and condensate from four FPSOs, plus an oil platform and an onshore gas processing plant.

This network is expanding to collect gas from an additional thirty FPSO facilities, with the potential for multiple entry points and the addition of two onshore gas plants. The network handles wet gas with varying composition and has pipeline lengths ranging from 10 - 380 km. It is also possible for FPSOs to import gas from this network.

Currently, high-fidelity, compositional, multiphase models have been developed for the Santos gas pipeline network as well as dynamic models for the FPSO export, oil platform, and onshore gas treatment facilities. All the models are integrated to accurately simulate the pressure, flow, and composition interactions throughout the system. The resulting integrated dynamic simulator – called Santos Operational Simulation System (Santos OSS) – is an important tool to assist flow assurance and production engineers in better understanding the behavior of these complex systems, conduct engineering studies, and create operating procedures for safer and more efficient operations.

All the Santos OSS data can be visualised remotely through either a desktop application or web browser using an integrated data management system built using a digital twin platform. These web-based data management systems and their ability to create and incorporate custom dashboards provides a convenient way for all authorised users to access relevant data.

The Santos OSS provides real-time monitoring, what-if studies, and predictive analysis, helping operators and engineers operate the Santos facilities and gas transport network safely and optimally.

Real-time monitoring includes hydrate monitoring, pig tracking, chemical tracking, corrosion monitoring, and slug monitoring, all which are enabled with a dynamic digital twin.

Steam distribution pipe network Figure 3. Steam distribution pipe network dynamic digital twin.

Figure 4. Oil shipping system and pipe network.

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World Pipelines / JANUARY 2022

Steam is widely used for district heating systems across the globe. Typically, centralised, high-capacity boilers provide saturated steam to residential and business customers via large, insulated pipe networks, either above or below ground.

Steam distribution systems; however, suffer from ever-changing supply and demand with significant lag times between boiler ramp-up and steam arrival to the customers.

This results in a highly dynamic, complex system.

Furthermore, condensate-induced water hammer (CIWH) is a serious problem in steam distribution pipe networks, which can cause fatalities and significant property damage (>12 Con Edison steam pipe explosions in New York City since 1987). CIWH happens when steam bubbles

become entrapped in cold condensed water, leading to sudden and violent collapse of bubbles, causing a pipe explosion.

A dynamic digital twin solution was recently developed for one of the world’s largest district heat providers with 100+ miles of steam distribution pipe network. It provides a real-time, simulation-based, decision support system for the owner-operator and accounts for not only the two-phase steam-water flow in pipe networks, but also the transient effects of steam traps, customer service flows, man-hole water levels, steam plant supply variations, and weather conditions. As such, it can also help predict CIWH. This real-time CIWH predictor model is the first of its kind applied on a district steam distribution network anywhere in the world and should be invaluable for the prevention of further accidents. This dynamic steam distribution model is also used to develop what-if scenarios and predictive analysis, incident investigation, estimate varying customer demand and condensate loss, and prepare for inclement weather conditions that can impact steam operations. The model is tightly integrated within the digital platform for wider visibility and use across the broader organisation remotely, providing end-users the tools they need wherever they are.

Oil shipping system (OSS) Down in Southcentral Texas, Kongsberg had the opportunity to develop a new model for an OSS. Typical volumes from the original handling facility were 60 - 80 000 bpd distributed out to four delivery points (customers). The plan was to ultimately ship total volumes from 105 000 bpd (design) to ~120 000 bpd (maximum, as limited by pipeline MAOP) with the nominated volumes shipped to each delivery point variable monthly.

Some of the challenges of the existing system included unwanted interactions between the control loops at the terminals. This was primarily due to pressure transients created by the start/stop of pumps associated with the daily batch shipment of oil to one of the delivery points. Another concern was frequent, over-pressurisation shutdowns resulting from the planned upstaging of the OHF shipping pumps from 8 to 15 stages to handle increasing production rates.

A scalable, dynamic, two-phase simulation was required to design a new control system. The new system needed to provide the best, overall control to meet the requirements of the OSS, considering several different operating scenarios through the various stages of commissioning – current operation, addition of new shipping terminal to the network, and planned increase in shipping rates via pump upstaging. An integrated, dynamic model was created using modeling tools and transient flow software that modeled the terminals and pipe network accurately. Incorporating simulators enabled the operator to try out various control schemes on both the shipping and delivery terminals.

The dynamic simulation model was used to make recommendations for which control strategies would be used at the OHFs and pipeline delivery terminals to achieve

robust, stable operation of the overall OSS across the range of expected shipping nominations at each delivery point.

Both batch and continuous shipments were considered in the developed models for thoroughness.

This new dynamic model provided a means by which the operator could improve their overall system while increasing capacity via: )) PID-controller tuning methods, tuning constants, and controller setpoint ramp rates. )) Optimum control valve actuator stroking speeds for

opening and closing directions. )) Optimum shutdown valve opening and closing speeds to

minimise the impact on the OSS while meeting facility constraints. )) Setpoints for protective devices, such as high-pressure

shutdowns and PSVs, which have a sufficient operating margin to avoid false trips. )) A means to minimise impact of one or all pump trip or

start-up at OHF. )) Ultimate shipping capacities when injecting drag

reducing agents (DRA) at the OHFs and its impact on the OSS equipment and controls.

This new model, which could be accessed remotely via a digital twin interface, also provided engineers with a perfect test-bench to perform what-if studies and operation planning, while simultaneously providing a set-up for operator training.

Conclusion Technology in this space is rapidly changing. New solutions to drive efficiency and safety improvements are becoming available and widely integrated. In the above examples, dynamic digital twins provide a platform by which highfidelity simulators can become accessible remotely for a broader network of end-users.

By combining physics-based models, data science approaches and cloud scalability, the Kognitwin digital twin helps operators streamline and test hypothetical scenarios to maximise performance. This allows for improved prediction of impact options and decision-making, leading to overall enhanced productivity, improved safety levels and more sustainable operations.

And as the digital transformation journey continues, these tools will be crucial for understanding and better managing remote operations.

Bibilography

TSANG, J., MUKATI, K., ‘Steam Simulator Model’, Thermal Distribution Workshop, CampusEnergy2020, Denver, Colorado.

ZAMPIERI, T., ROTAVA, E., KHATIB, H., SERPEJANTE, C., RUSSO, E., TEIXEIRA, A., A. INACIO, A., BASTOS, M., GOMES, A., MUKATI, K., ‘Santos Operational Simulation System: Integrated Dynamic Compositional Simulation of Multiphase Pipeline Network and Treatment Facilities to Assist in Planning, Operation and Production Management’, Rio Pipeline 2015, Rio de Janeiro, Brazil.

JANUARY 2022 / World Pipelines

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Eitan Elkin, Prisma Photonics, Israel, discusses the shift in how operators view pipeline monitoring, and what they can do to optimise their solutions.

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ecently Prisma Photonics had the opportunity to exhibit at one of the industry’s largest oil and gas tradeshows. After a long hiatus, returning to an in-person exhibition was exciting. Several conversations we had with visitors to our booth can be summarised with one visitor’s quote: “the industry is changing. You would not have been here three years ago.

Pipeline monitoring wasn’t that big of an issue.”

Further inquiry has revealed an underlying truth.

Advanced pipeline monitoring and leak detection have shifted to a hard necessity dictated by public perception, environmental impacts, and a regulatory demand in an increasing number of countries. This is, of course, on top of the operator’s own commercial and operational needs. In some cases, regulators are starting to demand redundancy in leak detection systems, using two methods based on different physical principals. So, driven by public image, regulators, and operational needs, the attention paid by pipeline operators to monitoring solutions is growing and will continue to grow, as pressure is not going to subside.

This article will look at the shift in the perception of leak detection and pipeline monitoring solutions, the increasing regulatory demand, and new regulations that appear worldwide. Finally, the article will offer a solution that fits these demands.

Leaks in the public eye “I think the environmental impact of this disaster is likely to have been very, very modest.” This is a famous quote by thenChief Executive of BP, Tony Hayward, in an interview following up on the Deepwater Horizon oil spill, which

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started in April 2018. To this day, it is known as the most significant marine oil spill in the history of the petroleum industry. Later, after a massive backlash by the public, the media, and even President Obama, Mr. Hayward apologised and was quoted saying, “I would like my life back.”

This incident and the response were significant markers of the change engulfing the industry. Environmental impacts make the headlines and open the evening news.

However, it is not limited to the oil and gas industry.

Unfortunately, many other cases of significant environmental impacts are created by man-made blunders involving critical infrastructure. For example, the 2018 forest fire in California, which caused the death of 86 people, was caused by a fault on an old power tower, part of the Pacific Gas & Electric (PG&E) grid. The Californian power company holds a troubling track record of wildfire incidents started because of their infrastructure failure (16 in 2021 and 16 in 2020, and that is just the last two years). However, with the state of the environment that most critical infrastructure is built into, pipelines, subsea pipes, and other energy transportation methods are becoming more fragile with changes to climate, population density, and rising demand for energy. In such a delicate balance, the chances of a simple fault becoming a significant problem are getting higher.

More than ever, leaks, breaks, and ruptures are in the public eye, and the public does not care if the incident was due to pipeline degradation, failures, vandalism, or theft.

The ecological impact makes headlines more than ever as the public sensitivity to the topic of climate change is high.

It can be a 2020 contained leak in Canada’s Trans Mountain pipeline when as much as 190 000 l. of light crude oil spilled in B.C., a 2020 NNPC oil theft incident in Nigeria causing several casualties, or the latest Amplify Energy submarine oil spill in Huntington Beach, Newport.

The stakes are high as demand for more energy is on the rise. However, renewable sources are currently insufficient, and dependencies on existing pipelines and new pipelines, such as the Nord Stream 2, will not disappear. Moreover, with infrastructure crossing more territories over lands and under the seas and lakes, the environmental balance is more fragile than ever.

It’s not that operators have not monitored these assets; they have been doing so for years. Pressure, temperature, flowmeters are all there on most pipelines. But the drivers to monitor their assets are now far stronger. As a result, pipeline operators need to be more diligent, as the spotlight is now on them, their activity, and their impact on the environment.

What can be done? Increase the priority of asset monitoring, invest more in updated technologies to ensure the response is fast, accurate, and on the spot.

Unfortunately, the public impact and the backlash spread faster than products spilled, and it is harder and longer to clean a brand name and perception than it is to clean spilled petroleum.

However, regulators are also looking into this matter, driven by the same forces and public pressure, tightening demands on operators.

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World Pipelines / JANUARY 2022

Regulators think twice As stated above, almost all pipelines have some sort of monitoring mechanism installed in valve stations, on the pipe, or along with it. But these solutions have been there for years and sometimes decades, and still, we see incidents that reach the news, so it means that something is not working well enough.

Take the Amplify Energy submarine oil spill in Huntington Beach in early October 2021. The early warning was oil sightings in the water. Obviously, there was a rupture, but it took hours to shut down the pipeline. Likewise, it took a long time to locate the underwater hole to assess the damage.

In these cases, redundancy is not a luxury. Therefore, in several places worldwide, regulators are starting to consider a demand for multiple monitoring systems based on different technologies. Two independent solutions based on different underlying physical principles offer far better reliability and lower zero false alarms.

False alarms or false positives, as these events are known, are the reasons systems are turned off or alarms are being ignored, failing to respond, sometimes to an actual event.

There is a term for it in the medical profession – alarm fatigue – when too many alarms go off, and you ignore them, which may lead to a risky situation. Lowering the false alarm rate (FAR) is crucial for any monitoring system, increasing its reliability and the trust of its operator.

An example of such a regulation is the new German TRFL 2017 (Technische Regel für Fernleitungen) regulation.1 TRFL are a set of technical rules which state how pipeline systems will be constructed and operated in Germany. It is subject to the Pipeline Ordinance of 2002 and looked after by the Committee for Pipelines.

TRFL 2017 section 11.4.1.1 reads, regarding leak detection systems: “Two continuously working technical processes based on different physical quantities must be used, which can determine the exit in the stationary operating state. One of these methods or another must also be able to detect leaks even during transient operating states. Measurement data from other systems (e.g. supply pipelines, downstream tanks) may also be used for the procedures for the detection of escaping substances if, in particular, the required data security, accuracy and availability are guaranteed for the operation of the pipeline systems.”

In short, it means that they require a hybrid solution, two different monitoring solutions, in parallel, to ensure that any leak is detected. However, it is not specific to Germany.

The German regulation is a front runner to other regulatory bodies like the American Petroleum Institute (API). API recommended practice 1175 (API1175 - Pipeline Leak Detection Program Management) follow the TRFL.2 Similar examples also include the Canadian CSA Z662 Annex, which states, “Leak detection strategies shall include multiple leak detection methods.”3 These emerging regulations tell the same story.

Monitoring solutions are more than an operational need as a stricter demand is coming from above. It reflects the same theme of regulator’s zero patience to incidents that may have a personal and environmental effect.

A hybrid solution exists As stated above, most pipelines have some leak detection system installed on them. Many of those also have an optical fibre installed in the right-of-way, on the pipe, or near it. A monitoring system based on that fibre is a perfect solution for many reasons. First, it is a modern technology that complements and sometime replaces the existing ones, to feature an improved solution. Second, looking at those emerging regulations, it completely adheres to these, with two independent, continuously working solutions based on different physical methods to ensure leak detection and prevention of substance spillage.

At ADIPEC 2021, Prisma Photonics and AVEVA recently presented a hybrid solution.4 AVEVA’s Pipeline Integrity Monitor (Real-time Transient Model - RTTM), which utilises the existing flow, pressure, and temperature measurement on the pipeline, is joined by PrismaFlow, Prisma Photonics’ next-generation fibre sensing solution. With its detection and classification abilities, PrismaFlow can locate leaks and alert on activities near the pipeline in real-time and with high location accuracy. Furthermore, integrating two such systems allows for cross-examination of alerts so the false alarm rates are no longer a nuisance. In terms of capital investment, PrismaFlow utilises any type of optical fibre installed, so there is no need for extra installation or touching the pipeline.

Such a dual solution offers many operational advantages.

It features the reliability that pipeline operators need to adhere to regulations and effectively monitor their assets to prevent the next event.

And if there isn’t an existing monitoring solution?

Well, PrismaFlow can handle this as well as most modern pipelines are built with an optical fibre as a communications infrastructure.

Conclusion The conclusion is simple. Pipeline operators must have an active monitoring solution, which is reliable, can locate and classify events fast but still keep the false alarm rate low enough to make sure that when the actual alert is coming through, no one will ignore it and an impactful event will be prevented, or at least contained fast enough as not to be the next opening headline.

References 1.

2.

3.

4.

Technische Regel für Rohrfernleitungsanlagen (TFRL) Bundesrecht, from 3 May 2017 (BAnz AT 07.06.2017 B6).

API RP 1175 Recommended Practice for Pipeline Leak Detection, STANDARD by American Petroleum Institute, 07/01/2017.

CSA Z662-15 - oil and gas pipeline systems (2015). (Seventh ed.). Canada: CSA Group.

SPE-207790-MS - A Paradigm Shift in Monitoring Pipeline Leaks - Combining Sensorless NPW with RTTM (2021), Paper presented at the Abu Dhabi International Petroleum Exhibition & Conference, Abu Dhabi, UAE, November 2021, https://doi.org/10.2118/207790-MS

Making the world a cleaner place...

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Max Wedekind, Managing Director of DENSO Group Germany, explores how the company’s new tape solution simplifies the process of corrosion protection.

Figure 1. SEALID® All-in-1 with outstanding cohesive separation pattern.

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R

eliable and permanent protection of pipe sections and weld seams are one of the main challenges in pipeline construction.

A wide range of often time-consuming processes that differ for every application have previously been used. However, DENSO Group Germany’s patented SEALID® All-in-1 provides protection against corrosion as well as mechanical loads in a single step – without additional primer and without the use of other devices.

“The framework conditions in the pipeline business have changed significantly: the challenges in the industry are constantly increasing with shorter project times, higher standard requirements and the complex application of products”, says Thomas Kaiser, Managing Director of DENSO Group Germany. “Besides the permanent protection of pipe sections and weld seams, speed, safety and efficiency are all essential requirements in the construction industry.” SEALID All-in-1 keeps pace with the ever-increasing demands in international pipeline construction by fulfilling the ISO and EN standards: a single wrap is enough to fulfil the requirements of ISO 21809-3 at operating temperatures of up to +70˚C (+158˚F). The requirements of EN 12068 and DIN 30672 for class C50 are also met with a single wrap.

One wrap for corrosion and mechanical protection Focussed on the goal of making corrosion protection even more reliable and efficient, after several years of development, DENSO presents a global innovation: SEALID All-in-1, which simplifies the protection of pipes and weld seams.

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“We set ourselves high standards when developing SEALID: no primer and just one wrap for both corrosion and mechanical protection. This required a tape with special adhesive properties as well as exceptional resistance. The outstanding cohesive separation pattern impressively shows the performance you get from SEALID”, explains Thomas Kaiser (Figure 1).

The new all-in-one solution is manufactured in a genuine multi-layer co-extrusion process. When wrapped in a spiral pattern the tape forms a completely closed protective hose with exceptional durability. Impermeable to water vapour, oxygen, soil bacteria and soil electrolytes, the protective hose achieves a minimised cathodic disbondment together with an outstanding peel and lap shear strength.

Efficient and low-cost application at the construction site The simple application of SEALID All-in-1 ensures sustainability with significant work, time and cost savings. In particular, the patented innovation is the ideal solution for complex construction projects and tight project timelines, where it significantly reduces time and effort. As a universal solution for new construction and rehabilitation, SEALID is suitable for a range of applications – whether for weld seam protection, whole-pipe wrapping, pipe bends or T-pieces. The product does not contain any harmful ingredients and it can be applied without using complex equipment or hazardous substances: an important contribution to environmental protection and occupational safety. “The flexible and easy application makes SEALID All-in-1 the universal solution for corrosion protection of pipelines,” says Thomas Kaiser.

primers and additional protective measures for people and the environment.

To avoid costly interruptions, pipe coatings or pipe sections are often repaired while the pipeline is in operation. Due to the risk of explosion, only corrosion protection systems that are applied cold (without a flame) can be used. To put the pipeline back into full operation quickly, the process for applying the product must be rapid and simple. SEALID makes it quick and easy: comprehensive protection with cold application, without preheating the pipe, melting the material or any additional products for mechanical protection. SEALID is simply applied by hand or using DENSOMAT® wrapping devices (Figure 2).

The construction and operation of power stations and refineries are subject to some of the world’s highest safety standards – due to their enormous influence on people and the environment as well as their technical complexity.

These requirements extend to all plants, pipeline systems and components with complex geometries: their durable corrosion protection and permanent waterproofing ensure operational health and safety to prevent accidents and faults. Even here, SEALID provides universal protection without any timeconsuming preparation or multi-stage workflows.

As an all-in-one solution, SEALID offers clear benefits compared to existing corrosion protection procedures.

Tapes and tape systems In contrast to conventional tapes and tape systems, there is no need for a primer or a second tape. SEALID is just wrapped once. This saves time, money and material. The absence of solvents means that people and the environment are better protected.

One solution for all applications

Heat shrinkable sleeves

When joining pipe segments, the weld joint coating must protect the seam against corrosion and mechanical loads.

The sensitive weld seam must be at least as well protected as the rest of the pipe; after all, a chain is only as strong as its weakest link. SEALID All-in-1 reliably protects the seam in a single step, with just one wrap. That’s because SEALID All-in-1 does not need multiple system components, time-consuming

It eliminates the need to preheat the steel surface as well as the shrinking and air removal, as is the case for heat shrinkable sleeves. Errors are prevented from occurring in the first place.

SEALID can be applied in just one step without additional devices (no gas burner) or time-consuming protective measures. Due to their properties, heat shrinkable sleeves can only be used almost exclusively on weld seams. However, SEALID can be used everywhere as a universal solution: on entire pipes, pipe bends and T-pieces.

Viscoelastic/petrolatum tapes In contrast to viscoelastic/petrolatum tapes, no additional products are needed for mechanical protection. This eliminates timely and costly work steps. SEALID also ensures a permanent bond with the pipe. There are no shifts in the longitudinal direction as a result of pipe movements or mechanical forces, as is often the case with the components of viscoelastic systems.

Paint and spray coatings

Figure 2. SEALID: easy application by hand.

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World Pipelines / JANUARY 2022

Compared to liquid paint and spray coatings, SEALID is not dependent on weather conditions, such as temperature and humidity. Protective equipment and additional devices are not necessary, because no harmful substances are used. No timeconsuming preparation is required. There is no need to follow

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preparation guidelines, such as mixing ratios, layer thickness or curing time.

Adhesive properties and toughness Products that are applied without a primer need to make sure that they coat the surface to be protected well. This is normally achieved by approaching a liquid state, such as by heating and melting the material (e.g. heat shrinkable sleeves

or hot-applied tapes) or due to the property of the material (e.g. liquid coatings, petrolatum and viscoelastic products).

The disadvantage of hot-applied products is that additional equipment is necessary, a naked flame is used and additional energy is needed. Materials with an intrinsically very high flowability (viscoelastic/petrolatum products) usually only have very low resistance to mechanical forces and – especially in viscoelastic systems – there is also a limited bond between the corrosion protection layer and the additional mechanical protection.

SEALID is the world’s first product that is mechanically strong as well as elastic and also coats the surface well.

“SEALID is a completely novel solution. The existing standard tests were simply boxes that needed to be ticked. In addition to this, we carried out performance tests that replicate the practical loads on corrosion protection materials”, explains Dr. Reha Cetinkaya, Director Engineering of DENSO. The performance tests were focused on the mechanical behaviour of SEALID: how well does the innovative product protect the pipe against external loads and if the pipe moves?

Even an underground pipeline is exposed to various mechanical forces during operation. These stresses, such as those caused by vertical loads and traffic loads, can impact on certain points of the pipeline depending on the type of bedding in the soil. What’s more, the pipeline is exposed to relative movement, which causes stress along the pipeline.

Both types of stress cause damage and impair the mechanical protection. “So we set up a test bench that can generate point loads and a force in the longitudinal direction,” explains Dr. Reha Cetinkaya.

SEALID performance test

Figure 3. Test setup for the SEALID performance tests.

The test bench replicated a permanently installed DN100 (4 in.) pipeline. A frame to guide a carriage lengthways along the pipeline was positioned on top. The carriage was able to be fitted either with two fixed contact points (approx. 1 cm2 contact area each) or one contact point and one rolling wheel as a contact point. It could also be loaded with weights. A pull cord allowed a force to be introduced along the pipeline – either as a constant load via an attached weight or as a forced movement, by winding the pull cord with a crank (Figure 3).

Test 1: Lap shear strength In a first test, two fixed contact points were fitted on the carriage and loaded with 23 kg (equivalent to approx.

112 N/cm2). After a conditioning time of five hours, it was loaded with a traction weight of 15 kg (equivalent to approx.

147 N traction force). The result: the carriage glided over the entire wrapping in around 70 minutes without displacing individual tape layers or the entire coating. Calculated at the contact surface, the tensile shear force amounted to around 73 N/cm2. The carriage travelled over the coating without damaging it. In this test, the real-life loads did not impair the coating or the corrosion protection.

Test 2: Elastic resilience Figure 4. Elastic SEALID All-in-1 with excellent elastic resilience.

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The findings from the first test were linked with an additional issue in the second test. The investigation intended to find

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out whether the tape would return to its original shape if it was displaced. This second test forced the displacement of a layer. Compared to the first test, the system load was changed from a load with constant force (147 N) to a defined displacement load. In practice, this simulates a longitudinal displacement of a pipeline that is ‘clamped’ in the bedding material.

In this test, the entire displacement was applied to just one fixed contact point. The simulation with just one contact point instead of two enhanced the effect. In this case, the contact point was permanently adhered to a layer with a two-component adhesive. The other carriage contact point

consisted of a wheel, so was not able to transfer any force in the longitudinal direction. For this test, the carriage was loaded with 28 kg. After pre-conditioning, a displacement of 0.5 mm was applied at 30 minutes intervals. The result: the maximum displacement was 6 mm. The test showed that the individual layer moved with the adhered permanent contact point (centre image, Figure 4). The load was then removed from the carriage and the tension released from the pull cord. After approximately twelve hours the layer had independently moved around 5 mm (as well as the carriage) back towards the starting point. This corresponds to a return of over 80% from the previously applied displacement.

SEALID clearly impresses with its exceptional elastic resilience.

This means that a single large particle (stone) impacting on a point of the coating would not lead to a permanent displacement of the corrosion protection material. “The performance test proved that SEALID is an extraordinarily durable material that also boasts exceptional elasticity. These properties are not something that you would expect to find in permanently freeflowing materials (viscoelastic/ petrolatum), as displacements are usually not reversible,” summarises Thomas Kaiser.

Conclusion SEALID All-in-1 is DENSO’s patented global innovation for universal application. It is the first stand-alone product to protect against both corrosion as well as mechanical loads, in just one step, while fulfilling all relevant standards.

The performance test shows that a pipe protected with SEALID can reliably withstand loads caused by external mechanical influences as well as pipe movements. It not only protects as effectively as other highquality tape materials, but is also extremely efficient: without timeconsuming preparation (primers), multi-stage application steps or various system components.

There is no need for timeconsuming protective measures for people and the environment.

Corrosion protection made easier than ever before.

How do constantly changing regulations in the oil and gas impact businesses in the industry?

Every organisation must adhere to the regulations that apply to their industry. While businesses in the oil and gas industry are always dealing with compliance and regulatory standards, the changing nature of regulations can have huge time and cost implications. When newer regulations are released, oil and gas companies must be able to adapt, and do so quickly.

Constantly changing regulations alter how operators perform their work. When new regulations cause operators to change their course, it can be extremely costly. This makes it crucial to have tools and partners in place to help businesses pivot quickly or find a solution to adhere to these new regulations in a timely and costeffective manner.

What is the purpose of operator qualifications, and what challenges does it present to businesses?

Bonney Hodges, Energy Operations Director at ISN, USA, answers some questions about changing regulations, operator qualifications and how contractor management systems can help oil and gas businesses.

Operator qualifications (OQ) are used to validate the competency of individual workers performing operations and maintenance work on pipelines in the US. The purpose is to ensure that each individual working on a pipeline is qualified for the work they’re performing on oil and gas sites. OQs are put in place to keep worksites safe, and to prevent spills or incidents from occurring.

Operators are responsible for tracking and validating OQs and are audited regularly by The Pipeline and Hazardous Materials Safety Administration (PHMSA) and other regulatory parties.

However, changing regulations pose a large administrative burden to these companies, which often track OQs for hundreds of individuals, and must implement and document a clear management of change process for any changes made to their OQs plan. This includes addressing audit findings and communicating the changes to contractor employees. In addition to the taxing nature of handling these changes, when operators lack the information they need during an audit, it can result in fines on the company. For operators dealing with OQs, it is important for them to have access to information that allows them to keep up with the changing requirements.

How can leveraging a contractor management platform help businesses keep up with changing regulations?

Leveraging a contractor management platform can assist businesses in the oil and gas industry by helping them keep up with ever-changing OQs. Contractor management platforms act as a centralised location for clients to access any relevant information that may affect their business. Contractor management software monitors changing regulations and ensures that all impacted customers are aware of them. Bulletin board and messaging features on a contractor management platform offer an easy solution for communicating changing requirements to these companies’ contractors when changes in regulation occur.

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Through contractor management platforms like ISNetworld®, businesses can participate in client roundtables and networking discussions to connect with other industry professionals on the best practices to address these changing regulations. This ultimately drives synergy across the industry.

Contractor management platforms also offer businesses easy access to tools and solutions that will help them address changing regulations in their industry. Through the collection of additional data, collaboration on company-specific policies, and the analysis of information from their contractor base, these tools support companies in responding appropriately to changes in regulations.

Contractor management platforms also permit businesses to track and archive all their data, so businesses can easily manage and access their data history.

Finally, partnering with a contractor management platform offers businesses a knowledgeable extension to their immediate team. Client-specific support teams provide guidance to businesses on the tools and services that best fit their needs.

These subject matter experts serve as resources to help apply changing regulations, but can also educate on various topics such as HSE, quality, insurance and sustainability.

safety culture. By clearly defining requirements and how contractors are evaluated, it helps workers to understand what a company’s safety priorities are, as well as how they are evaluated.

Leveraging digital solutions can help streamline the contractor qualification process by promoting transparency, improving communication, increasing due-diligence and allowing for opportunities to benchmark performance. A few examples of digital safety culture tools include: )) An ID badging system, which provides a green and red-light system to help companies ensure that every employee coming on site is properly qualified and prepared to complete their tasks safely.

What digital solutions can allow companies to increase their safety culture, and ensure workers are prepared to complete tasks properly?

)) Safety culture assessment surveys that gather feedback

A third-party contractor management platform can help an organisation clearly communicate their policies and expectations to contractors, helping them enforce a strong

)) Analytics dashboards to quickly assess overall contractor

compliance and help organisations identify gaps in training, compliance or safety standards. )) Online training and learning management system (LMS)

platforms to post orientation and safety trainings for contractor employees to complete before coming on site.

from a company’s employees and and their contractor employees on their perception of safety at the organisation. This allows a company to assess misalignment between management, frontline and field workers and provides action planning to address the gaps and improve safety culture over time.

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Darran Pledger, STATS Group, UK, explores how combining equipment can lead to safe and efficient isolations for subsea pipeline repair and maintenance.

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he global oil and gas industry is reliant on the long term dependability of pipelines. Pipelines are vital to the safe and efficient transportation of hydrocarbons and failures of these pipelines can have huge energy supply, environmental, safety and reputational implications. As the global demand for energy increases, so do the consequences of any potential pipeline failure.

In many instances, pipeline operators encounter difficulties when attempting to isolate and depressurise a section of their pipeline to facilitate repair or maintenance activities, especially when suitably located valves are not available or are not functioning correctly. Often it is the isolation valves themselves that need to be replaced, repaired, or retrofitted.

There are many reasons for removing a section of subsea pipeline. Sometimes a degraded or corroded section needs to be removed to increase the operating life of a pipeline. Other reasons for compromised pipeline integrity could be dents or gouging from external mechanical damage or highly stressed deformations.

Although, more often the situation is that even well managed

pipelines with good integrity need to be isolated and have sections removed, to allow infrastructural reconfiguration, as offshore facilities are being decommissioned and removed.

When a pipeline section must be removed, it may initially be assumed that to conduct the intervention with as low risk as possible, the entire pipeline needs to be fully depressurised, thus removing any pressure threat, and that the pipeline needs to be flushed and flooded to displace all hydrocarbons, so removing any environmental impact.

However, in many cases achieving the lowest possible risk is not reasonably practicable; for instance, when the pipeline has many assets producing into it, or when venting off the line pressure, flooding the pipeline and then dewatering and drying the line, would lead to a production outage of many months and large discharges to the atmosphere or environment.

If it turns out that it is not reasonably practicable to depressurise and hydrocarbon-free the pipeline, then it may be necessary to break containment with the pipeline pressurised and full of its production inventory. In such a scenario a safe, pressure capable

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isolation barrier complying with industry isolation standards and recommended practices will be required – typically this is a proved double block and bleed barrier.

Subsea tie-in and pipeline reconfiguration To enable new field developments the most cost-effective solution may require a tie-in or connection into existing subsea pipeline infrastructure. When no pre-installed tie-in point exists, it will be necessary to install a new tie-in connection into the pipeline. Ideally the new tie-in connection can be done by disconnecting a pipeline flanged spool and replacing it with a pipeline tie-in, such as a tee or wye spool. However, in some cases a suitable removable spool is not available at the required location, and a tie-in connection must be retrofitted, either by fitting a tie-in clamp and performing a hot tap or by removing a section of the pipeline and installing a new tee.

The strategic use of STATS’ piggable Remote Tecno Plug® isolation tool and SureTap® hot tapping equipment facilitated a recent subsea pipeline reconfiguration in the North Sea. The pipeline infrastructure redevelopment was required as two offshore platforms were being negatively affected by seabed subsidence, and redevelopment activities would enable economic production of the fields’ tail-end production profile. While the platforms were being redeveloped, the production pipelines needed to be disconnected from the platforms to enable efficient reconnection of the 26 in. and 22 in. production pipelines to the platforms’ Subsea Isolation Valve Skids. The subsea pipeline reconfiguration was done without

Figure 1. SureTap ST910-90 hot tap machine and 18 in. mechanical hot tap clamp class 900 with a 12 in. branch designed to class 1500.

depressurising the entire 100 km long 26 in. gas export pipeline, operating at 85 bar. The use of a Remote Tecno Plug isolation tool provided a fully proved double block and monitored isolation which enhanced safety, reduced the project execution time, and led to significant cost savings.

In order to provide fuel gas to the platform during an extended shutdown a new 8 in. pipeline was tied-in to a 24 in. pipeline using a class 900 mechanical hot tap fitting. STATS supplied the mechanical hot tap clamp and SureTap hot tap machine to cut an 8 in. hole into the 24 in. pipeline and recover the pipe coupon. The 8 in. pipeline was then successfully connected to the tie-in valve safely completing the tie-in workscope.

New field development In 2021, STATS were contracted to provide a 12 in. tie-in point into an existing 18 in. pipeline to allow a new gas field to be brought online in the Bass Strait, offshore Australia. To enable this, STATS provided a subsea mechanical clamp and SureTap hot tap machine. The clamp was designed and manufactured based on the pipeline parameters and to the client’s exact specification.

The 18 in. clamp was designed to class 900 with the 12 in. branch designed to class 1500.

STATS mechanical clamp design incorporates dual seals and locks – the locks are mounted outside the pressure boundary, which positions the locks away from the pipeline contents and provides optimal loading to the pipeline. Clamp seal compression flanges were initially actuated to set the seals, which are energised against the pipe wall, without setting the clamp locks. This allowed a pressure test of the dual seals, via the annulus cavity, which confirmed both seals were leak-tight and the dual seal pressure boundary was sound. Once the seal test was successfully completed the structural grip locks were set. Independently activated lock segments ensure that each lock fully engages onto the pipe wall. This feature is particularly beneficial on pipelines that are oval, ensuring full structural gripping and reinforcement of the pipeline. A final seal test ensured the clamp integrity prior to hot tapping into the pipeline.

Gareth Campbell, Regional Manager for Asia Pacific at STATS Group, said: “The subsea tie-in was safely completed while the pipeline remained at 72 bar and provided the new tie-in point for the 6 km flowline. The project was successfully completed without incident and is testament to the teamwork and good communication between all parties.”

Subsea pipeline repair

Figure 2. 14 in. class 2500 mechanical connector.

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World Pipelines / JANUARY 2022

During the offshore installation phase of a new field development in the North Sea, spool pieces where installed and the new piping infrastructure was leak-tested between the subsea isolation valve and platform riser. While conducting the leak-test, damage was discovered on the sealing face of the platform riser base flange, allocated for the tie-in of the pipeline. At this stage the operator put plans in place to carry out an in-situ repair of the damaged flange. However, in case the repair was unsuccessful a contingency solution was developed. This allowed the damaged flange to be cut and removed and replaced with a 14 in. class 2500 mechanical flanged connector, installed directly onto the bare pipe end. This would ensure the schedule for commissioning the new tie-in would not be jeopardised if the subsea flange repair failed.

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Figure 3. Remote Tecno Plug inline isolation tools.

STATS provided two mechanical connectors as, for technical assurance, one of the connectors was subject to bend fatigue testing, and as the fatigue test was a test to destruction, a primary connector could not be used. A factory acceptance test was carried out first at STATS headquarters in Aberdeenshire, Scotland, before the connector was shipped to a third party for the bend test, with all testing witnessed by an independent verification body and the client.

In operation the connector is offered onto the pipe end and a seal compression flange is actuated to set the seals. The seals can then be pressure tested to prove the effectiveness of both seals prior to setting the locks. Once the seals are verified, the lock bowl is actuated, by torquing a separate array of bolts to set the locks onto the pipe. A final localised code-compliant strength test and seal leak test verifies that the connector is structurally secured to the pipeline and the seals are leak tight. An environmental seal is included in the compression flange to allow the lock cavity to be flushed with an inert fluid.

bleed isolation barrier from the pressurised pipeline. This level of isolation complies with industry guidance on isolation and intervention for diver access to subsea systems, ensuring diver and worksite safety. The pipeline repair solution incorporated installing a permanent bypass pipeline, which allowed the operations to be completed without the need for shutting-in pipeline production or depressurising, thus, ensuring production was maintained uninterrupted.

In order to provide a barrier to the marine environment for long term wet storage of the damaged pipe section, STATS supplied three 8 in. class 150 subsea abandonment plugs. The mechanically activated abandonment plugs incorporate a set of taper lock grips and a single seal.

Once the damaged pipeline section was cut away, the bare ends of the original pipeline were left exposed. To provide a pressure competent termination, STATS supplied subsea mechanical connectors, complete with a blind flange that were fitted to the three bare pipe ends.

Pipeline decommissioning In recent decades, the North Sea and Gulf of Mexico have seen an increase in decommissioning activity as hydrocarbon reservoirs are depleted. As oil and gas wells and installations developed from the 1970s onward reach the end of their useful lives, decommissioning hot spots are now emerging around the globe. Over the coming years, hundreds of offshore assets are scheduled to be decommissioned worldwide.

As fields reach the end of their economic life, specific parts of the pipeline system naturally become redundant, and with no potential future use, are required to be decommissioned.

Isolation plugs and intervention equipment can be used to safely and effectively decommission, abandon or re-route hydrocarbon pipelines and infrastructure.

Subsea pipeline isolation and repair

Conclusion

When an 8 in. gas condensate export pipeline had been dragged out of position by a vessel anchor and needed repaired in the Gulf of Thailand, STATS were contacted to provide an isolation and intervention solution. The pipeline was situated at a water depth of 60 m and was operating at pressure ranging between 7 and 21 bar.

STATS utilised its range of subsea products to facilitate the repair, which included hot tap installed BISEP’s, slab valves, hot tap clamps, completion plugs, end connectors and abandonment plugs.

This comprehensive suite of tools was engineered, manufactured, tested and deployed in-field, allowing successful pipeline repair to be completed.

Following a detailed engineering and risk assessment, a repair methodology and solution was developed, whereby an 8 in. bypass was installed on the seabed as a permanent repair to re-route the pipeline medium away from the damaged pipeline section.

The isolation and repair solution allowed the damaged section of pipeline to be isolated and safely removed from the system, with no impact to production, the environment or risk to diver safety.

STATS’ patented BISEP was selected to provide leak-tight isolation of the pressurised pipeline. The BISEP is deployed through a full bore hot tap penetration at the isolation location through a mechanical hot tap clamp. The DNV type approved BISEPs provided a fully proved, fail-safe, double block and

STATS pipeline isolation plugs (Tecno Plug and BISEP) are Type Approved and fully certified by DNV to verify that the design criteria satisfy the requirements for pipeline isolation plugs to provide dual seal and isolation in accordance with Offshore Standards; DNV-ST-F101 (Submarine Pipeline Systems) and recommended Practices; DNV-RP-F113 (Subsea Pipeline Repair).

These devices provide the highest level of safety for divers and protection to the environment during subsea pipeline repair and maintenance.

“STATS pipeline isolation, intervention and repair technology provides clients with high integrity, cost effective solutions, which increase levels of safety and reduce system downtime during subsea pipeline repair and maintenance” said Ron James, Sales Director for STATS Group. “Our extensive global track record and commitment to first-class delivery, provides operators a turnkey service for pipeline repair and maintenance on piggable and unpiggable pipelines.”

Often, utilising a single product line cannot on its own achieve the desired end state, but when inline isolation plugs and hot tap installed plugs are used in combination, safe, pressure competent access points into piping systems and pipelines can be made, allowing the operator to safely isolate or disconnect infrastructure from hydrocarbon production.

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World Pipelines / JANUARY 2022

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Francis Norman, National Energy Resources Australia, explains how the the Centre of Decomissioning Australia (CODA) will support the country’s increasing offshore decommissioning needs.

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ustralia’s offshore oil and gas industry is embarking on a potentially US$40 billion decommissioning workload, with around 50% of this work anticipated to commence in the coming decade. The size of the decommissioning workload is considerable: 1700 km of in-field flowlines, 130 static umbilicals, almost 5000 km of export and inter-field pipelines, and 126 flexible risers and dynamic umbilicals. This is alongside 1008 wells to plug and abandon, 11 floating facilities and 57 fixed facilities.

Although the precise dates and end states of this decommissioning activity will only emerge over time, when facilities reach their end of life and reuse and repurposing options are explored, the overall volumes of material speak for themselves, with the total installed offshore infrastructure estimated to weigh almost six million t. The scale and complexity of this work – as well as the new pressures put on different parts of the supply chain – will undoubtedly open up new opportunities both in Australia and internationally if multiple players come together to undertake the work safely, efficiently and in compliance with the regulatory and environmental expectations.

To date, the Australian industry has performed relatively small decommissioning scopes, but as larger volumes of infrastructure now near cessation of production, the demand is expected to rapidly ramp up. While Australian industry currently has the skills and capability to undertake a portion of this coming work, a low level of visibility of the entirety of the future workload has meant it has been difficult to invest in the necessary skills, capacity and facilities at the scale required. As a result, there is a risk the supply of skills and technology (along with necessary facilities and networks) may make delivering on this increasing demand highly challenging, particularly during the next few years.

Additionally, the growth in demand for decommissioning skills and technologies is occurring elsewhere in the Asia Pacific region, as fields there also reach their end of life. This growing demand opens up further valuable opportunities for emerging Australian businesses to be part of regional decommissioning activities, working alongside local companies and sharing skills and insights to ensure all decommissioning work is performed to the highest possible standards and that learnings from each region are shared broadly.

With the immediacy and volume of the Australian decommissioning workload now increasingly apparent, so too is the need for an independent

41

development and deployment of new and novel technologies. CODA is also working to help industry identify or establish pathways for the optimal recycling and reuse of offshore infrastructure to enable circular economy opportunities and support emerging lowemissions technologies.

Importantly, CODA is focussed on maximising opportunities for the local workforce, service, and technology companies, who will have the opportunity to participate in decommissioning work, increase their Establishing the Centre of Decommissioning workforce and establish themselves in different locations Australia (CODA) adjacent to much of the work. It is anticipated many of Recognising that the decommissioning industry is these locations may be in remote or regional Australia, relatively unprepared for much of the emerging workload, resulting in the growth of long-term opportunities in these National Energy Resources Australia (NERA) established communities. the Centre of Decommissioning Australia (CODA) to lead Learning from the experiences of other centres, CODA a transformational approach to late life planning and has been constituted to work as a wholly independent, decommissioning execution that returns maximum value to not-for-profit organisation, supported jointly by the Australia. Built on the foundation of collaboration, CODA facility operators, the service sector, and government. The connects technology innovators, research organisations Centre’s vision is to connect all the disparate parts of the and governments to support joint projects, knowledge emerging Australian decommissioning industry, providing transfer and innovations that help to harness the nation’s visibility of the emerging workload, identifying peer decommissioning challenge as an economic, environmental organisations alongside suppliers and clients to the service and social opportunity. sector, facilitating independent discussions between CODA works towards the fundamental goal of ensuring industry and those responsible for its regulation, and that industry is ready to perform decommissioning serving as a vehicle to share best practice and insight. activities safely, efficiently and in environmentally The first work undertaken by CODA, alongside a conscious ways while also pursuing a reduction of number of operators, was commissioning the production decommissioning costs (where possible) and the of a decommissioning liability report. This report, which for the first time shows the size and shape of the upcoming workload, has become the baseline document for describing the volume and immediacy of Australian decommissioning. 1, 2 CODA is now building on this report by generating follow-up work that is helping to highlight global best practice for the planning and execution of decommissioning work, setting Figure 1. Australian offshore oil and gas decommissioning liability by asset typology. out a technology roadmap that highlights opportunities to deploy emerging or proven equipment elsewhere in Australia, and identifying opportunities for recycling and disposal of decommissioned and removed offshore infrastructure.

To provide guidance and strategic insight to its operations, CODA recently appointed a sixperson supervisory committee.3 This committee comprises two senior representatives from both the operator community Figure 2. Australian offshore oil and gas decommissioning liability timeline. and the service sectors, as organisation that can work to bring together all interested and involved parties to address both the challenges and opportunities of decommissioning Australia’s ageing oil and gas infrastructure. Other, more mature international jurisdictions such as the North Sea and Netherlands have each established their own such entities to undertake this task as their workloads grew, but no such organisation previously existed in Australia.

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World Pipelines / JANUARY 2022

Acc u r at e • To u g h • r e l i a b l e THE LEADING BRAND OF HOLIDAY DETECTION EQUIPMENT SINCE 1953

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•

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•

Figure 3. Australia’s offshore oil and gas inventory.

well as two independent representatives with significant decommissioning expertise. This committee is helping CODA to shape its strategic future, prioritise activities, and plan to deliver the greatest value. Having access to this network of experts allows CODA to accelerate much of its activity and ensures it can focus on the most pressing and critical needs of the sector.

CODA continues to engage across the entire supply chain, gaining insights from large, medium and small businesses, technology companies and engineering companies. These discussions enable CODA to best understand and serve the needs of as many parts of this cohort as possible. Similarly, CODA has ongoing discussions with parts of the Australian government at state, territory and federal levels. Governments are a significant participant in the future of decommissioning and are providing valuable guidance and insight to support CODA’s future plans.

CODA has also established relationships with many of the other international decommissioning organisations and those working in related fields. This network of similarly minded communities has a strong focus on ensuring decommissioning activity in their own regions is undertaken to the highest possible standards and with the best achievable outcomes.

Sharing insights and views across this network will help all regions grow and move forward as quickly as possible.

Next steps in planning for the decommissioning workload As CODA moves into 2022, it has a number of key priority actions to pursue. The Centre is looking to establish several best practice working groups to investigate opportunities to significantly enhance current approaches, codify best practice, and identify how different categories of decommissioned equipment such as flexible pipelines, umbilicals, platforms and fixed pipelines will need to be evaluated to determine their decommissioned end state. CODA is also beginning to

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World Pipelines / JANUARY 2022

develop an online decommissioning capability directory to showcase all of the Australian businesses involved in decommissioning activity. This directory will allow businesses for the first time to connect to one another more rapidly and be more easily found by potential clients and suppliers alike.

An evaluation of the nation’s capability is also showing there is a need to identify and equip coastal ports and hubs where decommissioning activity can take place. While there are a number of such locations, the low level of activity to date means having the right facilities in the best locations with all of the required functionality has not previously been a priority. CODA is working with industry and government to support the identification, and in some instances the establishment, of these facilities. Once in place, these will become the heart of much of the disposal work required when decommissioned facilities are removed.

Oil and gas decommissioning is not limited to offshore infrastructure. There is a significant inventory of onshore wells and equipment that will begin to be decommissioned over the coming years. This onshore work is as much a part of CODA’s focus as is the offshore scope. As many of the skills and services are immediately transferable between offshore and onshore, learnings from one can be immediately transferred to the other, and both will depend on much of the same disposal industry to remove and recycle equipment.

As such, CODA is including onshore work in its current and future planning.

Meeting Australia’s future decommissioning needs In the coming years and decades, the volumes of Australian decommissioning activity are anticipated to increase significantly. This work will create opportunities for established companies to grow, new companies to emerge and a significant additional volume of material to be put into growing recycling value chains as the need to safely recycle or dispose of removed equipment also increases. Like any new industrial activity, however, careful planning and broad cooperation and sharing of knowledge will ensure that it is undertaken safely and generates the best possible value for the Australian economy. As an independent and trusted connector, CODA has a critical role to play in the growth of this industry and is working hard to meet the needs of industry as it coalesces around the challenge.

References 1.

2.

3.

https://www.nera.org.au/Publications-and-insights/Attachment?Action=Do wnload&Attachment_id=358 https://www.nera.org.au/coda-projects https://www.nera.org.au/CODA-Supervisory-Committee

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19/12/2019 09:59

David Evans and Graeme Peacock, Tata Steel, UK, discuss some key points regarding the pipeline materials and standards required to assist in a smooth energy transition.

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s the world moves forward in the energy transition, the range of solutions to support our future energy needs and questions about how they will be delivered to markets become increasingly more complex.

While the oil and gas sector will continue to have a large say in the future direction of the global energy mix, renewable energy will play an

increasingly greater role. This was reaffirmed at the recent COP26 conference in Glasgow alongside national commitments to net zero carbon emission targets.

The contribution made by renewables to UK power has more than doubled since 2014: the country’s target for offshore wind capacity by 2030 is 40 gigawatts (GW), compared to current capacity of 11 GW.1

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The use of hydrogen is also expected to feature prominently in future energy provision. The International Energy Agency has stated that the time is right to tap into hydrogen’s potential while UK Government analysis suggests up to 30% of the country’s energy consumption by 2050 could be hydrogen-based. 2, 3 In support of net zero emissions targets, momentum in the carbon capture utilisation and storage (CCUS) sector is increasing. In the UK, the first two CCUS projects have already been approved for development while the Government has committed to increasing to four CCUS clusters by 2030 at the latest, with an ambition to capture 10 million t CO2/year by 2030.4 Almost every aspect of the UK Government’s decarbonisation plan is steel intensive – huge amounts of steel will be needed for renewable energy, low-CO2 transportation, and infrastructure schemes for large-scale hydrogen production and distribution, and carbon capture, usage and storage. It will be needed to build and power electric vehicles of tomorrow, as well as creating sustainable buildings and major infrastructure projects, which will help the nation achieve its net zero goals.

Figure 1. Tata Steel has increased its maximum wall thickness for HFI pipe to 17.5 mm.

Each of the different pieces in the energy mosaic generates questions around delivery, specifically regarding infrastructure and pipeline provision. How can we ensure the power we need is delivered to the end user in the safest, most environmentally effective and financially efficient way? Furthermore, how can we make our steel and pipe making processes as sustainable as possible?

It’s worthwhile examining some of the key sectors within the energy transition, to consider current trends and to explore what the future pipeline and steel requirements might be in each case.

Higher strength for more challenging applications While many analysts suggest consumption and production of oil and gas will decline in future, there is a widespread recognition that it will continue to have an important role to play well into the middle of this century. However, many of the more accessible reservoirs and easier plays around the world have already been exploited, resulting in the need for operators to venture into more challenging and difficult environments, specifically deeper and colder offshore locations.

Meeting the demands found in these more challenging environments is encouraging operators to consider higher strength, high frequency induction (HFI) pipes with higher toughness and greater wall thickness to withstand the impact of hydrostatic pressure. Traditionally 16 mm pipe has been widely used in subsea applications. However, the trend for greater thickness is inspiring some steel manufacturers to increase their manufacturing limits.

Tata Steel, for example, has increased its maximum wall thickness for HFI pipe up to 17.5 mm.

The increased use of HFI in deepwater application is another trend that we are likely to see grow. The use of HFI pipe creates significant advantages compared to seamless pipe, but the key is in the manufacturing process. The tight dimensional control that HFI provides can deliver highly consistent wall thickness and diameter.

This is a benefit to lay contractors because consistent dimensions across multiple pipes can help speed up their welding processes. It also has potential advantages for possible future applications where data sharing between the manufacturing and welding processes will assist in streamlining operations. An additional benefit over seamless pipe manufacture is that HFI is manufactured by a less energy intense process, which provides considerable cost advantages.

Maximising hydrogen’s potential

Figure 2. Reel lay line pipe.

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World Pipelines / JANUARY 2022

Hydrogen is attracting significant interest in the drive to reduce carbon emissions and a vast amount of research is currently underway across various industrial sectors to understand how this resource can be most effectively exploited. A major aspect of this research focuses on what the infrastructure requirements will be for hydrogen and how these can be met. How much new infrastructure will be needed and how much of the existing infrastructure

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Another aspect to consider is that the degree of preprocessing experienced by the gas onshore will likely have an influence on the potential for corrosion to be suffered by pipelines transporting it to disused fields offshore.

Winds of change Over half of Tata Steel’s tube products go into structural applications, including offshore wind turbines and the infrastructure associated with them, such as transformer stations. As the offshore wind industry continues to expand, demand for structural products in this sector is only expected to increase.

Figure 3. Manufacturing HFI pipe at Tata Steel’s 20 in. mill in Hartlepool, UK.

will still be usable is a key consideration. The fact that the existing pipeline network across Europe ranges in age from approximately 100 years old to modern line pipe-type steel adds to the challenge.

One of the main issues with hydrogen for pipelines is embrittlement, where hydrogen diffuses into the metal and weakens it. To reduce the potential and impact of embrittlement on pipes will require a high degree of toughness and wall thickness. Some standards organisations such as the American Society of Mechanical Engineers (ASME) have established design standards with safety factors included for increasing the wall thickness of pipe. However, lack of a complete understanding of the impacts of hydrogen embrittlement on pipelines creates a potential for over conservatism in material selection.

More research is required to fully understand hydrogen embrittlement on pipelines and to more fully explore the safety standard issues.

The European Pipeline Research Group, which includes Tata Steel among its members, has commissioned significant research into the requirements, while Tata Steel is currently testing hydrogen embrittlement and fatigue life of its own materials at Swansea University. Within the next two years it is expected the industry will have a more settled view on the effects of hydrogen embrittlement on pipelines.

A carbon copy?

Like hydrogen, the methodology for the development of CCUS systems is established but the infrastructure implications are still under consideration. Questions about the use of existing pipelines versus new ones are as relevant for CCUS as for hydrogen but, again, higher toughness is expected to be a requirement for pipes bearing CO2. If old and new systems are to be linked together, it is important for pipeline operators to have access to as much of the old pipeline’s history as possible so that the degree of deterioration can be accurately assessed. Furthermore, different countries have their own regulations and it will be essential for operators to be mindful of these when planning new infrastructure networks.

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World Pipelines / JANUARY 2022

Avoiding over conservatism There are justifiable concerns and considerations when it comes to selecting pipeline steels, but there are occasions when the comfort of over conservatism is unnecessary and uneconomic. The trend for the over specification of materials in the oil and gas industry is well understood but it doesn’t always make for the most lean and efficient operations. As industry explores the pipeline requirements of other energy sources, there is a concern that the culture of over specification in, for example, wall thickness or test temperatures beyond the already-conservative boundaries set by design standards, may spread into these sectors too.

It is right to be cautious but it can be counter-productive to be overly cautious.

The value of early engagement The expansion into unchartered territories – whether that is new pipelines for deepwater oil and gas or a network for hydrogen production and transportation – will not be straightforward for asset owners. It is therefore important for them to call on as much available expertise and support as possible, including the experience of pipeline and steel manufacturers.

Engaging with the supply chain as early as possible in the project design phase can help ensure budgets remain within scope and that the supply chain is able to meet project requirements.

A vital link in the energy transition The future of our energy systems is set to create many challenges but also significant opportunities as we transition from dependence on fossil fuels to more environmentally acceptable sources. Delivering these well established and new energy sources from the point of production to the end user will be one of the most critical components in ensuring national energy stability. Achieving this will require pipelines and networks that are fit for the intended purpose.

References 1.

2.

3.

4.

https://www.spglobal.com/platts/en/market-insights/latest-news/energytransition/100421-uk-targets-power-from-100-renewable-sources-by-2035 https://www.iea.org/reports/the-future-of-hydrogen https://www.iea.org/reports/the-future-of-hydrogen https://www.gov.uk/government/publications/design-of-the-carboncapture-and-storage-ccs-infrastructure-fund/the-carbon-capture-andstorage-infrastructure-fund-an-update-on-its-design-accessible-webpage

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Murray Peat, Manager at Linewatch, UK, discusses the importance of pipeline awareness and safety procedures when it comes to new digging work.

T

he volume of digging work being undertaken in the last 20 years has risen exponentially, which has had a clear and substantial impact on the UK’s underground oil and gas pipelines.

While many of these pipes have been in situ for more than half a century, the type and volume of excavation work now taking place is posing an increased risk to these systems. Any third-party strikes will have a major environmental impact and cause restrictions in supply. As we know, if these pipes are damaged, they may be shut down for prolonged periods, seriously affecting customers who benefit from their resources.

As new innovations, technologies and machinery have come along, projects that were once dug by hand over many days, just a few feet below the surface, can now be completed in minutes to much greater depths. While these advancements have been proactive for the industry, it does put the UK’s pipelines at greater risk of being ‘hit’ – the more digging work taking place, the more chance there is of a ‘strike’. This could of course lead to serious injury or even fatalities, as well as irreversible damage to the environment should the pipeline be breached.

This is not the only issue that has arisen from this increased speed and volume of work. Contractors are also working to much tighter timeframes than ever before, which means that the correct protocols are not always being adhered to. While we understand

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that work needs to be completed quickly, ignoring regulations and not discussing the presence of pipelines with the correct authority should never be considered as best practice to save time. Whether planting a tree or installing a new road, if there is a pipeline nearby, the proper care must be put in place.

How does Linewatch operate?

The seriousness of these issues indicates why organisations such as Linewatch have become so important, in terms of locating and then protecting our network of pipes, as well as encouraging safe practice as a priority. We provide awareness of our members’ pipeline networks around the UK and detail how to identify the appropriate operators. Currently our Members account for almost 14 000 km of buried oil and gas pipelines across the UK. That’s more than double the length of the River Nile. This means we have a real responsibility to keep people and these pipes as safe as possible.

The importance of keeping people safe from injury and the environment damage-free cannot be overstated. We work on behalf of our members, including Shell, Ineos and Esso, to raise

Figure 1. A contractor locating a pipeline prior to excavation.

awareness through any medium necessary. This includes safety literature, e-learning modules, exposure at industry exhibitions, and our free, in-person safety presentations, which allowed us to speak to 1500 people last year. All of these provide vital data to both landowners and companies, preventing them from suffering any issues during future digging projects. We certainly encourage everyone to check for markers and contact the relevant pipeline operator before embarking on a project.

Protecting the pipes Linewatch exists to help combat pipeline damage, and reallife examples highlight the necessity of groups like Linewatch in order to keep everybody safe. In fact, we were recently alerted to an incident where a high-pressure ethylene pipeline had been damaged by a drainage contractor working on behalf of a landowner. Works had taken place without the necessary utility checks being undertaken or the contractor being aware of the special requirements needed for working so close to a live pipeline. The damage was so severe that if the operator had not been alerted and shut down the pipeline, the consequences could have been catastrophic. Excavation of the pipeline and additional investigation revealed that considerable damage had occurred in four locations, caused by the use of a drainage trenching machine.

To fix this issue, the pipeline was isolated at four different points whilst work was carried out to replace the damaged pipe. 10 further excavations were necessary at 6 m intervals to check that no further damage had occurred to the pipeline or its protective wrapping. This was all at additional cost to the operator, while putting the safety of its staff at unnecessary risk to fix the problems.

The potential costs for depressurising and decommissioning a pipeline, cutting off supply to customers, and carrying out repairs, then recommissioning the network can run into millions of pounds. This situation could have been easily prevented had the contractor done a simple utility search using LSBUD’s free online tool at the start of the project and contacted the pipeline operator too. Instead, it ignored the problem until it was too late.

If the damage had not been discovered, the pipes would have failed, causing a major incident. Had the ethylene leaked and ignited, this would likely have caused serious injury or even fatalities on site.

Checking for pipelines before starting work is a simple task, and one that takes less time that it does to make a cup of tea. The element of preparation simply can’t be ignored as it ensures that incidents like this can be avoided.

Where are we now?

Figure 2. A general oil pipeline repair and reinstatement.

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World Pipelines / JANUARY 2022

It is estimated that there are currently around four million excavation projects taking place in the UK each year.

LSBUD data recently revealed that 3.4 million of these were researched on their portal before any work had started, which means that at least 85% of all digging activities occurred with the correct protocols in place. This is a 13% increase compared to 2020, demonstrating that our work, amongst other factors, is having the desired effect and the number of searches pre-digging is increasing.

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Although this is a great start, there is still more work to do, with the number of excavation projects likely to have increased by up to 20% as a result of the Government’s significant investment in large scale infrastructure projects in a bid to kickstart the economy post-COVID. Further to this, our 2020 Infringement Report suggested that there were five high risk incidents recorded which would have caused serious damage to densely populated areas, schools, and hazardous areas had the works breached the pipelines. Only one of these had involved pre-notification to a pipeline safety team, demonstrating that our mission is not yet complete.

The future of pipelines There is a diverse range of activity involving groundwork taking place now which requires the focus of groups like Linewatch to ensure that they occur as safely as possible.

These include the rollout of 5G and the installation of fibre broadband across the country. These activities require a huge amount of digging, often highly concentrated in rural areas. This means that many sites are being used where the information about the underground pipeline network has never been requested. As a result, contractors need to be vigilant to ensure that no one is harmed and pipelines and the environment that surrounds them are left as undisturbed as possible.

Another factor to consider is the expansion of the UK’s electrical networks to prepare for the introduction of heat pumps and electric vehicle charging points. Despite the pressure that contractors are already under to install them, proper care and planning must be taken to ensure the UK’s pipeline network is not damaged in the process.

Elsewhere, hydrogen is becoming increasingly prominent within the UK, with projects such as HyNet North West – aimed at unlocking the UK’s low carbon economy in the hopes to reach net zero – already ongoing, carrying hydrogen around the UK is going to be an essential target in the future.

This means that the importance of pipelines is only going to increase, and therefore the need for pipeline education is more relevant than ever.

Conclusion With the nominal depth of a pipeline just 3 ft, the same length as a cricket bat, most digging activity is likely to put the safety of pipes at risk, especially if no prior search has been performed. Our objective is to continue raising awareness of the issues related to digging near pipelines and we will continue to do this, especially as it can be the difference between life and death. The evidence provided by LSBUD, as well as the information in our Infringement Report, is proof of that.

With the estimated cost of hitting a pipeline reaching as much as £15 million, and the safety of the UK’s workers at stake every time a spade or digger bucket hits the ground, it is everyone’s responsibility to do what they can to help.

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