Case study

Pipeline pre-commissioning:
Russia to Turkey
Baker Hughes, Process & Pipeline Challenge
Services demonstrated its
The TurkStream Pipeline Project pre-commissioned the dual gas transmission pipeline
advanced technology through
that included a special wet buckle contingency by dry pre-commissioning two 32-inch
its support in executing the gas export pipelines. The pipelines, which run approximately 930 kilometers (about 578
TurkStream Pipeline Project miles) from Anapa, Russia to Kiyikoy, Turkey, through a depth of 2,200 meters of water,
with the “new” dry pre- directly connect Russia’s largest gas reserves to the Turkish gas transportation network
commissioning scope completed supplying reliable energy to Turkey and the south and southeast European regions.
on an accelerated schedule, while With construction completed during the second and third quarters of 2019, Baker
meeting or surpassing project Hughes Process & Pipeline Services (PPS) was chosen for the TurkStream project
specifications. because of our,
• expertise
• track record
• broad base of services
• superb teamwork
• and our positive engagement resolution of tough challenges
The TurkStream project teams faced specific and difficult challenges. The project and
its crews confronted an untested pre-commissioning philosophy facing a high-profile,
political project administered between the two countries. In addition, teams were
challenged by high ambient temperatures, the requirement for massive volumes of
nitrogen, complex equipment, extensive pipeline lengths, continuous run times and a
compressed schedule. PPS’ adaptation to working in Turkey and with unfamiliar Turkish
customs revealed further challenges, including logistics, permits and other essential
documentation.
Ultimately, our global knowledge and experience in addressing multiple scenarios
helped us to achieve the overall goals for the TurkStream Pipeline Project. Our highly-
trained workforce, specialized equipment, and extensive knowledge of engineering
solutions to meet challenges reduced risk to personnel and property, and allowed us to
customize a solution that produced the best possible result for our customer.

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 Solution to Hydrotesting) made it difficult to establish the dryness of a
pipeline this length just by measuring it at either end.
South Stream Transport B.V. (SSTBV) established its high-level
pre-commissioning philosophy, developed and executed by Considering the pre-commissioning challenges specific to the
PPS and supported through extensive collaboration from the TurkStream pipeline, the operator and DNV developed a set of
pipe operator. Early engagement by PPS at the tender phase of criteria to waive the hydrotest requirement, including stringent
the project demonstrated a clear understanding of the issues. fabrication and installation procedures, enhanced cleanliness
PPS further supported our abilities and commitment with a and a final ROV survey of the pipeline.
solid base of essential equipment and experienced personnel, The “new” philosophy developed jointly by Baker Hughes and
delivering the solution and real-time data acquisition through a SSTBV were intended only to clean and gauge the pipeline
client website. with bi-directional pigs and an inspection caliper tool. Brushes
PPS first confirmed that flammability issues existed within the and magnets provided the cleaning function on the pigs and
initial operational philosophy, subsequently developing a safe fluid slugs of MEG between certain pigs. The engineering and
“full nitrogen” solution. A Computational Fluid Dynamic (CFD) operational challenges focused on sizing of the MEG slugs, the
study on the Mono Ethylene Glycol (MEG) and air interfaces led nitrogen pack pressure in the pipeline, the nitrogen’s flowrate to
to the conclusion to use nitrogen instead of air. The multi-phase propel the pigs, predicting pig speed excursions, and managing
separator on Turkey’s side of the installation vented the nitrogen the MEG/nitrogen interfaces in Turkey.
and pumped MEG into storage tanks for disposal. Remotely- PPS performed the new “dry” pre-commissioning methodology
actuated control valves kept personnel out of the line of fire, with a DNV waiver in place to eliminate the hydrotest operation
protecting both on-site personnel and pipeline assets. that included the typical process of pipeline flooding,
Next, PPS led a pigging computer simulation study using OLGA hydrotesting, dewatering and air drying. As well, the company
software that optimized the Russia-to-Turkey pigging operation. identified significant limitations of the conventional process
The key competing parameters included the pipeline profile when applied to large diameter, long length, deepwater gas
(depth, steepness, volume, and length), nitrogen pressure and export pipelines, specifically for Hydrotesting, dewatering and air
flowrate, and the MEG slug volumes/spacing. Our team chose to drying.
deploy nitrogen membrane units when MEG is used as a pre- The new operation required a high level of up-front engineering
commissioning fluid. that satisfied all parties with the validity of the solution proposed
Hydrotesting required pipelines of such a vast volume that by PPS. Ultimately, the project team executed the operations as
detecting a leak by taking pressure measurements at either per the procedures and delivered the pipeline cleaned, gauged
end had limited accuracy. As well, designing and installing the and MEG-swabbed in line with the accelerated schedule and
pipeline so it would not buckle when subjected to hydrotest client specifications.
pressure added significantly to the cost and schedule. In Optimizing these essentials produced a safe, efficient,
addition, the collapse pressure at 2,200m deep required a more economical, and successful pre-commissioning operation and a
robust design requirement than the internal pressure required by solution that reduced carbon emissions.
a hydrotest.
Furthermore, the air spread needed during dewatering the Benefits
fully flooded pipeline would have generated at least twice the
Our specialized engineers successfully engineered a solution
flowrate and ten times the pressure of the one used. Along
that allowed us to conduct ‘dry’ pre-commissioning of the
with basic equipment costs, the schedule would have taken
pipeline with our highly trained workforce and specialized
four times longer to manage and execute while disposing the
equipment, meeting the customer’s accelerated schedule.
massive volume of chemically treated flood and test water
near the Turkish coast. Finally, the process of air drying (similar

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