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Hot Tapping
Pipeline Pigging
PSI - Offshore |
US Toll Free
1-888-839-6766
International
1-918-447-5100
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Explainign the process
Late in 2006, T.D.Williamson was awarded an urgent on-stream natural gas pipeline cleaning project in southern Mexico that centered on the removal of black powder from three pipeline sections measuring 168, 166, and 100 miles in length. This particular pipeline had not been cleaned since its construction seven years ago. Maintenance problems were being experienced by delivery stations all along the length of the system. The ultimate problem was that considerable amounts of black powder were overwhelming filter systems required to protect the quality of the gas being used in a power generation plant. To compensate for the threat of contamination to the plant, line flow had been reduced by the operator to slow the accumulation and movement of black powder. The immediate result was reduced revenue for the line operator. Still, the black powder continued to accumulate. If flow had to be reduced further, the operator risked having to pay expensive fines to the customer for not delivering
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Black powder. It is the scourge of gas pipelines worldwide. Basically, black powder is iron oxide,
or rust, and it is the result of an internal corrosion process. Causes of the chemical reaction that affect the inner wall of pipelines and produce black powder include the presence of H2S and moisture or humidity by itself, and bacterial or organic contamination. Contact with hydrocarbons in the line turns the iron oxide black. The flow of gas through a line carries black powder down stream to critical areas where accumulations can cause serious problems such a clogged filters and damage to instrumentation such as metering and pressure reducing systems.
Monitoring the separator
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| adequate gas supplies. The only solution was to remove black powder accumulations from all three line sections. |
The logistics involved with moving TDW technicians and equipment from Tulsa to Villahermosa, Mexico, an overall distance of approximately 1,800 miles, were considerable. The order for the job was received on November 13th. Equipment preparation began on the 15th, and the last shipment left on November 19th. By November 27th, two trailers, one tanker and one separator were on site. Two of the travel days were actually lost at the U.S./Mexico border due to holidays. Coordination
of trucks, customs and sub-contractors was quickly arranged on short notice by the
TDW Tulsa and Mexico teams.
Because a power plant at the receive-end of the middle section was not protected by a filtering system, line segment cleaning actually had to take place in reverse order. This caused equipment and technicians to cover much more territory than normal due to required back-tracking. Intensive detergent cleaning was the process selected for clearing the pipeline and removing black powder deposits.
Checking for solids content
| A detergent chemical and a carrier liquid mix was injected into the pipeline under high pressure (900 to 1,000 psi) between cleaning pigs. |
The trailing pigs were a special TDW design that efficiently wiped the walls of the pipeline to remove black powder and debris while moving them ahead suspended in an emulsion. Because of time constraints, only a limited number of cleaning runs on each line section was possible. When the slug of fluid reached the receiver site, it was piped into a TDW Services separator. Samples of the fluid were tested after each pig run. After five cleaning runs, a 166 mile section that had a particularly significant build-up of black powder was cleaned to a level of 0.5 percent solids per volume of liquid removed.
Normal throughput was restored with no black powder evident at the receiving station. Approximately 100,000 gallons of cleaning fluid and 25 TDW pigs were used to successfully rid the line sections of the black powder problem.
TDW Services is widely recognized as the industry leader for line cleaning projects that are properly engineered, properly staffed and safely executed. For additional information about the complete range of TDW products and services,
visit www.TDWilliamson.com
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Successful removal of black powder
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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.
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April |
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| Hot Tapping & Plugging for High Pressure Transmission Pipeline |
9-12 |
Tulsa, OK - USA |
| Hot Tapping & Plugging for Low Pressure Distribution Pipelines |
16-19 |
Tulsa, OK - USA |
| Mechanic Maintenance Training for Hot Tapping & Plugging Equipment |
23-26 |
Tulsa, OK - USA |
New European Program call:
32-67-28-36-44 |
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Nivelles, Belgium |
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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
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 2007 show listing on the website.
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