iTAC Solutions for Energy/Pipeline
Intelligently manage Pipelineswith the iTAC.MES.SuitePipe Tracking System
Pipe Tracking System
With the iTAC.MES.Suite, it is possible to represent the entire
construction phase of a pipeline.
The process parameters of all contractors for each length
of pipe are thereby seamlessly recorded and automatically
analyzed for correctness and completeness. Even during the
operational phase spanning decades, all necessary inspec-
tions and the corresponding results are documented.
The constantly growing demands for energy and calls for
secure supply have resulted in energy suppliers relying
increasingly on digital management of their networks.
Regardless of whether the supply lines transport gas, oil,
water or other resources, it is becoming increasingly impor-
tant to know which material was mounted where and with
what characteristics. This is particularly the case if failures
occur and if further failures are to be avoided.
In order to automatically capture data over the entire
creation process , state-of-the-art information technology
is essential. The iTAC.MES.Suite, a, platform-independent
standard solution based on modern Internet technologies,
is such a solution.
The Pipe Tracking System from iTAC Software AG is the only
standard solution of its kind. With its extensive functional
portfolio, it supports the planning, construction and opera-
tion of a pipeline. The proven MES system is both a valuable
tool for pipeline builders and operators as well as for con-
tractors and suppliers – where it is already in use.
Comprehensive documentation & transparency
Manufacture >> Refinement >> Transport >> Storage >> Concrete casing >> Construction >> Operation
With the iTAC.MES.Suite, each step in the production and
logistics chain of a pipeline is documented and can be
examined. During this process, a unique serial number is
assigned to each segment of the pipeline (pipe, valve, buckle
arrestor, pig trap etc.).
In the Pipe Book, all information is made available together
with history. The iTAC.MES.Suite’s TR-Service captures all
information associated with a pipe (batch information of the
smelter, component data, coating, concrete weight coating,
stock movements, laying & as built data etc.) fully automati-
cally making this information available in the iTAC.MES.Suite
in a clearly-organized manner.
The iTAC.MES.Suite accepts all information and parameters
for the respective pipe number, such as test results and test
plans provided by the global data suppliers (manufacturers,
coaters, transporters, warehouse keepers etc.), as XML files
via File Transfer Protocol. Extensions or changes to the indi-
vidual test specifications can be amended at any time within
the iTAC.MES.Suite without additional programming work.
iTAC Solutions for Energy/Pipeline
With the iTAC.MES.Suite
• comprehensive documentation is possible for the
entire construction process - providing transparency
across all manufacturing and logistics steps as well
as across all components and contractors
• it is possible to perform an automated inspection
(verification) of deviations of the CURRENT state
with respect to a specified TARGET state
• unreleased or faulty components (e.g. pipes)
can be blocked
All contractors use a common interface for data transfer.
The captured data can be accessed by all participants from
anywhere in the world via the Internet (Pipe Tracking Portal).
Since the iTAC.MES.Suite is a web-based application, no
additional software installation is necessary on the evaluati-
on clients.
The passing of target data and the specification of limit
values enable the release or preliminary release of the pipe
for the laying process. Furthermore, failures and deviations
can be detected even during the production process and
remedial actions initiated.
Failures and failure states, such as incorrect or insufficient
wall thicknesses or the welding together of pipes from dif-
ferent lots/smelters, can be detected in advance. If a failure
is detected, all pipes from the respective lot or pipes with
identical parameters, such as anticorrosion coating, can be
inspected and, if necessary, blocked or replaced.
With the aid of the TR-Service, the following information
can be called up over decades:
Trace down
• What materials are contained in the pipe?
• Which suppliers/contractors were involved with
which parameters and features?
Trace up
• Which other pipes have the same features,
failures or characteristics?
Laying information
• Where does which pipe lie with which GPS coordinates?
• Which pipe is welded to which other pipe with
which weld seam?
Finding failures / automated verification
The use of high-quality raw materials (pipes, valves, buckle
arrestors) is essential when constructing a pipeline, espe-
cially since faulty lines or, much worse, leakages can have
immense consequential costs and catastrophic impacts on
the environment, particularly when transporting gas or oil.
In order to evaluate the quality of the pipes being used as
well as the laying process, including the welding of pipes,
the iTAC.MES.Suite’s QM-Service provides extensive analysis
functions that answer the typical questions posed by a
network operator.
The standard quality analyses available in the iTAC.MES.
Suite enable direct evaluation in real-time and thus always
reflect the current quality situation. Using measurement
data, failure data and the statistical evaluation of this data,
both the production process of the pipes as well as the
laying process can be analyzed in detail.
The following analyses are possible with the aid of the
QM-Service
• Analysis of all measured values for each pipe
• Analysis of a given measured value across all pipes
• Fault analysis
• Deviation analysis with respect to the specifications
of each supplier, product etc.
• Certificate report for each pipe
Fully integrated, flexible reporting visualizes the results
of these analyses. Furthermore, with the aid of an alarm
management system, corresponding information is automa-
tically sent (e-mail notification) to suppliers or
the responsible persons at the pipeline operator in the event
of deviations or failures.
Optimum material flow
For greater planning security, iTAC has also developed its
own Material & Logistic solution (ML-Service). The
ML-Service uses an interface to capture the current movement
of goods, even including the rate of pipe laying, thereby
allowing the operator to monitor the logistical processes.
The ML-Service answers the following questions
• Exactly where is the serial-numbered pipe?
(warehouse, transport, laying ship, installed)
• How long will the stock in store suffice at
time point x with a daily rate of pipe laying y?
(range check)
After the pipe is laid, the position of each individual pipe can
be mapped on a geographic map with the aid of correspon-
ding stored GPS data. This visualization tool (GIS-System) is
provided by iTAC’s partner P-Systems and is fully integrated
in iTAC.MES.Suite.
Partner for Line-Management-Systems and Cartography of
pipelines, networks and alignments.
iTAC Solutions for Energy/Pipeline
With the iTAC.MES.Suite, lines and networks can
be managed in all areas of the energy industry. The
standard software is a valuable tool in the logistical
processing, documentation as well as operation of
the individual network segments.
• Automated, electronic capture and comprehensive
documentation of the entire construction process
• Transparency across all steps and service providers
(contractors)
• Automated inspection (verification) of deviations
of the current state with respect to a specified
target state
• Information on process deviations via the
Alert Management System
• Flexible reporting with e-mail integration
• Continuous visualization of material movements
and material states
• Visualization of the network and segments of the
network classified as defective on a geographic
map (GIS-System) on the basis of the coordinates
assigned to the individual pipes
• Simple integration in leading business software
systems such as SAP
• Global, web-based access
• Reliability through documentation of all
inspection data during the entire uptime of a
pipeline, e.g. periodic capture of "pigging data"
• Investment security for the system through
platform-neutral JAVA technology
Through the deployment of unique serial numbers, each and every pipe segment is seamlessly documented across the entire supply chain.
iTAC Solutions for Energy/Pipeline
Data supplied by contractor
Antifriction coating of inner surface of pipes 3 Pipe number (Tube number) containing information on:•Coating•Coatingparameters•Testresultsetc.
>> Coating information
Anticorrosive coating of outer surface of pipes 4 Pipe number (Tube number) containing information on:•Coating•Coatingparameters•Testresultsetc. Asbefore,identicalprocess
>> Coating information
concrete coating 5 Pipe number (Tube number) with concrete coating:•Coatingparameters•Lots•Testresultsetc. Asbefore,identicalprocess
>> Concrete weight coating information
Productionofsteelplates1 Platenumbercontaining information on heat number (melt)•Chemicalproperties ofthesteel - Component information -Chemicaltest analysis
>> Batch information
Production of pipes2 Pipe number (Tube number) containing information on:•Testinformation (tensile,chappy impact, hardness etc., hydrostatictestetc.)
>> Component information
Storageinhandlingfacilities6 Stock movement• Stocklocation• „Intransport“ information
>> Stock movements
Layingofthepipeline7 Layinginformation•Weldingparameters•Bucklearrestor (reinforcement)
>> Layinginformation& asbuildinformation
iTAC Solutions for Energy/Pipeline
www.itacsoftware.com
iTAC Software AG
fon +49 2602 1065 - 0
certified: DIN ISO 9001:2000
iTACworldwide:
Germany · France · USA · China
E.08
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es: N
ord
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The iTAC.MES.Suite in use at Nord Stream
The iTAC.MES.Suite is being used during the construction
and operation of the 1,220 kilometer long natural gas
pipeline, which will connect Russia and the European
Union across the Baltic Sea beginning in 2010.
Due to its high standardization level, the Pipe Tracking
System from iTAC Software AG was employed
productively within just a few months. Nord Stream AG
is an international joint venture (Gazprom, E.ON Ruhr-
gas, Wintershall, N.V. Nederlandse Gasunie), which was
founded for the purpose of planning, constructing and
subsequently operating the new Baltic Sea pipeline.
iTAC Software AG
iTAC Software AG is a leading provider of manufacturing
execution systems (MES). As a system and solution provi-
der, iTAC develops, integrates and maintains its platform-
independent iTAC.MES.Suite for productive enterprises and
network operators around the world.
FACTS ABOUT THE NATURAL GAS PIPELINE ACROSS THE BALTIC SEA
ISSUE 7 | 08 – 2008
FACTS
steel chemistry are also retained in the central data
bank, which stores data on all individual pipe seg-
ments, valves and other components. Consequently,
initial information is automatically checked against
the target data resulting from regular inspections.
The pipeline safety inspection process takes place at
three levels. Steel pipe manufacturers, Nord Stream
assessors and independent pipeline experts conduct
inspections and quality control. The involvement of
independent certification bodies employed by Nord
Stream such as the Norwegian company DNV is a
crucial part of quality assurance.
With full access to the central databank, DNV in-
spectors will make regular checks at every stage of
the logistics chain of the permanent quality control
system put in place by Nord Stream. They attest that
standards are maintained in practice. These checks
cover the quality of materials delivered by Nord Stream
service companies, the loading of pipes on to the lay
barges and the pipe welds made on board. This
multi-stage process ensures that the exact location
of each pipeline segment in the corridor is recorded.
All components for the two lines – comprised of
more than 100,000 elements each – comply with
predetermined technical specifications.
Safety is Nord Stream’s first priority. An advancedpipe-tracking system is one of the innovations setting new standards for the planning, constructionand operation of natural gas pipelines. Pipe-trackingenables the company to monitor and document thepipe production and logistics. Pipe-tracking main-tains detailed information on each and every one ofthe individual pipe segments that will make up thetwo 1,220-km lines of Nord Stream.
Pipe-tracking is a multi-stage survey tool that collects
data at every stage of the logistics chain – manufac-
ture, transportation, storage, concrete weight coating
and installation in an integrated database. This data-
base will secure constant quality control over decades,
contributing to the pipeline system’s operational safety.
How does pipe-tracking work in detail? Each pipe
segment – made from X70 special steel and certified
according to the internationally acknowledged DNV
(Det Norske Veritas) OS-F101 Offshore Standard –
receives a unique serial number. This allows Nord
Stream to maintain constant quality control during
initial production, transportation, concrete coating,
storage and final welding on board the pipelay ves-
sel. The results of random material tests such as
ADVANCED PIPE-TRACKING OPTIMISES OPERATIONAL SAFETY
A unique serial number for each segment of the
planned Nord Stream pipeline across the Baltic Sea
will be traceable during the entire logistic chain.
3
710
15
16
8
111
Vyborg
Greifswald
Switzerland
France
BelgiumLuxembourg
The Nether-lands
Germany
Czech Republic
Austria
Italy
UnitedKingdom
Denmark
Nord Stream has received the go-ahead from itsshareholders for two major contracts for its projectto build a 1,220-km natural gas pipeline across the Baltic Sea.
The contracts – with EUPEC PipeCoatings S.A.
(Dunkirk, France) for concrete weight-coating and
logistics as well as with Saipem S.p.A. (Milan, Italy)
to lay the pipeline on the seabed – represent major
investment commitments to the project. Nord Stream
signed the contract with Saipem on 24 June 2008.
The signing of the contract with EUPEC followed
on 29 July 2008.
The Shareholders approved a project plan for
construction of the first of two parallel lines to start
in 2010. Matthias Warnig, Managing Director of
Nord Stream AG, said: “Nord Stream is the most
advanced of all gas infrastructure projects classified
by the European Union as ’of European interest’.
We are aware of the environmental concerns and
are taking sufficient time and effort to address them.
Based on intensive planning and preparation, we
will be able to supply additional gas from 2011.”
IMPORTANT STEP OF THE PROJECT UNDERWAY: CONTRACTS FOR PIPELINE INSTALLATION SIGNED
Nord Stream has published its so-called WhiteBook, responding to the more than 200 commentsand questions from stakeholders in all Baltic Seacountries since notification of the pipeline projectin November 2006.
Reflecting the project status of June 2008, the White
Book is a key element in the on-going dialogue be-
tween Nord Stream, as project developer of a gas
pipeline across the Baltic Sea, and the public in all
states bordering it.
It serves two main functions: First, it provides an
overview of how all comments have been taken into
account. Second, it summarises the general approach
in a way that gives non-experts in the various fields
(natural science, engineering, legal aspects etc.)
access to and understanding of the complex issues
involved. The White Book is structured to highlight
the most important topics – from the various possible
types of impact of the project to questions of alter-
natives and safety provisions.
For more information please download
the White Book at:
www.nord-stream.com/project/whitebook.html.
“WHITE BOOK” RESPONDS TO PUBLICCOMMENTS ON PIPELINE PROJECT
PIPELINE INFORMATION TOUR PLANNED TO VISIT BALTIC SEA COUNTRIES
NORD STREAM: FACTS | ISSUE 7 | 08 – 2008
Nord Stream has developed a mobile exhibition de-
voted to its project. The “Pipeline Information Tour”,
designed to provide the general public with informa-
tion on all aspects of the pipeline. It is housed in
a bus which will travel to major cities on and near
the Baltic Sea coast. Visits to Finland and Sweden
have already taken place. A tour through Germany,
Denmark and Russia is planned. The Pipeline Infor-
mation Tour is designed to explain all aspects of the
pipeline project in a way that is accessible to all
those interested. Visitors will be able to familiarise
themselves with the Nord Stream project using such
devices as an interactive multimedia terminal provid-
ing facts and figures on environmental issues, the
use of gas, pipeline safety, construction and opera-
tion. All information will be available in the languages
of the countries to be visited as well as in English.
For additional information please visit:
www.nord-stream.com/infotour.html.
333
4477
101010
1313
1717
1414
151515
161616
881212
111111
55
22
11
AA
II
BB
EE GG
FF
DDHHCC
JJ
An important link in the EU gas supply chain –Nord Stream
Pipeline planned
Gas storage in operationGas storage planned
Status of countries presumably receiving Nord Stream gas (June 2008)billion cubic metresbcm
Pipeline in operation
Sr(
StorageSelection of major storage facilities
A Haidach, Austria B Rehden, Germany C Humbly Grove, UK D Saltfleetby, UK (planned) E Jemgum, Germany (planned) F Poederlee, Belgium (planned) G Hinrichshagen, Germany (planned) H Etzel, Northern Germany I Epe, Western Germany J Bierwang, South Germany
ProductionShtokman field (planned)Nadym-Pur-Taz district Yamal Peninsula fields (planned)
Transport
1 NORD STREAM (planned) 2 BALTICCONNECTOR (planned) 3 BBL 4 YAMAL 5 SOUTHERN CORRIDOR 6 NEL (planned) 7 OPAL (planned) 8 JAGAL 9 MIDAL 10 STEGAL 11 SKANLED (planned) 12 NETRA 13 DEUDAN 14 MEGAL 15 IUK 16 SEL (planned) 17 BALTIC PIPE (planned)
Selection of major pipeline-transportation routes
ImportImport gap 2025, 195 bcm
EU domesticgas production
42%
58%
2005543 bcm
Demand
Source: European Commission, Directorate-General for Energy and Transport, 2008
140 bcm additionalgas import needs
55 bcm of the gap is to be secured by Nord Stream
19%
81%
2025629 bcm(Forecast)
1919%%
8181%%
2025629 bc(Foreca
%%
%%
5cmast))
3800Shtokman
field
bcm10400
bcmYamal
Peninsulafields
Nadym-Pur-Tazdistrict
13900bcm
VyborgVyborgVyborg
GreifswaldGreifswaldGreifswald
SwitzerlandSwitzerlandSwitzerland
FranceFranceFrance
BelgiumBelgiumBelgiumLuxembourgLuxembourgLuxembourg
The Nether-lands
The Nether-lands
The Nether-lands
GermanyGermanyGermany
Czech RepublicCzech RepublicCzech Republic
AustriaAustriaAustria
ItalyItalyItaly
UnitedKingdom
UnitedKingdom
UnitedKingdom
DenmarkDenmarkDenmark
Nord Stream welcomes the recent debate in theEuropean Parliament (EP) on its pipeline projectand is working on the final draft of an EnvironmentalImpact Assessment (EIA) report. It will present thisdraft report within the Espoo process for final con-sultations in October 2008.
The report emphasizes Nord Stream’s policy of trans-
parency and presents results from the most detailed
scientific surveys and research ever undertaken in
the Baltic Sea. It will contain responses to the hun-
dreds of comments received from governments,
non-government organisations and individuals since
November 2006.
Nord Stream believes the EIA report will add to
growing understanding for the pipeline project at the
level of European politics. On 8 July 2008, in a posi-
tive and unusual move, the EP debated and approved
more than 50 amendments before adopting a report
from its Petitions Committee (PETI).
A Polish Member of the European Parliament initiated
the original, more critical, report after submissions
from Lithuanian and Polish petitioners in 2006. It
sought direct European Commission involvement in
assessing Nord Stream’s environmental impact. EU
Environment Commissioner Stavros Dimas emphasi-
zed that this is the legal responsibility of national
governments.
Nord Stream welcomes the changes made to a
“inaccurate report.” In particular, the amendments
adopted by the EP plenary voting recognise:
• Nord Stream’s status as a TEN-E project of Euro-
pean Interest, as approved by the Parliament in 2006.
• The need for joint European action to secure future
energy supplies.
• Continued growth in European gas demands
requires analysis and promotion of new gas pipe-
line routes.
EUROPEAN PARLIAMENT STRESSES THE IMPORTANCE OF NORD STREAM FOR SECURING EUROPE’S ENERGY SUPPLY
Swedish and Polish ambassadors to Latvia, as well
as officials from Latvian ministries attending, the
Baltic Youth Philharmonic played a repertoire ranging
from Beethoven to Dvorák.
The Baltic Youth Philharmonic will come together for
a second round of rehearsals in 2008 at the Usedom
Music Festival, a major classical music event in Ger-
many. A second concert is schedule for 21 Septem-
ber 2008 during the festival in Peenemünde, Germany.
For additional information please visit:
www.baltic-youth-philharmonic.org.
Seventy of the most outstanding young music students from ten nations around the Baltic Seaconvened in Riga, Latvia, to perform music to-gether without borders.
Nord Stream and the Usedom Music Festival initiated
the Baltic Youth Philharmonic. The common idea
behind the orchestra is to unite the Baltic Sea region.
Both partners have laid the foundation for a promis-
ing project – an orchestra that will transcend geo-
graphical and artistic boundaries and will give young
musicians at the beginning of their careers a unique
opportunity to develop. The Baltic Youth Philhar-
monic will contribute to the understanding between
young people from around the Baltic Sea and
emphasize their shared cultural heritage.
Renowned conductor Kristjan Järvi leads the Baltic
Youth Philharmonic and offers the ideal artistic per-
sonality. The talented musicians, who had previously
never played together, re-hearsed from 30 May to
5 June 2008. These rehearsals culminated in a con-
cert at the Great Guild in Riga. Under the patronage
of Latvian Prime Minister Ivars Godmanis, and with
UNIFYING THE BALTIC SEA REGION – THE BALTIC YOUTH PHILHARMONIC’SPROMISING DEBUT CONCERT
NORD STREAM: FACTS | ISSUE 7 | 08 – 2008
Head OfficeNord Stream AG
Jens D. Müller
Grafenauweg 2
6304 Zug, Switzerland
Tel +41 41 766 91 91
Fax +41 41 766 91 92
Moscow BranchNord Stream AG
Irina Vasilyeva
ul. Znamenka 7, bld 3
119019 Moscow, Russia
Tel +7 495 229 65 85
Fax +7 495 229 65 80
[email protected] | www.nord-stream.com
Contacts
DID YOU KNOW …
• The Nord Stream pipeline will supply Europe
with 55 billion cubic metres of natural gas per
year, equal to energy transported by 550 LNG
(liquefied natural gas) tankers or produce by
240,000 average windmills.
• These 55 billion cubic metres would be enough
energy to satisfy the demands of 26,5 million
European households (EU-27) for one year.
• Using this much natural gas instead of lignite
would reduce CO2 emissions by 55 million tons –
as much as Denmark produces per year.
NORD STREAM’S AGENDA
September 10–13 Economic Forum of Central
and Eastern Europe, Krynica, Poland
September 21 Baltic Youth Philharmonic, concert
at the Usedom Music Festival, Peenemünde, Germany
For subscription to subsequent issues
of “Nord Stream: Facts”, please go to:
www.nord-stream.com/newsletter.html.
If you have any comments or requests,
we look forward to hearing from you.
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