Seamless Service for Successful Station Upgrade

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Project

Manor Gate Station Upgrade

Location

Maryland

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Background

Baltimore Gas & Electric (BGE), the company that operates the entire Baltimore area gas distribution system and serves more than 650,000 customers, contracted EN Engineering to upgrade their existing Manor Gate legacy station. This station takes the transmission gas from TransCanada at 720 PSIG and lowers the pressure to 269 PSIG to feed BGE’s Beaver Dam and Notch Clift transmission lines.

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Challenges

The original BGE drawing showed 16” steel, but the pipe was 24”, so the spherical tee that was ordered for 16” did not work. A custom-made tee was ordered, which resulted in a 14-week delay. In addition, commissioning was delayed due to the frigid ambient temperature and weather forecast.

Solutions

The Manor Gate Station upgrade project included two meter runs, four regulator runs, a separator/filter, heater, odorization, controls, and fire suppression, in addition to considerable construction of buildings and concrete to house this equipment. EN Engineering took the design work from conception through completion and also provided the environmental and construction materials testing, resulting in time and cost efficiencies. The team developed accurate and detailed as-built drawings, which required minimal field changes. The construction management team was on site and eliminated time lapses for design questions during construction. Throughout the project, they focused on jobsite safety, contractor oversight, adherence to BGE standards, and cathodic protection. In addition, they interfaced with the compliance team, Certified Weld Inspector, and NACE coating inspection. Weekly meetings with the client’s senior management team assured the project was on track, and the EN Engineering team’s expertise was welcome and respected.

“EN Engineering took the design work from conception through final design and also provided the environmental and construction materials testing, resulting in time and cost efficiencies.”

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Multiple Product Areas Join Forces on Pipeline Project

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Project

New Pipeline and Injection Facilities

Location

Texas

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Background

A new midstream energy company called on EN Engineering for a wide array of services supporting a new pipeline system and injection facilities.

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Challenges

As a new company, the client had not yet developed comprehensive project procedures, so one challenge involved working together to establish new processes and standards. In addition, the project had an aggressive timeline and required the team to work at an accelerated pace.

Solutions

EN Engineering provided project management, engineering, and design services for a new pipeline system consisting of more than 70 miles of 8” and 12” diameter pipeline, as well as five new injection facilities for multiple third-party producers.

Experts from EN Engineering’s entire service portfolio came together to successfully complete the project. The pipeline design team provided oversite of the pipeline routing as well as development of engineering design details, while a facility team provided full mechanical, electrical, civil, and structural design packages, along with hydraulic and surge analysis.

Environmental experts oversaw an environmental survey and provided recommendations for both compliance measures and installation best practices along the pipeline. Several scenarios for flow modeling were evaluated by the integrity team, who also provided recommendations for emergency flow restricting device (EFRD) valves. GIS services were utilized to evaluate alternate pipeline routes and make a commercial recommendation. Designs for cathodic protection were provided by the corrosion team. Finally, procurement experts provided comprehensive support on all equipment, material, and labor contracts, from specification development to expediting and tracking deliveries.

EN Engineering also provided several specialty services, including in-house HAZOP facilitation and shop inspection services, and managed geotechnical, environmental survey, and mill inspection subcontractors. The automation team developed the control philosophy for the injection facilities and interfaced with third-party programmers and PLC integrators.

The EN Engineering team was instrumental in guiding industry best practices and helping the client develop new procedures and standardizations. In addition, they facilitated communications despite several changes in client stakeholders at critical stages during front-end loading and worked at an accelerated pace to meet project deadlines.

“Experts from EN Engineering’s entire service portfolio came together to successfully complete the project.”

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Metallurgical Analysis Determines Root Cause of Line Failure

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Project

Metallurgical Failure Analysis

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Background

Our client experienced a rupture failure on a 16-inch OD by 0.250-inch WT API 5L X42 electric resistance welded longitudinal seam pipe. The pipeline was installed in 1947.

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Challenges

The client called on EN Engineering to perform a failure analysis on the rupture and to determine the root cause of the failure.

Solutions

EN Engineering performed a formal metallurgical evaluation on the pipe rupture failure that included a visual examination of the fracture and the failed pipe; nondestructive examination of the internal and external pipe surfaces; and scanning electron microscope (SEM) evaluation. In addition, the engineers documented the fracture dimensions, including pipe wall thickness along the fracture surface, and the circumferential position of the electric resistance weld longitudinal seam. They also visually examined the pipe for internal and external corrosion; conducted a metallographic examination of the fracture surface, including preparation and examination of metallographic cross sections under a light microscope; and completed a chemical analysis.

The team’s mechanical testing included:

  • Transverse pipe body and transverse weld tensile test samples were prepared, and rings were taken from the pipe upstream and downstream where the fracture arrested
  • Transverse pipe body and transverse weld Charpy specimens prepared from both the upstream and downstream pipe rings
  • Vickers mircro-hardness tests conducted in the area of the fracture origin

Upon completion of the project, EN Engineering delivered a report showing the cause of the rupture was high-pH stress corrosion cracking.

Based on physical evidence, EN Engineering determined the cause of the rupture was high-pH stress corrosion cracking

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Compliance Review for Pipeline Transmission

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Project

Compliance Review for Pipeline Transmission

 

Location

Multiple Locations

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Background

Pipeline transportation is one of the safest methods of delivering natural gas and hazardous liquids. Ensuring pipelines are operated and maintained in compliance with federal, state, and local regulations is critical to ensure the safety of pipeline operations and the surrounding public. EN Engineering provides comprehensive compliance review services to ensure conformance with applicable regulations including 49 CFR Parts 192 and 195.

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Challenges

Following a restructuring of their infrastructure and integrity management responsibilities, a pipeline operator was struggling to confirm critical pipeline records, including integrity assessments. The records were not organized, nor were they available to all pipeline integrity stakeholders. Our client wished to establish traceable, verifiable, and complete records containing reliable information and to confirm the maximum operating pressure (MOP) for each pipeline. In addition, the client requested an Information Analysis to evaluate the integrity of each pipeline segment in compliance with 49 CFR 195.

Solutions

EN Engineering was retained to support the improvement of the client’s pipeline integrity management and confirm pipeline features with traceable, verifiable, and complete (TVC) records. This included creating a guidance document defining key components and assumptions, developing guidance to track pipeline characteristics, pressure test data, operating pressure, document quality, pipeline repair sleeves, casings and other related features; performing line “builds” to capture fittings and other important pipeline characteristic changes; conducting thorough quality control and quality assurance checks; validating the MOP based on verifiable information; identifying features requiring additional investigation to confirm properties and characteristics; updating the company database with TVC data; and performing an Information Analysis about the integrity of the entire pipeline and the consequences of a failure to determine if any changes to future integrity assessment plans may be needed.

EN Engineering successfully completed the project, providing the client updated TVC data in their database with linked pipeline records, as well as a detailed process for establishing records supporting MOP. In addition, the team confirmed MOP for each pipeline segment and completed an information analysis of each pipeline segment.

The team enhanced the pipeline integrity management system and confirmed pipeline features with traceable, verifiable, and complete (TVC) records.

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