Proceedings of the 2018 12th International Pipeline Conference
IPC2018
BREATHING NEW LIFE TO AGING PIPELINE INFRASTRUCTURE USING UNIQUE
WIRELINE INSPECTION TECHNIQUES AND PIPE-LINING TECHNOLOGY
Clay Goudy
Q-Inline – A Quanta Services Company
Houston, Texas, United States
ABSTRACT
Mexico’s Energy Reform has opened up various interesting
and unique opportunities for energy infrastructure. A CO2
pipeline project that was recently completed in southern Mexico
provides a perfect example of how to breathe new life to
deteriorated pipeline infrastructure – infrastructure that would
have typically been written off. By coupling a unique pipeline
inspection method with a novel lining system, two 28-kilometer
(17 mile) pipelines were rehabilitated in record time and in a
cost-effective manner. The project consisted of two 12 and 18-
inch (300 and 450 millimeters) CO2 transport pipelines that had
been out of service for 22 years and that are a central component
for a high-profile fertilizer project. Replacing these deteriorated
assets with a new transport pipeline was not an option due to
time, environmental, permitting and budgetary constraints. The
rehabilitated system had to offer a minimum 25-year service life
required by the owner.
To put this aging infrastructure back into service, it was
essential to assess the condition of the pipelines with a high level
of accuracy and precision which would allow for the
rehabilitation of the pipeline and installation of an interactive
liner to extend the system’s serviceable life for a minimum of 25
years. The challenge, however, was that these pipelines were
non-piggable by traditional methods.
By using a tethered MFL and Caliper ILI solution, the
pipelines were each inspected in 13 separate sections with the
level of detail necessary to assess the condition and suitability of
the rehabilitation strategy selected for the project. Fast-track
scheduling constraints required 24-hour data analysis turn-
around of reports identifying and discriminating areas of modest
and significant corrosion as well as deformations including areas
of significant weld slag which could complicate the installation
of the liners.
Once high-quality data was available, pinpoint repairs were
possible with a combination of carbon fiber reinforcement and
steel pipe replacement. Afterwards, the pipelines were internally
lined with a patented process that effectively provides a double
containment system. A grooved liner and the host steel pipe
September 24-28, 2018, Calgary, Alberta, Canada
IPC2018-78594
Alex Gutiérrez
United Pipeline de Mexico – An Aegion Company
Queretaro, Queretaro, Mexico
create an annular space that is pressurized with air and remotely
monitored. The system is able to detect even a small pressure
drop in the annulus that would occur in case the integrity is
breached, or a pinhole develops in the steel pipe. With the
grooved liner, external repairs can be conducted while the line
continues to operate without interrupting CO2 service to the
plant.
By applying these novel solutions, the rehabilitated
pipelines will transport carbon dioxide to a revitalized fertilizer
plant in a safe and efficient manner for the next 25 years.
INTRODUCTION
Mexico’s Energy Reform enacted into law in 2014 has
turned Mexico into one of the most attractive markets for
investment in infrastructure development. In the midstream and
downstream arena, the rehabilitation of existing infrastructure
opens up an interesting alternative to the construction of new
assets due to the strategic and logistical access to markets,
locations and coverage offered by existing tank farms, port and
railway terminals, as well as pipelines.
This is especially true in the case of pipelines where giving
new life to distressed infrastructure at a fraction of the cost and
time required to build new facilities provides a compelling and
cost-effective business case offering rapid access to markets
which would be difficult or costly to replicate with new
investments.
For a rehabilitation program to effectively work though, it is
essential to have precise and accurate information regarding the
condition of the infrastructure that will be rehabilitated to ensure
fitness for service requirements are met and to design a rehab
program that minimizes cost and time while improving
operational reliability and safety – information that in many
cases is non-existent or obsolete. A recent CO2 pipeline project
in Mexico’s southern state of Veracruz highlights the value of
coupling adequate integrity data with a solid rehabilitation
strategy.
1 Copyright © 2018 by ASME
CO2 PIPELINE PROJECT SUMMARY
In 2013, Pemex purchased a urea production facility in
Pajaritos, Veracruz that had been out of service since 1996 with
the intent of re-activating fertilizer production in Mexico by
2018. To feed the urea facility, the plant is supplied by two 28-
kilometer (17 mile) CO2 pipelines that had been out of service
since 1996. These pipelines were designed to operate at 406 psi
(28 bar) with a combined transport capacity of 803,000 metric
tons of CO2 per year, or 2,200 metric tons per day.
After carrying out a preliminary integrity assessment, the
pipelines were found to have multiple leaks, generalized internal
and external corrosion and wall thickness loss. It was concluded
the pipelines could not be used to supply the plants with the
necessary CO2 feedstock in the condition they were in (figures 1
and 2).
Figure 1 – Internal corrosion found in the CO2 pipelines is
indicative of the presence of humidity in the flow stream.
Figure 2 – External corrosion found in various locations
along the pipeline right-of-way after years of abandonment.
Nonetheless, up to date information on the condition of
these pipelines as well as the precise location of anomalies was
not available or inadequate since the transport system was not
designed to accommodate traditional in-line inspection tools
normally used to inspect transport pipelines.
Building a completely new pipeline was considered but
viewed as a challenging endeavor given that the petrochemical
plant, which is the CO2 source, and the urea facility are separated
by 18 kilometers (11 miles) of environmentally protected swamp
and marshland, 8 kilometers (5 miles) of populated areas, the
Coatzacoalcos River and an operating petrochemical complex.
Furthermore, this part of the country poses a significant
challenge for securing right-of-way access not only because of
environmental regulations, but because of land-owner issues and
difficulties.
After evaluating various alternatives, the customer opted for
a rehabilitation strategy that required the acquisition of precise
pipeline integrity data using tethered in-line inspection tools.
The resulting data would provide the visibility on the actual
condition of the pipelines that would permit repairs using a
combination of carbon fiber reinforcement and traditional pipe
replacement along with the installation of a liner system that
improves the system’s operational reliability and could assure its
safe operation for the next 25 years. Selecting a method that
allows for pinpoint repairs also reduced the cost, risk and
challenges related to securing the necessary right of way and land
access rights for the rehabilitation project.
ACQUIRIING PIPELINE INTEGRITY DATA
Along with performing a full-blown Close Interval Survey
(CIS) and Direct Current Voltage Gradient (DCVG) assessment,
the customer requested an In-Line Inspection (ILI) survey to
adequately assess the internal and external condition of the
pipelines. Even though the pipelines had the appurtenances
required for launching cleaning pigs, they were un-piggable by
traditional methods lacking typical launching and receiving
stations. Furthermore, even if temporary pig launchers could be
fitted to the pipelines, they did not have the structural integrity
required to drive traditional in-line inspection tools with a liquid
medium as several leaks had been detected when the pipelines
were air tested at pressures as low as 100 psi (6.8 bar).
It was obvious that tools required to detect and characterize
the corrosion and geometric anomalies would have to be both
MFL and Caliper type tools. However, the project required a
vendor that was adaptive and capable of full report turn around
within 24 hours. Q-Inline was approached as they had prior
experience inspecting river crossings, facility piping, storage
fields and un-piggable distribution lines with tethered tools.
They were fully capable to conduct field operations and had
systems to remotely submit data to analysts at their data center
and complete processing and final report presentation within 24
hours. Furthermore, Q-Inline’s highly capable MFL tools with
Triax sensors could be combined with modified geometry tools
using flexible sensor bars that assured all girth weld icicles and
weld slag anomalies were not missed – something that was
essential for the successful installation of the pipeline liner.
2 Copyright © 2018 by ASME
 Tethered High Resolution Triax Sensor MFL and Caliper
ILI tools were deployed which allowed for each pipeline to be
broken up into 13 separate sections ranging from 800 to 3,500
meters in length (2,600 to 11,500 feet). By using wireline
equipment and tethered ILI tools at precisely controlled speeds,
very high-quality data was acquired providing the level of detail
the project required.
Fast-track scheduling constraints required 24-hour turn-
around of data analysis and reports identifying and
discriminating areas of modest and significant corrosion,
deformations, and areas of unacceptable weld slag. Data from
each tool was downloaded after each run and transmitted via a
wireless connection for processing at Q-Iline’s data center in
Houston where the data was analyzed with reports and
indications turned around in a day’s time (figures 3, 4, and 5).
Using the guidelines in ASME B31G, Modified ASME
B31G, and the “Remaining Strength of Corroded Pipelines
Assessment Procedure” (RSTRENG), data was classified based Figure 4 – Field transmittal of collected in-line inspection tool
on coating and pipe defects, corrosion mapping, pitting, data to Houston downloaded from the tethered MFL and
deformations, and remaining strength calculations [5][6]. caliper tool for fast-track data processing.

Figure 3 – Lowering of combo tool in tight working conditions. Figure 5 – Wireline unit pulling a tethered ILI tool.

Figure 6 – Mapping of girth weld and internal corrosion indications detected at the 6 o’clock position in the 18-inch pipeline.

3 Copyright © 2018 by ASME

 Of the more than 18,000 indications found during the inline
inspections, classification of more than 600 indications allowed
the development of a repair and rehabilitation program that
allowed pinpoint repairs of the pipelines in sections where wall
loss exceeded acceptable limits, while the remaining pipeline
was reinforced with an active liner system.
During the inspection, it was found that a large part of the
wall loss in both pipelines was attributable to internal corrosion
and pitting, indicative of the presence of moisture in the CO2
flowstream which can be adequately handled by the interactive
plastic liner.

PINPOINT REPAIRS
From the planning stages with the customer it became
evident that precision and accuracy of the pipeline assessment,
or lack thereof, would make or break the project. To successfully
meet the time constraints and tight schedule in a cost-effective
manner, it was essential to map and detect anomalies so that Figure 7 – FRP repairs under multiple pipeline crossings.
unnecessary excavations were avoided, right of way disruptions
were minimized, and construction crews could efficiently and
surgically focus exclusively on areas requiring repairs.
Prior inspections of both pipelines had shown the level of
deterioration at a very broad and general level. While some
crude data collected previously through the use of ILI tools
driven with compressed air had shown internal and external
corrosion, the surveys did not provide the granular detail and
pinpoint accuracy the project required for a successful
rehabilitation program. In contrast, the pinpoint accuracy and
precision Q-Inline was able to provide with its tethered High
Resolution Triax Sensor MFL and Caliper ILI solution did.
Classification of indications found through the tethered
tools showed more detail and the exact location of pipe
deformations and dents, the presence of excessive weld slag and
icicles, areas of internal corrosion in sections where moisture had
accumulated, pitting, external corrosion due to coating defects
and areas where AC current interference under power utility
Figure 8 – 18-inch FRP reinforcement inside a petrochemical
lines and pipeline crossings had caused widespread damage
plant where hot-work and welding restrictions were avoided.
(figure 6).
In some damaged sections of pipe where the steel was below
acceptable limits or where dents and deformations were found,
pipe was replaced with new steel. In other damaged sections,
pipe replacement was avoided by using Aegion’s Tyfo, carbon
fiber reinforced polymer (FRP) system. This proved to be a
valuable alternative in pipeline crossings, in-plant environments
where hot-work or welding restrictions could cause significant
delays, as well as in areas where the speed and ease provided by
FRP reinforcement made more economic and technical sense
than steel replacement (figures 7, 8 and 9).
Reinforcement with FRP was conducted following the
guidelines, requirements and recommendations set forth in the
ASME PCC-2 and ISO-24817 standards, where the pipeline
strength was brought back to the original design criteria while
avoiding costly spot repairs or steel replacement [7][8].
The FRP reinforcement process starts with determining the
level of deterioration of the steel and calculating the FRP design
requirements [7][8]. Figure 9 – Localized pinpoint FRP pipe reinforcements.

4 Copyright © 2018 by ASME

 After adequate surface preparation is achieved, an epoxy
impregnated fiberglass layer is applied to the pipe followed by
additional layers of carbon fiber tape to provide the structural
reinforcement of the pipe.
The pinpoint accuracy provided by the tethered In-Line
Inspection (ILI) tool data combined with the flexibility and
speed of FRP reinforcement and spot repairs minimized
excavations and right-of-way disruptions while maximizing
construction crew resources during the rehabilitation process.
well as to monitor the annular space pressure between the pipe
and the liner.
Pressure sensors placed along the pipeline are programmed
to continuously monitor the annular space pressure that should
remain relatively constant during the system’s operation. In case
the pipeline develops a pinhole in the steel due to external
corrosion, pressurized air in the annular space will escape,
reducing the annular space pressure (figure 11).

THERMOPLASTIC PIPE-LINING DESIGN

Once the pipeline had been repaired and reinforced,
United’s unique Safetyliner™ interactive thermoplastic liner
was specifically designed and installed to provide additional
structural strength along with internal corrosion protection. The
thermoplastic liner was installed within the existing pipe,
requiring a minimum of excavations and allowing the pipelines
to be rehabilitated quickly, safely and economically. This was
key in reducing delays due to problems with right-of-way access
that can be decisive in meeting a project’s schedule. The Figure 10 - Modeling the behavior of an interactive liner at
system’s operating conditions also required the pipelines to be a failure point with an operating pressure of 406 psi (28
protected against corrosion due to the presence of wet-CO2 gas, bar). shows the deformation of the liner pipe. Modelling
which was confirmed by the integrity assessment showing a high the behavior of the thermoplastic liner was used to
incidence of internal corrosion indications. determine the limits and failure modes of the liner as a
Tight fitting thermoplastic liners have been used for decades function of the wall thickness.
to protect steel pipes against internal corrosion and abrasion [1].
This type of solution combines the benefits of thermoplastic
materials with the strength of a steel pipeline. The most common
thermoplastic liners are made from HDPE due to their low cost,
wide range of sizes, chemical compatibility along with physical
properties that are favorable for abrasion resistance [9]. In
addition to avoiding internal corrosion, thermoplastic liners can
significantly improve flow characteristics by compensating for
the slight reduction of the pipe's internal diameter with a
substantial improvement in the coefficient of friction [4].
Furthermore, when properly designed, United has used
liners as an interactive method for complementing the strength
of a deteriorated pipeline. The thermoplastic liner for this
project was designed to reinforce the steel pipeline in areas of
pitting or in case a breach occurred due to external corrosion. At
the pipeline’s 406-psi (28 bar) operating pressure, the interactive
liner installed was designed to bridge holes of up to 4 inches in
diameter for the 12-inch pipeline and 6 inches in diameter in the
case of the 18-inch pipeline (figure 10).
Using specialized thermoplastics, greater resistance to Figure 11 – Annular space air-leak concept with grooved
temperature is obtained as in the case of liners made with Raised liner used as a leak-less breach detection system. Grooves
Temperature Bimodal Polyethylene Resin (PE-RT), or resistance in the outside surface of the liner are interconnected every
to various fuels and gases as in the case of polyamide nylon (PA- 14 meters (46 feet) through axial grooves cut in each but
11 and PA-12) [2]. For temperatures up to 260°C, engineered fusion. Pressurized air within the annual space grooves
plastics such as PEEK (Poly-Ether-Ether-Ketone) have been along with pressure monitors spaced along the pipeline, act
successfully used. Polyamide nylon (PA-12) also has the added as a means for determining any failure in the steel during
benefit of having very low permeation to CO2, a relevant feature the system’s operation.
for this pipeline system [2].
In the case of this project, the thermoplastic liner also
incorporated a patented design with external grooves through By monitoring the annular space pressure along the pipeline,
which compressed air could be used to vent permeated gases as any reduction in pressure can be detected real-time with its

5 Copyright © 2018 by ASME

location extrapolated by the pressure difference between sensors
– all without an actual leak occurring as would happen with a
bare pipeline that developed the same anomaly.

THERMOPLASTIC LINER INSTALLATION

Installation of the thermoplastic liner within the CO2
pipelines consisted of dividing them into twenty-four 12-inch
and twenty-six 18-inch sections. The liner pipe was
manufactured in 14-meter (46 foot) sticks that were fused to form
monolithic sections of a length equivalent to each lined section.
The liner was then pulled from end to end using wireline
equipment that can carefully control the tension during
installation (figure 12, 13 and 14).
The tight-fitting liner has a larger outside diameter than the
ID of the host pipe. The liner is compressed during installation Figure 13 – View of a roller reduction box and installation of
using a roller reduction box while it is pulled into the host pipe. a grooved liner in the Coatzacoalcos River crossing using
For this project the lined sections were as short as 200 meters polyamide PA-12 liner pipe with improved CO2 gas
(656 feet) and as long as 1,737 meters (5,700 feet). permeation characteristics.
Once the tension in the liner is relaxed, the liner pipe
expands and forms a tight fit with the host steel pipe. Lined
sections are then re-joined using a modified flanged connection
for aboveground connections (figure 15) or a patented welded
joint for underground connections (figure 16).
United’s proprietary welded connection provides a
continuous plastic joint for the liner achieved by using an
electrofusion coupler along with a welded steel hub and sleeve
design that has been successfully tested to 9,000 psi (600 bar)
[3].
Figure 17 shows a completed 18-inch welded connection
prior to the application of its external corrosion protection
coating. Figure 18 shows a close-up view and detail of the liner
whose grooves will be pressurized with compressed air.

Figure 14 – View of a high capacity track mounted wireline

pulling unit installing a liner section. This picture shows the
liner pipe exiting the pipeline at the CO2 compressor station.

Figure 12 – 14-meter (46 foot) liner pipe sticks were Figure 15 – Flanged liner connection used for above ground
transported to the jobsite and then fused into monolithic joining of lined pipeline sections used in valve stations and
sections ranging in length from 200 meters (656 feet) to 1,737 facilities. This picture shows a 12-inch PA-12 stub-end and
meters (5,700 feet). flange connection.

6 Copyright © 2018 by ASME


Figure 16 – Welded connection process performed inside an
under-water habitat in a swamp section of the pipeline.
Figure 17 – Completed 18-inch welded connection.
Figure 18 – PA-12 grooved liner close-up view.
FLOW IMPROVEMENT
Once all of the pipeline sections were reconnected, the
complete system was hydrostatically tested and commissioned
so it could supply CO2 to the revamped urea facility. As part of
the customer’s testing protocols conducted during
commissioning, the flow characteristics and transport capacity of
the CO2 pipelines was verified to confirm the renovated system
met the design criteria and plant’s requirements. During these
tests, the customer found a 23 percent improvement in the
pipeline’s flow capacity underscoring the benefit of the liner’s
reduced friction coefficient. This translates to the customer
being able to reduce the pipeline operating pressure by 8 percent
from its original 406 psi (28 bar) design pressure to 369 psi (25.5
bar) to carry the same 2,200 tons of CO2 required by the urea
plant – something which will reduce energy costs and wear and
tear on equipment over time.
CONCLUSION
Rehabilitation of the combined 57 kilometers (34 miles) of
12 and 18-inch pipelines including, land access and right-of-way
permits, ILI inspections, pipe replacement, FRP reinforcement,
liner installation, testing and commissioning took a mere 10
months from start to finish in challenging right-of-way
conditions at a fraction of the cost of a new pipeline.
An essential component for the successful completion of
this project was the project team’s ability to assess the condition
of the pipelines with precise and accurate ILI data acquired with
tethered MFL and Caliper tools in pipelines that were not
equipped or capable of traditional ILI inspections. Fast-track
data analysis and turn-around of inspection reports identifying
and discriminating areas of modest and significant corrosion
were of great importance to meet the project’s schedule.
By using pinpoint repairs with a combination of carbon fiber
reinforcement and steel pipe replacement, land access challenges
were efficiently overcome, and costs were reduced. Finally, and
equally important, by internally lining the existing pipelines with
a process that provides a double containment system while
mitigating corrosion damage arising from the transport of wet-
CO2, the operator was able to increase the operational reliability
and integrity of the system for its projected 25-year service life.
The flow improvements resulting from the friction reduction
provided by the liner, will allow the customer to reduce
operational and maintenance costs throughout the life of the
infrastructure.
By breathing new life to a pipeline system that would have
been written off, this project demonstrates the value of using
unique inspection techniques coupled with innovative
rehabilitation methods. This combination can be applied for
evaluating and renovating pipeline networks and systems in
storage fields, gathering lines, plants or anywhere where the
service life of aging assets needs to be extended.
The following pages show images of the ILI inspection
work, pipeline testing and a sample of indications found during
the project (figures 19 through 25).
ACKNOWLEDGMENTS
The authors would like to acknowledge United Pipeline
Systems, Inc. (An Aegion Company) and Q-Inline (A Quanta
Services Company) for their support in the preparation of this
paper.
7 Copyright © 2018 by ASME
REFERENCES
1. “High Density Polyethylene Liner for High Temperature
and Gaseous Applications” - Paper No. 10073, 13th Middle
East Corrosion Conference, Feb. 2010, Schmitz.
2. “High Performance Polymers for Pipeline Applications in
Oil & Gas Harsh and Demanding Conditions”, from the
proceedings of the 9th Congreso Mexicano del Petróleo, Jun.
2014, Gadkari, Delgado.
3. “Joining methods for Thermoplastic Lined Pipelines”, from
the Proceedings of the 17th Plastic Pipes Conference, Sep.
2014, Compton, Schell.
4. “Plastic Liners for Oilfield Pipelines”, Technical Committee
Report, NACE International Publication 35101, Feb. 2001,
J. Mason.
5. “Remaining Strength of Corroded Pipelines Assessment
Procedure (RSTRENG)”, 2015 Revision, American Society
of Mechanical Engineers.
Figure 19 – 18-inch launch pad in swamp section.
Figure 21 – 18-inch MFL-Caliper combo tool data loading.
6. Standard - ASME B31G-2012 – “Manual for Determining
the Remaining Strength of Corroded Pipelines”, 2012
Revision, American Society of Mechanical Engineers.
7. Standard - ASME PCC-2 – “Repair of Pressure Equipment
and Piping”, 2015 Revision, American Society of
Mechanical Engineers.
8. Standard - ISO-24817:2015 – “Petroleum, petrochemical
and natural gas industries – Composite repairs for pipework
– Qualification and design, installation, testing and
inspection”, 2015 Revision, International Organization for
Standardization.
9. Standard – NACE RP0304-2004 – “Standard
Recommended Practice – Design, Installation, and
Operation of Thermoplastic Liners for Oilfield Pipelines”,
NACE International, 2004 Revision.
Figure 20 – 18-inch MFL-Caliper combo tool prior to run.
Figure 22 – CO2 pipelines during testing and commissioning.
8 Copyright © 2018 by ASME
 Figure 23 – Indications shown on the MFL and Caliper logs which were verified in the field for section A. This indication
shows a dent and metal loss on the inside of the pipe which was verified during the pipeline repairs (Figure 24).

Figure 24 – Dent and corrosion indications shown in the Figure 25 – An example of the type of weld slag detected
MFL-Caliper logs (Figure 23) were replaced with new steel throughout both pipelines which would have prevented the
on the 18-inch pipeline. More than 600 anomalies like this installation of the liner pipe or would have damaged it during
one were repaired during the project. the pulling process.

9 Copyright © 2018 by ASME