Innovations Magazine for the second quarter of 2013 brings you stories including the following: “History in an Ancient Place” - TDW achieves two firsts as it introduces Kazakhstan to STOPPLE® Train plugging technology, “Where We Work”- President and CEO Bruce Binkley discusses the story of where TDW works, “Safety Matters: A Show of Hands” - TDW mitigates hand and finger risks associated with inline inspection magnets, “Faces and Places” - Looking at TDW events and projects from around the globe, “Special Event: Creating Industry Leaders” - The Southern Gas Association teams with T.D. Williamson, “Five Questions: Clamp Installation Tool” - Diverless, remote-controlled system for installing subsea fittings or clamps, “TDW on Tour” - Find out where and when you can see TDW technology in person.
4. A few years back, I was part of a meeting in which the topic was our need
for a new corporate brochure, something to document who TDW is as
a company and what we offer the marketplace. During the discussion,
someone mentioned that we need to include a job site photo to show where
we work. I remember thinking, sure, it’s great to show a photo of TDW
equipment and technicians at work on a customer’s pipeline, but that does
not fully capture what we do once we are inside the line. After all, that’s
really where we work: inside pressurized systems of all shapes and sizes.
More recently, a business colleague asked me about the “meaning” of the
TDW logo. “What story does it tell?” was his exact question. “Well,” I said,
“it tells the story of where TDW works: inside pressurized piping systems.”
And the more I’ve thought about it, the more I see how true that is.
Of course, to some eyes, our circular logo with a descending blade may
only seem to show a tapping operation. That’s understandable, especially
since hot tapping has long been synonymous with TDW. But, in essence,
the logo also represents the full range of TDW inline capabilities: hot
tapping and plugging, pigging, pressure isolations, and integrity inspections.
All of these activities take us inside our customers’ pressurized systems,
from transmission and distribution lines to gathering systems and subsea
networks. At the end of the day, I think the TDW logo says far more
about where we as a company actually work than a single job site
photo ever could.
One of the chief reasons our customers allow us inside their valuable assets
is our repeatedly demonstrated ability to provide products and services not
offered by anyone else. A great example of this is the recent intervention
work we did on a high temperature steam line in Kazakhstan. You can read
more about that innovative project in the Cover Story beginning on page
8. As you read that story and the other features in this issue of Innovations™
magazine, I hope you’ll be reminded of precisely where TDW works, each
and every day.
Until next time,
4
by Bruce Binkley,
President and
Chief Executive Officer
Innovations | April-June 2013
At the end of the day, I think
the TDW logo says far more
about where we as a company
actually work than a single job
site photo ever could.
Where We Work
5. In 2012 TDW began to experience notable company-wide
improvement resulting from the organizational implementation
of Lean Six Sigma (LSS). As a Health, Safety and Environment
(HSE) specialist, I was asked to participate in LSS Green Belt
training. At the time, it was difficult for me to imagine how LSS,
a waste and variance reduction methodology, could improve
TDW safety performance. To my surprise, I was able to identify
specific areas where LSS would contribute vital process changes,
resulting in the significant reduction in incident rates.
I began by researching TDW incident trends, utilizing the
DMAIC process (Define, Measure, Analyze, Improve and
Control). The prime attraction of DMAIC is being able to make
specific improvements following the first three phases (Define,
Measure, Analyze). Gut-feelings and guesswork are removed as
the statistics highlight the processes that require improvement.
The results spoke for themselves and told me precisely where
I needed to focus. Approximately one-third of TDW’s overall
injures were hand and finger related (2010-2012). Although
this rate was on
par with our
industry peers, it
provided us with
an opportunity
to be better, safer.
My challenge to
TDW: significantly
reduce hand and finger related incidents to meet our new HSE
performance goals.
Although my research was revelatory, the improvement phase was
the most exciting, as it involved working directly with operations
management to implement very specific and actionable
improvements. I was tasked with demonstrating how conceptual
process improvements would practically reduce hand and finger
related incidents. As a testament to TDW thought leadership,
every management group that I worked with was eager to
implement the proposed improvements.
Global Pipeline Integrity, also
known as the Inline Inspection
(ILI) group, was most eager to
review my findings and begin global
implementation, particularly of those
improvements related to magnets.
Many ILI members work with or
around ILI tools containing powerful
magnets. Due to the extreme level
of magnetism required for the tools, they can be quite hazardous,
accounting for a large portion of the ILI hand and finger related
incidents. My conversations with operations brought to light
several anecdotes, such as when a courier was walking through
an ILI shop with a metal clipboard and inadvertently passed too
close to a magnetic tool. His metal clipboard was ripped from his
hands, resulting in a familiar loud “CLANK.”
Throughout the years of innovating with such powerful magnets,
TDW has adopted and developed many industry best practices
and procedures, including specialized training, isolation
storage and work cell design (developed to spatially reduce
magnetic hazards). Building on their commitment
to safety, TDW has already fully implemented
several of the LSS ILI improvement proposals,
with more currently in pilot testing, including
work cells constructed of non-magnetic materials
and use of non-magnetic hand tools.
The adoption of Lean Six Sigma,
in conjunction with a
team effort from safety
stakeholders, is making
a quantifiable difference
in how we approach and
mitigate hazards within
TDW. l
by Steve Sorensen,
HSE Specialist
SafetyMatters
TDW mitigates hand and finger risks associated with inline inspection magnets.
A Show of Hands
I was tasked with demonstrating how
conceptual process improvements
would practically reduce hand and
finger related incidents.
5
6. 1
2
3
6
Innovations | April-June 2013
1. Illinois / 109-miles and 20-inches
TDW recently launched its new 20-inch Multiple
Dataset (MDS) inline inspection tool with the
successful run of a 109-mile, 20-inch pipeline
in Illinois. The tool contained Deformation,
axial Magnetic Flux Leakage (MFL), patented
SpirALL®MFL (SMFL), Low Field MFL (LFM) and
XYZ Mapping. The 20-inch MDS tool continues
a TDW tradition of introducing ground-breaking
inline inspection technology to assist operators
in improving pipeline integrity.
2. New Hebron, Missouri / Putting on the Brakes
In May, a gas distribution operator approached TDW requesting
geometry and metal loss inspection of two high flow natural gas
pipelines, 36-inch and 42-inch, operating at speeds exceeding the
limits of standard inline inspection tools.TDW’s collapsible magnetizer,
utilized for metal loss inspection of pipelines with compressible
mediums, naturally allows bypass across the device. Combined with
TDW’s speed control drive section, which has a cavity allowing gas
to flow through, the tool was slowed for successful inspection. The
tool also included high resolution deformation technology, allowing a
geometry and metal loss inspection to be performed in the same run.
4. Houston, Texas /
Uniquely Tasked
TDW recently hosted a
Southern Gas Association
three-day inline inspection
workshop (pg. 12). Building
on the momentum of this
event, SGA invited TDW to
contribute to their most
recent three-day training
program, Pipeline Repair
Methods Workshop —
Safely Managing the
Lifecycle of Pipelines, held
May 21-24 at the SGA
facility in Houston, TX. This
workshop was designed
to provide operations and
maintenance personnel
with the requisite
knowledge and industry
expertise to assess and
address the full range of
pipeline repair challenges
and solutions.
3. Louisiana / Swallowed by the Swamp
In the swamps of Louisiana, TDW customized a unique smart tool
tracking solution. After a valuable tool became lodged in the miles
of hidden pipe, TDW coupled existing SmartTrack®technology
with innovative methodology to overcome the varying swampland
challenges and locate the lodged tool.
4
7. 7
5
6
Looking at TDW events and projects from around the globe.
7
7. Warsaw, Poland / Anniversary Celebration
TDW just celebrated its 20th anniversary in Poland by hosting “TDW Poland 20th
Anniversary,” a pressurized pipeline technology conference in Warsaw. Special
guests from the oil and gas community enjoyed a wide range of lectures given by
TDW’s industry experts. In addition to providing empowering insights into evolving
and emerging technologies, lecturers emphasized the latest developments in
pipeline isolation and inspection, including the STOPPLE® Train intervention
system, LOCK-O-RING® Plus fittings, and the SpirALL® magnetic flux leakage inline
inspection tool. The conference served as a genuine thank you to the operators
and partners that have helped TDW flourish in Poland. It also provided attendees a
unique opportunity to interact with the technology and the subject matter experts
who drive TDW innovation.
6. Stavanger, Norway /
Saving Technology
TDW announced the introduction
of its Clamp Installation Tool (pg.
14), a new remote-controlled
system that makes it possible
to install any proprietary fittings
or clamps on subsea pipelines
in need of repair or to prepare
for tie-ins to new pipelines. The
lightweight CIT is operated via
remote control through a laptop
by an experienced technician
on-board a platform or a diving
support vessel (DSV). As a result,
operational safety is enhanced,
and control over fitting installation
operations is greatly improved.
5. Australia / Extreme Pressure
Just outside of Karratha, in the remote
desert of the Pilbara Region in Western
Australia, at an operating pipeline pressure
of approximately 1480 psi (102 bar), TDW
performed the highest pressure STOPPLE®
Train pipeline intervention in the company’s
history. Assisting the operator in avoiding
a costly shutdown and depressurization
of a significant section of the line, TDW
maintained pressure and production flow,
while making it possible for the operator to
safely remove and replace a valve.
8. Innovations | Jan-Mar 2013
Nestled between Russiaand China, this multiethnic, multifaith,
multifaceted nation of 17 million has engineeredits own
evolutionand recent participation on the global stage,
in part, through the cultivationof its energy industries.
9. Historically renowned for its equestrian skills and horse
husbandry, and more recently for its vast oil and gas resources
and growing energy infrastructure, Kazakhstan is a beautiful
and unique country merging cultural antiquity with vibrant and
modern Eurasian culture.
Nestled between Russia and China, this multiethnic, multifaith,
multifaceted nation of 17 million has engineered its own
evolution and recent participation on the global stage, in part,
through the cultivation of its energy industries. Confirmed
oil production estimates position Kazakhstan as one of the 10
largest oil producers in the world. With development of these
national resources, Kazakhstan has received tens of billions
in infrastructure investments over the last two decades. These
investments have been accompanied by thousands of miles of
gathering, transmission and distribution pipelines, as well as an
increased expectation of safe and efficient maintenance of
these assets.
220° OF SEPARATION
In the spring of 2013, a Kazakhstan-based customer approached
T.D. Williamson (TDW) for isolation services. This time, it was
a key oil and gas processing operator needing line isolation to
replace a leaking valve on a six-inch, high temperature (220°C)
steam line in a processing plant. Already familiar with TDW’s
long history of hot tapping and STOPPLE® plugging isolation
within Kazakhstan, the operator trusted that TDW could provide
a safety-enhanced double block method to quickly isolate the line
so the faulty valve could be replaced, without forcing a shutdown
and line bleed.
The traditional, and often most familiar, method for isolating a
section of pipeline, using a double block, would require cutting
two holes upstream from the area designated for repair. A
single plugging head would then be inserted into each opening,
stopping the downstream flow and effectively isolating the area
between the two heads and the nearest downstream valve. Once
the isolated material was removed from the line, work would
begin. The workable area required for this method is significant,
as it must accommodate the installation of two hot tapping and
plugging stacks.
The operator, in order to achieve the desired double block
isolation, was prepared to take the traditional approach, willing
to double both the cost and safety risks associated with twice
entering a pressurized line. However, during the consultation
process, TDW personnel discovered that the leaking valve was
in a tightly confined area of the plant, which created a barrier to
the traditional isolation method. In response, TDW technicians
offered the operator a game-changing alternative.
A skilled rider deftly racing through the steppe on the back of a prize stallion
is a majestic sight for sure, albeit a common one in Kazakhstan, having been
observed there for the last 5,500 years.
History in an Ancient Place
TDW achieves two firsts as it introduces
Kazakhstan to STOPPLE® Train plugging technology.
THE COVER STORY
9
10. DOUBLE BLOCK AND BLEED
TDW originally developed the STOPPLE® Train double block
and bleed plugging technology for use on high pressure systems,
but the technology proved to be well-suited for applications such
as this. A true innovation in line isolation, the system allows two
plugging heads – fitted with next generation Ethylene Propylene
Diene M-class (EDPM) rubber sealing elements – to be inserted
through a single fitting. In this operator’s scenario, the insertion
was accomplished without even hot tapping the line, as the
system entered through an existing gate valve.
Since the STOPPLE® Train technology only requires a single
point of entry, the operator’s space challenges were easily
overcome. The operator’s safety concerns and desire for a double
block isolation were simply addressed through the inherent
double block function of the system. But as a bonus, by installing
a release valve between the two plugging heads, the pressure
was bled out – double block and bleed – creating a safe zone of
zero energy, allowing the valve to be replaced without the safety
risks and worry of seal leakage or, worse, catastrophic failure.
Throughout the operation, TDW technicians monitored the
pressure in the high temperature line, making certain that a safe
operating pressure of 20 bar (290.07 psi) was maintained.
10
Innovations | April-June 2013
Since the STOPPLE®Train technology only requires a single point
of entry, the operator’s space challenges were easily overcome.
“Because the customer chose to use the STOPPLE® Train
intervention method, the steam line was successfully isolated with
minimal intrusion, ” said Yerlan Andashev, Country Manager –
TDW Kazakhstan. “The resulting stable environment was critical
to the customer’s maintenance and servicing of the line. And since
we were able to perform the isolation without shutting down
production, we saved the operator substantial cost.”
HISTORY IS MADE
The global rise in STOPPLE® Train isolation operations can be
attributed to TDW’s ongoing efforts to build upon its record
in the United States, where it has carried out STOPPLE® Train
pipeline interventions onshore and offshore for nearly every major
operator. Although TDW’s STOPPLE® Train system was brought
to the international market in 2009, this particular double block
and bleed isolation was the first for Kazakhstan. It was also the
system’s first use on an extremely high temperature line. Two
historic firsts, both worth celebrating.
This successful isolation in Kazakhstan demonstrates
TDW’s commitment to offering its comprehensive service
suite to pipeline, refinery and petrochemical plant operators
throughout the world. l
THE GOLDEN EGG
The Bayterek Tower, located in the Kazakhstan capital
of Astana, is one of the country’s most identifiable
structures and a notable tourist attraction.
While we may have become somewhat desensitized
to artistic architecture so easily brought to us via
the Internet, travel television and film, the Bayterek
Tower, at 105 meters tall, isn’t simply a fanciful
design dreamt by a struggling young architect trying
to create a legacy. If you step back and take the
design in as a whole, you can’t miss that the 22
meter golden sphere resting among the spires
strongly resembles an egg sitting in a nest.
This egg and nest design pays homage to a popular
Turkic folktale, which tells how the magical bird
of happiness, Samurak, laid its golden egg in the
branches of the sacred tree of life. Visitors are
invited to travel up Bayterek – which translates to
“tall poplar” – and into the “egg of happiness.”
With a 360 degree view, visitors can see Kazakhstan
as a wonderfully complex country steeped in ancient
history, yet brimming with innovation and modernity.
Taken a step further, if the Bayterek Tower is viewed
in the context of Kazakhstan’s massive oil reserves
and global position, the country does indeed
possess the golden egg.
11. ®Registered trademarks of T.D. Williamson, Inc. in the United States and other countries. / TM Trademarks of T.D. Williamson, Inc. in the United States and other countries.
Chris Goller
TDW Senior Engineer
GLOBAL PIPELINE INTEGRITY CENTER: 801-747-1400
NORTH & SOUTH AMERICA: 918-447-5500
EUROPE/AFRICA/MIDDLE EAST: 32-67-28-36-11
ASIA/PACIFIC: 65-6364-8520
OFFSHORE SERVICES: 832-448-7200
At TDW, we believe in total
pipeline integrity solutions. Solutions driven
by unprecedented multi-dataset capabilities.
Leading-edge data analysis. And more than
90 years of engineering expertise. After all,
inspection technology is only as good as the
people behind it. And we think ours
are the best.
For more information about SpirALL MFL technology
and our entire line of pipeline integrity solutions,
contact your nearest TDW representative or
visit www.tdwilliamson.com.
SpirALL®MFL Technology
Patented SpirALL MFL technology lets you
see what you’ve been missing.
We’rechanging thefaceof
…with a whole new look at mechanical damage.
inlineinspection
12. 12
by Chuck Harris, Manager
Strategic Commercialization,
Pipeline Integrity Solutions
Special Event
The Southern Gas Association teams with T.D. Williamson.
Creating Industry Leaders
As federally mandated pipeline integrity requirements have
become increasingly stringent, pipeline operator personnel
are under greater pressure to keep pace. In an effort to assist
its members in acquiring a broader scope of inline inspection
training, the Southern Gas Association (SGA), based in Dallas,
TX, now offers its respected four-day Pipeline Inspection Using
Intelligent Pigs Workshop as two distinct three-day programs:
Practical Inline Inspection and Advanced Inline Inspection. One-
half of this fresh format was recently and very successfully
implemented, in conjunction with T.D. Williamson (TDW),
with the first-ever Practical Inline Inspection Workshop.
The three-day workshop was conducted May 7-9th at TDW’s
manufacturing plant in Tulsa, OK. The TDW Technology Center
housed the classroom portion of the training, while its 1100-
foot, 12-inch test loop was the site for much of the hands-on
portion. SGA’s curriculum included topics such as: Introduction
to Intelligent Pigging, Pigging Field Operations Success Factors, Data
Handling and Reporting, Data Analysis Demonstration and Pipeline
Defect Analysis.
JOINING FORCES
Due to the extensive pipeline histories of both SGA and TDW,
combining expertise and efforts on the new Practical Inline
Inspection Workshop made sense. The purpose was to provide
operations and maintenance engineers, and pipeline field
technicians with the knowledge to establish and manage an
intelligent pigging program that contributes optimum value
toward improved pipeline integrity.
“Hosting the workshop at the TDW facility really added value
to the training experience,” says Mike Grubb, President and
CEO of SGA. “Seeing equipment and tools up close helped
the participants better understand how inline inspection works.
Innovations | April-June 2013
John Morrow, of TDW, prepared attendees for physically locating and
tracking a pig at TDW’s test loop.
TDW worked really hard to make sure the students got to
experience, in a lab environment, something similar to what they
will experience in the field.”
“Offering to host SGA’s inaugural workshop was a win/win
situation,” says John Morrow, Training Manager – TDW Global
Services Development. “We engineer the customer solutions that
the attendees will actually utilize in the field. What better place
for them to get hands-on experience and training, than from the
manufacturer of the equipment and technology they will use?”
13. 13
WORKING FOR THE INDUSTRY
Fraser Farmer, Director of Operations Support for SGA, kicked
off the Practical Inline Inspection Workshop by bringing attention
to the many talented contributors who were in attendance
and would be presenting, including two of the original course
founders: Dr. Tom Bubenik of DNV Columbus and Dr. Bruce
Nestleroth of Battelle. Farmer promised that the students would
receive an empowering three days of knowledge sharing and
unparalleled hands-on experience.
One of the first lectures of the multiday training event was
presented by Bruce Nestleroth, of Battelle. He introduced the
class to a variety of inline inspection technologies including
Magnetic Flux Leakage (MFL), Ultrasonics (UT) and Electro-
Magnetic Acoustic Transducer (EMAT).
Discussing tool launcher and receiver design, Lee Shouse,
Manager – TDW Special Research and Development Projects,
and John Morrow prepared attendees for physically locating
and tracking a pig at TDW’s test loop. At the loop, Shouse
shut down the pumps to stall a tool in the line. Morrow then
demonstrated the location/tracking process with TDW’s
TracMaster™ Magnetic Pig Tracking and Locating System.
TracMaster provides a visual display, as well as an audible
signal, of pig movement within a pipeline.
Another technology driven lecture, NDE Techniques for Field
Validation of Inline Inspection Results, was presented by TDW’s
Non-Destructive Evaluation (NDE) Coordinator, Jeremy Clark,
who led the groups through various types of cutting edge NDE.
Clark’s presentation included rapid corrosion assessment, quick
repair determination and thorough anomaly reporting.
Arguably the most popular activity, the Defect Scavenger Hunt,
was led by Bruce Nestleroth, who created this session during the
early implementation of the course. Attendees take what they
have learned from the workshop, including technologies, defect
detection capabilities and detection signatures, and they attempt
to match actual defects with recorded signatures from “raw”
inspection data. In this session, an 8-inch by 20-foot pipe section
was provided with known defects. TDW’s Multiple Dataset
technology (MDS) had been pulled through the pipe prior to the
exercise. Raw data samples for a defect set were then provided
from both axial MFL and SpirALL® MFL technologies. SGA
attendees set out to match the raw data signatures to actual defect
geometries, which included typical volumetric anomalies, as well
as notch or crack-like shapes.
ADDING TANGIBLE VALUE
Over the course of the workshop, there were many additional
hands-on discussions of technologies and their applications,
including Deformation (DEF), MFL, GMFL and TDW’s
KALIPER® 360 and SpirALL® MFL.
SGA is very pleased to report that, with their partner TDW,
the first Practical Inline Inspection Workshop was a tremendous
success. Grubb wrapped up the inaugural workshop by stating,
“SGA is a member driven organization. It is the support of our
members like TDW that helps keep us relevant. We very much
appreciate our long standing relationship and are thankful for the
opportunity to serve our members.” l
Lee Shouse, of TDW, discussing tool launcher and receiver design.
14. Innovations | April-June 2013
14
What is the Clamp Installation Tool?
The Clamp Installation Tool (CIT) is a diverless, remote-
controlled system for installing fittings or clamps on subsea
pipelines for repair or to prepare for tie-ins to new pipeline
networks. The tool is remotely operated via laptop by an
experienced technician onboard a topside diving support
vessel or platform.
What makes the CIT so special?
When coupled with TDW’s remote-controlled Subsea 1200RC
Tapping Machine, the entire subsea process, from clamp
installation to hot tapping, can now be performed without diver
involvement. Unlike other clamp installation systems, the TDW
CIT has the following unique features: topside operated remote-
control; can be configured to install any third-party supplied
clamp or fitting; continuous real time viewing and monitoring
via laptop; passive, remotely-operated vehicle interface makes it
easy to operate and minimizes ROV maneuvers.
What is required to use the CIT to install a
fitting or clamp?
The CIT is a self-contained tool with a built-in control and
hydraulic system. The CIT is a topside-driven machine with a
passive Remotely-Operated Vehicle (ROV) interface. The full
installation package consists of four basic units: an installation
frame that incorporates the installation tool, a control skid, a
third party-supplied work class ROV, and a clamp or fitting
provided by a third-party supplier.
In each issue of Innovations™
magazine, we answer a handful of questions
about one of the innovative products or services offered by T.D. Williamson.
on the Clamp Installation Tool
For more information, call 832-448-7200 or visit www.tdwilliamson.com
Is the CIT really faster and more accurate than
other similar systems?
Yes. Unlike other remote-controlled CITs, it employs passive
ROV interfaces. It also offers more accurate control than
other diver-assisted CITs because, as with the Subsea 1200RC
Tapping Machine, the technician can actually view and
control the installation operation as it takes place subsea,
rather than receiving only verbal updates from a diver via
radio. This allows for faster and more accurate decision-making
as to how the clamp should be manipulated throughout the
installation operation.
Does the CIT have applications for
emergency situations?
The remotely-operated CIT is ideal for use in emergency
situations where pipeline intervention and repair must be
carried out in hazardous environments, and concern for safety
is particularly high. With its ability to install fittings and
clamps of any type, the CIT plays a central role in assisting
customers with design and implementation of individual
Emergency Pipeline Repair Service (EPRS) programs. EPRS
involves preparing emergency repair solutions prior to a
failure event. l
15. Mark your calendars to see TDW technology in person.
2013
JULY
22-24 Southern Gas Association Operating Conference,
Houston, TX, USA
22-26 Louisiana Gas Association Pipeline Safety Conference,
New Orleans, LA, USA
AUGUST
13-15 Midwest Energy Association, Rochester, MN, USA
26-28 Tulsa Pipeline Expo, Tulsa, OK, USA
SEPTEMBER
10-11 Oil Sands, Fort McMurray, Alberta, Canada
10-12 Expogaz, Paris, France
17-19 Developing Unconventional Gas (DUG) Eagle Ford,
San Antonio, TX, USA
24-26 Rio Pipeline 2013, Rio de Janeiro, Brazil
OCTOBER
1 TDW Aberdeen Customer Appreciation Celebration,
Aberdeen, Scotland
12-15 APIA Annual Convention and Exhibition,
Adelaid, Australia
22-24 Offshore Technology Days, Stavanger, Norway
15
Need more information or want to schedule an appointment with TDW personnel at any of the events? E-mail us at tdwontour@tdwilliamson.com.
White Paper: George Lim on overcoming ultra deepwater hot
tapping challenges by remote control.
White Paper: Chuck Harris on the use of speed control technology to enable
inline inspection on a high flow line.