United States
Environmental Protection
Agency
Office of Air and Radiation
(6202J)
EPA430-F-00-015
June 2000
&EPA
Reducing GHG Emissions
Through International
Technology Transfer
Demonstration Projects of the US/Gazprom Working Group
— DRAFT—
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Table of Contents
Mission to Improve Russia's Natural Gas System 1
Demonstration Projects 3
Surveying Pipeline Stress Corrosion 3
Valve Sealing Demonstration 4
Measuring Methane Emissions at Compressor Stations 5
Setting Pipeline Maintenance Priorities Using GIS 6
Pipeline Coating Removal and Surface Preparation 8
Pipeline Repair Training In-Service 9
Key Results and Next Steps 11
For More Information 12
Reducing GHG Emissions through International Technology Transfer
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Mission to Improve Russia's Natural Gas System
Russia is the world's largest producer, transporter, consumer, and exporter of natural gas. Gazprom,
a joint stock company partially owned by the Russian government, produces about 25 percent of the
world's natural gas. As a result, natural gas is a critical part of the Russian economy, accounting
for approximately 25 percent of the federal government tax revenues.The Russian natural gas system
is also one of the world's largest emitters of methane, a potent greenhouse gas (GHG).
An international working group was created in 1992 to improve the overall efficiency and environ-
mental soundness of the Russian natural gas industry.This organization, known as the US/Gazprom
Working Group, was established as a cooperative public/private initiative under the auspices of the
Energy Policy Committee of the U.S.-Russian Joint Commission on Economic and Technological
Cooperation (the Gore-Chernomyrdin Commission).
In 1998, Gazprom
produced more
than 550 billion
cubic meters of
natural gas.The
company operates
150,000 kilometers
of trunk gas
pipelines, 250 com-
pressor stations,
and 22 storage fields.
Gore-Chernomyrdin Commission
The U.S.-Russian Joint Commission on Economic and
Technological Cooperation, which is chaired by U.S.
Vice President Al Gore and was originally co-chaired
by Russian former Prime Minister Viktor
Chernomyrdin, coordinates initiatives to improve
Russia's economic and energy infrastructure in an envi-
ronmentally safe and economically efficient manner,
while encouraging investment by the U.S. private sector.
The commission includes eight committees chaired at
the cabinet level and several working groups.
Demonstration Projects of the US/Gazprom Working Group
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The US/Gazprom Working Group includes representatives from two U.S. federal agencies—the U.S.
Department of Energy (DOE) and the U.S. Environmental Protection Agency (EPA)—as well as 15 U.S.
private sector equipment and services companies that volunteer their efforts. Russian members include
key personnel from Gazprom's Board of Directors and production and transmission directorates.
^^^^^^—^-^^^^^^^^^^^—i Goals
The US/Gazprom Working Group's goals are to increase
hOldS reserves Of natural gaS the efficiency of the Russian natural gas industry; reduce
methane emissions to the atmosphere to help mitigate
estimated at 212 trillion CUbiC meterS and the threat of global climate change; reduce air, soil, and
exported 1 90 billion CUbiC meterS Of groundwater pollution associated with the production and
transmission of natural gas; and promote commercial
natural QaS in 1 998. cooperation.These endeavors are particularly important
as Russia continues to develop the fragile arctic tundra of
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^M western Siberia.
Activities and Projects
The US/Gazprom Working Group has sponsored a number of activities, including demonstrations of
technologies and practices that can reduce methane emissions while providing net economic benefits.
Among the initiative's successes were a series of demonstration projects administered by DOE and
the Oak Ridge National Laboratory and implemented from 1994 to 1998.These projects, which advanced
the Working Group's goals of promoting commercial cooperation and reducing methane emissions
are listed below (with the U.S. companies that conducted the projects in parentheses):
• Surveying pipeline stress corrosion to demonstrate repair
technology (PIM Pipeline Services, Inc.)
• Demonstrating valve sealing technology for pipeline maintenance
(Sealweld Corporation)
• Measuring methane emissions at compressor stations to enhance
efficiency (Indaco Air Quality Services)
• Using geographic information systems (GIS) to set priorities on
pipeline maintenance and repair (Michael Baker Corporation)
• Pipeline coating removal and surface preparation (CRC-Evans
Pipeline International, Inc.)
• Pipeline repair training in-service (Edison Welding Institute)
These six demonstration projects have significantly contributed to understanding Russian sources of
methane emissions and opportunities for reducing those emissions.To demonstrate the potential for
replication, the projects were conducted in Russia in collaboration with Gazprom.The projects
address Gazprom priorities and rely on technology not widely available in Russia. As indicated by the
project descriptions that follow, these collaborative efforts illustrate the advantages of international
cooperation in reducing greenhouse gas emissions.
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Surveying Pipeline Stress Corrosion
Between 1991 and 1994, a section of the Russian natural gas pipeline in Siberia suffered nine in-service
pipeline explosions. Hydrostatic testing pointed to stress corrosion cracking as the probable cause.
As a temporary measure, operating pressures were reduced by 10 percent.
Stress corrosion cracking, which begins from the soil side of buried pipelines and is generally
observed some 10-15 years after installation of the line, has been a source of concern about pipeline
reliability and safety worldwide. Groups of cracks grow slowly and coalesce until they reach the crit-
ical size for failure—often when the cracks have expanded to half the wall thickness of the pipe. All
of the failures have involved pipelines that have a cathodic protection system. One reason is thought
to be that the cathodic protection generates the specific carbonate/bicarbonate environment that
promotes susceptibility to stress corrosion.
Project Description
In 1994, Gazprom, EPA, and DOE sponsored
a field survey of one section of the Siberian
pipeline to assess the problems and formulate
a rehabilitation program.The assessment,
which was conducted by PIM Pipeline Services,
Inc., a U.S. company located in Houston,Texas,
confirmed that overpressurization
contributed to the failures, combined with
extensive degradation of the pipe's polyethyl-
ene tape coating and inadequate maintenance
of the cathodic protection system.The
combination of these factors created a
positive environment for stress corrosion
cracking to occur.
5 Year Plan For Pipeline Rehabilitation Programme
Initial Prioritizing of Pipeline
Right or Way (ROW) and Cgtfiodic Protection (CP) System Audit
Initial ROW and CP System Redesign
Initial CP and ROW Rehabilitation
iCJtpse Interval Potential Survey and DCVoilage Gradient Survey •
Report and Recommendations
Costing Rehabilitation
Final ROW and CP Redesign
Final ROW and CP System Upgrade
GPand ROW ft
High Priority: Pi evious
ffflluiemeas sections
o( line within 30 kms
flinl I'kjh j.filiation
rtensrtj areas.
Medium Priority:Swarnp
mounlairi.
LHW Prior ityAll other
the atTOW indicates that
this work is ongoing
The field survey consisted of detailed inspection using a combination of the Close Interval Potential
Survey (CIPS) and the DC voltage gradient (DCVG) techniques to locate individual defects. DCVG is
used to locate coating degradation and breakdown accurately, while CIPS can determine whether
the underlying steel in such areas is adequately protected by the cathodic protection system.
Results
A total of 284 coating defects were located. A calculation based on the operating conditions at the
Krasnoturinsk compressor station indicates that volumes on the order of 33 million cubic meters of
methane per hour (1,170 million cubic feet) would escape from a typical 56-inch line rupture.
The study concluded that the only measure that will prevent additional failures in the short term is
to reduce operating pressures significantly. Since this step would pose significant economic challenges
for Gazprom, the study also recommended that the whole corridor be bulldozed to improve access
for routine maintenance and to remove mature trees and roots, which force their way under the
coating and expose bare steel.
Additional recommendations were to construct a windrow (earth works) to cover exposed pipe,
improve collection of data on future operational failures, upgrade the cathodic protection system,
replace deteriorating tape coatings with polyurethane or epoxy coatings, and install test posts for
routine surveying to monitor the condition of the lines. PIM recommended that the survey program
be expanded to include the remainder of the Russian gas transmission system, starting with sections
that have already suffered corrosion-related failures.
Demonstration Projects of the US/Gazprom Working Group
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Valve Sealing Demonstration
Some 70 to 80 percent of valves in the Russian natural gas system may have leaks, according to one
assessment based on observation and comments from Gazprom crews. At present, Gazprom uses
heavy flange sealants that harden quickly once injected into a valve. Proper application of lubricants
and sealants could prolong valve life and prevent fugitive emissions into the atmosphere.
Project Description
In November"! 994, representatives from Sealweld Corporation, a pipeline valve
maintenance company headquartered in Houston, Texas, conducted a training course
and valve sealing demonstration for 40 representatives of Gazprom and its affiliates.
The demonstration began with a four-hour seminar on valve sealing technology.
Participants learned how to use the latest equipment and techniques, including
pressure gauges, cleaners, sealants, lubricants, and lubricating equipment. Each trainee
received a handbook in Russian describing the steps involved.
The seminar was followed by a hands-on demonstration in the field. Prior to the
field demonstration, Sealweld had visited two sites about 30 miles outside Moscow
and examined nine valves along a 2-mile segment of 32-inch pipe. All nine valves,
which were buried below ground level in pits up to a meter deep, were partially
submerged from spring water half filling the pits. All nine were leaking gas into the
atmosphere. The valve selected for the field demonstration was a badly corroded
Grove 24-inch ball.The leaking gas was causing bubbling on the water's surface that
was audible 20 feet away.
During the field demonstration, Sealweld cleaned, lubricated, and sealed the leaking
valve but did encounter a number of difficulties. First, the button head fitting was
badly corroded and had to be replaced. To evacuate the valve cavity and remove the
damaged fitting safely, Sealweld had to seal leaks past the main seal and between the
line pressure and the ball. At this point, the damaged stem seal fitting malfunctioned
and locked the coupler onto the fitting. When injecting cleaner to clear residue
from behind the seat rings, Sealweld encountered "kick back" through worn injection
fittings in the valve body.
In the end, the valve was sealed successfully, which was verified by venting the valve
body and monitoring the valve for more than 30 minutes. With appropriate thread
adapters and with the pits pumped out in advance, a two-man crew could seal four
or five valves per day.
Results
Generally, the process of valve replacement is costly. However, if proper maintenance is performed
so that a valve can maintain its bubble-tight seal and 100 percent operability, many, if not all, of the
expenses related to valve replacement could be eliminated. Properly sealing problem valves would
reduce lost gas to the atmosphere and save lost production time, the cost of new valves, and labor
overtime expenses.
Given the success of the demonstration, Sealweld estimated that the widespread application of valve
sealing technology could reduce methane emissions from valves in Gazprom's natural gas system by
75 to 80 percent.
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Measuring Methane Emissions at Compressor Stations
Gazprom's gas transportation system includes approximately 250 compressor stations and 4,000
compressors. Measurement of leaks at compressor stations is an effective first step toward developing
overall estimates of methane emissions from the Gazprom system. Such efforts also help identify the
most cost-effective strategies and opportunities for reducing emissions.
Project Description
In 1995, EPA and Gazprom undertook a cooperative
program to take field measurements of leaks at four
Russian natural gas compressor stations. The four sta-
tions were Storojovka and Petrovsk, located near the
city of Saratov, and Pervomaiskaya and Chaplygin, near
the town of Michurinsk.
Leaks at the compressor stations were detected by
spraying a soap solution on components such as
valves, pipe thread connectors, and tubing connectors,
or screened using Bascom-Turner CGI-201 Gas
Sentries on flanges and open-ended lines. When soap
bubbles formed indicating a leak, the rate was meas-
ured using a state-of-the-art High Flow Sampler, which
uses a high flow rate of air to completely capture the
gas leaking from a component.The High Flow Sampling
System was developed in the United States by the Gas
Research Institute, a natural gas industry research
company located in Chicago, Illinois, and Indaco Air
Quality Services, a U.S. emissions measurement company
in Fayetteville, North Carolina.
Results
Leaks were found at 348 of the 1,800 components screened. The survey found that a small number
of compressor station components accounted for the vast majority of the volumes leaked. At a sta-
tion near the city of Saratov, the total leak rate from four unit valve leaks was 4.36 million cubic
meters (156 million cubic feet) per year. At a price of $56 (U.S.) per 1,000 cubic meters of gas
(35,714 cubic feet),* these leaks represent an average loss of $244,000 annually.
Based on the measurements taken at the four stations, total losses at Russian compressor stations
were estimated at about 2 billion cubic meters (BCM) per year, worth an estimated $112 million.
Since the sample was relatively small and did not include measurements from a large number of
components that would normally be expected to have leaks, this estimate is considered preliminary.
The study suggests that one of the most applicable and cost-effective best management practices for
mitigation of leaks at compressor stations is a directed inspection and maintenance program.The
measurements were generally consistent with findings at U.S. facilities, where a small number of leaks
account for the majority of methane losses at compressor stations. The results of the study suggest
that focusing repairs on the largest leaks—those at unit valve vents—potentially could eliminate 48
percent of the total estimated emissions, possibly saving Gazprom $54 million.
*Provided by Gazprom as an expected world price for natural gas at the time of the measurements.
Demonstration Projects of the US/Gazprom Working Group
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Setting Pipeline Maintenance Priorities Using GIS
A geographic information system (GIS) computer model is the ideal vehicle for effectively storing
several layers of diverse spatial and attribute data for specific geographic locations. Once the spatial
framework is created, additional data can be added easily and used for correlative and statistical
tasks. For example, GIS technology could be applied to evaluate Gazprom's gas transmission network
for the risk of pipeline failure and to set priorities on maintenance of those lines.
Project Description
In 1996 and 1997, DOE commissioned the
Michael Baker Corporation of Coraopolis,
Pennsylvania, to demonstrate the use of
state-of-the-art GIS technology as a
pipeline planning and management tool for
Gazprom.The purpose was to develop a
GIS model that Gazprom can evaluate and
use to enhance operational efficiency by
setting priorities on pipeline maintenance
and rehabilitation requirements. The other
major goal was to use the GIS tool to aid
in the identification and location of
methane emissions. Baker collected historical
maintenance records on the pipelines and
used the GIS application to identify those
with the highest likelihood of failure—
and thus the greatest probability of leak-
ing methane.
The Gazprom project focused on a 50-kilometer (31.05 miles) section of 1,219-millimeter (48-inch)
pipeline that is operated by the VolgogradTransGaz trunkline, which carries gas from Siberian gas
fields west through the Ukraine to Europe. An initial site visit to Volgograd was conducted in 1996 to
conduct interviews and collect data, including pipeline design and construction drawings, maps, and
the operations and maintenance history.
The identified segment of pipeline, which was put into operation in 1975, is located in corrosive soils
subject to landslides and is considered to be mid- to old in age. A visit to the Kalininskii Compressor
Station was arranged to collect additional site-specific data on operations and maintenance for the
identified segment. A hand-held GPS receiver was used to collect coordinate readings of the pipeline
and major local valves.
After the site visit, the Michael Baker Corporation developed a computer model and then demonstrated
its use for Gazprom officials and environmental specialists in 1997.
The model focused on operational data such as pipeline routes, diameter, wall thickness, construction
data, and, when available, information on maximum allowable operating pressure, current operating
pressure, corrosion records, leak history, and other variables.The parameters of the project did not
include gathering data on natural hazards such as the frequency and magnitude of landslides, frost
heaves, floods, snow loads, storms, forest fires, and seismic potential.
Reducing GHG Emissions through International Technology Transfer
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Results
Gazprom expressed enthusiasm for the software's success in storing a range of data and the powerful
capabilities of GIS both as a planning and management tool.The Michael Baker Corporation was
impressed by the cooperation of Gazprom officials and the quality of data maintenance records in
Russia. At the conclusion of the demonstration, Gazprom requested that a follow-up seminar be
presented to the company's operations managers and information technology experts. The request
was a strong indicator of the Russian interest in GIS and the success of the project in educating
Gazprom management and staff on the potential of GIS technology.
Demonstration Projects of the US/Gazprom Working Group
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Pipeline Coating Removal and Surface Preparation
Before any new coating can be applied to natural gas
pipelines in the field, the original coating must be removed
and the pipe surface must be prepared to accept a new
coating. Even the best quality coating materials may fail when
applied over a poorly prepared surface, so this step is the
single most important factor in controlling the success or
failure of a protective coating.
When a coating fails, the consequences can be much more
serious than a lost investment in coating material. Other
losses include replacement of the corroded steel; disruption
of pipeline transport services; environmental remediation of
contaminated soil if the pipeline product is liquid; and
inspection and engineering services to determine "what
went wrong," where else the condition might exist, and what
to do to prevent it again. If a pipeline "blows-out" in a
populated area, there is the risk of a fire and harm to the
population affected.
Project Description
In 1996, CRC-Evans Pipeline International, Inc., a U.S. company in Houston, Texas, conducted a field
demonstration for Gazprom of the removal of pipeline coating and surface preparation at a site near
Moscow.The four-day demonstration was performed on an 820-millimeter (32-inch) section of gas
pipeline belonging to Mostransgaz, a Gazprom affiliate, with representatives from that company and
Gazprom observing.
The first phase of the demonstration consisted of removing the existing bitumen coating using CRC-
Evans' patented HydroKleaner™. Operating at pressures of 1,400 bar (20,000 psi), this water-jetting
technology removes the old coating, corrosion deposits, and contaminants such as water-soluble
salts, and cleans weld seams.
The water jet removed the bitumen coating in one pass at a rate ranging from 1.0 to 1.3 linear
meters per minute. It cleaned the pipe sufficiently to allow for visual assessment and nondestructive
evaluation of the underlying steel surface.
After this operation, the cleaned line was ready for surface preparation using the CRC-Evans'
patented OAB™ abrasive blast system.The OAB system uses three oscillating blast nozzles that prepare
the surface of the pipe from a fixed stand-off distance.The blast nozzles prepared the surface at a
rate ranging from 0.4 to 0.5 linear meters per minute.
After this phase of the demonstration, the line was ready for application of the new coating. As this
step was not within the scope of the demonstration, Gazprom used its existing equipment for the
coating application.
Results
The equipment met or exceeded all performance indicators. However, the inability to obtain sufficient
quantities of contaminant-free water and properly cleaned water trucks needed for the water-jet
process created difficulties.To compensate, a filtration system was used on the high pressure pump.
Although this was adequate for the demonstration, a water processing unit would be needed for
major projects in the future.
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Pipeline Repair Training In-Service
In Russia, the method currently in use for repairing gas transmission pipelines is to remove the defective
section from service and replace it as a cylinder. First the upstream valve is closed, thereby reducing the
pressure as much as possible. Then the downstream valve is closed, and the remaining natural gas is
vented into the atmosphere.
Incentives for performing repairs without removing the pipeline from service are significant. Maintaining
consistent delivery of gas during repairs and avoiding the loss of thousands of standard cubic meters of
natural gas is a strong economic incentive. Avoiding the release of large quantities of methane is also
a major environmental benefit.
The predominant method of repair in the United States is the installation of a full-encirclement repair
sleeve while the pipeline remains in service.The use of in-service repair in Russia could significantly
reduce the quantity of methane vented to the atmosphere.
Project Description
In April 1998, Edison Welding Institute, an engineering consulting company in Columbus, Ohio, prepared
and delivered a workshop in Russia on in-service pipeline repair.The purpose was to transfer the lat-
est U.S. techniques to Gazprom and its affiliates.The goal was to show that safe and effective repair
of pipelines under pressure—up to and above 720-millimeters in diameter (28 inches)—can be prac-
ticed safely in Russia.
Fifteen participants took part in the
three-day workshop, which was held at
the Mostransgaz Training Center in the
Tambov Region, approximately a five-
hour drive from Moscow.The workshop
began with lectures and concluded with
a hands-on demonstration in the court-
yard outside the lecture hall. At the
conclusion, each attendee received a
certificate prepared by Gazprom.
Demonstration Projects of the US/Gazprom Working Group
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Pipeline Repair Training In-Service (continued)
Results
The techniques were well received by the 15 participants from a technological standpoint, particularly
the use of hot tap branch connections and full-encirclement sleeves. One benefit of the project was
the identification of regulatory barriers to using these techniques. Another benefit of the training
was the improvement in technical knowledge among the Gazprom field staff.
From Gazprom's perspective, the use of these techniques will improve the environmental aspects of
Russia's gas operations by reducing methane emissions. It also will allow consistent delivery to be
maintained during repair, avoiding the loss of revenue from venting thousands of standard cubic
meters of natural gas.
Workshop Lecture Topics Workshop Demonstrations
• Assessment prior to repair • Control of weld hydrogen levels
• Hot tap branch connections • Monitoring required heat input levels
• Full encirclement repair sleeves • Qualification of welding procedures
• Weld deposition repair • Full encirclement repair sleeves
• Burnthrough and related safety concerns • Weld deposition repair
• Hydrogen cracking concerns
• Practical aspects of hot tap and repair sleeve
welding
10 ^^^^^^^^^^^^^^^^™ Reducing GHG Emissions through International Technology Transfer
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Key Results and Next Steps
The six projects conducted under the framework of the U.S./Gazprom Working Group clearly
demonstrate the advantages of international cooperation in reducing GHG emissions.The Russian
and U.S. experts and engineers worked side-by-side in meeting rooms and in the field to select
the best ways of applying state-of-the-art emission abatement technologies to Russian natural gas
facilities. Preliminary results of their efforts indicate new directions for improving the effectiveness of
the Russian natural gas transmission system and achieving substantial reductions of GHG emissions.
The six demonstration projects produced significant and useful information that will be critical in
designing future projects and expanding the use of the demonstrated technologies. Key lessons
learned include the following:
• Direct interaction of experts and engineers from both countries
is essential to successful technology transfer.
• A fresh look at natural gas facilities by international technology
experts may unearth new opportunities to reduce emissions and
improve efficiency.
• To be useful, even the most advanced emission abatement tech-
nology will need to be adapted to conditions in the host country.
The U.S./Gazprom demonstration projects point to three principle directions for reducing methane
emissions from the Russian natural gas system:
1. Continue to identify and measure major emissions sources. The compres-
sor station measurements performed by the Indaco and Gazprom
technicians quantified system leaks and prompted methods for their
elimination. Similar measurements performed at other components
of the Russian natural gas system, including production and distribu-
tion sectors, will lead to better understanding of current emissions
and will help in the design of adequate abatement measures and policies.
2. Continue to demonstrate advanced abatement technologies. The overall
success of the six projects undertaken by the U.S./Gazprom Working
Group can be leveraged by demonstrating additional ways of reducing
GHG emissions profitably in all sectors of the natural gas industry,
including production, processing, and distribution. Training Russian
personnel in the use of these technologies should become a key element
of new demonstration initiatives.
3. Jointly develop and implement emission reduction projects. Technology
demonstrations described in this document pave the way to designing
and implementing cost-effective projects to reduce GHG emissions
from the Russian natural gas transmission system.
Demonstration Projects of the US/Gazprom Working Group
11
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For More Information
Paul Gunning
Manager, Natural Gas Star Program
U.S. Environmental Protection Agency
Phone: 202-564-9736
Email: gunning.paul@epa.gov
Dr. Robert B. Shelton
Energy Division Director
Oak Ridge National Laboratory
Email: sheltonrb@ornl.gov
Teresa D. Ferguson
Administrative Assistant
Oak Ridge National Laboratory
Email: fergusontd@ornl.gov
12 ^^^^^^^^^^^^^^^^™ Reducing GHG Emissions through International Technology Transfer
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U.S. GAZPRO
WORKING GROUP
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