Carbon Footprint of Pipeline Projects - IPLOCA.com

Carbon Footprint of Pipeline Projects44 th Annual IPLOCA Convention, Venice27 September - 1 October 20101

Carbon Footprint of Pipeline ProjectsHow does Nacap decrease the emission of carbon dioxidewhile bringing energy to its destination?2

Carbon Footprint of Pipeline ConstructionDefinition“The Carbon Footprint is a measure ofthe exclusive amount of carbon dioxideemission that is directly and indirectlycaused by an activity”3

Carbon Footprint of Pipeline ConstructionWhy?Carbon footprint is estimated in order to find out the environmental impact ofexecuting pipeline projects.The outcome is useful both for Nacap, in order to offset the emissions andreduce energy consumption (costs), as well as for clients who may wish toconsider the results in their decision making process.Except for some research on CO 2 emission for the production of certain typesof steel and plastic used in the pipeline industry, no in-depth research has beenexecuted for CO 2 emissions of pipeline construction in the past.4

Carbon Footprint of Pipeline ConstructionHow is it calculated?This research is based on five different pipeline diameters:16, 20, 24, 36 and 48 inch diameter.This approach is chosen in order to show the difference in emissions perdiameter and to establish a trend line for understanding the emission behaviortowards pipeline projects of different diameters.The specific diameters were chosen because of their common occurrence inprojects.5

Carbon Footprint of Pipeline ConstructionSteel pipe production emissionThe production process of the pipes is by far the largest emitter ofcarbon dioxide in the carbon footprint of pipeline projects. It requiressignificant energy to convert raw material into steel pipes.6

Carbon Footprint of Pipeline ConstructionTransportation emissionThe transportation of various diameter line pipes over 1,000 kilometersis given in kilograms CO 2 whereby 1,000 km are taken as an average.This component only concentrates on the heavy transportation ofpipeline projects. The transportation of personnel and business flightsis included in the overhead.7

Carbon Footprint of Pipeline ConstructionEquipment fuel usage emissionThe equipment used during pipeline construction is an importantcontributor of the total emission during a pipeline project.The equipment is grouped into five separate equipment sections:the earth moving equipment, heavy lifting equipment, typical pipelineequipment, transportation equipment and others (compressors, pumpsetc.).8

Carbon Footprint of Pipeline ConstructionWelding, coating and miscellaneousThe group “others” consists of consumables or small equipment whichare consumed, destroyed, wasted and or spent during theproduction/execution period of a pipeline project. Nacap focuses onthe welding consumables and coating material used during pipelineconstruction.9

Carbon Footprint of Pipeline ConstructionFacilities and overheadThe emission caused by overhead consists out of business flights,transportation of personnel working in 8 different regional officesand on construction sites as well as the emission caused by thefacilities.10

Carbon Footprint of Pipeline ProjectsOverview14001200tons CO2 per km pipeline1000800600400OverheadCoating & weldingEquipment fuel usageTransport (1000 km)Steel production & pipe rolling200016 20 24 36 48Pipe diameter (inch)11

Carbon Footprint of Pipeline ProjectsSteel pipe productionDiameter(inch)Thickness(mm)Weight(ton/kmpipe)Blast furnaceCO 2 emission (ton/km pipe)ContinuouscastingRolling &pipeproduction16 7.95 77.9 120.7 1.1 11.9 133.720 9.82 120.3 186.4 1.7 18.4 206.424 10.25 150.6 233.5 2.1 23.0 258.636 14.35 316.3 490.3 4.4 48.3 543.048 19.30 567.2 879.2 7.9 86.7 973.7CO 2 emission for steel pipe productionTotalThe carbon steel for pipes used in the pipeline industry is produced in blastfurnaces. This process consumes a huge amount of energy.12

Carbon Footprint of Pipeline ProjectsSteel pipe productionOne of the major components in the amount of CO 2 emission throughoutthe process is the production of steel pipes, a process pipeline constructioncontractors cannot influence.13

Carbon Footprint of Pipeline ProjectsHow does Nacap contributeto the reduction ofCO 2 emission?14

Carbon Footprint of Pipeline ProjectsContribution by NacapThe areas in which Nacap has influence on reduction of CO 2 emission are:- Selection and use of heavy equipment;- Transportation of the pipes;- Welding and coating process; and- Transportation of equipment and personal (overhead).15

Carbon Footprint of Pipeline ProjectsTransportation• The transportation activity is divided into two different parts; equipment and pipes.• The calculation of transportation emission is based on an average of 100 grams ofCO 2 per ton/km for the combination of boat, rail and road transportation.• The weight of pipes to be transported depends on the pipe thickness.• The weight of equipment per km pipe was calculated by dividing a ‘typical’ spread fora certain diameter by a ‘typical’ project length.Weight (ton/km pipe)CO 2 Emission (ton/km pipe)Diameter(inch) Pipes Equipment Pipe transportEquipmenttransportTotal16 77.9 16.8 7.79 2.07 9.8520 120.3 32.0 12.03 3.94 15.9624 150.6 58.7 15.06 7.22 22.2836 316.3 139.2 31.63 17.12 48.7548 567.2 234.7 56.72 28.86 85.5916

Carbon Footprint of Pipeline ProjectsTransportationThe previous table shows the difference between the transportation of equipment and thetransportation of pipes. Equipment is in most cases comparable in weight to a truckload fullof pipes, but equipment is used over a much longer stretch.The table shows an almost linear growth of the transportation activities.The larger the diameter the more equipment is required to lay a pipeline. The weight of thepipelines with similar thickness is also more or less linear in their emission.17

Carbon Footprint of Pipeline ProjectsEquipmentCO 2 emissions (ton/km pipe)Diameter(inch)EarthmovingequipmentHeavy liftingequipmentPipelineequipmentTransportequipmentOtherequipmentTotal16 27.8 1.3 3.4 15.9 3.3 49.220 24.2 10.5 11.2 3.4 4.3 53.424 37.3 5.5 7.4 6.5 27.3 84.036 54.1 25.5 14.6 18.0 7.6 119.748 68.6 25.8 10.8 24.9 8.5 138.6CO 2 emissions of different type of equipment• The equipment used during pipeline construction is an important contributor to thetotal emission. The equipment is grouped into five separate equipment sections.• The table illustrates the emission of the equipment. The emission is calculated bymultiplying the equipment fuel usage by the CO 2 conversion factor for diesel.18

Carbon Footprint of Pipeline ProjectsEquipment140CO2 emissions (ton/km pipe)12010080604020Other equipmentTransport equipmentPipeline equipmentHeavy lifting equipmentEarth moving equipment016 20 24 36 48Pipe diameterCO 2 emission for different types of equipment is based on the fuelconsumption on real projects.19

Carbon Footprint of Pipeline ProjectsEquipmentThe previous chart highlights the difference in emissions between a 24” and a 36” pipelinebeing higher than emission between 36” and 48”, while their difference in diameter is thesame (12”). The explanation is the usage of heavy lifting material. For instance,pipeline projects below a 30” diameter use less side-booms in terms of hours and fuel usage.However the largest emitter group within the equipment section is the earth movingequipment due to the high fuel consumption required to move large amounts of soil tolay the pipeline.20

Carbon Footprint of Pipeline ProjectsWelding & coatingUse of welding consumables & pipe coating• The use of welding consumables hardly has any impact. The electricity used for thewelding is produced by generators, of which the fuel consumption is taken intoaccount under ‘equipment’.• The application of pipeline coating has a substantial impact on the total footprint.To produce one ton of polypropylene and polyethylene, 1.7 tons of CO 2 is emitted.Weight (ton/km)CO 2 emissions (ton/km pipe)Dia (inch) Coating Electrodes Coating Electrodes Total16 4.0 0.04 6.8 0.06 6.920 5.0 0.07 8.5 0.12 8.624 6.0 0.09 10.2 0.16 10.436 9.0 0.27 15.3 0.47 15.848 12.0 0.66 20.4 1.13 21.521

Carbon Footprint of Pipeline ProjectsOverheadCO 2 emission by overhead is based on business flights, personnelcar transportation and facilities.22

Carbon Footprint of Pipeline ProjectsOverhead• The emission from facilities is based on an average office and extrapolated to thetotal number of buildings. The Nacap head office emits an average of 121 tons ofCO 2 annually.• The emission from business flights is based on flights for Nacap Head Office andextrapolated to the total organization. In 2008, Nacap Headquarters booked morethan 600 flights which led to 342 tons of CO 2 emissions.• The emission from traveling by road are based on the total number of employees andthe average traveling distance. The table shows that the transportation of personnelis by far the largest emitter within the overhead activities.CO 2 emissions (ton/km pipe)Facilities Flights Cars TotalCO 2 total (ton) 967 1,368 14,400 17,701per km pipe 2.4 3.3 35.0 40.723

Carbon Footprint of Pipeline ProjectsResults1 KMThe amount of CO 2 produced by constructing 1 km of 48” pipeline is similar tothe amount of CO 2 caused by burning the gas that is stored under 80 bar in7.3 km of the same pipeline.Despite the fact that the majority of the emission is caused by the steel pipeproduction, the results give the construction industry valuable insights.24

Carbon Footprint of Pipeline ProjectsResultsDiameter(inch)Steelproduction& piperollingTransport(1000 km)CO 2 emissions (ton/km pipe)Equipmentfuel usageCoating &welding Overhead Total16 133.7 9.85 49.2 6.9 40.7 240.420 206.4 15.96 53.4 8.6 40.7 325.124 258.6 22.28 84.0 10.4 40.7 415.936 543.0 48.75 119.7 15.8 40.7 768.048 973.7 85.59 138.6 21.5 40.7 1,260.1Total CO 2 emissions for laying a pipelineThe above table shows the total CO 2 emission for the construction of 1 kmpipeline of several diameters (based on the assumptions given).25

Carbon Footprint of Pipeline ProjectsPipeline CO 2 emissionHow to calculate CO 2 emission of a pipeline project?www.nacap.com: Pipeline carbon footprint calculator26

Carbon Footprint of Pipeline ProjectsTypical 48” Pipeline ProjectHow does Nacap decrease the emission of carbon dioxide while bringingenergy to its destination?- Use of new sidebooms and paywelders compared to old models from the 90'sreducing fuel consumption by up to 40%;- Efficient transportation and just-in-time delivery of line pipes resulting in reductionby 10%;- Use of coating process with Stopaq method and new happy happer reduced energyconsumption by 5%;- Mostly local staff is hired on projects, reducing travelling by 30%.27

We bring energy to its destination28