World Pipelines May 2022 by PalladianPublications

Volume 22 Number 5 - May 2022

The leading alternative to voluntary venting or flaring. ReCAP safely recovers valuable natural gas from 8.5 miles of pipeline in central Texas—keeping it out of the atmosphere.

Responsible Pipeline Operations Emissions Recovery System

As the leading innovator, we continue to supply our customers with the technology, methods, and consultancy to make the best integrity management decisions for their assets. No matter what the future holds, renewable hydrogen as a flexible energy carrier plays a vital role in moving the industry further; we want to make sure you are ready.

Fit for the Future. Ready for Hydrogen.

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CONTENTS WORLD PIPELINES | VOLUME 22 | NUMBER 5 | MAY 2022 03. Editor's comment 05. Pipeline news

Updates on the Mountain Valley pipeline, Poland-Norway gas pipeline and South African LNG.

METERING AND MONITORING 25. Newer NDT for pipeline monitoring

Bruce A. Pellegrino and Michael J. Nugent, Sensor Networks, Inc., USA.

33. Going with the flow Nicola Curtis, Rotork, UK.

KEYNOTE ARTICLE: PROJECT MANAGEMENT 08. Managing risks efficiently

37. Feeling the pressure

Matthew Hawkridge, Chief Technology Officer, Ovarro, UK, explains how remote telemetry units (RTUs) can be used to optimise performance and reduce failures in oil and gas pipelines.

Steven Hocurscak, Neles, Finland.

PIPELINE SAFETY 41. Constant commitment to pipelines Cliff Johnson, President, PRCI, USA.

Matthew Hawkridge, Chief Technology Officer, Ovarro, UK, explains how remote telemetry units (RTUs) can be used to optimise performance and reduce failures in oil and gas pipelines.

he US Energy Information Administration (EIA) predicts that global use of petroleum and other liquids will return to pre-pandemic, or 2019, levels by 2023 and remain the world’s largest energy source in 2050. Pipelines are among the most significant and safest methods for transporting oil and gas, but they are not fail-safe and accidents occur that lead to significant consequences. Pipelines are essential to upstream, midstream and downstream operations in the oil and gas industry. While new drilling techniques and transportation systems are safer than ever before, failures do occur – including corrosion, cracks and leaks – and must be resolved, quickly and effectively. Consequences of pipeline damage not only include downtime, interruptions and decreased operational efficiency but also “ignitions, injuries [and] fatalities” according to a report by the Department of Civil Engineering at University of Calgary, Canada. The report found failure rates in pipelines to be consistent between 2010 and 2015, with hazardous liquid pipelines having the highest failure rates each year. Incidents directly or indirect impact wildlife and the natural environment, and these issues also pose a threat to workers and the population. The growth in demand for fuels predicted by the EIA increases the importance of identifying, analysing and evaluating the risks associated with pipelines. It also places the onus on oil and gas companies to constantly monitor the environmental impact of their operations and, above all else, ensure the safety of staff and the general public. Relevant key performance indicators (KPIs) should be implemented, where possible. However, oil and gas companies have run into obstacles when implementing the necessary hardware and software to guarantee safety and performance in their networks. One of the main reasons software implementations have failed is because the scale of the project was misjudged from the outset. Another mistake has been that specific,

PIPELINE STEELS AND FABRICATION 47. Large-scale 3D printing

measurable, achievable, relevant and time-bound KPIs – otherwise known as SMART goals – weren’t properly set.

Better performance To solve these issues, oil and gas network operators must aspire to better communicate, implement and supervise these SMART objectives throughout their networks and organisation – but how? To address this, one of the most appropriate devices to collect and process this information is the remote telemetry unit (RTU). For decades, RTUs have been a key component of data chains and managing information flows from equipment input/outputs (I/Os) right up to the CEO. These devices have a longstanding track record of sitting on remote pipelines, wellheads and offshore platforms. The RTU is a field mount computer that can be deployed on a vast range of assets. Once in place, it collects data locally, regardless of the surrounding environment, and acts upon it immediately. That means it reports data back to the central supervisory control and data acquisition (SCADA) control room and maintains a local historical store as an additional backup. The real value of an RTU is that it can perform autonomous control in real time, and then report to the supervisory SCADA system that it has everything under control. With these capabilities, the RTU can collect and act upon new data in ways that are needed for a modern, efficient and profitable organisation. Operators at the SCADA interface can supervise the operations by centrally establishing and enforcing KPIs. These indicators can include set points or instructions which relate specifically to devices in the networks – instructions like ‘open/close this’ or ‘start/stop that’, for example. The RTUs can act up upon and manage these instructions locally.

Mark Douglass, Business Development Manager, Lincoln Electric Additive Solutions, USA.

AUTOMATION 51. The path to lights-out manufacturing

Shriram Ramanathan, Ph.D., Vice President and Group Director, Lux Research, USA, and contributor Miraj Mainali.

PAGE 8

HOT TAPPING 13. Modifications for the modern world

Shriram Ramanathan, Ph.D., Vice President and Group Director, Lux Research, USA, and contributor Miraj Mainali analyse the timeline for lightsout manufacturing processes for the oil and gas industry.

ights-out manufacturing is fully automated and requires no human presence, so that lights and even ventilation can be shut off, hence the term ‘lights-out’. While lights-out manufacturing sounds futuristic, the concept has been circulating for a couple of decades now. In fact, many organisations, including IBM, GE, Fanuc, and Philips, have operated several forms of lights-out factories.

Drivers for lights-out manufacturing During the past five years, investors have shown steadily rising interest and activity in lights-out manufacturing, which we can see using Lux Research’s internal tools that analyse

David Stordeur, Senior Product Manager, T.D. Williamson, Belgium.

PIPELINE INTEGRITY MANAGEMENT 20. IoT asset integrity solutions William McLean, Director, OMNI Integrity, UK.

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William McLean, Director, OMNI Integrity, UK, outlines how OMNI is helping businesses utilise data effectively to manage and plan their integrity programmes.

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Reader enquiries [www.worldpipelines.com]

WORLD PIPELINES

ON THIS MONTH'S COVER

Volume 22 Number 5 - May 2022

WeldFit offers services and engineered products that make pipelines more productive without compromising ESG objectives. Strategically located in Houston, Texas, WeldFit has more than 50 years of experience providing hot tapping, plugging and methane reduction solutions that are safe, efficient, and reliable. A leading supplier of state-of-the-art pigging systems, WeldFit also produces high-quality fittings, slug catchers, extruded headers, and manifolds.

The leading alternative to voluntary venting or flaring. ReCAP safely recovers valuable natural gas from 8.5 miles of pipeline in central Texas—keeping it out of the atmosphere.

www.worldpipelines.com

Member of ABC Audit Bureau of Circulations 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.

Responsible Pipeline Operations Emissions Recovery System

OFC_WP_May_2022.indd 1 May Cover - Proposed Option C••••• 2022.indd 1

20/04/2022 15:29 4/20/22 8:58 AM

ISSN 1472-7390

stablished in 2020, OMNI Integrity (OMNI), a wholly owned subsidiary company of ICR Integrity, has launched a software platform which uses process automation to drive efficiency and improve data set integration throughout the integrity lifecycle workflow. OMNI’s single source platform streamlines traditional data capture methods by providing a cloud-based solution capable of integrating with the latest advancements in inspection technology, to store all inspection and condition monitoring methods in a centralised location for more informed business decisions.

EDITOR’S COMMENT CONTACT INFORMATION MANAGING EDITOR James Little james.little@palladianpublications.com EDITORIAL ASSISTANT Sara Simper sara.simper@palladianpublications.com SALES DIRECTOR Rod Hardy rod.hardy@palladianpublications.com SALES MANAGER Chris Lethbridge chris.lethbridge@palladianpublications.com DEPUTY SALES MANAGER Will Pownall will.pownall@palladianpublications.co PRODUCTION MANAGER Calli Fabian calli.fabian@palladianpublications.com EVENTS MANAGER Louise Cameron louise.cameron@palladianpublications.com VIDEO CONTENT ASSISTANT Molly Bryant molly.bryant@palladianpublications.com DIGITAL ADMINISTRATOR Leah Jones leah.jones@palladianpublications.com ADMINISTRATION MANAGER Laura White laura.white@palladianpublications.com Palladian Publications Ltd, 15 South Street, Farnham, Surrey, GU9 7QU, UK Tel: +44 (0) 1252 718 999 Website: www.worldpipelines.com Email: enquiries@worldpipelines.com Annual subscription £60 UK including postage/£75 overseas (postage airmail). Special two year discounted rate: £96 UK including postage/£120 overseas (postage airmail). Claims for non receipt of issues must be made within three months of publication of the issue or they will not be honoured without charge. Applicable only to USA & Canada: World Pipelines (ISSN No: 1472-7390, USPS No: 020-988) is published monthly by Palladian Publications Ltd, GBR and distributed in the USA by Asendia USA, 17B S Middlesex Ave, Monroe NJ 08831. Periodicals postage paid New Brunswick, NJ and additional mailing offices. POSTMASTER: send address changes to World Pipelines, 701C Ashland Ave, Folcroft PA 19032

or the past few months I have been working on the Palladian Energy Podcast, planning episodes and talking to guests, along with my co-host Callum O’Reilly. The theme of the first series of the podcast is digitalisation in the oil and gas sector and it’s proving a rich seam to mine. We have covered the growing importance of collaborating on data and digital services, and we’ve shone light on some inherent vulnerabilities in SENIOR EDITOR Elizabeth Corner hydrocarbons infrastructure (both IT and elizabeth.corner@palladianpublications.com OT) and how to address these pressure points with digital solutions. Guests have spoken about industry-critical trends, they have offered insight on implementing a digital strategy and, crucially, on how to embrace change. Upcoming episodes will tackle the shortcomings of digitalisation in the energy sector, mastering remote monitoring and management, the emergence of new cyber threat groups, the establishment of OT/ICS-focused security operation centres, and the important relationship between digitalisation and sustainability. So where are you making digital investments this year? Where will your CIOs spend their budget? Among the top spend categories in a recent study of UK businesses and their IT budgets, were: increasing cybersecurity protections, increasing operational efficiency and transforming existing business processes.1 Further down the list came: meeting compliance requirements, monetising company data and new product development. The top three planned investments in terms of product purchases were: cyber and information security, business intelligence/data analytics, and cloud platforms. Hiring more tech staff is a priority across the board. In this issue of World Pipelines, William McLean, Director of OMNI Integrity, writes about helping the sector utilise data to manage and plan pipeline integrity programmes (p. 20). The article describes the build-out of an integrity management product and demonstrates how the capabilities of software continue to grow, to encompass data capture, integration, analysis, management and storage. There is a strong argument for collaborating with a digital partner here, as the industry moves towards its netzero, safety and compliance goals. Starting on p. 8, Ovarro contributes a piece on using remote telemetry units (RTUs) to optimise performance and reduce failures. Read the article to learn more about real-time control and monitoring systems, and for an interesting case study on the second line of the China-Russia pipeline (where remote equipment must work in temperatures ranging from -40˚C to +70˚C). Ovarro writes that “RTUs already function as ‘mini PCs in the field’ and, going forward, the systems will help harness the power of the Industrial Internet of Things by making older assets smart”. That brings me back to the podcast, because I sense it is making me smarter, with every episode! You can find all episodes of the Palladian Energy Podcast here: https://anchor.fm/pep-podcast1 1.

https://www.raconteur.net/report/strategic-cio-2022/

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WORLD NEWS AGA members ready to implement new valve requirements

FERC approval boosts outlook for Mountain Valley pipeline

American Gas Association (AGA) members stand ready to implement new requirements for automatic and remotely controlled shut-off valves as part of their ongoing commitment to enhancing safety. The US Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (PHMSA) announced a new rule regarding the installation of remotely controlled or automatic shut-off valves, or alternative equivalent technologies, on new and fully replaced onshore natural gas transmission pipelines, carbon dioxide pipelines, and hazardous liquid pipelines. “Safety is our top priority, and we are glad to see that PHMSA listened to industry’s input when finalising the requirements that allow for faster response and help minimise the risk to the communities our members serve. The changes within the final regulation continue to help move the needle on safety, while ensuring AGA’s members are maintaining reliable and affordable natural gas service,” said Christina Sames, AGA’s Senior Vice President, Safety, Operations and Security.

The Federal Energy Regulatory Commission has approved Mountain Valley Pipeline’s request to change water crossing methods in a decision that cleared one obstacle for the longdelayed natural gas pipeline project. Finding that boring under water bodies would cause less environmental damage than the open-cut method, the FERC order allows MVP to amend the pipeline’s 2017 original certificate that had called for the developers to dig a trench along the bottoms of the water bodies to bury a 42 in. diameter pipe. “Mountain Valley’s usage of trenchless waterbody crossings will result in fewer environmental impacts than the crossing method that the commission approved under the original certificate, meaning that today’s order amending Mountain Valley’s certificate will almost certainly represent an improvement over the status quo,” FERC Commissioner, Richard Glick and fellow Democratic Commissioner, Allison Clements wrote in a statement.

Work resumes on Poland-Norway gas pipeline Construction of the Danish part of Baltic Pipe, which will connect Poland to Norwegian gas fields and reduce Poland’s reliance on Russian gas, is resuming following a nine month hiatus. Construction was suspended in May 2021 due to an issue with its environmental permit, but barely a week after Russia’s invasion of Ukraine, the Danish environmental authority granted a permit to continue works. “We expected it to be approved soon, but of course, the war has made the issue more urgent,” said Trine Villumsen Berling, a researcher at the Danish Institute for International Studies. Energinet expects the pipeline to be partially operational

from 1 October 2022 and running at full capacity of up to 10 billion m3 from 1 January 2023. The suspension has already delayed the start date by three months. “It’s also about having the gas in the Danish system, but above all to help the gas system of our good neighbours and Polish friends,” Søren Juul Larsen, Project Manager at the Danish operator Energinet, told AFP news agency. “We really have good cooperation with all the contractors to speed up, do everything we can to keep to the schedule.” The gas pipeline should make it possible to guarantee half of the consumption of Poland, which announced three years ago the end in 2022 of its vast contract with the Russian giant Gazprom.

Sasol opts for LNG over pipeline gas from Mozambique offshore South Africa’s chemical and synthetic fuels giant Sasol Ltd. is ditching plans to import natural gas via the proposed African Renaissance Pipeline (ARP) from the Rovuma Basin, opting for tanker deliveries of LNG to best tap into Mozambique’s offshore gas reserves. Sasol doesn’t want to get stuck with the infrastructure as the world shifts away from fossil fuels, Sasol’s CEO, Fleetwood Grobler told Bloomberg in an interview at Sasol’s Johannesburg headquarters. “Gas in the long term is also a fossil fuel and we said we want to get to net-zero,” Grobler said. “It’s a no-regret move because you know that will deplete and then when you don’t need the gas you don’t develop more gas. You need to bridge 10 to 15 years and then you need to go out.” Sasol, the world’s largest producer of synthetic fuel from coal, is South Africa’s second-highest emitter of greenhouse

gases (GHG), after state-owned power utility Eskom; although in terms of single-plant GHG production, Sasol’s Secunda synfuels plant ranks first globally, according to carbon watchdogs. In 2020, South Africa still relied on coal to satisfy 74% of its energy needs, more than twice the average of 31% among the G20 group of industrialised and developing nations, according to Climate Transparency, an organisation that tracks the energy transition in the G20. Sasol has now targeted a 30% reduction in emissions by 2030, largely through replacing a portion of the coal it uses to make synthetic fuel and chemicals, with natural gas. Sasol’s nixing of the proposed ARP leaves it with two options for sourcing additional gas: LNG imports and the development of South Africa’s own gas reserves. The company reflects a rapidly changing energy landscape that ultimately will see gas demand follow an exit from coal.

MAY 2022 / World Pipelines

CONTRACT NEWS EVENTS DIARY 2 - 5 May 2022

Offshore Technology Conference Houston, USA https://2022.otcnet.org/

2 - 6 May 2022 PLCAC

Maui, USA https://pipeline.ca/

10 - 12 May 2022

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

23 - 27 May 2022

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

7 - 9 June 2022

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

5 - 8 September 2022 Gastech

Milan, Italy https://www.gastechevent.com/

19 - 23 September 2022 IPLOCA

Prague, Czech Republic https://www.iploca.com/events/annualconvention/2022-convention/

24 - 30 October 2022 bauma

Munich, Germany https://bauma.de/en/

31 October - 3 November 2022 ADIPEC

Abu Dhabi, UAE https://www.adipec.com/

World Pipelines / MAY 2022

Wood and Gassco team up to secure European energy supply Wood, the global consulting and engineering company, has secured a three year contract with Norwegian state-owned operator Gassco to support the safe and secure transportation of gas from the Norwegian Continental Shelf to terminals across the UK and Europe. The contract will see Wood work closely with Gassco to renovate the gas receiving facilities through the provision of engineering, procurement and construction management services across the Easington (UK), Zeebrügge (Belgium), Dunkerque (France), Dornum (Germany), and Emden (Germany) gas receiving terminals. Combined, these terminals receive around 100 billion m3 of natural gas from the Norwegian Continental Shelf annually, meaning they are critical to ensure safe, secure and efficient energy supply to Europe in the face of increasing demand.

TC Energy and Coastal GasLink celebrate historic equity agreement with Indigenous partners Coastal GasLink is proud to announce that TC Energy has signed option agreements to sell a 10% equity interest in Coastal GasLink. The opportunity was made available to all 20 Indigenous communities holding existing agreements with Coastal GasLink and is an important step on the path to true partnership through equity ownership in the project. “The finalisation of the option agreements represents a historic milestone in our desire to participate as equity owners in Coastal GasLink. For many, this marks the first time that our Nations have been included as owners in a major natural resource project that is crossing our territories,” states Chief Corrina Leween of the Cheslatta Carrier Nation, and member of the CGL First Nations Limited Partnership Management Committee. Coastal GasLink’s Indigenous partners have been instrumental in the construction of the company. Since construction began, Coastal GasLink have had hundreds of key roles held by local Indigenous people, and over CAN$1 billion in project contracts have been awarded to local Indigenous businesses. In 2021 alone, Coastal GasLink invested over CAN$550 000 in local Indigenous communities to support community initiatives, skills training and education.

Craig Shanaghey, Wood’s President of Operations across Europe, Middle East and Africa, comments: “We are delighted to grow our relationship with Gassco and expand our operational footprint in Europe with this award which further propels our geographical and portfolio diversification. “With complete alignment to Gassco’s vision of securing energy supply, we will renovate and increase the efficiency of their onshore terminals, helping to ensure safe and efficient gas receipt across the UK and Europe and, in turn, providing critical energy security as we transition to a net-zero future.” Lars Fredrik Bakke, Wood’s Vice President of Operations in Norway, adds: “We will bring our extensive experience in operating, maintaining, and upgrading critical energy infrastructure to ensure Gassco’s operations remain resilient.

THE MIDSTREAM UPDATE •

Volvo CE offers tailored support for customers to reach carbon reduction goals

•

TC Energy launches binding open season for the Marketlink Pipeline System

•

Gas Industry Awards 2022 shortlist announced

•

CenterPoint Energy to further modernise its natural gas distribution system

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Matthew Hawkridge, Chief Technology Officer, Ovarro, UK, explains how remote telemetry units (RTUs) can be used to optimise performance and reduce failures in oil and gas pipelines.

he US Energy Information Administration (EIA) predicts that global use of petroleum and other liquids will return to pre-pandemic, or 2019, levels by 2023 and remain the world’s largest energy source in 2050. Pipelines are among the most significant and safest methods for transporting oil and gas, but they are not fail-safe and accidents occur that lead to significant consequences. Pipelines are essential to upstream, midstream and downstream operations in the oil and gas industry. While new drilling techniques and transportation systems are safer than ever before, failures do occur – including corrosion, cracks and leaks – and must be resolved, quickly and effectively. Consequences of pipeline damage not only include downtime, interruptions and decreased operational efficiency but also “ignitions, injuries [and] fatalities” according to a report by the Department of Civil Engineering at University of Calgary, Canada. The report found failure rates in pipelines to be consistent between 2010 and 2015, with hazardous liquid pipelines having the highest failure rates each year. Incidents directly or indirectly impact wildlife and the natural environment, and these issues also pose a threat to workers and the population. The growth in demand for fuels predicted by the EIA increases the importance of identifying, analysing and evaluating the risks associated with pipelines. It also places the onus on oil and gas companies to constantly monitor the environmental impact of their operations and, above all else, ensure the safety of staff and the general public. Relevant key performance indicators (KPIs) should be implemented, where possible. However, oil and gas companies have run into obstacles when implementing the necessary hardware and software to guarantee safety and performance in their networks. One of the main reasons software implementations have failed is because the scale of the project was misjudged from the outset. Another mistake has been that specific,

measurable, achievable, relevant and time-bound KPIs – otherwise known as SMART goals – weren’t properly set.

Remote locations Pipelines are one of the safest and most effective ways to transport oil and gas. There were a total of 649 operational oil pipelines and 1732 gas pipelines in the world as of December 2020, with a further 33 oil pipelines under construction. With thousands of miles to cover across some of the world’s harshest environments, monitoring performance and condition can be challenging, to say the least. To solve these challenges, RTUs can receive commands from the supervisory system and transmit them to the end devices as well as retaining an ability to act autonomously. RTUs can also do this over large and remote pipeline networks, handling the data acquisition portion of SCADA, and providing early warning of impending issues such as a rise in temperature of a holding tank or decreased pressure in a pipe. This helps avoid asset failure and potential environmental incidents. It should also be considered that communications may be slow, intermittent or unreliable in remote locations. The RTU is the device at the edge, sitting between the control room and the field instruments, which provides a low latency response to changing site conditions as well as performing data filtering. Crucially, RTUs can collect, report and act on critical data even in extreme and remote conditions. Within the downstream sector, for instance, refineries operate 24/7. They require RTU systems that are robust, secure, reliable and flexible enough to be able to manage and monitor extensive pipeline networks. RTUs are integrated with sensors across these sites and provide data to the SCADA system. The RTU ensures that only key, critical information is passed through the narrow communications links. They can address specific issues including monitoring of flow, pressure, temperature, natural gas flow measurement, optimisation and secondary recovery, storage facilities and pressure monitoring. At the same time, data throughput is minimised while information throughput is maximised.

Figure 1. For PetroChina Pipeline Company Limited, Ovarro provided 22 TBox-MS Modular RTUs designed for pipeline monitoring and control in extreme conditions.

World Pipelines / MAY 2022

However, several practical considerations must be accounted for when choosing an RTU system to deliver these benefits.

The right choice The key features required in an RTU are resilience to the site environment, an ability to operate with minimal drain on local power resources, and the processing power to run any local control algorithms autonomously. It is also beneficial for an RTU to have extensive diagnostic capability and a low mean time to repair (MTTR) as this reduces the time required for technicians to spend onsite, improving efficiency and personnel safety. This ability to provide accurate, real-time data enables management teams to make better, more informed decisions. In addition, because RTUs do everything locally, it means if communications break down, they continue to run, maintaining a historical log, and reporting back later. In remote locations, communications will fail regularly, although RTUs can manage this. For instance, the data that the RTU collects can be used to support maintenance decisions, and to verify that environmental obligations are being adhered to. As well as being used for operations, RTUs can support maintenance teams, health and safety initiatives and environmental management. RTUs offer a solution to many of the common issues facing pipeline operators, whether structural failures or pressure monitoring, asset optimisation or logging critical data in remote locations. By choosing RTUs carefully, operators can improve efficiency, environmental protection and personnel safety.

Cold environment The second line of the China-Russia crude oil pipeline began commercial operation in January 2018 and, at the time, doubled China’s annual imports of Russian crude oil from 15 million to 30 million t. The company behind the project, PetroChina Pipeline Company Ltd, set a new record by constructing over 800 km of pipeline in 180 days, in a high latitude, extremely cold environment. The China-Russia pipeline begins in Mohe, China’s most northern city. Located almost 53˚ above the equator and 850 km inland, this remote location exposes the pipeline to extreme environmental conditions. Part of the specification for the pipeline’s control system was the need to operate in temperatures between -52.3 and +39.8˚C, the record temperatures for winter and summer in the region. Control and monitoring systems were needed that could handle these extreme conditions. That’s why PetroChina Pipeline Company Ltd turned to the Ovarro team, who – in collaboration with ZKCiT – provided 22 TBox-MS Modular RTUs for pipeline monitoring and control. The RTUs perform all data acquisition, control and communication functions, and also periodically report the status of all communication equipment to the SCADA control room. There is no heat tracing in the valve chamber and the entire control system relies solely on ambient heating from the process and other equipment. TBox RTUs are designed

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to withstand temperatures across the range from -40 to +70˚C but are pushed further than these limits during type testing. After the pipeline’s first month of operation, ZKCiT was congratulated on the system’s performance. During January 2018, shortly after oil transportation had begun, local temperatures of -43˚C had been recorded. Despite exceeding their stated operational limits, the TBox RTUs continued to operate successfully. For the PetroChina Pipeline Company Ltd, RTUs offered better control and management capabilities, reliability, situational awareness and reduced maintenance costs – even in such remote locations and extreme conditions.

The future RTUs have come a long way in the last few years. As pipeline operators face continued pressure to improve efficiency, maintain safety and deliver shareholder value, their use is set to increase. Continued innovations will help drive this change and it is already possible to deploy RTUs on most equipment, irrespective of size or age. Inbuilt redundancy and resilience are also helping to avoid system failures. At the same time, improvements in processing power and throughput are helping RTUs keep up with the increasing demand for data. RTUs already function as ‘mini PCs in the field’ and, going forward, the systems will help harness the power of the Industrial Internet of Things (IIoT) by making older

assets smart. Edge computing will come into the mix at some stage, although increased processing power of RTUs means they are already part of a distributed network, processed at the edge of the network. The benefit of this is low latency, by computing the data where it is generated, which is essential for real-time monitoring. This edge capability also provides linear scalability. As mentioned, scalability has been an obstacle for oil and gas operators in the past, so will be essential to support the increased deployment of communication devices that reduce pressure on the central network infrastructure. With geographically spread assets and multiple processes that all generate massive amounts of data, key to ensuring these improvements help business performance is being able to capture and interpret it in real-time. The latest, ruggedised RTU technology focuses specifically on that, helping pipeline operators meet their investor and customer commitments, even as the global use of petroleum and other liquids returns to prepandemic levels by 2023.

References 1. 2. 3. 4. 5.

https://www.eia.gov/todayinenergy/detail.php?id=49876 https://www.witpress.com/Secure/ejournals/papers/SSE070201f.pdf https://www.statista.com/statistics/1131423/oil-pipelines-by-statusworldwide/ https://www.ovarro.com/en/europe/solutions/telemetry/scope-scadasystem-from-ovarro-/ https://www.ovarro.com/en/europe/solutions/monitoring--control-devices/ rtus/tbox/

IPLOCA - advocating the protection of biodiversity and ecosystems during pipeline construction Supporting HSE & CSR Monitoring and Awards

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International Pipe Line & Offshore Contractors Association Geneva - Switzerland

David Stordeur, Senior Product Manager, T.D. Williamson, Belgium, discusses hot tapping large transmission pipelines.

s the demands of an energy-thirsty planet have grown, pipelines have, too. They’ve gotten larger in diameter, and they carry more product under higher pressure. In general, modifying these systems can be done in much the same way as making changes to networks comprising smaller pipelines. There is one time when equipment capability definitely matters, though, and that’s during hot tapping. Hot tapping and plugging (HT&P) enables repairs, maintenance and modifications to be done under normal pipeline operating conditions, without interrupting service or emptying a large section of pipe. During hot tapping, the technician cuts into the live pipeline with a tapping machine that also catches the coupon, the curved piece of pipe removed to allow access into the line. Regardless of how large or small the pipe is, the process is essentially the same – but the equipment isn’t. Not just any tapping machine can cut into today’s more common 30 - 60 in. pipe. For one thing, the machine’s travel distance has to be long enough for the cutter to pass through what could be hundreds of inches of valves, fittings and spools before even reaching the pipe’s surface. The machine also must be able to withstand pressure without losing torque and to ensure the cut is centred in the pipeline.

To meet those criteria, T.D. Williamson (TDW) developed the largest and most advanced tapping machine in its HT&P portfolio: the TM 2460 3XL (Figure 1). Introduced in December 2021, it was designed specifically for 30 - 60 in., high pressure gas and liquid transmission pipelines. Ed Guidry, Senior Director, Intervention and Isolation, sees the new tapping machine as part of a natural progression in the industry. After all, he says, the trend of using larger pipe at higher pressure was bound to affect hot tapping activities.

“There are many intervention and isolation configurations available to resolve operators’ modification challenges,” Guidry said. “Intervention and isolation solutions and tie-in connections have all evolved considerably over the past 50 years, mainly responding to market requirements and challenges. From the original TM 2400 that TDW introduced in 1975, we’ve steadily progressed the equipment’s capabilities. The TM 2460 3XL represents the next phase in the evolution of tapping machines.”

Common but never routine Performing a hot tap begins by attaching a split tee fitting to the pipeline to facilitate the connection of new pipework. A permanent or temporary valve, which allows entry into the pipe, is then installed onto the split tee, and the tapping machine, which has been pressure tested ahead of time, is attached to the valve. The tapping machine’s boring bar extends the cutter through the valve and fitting to the pipe’s surface, where it makes the tap and removes the coupon (Figure 3). Once the tap has been made and the boring bar fully retracted, the valve can be closed, and the tapping equipment removed. Though hot tapping is common, it should never be considered routine. There’s too much at stake from a personnel, asset and environmental perspective. To document important precautions, the American Petroleum Institute (API) published ‘RP 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries’. ASME PCC-2 Article 216 provides similar information. The API publication offers far-ranging guidance. One of the most important things it says is this: the hot tap machine must be “special equipment which will provide proven effective protection for employees.” Choosing a tapping machine to meet that criteria means considering at least four key factors: design condition, applications and capabilities, functionalities and accessories (Figure 2).

Design condition The tapping machine and its accessories will be exposed to, and must be compatible with, the pipeline product. They must also be capable of operating safely under the pipeline’s maximum working pressure and temperature.

Applications and capabilities The primary function of the tapping machine is to travel to the surface of the pipe and drill an appropriately sized hole. The drill or cutter must be designed to penetrate the wall material of the pipe or vessel being tapped.

Functionalities

Figure 1. The TM 2460 3XL was designed for hot tapping large diameter, high pressure gas and liquid transmission lines.

World Pipelines / MAY 2022

Tapping machines can be operated manually, electrically, hydraulically or with air. They may be equipped with variable or fixed feed, have pressure balance capabilities and should be able to set various configurations of the completion plug, which is put in place to allow recovery of a temporary valve, such as the SANDWICH® valve in Figure 2.

The S-500 is manufactured in diameters ranging from 2” to 52” (DN50 to DN1300) and pressure series 150 through 2500. Based on the industry’s desire for robust and cost-effective solutions, Stark improved upon the standard design to bring operation to a new level. Features to avoid hammering and strengthen operator control were incorporated into the otherwise proven design.

Accessories Accessories include the twist drill, hole saw, cutter and pilot drill. They are housed in a tapping machine adapter compatible with pipeline product and pressure. Those factors contribute to both operational effectiveness and safety, and they’re built into the TDW tapping machine product line. But with the TM 2460 3XL, TDW also eliminated the risk that comes from working at height. Because the

machine is operated remotely from a portable console, the technician no longer has to climb to a platform in all kinds of weather to reach the hydraulic controls, gear handle and measuring rod. Instead, he performs the hot tap operation while remaining firmly on the ground. As for the control system itself, among other functions it enables the technician to activate a hydraulic actuation mechanism to engage and disengage the completion plug holder and to catch the coupon, preventing it from falling into the pipe (Figure 4). Features like this rank the TM 2460 series among the safest tapping machines, according to Technician Supervisor Hugo Franceschini, who’s operated TDW tapping machines since 2008. “The control system allows continuous monitoring, precise control and real-time adjustment of operational parameters such as boring bar travel, RPM and tapping machine hydraulic system, all while the technician stays in a safe zone” Franceschini said.

Going the distance

Figure 2. A typical tapping machine stack-up.

World Pipelines / MAY 2022

Valves and fittings are essential to hot tapping, and the larger the pipe, the larger those valves and fittings need to be – meaning they add to the length the cutter has to travel to reach the pipeline. This makes the tapping machine’s ability to ‘go the distance’ not just an advantage, but also a necessity. The TM 2460 3XL can travel farther than any other TDW tapping machine – up to 180 in. That’s 30 in. farther than the TM 2460 2XL, 72 in. farther than the TM 2400 and equal to the longest travel length on the market. What happens when using a permanent valve could require going beyond the tapping machine’s travel ability? There are safe and effective alternatives to permanent valves that help reduce cutter travel distance. For example, when a permanent valve is not required, the hot tap can be made by using a 3-WAY™ tee and hot tapping through a temporary SANDWICH valve. SANDWICH valves are optimised to reduce the travel length and to allow the use of a completion plug. This means the valve can be removed, and a blind flange installed. It’s impossible to talk about large taps and long travel without mentioning the importance of centring devices and coupon reinforcement. Ensuring the cut is centred is critical and more difficult to achieve with larger pipelines. If the pilot drill doesn’t cut symmetrically, it can create vibration that damages the cutter teeth, affecting the quality of the cut and possibly jeopardising the operation. With its larger boring bar, the 2400 series tapping machines provide great rigidity to transfer the torque and keep the tap centred. However, there is nothing better than a centring device and coupon reinforcement to ensure the cut is centred. “As we made longer tapping machines, the diameter of the bar was increased and that is one reason why we moved to pressure balance,” says Laurent Fabry, Senior Director, Sales and Operations, TDW Eastern Hemisphere. “But ultimately, it is not possible to make a machine that can go these long distances without adding flexibility to the system. That’s the reason we must use a centring device.” (Figure 5).

The importance of balance The boring bar controls the movement of the cutting tool, but that’s not its only job. It also transfers the necessary torque to make the tap. That requires the boring bar to act against pipeline pressure equalling tons and tons of force. For example, the boring bar of a non-pressure balanced TM 2400 tapping machine operated at 69 bar (1000 psi) will need to resist a force of 150 kN, which is roughly equivalent to supporting 15 t. Increase the pressure to 102 bar (1480 psi), and resistance goes to 22 t; at 151 bar (2200 psi), the figure is closer to 33 t. Clearly, making the tap requires overcoming a significant amount of stress and friction. With the TM 2460 3XL, however, those issues aren’t quite so daunting. The machine was developed for high-pressure environments up to 102 bar, or 1480 psi. Its pressure balance mechanism equalises pressure across the boring bar. As a result, less force goes into fighting against pipeline pressure so more can go into cutting the pipe. In fact, the boring bar transfers only 10 - 12 kN, removing friction and replacing it with power. This also makes the operation smoother for the hot tap technician and reduces stress on key components, extending the machine’s life. Incidentally, TDW has used pressure balanced tapping machines for years in high pressure, large diameter and subsea applications where seawater puts force on the pipe and equipment. Without pressure balance, tapping these pipelines would be extremely challenging. Pressure balance also prevents seawater from entering the tapping machine and damaging parts like gears and screws.

Figure 3. Hot tapping machine adapter with cutter and pilot, recovering the coupon after the tap.

Machines for tomorrow We’ve yet to make a machine that taps into the future, and there’s no crystal ball to tell us exactly what tomorrow will look like. What we do know is that as the world transitions to new fuels, including hydrogen and bio-methane, it is changing the way the industry views its pipeline assets. For example, hydrogen will require thicker-walled pipe to minimise the effect of hydrogen embrittlement. Hydrogen pipelines will also need to be larger to accommodate the higher volumes required to move energy at the same rate as natural gas. That means tapping machines may have to change to be effective. And as for meeting the world’s carbon-neutral objective, that will require operators to reduce product venting. Fortunately, that’s an area where HT&P already has a proven track record, allowing pipeline modifications to be completed with the least amount of product released. While it’s not completely possible to anticipate what the years ahead will bring, it’s safe to say modifications will continue to be a part of the pipeline lifecycle – and TDW will continue to develop technology that facilitates those changes. As Fabry says, it takes a spirit of innovation to keep up with a changing world, and that’s something TDW has been passionate about for 100 years and counting. “We’re continually working to improve our products, services and procedures to reduce risk to pipelines, personnel and the environment,” Fabry said. “The TM2460 3XL is latest example of our commitment.”

Figure 4. Cutter and pilot with positive retention latch, hydraulically operated by the TM 2460 3XL.

Figure 5. Coupon with reinforcement (also called a stiffener) and centring device.

MAY 2022 / World Pipelines

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William McLean, Director, OMNI Integrity, UK, outlines how OMNI is helping businesses utilise data effectively to manage and plan their integrity programmes.

Collaboration project A project funded by Innovate UK saw a joint collaboration between OMNI Integrity, STC Insiso and Ionix Advanced Technologies where the Ionix HotSense™ ultrasonic corrosion monitoring sensor was used to achieve a proof of concept for OMNI’s Internet of Things (IoT) data capture product. The project was undertaken to create a centralised hub for connecting advanced inspection technology into an integrity management platform through an IoT application, in order to improve the efficiency of collating, interpreting and managing the resulting activities. This achieved a product capable of connecting with and receiving data from any technology or device, including wireless corrosion monitoring sensors, mobile tablet reporting, process data systems, drones, robotics and ROVs. By integrating this all-encompassing data capture product with OMNI’s already existing full lifecycle suite of integrity management modules, the resulting solution means OMNI’s software offers a single source data capture solution, able to conduct real-time analysis and seamless integration of results back into the integrity lifecycle. The development has made OMNI a complete end-to-end integrity management technology that enables organisations to consistently record and leverage empirical data to make more informed business decisions.

Key project challenges There were some key challenges behind the design and build of the product – to develop an application that 1) was agnostic and able to be integrated with various technology configurations, 2) could interpret results and identify anomalous data or defects real-time, and 3) notify the users and allow for assessing defects and generating remedial action.

To create a software product that is not restricted and can be integrated with even the latest advancements in technology, it was essential that the technology stack was designed in such a way that enabled a more ‘generic’ interface and could be configured to other technologies with minimal complexity or need for drastic modification. The project allowed for extensive trial and error with various technology stack configurations being tested, until a suitable design and prototype was achieved. Addressing the next challenge, the software capability was extended to provide real-time identification of anomalous data. This was accomplished through the development of an Integrity Operating Window (IOW) feature, to provide a baseline in which newly acquired data could be benchmarked against and defects easily identified. The final challenge was to provide the users of the software with a mechanism for being notified in the system and being able to process the notification through to anomaly assessment and repair. This was achieved by the integration of the data capture and notification function back into OMNI’s already established suite of integrity modules. This includes a suite of five integrity modules – risk based assessment, workpack, inspection, anomaly and repair modules in which the new IoT data capture product now forms an integral part and provides a complete end-to-end integrity management capability. This concluded the project and enabled OMNI’s new IoT application the ability to autonomously achieve: )) Live corrosion sensor data integration. )) Automatic data analysis and defect detection, through

integrity operating windows (IOWs). )) Workpacks, inspections and anomalies to be raised and

assessed.

Figure 1. OMNI’s KPI Dashboard, showing automated reporting updates of key performance indicators.

World Pipelines / MAY 2022

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)) Repair work orders to be raised and planned, with

live API connection to cloud-based maintenance management software. )) Full tracking and visualisation through an automated

key performance index (KPI) dashboard.

)) Improving enterprise data to support business

decisions, reducing integrity costs, energy and CO2 from integrity related activities. )) Enhancing operational safety and reducing Scope 3

emissions by reducing asset visits through real-time sensor connections.

)) All activities to be communicated through the built-in

communications hub. Organisations today face increasing challenges in the changing geopolitical and industry dynamics, which can impact the overall success of the business. Constraints such as resource and experience shortages make it ever more difficult for organisations to achieve the efficiency levels required to maintain profitability, whilst maintaining optimum safety and environmental levels. Within all industries, visibility is key and that is why OMNI has been developed in such a way that it can be applied to various energy sectors including renewables, nuclear and traditional oil and gas, providing organisations with the latest empirical data in which to take highly informed business decisions. As a trusted provider of asset integrity software, OMNI is assisting with improving the remote inspection process, helping operators extend asset life in a more efficient yet cost effective way, whilst allowing organisations to rapidly deploy a full-lifecycle digital solution and implement best practice. Additional benefits of OMNI include: )) Replacing fragmented operational process flow with single source data capture and integrated full-lifecycle processing.

World Pipelines / MAY 2022

The OMNI team are actively working with clients to benchmark their core integrity management systems and integrate those with the OMNI framework with a view to digitising their full asset integrity lifecycle and optimise performance. By working closely together, OMNI and its clients are able to become digital partners planning their technology roadmap for the future. In a world where digitalisation is key, this further allows clients – namely operators, large contractors and service companies – to keep ahead of the curve. The safe and efficient manner in which assets are managed can only be enhanced through continuous development in digital technology. Implementing OMNI allows businesses to reduce overall integrity cycle time by up to 40%, avoid spreadsheet tracking and management, remove duplication in assessments, enhance enterprise collaboration and operational efficiency, and improve visibility and control. Within the wider ICR Group, OMNI is working with the other business units to perform gap analysis and identify any opportunities for collaboration, including actively pursuing tying in digital twin technology, for example with Sky-Futures™, the drone inspection arm of the business.

Bruce A. Pellegrino and Michael J. Nugent, Sensor Networks, Inc., USA, focus on several specific damage mechanisms and NDT methodologies to detect, size and monitor damage, both online and during shutdowns, to assess and prioritise the conditions of plant equipment.

echanical integrity is the focal point of a multidisciplined operational philosophy in which knowledge of equipment damage mechanisms and judicious application of non-destructive testing (NDT) can allow safe and reliable plant operation under normal and aberrant conditions. When incorporated into an evergreen risk based inspection (RBI) programme, these tools can provide valuable material data and condition assessment information that allows operators to make informed decisions about whether to run/replace or approve continued operation of pressure equipment and piping. Sensor Networks, Inc. (SNI) specialises in NDT technologies, specifically ultrasound (UT) and remote visual inspection (RVI) mechanisms. Both of these inspection disciplines are able to leverage significantly larger investments being made in the

healthcare and consumer market segments. Over the past few years, advances in micro-electronics and optics, imaging, data and digital-signal processing (DSP) and software have all been adapted to a next generation of field-deployable NDT equipment capable of enhanced inspection productivity at refineries, chemical plants, pipelines and offshore production sites. Detecting, sizing and monitoring for metal loss due to corrosion and erosion continues to be an important maintenance and operational challenge at large industrial facilities within the oil and gas community. In the US, the Department of Labour, Occupational Safety and Health Administrations’ (OSHA) Process Safety Management (PSM) Standard 29 CFR 1910.1191 (adopted into law in the 1990s), requires that hazardous materials processing be performed

in accordance with public and worker safety as a primary objective. Since then, organisations such as the American Petroleum Institute (API) have provided specific guidelines and recommended practices for asset owners to better manage risks associated with equipment failure due to metal loss, material degradation, etc. and provide input for RBI and fitness for service (FFS) methodologies as found in API 580, 581, and 579.2, 3, 4 This article presents six specific examples of how asset owners and NDT service suppliers are deploying newer NDT techniques for the improved detection, sizing or monitoring of metal loss. Improvements are seen via better image clarity, yielding increased productivity and probability of detection (POD) with these tests. Furthermore, the costs and risks associated with deploying inspection personnel into difficult or harsh field environments can be better optimised.

1. Corrosion under insulation (CUI) sizing with digital radiography (DR) CUI is corrosion of piping, pressure vessels and structural components resulting from water trapped under insulation or fireproofing. The typical materials affected by CUI are carbon steel, low-alloy steels, 300 Series SS, and duplex stainless steels.5 It affects externally-insulated vessels and those that are in intermittent service or operate between:

Figure 1. Illustration of digital X-ray functionality.

Figure 2. Field deployment of digital X-ray (DXR) imaging system for insulated pipe inspection.

World Pipelines / MAY 2022

)) 10˚F (-12˚C) and 350˚F (175˚C) for carbon and low-alloy

steels. )) 140˚F (60˚C) and 400˚F (205˚C) for austenitic stainless

steels and duplex stainless steels. Corrosion rates rise with increasing metal temperatures up to the point where the water evaporates quickly. For insulated components, corrosion becomes more severe at metal temperatures between the boiling point 212˚F (100˚C) and 350˚F (121˚C), where water is less likely to vaporise and insulation stays wet longer. Cyclic thermal operation or intermittent service can increase corrosion. Equipment that operates below the water dew point tends to condense water on the metal surface, providing a wet environment and increasing the risk of corrosion. Plants located in areas with high annual rainfall or warmer marine locations are more prone to CUI than plants located in cooler, drier, midcontinent locations. Environments that provide airborne contaminants such as chlorides (marine environments, cooling tower drift) or sulpher dioxide (SO2 stack emissions) can accelerate corrosion. An inspection plan for CUI should be a structured and systematic approach starting with prediction/analysis, then looking at the more invasive procedures. The inspection plan should consider operating temperature, type and age/condition of coating, and type and age/condition of insulation material. Although external insulation may appear to be in good condition, CUI damage may still be occurring. CUI inspection may require removal of some or all insulation. If external coverings are in good condition and there is no reason to suspect damage behind them, it may not be necessary to remove them for inspection of the vessel. Portable, digital radiography has had a profound impact on the work of inspection companies in a variety of field applications. This technique was discovered to be an effective solution to the challenge of CUI detection in harsh climates and on aged assets. Portable DR used with an electro-mechanical crawler provides the inspector with the ability to perform 100% inspection for extensive sections of horizontal pipeline, detecting and sizing both inner diameter (ID) and outer diameter (OD) metal loss. This type of inspection is enabled by formless, flat panel detectors. Light is converted and emitted by the absorption of X-ray photons by the cesium iodide scintillator. A lownoise photodiode array, where each photodiode represents a pixel, absorbs the light and subsequently translates it into an electronic charge. Finally, low-noise digital electronics read out the charge at each pixel. SNI has found the advantages of this technology are several. DR has been field proven to significantly reduce inspection times by >95% by shortening radiation exposure time, eliminating film chemical processing and minimising the safety-affected work area. DR also reduces overall image noise levels, yielding improved image quality, while further image enhancement highlights ID and OD edges better so that very accurate wall thickness measurements can be with the software tools. These combined factors improve

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the detective quantum efficiency (DQE) metric, a widelyaccepted metric for full-field digital detectors.

2. Compressor blade pitting sizing with phase measurement and RVI

Figure 3. Phased measurement analysis of the isolated pit.

Compressor blades may suffer damage and pitting on the surface of the blades from corrosion. When left unmonitored, compressor blade pitting can lead to lower efficiency, cracking, blade failure and additional compressor damage.6 3D phase measurement provides accurate three dimensional surface scans allowing measurement of all aspects of surface indications. Inspectors can view and measure a defect using a single probe tip, eliminating the extra steps required to back out, change the tip and then relocate the defect. 3D phase measurement provides accurate measurement ‘on-demand’, while simplifying the inspection process. Utilising an RVI such as the Hi-Def 4.3 Remote Visual Inspection Tool from SNI to perform visual inspection and detection, flaws such as leading-edge pitting as small as 0.004 in. (0.1 mm) diameter and 0.001 in. (0.025 mm) in depth can be discovered and addressed in a timely fashion.

3. Pipe wall pitting characterisation with phased-array UT (PAUT with dual transducer)

Figure 4. PAUT system electronically profiles the defect, allowing for faster inspections, increased area coverage and improved pit sizing.

Pitting corrosion is a form of highly localised metal loss that can be elusive for detection and detailed characterisation. Pitting can occur on piping, vessels, tank bottoms, sometimes close to the side wall, in stagnant zones, or under deposits. These areas have traditionally been difficult to inspect and size with any accuracy with conventional UT transducers, due to limited inspection area. Phased-array dual transducer ultrasound technology was recently developed in response to these challenges. A system such as the General Purpose Linear Array from SNI has the ability to transmit a signal that can penetrate the piping wall or tank bottom, reflect, and be picked up by multiple receiver elements. The v-path created by the phased-array dual transducer makes it possible to identify the size and dimensions of the pit much more precisely than conventional transducers.

4. Real-time monitoring of wall thickness with permanently-installed monitoring sensors (PIMS)

Figure 5. Ultra-High-Temp microPIMS attached with a band clamp.

World Pipelines / MAY 2022

It is common in the oil production, refining, and transportation industries to have equipment in difficult and inaccessible locations such as unmanned, offshore platform installations or crude unit overhead lines. These assets may require frequent or periodic scheduled wall thickness measuring: either for inspection planning or regulatory compliance in an effort to assess corrosion. High corrosion/ erosion rates can be experienced at places in the process where the flow increases dramatically or process conditions change from established parameters. The integrity of these assets is critical since a failure could lead to catastrophic events and loss of production. For these unmanned and/ or remote locations, a system configuration allowing for

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contain functionality that automatically compensates for the temperature difference to within +/- 2˚F (1˚C) accuracy. Use of permanently installed sensors facilitates better planning and forecasting around maintenance. Shutdowns can be avoided, or planned alongside other required maintenance, since consistent, traceable data is available for analysis. Thus, permanently-installed sensors prevent catastrophic failures enabling reduced downtime. Downloading and analysing the data can be performed manually or via remote monitoring with wireless technology and informed decisions can be made on each specific location. The technology allows for precise corrosion rates to be determined, highlighting exactly when and where problems exist.

5. Electromagnetic inspection of heat exchanger tubing for damage and wall loss

Figure 6. Ultra-High-Temp microPIMS attached with a magnetic clamp.

real-time, automated readings and transmission of such data on remaining pipeline wall thickness has numerous advantages. One such permanently installed monitoring system is microPIMS® Intrinsically Safe from SNI, a system that can measure wall thickness continuously by using permanentlyinstalled UT transducers, is rated intrinsically safe and has been successfully field deployed for over six years. Ultrasonic wall thickness measurement is direct, absolute and well-proven. The area-array transducer system can be used in temperatures up to 248˚F (120˚C), above which the functionality of the transducers will be compromised. Further, with additional complexities like high-temperature service, the value of this technology which can handle such environments is even greater. A high-temperature PIMS system can be used for multiple single-point measurement up to 932˚F (500˚C) for real-time wall thickness monitoring. Performing ultrasonic tests in high temperature environments has the additional challenge of accurate calibration. Calibration changes as the material’s temperature increases due to lowering of the acoustic velocity. Instruments that have been calibrated under normal temperatures will generate different measurements when being used to test the same material at a higher temperature. Newer PIMS

World Pipelines / MAY 2022

Electromagnetic methods, namely eddy current, have been developed for the nuclear steam generator industry into a next-generation technique to perform NDT on installed heat exchanger tubing from the tube ID. Eddy current technology (ECT) safeguards against failure during service by detecting small discontinuities. This next generation technology has been applied in both ferromagnetic and non-ferromagnetic materials efficiently and precisely. Eddy current signals can characterise OD or ID forms of corrosion via an alternating frequency-energised probe inserted through the length of the tube. Impedance depends upon numerous factors such as conductivity, metallurgy, mechanical work, dimensions, and location. As signals are received, they are processed and displayed for evaluation. The results are compared to signals obtained during the calibration process, in which the calibration tube used is of the same material as the tube being inspected. Prior to the development of remote field eddy current testing (RFT) the only existing methodology for ferromagnetic material was ultrasonic – Internal Rotary Inspection System (IRIS). While IRIS is used in numerous situations for its high level of precision, it is known to be a much slower, less efficient process. Important uses for IRIS as a complementary inspection with electromagnetic methods include detection for first-time testing signals, or for verifying RFT measurements. The benefits of electromagnetic methods are extensive. The primary benefit is the speed at which testing can occur. Eddy current assessments are completed significantly faster than the alternative IRIS method. Additional benefits of eddy current RFT include equipment portability and flexibility, paired with reliable and reasonably-precise flaw detection, allow operators to perform testing quickly and effectively. Use of the RFT application is particularly ideal in the detection and sizing of large volume defects. As the market and technology continue to mature, electromagnetic instrumentation are designed for longer life There are limitations to all of the aforementioned NDT methodologies. While RFT can detect both ID/OD discontinuities, it cannot distinguish between the two types of flaws. In addition, in certain materials, the flaw detectability is less precise than alternatives.7 A variety of probes exist for eddy current testing. For heat exchanger corrosion detection, there are several benefits to

using motorised rotating pancake coil and/or array probes. Advantages include circumferential crack detection, improved ID-initiated crack sizing, detection of either single or multiple cracking in the same plane/axis and improved volumetric damage sensitivity. In addition, near field testing (NFT) is primarily used for the inspection of carbon steel tubes with aluminum fins. NFT allows for the detection and sizing of ID pitting and erosion defects. A distinct challenge facing the RFT market is the lack of qualified operators to perform the tests and analyse the results. This is particularly due to the complexity of evaluating material magnetism, and the degree of changes in magnetism. For the same material, changes in magnetism can occur based on test location (i.e. field test permeability varies from lab permeability, sometimes due to magnetic scale deposits), adding to the degree of testing difficulty, and requiring highlyspecialised field technicians. Recent ECT advances in electronics come from newer digital signal processing (DSP) circuits which aid in instrument stability, repeatability and defect probability of detection (POD). In addition to enhancements in the areas of lifecycle management and signal-to-noise ratios, future technological and design improvements will continue to occur especially with multi-channel, multi-frequency array probes which will enable both 2D and 3D ECT imaging.

6. High temperature hydrogen attack High temperature hydrogen attack (HTHA) is a longstanding problem in the oil refining Industry. This phenomenon has

been usually defined by empirical operational experience from API 941 (The Nelson Curves).8 The temperature-pressure limits below which no attack occurs for long exposures are given in a chart devised by G.A. Nelson. The Nelson curves provides a go/no-go basis of selecting steels for hydrogen service; however, they give no quantitative indication of the time required to produce attack and corresponding degradation of mechanical properties when the temperaturepressure limits are exceeded. Hydrogen attack can be described as a loss of strength and ductility that can occur in steel exposed to hydrogen at high pressure and elevated temperature. This damage is attributed to the diffusion of atomic hydrogen into the steel. The reaction between the hydrogen and the iron-carbide in the steel forms methane internally at grain boundaries. Since methane is a larger molecule than hydrogen, it cannot diffuse out of the metal. The methane accumulates at the boundaries and may develop pressure to cause cracking along the boundaries. Steel which is exposed to hydrogen attack conditions will pass through an incubation period before actual attack is initiated. During the incubation period, steel which has absorbed hydrogen may suffer a loss in ductility which can be restored by a relatively low temperature heat treatment. While undergoing this incubation exposure, no changes in structure, composition, or physical properties can be detected. After incubation, hydrogen attack is characterised by decarburisation and formation of methane. Further attack produces more decarburisation, fissuring

Figure 7. Eddy current graphic of a terrain plot of data demonstrating detected wall thinning, pitting, erosion, and cracking.

Figure 8. High magnification photomicrograph showing linkup of microfissures to form continuous cracks and damage is accompanied by a significant amount of decarburisation.

at grain boundaries and eventual crack formation in the structure. Since its development in the early 1970s, these ultrasonic methods have been considered the primary non-intrusive inspection techniques for the detection of hydrogen attack. The major challenge is that it is difficult to obtain consistent and interpretable results from one inspection period to the next, or from a different methodology/vendor at the same inspection. There have been three primary techniques commonly evaluated for detection and characterisation: )) Ultrasonic sackscatter. )) Ultrasonic velocity ratio. )) Ultrasonic attenuation.

World Pipelines / MAY 2022

Throughout the 1980s, many owner-users struggled with NDE assessments of C-1/2 Mo equipment assessment. After many inspections employing different techniques, many operators replaced piping the suspect range for maximum assurance from HTHA concerns. Some of the larger equipment (exchangers, reactors) were either restricted in operation or replaced due to uncertain results of HTHA NDE inspections. The C-1/2 Moly curve was removed from API 941 in 1991. The C-1/2 Mo experience is mentioned since recently, some carbon steel may hay suffered HTHA in conditions significantly below the Carbon Steel Nelson Curve.9 There is discussion in certain industry groups as to potentially downward adjustments of the curve. Should this occur, the industry would be faced with a similar challenge as found in the mid-1980s for C-1/2 Mo. The aforementioned NDE methodologies for screening and detection have proven questionable in reliability and repeatability. Owner-users often employ destructive metallographic samples for confirmation of HTHA. It should be noted that HTHA is not uniform even on the microscopic level and the depth and severity of attack can be significantly influenced by variations in chemistry, thickness, applied or residual stresses from microsample to microsample. A fourth and new technology has recently been developed and has shown excellent results in locating and sizing HTHA. It is a highly-focused PAUT technique combined with application-specific, hand’s-on training and technician certification. Essential to the UT exams are very specific PAUT transducers, instruments and software. The authors have attempted to summarise some of the current challenges that face the owner-users of oil production, transportation and refining assets. In some applications, technology has been imported from other industries to create cost-effective solutions for existing problems in this industry. In other situations, technology has evolved to overcome some historic challenges or produce previously unachievable accuracy.

References 1. 2. 3. 4. 5. 6. 7. 8. 9.

Code of Federal Regulations (CFR) 1910- Occupational Safety and Health Standards. US Department of Labour. Risk-Based Inspection. API Recommended Practice 580. American Petroleum Institute. Risk-Based Inspection Technology. API Recommended Practice 581. American Petroleum Institute. Fitness-For-Service. API Recommended Practice 579. American Petroleum Institute. Damage Mechanisms Affecting Fixed Equipment in the Refining Industry. API Recommended Practice 571. American Petroleum Institute. 3D Phase Measurement. (n.d.). Retrieved from http://www.ge-mcs.com/en/remotevisual- inspection/video-borescopes/1845-3d-phase-measurement.html Procedure: Electromagnetic Testing, Eddy Current Inspection, Installed Heat Exchanger Tubing. (10 June 2009). Retrieved from http://www.eddy-test.com/ procedure.pdf Steels for Hydrogen Service at Elevated Temperatures and Pressure in Petroleum Refineries and Petrochemical Plants. API Recommended Practice 941. American Petroleum Institute. Carbon Steel Degradation in High Temperature Hydrogen Service. API Industry Alert, American Petroleum Institute. 7 September 2010.

Nicola Curtis, Rotork, UK, discusses the critical pipeline safety functions provided by flow control.

low control is the management of liquids and gases in industrial applications, and actuators are key items of equipment that control valves at critical points within oil and gas operations. Flow control equipment is found across all three sectors/areas within oil and gas: upstream, midstream and downstream. Pipelines fall under midstream operations, moving oil and gas from one place to another. In the current energy climate, pipelines remain an essential tool of, in particular, transporting gas from North America and the Middle East to the markets that have very high demand in Europe and Asia. The demand for gas has largely returned to pre-pandemic levels and globally is predicted to continue to rise in the lead-up to 2030. Midstream infrastructure must therefore continue to provide efficient and reliable operation. This includes the actuators that can ensure safety functions and efficient flowing of oil and gas from the areas that produce it to the areas that need it. Actuators provide automation of what would otherwise be a manual operation. They must withstand harsh environments and extreme conditions, usually requiring explosionproof and hazardous location certification. Operators choose different actuators according to different requirements, such as medium being controlled, locations, valve size, available power supply and frequency of operation. Within oil and gas, actuators can operate in such diverse applications as wellheads, tank farms, processing sites, fuel terminals, metering skids and pipelines, to name a few. They provide day-to-day flow control and safety functions. Electric

actuators are especially valuable within oil and gas operations because they do not release or vent gas emissions during their operation, aiding in attempts to reduce impacts on the environment. Fluid powered actuators, driven hydraulically, pneumatically or electro-hydraulically, are still often used within oil and gas.

Operation in remote areas and challenging environments Flow control technology has evolved to ensure accurate, effective and reliable actuation, even in the extreme environments that pipelines often operate in. Oil and gas pipelines, by their nature, transport material across hundreds and sometimes thousands of miles. This often means they run across remote and extreme areas (including deserts, mountains, forests and frozen terrain), making them difficult to access. They operate valves on pipelines in extreme temperatures (both very hot and very cold) and coastal locations (with high possibility of corrosion), exposing them to various environmental impacts. Valve operation in extreme

environments presents clear challenges and these demanding locations require flow control that offers high degrees of reliability and robustness. The challenge of remote and isolated locations in midstream oil and gas operations requires innovative engineered solutions for pipeline actuators to operate efficiently and safely. The most effective actuators in these situations must offer environmental protection of the highest degree. IQ3 electric actuators from Rotork have a double-sealed terminal compartment, preventing ingress of water and dust from the ambient environment, meeting IP66/68 standards. They can operate within an ambient temperature range of -50 to +70°C (-58 to +158°F) and for the most extreme temperatures, the IQ range (multi-turn and part-turn) is certified for operation down to -61°C for use within the Russian market. Traditionally, flow control equipment in very low temperatures were installed with heaters alongside to prevent cold and condensation affecting internal electronics. Innovative design means that some modern electric actuators can operate without this reliance on external heaters, which removes the needs to supply additional power to each actuator and reduces overall power consumption.

Safety concerns addressed by emergency shutdown and fail-safe functions

Figure 1. Rotork SI electro-hydraulic actuator operating on a pipeline.

Figure 2. Rotork IQ3 actuators on a pipeline in extreme conditions.

World Pipelines / MAY 2022

Especially when operating in remote (and often unmanned) locations, the ability of actuators to stop the flow of oil or gas is of paramount importance. A requirement of actuators to offer fail-safe or emergency shutdown (ESD) functionality is always requested by operators. Continued flow of oil or gas can have environmental consequences, such as impact on wildlife and nature habitats. There are also economic impacts; this can be for the operator from loss of product and damage to reputation, as well as negative effects for local economies. The gas or oil that runs through pipelines can be dangerous when not dealt with in the correct manner. Safety should be the number one consideration for pipeline operators. With effective shutdown options provided by an actuator, impacts are reduced or nullified and the process of stopping the flow of gas or oil can be safely controlled. Electro-hydraulic actuators combine the speed and flexibility of hydraulic operation with the convenience and control benefits of an electric actuator. From a safety standpoint, they use a simple and reliable mechanical spring to provide fail-safe valve control. An actuator like Rotork’s Skilmatic can fail-safe on loss of ESD signal and/or loss of power supply. It can close a valve in seconds if necessary. This can ensure the process stops in a safe operating state, avoiding safety issues and monetary consequences. In safety critical applications such as pipelines, this functionality is essential. For example, Skilmatic actuators were installed to provide ESD functionality on two newly constructed pipelines in China. These pipelines brought oil and gas into China from offshore fields in the Bay of Bengal. The actuators operate remote-operated shut-off valves

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Figure 3. Rotork IQT Shutdown Battery.

(ROSoV) to isolate sections of the pipelines in the event of an emergency. At a pipeline in southern India, Skilmatic actuators were installed to provide safety critical failsafe duties. They were selected due to SIL3 certification requirements and their high torque output that allows them to work with large valves. Fluid powered actuators are also often specified on pipelines because gas from the pipeline can sometimes be the only available motive power for the actuator. Actuators powered pneumatically or hydraulically often have failsafe capability, high torque and thrust capacity and are fast acting. Spring-return pneumatic actuators provide a simple and reliable way of achieving a fail-safe action. Large actuators such as Rotork’s GP range are often used in safety roles. For example, over 80 of these actuators were installed on a 1000 km Gas Authority of India Limited owned pipeline (the Kochi-Koottanad-Bangalore-Mangalore pipeline) to provide safety functionality. They control ball valves along the length of the pipeline, which carries natural gas. Fluid powered actuators are also often found within LNG applications. Actuators that convert gas into hydraulic pressure were installed on a cryogenic pipeline in northern Venezuela that transports gas and LNG between sites. These Rotork actuators provide control of ball valves along the pipeline and provide essential ESD functionality. Fluid power actuators are also found on peripheral systems, such as compressor stations that maintain a predictable pipeline flow and to preserve the pressure level in the network.

outage, if desired (until the battery charge runs out) or bringing the process to a safe stop if power cuts out. The Shutdown Battery offers the functionality of an IQT actuator, with the additional capability of fail-safe, fail-close, failopen or stayput functions all on battery power when needed. Processes finish in a safe operating state, preventing any safety issues and avoiding monetary consequences due to loss of control after loss of power. Normal operation resumes once power is restored. An example of use would be a remote pipeline station that operates on solar energy and loses power temporarily. Operating in freezing conditions, this is the kind of engineering innovation that brings additional reliability to pipeline applications that require flow control. Because pipelines are increasingly found in these extreme or remote environments, it has been necessary for technology to swiftly evolve in this way to ensure continued effective and reliable actuation.

Pipeline monitoring Flow control technology plays an important role in monitoring the health, efficiency and productivity of pipelines. The isolation of a break in a remote pipeline ensures a continuation of the efficiency and safety of pipeline operation. Equipment such as an Electronic Line Break (ELB) from Rotork can be either be mounted on an actuator, or used remotely. This technology provides early detection of pipeline breaks (by continuously monitoring pipeline pressure dynamics) and initiates a movement of the actuator to a pre-defined emergency position. It quickly identifies and facilitates the isolation of a ruptured section of a pipeline, then sends data about the condition of the rest of the system. When used in conjunction with an actuator (usually fluid-powered, using pipeline gas as the motive power source), line break equipment can help to reduce damage to equipment and the environment as a result of a leak. Line break equipment overcomes operational challenges of transporting oil and gas over large distances. In the case of the ELB, detection is based on rate-of-drop (RoD) and rate-of-rise (RoR) as well as high and low-pressure limits. An example of use and benefits derived is a project where ELB units were combined with fluid power actuators on valves on a natural gas pipeline in China. The operators benefited from the ability to swiftly close the appropriate valves and isolate problems when they arise.

Safety control with battery options

Conclusion

The safety requirements for pipeline operations are clear. In the case of intermittent or unreliable power supplies, how can operators guarantee this essential safety function? The answer is battery powered flow control. Expensive external batteries can be used, but a better solution is an integral battery within an actuator. This is especially relevant in remote or unmanned sites. A solution that provides a fail-safe option and increased operational flexibility in these remote locations is Rotork’s IQT part-turn Shutdown Battery. This was engineered to meet the requirement of continued operation after a power

Pipelines are a key component of midstream oil and gas operations. For them to work effectively, they require flow control technology to operate valves. Actuators provide more than day-to-day control. They offer critical safety functionality and can shut down operations in an emergency. This is especially necessary in the remote and extreme landscapes pipelines often run through, which are often unmanned and inhospitable. The robust and reliable nature of the actuators on oil and gas pipelines means that operators can rely on them to provide efficient, safe and reliable flow control.

World Pipelines / MAY 2022

Steven Hocurscak, Neles, Finland, offers a case study in which a pipeline terminal operator needed a solution for a problematic pressure letdown valve, which was causing complex problems.

hen it comes to midstream pipeline applications, end users need a robust anti-cavitation solution that is not prone to clogging. The pressure letdown valves at a midwest US petroleum pipeline terminal required routine shutdowns every three months for cleaning and maintenance. This maintenance required between four to 24 hours to perform and resulted in tremendous amounts of lost production. When Neles representatives visited the installation, they discovered a nonNeles solution comprised of two 20 in. globe valves being used to stage the pressure drop from approximately 500 - 100 psi before delivering the product downstream in the terminal. The pressure differential across the valves generated excessive noise and vibration, which resulted in damage to the valve. The excess noise was caused by cavitation, which is a damaging phenomenon that occurs within and downstream of control valves under certain temperature, and pressure conditions. At its very worst, progressive cavitation damage undermines the life of the control valve and may mandate performing unscheduled maintenance to replace the valve and nearby eroded piping, incurring substantial product-loss and labour costs. Vibration damaging the valve was not the only problem though. To prevent clogging of the valve’s anti-cavitation trim, a large strainer was placed upstream of the valves to remove debris from various grades of crude before it could clog the valve. The terminal operators explained that after a few months the strainer itself would become clogged. It would have to be removed and cleaned along with the valve’s anti-cavitation trim. This

Figure 1. When the pressure recovers above the vapour pressure of the media, the vapour (or gas) turns back into a liquid.

FLOW DIVISION SELF FLUSHING

Q- TRIM ATTENUATOR PLATE SMALL JET STREAMS

required hiring a crane, a maintenance crew and hours of lost production while this maintenance was being performed. Maintenance and lost productivity cost the pipeline operator US$150 000 - 200 000 with each occurrence. Before Neles could solve the issue for the customer, we had to fully understand the challenges to overcome. We would need a solution that incorporated an anti-cavitation trim to deal with the noise and vibration – as well as the ability for that trim to not clog when subjected to dirty media – to increase the customer’s uptime. While there’s no way for us to circumvent the laws of physics, we certainly can create conditions in which they operate more favourably for us and the environment. The great news is that managing noise and vibration is not only possible but also easier and more effective than it has ever been before with the latest technology, putting greater control, safety and efficiency within easy reach.

Hydrodynamic noise – the hidden danger of bubbles

RECOVERY

In oil pipelines, dramatic changes in pressure and velocity can result in a phenomenon known as cavitation. Cavitation can become an issue when the PRESSURE DROP STAGING pressure of the oil flowing through the P1 valve drops below the vapour pressure, Q- TRIM VALVE P2 the point at which the oil boils or VALVE WITHOUT vaporises. Q- TRIM INCREASE LOWEST TRIM When vaporised, the liquid oil is PRESSURE converted to gas, which materialises as bubbles. This typically happens at the vena contracta, the point of the highest velocity and lowest pressure. Figure 2. The four design principles of the variable resistance Q-Trim are pressure drop When the velocity of the oil staging, flow division, peak frequency shifting, and self flushing. decreases, its pressure conversely recovers until it is above the vapour pressure of the oil. This results in the vapour bubble ‘popping’, as it implodes and returns to its liquid state. The implosion lasts an infinitesimal amount of time: around 3 msec. But in those few milliseconds, there’s a lot of energy transferred in the form of powerful shock waves. These shock waves are produced because liquid molecules moving at extremely high velocities rush in to fill the voids created as the bubbles collapse. The larger the bubble, and the faster the bubble collapses, the more powerful the shock wave’s kinetic energy. Shock waves are the predominate source of vibration caused by cavitation. In addition to the shock waves of Figure 3. Spectral analysis shows Q-Trim attenuating lower pitched frequencies to concentrated energy, these implosions also reduce vibration. produce powerful microjets of directional

World Pipelines / MAY 2022

energy. These erupt through the surface of the bubbles with unidirectional force that is typically in the millions of psi. Microjets are responsible specifically for the erosion to the valve trim, valve body, and downstream piping that occurs when cavitation is present. Cavitation bubbles are the root cause of the localised hydrodynamic noise you can hear in piping systems when cavitation is present. Though usually not overly loud, this seemingly innocent bubble bursting can produce enough power, in the form of shock waves and microjets, to cause significant erosive damage, including mechanical damage to valve assemblies. So this needs to be addressed with a certain level of urgency.

Attention to detail reduces risk and amplifies efficiency Noise and vibration can shake up every part of your operations through unplanned maintenance costs, replacement of vital parts, lost uptime, missed revenue and other problems. In addition, noise and vibration present significant issues in both safety and community relations. Even the safest operation isn’t successful if it is so loud as to be disruptive to the surrounding community. Neles™ Q-Trim™ control valves are ideally suited for oil pipelines and uniquely equipped to reduce noise and vibration using well-designed and state-of-the-art features. First designed in 1978, Q-Trim incorporates three perforated plates that are installed inside, and rotate with, the ball. When opening the valve and Q-Trim together, the flow passes through the three perforated plates, which is the key to its ability to reduce noise and remain self-flushing.

Reducing cavitation or eliminating it completely Here are a few of the ways that the Q-Trim helps solve pipeline problems: )) Pressure staging to reduce or eliminate cavitation: The Q-Trim attenuator plates stage pressure drops into multiple, smaller pressure drops, preventing or mitigating the massive pressure drops that cause cavitation – and the resulting shock waves, microjets and attendant destruction. )) Flow division for quieter, safer throughput: By dividing

the flow into multiple streams, the intensity of the noise generated by a single orifice decreases rapidly as the diameter of the hole narrows down. This means that a number of smaller holes attenuate noise more effectively than just one big hole. A rule of thumb is every time the number of holes is doubled, the noise is reduced by 3 dBA. )) Variable-resistor design for greater control over pressure

and noise: Q-Trim’s variable-resistor design puts the entire solution inside the valve, optimising pressure flow and helping to reduce noise by up to 15 dBA. Competitors fixed-resistor designs have little effect on minimum flowrates, where larger differential pressures generating creating cavitation and noise.

)) Peak frequency for less vibration: Lower frequencies

produce larger wavelengths, which travel more easily through matter. This means that, like loud bass emanating from a car speaker, the lower frequencies generated in a valve can become a nuisance for people in quiet residential areas. Spectral analysis of noise levels in control valves with Q-Trim technology versus those without it, shows that Q-Trim has a significant advantage in reducing both noise and vibration. )) Self-cleaning valve trim for maximum reliability: Q-Trim uses

process media to flush buildup away from the attenuator

plates as the trim rotates. This keeps the valve in peak working condition, bringing considerable cost savings each year and giving greater control over process variability.

Conclusion The problems experienced with the letdown valve were something the Neles representatives had seen many times before and they had an ideal solution. After presentations with corporate engineering, the pipeline company elected to replace the two non Neles 20 in. globe valves with a single, Neles 16 in. rotary ball valve with patented Q-Ball™ technology. The valve was sized in our valve sizing software, Nelprof, to confirm it could accommodate higher flowrates anticipated in the future. Thousands of Neles rotary valves equipped with the Q-Ball design have been installed in liquid applications involving high-viscosity fluids containing impurities. Crude oil is a prime example. The rotation of the Q-Ball attenuator, attached to the valve closure element, is the key to the unique Q-Ball properties not found in other noise/cavitation trim valves. Due to this variable attenuation, Q-Ball valves optimise noise attenuation, pass impurities, provide very high rangeability and help increase uptime for our customers. The terminal yard installed the Neles letdown valve with Q-Ball in December 2010. In over a decade, the strainers have been removed, noise and vibration continue to no longer be an issue, and the valve has never clogged. The results have been so positive, they have standardised on Q-Ball technology for the pressure letdown application. The Q-Ball solution can be applied to many applications with this same scenario. Fixed resistors that are in applications with debris will inevitably clog, leaving the customer in a difficult situation of not being able to pass their required flow, the valve can potentially seize, and in a worst case scenario, they have to immediately shut down their process to fix the issue. Q-Ball’s self-flushing technology sets the industry standard in dirty media for reliability and uptime.

Pipeline Research Council International (PRCI) President, Cliff Johnson, USA, reflects on the council’s constant commitment to the safety and integrity of pipeline systems through its multi-faceted research programme.

he Pipeline Research Council International (PRCI), a non-profit research association, was formed in 1952 to solve the problem of brittle cracks in energy pipelines. After recognising the immense value of collaboration, PRCI grew to produce a broad range of solutions for a vast array of problems.

Over the past seven decades, PRCI has performed research divided into eight technical disciplines resulting in thousands of reports and hundreds of solutions, impacting many industry standards and regulations that enhance the safety, integrity, and reduce the environmental impact of the global pipeline network. With a core philosophy

of collaboration, PRCI has advanced the development of their research portfolio through the establishment of strategic research priorities (SRP) that will have significant impact on both their members and the pipeline industry. Important assets to achieving these goals are the PRCI Technology Development Centre and the Virtual Technology Development Centre. In the last year, PRCI has reinforced its environmental commitment by establishing the Emerging Fuels Institute (EFI) to enable PRCI members and nonmembers to define and execute the research needed to ensure the safe and efficient transportation and storage on the next generation of fuels and launching an initiative to reduce greenhouse gas (GHG) emissions.

PRCI’s commitment to drive strategic industry research Pipelines and their associated assets are the safest mode of transportation and storage of the world’s vital energy resources. PRCI continually works to develop solutions that enable the energy pipeline industry to transport and store this critical energy supply. Currently, PRCI actively performs over 100 research projects annually, working in eight key technical areas: )) Preventing, detecting, and controlling corrosion. Figure 1. Setting up the flow loop at PRCI’s Technology Development Centre for a Crack Management Strategic Research Priority project.

)) Ensuring the safety and integrity of compressor and pump

stations. )) Enhancing the design factors and materials selection

for pipeline infrastructure, and advancing construction practices. )) Continuously improving the integrity and inspection tools,

processes, and procedures needed to advance towards zero failures. )) Enabling improved measurement of product throughout

the pipeline network to reduce the environmental footprint of the systems. )) Strengthening surveillance, operations, and monitoring in

the corridors through eliminating threats along pipeline right of ways. )) Maintaining and developing a robust subsea pipeline

infrastructure. )) Designing, constructing, and maintaining a robust

underground storage network for energy storage.

Figure 2. Testing at PRCI’s Technology Development Centre in Houston, Texas (USA).

World Pipelines / MAY 2022

Collaboratively addressing SRPs allows the PRCI technical committees to identify and execute key strategic industry issues and initiatives in which there are near term opportunities to develop significant outcomes for the industry in the interest of public safety. Already, over 20 important candidate SRPs have been identified. Through an objective prioritisation process supported by data-driven metrics, PRCI started with the following two SRPs:

1. Optimise the detection and mitigation of mechanical damage A key priority is to close the research gaps around mechanical damage (MD) by producing a comprehensive set of guidelines and engineering assessment tools that are aligned with current ILI and NDE inspection technologies for managing the threat of MD. The consolidation of dent and dent management research is the target of this SRP. Results will provide all pipeline operators with technically defensible cases to effectively manage deformations identified through condition assessments, and in turn, focus energies and resources to ensure repairs are being made when and where repairs are truly needed.

THERE IS A SYMBOL FOR SUCCESSFUL PLANNING Quality & reliability make Böhmer ball valves the ﬁrst choice of successful Pipeline planners all over the world

2. Pathway to achieving efficient and effective crack management Operators continually strive to make their crack management programmes more effective and efficient. The efforts of this SRP will strengthen the management of integrity resources and lead to more comprehensive risk reduction, including improved cracking threat risk assessment, improved matching of inline inspection tools to threat, and optimised operational practices mitigating cracking mechanisms. Being more strategic and intentional about working cohesively across disciplines to solve problems and breaking down the traditional research silos among their members, governments, and the industry. By executing these and future strategic research priorities, PRCI magnifies a greater focus on the key challenges facing the industry that impede the goal of attaining zero failures and leads industry research by making impactful advancements in technology and R&D to improve pipeline safety and performance.

PRCI Technology Centres enhances pipeline safety and integrity systems When the PRCI Technology Development Centre (TDC) opened in Houston, Texas, it became a game changer in PRCI’s commitment to addressing key safety and integrity issues facing the national and international energy pipeline industry. Featuring a flow loop, dry and wet pull-string tests, and a large amount of workspace that includes large conference rooms, this world class facility enables PRCI to partner with the industry to enhance the tools, processes, and people that are key aspects of pipeline integrity management as well as provide opportunities to develop and characterise new non-destructive evaluation tools and techniques. The TDC has

Figure 4. Pipeline industry improvment goals for reducing GHG emissions.

www.boehmer.de

collected a library of over 1500 pipe samples with defined and measured defects that allow service companies to work on real world samples to improve inspection technologies and provide a greater degree of assurance of the integrity of pipeline systems. Opportunities for industry collaboration at the TDC are especially apparent by the commitment and technical expertise of PRCI members. The strategic research priorities they developed are devoted to identifying, prioritising, and

implementing the industry’s core research objectives and as a result, use every facet of the TDC. It is the catalyst for allowing PRCI to expand its research portfolio, including determining ways to introduce emerging fuels into the global energy pipeline for a safer tomorrow. Building upon the collaborative opportunities of the TDC, PRCI has launched the Virtual Technology Development Centre (VTDC). This platform for PRCI members and non-members will contribute learnings from operations and near misses to provide insight and guidance as well as leverage the vast amount of data and learnings available to advance safety and integrity and reduce the environmental impact of the pipeline networks globally. When exploring the common factors impacting pipeline operator underneath river crossings, for example, a shared, uniform knowledge of scour, soil depth, currents, and other assets in the right of way under a river is beneficial for all operators in the same location. Sharing data from integrity tool runs to more fully understand similar operating conditions and enhance future decisions making regarding safety is beneficial for all operators. Sharing knowledge and lessons learned protects everyone and the environment, and the VTDC is a globally accessible way to achieve that goal.

PRCI’s environmental commitment As PRCI members and the energy pipeline industry continue to work towards zero releases and a low carbon future, PRCI is advancing efforts to assist in attaining these goals. It is imperative that PRCI and its members continue to provide industry leadership to ensure the safety and integrity of our current pipeline infrastructure which is vital for the transport and storage of carbon-based fuels today and critical as we transition to future needs. The greenhouse gas SRP and the EFI are the newest examples of PRCI’s longstanding commitment to the safety and integrity of pipelines and reducing their impact on the environment.

Greenhouse gases emissions reduction While the pipeline industry has already made significant improvements in reducing GHG emissions, there is a drive to address this issue more aggressively through efficiency improvements and reducing methane emissions. The greatest amount of GHG emissions from pipeline transportation is created by the power used to drive compressors and pumps. Thus, even marginal improvements in the efficiency of highly utilised equipment can have a clear impact in the reduction of GHG emissions. PRCI leads the drive by establishing an SRP to advance the reduction of GHG emissions in the pipeline system.

PRCI Emerging Fuels Institute

Figure 6. PRCI’s Emerging Fuels Institute partners with associations, governmental agencies and societies to address the challenges of transitioning pipelines to the next generation of fuels.

World Pipelines / MAY 2022

The EFI was launched April 2021 to address the challenges facing the transition of energy pipelines to the next generation of fuels. As many governments are planning or have begun mandating transitions to renewable energy sources to achieve the goal of stabilising the climate, low carbon footprint fuels are a foundational component for a sustainable energy society. The EFI’s current research priorities follow market focus on the storage and transportation of hydrogen and renewable natural gas (RNG). The scope of the EFI addresses hydrogen, RNG, carbon

capture and sequestration (CCS), ammonia, and biofuels. Project emphasis areas include: )) Integrity of pipeline system steel and non-steel components.

impacts of blending hydrogen into the existing natural gas infrastructure. )) DNV guidelines for integrity management of hydrogen

)) Compressor stations and facilities.

pipelines.

)) Pressure control and over-pressure safety devices. )) Design requirements for electrical classification and fire safety. )) Downhole reservoir and cavern storage.

)) ASU/PHMSA Competitive Academic Agreement

Programme (CAAP) development of knowledge-based system for integrity management of ageing pipelines.

Network management and compression

)) GMRC analysing compression system changes with An important output of the EFI is developing a guide to safely hydrogen blending. convert and operate pipeline systems to allow for the transport and storage of the next generation of fuels. Membership to the EFI is open to ® PRCI members and non-members and offered at two levels for participation: vanguard and champion. Vanguard Introducing the next generation PosiTector membership includes leadership gauge body for all your inspection needs. roles within the EFI. As projects are developed within the EFI, both PRCI members and non-members will All Gauges Feature... be able to participate in individual n NEW Larger 2.8” impact resistant color touchscreen projects. with redesigned keypad for quick menu navigation To ensure a comprehensive and n NEW On-gauge help explains menu items at the touch continued awareness of ongoing work of a button within the industry, a key task of the n NEW Weatherproof, dustproof, and water-resistant EFI is partnering with global research —IP65-rated enclosure associations to share respective n NEW Ergonomic design with durable rubberized grip roadmaps so that work is incorporated n Shock-absorbing protective rubber holster for added efficiently and comprehensively into impact resistance EFI deliverables. This collaboration n Two year warranty on gauge body AND probe with industry stakeholders is critical to n Conforms to national and international standards ensure the optimisation of the overall including ISO and ASTM transition effort. n NEW Auto rotating display with Flip Lock As the opportunities around n NEW Screen Capture—save 100 screen images for emerging fuels continue to advance, record keeping and review it is important that PRCI works closely with government, industry, and standards developing organisations to ensure that the leading research defines how the energy pipeline industry makes progress to transport Customized Inspection and store the next generation of Kits... Build your own kit from fuels. There are a number of efforts a selection of gauge bodies and progressing globally, and to be able probes to suit your needs. to achieve the timelines that policy makers have set, it is imperative that we work closely together. The following are active EFI projects:

PosiTector Inspection

Integrity of pipeline system steel and non-steel components )) NREL HyBlend project on

operational and performance

Backwards Compatibility! The PosiTector gauge accepts ALL coating thickness (6000/200), environmental (DPM), surface profile (SPG/RTR), salt contamination (SST), hardness (SHD/BHI), gloss (GLS), and ultrasonic wall thickness (UTG) probes manufactured since 2012. DeFelsko Corporation l Ogdensburg, New York USA Tel: +1-315-393-4450 l Email: techsale@defelsko.com

Figure 3. Pipe strings over 150 m (500 ft) in length, ready for pull tests at the Technology Development Centre.

)) GTI development of a centralised RNG database to track gas

quality. Figure 5. Current members of PRCI’s Emerging Fuels Institute are committed to the safe transportation and storage of emerging fuels.

)) Solar, in partnership with UC Irvine, CSU, SWRI, and ERC

to develop a turbine retrofit solutions for hydrogen blend pipelines.

Metering and gas quality )) NewGasMet project to identify the impact of renewable

gases on accuracy and durability of meters in the market today.

Safety )) Proposed co-operative research and development

agreement (CRADA) between Sandia National Laboratories (SNL) and PRCI to address risks associated with leak scenarios for H2 blends >20%.

Conclusion From coming together to resolve brittle cracks in 1952 to expanding the scope of core research to the transition of global pipelines for emerging fuels, the Pipeline Research Council International mission is to collaboratively deliver relevant and innovative applied research to continually improve the global energy pipeline systems.

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

Unmatched Performance and Proven Results

Mark Douglass, Business Development Manager, Lincoln Electric Additive Solutions, USA, demonstrates how to keep operations up and running using metal additive production for valve bodies, components, fittings, and other complex parts.

ime is money, and the long production and transit lead-times to get largescale metal parts using traditional manufacturing methods, such as casting or forging, create costly delays to operations. Metal 3D printing, otherwise known as additive manufacturing (AM), can solve supply chain challenges and lead-time delays. AM is rapidly establishing itself as a key technology in many industries, such as aerospace, defence, energy, and transportation because it offers operational efficiencies and expands product design capabilities. In the case of Lincoln Electric’s AM services business, for example, we use what is probably the most common

subcategory of AM: wire additive arc manufacturing (WAAM). A relative newcomer to AM, WAAM is becoming increasingly relevant for manufacturing large-format parts. While many AM technologies are based on relatively novel processes, such as powder bed fusion, WAAM is based on arc welding; a well-established process manufacturers rely on every day even in safety-critical applications. Large-scale WAAM platforms have produced parts up to 7 ft (2.1 m) high, and weighing more than 5000 lb (2265 kg). Engineers use software that rapidly converts existing CAD-file part designs to a robotic printing pathplan. Parts are then produced in robotic cells and are managed by weld engineering application experts. These individuals walk a part through the entire process, from design to production to quality assurance, ensuring parts are delivered quickly. As a proven production process, large-scale metal 3D printing using weld metal significantly reduces manufacturing lead times and shortens supply chains to reduce bottlenecks. The pipeline industry could greatly benefit from this technology.

What is wire arc additive manufacturing? How does it work? Traditional manufacturing relies on slower processes and technologies, such as machining, casting, or forging to make complex shapes and parts. WAAM, on the other hand, often delivers parts at a fraction of the time and with less waste, while providing the same, or better, Figure 1. Determining the proper number of layers and performance characteristics in the parts as traditional programming and planning the robotic welder’s path is complex. manufacturing methods. The software must take the part’s geometry and features into The WAAM process for large-scale components starts account to ensure the 3D printing is a success. with the part’s computer aided design (CAD) file, which is sent to the manufacturing facility and uploaded into the WAAM software. This software digitally ‘slices’ the part’s CAD model into layers and creates an optimal metal deposition path. The software then programmes the robotic system with process settings and robot positions. While it sounds straightforward, determining the proper number of layers, the path planning within each layer, and programming the robot so that it effectively deposits metal is complex. The software must consider part geometry and features, wire feedstock, and support Figure 2. Robotic welding systems use solid alloy wire to print parts from the ground up, depositing structures (if necessary) to metal in layers through individual, successive welding passes. This involves stacking hundreds of layers at different orientations. produce high-quality parts.

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Once the software determines the path-planning strategy and programs the system, it’s time to properly execute the WAAM process. Building a robust automation system with proper controls is important because WAAM involves stacking hundreds or even thousands of weld metal layers (sometimes at different orientations), making it far more complex than conventional robotic welding. Using solid wires of various alloys, including steel, stainless steel, Invar®, and nickel alloys, the robotic system prints parts from the ground up using individual welding passes in succession to create a free-form, 3D shape. Once the printing is completed, the part is ready for machining to achieve its final dimensions.

Figure 3. Metal 3D printing based on welding processes can solve supply chain challenges and help pipeline operators get the parts they need in days or weeks, not months.

What are the benefits of WAAM? WAAM can maximise uptime with quick-turn parts supply. This process yields the near-net, high-quality components needed in a range of metal alloys, in weeks, not months. For industries that rely on large-scale parts manufacturing, it’s proving to be a true game-changer. Operators can also advance R&D with functional prototypes, reduce the complexity in operations with fewer handoffs, and optimise working capital with lower inventory carrying costs. Be sure to look for manufacturers that provide WAAM services, such as Lincoln Figure 4. Wire-arc additive manufacturing provides the same, if not better, performance characteristics as traditionally fabricated parts. Electric, that are committed to qualifying their processes to the ASME Boiler and Pressure Vessel As the pipeline industry looks for more viable ways to Code Section IX Case 3020 for gas metal arc additive increase uptime and speed, large-scale parts manufacturing, manufacturing (GMAAM). Even better, also ensure that metal 3D printing using weld wire and WAAM needs to they have produced components for an oil and gas be considered. 3D printing offers quick turnaround on downstream applications to API Standard 20S, ‘Additively prototypes and replacement parts, delivering a competitive Manufactured Metallic Components for Use in the advantage over traditional manufacturing methods. Petroleum and Natural Gas Industries’. As an operator gets more familiar with metal 3D The continued advancement of WAAM technology, printing and understands the value proposition of speed the understanding of deposit properties, and the to market, high-quality deposits, design flexibility, and development of standards will ensure this productionreduced costs, they can feel confident in exploring ready manufacturing process for large-format metal parts and using 3D printed, large-scale metal parts with remains a reliable option for components. confidence.

MAY 2022 / World Pipelines

Shriram Ramanathan, Ph.D., Vice President and Group Director, Lux Research, USA, and contributor Miraj Mainali analyse the timeline for lightsout manufacturing processes for the oil and gas industry.

patents, publications, and funding (Figure 1). Ideas developed in the late 20th century around lights-out manufacturing are now resurgent because of current advances like advanced robotics, computer vision, industrial IoT, machine learning algorithms, and improved computing. Similarly, funding for robotics and automation in manufacturing has also increased significantly since 2015. While most of the funding is in the form of venture capital investments in emerging startups, public companies have also raised millions in post-IPO funding (Figure 2). Besides technical enablement, there are non-technical factors responsible for the growing demand for lights-out manufacturing.

Reducing downtime Human error accounts for a large percentage of unplanned downtime in manufacturing, which can lead to millions of dollars in lost revenue. In addition to the unplanned downtime, the lack of flexible production systems and the need for manual inspection, maintenance, and repair entail planned downtime in manufacturing.

Operational efficiencies

Human labour demands

Minimising operational costs While robots have high upfront costs, they can be less expensive than human labour over time. The push to increase minimum wages and benefits for factory workers is also driving large corporations towards increased levels of automation.

Rising worker safety concerns and costs Adopting worker safety measures to create a safe workplace for factory employees has several advantages, but it comes at an increased cost. While replacing some workers with robots can help save operational costs, the use of collaborative robots (cobots) requires further worker safety measures for the remaining workers. Therefore, companies are interested in full automation.

Achieving higher efficiency Unlike human workers, a robustly built robotics system can run 24/7 without the need for breaks, vacations, or shift changes.

Minimising wastage for sustainability reasons In addition to operational and maintenance costs, inefficiency and downtime caused by workers and inflexible manufacturing systems lead to increased material wastage and carbon footprint.

Labour shortages Some industries, such as oil and gas, have been suffering from significant labour shortages caused by both an ageing workforce and the lack of fresh graduates interested in working in the field. Even for other industries, knowledge transfer and worker training for new hires are difficult and expensive. COVID-19 The COVID-19 pandemic has been an unprecedented driver for several tech innovations, including automation. Companies like Hitachi, Mitutoyo, and Omron have said COVID-19 motivated their investments and M&A initiatives in automation since 2020.

Product customisation Figure 1. Lux Tech Signal for lights-out manufacturing. Source: Lux Research.

Meeting the growing demand for customised products is difficult using workers and even for companies using robots to manufacture parts in siloed environments. The optimal use of resources and flexible processes required to manufacture custom products based on demand can be achieved using complete automation or lights-out manufacturing.

Barriers to lights-out manufacturing At the same time, there are also several barriers to lights-out manufacturing, such as:

Technology bottlenecks

Figure 2. Funding amount raised for robotics and automation. Source: Lux Research.

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Lack of technology maturity While there have been ongoing developments in smart manufacturing, the technologies required for full automation or lights-out manufacturing still lag behind demand.

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Technologies

Overall technology maturity

Autonomous mobile robots (AMRs) Robotic arms End effectors Indoor drones Legged robots

Figure 3. Different robotics technologies and their overall technology maturity. Source: Lux Research.

lax worker safety regulations. However, newer business models like renting and leasing robots are making it easier for companies to avoid large upfront fees and adopt robotics systems.

Regulatory hurdles and cultural pushbacks Automation is often a topic of criticism, as it can eliminate jobs and threatens widespread unemployment, which is driving demand for regulations against such large-scale automation.

Robotics technologies

Figure 4. The significance of drivers and barriers to automation of the manufacturing task: cleaning tanks/pipes. Source: Lux Research.

Factory automation tools like programmable logic controllers have been used in manufacturing facilities for a long time to automate higher-level processes like relay control, machine functions, motion control, and process control. Lux Research interviewed several industry leaders who shared their front-rowseat perspective on automating manufacturing tasks. Most of the interviewees mentioned that their organisation still focuses on automating such higher-level manufacturing processes. However, achieving lights-out manufacturing will also require automation of production processes at lower levels, such as moving materials, cleaning tanks, and inspecting products and assets. While dozens of robotics technologies can automate lower-level manufacturing processes, Lux has identified the most important ones and used the findings from these interviews in addition to its existing research in the space to assign the individual average maturity of these technologies (Figure 3).

Analysing the timeline for lights-out manufacturing (Lux’s framework) Performing manufacturing tasks requires a combination of different robots. We have listed several manufacturing tasks and linked them with the five types of robots (along with their technology maturity) that can be used to automate them. Following that, we assigned a high, medium, or low score to the significance of the drivers and barriers for each task (Figure 4). Here is an example:

Cleaning tanks/pipes )) Manual cleaning of tanks/pipes must be performed Figure 5. Scatter diagram of manufacturing tasks based on different drivers and barriers to automation. Source: Lux Research.

Skill gaps While lights-out could put tens of thousands of factory workers out of work, it will also create demand for a new type of workforce that designs and develops the necessary hardware and software for these systems, which will add to the already-existing shortage of skilled workers in areas like data analytics.

Financial feasibility Although robots might be less expensive in the long run, their excessively high initial cost often becomes a barrier to adoption, especially for small manufacturing companies. Using robots is still more expensive for countries with low human labour costs and

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during fixed periods (e.g. every month) depending on the application. While cleaning the exterior of tanks/pipes is comparatively easy, cleaning the inside is time-consuming, difficult, and often very risky. As a result, operational efficiency and human labour are significant drivers for automation for this task. )) Tanks and pipes can be automatically cleaned using a

combination of robotic arms and end effectors (such as a cleaning brush). Since these robotics tools are technologically complex and expensive, the significant barriers for automation are technology bottlenecks and financial feasibility. This process is continued for all remaining tasks and built into a scatter diagram that visualises manufacturing tasks in four quadrants with the following distinct characteristics (Figure 5): Quadrant I contains continuous and repetitive tasks that require extensive person-hours and can therefore highly benefit

from automation. Most of these tasks, such as cutting and carrying heavy loads, also have worker safetyrelated issues in addition to a low cultural pushback against automation. The robotics technologies required to automate these tasks are sufficiently mature. Companies interested in automation should first target these tasks, especially in regions where workers’ wages are a significant operational cost. Quadrant II contains lacklustre tasks that have neither strong drivers for automation nor strong barriers. Most tasks in this category can benefit from automation in terms of operational efficiency, but the ROI must be analysed before jumping in. Companies Figure 6. Predicted timeline of lights-out manufacturing for different that have specific requirements to automate these manufacturing tasks. Source: Lux Research. tasks – for example, cleaning tanks or pipes filled with hazardous materials that can lead to unsafe working conditions – should target automation. Most of these tasks can Quadrant IV includes tasks that can heavily benefit from be automated with today’s technology and can reach the state of automation but are equally challenging. Performing automated lights-out manufacturing in several years. asset and product inspection can be highly beneficial in Quadrant III has tasks that have weak drivers and strong terms of operational efficiency, reductions in downtime, and barriers to automation. Installing new equipment or replacing quality control, but the technologies required to perform existing equipment is typically done once per decade in such automation, such as AI and computer vision, must still be manufacturing plants; therefore, it isn’t the most urgent task to improved in regards to accuracy and the availability of annotated automate. On the other hand, while repairing equipment occurs training data sets. Similarly, while sanding and packaging are more frequently, it is extremely difficult to do with robots, repetitive tasks that can benefit from automation, robotic grippers considering how unstructured repairing equipment can be. can’t replicate human dexterity. Companies should test solutions Companies shouldn’t target automating these tasks, at least for that can automate these tasks but should be mindful of the the next decade. technology-related barriers.

Timeline

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Finally, we used our framework to build a predicted timeline of automation for each manufacturing task (Figure 6). Looking at the chart, most manufacturing tasks that require one or two technologically mature robots will be fully automated between the late 2020s and early 2030s. By 2030, companies will be able to manufacture products autonomously using robots but will need some human intervention in manual sanding, inspecting, packaging, and palletising until 2035. All asset-related tasks, such as inspection, repair, and installation, will be fully automated only after 2035. As previously mentioned, tasks like repairing and installing equipment require a complicated setup of robotics systems, have low drivers and high barriers, and may never be fully automated.

Outlook Lights-out manufacturing will not be the end goal; instead, it will unlock these new opportunities:

Alternative manufacturing systems As product customisation is increasingly becoming a significant driver for automation, lights-out manufacturing will unlock flexible systems that allow for end-to-end automation and customisation of products. Customers will be able to configure products based on their needs and design choices, and they will be manufactured on demand. This is almost impossible to do with with today’s traditional linear manufacturing systems. In addition, other manufacturing paradigms, such as factory in a box, in which a fully automated but miniaturised version of a factory is operated near a high-demand location, will reduce shipping and logistics costs. Furthermore, companies could set up automated factories in remote locations where resources like raw materials and power are cheaper.

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While building a fully automated factory is a big feat on its own, organisations can achieve a larger milestone with lights-out automation when they also automate administrative tasks like HR and finances, have a supply chain (including the last mile) with autonomous vehicles, and perform field operations (inspections, maintenance, repairs) with remote sensing technologies like drones, satellites, and robots. Some of these automations will happen in parallel with lights-out manufacturing.

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Off-Earth manufacturing The concept of lights-out manufacturing can be carried into manufacturing goods on a satellite to repair faulty components or in a space vessel during long-distance space travel. Even more futuristically, there has been growing interest in space exploration and colonisation of other planets like Mars. One of the biggest challenges in colonising another planet is manufacturing items required for human survival. Building a lights-out factory on a new planet will be crucial for such a challenging venture.

The June 2022 issue of World Pipelines will include a special feature on hydrogen pipelines Hydrogen is set to make a significant contribution to the future energy mix Many midstream companies are incorporating hydrogen into their business The special feature will cover: • Infrastructure: Hydrogen pipeline networks • Funding: Hydrogen technology development clusters • Regulatory landscape: Pipeline design, operation and maintenance • Projects: Global overview and outlook • Construction: Repurposing gas pipelines for hydrogen transport • Integrity: Materials challenges for hydrogen pipelines Confirmed distribution of the June 2022 issue at: • Hydrogen Expo USA (14 – 15 June 2022, Houston, USA) • Hydrogen Technology Expo (19 – 20 October 2022, Bremen, Germany)

Also in the June issue: EPC case studies • ILI • pipeline sensing • subsea pipeline services • corrosion • welding • pipeline networks and the biannual Readex Research readership survey

***All articles are published subject to the Editor’s appoval***

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