Crude Oil Pipeline Rehabilitation and Repair Project

Project Overview

ESNAD Energy was entrusted with a critical infrastructure project by Dar Petroleum Operating Company (DPOC), South Sudan’s leading oil producer.
The initiative focused on the repair and maintenance of DPOC’s 32-inch export pipeline and associated interfield pipelines, which are vital for transporting crude oil from production sites in Blocks 3 and 7 to international markets via Port Sudan.

The project’s primary objectives were to address structural defects, enhance pipeline integrity, and ensure the uninterrupted flow of crude oil — supporting South Sudan’s economic stability and energy security.

Key Achievements

Structural Repairs
Executed over 300 repairs by type B sleeve welding to rectify identified defects and restore pipeline integrity.
Operational Continuity
All rehabilitation activities were conducted while the pipeline remained in service, maintaining consistent crude oil flow.
Safety Milestone
Achieved over 150,000 man-hours without any Lost Time Injuries (LTIs), underscoring ESNAD Energy’s commitment to safety excellence.

Challenges & Solutions

1. Aging Infrastructure

Challenge: Numerous structural defects and coating deterioration due to pipeline age.
Solution: Deployed advanced pipe locating and non-destructive testing (NDT) techniques to accurately identify defect locations and verify severity for targeted repairs.

2. Remote and Harsh Environments

Challenge: Sections of the pipeline crossed remote areas with challenging terrains and climates.
Solution: Mobilized specialized field teams equipped with portable equipment, ensuring efficient operations in all locations.

3. Safety and Environmental Concerns

Challenge: Ensuring personnel safety and minimizing environmental impact during rehabilitation.
Solution: Implemented stringent HSE protocols aligned with DPOC’s standards, achieving zero LTIs throughout the project.

Technologies & Methodologies Employed

Non-Destructive Testing (NDT):
Utilized ultrasonic testing and magnetic particle inspection to detect subsurface defects without compromising pipeline integrity.
Sleeve Welding:
Applied full-encirclement sleeve welding techniques to reinforce and repair defective pipeline sections.
Coating Systems:
Employed advanced coating materials and application methods to restore protective layers and prevent future corrosion.

Outcomes & Impact

1. Enhanced Pipeline Integrity

Significantly improved the structural soundness of the pipeline, reducing risks of leaks and failures.

2. Extended Service Life

Through meticulous repairs and coating restoration, the pipeline’s operational lifespan was effectively prolonged.

3. Operational Efficiency

Maintained uninterrupted crude oil transportation during the project, ensuring DPOC’s supply chain remained unaffected.

4. Safety Milestone

Achieved over 150,000 man-hours without any LTIs, demonstrating ESNAD Energy’s unwavering commitment to safety.

Client Testimonial

“ESNAD Energy’s expertise and dedication were instrumental in the successful rehabilitation of our pipeline. Their commitment to safety, quality, and operational excellence aligns perfectly with DPOC’s values.”
— Eng. Padiet Deng, Dar Petroleum Operating Company