How a Dubai Crude Pipeline Recovered 990,000 Barrels a Year
A 380 km crude pipeline was losing approximately 1.08 million barrels annually to recurring spurious safety trips. Apter Power supplied and validated Emerson SLS1508 SIL3 logic solvers, helping reduce annualized unplanned shutdowns by 92%.
fewer unplanned shutdowns
From 18 to an annualized average of 1.5
barrels recovered per year
Lost production reduced to approximately 90,000 barrels
estimated annual production value recovered
At the project reference price of USD 80 per barrel
The Opportunity
A critical pipeline project with no room for uncertainty
A leading oil-and-gas service company in Dubai had been awarded a critical crude-pipeline project by a local government authority. The 380 km trunk line transports approximately 900,000 barrels per day across desert, salt-marsh and densely populated areas.
At that scale, safety-system reliability directly affects production continuity, operating risk and delivery commitments. The requirement was bigger than finding a replacement component: the customer needed a safety-rated solution that could be verified before release and moved to site without adding further risk.
The Challenge
Recurring trips were turning milliseconds into millions
The pipeline's legacy safety system suffered from slow logic response and recurring spurious trips. It was experiencing approximately 18 unplanned shutdowns per year.
At the project reference price of USD 80 per barrel, each interruption represented approximately USD 4.8 million in production value. Across a year, lost production reached approximately 1.08 million barrels.
The customer needed a partner that could:
- Identify a suitable SIL3 safety logic solver.
- Confirm the equipment before it reached the site.
- Reduce the risk of another unreliable replacement.
- Protect the project schedule through fast release.
Our Response
Supply, verification and release handled as one response
Following a competitive technical review and detailed due diligence, the customer selected Apter Power to supply Emerson SLS1508 SIL3 safety logic solvers.
Requirement confirmed
The SIL3 application requirement was reviewed against the pipeline's safety-critical functions.
Specified units supplied
Emerson SLS1508 safety logic solvers were prepared for the customer's project.
12-hour test completed
The units recorded zero faults during a continuous fatigue test before release.
Released without delay
Verified equipment was released to site immediately, avoiding another testing delay.
“The customer did not need another product catalogue. They needed certainty: the correct safety-rated module, verified before dispatch and ready to move to site.”
The Successful Outcome
Production continuity improved—and the result was measurable
Customer project data for 2024–2025 showed a substantial improvement in operational reliability.
“The SLS1508 paid for itself in four months and is now the benchmark for every future expansion.”
All performance and financial figures are based on customer project data for 2024–2025. Production-value estimates use the stated project reference price of USD 80 per barrel.
Frequently asked questions
Project details, clearly answered
What problem was the pipeline operator trying to solve?
The legacy safety system was producing recurring spurious trips. The pipeline was experiencing approximately 18 unplanned shutdowns per year, interrupting about 60,000 barrels of production each time.
Which automation component was supplied?
Apter Power supplied Emerson SLS1508 SIL3 safety logic solvers for the customer's safety-critical pipeline application.
How was the equipment verified before release?
The supplied units completed a 12-hour continuous fatigue test and recorded zero faults before release to the project site.
What operational result did the customer report?
Customer data for 2024–2025 showed annualized unplanned shutdowns falling from 18 to 1.5, with approximately 990,000 barrels of annual production recovered.
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