iTAC Solutions for Energy/Pipeline

Intelligently manage Pipelineswith the iTAC.MES.SuitePipe Tracking System

Pipe Tracking System

With the iTAC.MES.Suite, it is possible to represent the entire

construction phase of a pipeline.

The process parameters of all contractors for each length

of pipe are thereby seamlessly recorded and automatically

analyzed for correctness and completeness. Even during the

operational phase spanning decades, all necessary inspec-

tions and the corresponding results are documented.

The constantly growing demands for energy and calls for

secure supply have resulted in energy suppliers relying

increasingly on digital management of their networks.

Regardless of whether the supply lines transport gas, oil,

water or other resources, it is becoming increasingly impor-

tant to know which material was mounted where and with

what characteristics. This is particularly the case if failures

occur and if further failures are to be avoided.

In order to automatically capture data over the entire

creation process , state-of-the-art information technology

is essential. The iTAC.MES.Suite, a, platform-independent

standard solution based on modern Internet technologies,

is such a solution.

The Pipe Tracking System from iTAC Software AG is the only

standard solution of its kind. With its extensive functional

portfolio, it supports the planning, construction and opera-

tion of a pipeline. The proven MES system is both a valuable

tool for pipeline builders and operators as well as for con-

tractors and suppliers – where it is already in use.

Comprehensive documentation & transparency

Manufacture >> Refinement >> Transport >> Storage >> Concrete casing >> Construction >> Operation

With the iTAC.MES.Suite, each step in the production and

logistics chain of a pipeline is documented and can be

examined. During this process, a unique serial number is

assigned to each segment of the pipeline (pipe, valve, buckle

arrestor, pig trap etc.).

In the Pipe Book, all information is made available together

with history. The iTAC.MES.Suite’s TR-Service captures all

information associated with a pipe (batch information of the

smelter, component data, coating, concrete weight coating,

stock movements, laying & as built data etc.) fully automati-

cally making this information available in the iTAC.MES.Suite

in a clearly-organized manner.

The iTAC.MES.Suite accepts all information and parameters

for the respective pipe number, such as test results and test

plans provided by the global data suppliers (manufacturers,

coaters, transporters, warehouse keepers etc.), as XML files

via File Transfer Protocol. Extensions or changes to the indi-

vidual test specifications can be amended at any time within

the iTAC.MES.Suite without additional programming work.

iTAC Solutions for Energy/Pipeline

With the iTAC.MES.Suite

• comprehensive documentation is possible for the

entire construction process - providing transparency

across all manufacturing and logistics steps as well

as across all components and contractors

• it is possible to perform an automated inspection

(verification) of deviations of the CURRENT state

with respect to a specified TARGET state

• unreleased or faulty components (e.g. pipes)

can be blocked

All contractors use a common interface for data transfer.

The captured data can be accessed by all participants from

anywhere in the world via the Internet (Pipe Tracking Portal).

Since the iTAC.MES.Suite is a web-based application, no

additional software installation is necessary on the evaluati-

on clients.

The passing of target data and the specification of limit

values enable the release or preliminary release of the pipe

for the laying process. Furthermore, failures and deviations

can be detected even during the production process and

remedial actions initiated.

Failures and failure states, such as incorrect or insufficient

wall thicknesses or the welding together of pipes from dif-

ferent lots/smelters, can be detected in advance. If a failure

is detected, all pipes from the respective lot or pipes with

identical parameters, such as anticorrosion coating, can be

inspected and, if necessary, blocked or replaced.

With the aid of the TR-Service, the following information

can be called up over decades:

Trace down

• What materials are contained in the pipe?

• Which suppliers/contractors were involved with

which parameters and features?

Trace up

• Which other pipes have the same features,

failures or characteristics?

Laying information

• Where does which pipe lie with which GPS coordinates?

• Which pipe is welded to which other pipe with

which weld seam?

Finding failures / automated verification

The use of high-quality raw materials (pipes, valves, buckle

arrestors) is essential when constructing a pipeline, espe-

cially since faulty lines or, much worse, leakages can have

immense consequential costs and catastrophic impacts on

the environment, particularly when transporting gas or oil.

In order to evaluate the quality of the pipes being used as

well as the laying process, including the welding of pipes,

the iTAC.MES.Suite’s QM-Service provides extensive analysis

functions that answer the typical questions posed by a

network operator.

The standard quality analyses available in the iTAC.MES.

Suite enable direct evaluation in real-time and thus always

reflect the current quality situation. Using measurement

data, failure data and the statistical evaluation of this data,

both the production process of the pipes as well as the

laying process can be analyzed in detail.

The following analyses are possible with the aid of the

QM-Service

• Analysis of all measured values for each pipe

• Analysis of a given measured value across all pipes

• Fault analysis

• Deviation analysis with respect to the specifications

of each supplier, product etc.

• Certificate report for each pipe

Fully integrated, flexible reporting visualizes the results

of these analyses. Furthermore, with the aid of an alarm

management system, corresponding information is automa-

tically sent (e-mail notification) to suppliers or

the responsible persons at the pipeline operator in the event

of deviations or failures.

Optimum material flow

For greater planning security, iTAC has also developed its

own Material & Logistic solution (ML-Service). The

ML-Service uses an interface to capture the current movement

of goods, even including the rate of pipe laying, thereby

allowing the operator to monitor the logistical processes.

The ML-Service answers the following questions

• Exactly where is the serial-numbered pipe?

(warehouse, transport, laying ship, installed)

• How long will the stock in store suffice at

time point x with a daily rate of pipe laying y?

(range check)

After the pipe is laid, the position of each individual pipe can

be mapped on a geographic map with the aid of correspon-

ding stored GPS data. This visualization tool (GIS-System) is

provided by iTAC’s partner P-Systems and is fully integrated

in iTAC.MES.Suite.

Partner for Line-Management-Systems and Cartography of

pipelines, networks and alignments.

iTAC Solutions for Energy/Pipeline

With the iTAC.MES.Suite, lines and networks can

be managed in all areas of the energy industry. The

standard software is a valuable tool in the logistical

processing, documentation as well as operation of

the individual network segments.

• Automated, electronic capture and comprehensive

documentation of the entire construction process

• Transparency across all steps and service providers

(contractors)

• Automated inspection (verification) of deviations

of the current state with respect to a specified

target state

• Information on process deviations via the

Alert Management System

• Flexible reporting with e-mail integration

• Continuous visualization of material movements

and material states

• Visualization of the network and segments of the

network classified as defective on a geographic

map (GIS-System) on the basis of the coordinates

assigned to the individual pipes

• Simple integration in leading business software

systems such as SAP

• Global, web-based access

• Reliability through documentation of all

inspection data during the entire uptime of a

pipeline, e.g. periodic capture of "pigging data"

• Investment security for the system through

platform-neutral JAVA technology

Through the deployment of unique serial numbers, each and every pipe segment is seamlessly documented across the entire supply chain.

iTAC Solutions for Energy/Pipeline

Data supplied by contractor

Antifriction coating of inner surface of pipes 3 Pipe number (Tube number) containing information on:•Coating•Coatingparameters•Testresultsetc.

>> Coating information

Anticorrosive coating of outer surface of pipes 4 Pipe number (Tube number) containing information on:•Coating•Coatingparameters•Testresultsetc. Asbefore,identicalprocess

>> Coating information

concrete coating 5 Pipe number (Tube number) with concrete coating:•Coatingparameters•Lots•Testresultsetc. Asbefore,identicalprocess

>> Concrete weight coating information

Productionofsteelplates1 Platenumbercontaining information on heat number (melt)•Chemicalproperties ofthesteel - Component information -Chemicaltest analysis

>> Batch information

Production of pipes2 Pipe number (Tube number) containing information on:•Testinformation (tensile,chappy impact, hardness etc., hydrostatictestetc.)

>> Component information

Storageinhandlingfacilities6 Stock movement• Stocklocation• „Intransport“ information

>> Stock movements

Layingofthepipeline7 Layinginformation•Weldingparameters•Bucklearrestor (reinforcement)

>> Layinginformation& asbuildinformation

iTAC Solutions for Energy/Pipeline

www.itacsoftware.com

iTAC Software AG

fon +49 2602 1065 - 0

info@itacsoftware.com

certified: DIN ISO 9001:2000

iTACworldwide:

Germany · France · USA · China

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The iTAC.MES.Suite in use at Nord Stream

The iTAC.MES.Suite is being used during the construction

and operation of the 1,220 kilometer long natural gas

pipeline, which will connect Russia and the European

Union across the Baltic Sea beginning in 2010.

Due to its high standardization level, the Pipe Tracking

System from iTAC Software AG was employed

productively within just a few months. Nord Stream AG

is an international joint venture (Gazprom, E.ON Ruhr-

gas, Wintershall, N.V. Nederlandse Gasunie), which was

founded for the purpose of planning, constructing and

subsequently operating the new Baltic Sea pipeline.

iTAC Software AG

iTAC Software AG is a leading provider of manufacturing

execution systems (MES). As a system and solution provi-

der, iTAC develops, integrates and maintains its platform-

independent iTAC.MES.Suite for productive enterprises and

network operators around the world.

FACTS ABOUT THE NATURAL GAS PIPELINE ACROSS THE BALTIC SEA

ISSUE 7 | 08 – 2008

FACTS

steel chemistry are also retained in the central data

bank, which stores data on all individual pipe seg-

ments, valves and other components. Consequently,

initial information is automatically checked against

the target data resulting from regular inspections.

The pipeline safety inspection process takes place at

three levels. Steel pipe manufacturers, Nord Stream

assessors and independent pipeline experts conduct

inspections and quality control. The involvement of

independent certification bodies employed by Nord

Stream such as the Norwegian company DNV is a

crucial part of quality assurance.

With full access to the central databank, DNV in-

spectors will make regular checks at every stage of

the logistics chain of the permanent quality control

system put in place by Nord Stream. They attest that

standards are maintained in practice. These checks

cover the quality of materials delivered by Nord Stream

service companies, the loading of pipes on to the lay

barges and the pipe welds made on board. This

multi-stage process ensures that the exact location

of each pipeline segment in the corridor is recorded.

All components for the two lines – comprised of

more than 100,000 elements each – comply with

predetermined technical specifications.

Safety is Nord Stream’s first priority. An advancedpipe-tracking system is one of the innovations setting new standards for the planning, constructionand operation of natural gas pipelines. Pipe-trackingenables the company to monitor and document thepipe production and logistics. Pipe-tracking main-tains detailed information on each and every one ofthe individual pipe segments that will make up thetwo 1,220-km lines of Nord Stream.

Pipe-tracking is a multi-stage survey tool that collects

data at every stage of the logistics chain – manufac-

ture, transportation, storage, concrete weight coating

and installation in an integrated database. This data-

base will secure constant quality control over decades,

contributing to the pipeline system’s operational safety.

How does pipe-tracking work in detail? Each pipe

segment – made from X70 special steel and certified

according to the internationally acknowledged DNV

(Det Norske Veritas) OS-F101 Offshore Standard –

receives a unique serial number. This allows Nord

Stream to maintain constant quality control during

initial production, transportation, concrete coating,

storage and final welding on board the pipelay ves-

sel. The results of random material tests such as

ADVANCED PIPE-TRACKING OPTIMISES OPERATIONAL SAFETY

A unique serial number for each segment of the

planned Nord Stream pipeline across the Baltic Sea

will be traceable during the entire logistic chain.

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Vyborg

Greifswald

Switzerland

France

BelgiumLuxembourg

The Nether-lands

Germany

Czech Republic

Austria

Italy

UnitedKingdom

Denmark

Nord Stream has received the go-ahead from itsshareholders for two major contracts for its projectto build a 1,220-km natural gas pipeline across the Baltic Sea.

The contracts – with EUPEC PipeCoatings S.A.

(Dunkirk, France) for concrete weight-coating and

logistics as well as with Saipem S.p.A. (Milan, Italy)

to lay the pipeline on the seabed – represent major

investment commitments to the project. Nord Stream

signed the contract with Saipem on 24 June 2008.

The signing of the contract with EUPEC followed

on 29 July 2008.

The Shareholders approved a project plan for

construction of the first of two parallel lines to start

in 2010. Matthias Warnig, Managing Director of

Nord Stream AG, said: “Nord Stream is the most

advanced of all gas infrastructure projects classified

by the European Union as ’of European interest’.

We are aware of the environmental concerns and

are taking sufficient time and effort to address them.

Based on intensive planning and preparation, we

will be able to supply additional gas from 2011.”

IMPORTANT STEP OF THE PROJECT UNDERWAY: CONTRACTS FOR PIPELINE INSTALLATION SIGNED

Nord Stream has published its so-called WhiteBook, responding to the more than 200 commentsand questions from stakeholders in all Baltic Seacountries since notification of the pipeline projectin November 2006.

Reflecting the project status of June 2008, the White

Book is a key element in the on-going dialogue be-

tween Nord Stream, as project developer of a gas

pipeline across the Baltic Sea, and the public in all

states bordering it.

It serves two main functions: First, it provides an

overview of how all comments have been taken into

account. Second, it summarises the general approach

in a way that gives non-experts in the various fields

(natural science, engineering, legal aspects etc.)

access to and understanding of the complex issues

involved. The White Book is structured to highlight

the most important topics – from the various possible

types of impact of the project to questions of alter-

natives and safety provisions.

For more information please download

the White Book at:

www.nord-stream.com/project/whitebook.html.

“WHITE BOOK” RESPONDS TO PUBLICCOMMENTS ON PIPELINE PROJECT

PIPELINE INFORMATION TOUR PLANNED TO VISIT BALTIC SEA COUNTRIES

NORD STREAM: FACTS | ISSUE 7 | 08 – 2008

Nord Stream has developed a mobile exhibition de-

voted to its project. The “Pipeline Information Tour”,

designed to provide the general public with informa-

tion on all aspects of the pipeline. It is housed in

a bus which will travel to major cities on and near

the Baltic Sea coast. Visits to Finland and Sweden

have already taken place. A tour through Germany,

Denmark and Russia is planned. The Pipeline Infor-

mation Tour is designed to explain all aspects of the

pipeline project in a way that is accessible to all

those interested. Visitors will be able to familiarise

themselves with the Nord Stream project using such

devices as an interactive multimedia terminal provid-

ing facts and figures on environmental issues, the

use of gas, pipeline safety, construction and opera-

tion. All information will be available in the languages

of the countries to be visited as well as in English.

For additional information please visit:

www.nord-stream.com/infotour.html.

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An important link in the EU gas supply chain –Nord Stream

Pipeline planned

Gas storage in operationGas storage planned

Status of countries presumably receiving Nord Stream gas (June 2008)billion cubic metresbcm

Pipeline in operation

Sr(

StorageSelection of major storage facilities

A Haidach, Austria B Rehden, Germany C Humbly Grove, UK D Saltfleetby, UK (planned) E Jemgum, Germany (planned) F Poederlee, Belgium (planned) G Hinrichshagen, Germany (planned) H Etzel, Northern Germany I Epe, Western Germany J Bierwang, South Germany

ProductionShtokman field (planned)Nadym-Pur-Taz district Yamal Peninsula fields (planned)

Transport

1 NORD STREAM (planned) 2 BALTICCONNECTOR (planned) 3 BBL 4 YAMAL 5 SOUTHERN CORRIDOR 6 NEL (planned) 7 OPAL (planned) 8 JAGAL 9 MIDAL 10 STEGAL 11 SKANLED (planned) 12 NETRA 13 DEUDAN 14 MEGAL 15 IUK 16 SEL (planned) 17 BALTIC PIPE (planned)

Selection of major pipeline-transportation routes

ImportImport gap 2025, 195 bcm

EU domesticgas production

42%

58%

2005543 bcm

Demand

Source: European Commission, Directorate-General for Energy and Transport, 2008

140 bcm additionalgas import needs

55 bcm of the gap is to be secured by Nord Stream

19%

81%

2025629 bcm(Forecast)

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8181%%

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5cmast))

3800Shtokman

field

bcm10400

bcmYamal

Peninsulafields

Nadym-Pur-Tazdistrict

13900bcm

VyborgVyborgVyborg

GreifswaldGreifswaldGreifswald

SwitzerlandSwitzerlandSwitzerland

FranceFranceFrance

BelgiumBelgiumBelgiumLuxembourgLuxembourgLuxembourg

The Nether-lands

The Nether-lands

The Nether-lands

GermanyGermanyGermany

Czech RepublicCzech RepublicCzech Republic

AustriaAustriaAustria

ItalyItalyItaly

UnitedKingdom

UnitedKingdom

UnitedKingdom

DenmarkDenmarkDenmark

Nord Stream welcomes the recent debate in theEuropean Parliament (EP) on its pipeline projectand is working on the final draft of an EnvironmentalImpact Assessment (EIA) report. It will present thisdraft report within the Espoo process for final con-sultations in October 2008.

The report emphasizes Nord Stream’s policy of trans-

parency and presents results from the most detailed

scientific surveys and research ever undertaken in

the Baltic Sea. It will contain responses to the hun-

dreds of comments received from governments,

non-government organisations and individuals since

November 2006.

Nord Stream believes the EIA report will add to

growing understanding for the pipeline project at the

level of European politics. On 8 July 2008, in a posi-

tive and unusual move, the EP debated and approved

more than 50 amendments before adopting a report

from its Petitions Committee (PETI).

A Polish Member of the European Parliament initiated

the original, more critical, report after submissions

from Lithuanian and Polish petitioners in 2006. It

sought direct European Commission involvement in

assessing Nord Stream’s environmental impact. EU

Environment Commissioner Stavros Dimas emphasi-

zed that this is the legal responsibility of national

governments.

Nord Stream welcomes the changes made to a

“inaccurate report.” In particular, the amendments

adopted by the EP plenary voting recognise:

• Nord Stream’s status as a TEN-E project of Euro-

pean Interest, as approved by the Parliament in 2006.

• The need for joint European action to secure future

energy supplies.

• Continued growth in European gas demands

requires analysis and promotion of new gas pipe-

line routes.

EUROPEAN PARLIAMENT STRESSES THE IMPORTANCE OF NORD STREAM FOR SECURING EUROPE’S ENERGY SUPPLY

Swedish and Polish ambassadors to Latvia, as well

as officials from Latvian ministries attending, the

Baltic Youth Philharmonic played a repertoire ranging

from Beethoven to Dvorák.

The Baltic Youth Philharmonic will come together for

a second round of rehearsals in 2008 at the Usedom

Music Festival, a major classical music event in Ger-

many. A second concert is schedule for 21 Septem-

ber 2008 during the festival in Peenemünde, Germany.

For additional information please visit:

www.baltic-youth-philharmonic.org.

Seventy of the most outstanding young music students from ten nations around the Baltic Seaconvened in Riga, Latvia, to perform music to-gether without borders.

Nord Stream and the Usedom Music Festival initiated

the Baltic Youth Philharmonic. The common idea

behind the orchestra is to unite the Baltic Sea region.

Both partners have laid the foundation for a promis-

ing project – an orchestra that will transcend geo-

graphical and artistic boundaries and will give young

musicians at the beginning of their careers a unique

opportunity to develop. The Baltic Youth Philhar-

monic will contribute to the understanding between

young people from around the Baltic Sea and

emphasize their shared cultural heritage.

Renowned conductor Kristjan Järvi leads the Baltic

Youth Philharmonic and offers the ideal artistic per-

sonality. The talented musicians, who had previously

never played together, re-hearsed from 30 May to

5 June 2008. These rehearsals culminated in a con-

cert at the Great Guild in Riga. Under the patronage

of Latvian Prime Minister Ivars Godmanis, and with

UNIFYING THE BALTIC SEA REGION – THE BALTIC YOUTH PHILHARMONIC’SPROMISING DEBUT CONCERT

NORD STREAM: FACTS | ISSUE 7 | 08 – 2008

Head OfficeNord Stream AG

Jens D. Müller

Grafenauweg 2

6304 Zug, Switzerland

Tel +41 41 766 91 91

Fax +41 41 766 91 92

Moscow BranchNord Stream AG

Irina Vasilyeva

ul. Znamenka 7, bld 3

119019 Moscow, Russia

Tel +7 495 229 65 85

Fax +7 495 229 65 80

press@nord-stream.com | www.nord-stream.com

Contacts

DID YOU KNOW …

• The Nord Stream pipeline will supply Europe

with 55 billion cubic metres of natural gas per

year, equal to energy transported by 550 LNG

(liquefied natural gas) tankers or produce by

240,000 average windmills.

• These 55 billion cubic metres would be enough

energy to satisfy the demands of 26,5 million

European households (EU-27) for one year.

• Using this much natural gas instead of lignite

would reduce CO2 emissions by 55 million tons –

as much as Denmark produces per year.

NORD STREAM’S AGENDA

September 10–13 Economic Forum of Central

and Eastern Europe, Krynica, Poland

September 21 Baltic Youth Philharmonic, concert

at the Usedom Music Festival, Peenemünde, Germany

For subscription to subsequent issues

of “Nord Stream: Facts”, please go to:

www.nord-stream.com/newsletter.html.

If you have any comments or requests,

we look forward to hearing from you.