T.D. Williamson Global Solutions- January 2006

by Bob Warterfield

Fact: During its life cycle, one hurricane can expend as much energy as 10,000 atomic bombs. When you combine that harrowing information with a year during which there were a record number of named storms (27 – previous record 21 in 1933) and hurricanes (14 – previous record 12 in 1969) in Atlantic waters, you begin to get a clear picture of the adverse operating environment faced by the petroleum industry in the Gulf of Mexico in 2005. Three of the six strongest hurricanes on record plowed wide swaths of destruction through the Gulf region. Hurricane Wilma was the strongest category-5 ever recorded and dropped over 60 inches of rain as it crossed the Yucatan Peninsula before setting its sights on Florida.

According to terradaily.com, the one-two punch of Hurricanes Katrina and Rita destroyed 109 oil platforms and five drilling rigs in the Gulf of Mexico. On its own, Katrina destroyed 46 platforms and four drilling rigs and caused extensive damage to another 20 platforms and nine drilling rigs. Close on the heels of Katrina, Rita destroyed 63 platforms and one drilling rig and damaged 30 platforms and 10 drilling rigs. Altogether, approximately 2,900 platforms were
in the path of the hurricanes.

Click image to enlarge hurricane storm track. Credit: WeatherChannel.com

While playing havoc with US oil production, Katrina and Rita also knocked out a number of refineries. Millions of barrels a day of refining capacity were shut down. Production came back online slowly as power was restored, but physical damages had to be quickly resolved to minimize downtime and get product flowing at optimum throughput levels.

As the world's leading pipeline maintenance provider, TDW has made its broad spectrum of products, services and decades of global hands-on field experience available to companies affected by the 2005 hurricane season. There is no company better prepared or equipped to assist in the repair and refurbishment process of pipelines of all types and sizes – both on shore and offshore. From platforms, to refineries to distribution lines, TDW is the partner of choice when the chips are down and pipeline performance has become a critical issue.

Randy Miley, Service Center Manager at TDW's Mid-South Service Center in Baton Rouge, Louisiana has remained close to ground zero and has a very clear perspective on regional needs and the progress being made in getting piping systems back online. Randy sees ongoing activity but admits, "Everyone affected is still playing catch-up and will be for quite some time. Damage is extensive and there is a shortage of boats and divers. Mother Nature is still not being entirely cooperative either. This time of year, a continuous series of cold fronts causes strong winds and rough waters throughout offshore production areas." In spite of such adverse conditions, TDW has already assisted pipeline operators in the wake of the storms and is in the process of helping others.

Rita near landfall - Credit: NASA/Jeff Schmaltz, MODIS Land Rapid
Response Team

Miley and the service center received a telephone call from a major pipeline operator on September 6, shortly after Hurricane Katrina struck Louisiana. An above ground 12" valve station located in Mandeville, Louisiana had been damaged by a fallen tree. The tree caused a significant dent, and although there was no leak of pipeline product, the operator wanted the damaged section of the line repaired. They e-mailed several photos of the jobsite and the dented pipeline.

The solution suggested by TDW Services was to perform a 12" single STOPPLE® plugging application. TDW then received an order to proceed and immediately shipped the STOPPLE fitting and accessories to the job location in Mandeville on September 8^th. The line operator had the STOPPLE fitting installed onto their pipeline. TDW was asked to be on site with all necessary equipment and ready to commence work on Friday, September 16^th precisely at Noon.

The 12" hot tap was completed and the STOPPLE was set into the pipeline just before midnight. The line operator began repair work at 6:00 a.m. Saturday morning. The pipeline repair was completed on Sunday morning. TDW's field technician retracted the STOPPLE, set the completion plug and a blind flange was then installed on the fitting. Job complete! The next week, the service center received a phone call from a representative of the pipeline operator expressing appreciation for TDW's ability to solve his problem in a safe and expeditious manner.

Another large pipeline company contacted TDW on October 11^th needing help on a 20" natural gas pipeline located in the Gulf of Mexico in 120 feet of water. The line had been kinked by an anchor line. The line was shut down and needed to be repaired but could not be cut without flooding approximately 23 miles of the pipeline with seawater. The water in the line would then be considered contaminated and would then have to be disposed of in an environmentally safe manner. Realizing the extreme potential expense involved, the pipeline operator came to TDW for ideas on how the line could be repaired without allowing the intrusion of seawater.

Katrina near landfall - Credit: NASA/Jeff Schmaltz, MODIS Land Rapid Response Team

Because the line was shut down, the TDW recommendation was a 12" by 20" Sub-Sea Folding STOPPLE plugging application. The plugging machine would have to be set 180º opposite of conventional (backwards) in the pipeline. This would allow the pipeline to be cut at the point of the damaged section and prevent the pipeline from being flooded.

TDW received the order. However, before the job was allowed to proceed, the pipeline operator requested a full site integration test to be performed at the Oil States Hydrotech facility in Houston to prove that the application could be done successfully. The site integration test was completed with no problems encountered. Given the green light, offshore job location work commenced on January 9^th and is scheduled for completion in early February of 2006.

A third project example now in development involves a major production company and a sub-sea plugging application in the Gulf of Mexico. The production company has an offshore platform that toppled during hurricane Katrina. There are two, 8" sub-sea pipelines attached to the platform that need to be abandoned. This is a project that is, unfortunately, very typical of the type of problems being faced by operators in the Gulf. According to Randy Miley, "There are a lot of damaged pipelines out there in the sub-sea environment that need to be repaired or abandoned. TDW stands ready to answer the challenge on short notice with performance proven equipment and expertise to handle pipeline maintenance and repair situations anywhere on shore or offshore in the Gulf region."

Visit us at www.tdwilliamson.com or call 918-447-5500 or 800-695-0535.