Document No.

GP 43-32
Applicability Group
Date 30 March 2004

Guidance on Practice for

Pipe Handling Logistics for Pipelines

GP 43-32

BP GROUP
ENGINEERING TECHNICAL PRACTICES
30 March 2004 GP 43-32
Guidance on Practice for Pipe Handling Logistics for Pipelines

Foreword

This is the first issue of BP Engineering Technical Practice (ETP) GP 43-32. This document will be
updated on a periodic basis to include new BP experiences and any additional pipe handling
logistics’ mandatory requirements. This is not a standalone document; it must be used in
accordance with the requirements of ETP document PR 43: Status of ETP Pipeline Documents. In
addition to the requirements for this document, those of relevant BP group standards also have to
be fulfilled.

Copyright © 2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.

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Table of Contents
Page
Foreword .............................................................................................................................................. 2
Introduction .......................................................................................................................................... 4
1. Scope.......................................................................................................................................... 5
2. Normative references ................................................................................................................. 5
3. General guidance ....................................................................................................................... 5
3.1. General............................................................................................................................ 5
3.2. The pipe supply chain ..................................................................................................... 6
3.3. Pipe tracking.................................................................................................................... 6
3.4. Supply chain simulation modelling.................................................................................. 7
3.5. Examples of simulation modelling .................................................................................. 7
3.6. Pipe handling and lifting .................................................................................................. 7
3.7. Pipe transportation .......................................................................................................... 9
3.8. Pipe storage .................................................................................................................. 11
Bibliography ....................................................................................................................................... 13

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Introduction

This document provides access to the repository of BP experience in pipe handling logistics for
pipelines. This includes items such as specifications, examples, lessons learnt, success stories, and
failures. Mandatory pipe handling logistics requirements are contained in the body of this document.

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1. Scope

a. This Guidance on Practice is concerned with the supply of pipe, including induction bends,
from the pipe mill to the pipeline construction site. It covers the following activities
associated with pipeline construction:
1. Modelling and optimisation of the pipe supply chain from pipe mill to pipeline work
site.
2. Pipe handling using cranes and other lifting devices at each stage in the supply chain.
3. Pipe transportation by road, rail and sea.
4. Pipe storage.
b. The supply, handling, transportation, and storage of linepipe and other materials required
for pipeline construction operations present considerable risks to pipeline projects. The
movement of very large numbers of pipe joints from mill to coating yard, pipe dump and
pipeline right-of-way or laybarge, is a very significant challenge in terms of logistics,
safety, and security. The pipeline construction industry is obviously highly experienced in
these areas, but there are still opportunities for improvement, particularly as pipelines are
being constructed in ever more remote locations.
c. This document is included in the ETP document set as a link to the repository of BP
experience as well as internal BP and external reference documents on the issues outlined
above.

2. Normative references

The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. The latest edition of the normative document
referred to shall apply.

American Petroleum Institute (API)

API RP 5L1 Recommended Practice for Railroad Transportation of Line Pipe.
API RP 5LW Recommended Practice for Transportation of Line Pipe on Barges and
Marine Vessels.

BP
GP 43-31 Guidance on Practice for Linepipe Procurement.

3. General guidance

3.1. General
This Guidance on Practice shall be applied to all BP projects. It shall be read by the Project
Management Team during the Select or Define stage of a project and applied during the writing
of invitations to tender for construction contracts and the supply of linepipe.
Clause 3.2 below describes the activities involved in the pipeline supply chain.
Clauses 3.4 and 3.5 below describe how the supply chain operation can be
optimised using a simulation model.
Clauses 3.6, 3.7, and 3.8 below give an outline of the requirements for pipe
handling, transportation, and storage. References to the standards and practices are
given in Clause 3 below.

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A link to a more detailed description of the simulation model is provided in the

Bibliography below.

3.2. The pipe supply chain

The pipe supply chain comprises a number of activities including pipe manufacture,
transport to the coating facility/bend manufacturer, coating/induction bending, and
onward transport to the central receipt and storage facility. For an onshore
pipeline, the pipe is then distributed along the pipeline right-of-way for installation,
either in single or double pipe joints. For an offshore pipeline, the pipe is
transported to a port for shipment to the installation vessel or to a fabrication yard
for reel laying, for example.
The pipe supply chain may also include the small quantities of pipe transported
separately to site for weld procedure qualification or to the valve supplier(s) for pup
pieces.
a. The project shall consider the contract strategy and the extent to which it directly manages
the pipe supply activities.
The selected contract strategy for pipe supply has a major impact on HSE, Quality,
and Integrity Management delivery, as well as project capital cost and schedule.
GP 43-03 explains the contract strategy options for pipeline project execution. The
BP Global Pipeline Agreement (GLA) shall be used, if possible, to procure linepipe.
Contract Strategy Options:
Option 1: The project awards separate contracts for pipe manufacture and
coating. The pipe mill could then be made responsible for manufacturing the pipe
and transporting it from the mill to the coating plant.
• After pipe coating, the coating contractor or the construction contractor is
responsible for transporting pipe to the project site storage facility, after which
the project takes over responsibility.
• Option 1 should be used when the pipe is being procured through the BP Global
Linepipe Procurement Agreement.
• Positives: Ensures the most competent body manages each activity.
• Potential to optimise shipping costs which can be significant.
• Negatives: Multi-interfaces that the project will need to manage.
Option 2: The pipe manufacturer is made responsible for pipe manufacture,
coating and onward transport to the main storage facility, after which the project
takes over responsibility.
• Positives: No interfaces, one organisation is accountable.
• Negatives: Pipe manufacturers are not normally competent to manage third
party coating contractors and associated ship loading after coating.
• HSSE and integrity management responsibilities and accountabilities are not
clear and their delivery is diluted.
b. The supply of induction bends should be contracted to the pipe supplier as more fully
explained in GP 43-31.

3.3. Pipe tracking

a. A pipe tracking system shall be established in the early stages of a project and shall be
referenced in all major pipe supply and construction contracts. The pipe tracking system
shall:

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1. Ensure that all activities are properly controlled and that an audit trail is in place from
steel making through to pipe forming, coating/bending, transportation, storage and on
through all construction activities.
2. Be capable of identifying and tracking unique pipe numbers and should ideally be
part of a pipe tracking data base that will continue to track pipe through construction
and testing activities.
b. A logistics expert with experience in the country or area of construction should join the
Project at an early stage.

3.4. Supply chain simulation modelling

Construction accounts for around half the overall cost of a pipeline project and as
the complexity of projects increase so the complexity of managing them increases
substantially. A computer based simulation model for the prediction of overall
construction performance, particularly for onshore pipelines, is a powerful tool for
managing this complexity, including identification of construction bottlenecks and
evaluation of the impact of engineering changes on the project.
Since the pipeline construction process comprises a number of discrete operations
or events, each with probabilistic durations, the logical approach is to use a discrete
event simulation package to model the supply logistics and construction process.
Discrete event simulation modelling of the line pipe supply chain achieves the
following:
• Right size and location of pipe storage.
• Just-In-Time (JIT) pipe delivery.
• Definition of resource needs (road, rail and sea transport).
• Optimal batch sizing from pipe mill.
• Quantification of risks of late delivery.

3.5. Examples of simulation modelling

BP has modelled the supply of line pipe from manufacturers, through coating mills
to the pipeline right-of-way for In Salah and BTC pipelines. A model has been
developed of the pipe-lay process to quantify resources and potential for technology
improvements.
The In Salah model was used to identify the optimal build-up rate of trucks to
transport pipe from the port of Mostaganem or from the Algerian pipe mills to the
main pipe dumps along the pipeline right-of-way. It was also used to identify the
benefit arising from transporting double- jointed pipe.
Shell has used a similar technique for supply of line pipe to Sakhalin Island that also
takes into account environmental conditions to determine weather windows for ship
transport of pipe. The model shows how many ships, trains and trucks are needed to
get materials to certain places at certain times.

3.6. Pipe handling and lifting

a. Pipe handling and lifting, including handling pipe in the coating facility, and working at
heights on land, pose serious safety risks and appropriate controls shall be put in place.
b. In line with the statement above, risk assessments should focus on pipe movement, lifting,
road transport, and ship loading and unloading.
c. Pipe handling on a project should be kept to an absolute minimum.
d. If pipe handling is necessary, task risk assessments shall be performed.

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These identify the associated risks and management controls to be applied in order
to avoid injury to personnel and damage to the pipe and coating.
e. Lifting plans shall be generated for lifts.
f. Persons employed in the handling of pipe, whether by manual or mechanical means, shall
be instructed in the relevant lifting plans and procedures and shall be trained in the use of
the lifting equipment employed.
g. If personnel, in addition to the lifting equipment operator, are required to assist with the
lifting operation, lift plans and procedures shall be put in place such that no personnel are
present in the lifting area when pipe is being lifted.
h. Pipe of different diameters shall not be lifted together.
Information including pipe diameter, weight per metre (foot), length to be lifted and
whether coated or non-coated is required for correct selection of the lifting
equipment. (This information would also be included in the task risk assessment
procedure)
i. Pipe of 150 mm (6 inch) diameter and greater shall be handled with lifting devices such as
fixed or mobile cranes, using vacuum lifting equipment or slinging methods agreed in the
job specific lifting plan.
j. If hooks are used these shall be padded on the lifting face to avoid damage to the pipe
ends.
Pipe handling at intermediate shipment locations such as ports and temporary
storage sites poses real HSSE and pipe damage risk issues. Such exposure warrants
extra attention.
Vacuum lifting is the preferred method of lifting pipe and is suitable for use with
cranes, side booms or excavators. Vacuum lifting is very effective in combination
with an appropriate excavator and the combination of vacuum unit with hydraulic
rotator mounted on an excavator allows the unit operator to handle pipe without the
need for additional personnel in areas around the pipe, thus reducing risk and cost.
Vacuum lifting was successfully used on construction of the AGT pipelines and the
In Salah Gas pipeline. This linked photograph shows a side boom crane with
vacuum unit attached, lifting a double joint of 48 in pipe. The photograph also
shows some key advantages of vacuum lifting such as personnel positioned well
away from the pipe and the pipe being lifted centrally.
Although vacuum lifting is suitable for handling pipe at all stages between the pipe
mill and the pipeline right-of-way, either as single or double joints, it is not
currently suitable for lowering a welded pipe string into the trench.
k. Safety devices shall be used with vacuum lifting equipment to reduce the risk of release of
the vacuum while the equipment is under load.
l. If the vacuum pump fails, warnings shall be activated and vacuum maintained at the lifting
head for sufficient time for the operator to safely lower the pipe.
m. For a pipe with a rough external surface such as some concrete coatings, a special vacuum
seal or an alternative lifting system should be used. In such cases trials shall be performed
to prove the system’s effectiveness.
The performance of vacuum lifting systems depends on the condition of the pipe
surface and the type of seal used.
Three failures occurred on AGT Pipelines Project when using vacuum lifting.
• Bolts over-tightened while attaching hydraulic rotator.
• Wood chips from dunnage accumulated on pipe resulting in vacuum release.

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• Vacuum skirts became worn due to crane operator placing/ sliding unit onto
pipe without using hydraulic rotator.
Another incident involving a crane lifting pipe with a vacuum unit resulted in pipe
being dropped due to operator error. This incident is described in an IPLOCA safety
alert.

3.7. Pipe transportation

3.7.1. General
a. Pipe may be transported by road, rail, or sea depending on the pipe mill and project
locations.
All methods of transport present a safety risk to personnel as well as a risk of
damage to the pipe and coating or even loss of the pipe.
b. Pipe shall be transported such that there is no harm to people and no damage to the pipe.
c. Pipe shall be secured during transportation so the load does not move and the pipes packed
with separators/dunnage so that they cannot impact each other or any other hard surface.
Damage to pipe can be caused in several ways, including:
• Pipe ends damaged during loading and unloading.
• Pipe ends damaged by longitudinal movement.
• Abrasion caused by rubbing against adjacent pipes or a protrusion such as a
weld.
• Longitudinal fatigue cracks caused by static and cyclic stresses due to
combinations of vertical movement, vertical loads and abrasion damage.
For future reference, studies are currently underway into the viability of alternative
means of transporting pipeline materials, including hovercraft and airships.
d. Dunnage should not include sawdust-filled bags if pipes are to be lifted with vacuum units.

3.7.2. Road transport

a. Linepipe transported by road shall cause no harm to people, satisfy gHSER, and cause no
damage to the pipe.
In general, road transport carries the highest risk of accidents on a pipeline project.
This applies to public roads, access roads and the pipeline right-of-way.
b. An early route survey of road transport infrastructure, including capacities of roads and
bridges, including weight restrictions shall be performed. The route survey should also
include identification and location of hazards. This information may be documented in the
project Geographical Information System (GIS).
c. Pipe carried on road vehicles shall be loaded such that vehicle axle loads are within
permissible levels.
d. The number and size of pipes comprising a load shall be governed by the capacity of the
vehicle.
e. Pipe lengths shall be carried on pre-formed supports, fixed to the flatbed trailer, to prevent
pipes from rolling. The supports should not extend over the sides of the trailer.
f. Pipes shall be strapped down to the trailer to ensure that no pipe within the bundle is free to
move longitudinally when the vehicle is on an incline.
g. Trailers shall be fitted with ‘head-boards’ to prevent pipes sliding forward into the cab area
in the event of violent deceleration.

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Polyethylene and polypropylene-coated pipes have very low friction coefficients,

especially when wet and accidents have occurred where such pipes have slid
forwards into the cab area or backwards onto the road.
h. The length and width of the load carried should be within the length and width of the
vehicle or trailer being used.
i. Pipe transportation by road must meet BP’s minimum HSE requirements, especially
regarding driving and road worthiness of vehicles.

3.7.3. Rail transport

a. Linepipe transported by rail shall cause no harm to people, satisfy gHSER, and cause no
damage to the pipe.
Damage to pipe can be caused in several ways including:
• Pipe ends damaged during loading and unloading.
• Pipe ends damaged by longitudinal movement.
• Abrasion caused by rubbing against adjacent pipes or against a protrusion such
as a weld.
• Longitudinal fatigue cracks caused by static and cyclic stresses due to
combinations of vertical movement, vertical loads, and abrasion damage.
• Deformation due to use of incorrect lifting slings.
b. Pipe shall be shipped in accordance with API 5L1.
c. In addition to the recommendations contained in API 5L1, pipe stacking height and the
effects of stresses repeated many times during the course of a long rail journey shall be
assessed using procedures developed by major pipe mills.
d. The project should ensure that the freight forwarding company is on good terms with the
rail authority to ensure the availability of sufficient wagons (cars).

3.7.4. Marine transport

a. Linepipe transported by ship shall cause no harm to people, satisfy gHSER, and cause no
damage to the pipe.
Damage to pipe can be caused in several ways including:
• Pipe ends damaged during loading and unloading.
• Pipe ends damaged by longitudinal movement.
• Abrasion caused by rubbing against adjacent pipes or against a protrusion such
as a weld.
• Longitudinal fatigue cracks caused by static and cyclic stresses due to
combinations of vertical movement, vertical loads, and abrasion damage.
• Deformation due to use of incorrect lifting slings.
b. Pipe shall be shipped in accordance with API 5LW.
c. In addition to the recommendations contained in API 5LW, pipe stacking height and the
effects of stresses caused by ship movement shall be assessed using procedures developed
by major pipe mills.
d. The project should ensure that ships carrying pipe have priority access to berths to avoid
demurrage charges.

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3.8. Pipe storage

a. Locations for pipe storage yards should be identified as soon as possible in a project,
including storage facilities at the reception port if pipe is shipped by sea.
b. The Project should consider preparing pipe yards early on behalf of the contractor, and
include in the pipeline tender package.
c. Pipe storage areas shall be reasonably level and shall provide a non-corrosive environment,
with adequate drainage to prevent the pipe from contacting still or running water.
d. The load-bearing capacity of the ground shall be sufficient to provide a firm foundation for
stacking pipe.
e. The pipe storage site shall be clear of buried or overhead pipes or cables. Overhead cables
can induce static electricity in the stored pipe and are a risk to lifting equipment.
f. The layout of the storage site shall allow sufficient space to ensure pipe does not need to be
stacked to a height above acceptable limits.
g. The storage site shall have sufficient space between the pipe stacks to allow safe access for
personnel, trucks, cranes, and other vehicles.
h. The storage site should be separated from the construction site to facilitate control of the
issue and receipt of pipe materials.
i. Security at pipe yards shall prevent unauthorised access. A security plan for pipe storage
yards shall be submitted for BP approval.
j. After receipt into the storage facility the pipe should be subject to a complete visual
inspection including internal and external surfaces and end bevels. Inspection records shall
be available to provide status of all pipe lengths to be loaded out. These records shall be
available to the reception location load-in team.
k. Pipe transported by sea should be visually inspected for damage immediately after
offloading from the ship.
This establishes whether any damage subsequently found in the storage yard has
occurred due to transportation on the ship or from the ship to the storage yard.
l. Defects shall be clearly marked for subsequent repair. Defective pipe should be segregated
within any storage area.
m. A condition monitoring system and preservation procedure shall be in place at the storage
area to ensure the pipe condition does not deteriorate during storage.
n. Pipe shall be stored in stable and uniform stacks on purpose designed storage racks or on
base layer supports with a means of preventing movement of the outer pipes, particularly at
the lower levels of the pipe stack.
An example of this is illustrated in a photograph of BTC pipe storage, referenced in
the Bibliography.
o. Pipe stacking height and the effects on the pipe and coating of stresses caused by the pipe
stack above shall be assessed, taking account of procedures developed by major pipe mills.
p. When access to the pipe stack is required for pipe tracking and inspection, standing on
platforms higher than 2 metres (6 feet) requires compliance with project construction
safety standards.
q. If sand windrows are used for supporting stored pipe, they shall be covered with suitable
polyethylene sheeting.
AGT Project (BTC/SCP) had a number of instances of pipes being supported on
sand bags that subsequently became frozen and dislodged the pipes.

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In Salah Gas Project also had to consider the effects of static electricity, generated
by wind blown sand and by pipe being stored close to overhead power lines. It was
found difficult to earth (ground) the pipe stack with the coating systems used, so they
had to rely on warning signs.

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Bibliography

The follow reference documents are available for use in planning logistics for pipe handling:

BP
[1] GP 43-03 Guidance on Practice for Pipeline Project Execution.

[2] OR Newsletter paper by Nigel Cummings.

[3] Paper on Pipeline Delivery and Construction Logistics Modelling by Lanner Group.

[4] Article on vacuum lifting by Vacuvietz.

[5] Photographs of BTC pipe storage.

[6] BP Bombax Pipeline Project Specification SS 029: Line Pipe, Material Handling and Transportation.

[7] AGT Pipelines Project Pipe, Tracking System Review.

[8] AGT Pipelines Project, Pipe Tracking System Specification.

[9] PipeTracker, PowerPoint Presentation.

[10] BTC Pipeline Project, Lessons Learnt.

[11] Details of BTC pipeline accident on 25 May 2004.

The Institution of Gas Engineers (IGE)

[12] IGE/TD/1 Edition 4 Supplement 1 Communication 1671 Transportation and Storage of Steel Pipe,
Bends and Fittings.

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