Norway
CORPUS Magazine

Gas highway across the Arctic Circle

Our energy needs are constantly growing. To meet them reliably and resource-efficiently, we have to go new ways. New gas fields at ever greater depths extend even beyond the Arctic Circle. The Polarled gas pipeline taps previously inaccessible gas fields.

Energy consumption and energy supplies are currently controversial social issues in Europe. Our comfort and economic performance depend in large part on the security and continuity of oil and gas supplies. But natural resources are finite.

Nevertheless, new oil and gas fields are now being discovered in ever deeper regions. Extraction and transport call for extreme feats of technology, materials, logistics, and personal effort. The Polarled gas pipeline of Statoil ASA has broken all records. The 482-kilometer long, 36-inch diameter pipeline extends from the Aasta Hansteen field being developed in the Norwegian Sea to Nyhamna on the west Norwegian coast. At a depth of some 1300 meters, it is deeper than all other gas pipelines of this size and the first to cross the Arctic Circle. Aasta Hansteen is a gas field of huge strategic and logistical importance for Norway. Its volume is massive, containing an estimated 47 billion cubic meters of gas beneath Arctic waters.

The pipe sections are checked and welded aboard the Solitaire before becoming part of the pipe string.

The planned production rate is also impressive: This pipeline of the superlatives has the capacity to transport up to 70 million cubic meters per day. This will only be possible, of course, given perfect conditions, since only the best and heav-iest-duty materials can withstand the harsh off-shore environment.

The field is being developed by the Norwegian company Statoil with participation of the BASF subsidiary Wintershall, which has shares in both the Aasta Hansteen development project and in the Polarled pipeline project. BASF Polyurethanes contributed the polyurethane elastomer, and laying was carried out by one of the world’s biggest pipe-laying ships, the “Solitaire” from Allseas. The gas pipeline took a total of six months to lay. Six months in which 300 pipe sections per day were supplied around the clock to the ship and subsequently processed on board, welded and checked before becoming part of the pipe string disappearing in the waters behind the Solitaire. Depending on weather conditions, between 3 and 5 kilometers were laid per day from the Solitaire.

2 to 3 boatloads of new pipeline sections are delivered per day – that is over 300 individual pipes.

The Polarled pipeline opens up a new dimension in gas transport to Europe. Our products for infrastructure help our partners to realize such challenging projects.

 

Dr. Friedhelm Lehrich,
Vice President Performance Materials Europe


 

The pipeline has to cover a distance of almost 500 kilometers from the gas field to the Norwegian coast. But not in a straight line. The seabed was meticulously studied beforehand so that larger rocks and reefs could be bypassed in planning the best route. All the same, this was a route that would not tolerate any error.


1: With a length of 12.2 meters and a weight of 12 to 15 tons per pipe, precision work is called for.
2: No pipeline in Europe’s Norwegian Sea is as deep: Polarled is as much as 1260 meters below the surface of the sea.


 



BASF produces a series of intelligent PU systems that reliably and sustainably protect gas pipelines – even under extreme conditions. Polyurethane is also the material of choice for superior protection of gigantic pipes. The PU Elastopor® opencell protects the pipeline from mechanical damage. External deepwater effects due to anchor movements or fishing nets are largely prevented, thus enhancing gas transport security as well as positioning the pipeline safely on the seabed. A second critical point is the prevention of corrosion at the welds. Attached to the steel pipe at regular intervals for this purpose are sacrificial anodes of a less noble metal that prevent the steel from rusting by binding electrons. Small stones are introduced into the cavities which are then filled with the compact PU elastomer Elastoshore®.

The development of the new gas fields also involves a novel Spar platform, the first and largest of its kind and the first platform of this type in the region. The gas is conveyed from the sea depths via the floating colums, fed into the Polarled pipeline and transported on toward the coast. The Polarled project is a landmark for energy supplies in the coming years and shows what is possible when superlative engineering combines with the best materials.

Featured products

Elastopor®

Elastopor® H is a closed-cell polyurethane rigid foam used for many applications in the field of heat and cold protection due to its excellent insulation properties. This "made-to-measure insulant" boasts extremely low thermal conductivity levels matched by no other conventional insulant. Good mechanical properties and excellent adhesion mean the material has a wide range of applications. Its insulation properties are very high even when thin.

Elastoshore®

Elastoshore® GSPU products are perfect for the wet insulation of ultra-deep flowlines and subsea structures. Elastoshore® GSPU employs the use of BASF ZEROHg technology. This mercury-free, high performance material is reliable under the extreme stress and temperatures of the deep sea. BASF Elastoshore is the record holder for the deepest use of GSPU at depths over 2900m. 

Related articles

infrastructure

At the mercy of the elements ...or protected by Elastocoast®.

Dikes protect Germany’s coasts and river banks – a task made more difficult by the predicted rise in the sea level. A revetment of Elastocoast® can strengthen existing coastal protection.

infrastructure

Poles apart – a high-performance material defies the storm

Wherever power is mainly distributed via overhead lines, outages caused by storms are by no means rare. Innovative materials are capable of making important infrastructure elements stronger – as demonstrated by utility poles in China made of the composite Elastolit.

infrastructure

On track for the cycle-friendly city of the future

Our cities are becoming smarter, one of the front runners being Copenhagen. Steen Savery Trojaborg, CEO of DISSING+WEITLING architects, reports on how the spirit of the city is coloring his work – and influencing it internationally as well.