www.tdwilliamson.com July 2005 In This Issue: Archives Check out the past issues of our newsletters. Click Here FeedBack Have a suggestion, comment, or idea? Let us know about it. Click Here Contact Us! Subscribe Print Version Click the printer above to print out the text version of this newsletter. TDW Job-Site Solutions Visit TDW's Web site to learn more about how professionals in your industry have teamed up with TDW to solve their pipeline maintenance problems! Visit TDW Job-Site Articles HotTapsTDW.com PiggingTDW.com US Toll Free 1-888-839-6766 International 1-918-447-5100 Your Source for Piping Solutions. Solving a Dual Diameter Dilemma By Bob Warterfield A Canadian company owns and operates the longest crude oil and liquids pipeline system in the world and has over 55 years of liquids pipeline operations experience. It transports approximately 60% of Canadian crude oil to markets throughout the United States and Canada. The operator's 36-inch/48-inch dual diameter pipeline, "Line 4," carries heavy crude from Edmonton, Alberta in Canada to Superior, Wisconsin in the United States. It's a long 1,097 mile journey made all the more interesting by the unique configuration of the pipeline itself. It is the only large diameter pipeline of its type in the world. Unique PitBoss™ brush design and special disc shown here reveal negligible wear after first run. The dual diameter pipeline with 27 pumping stations traverses the Canadian/US landscape. At the head of each segment, there is a launch trap entering the 36-inch portion of the line. At the end of each of the 28 segments, a receiving trap collects dual diameter 36-inch by 48-inch pigs. Approximately two-thirds of the distance from each launcher, the line expands from 36 inches to 48 inches. While crude movement flows at a brisk and turbulent pace, keeping particles in suspension in 36-inch line segments, there is a defined reduction in the fluid velocity each time the line expands to 48 inches. When the crude flow slows at the 36-inch to 48-inch transition point, debris and water, which is heavier than oil, can precipitate to the bottom of the 48-inch line and lay down an ideal environment for internal corrosion. Void of active pigging, precipitants steadily accumulate and affect the pipeline flow. Based on careful review, the customer determined that a re-design of the existing cleaning and batching tools was required. Bidding began in mid-2004. Candidates were required to explain how they would meet the dual diameter challenge and provide a methodology to measure tool effectiveness. Tool effectiveness is a critical element in light of the substantial annual investment the company makes in anti-corrosion chemicals. 48" pipeline segment and receiver. TDW had already been providing successful service in the 36-inch X 48-inch lines with the KALIPER® geometry inspection tool. The line owners approached T.D. Williamson and Williamson Industries, Inc. with an invitation to engineer a custom solution for cleaning and batching project. A team headed by Jack Rankin, Manager, Engineered Solutions and New Products for TDW's Pigging Division flew to Canada to meet with company representatives. TDW made the trip to gain first-hand knowledge of the system and the pipeline's unique needs. The objective of the team was to clearly define a desired outcome. Back in Tulsa, Rankin and his team were able to draw from TDW's long history of providing innovative solutions for some of the industry's most difficult pipeline pigging challenges. Previous experience has included pigging dual-diameter pipelines. The design team was able to reference a large TDW collection of proven and patented technologies that apply to nearly any given pigging application. After a detailed review of the pipeline operator's needs, the team set the goal of proposing a solution that would not only satisfy, but also exceed many requirements. The result was the design of cleaning and batching pigs exclusively for the company's dual diameter 36-inch to 48-inch pipeline. The team incorporated a variety of field-tested techniques to address all issues and concerns. 36" x 48" PitBoss™ cleaning pig shown in transport container. Going into the design process TDW knew from the pipeline's historical data that: Debris exists in the bottom of the line for several miles beginning at the 36-inch to 48-inch transition. Internal pitting on the bottom of the 48-inch pipe is likely a result of water and debris settlement. Significant loss of inhibitor may occur due to bypass as the pigs enter the 48-inch pipe. TDW's design team quickly created a list regarding the requirements and considerations that would be included in their pig designs. The time frame for completion of the project was very tight. "It was less than six months from the time proposals went out to having new tools in the pipeline," said the line operator's senior engineer. It was helpful that TDW's turnaround time for design, fabrication and delivery was only eight weeks. The design for the dual-diameter cleaning pig incorporated many successful features currently used on other TDW pig designs. Overall body weight was reduced to help assure that the tool remained centered in the line. PitBoss™ brush assemblies were used for vigorous cleaning of pipe walls and to break up and remove deposits from pits. Discs on the cleaning pig and the batching pigs were all made of tough, abrasion-resistant polyurethane. All tools were designed for ease of maintenance. Several tool runs have been completed to date, and the development of a method to measure tool effectiveness is underway. However, for the customer, the project came with a valuable bonus. According to the operator's senior engineer, "The service component from a vendor is key to a baseline relationship where all participants can be involved in solving issues together." 36" x 48" batching pig (w/transmitter) being transferred from 48" receiver to 36" launcher. For a final perspective on the Canadian dual diameter line project, Jack Rankin stated, "In my 40 years, this was the toughest application to design a pig for. We pulled out all the stops." The senior engineer's final comment about TDW – "They've met the challenges to date and we look forward to continuing a strong working relationship." For more information about TDW's complete line of Pipeline Pigs call 1-918-447-5400; Launchers & Receivers call 1-918-447-5509. LineMaster™ 2005 Schedule T.D. Williamson, Inc. continues to provide the most comprehensive hot tapping, plugging and pigging instruction available in compliance with Department of Transportation covered tasks, standards and requirements. Rigorous hands-on training and operator qualification LineMaster™ programs are TDW's commitment to the industry. LineMaster Training assists you with ensuring that your technicians are trained at the highest level available. In our state-of-the-art facilities and with our pressurized simulated pipeline, TDW's LineMaster Training program is an in-depth series of classes designed to fulfill DOT Pipeline Safety Operator Qualification rules. To meet DOT requirements, training programs must include classroom time, written exams and hands-on simulated conditions. TDW's LineMaster Training meets these requirements. TDW LineMaster Training is the best in the business. The company you've trusted with your piping maintenance needs for more than 80 years has the experience to train your technicians and operators effectively and efficiently. 2005 LineMaster Training Dates Locations T-101 Class Sept 13 Tulsa, OK - USA Pigging Class Sept 14-15 Tulsa, OK - USA Transmission Class Sept 19-22 Tulsa, OK - USA Gas Distribution Class Sept 26-29 Tulsa, OK - USA New European Program call: 32-67-28-36-44 Nivelles, Belgium Class Information and Registration Form For more information, contact TDW at 918-447-5100 or toll-free at 888-839-6766. Or call your local TDW representative. New European LineMaster Training Program in Nivelles, Belgium contact Anne.Roberfroid@TDW.be or Call 32-67-28-36-44 Upcoming Trade Shows Don't forget to visit TDW's booth at upcoming trade shows. We are attending several in the next few months, including: Please check the entire 2005 show listing on the website. 2005 Trade Shows Dates Locations Western Regional Gas Conference August 24-25 Tempe, AZ Offshore Europe September 6-9 Aberdeen, Scotland Deepwater Operations Forum October 4-6 Galveston, TX Rio Pipeline 2005 October 17-19 Rio, Brazil You can submit other e-mail addresses by simply completing the fields below. Enter the email address you wish to add and select which version you wish to receive. email name Please choose the mailing list(s) you wish to join HTML Only Text Only To unsubscribe, forward this email and note "unsubscribe me". ® Registered trademarks of T.D.Williamson, Inc., in the United States and in foreign countries. TM Trademarks of T.D.Williamson, Inc., in the United States and in foreign countries.