Main Technical Solutions for the Nord Stream 2

Gas Pipeline Offshore Section

European Business Congress
Vienna, May 26, 2017. Sergey Serdyukov, Chief Technical Officer of Nord Stream 2 AG
Improved clone of the Nord Stream gas pipeline system

Nord Stream 2 gas pipeline is an immediate successor of

the first successfully implemented twin pipeline system.
> Also, directly connects the major gas reserves of Russia
with the EU gas markets.
> Also, ensures reliable and efficient route of supplying
over 12% of the EU cumulative demand in natural gas
(478 bln m3 in 2012).
> Also, comprises 2 parallel gas lines 48 inches measuring
ca. 1220 km in length each.
> Also, environmentally impeccable both in materials
composition and installation method.
> Also, bypasses all known zones of sunk chemical
weapons of the 2nd World War.

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Selecting the route in Russia

There have been three stages of

research work for the Nord Stream 2
project, which began in 2012:
> Stage I - Evaluation of the
Corridor to the North of St.
Petersburg
> Stage II – Choosing a Landfall on
the Southern Coast of the Gulf of
Finland
> Stage III – Evaluating Landfall
Options in the Kingisepp District

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Nord Stream 2 pipeline: facilities & infrastructure

Pig-Trap Pig-Trap
Gas
Receiving
area area Compressor
(Pipeline NSP2 (Pipeline
Terminal Station
Service Service
Facilities) Facilities)

Feeder
Line
EUGA
AL

NEL
Nord Stream 2 Pipeline Unified Gas
Supply System
Associated Facilities

Infrastructure Not Associated with NSP2 Project

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What is the basis of the main design solutions?

Main design factors: max. diameter of the offshore gas pipeline – 48”, length – 1220 km, and maximum
pressure 220 bar.
Additional conditions:
> Both lines are to be constructed in parallel with a completion deadline in 2019.
> No compressor station on the German Landfall (recreational area).
> Final temperature of Nord Stream 2 – according to 2К criteria (2 degrees less than T of the seabed).
> Three-sectional design with operating pressure 220-200-170 bar respectively.
> Burying of the pipeline into the seabed in navigation areas at the 1 m depth.
> No blasting operations for seabed leveling.
> Stability of gas pipelines during wreck of any known type of civil vessels.
> Highest reliability criteria SIL 3 with fault level 1х10 to minus 5 cases per 100 km per year should be ensured.
> Intra-day supply schedule of 0-50-100 % should be ensured.
> Internal intelligent pigging with pigs 7 meter long and weight 10 tons should be ensured – in order to guarantee permanent
internal diameter of 1153 mm.

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Pipe material: why Х70 steel should be used?

1. Selection of 48” pipeline diameter (Internal diameter = 1153 mm) –

max. offshore size – creates strict requirements for pipe material to
be selected.
2. The most critical pipe material parameter – strong resilience, i.e.
required steel should have ratio: σ yield strength/ σ tensile strength <
0.92.
3. World leading steel manufacturers spent from 10 to 18 months to
create such steel (First Alpine, Europipe, Nippon Steel, Sumitomo,
JFE, Severstal, NLMK, ММК).
4. Х-80 steel promoted by leading pipe manufacturers can not in
principal ensure compliance with this requirement.
5. Offshore is an area for Х-70 steel to be used, this is where proven
solutions are to be implemented!

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Reliability of protective coating of the gas pipeline
There are three types of pipe coating:
> Internal epoxy antifriction coating with design roughness
less than 6 μm.
> External three layer anti-corrosion epoxy-polyethelene
coating (4.2 mm).
> Concrete weight coating to ensure stability on the seabed
(60 -110 mm).
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> Use of state-of-the art chemical technologies for
the Nord Stream project has allowed to achieve 1.8
μm roughness
> Use of JCO method for pipe bending has allowed
pipe mills to achieve out-of-roundness of less than
1 mm
> Use of iron ore supplied from Swedish deposit has
completely excluded possibility of concrete coating
defects.
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Optimal technical design

Task Technical design Pressure Achievements

3 220 0
1 224 sections with different bar at Landfall intermediate
km – two pipelines pressure – less steel Russia – 102 bar compressor stations
via the Baltic Sea consumption Landfall Germany

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Update of technical solutions

Experience of the Nord Stream operation was taken into consideration during development of technical concept of the
Nord Stream 2 project, with several technical changes proposed such as:
> 1 x Gate Valve changed (DEGV) to 2 x Ball Valves (PTR and PTG)
> 2 x 28” New Ball Valves for Isolation
> New Flanged 28” Filter
> 28” Flow Meter Flanged
> 28” Isolation Joint

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Innovative pre-commissioning concept

Considering the standard DNV-OS-F101 (2013), an innovative pre-commissioning concept will be used for
the Nord Stream 2 project, i.e. without hydraulic tests of the offshore gas pipeline with the required safety
level to be ensured through alternative measures. This concept is applicable only to 48-inch gas pipeline due
to its specific characteristics.

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Alternative methods of the gas pipeline control and reliability
assurance

The required safety level is ensured through alternative methods such as:
> Highest quality standards and control over their implementation at all stages of the Project (selection of the supplier,
selection of the material, control over pipe manufacturing, control over welding and installation, etc.);
> Ensuring strength of pipes during manufacturing (double independent automated ultrasonic inspection of weld joints,
additional non-destructive test of weld joints, 100% expanding of pipes up to the yield stress throughout the whole
length, factory hydraulic test of pipes at pressure corresponding to 96% specified minimum yield strength direction
from the center out;
> 100% automated 8-beam ultrasonic inspection of cross weld joints and additional methods of non-destructive test
when assembling pipes on a pipelaying vessel;
> As required, manual ultrasonic inspection and magnetic-particle non-destructive test (MPI NDT) to obtain more
detailed information;
> Bevel edge to be formed and its geometry for a cross weld joint to be controlled immediately before welding;
> Continuous recording of welding parameters;
> Continuous control of the curve degree of the pipeline being installed.

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Pipelay installation and inspection tool

S-Lay Offshore Pipeline Installation

Pioneering Spirit

Solitaire

48” ART Scan™ Tool

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Internal inspection

Intellectual COMBO pig was developed for Nord Steam

project having the following parameters:
> Length - 7 m
> Weight – over 7 t
> Travel speed: 1.5 m/s (moving with gas flow)
> Travel time: 1224 km in around 10 days
> Memory size: 10 Tbyte of high-resolution data
> Powerful system of magnets due to wall thickness 41 mm
The pigs are launched from the Russian landfall and
extracted from the pig receiver at the Germany landfall

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External inspection of the gas pipeline offshore section

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Use of innovative solutions as a way to optimize the Project

No hydraulic testing will allow avoiding such negative consequences as

> Significant impact on the environment due to discharge of 2,600,000 m3 of water with
conserving agents and debiotics;
> Rockfilling in the process of hyperbaric welding between sections;
> Additional loads on the offshore pipeline at the clear span sections.

No hydraulic testing will allow significantly reducing the capital investments into
construction and ensure the project is implemented as per the schedule.

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Contacts

Nord Stream 2 AG
Baarerstrasse 52
6300 Zug / Switzerland
Phone: +41 41 414 54 15
www.nord-stream2.com

Sergey G. Serdyukov
Chief Technical Officer
sergey.serdyukov@nord-stream2.com

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