pigging takes aim at paraffin content in shale play pipes...managers for pigging technology....

42 | Pipeline & Gas Journal • August 2015

t a meeting of the American Fuel and Petrochemical Association, Michael Wojchiechowski, an economist at global energy con-sultant Wood Mackenzie, referred

to the production from U.S. shale deposits as a “tight-oil tidal wave” — in other words, a large, unstoppable, liquid force.

But as operators from the Bakken to the Eagle Ford and Niobrara to Marcellus know, there are plenty of challenges to keeping that enormous flow going, one being the high paraffin content of shale oil.

Shale oil is full of highly variable paraf-fin. In fact, as many as 70 different types turned up in a single oil sample taken

from the Eagle Ford, according to a recent Hydrocarbon Processing report. In addition to creating processing and refining prob-lems, shale oil paraffin can lead to financial disasters closer to the wellhead.

For example, stubborn waxy deposits accumulating on gathering line walls can reduce the pipe’s effective internal diameter, causing flow rate to slow or production to cease altogether. What’s more, when wax adheres to the sides and top of pipe interi-ors, water can collect in low spots, encour-aging bacteria growth that can lead to corro-sion and pinholes. Compressors also have to work harder to pump through paraffin-filled lines, and that adds to operating costs.

It’s no surprise, then, that paraffin control is a key concern in shale plays. This goes beyond simply keeping the pipe bore open; the ultimate goal is to completely clear the pipeline, then prevent future wax buildup.

Not only is a clean line fundamental to maintaining performance, getting the wax out improves pipeline integrity by facilitat-ing first-run success of an inline inspection tool - which is becoming more important as the Pipeline and Hazardous Material Safety Administration (PHMSA) considers regu-lating gathering line integrity inspections. PHMSA spokesman Damon Hill said that although PHMSA hasn’t seen any particular evidence that shale oil has affected pipeline

Pigging Takes Aim at Paraffin Content in Shale Play PipesBy Jeff Wilson, Ph.D., Chief Technology Officer, T.D. Williamson, and Abdel Zellou, Ph.D., Market Development Director - Gathering & Midstream, T.D. Williamson, Tulsa, OK

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“Operators have had to manually run as many as 60 pigs to get a single dirty line completely cleared,” he said.

Once the pipe-line is clean, routine maintenance pig-ging — generally performed weekly for most waxy crude

lines — is in order to prevent contaminants like paraffin from accumulating, and to max-imize throughput.

To help operators reach those goals, global pipeline service provider TDW has developed an automated pig-only launcher that can be remotely programmed to launch several clean-ing pigs, sequentially, at designated times and intervals. The SmartTrap® Automated Pig System — or “AutoPig launcher,” for short — is an extension of the SmartTrap product line, which already includes the AutoCombo system. The launcher is currently in the design validation phase with commercialization anticipated later this year.

The launcher was created at the request of operators who appreciated the capabilities of the AutoCombo — which launches both spheres and pigs — and asked TDW to meet

their needs for a pig-only launcher. Geren said the launcher will help opera-

tors respond to cost pressures by signifi-cantly reducing the number of trips crews make to the field. He also estimated a substantial safety increase, compared to traditional manual launchers.

“The riskiest part of a pigging operation is opening and closing the door,” Geren said. “With the AutoPig launcher the closure door is opened and closed fewer times than if you were manually launching one pig a day. The line is also pressurized and depressurized less often.”

With a torrent of shale oil continuing to lift the North American oil and gas industry, operators are constantly seeking new ways to increase throughput. Innovations that increase safety and performance, while reducing costs, will keep them doing just that — riding atop the “tight-oil tidal wave.” P&GJ

integrity, the agency continues to study potential gathering line hazards.

Increasing Throughput: Easier, Less Expensive, Safer

It can take a combination of mechanical, chemical, and other cleaning techniques to eliminate all of the wax and debris from pipelines that carry shale oil, waxy crude, or natural gas liquids (NGL), said Troy Geren, one of T.D. Williamson’s (TDW) global pigging technology product managers. A good place to start is to soften the wax with chemicals, then deploy a progression of cleaning pigs, gradually working up from light tools — like foam pigs — to more aggressive tools, including urethane blades, cups, discs, and metallic brushes.

Geren also suggested having plenty of patience on hand.

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Pigging Help DeskAlthough operators agree on the “why” of pigging — to keep the

pipe bore open and product flowing — many find that the “hows” and “whens” can be a little bit trickier to determine.

Another challenge? Knowing exactly which pig to run. Whether pigging is being planned to clear a dirty line or as part of a routine maintenance strategy, decisions like these are all part of the calculus.

Despite some widely accepted industry guidelines, establishing an appropriate pigging practice isn’t a completely cut-and-dried proposition, said Stephen Miska, P.E., one of TDW’s global product managers for pigging technology.

“Pigging choices depend on several variables, such as product composition, temperature, flow rate, and pigging history, as well as pipeline conditions, wall thickness, bore reduction, bend sizing, valves etc.,” Miska said.

The type of deposit that forms in the pipeline — iron sulfate, mineral scales, bacteria, paraffin, black powder, asphaltene, degrad-ed compressor oil, amines, and glycol, to name a few — also affects pigging decisions.

In other words, making the wrong pig choice might result in an inef-fective cleaning with no real benefit, not to mention a waste of money.

Or the consequences could be far worse, such as launching an overly aggressive pig into a line that hasn’t been pigged frequently enough and it gets stuck, ultimately causing an entire system shutdown.

To help operators fully leverage their pigging programs, Miska said, T.D. Williamson offers consultation about pig selection and pigging frequency, and can custom-engineer pigs to match specific operational requirements. It also installs pigging equipment. n

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Srira

m F

oam

s (P

) Ltd

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l

FREETECHNICAL

INFORMATION SERVICE

Contact our members and panel of advisers to answer

your questions about pigging and pipeline integrity at:

[email protected]

CENTRE FOLD FOLD IN

PIPE

LIN

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PIG

SPI

PELI

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PIG

GIN

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OM

PON

ENTS

AN

D E

QU

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ENT

PIPE

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GG

ING

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RVI

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IN L

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INSP

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CSIN

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GIN

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“Tra

nsne

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l

jd 216 id 2015 Am i n.indd 1 25/06/2015 13:18

www.pgjonline.com | 49



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BUYERS’ GUIDE

www.ppsa-online.com


BUYERS’ GUIDE


PIPE

LIN

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PIG

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jd 216 id 2015 Am i n.indd 1 25/06/2015 13:18


Rosen article

Reverse gatefold 6 page formOutput from other file

Page size differs

he ROSEN Group brought key industry stakeholders together for a roundtable on the topic of “Linear Threats in Pipelines,” on May 28. The event attracted over

100 attendees from throughout North America and Europe who were hosted at the ROSEN facility in Gahanna, OH.

The roundtable began with an offi-cial welcome by ROSEN Executive Vice President Chris F. Yoxall, who emphasized the importance of “why we are here.” He addressed the goal and set the tone for the day – bringing together all stakehold-ers to collectively work on common top-

ics of interest.The keynote

address from the company presi-dent and founder, Hermann Rosen, emphasized the need of being pro-active by undertak-ing preventative measures to miti-gate or minimize the effect of con-sequence manage-ment. Recognizing complexity, Rosen compared the human body to a

pipeline network, saying without good integrity management, failures can occur with unwanted consequence.

“Whether we talk about the pipeline network, an aircraft or the human body there are a lot of similarities,” he said. “We are talking about different diame-ters, flow rates, gravity, pressure, debris, scale, wall thickness, as well as valves and y-pieces, reductions, lifetime. There is a lot in common. If the integrity of such a system fails to due blockage, leak-age or rupture, this will cause a disaster, for example, a heart attack.”

Rosen recognized three groups of stakeholders, each having accountability – those involved in generating rules, the operators, and those proving technolo-

ROSEN Sponsors Roundtable on Linear ThreatsSpecial to Pipeline & Gas Journal

T

gies or services. In the short-term, these groups are all driven by performance indicators, while in the mid-term there has been more of a direction toward bet-ter alignment. In the long-term, there is a need for more alignment driven by cooperation, this is needed to achieve the ultimate no incident industry objective.

Rosen concluded by urging more assemblies of this nature. He also sug-gested “pro-active management and col-laboration of [all] stakeholders to avoid consequence management.”

Steve Nanney, representing the fed-eral Pipeline and Hazardous Materials Safety Administration (PHMSA), spoke on behalf of the regulatory environment, reflecting on past incidents and the effects on rule-making and recommendations. His presentation generated questions per-taining to some of the future rules that may be introduced including the Integrity Verification Process, as well as the need for hydro-testing at 1.25 X MAOP.

Stuart Saulters, representing the American Petroleum Institute (API), spoke about the institute’s strategic ini-tiatives. He referenced standards that relate to addressing linear threats, API6. RP 117.

David Chittick, director of Pipeline Engineering from TransCanada

Steve Nanney (PHMSA), Dr. Brian Leis (Consultant), Thomas Beuker (ROSEN Group) and David Chittick (Director TransCanada) (l to r).

A wide array of tools were displayed at the meeting.

Hermann Rosen


Pipelines (TCPL), offered an operator’s historic overview, keeping a perspective of technology and standards, manage-ment systems, and improved culture. Chittick reflected upon all the differ-ent efforts undertaken by TCPL over the last three decades, emphasizing the importance of reliable and accurate technology to support the decisions being made by operators. He also rec-ognized that all stakeholders need to be fully committed to achieving the long-term needs.

Thomas Beuker, ROSEN corporate marketing director, complemented Chittick’s presentation by discussing the need to understand big data. Beuker provided an overview on the process associated with advanced analytics, keeping the need for dynamic learning, accuracy and confidence and predic-tion in focus. Data-gathering capabili-ties are growing exponentially and the importance of being able to manage this accordingly, needs to be understood, he said.

Beuker gave an overview of the process

and expectations. However, today’s capa-bilities make more data available offline, allowing for more support in the interpre-tation process. IT changes outside the ILI tool are also required to support big data. This includes remote control, which offers scalable storage globally to remotely access data in shorter time frames, allowing for quicker decisions to be made.

Rounding out the event, Brian Leis of Battelle Research Center summa-rized the presentations and provided some f inal thoughts. His observations included: n Blunt vs. Sharp (planar vs. volumetric) n Quantif ication of the size? Or the

shape? n The failure process and implications

of collapse versus fracture control n Understanding the importance of bal-

ancing conservatism with accurate models

He concluded by recognizing industry gaps and needs, encouraging big picture thinking and emphasizing that cooperation by all stakeholders is a key parameter to the way forward. P&GJ

Thomas Beuker, ROSEN Corporate Marketing Director

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ipeline engineering specialist STATS Group was contracted by Apache North Sea Ltd. to isolate the Forties Pipeline System (FPS) so that subsea isolation valves

(SSIV) and piping spools could be safely installed and leak tested, avoiding the need to depressurize the entire pipeline system.

The 36-inch main crude oil line is a major pipeline network in the North Sea carrying 40% of the UK’s oil, with over 50 offshore assets flowing into the 169-km FPS, which runs from Forties Charlie platform to Cruden Bay terminal, transporting 700,000 bpd.

Aberdeen-based STATS provided two remotely controlled Tecno Plugs™, the first offering double-block isolation from pipeline pressure, with the second providing a local leak test boundary. The two-plug method maintains a safe isolation and provides a leak test boundary which prevents pressurizing the entire pipeline up to leak-test pressure.

A detailed engineering and piggability assessment confirmed the fitness-for-pur-pose of the Tecno Plug and identified a suitable set-location for the isolation plugs. An isolation committee from a subsea engi-neering and construction company assessed the suitability of the high-pressure remote isolation plug as a double-block barrier for diver-breaking containment activities.

The plugs were deployed and pigged in a train with two bi-directional batching pigs positioned ahead of the plugs. The complete plug train was pigged to the set-location using inhibited seawater to ensure the section of pipeline being removed was fully de-oiled, prior to breaking of containment preventing any oil release into the environment.

With the plug accurately positioned, it was hydraulically set to activate the locks and dual seals. Precise positioning and accurate tracking was provided by means of an assured subsea extremely low frequency (ELF) control system; this system also provides continuous monitoring throughout the isolation. The second plug was at loca-tion but was not hydraulically set until the construction scope was completed.

Independent testing of each seal with full pipeline pressure confirmed leak-tight isola-tion and the pipeline was bled down to subsea ambient from the platform launcher to the rear of the plug. The annulus between the seals was vented to ambient to create a zero-energy zone.

After an eight-hour isolation stability hold period, an ‘Isolation Certificate’ was

signed and the plug was confirmed as pro-viding double-block isolation of the Forties Pipeline, allowing the subsea construction phase to commence. Two pipeline spool pieces were removed to allow installation of the two metrology spools required to tie in the pre-installed SSIV arrangement to the pipeline and the Forties Charlie platform.

With subsea construction completed, the newly made-up flange joints were locally leak-tested at each gasket to provide initial confirmation of the joint integrity. This allowed the pipeline pressure to be equal-ized behind the isolating plug and the seals and locks were actively unset.

The rear plug was remotely operated to hydraulically set the seals and locks; once the barrier was proven, a reinstatement leak test of the newly installed SSIV was conducted by raising the pipeline pressure from the platform launcher to 158 bar against the leak-test plug.

The leak-test plug was then unset and the pipeline pressure equalized, allowing the plug train to be pigged through the newly installed SSIV back to the launcher on the Forties Charlie platform for recovery.

Pete Duguid, CEO of STATS Group, cited “the team effort across all par-ties involved” for the success of the project which was com-pleted incident-free and three days ahead of schedule.”

Mark Richardson, Apache North Sea Limited Projects group manager, noted that the complex pipeline isolation formed a major part of the SSIV project.

DNV GL Approves Isolation Tools

STATS Group said it has received the DNV GL seal of approval for its Tecno Plug and BISEP range of pipeline isolation tools. A world leading accreditation body, DNV GL has issued certificate P-15082 for the 3-48-inch range for both Tecno Plugs and BISEPs. According to STATS, the approval means that the products are fully compliant to the highest standards and do not require further work or adaptation by the end-user.

To date, STATS said it has completed

over 200 Tecno Plug deployments, includ-ing recent isolations in Oman, Malaysia, Canada and the UK Central North Sea.

STATS patented BISEP provides high-pressure intervention and isolation through a single hot tap penetration. Since its devel-opment less than 10 years ago, STATS has deployed over 60 hot-tapped isolations, enabling maintenance work to be carried out while meeting industry-led double block and bleed requirements.

Targeting the Americas for Long-Term Growth

Meanwhile, STATS said it has invested $2 million (£1.3 million) in new facilities in Houston to expand its services in the U.S. and South American oil and gas markets. The com-pany, which designs, manufactures and installs a range of high-tech pipeline isolation and intervention tools, has opened a 25,000-square-foot office and workshop facility on Brittmoore in northwest Houston and said it expects to add to its U.S. headcount over the next year.

Stephen Rawlinson, previously general manager in Canada, was promoted to vice president for the Americas, while Scott McNae was elevated from global projects manager to general manager for U.S. operations.

Rawlinson said: “We recently won con-tracts worth more than $15 million to provide intervention (hot tapping) and isolation ser-vices to one of North America’s largest ener-gy infrastructure companies and we believe we can replicate that success in the U.S.

“To be able to make the best out of emerg-ing opportunities we need local facilities in the Gulf of Mexico and feet on the ground. This investment in Houston will provide us with a framework to get in to the tendering rounds, quickly start mobilization when projects are confirmed and build on our track record of project execution in North America.”

STATS Group Completes Complex Isolation of North Sea Pipeline A Pipeline & Gas Journal

Staff Report

P

Pete Duguid, CEO, STATS Group

Stephen Rawlinson, vice president for the Americas

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