New technology and bundled services benefit pipeline operator

A pipeline integrity management plan (IMP) is a complex process that requires a broad framework of interoperable procedures and practices. A comprehensive IMP requires a pipeline operator to use extensive internal and external resources to accomplish its goal of operating a safe, reliable, and cost-effective system. In doing so, an operator must manage a small army of vendors, contractors, and consultants to perform the specialist integrity services not always available within its own workforce.

Vendor selection for completing integrity work is an essential process that requires an operator to accurately define the project’s technical and business requirements, as well as have an awareness of the latest technologies and methodologies available for completing the specialised work. Once the project’s parameters are understood by internal stakeholders, the next step is identifying the most experienced and qualified service provider whose ideologies align themselves best with the predetermined requirements, and who will complete the work in the safest and most economical manner.

The project

A major South Australian gas transmission pipeline company recently went through the vendor selection process to complete the final stages of their most recent integrity program for their 559 mm
pipeline. With the in-line inspection (ILI) surveys previously completed, it was now time to investigate the findings of the ILI reports. The company’s integrity engineers determined that 29 pipeline locations needed direct examination. The dig locations spanned a distance of 320 km over remote and inhospitable terrain.

The vendor

Mears Integrity Solutions, a Quanta Services Company with over 40 years’ experience in the pipeline services industry, presented the pipeline owner with a unique service package that included the bundling of a broad range of integrity and engineering services, as well as a proprietary web-based software solution that would expedite the decision-making and remediation process extensively.

The advantage of using one service provider is in the transparency of the relationship. With one point of contact and one point of responsibility, without the need for additional sub-contractors, operators free up a significant number of their own resources – resulting in substantial internal cost savings.

Direct assessment with integrated crews

The Mears integrated pipeline crews consisted of two teams of Mears employees, including supervisors, abrasive blasting operators, non-destructive testing (NDT) technicians, coating applicators and labourers. Each team was supported by senior project and construction managers, as well as 24-hour access and support from engineers specialising in metallurgy, corrosion, and pipeline integrity. Crews completed approximately one dig location per day for 26 continuous days at excavation lengths ranging from 8-18 m. The initial assessment of each location included the excavation, coating removal, abrasive blasting, and NDT of anomaly locations.

The advantage of embedding crews with specialised personnel, for example NDT technicians, was that it eliminated the need for the operator to provide one of their own engineers or specialists onsite. The integrated crews also created efficiencies in scheduling, and time and resource management.

Transmission corrosion assessment tool

Mears have developed a proprietary data collection and analysis software package that utilises hand-held tablet computers along with global positioning system (GPS)-enabled cameras to bring the most modern technologies to the excavation site. The result is real-time access to direct assessment data, which enables immediate analysis and decision-making capabilities. The secure, web-based software ensured data quality, increased efficiencies, and was fully customisable to accommodate specific operator requirements.

NDT technicians used the transmission corrosion assessment tool tablet computer to directly upload pipeline data from the trench, including photos with GPS co-ordinates, pipe to soil measurements, soil resistivity, corrosion profiles for RSTRENG calculations, anomaly mapping, corrosion cell pit depths, weld types, wall thickness and magnetic particle inspection results. When connected to the internet, the tablet then provided remote real-time access to the field data, enabling offsite engineers to complete the analysis and risk calculations associated with the findings, which resulted in a quicker decision-making process with regards to making necessary repairs and remediation. Recommendations for repairs (where required) were provided to the operator within 24 hours, with most averaging 12-18 hours, thus allowing the operator to act and address any matters quickly, and return the line to full operating pressure faster, post-repair.

Remediation

Specially trained Mears installers completed the required composite repairs using an approved pipeline wrap repair system. Once again, crews were embedded with trained personnel and equipment to make the necessary repairs without the need for scheduling additional personnel and resources on what was a very remote jobsite.

The excavation locations were then recoated by coating specialists with an approved coating system and the pipe was backfilled, completing the inspection and remediation process.

The outcome

The project was completed two weeks ahead of schedule, with no lost-time incidents or injuries. The estimated cost savings to the client were significant as the pipeline operator was able to save on resources, time and money by bundling services and utilising new technologies that resulted in efficiencies that were previously unavailable. This was achieved because of the exceptional planning and communication between the operator and the contractor, and the use of new technologies that allowed for expedited analysis and decision-making.

Upon completion of the project, the Pipeline Operator’s Manager of Engineering Services said “This is the first time we have utilised a specialist contractor to perform all services on our pipeline dig-up program, including the NDT, engineering assessment and repair recommendations. We are happy with the way the project was delivered safely, ahead of schedule and under budget. It demonstrated excellent co-operation between our own staff and the contractor, Mears.”

Scope of Mears’ in-line verification work on the South Australian pipeline project