future net shape manufacture technology for subsea ... · pdf filefuture net shape manufacture...

0.72m NS&NNS Machined Demonstrator Schedule

*TTI HIP Vessel is currently broken.

Future Net Shape Manufacture Technology For Subsea Applications

Charley Carpenter Net Shape Technology Manager

Manufacturing Technology Centre

0.72m NS&NNS Machined Demonstrator Schedule

*TTI HIP Vessel is currently broken.

HVM Catapult

0.72m NS&NNS Machined Demonstrator Schedule

*TTI HIP Vessel is currently broken.

Taking Research into Production

Spun Demonstrators .completely changing the way that something is done, thought about or

made. Hot Isostatic Pressing An alternative to large castings and forgings.

Game Changing Technologies

Traditional Manufacturing Methods Main methods of manufacturing components:

Casting

Welding

Forging

Extruding

Inter-stage Heat treatments and post-processing

Potential for defect development or non-uniformity

Extra time/cost

Com

plex

ity

Subsequent defect development

Main defects produced by these methods:

Porosity

Internal shrinkages

Interdendritic cracks

Heat Affected Zone segregates

Inclusions

Hydrogen embrittlement in SS

Distortion due to residual stresses

Anisotropic mechanical behaviour

Chemical segregation

Microstructural variation

Porosity

[3]

Grain structure

[4]

Stress Corrosion Cracking

[1] [2] [1]

Repair Technologies & High Integrity Manufacture Methods

Tolerate if Repair If Alternative Manufacture Method If

Defects do not significantly impact component function or life

Defects are well understood (NDE)

Defects remain stable over component life

Cost of repair is low vs replacement

High lead time for replacement Repair does not reduce part

performance

Component performance can be increased

Cost can be reduced (at manufacture or in life)

Greater or new functionality can be attained

All manufacture methods may cause defects to a greater or lesser extent

Hot Isostatic Pressing

Properties produced via HIP Isotropic grains structure

Refined grain size

No chemical composition variation

100% densification

[5]

HIP component properties Isotropic mechanical behaviour Greater corrosion resistance/life High Ultrasonic inspectability Welds can be eliminated Near Net/Net shape less machining

HIP produced near net-shape part

Milling + heat treatment

End component

[6]

Metso Materials Technology

Component Life Aging equipment is one of the biggest challenges facing the industry. The UK Health and Safety Executive's plant-aging initiative is centred on

an inspection programme HSE's plant-aging guide (RR509) states: Aging is not about how old the equipment is. It's about what is known about its

condition, and how that's changing over time. 7

Products produced via HIP

Manifolds First PHIP manifold in North Seas Jade Field

2000

Water injection manifold installed in Heidrun field, decreasing the number of welds by 85%, manufactured in just 4 HIPed parts8

Manifolds X-trees Well-heads Swivels Barrel Casings and hubs Wye Pieces

[6]

Products produced via HIP

Manifolds X-trees Well-heads Swivels Barrel Casings and hubs Wye Pieces

Swivels (5-16 tons) Multi-phase swivel containing complex

internal flow channels, used for Floating Production Storage Offloading (FPSO)

Claimed 10 week lead time & UT inspectable

Just under 240 tons of HIP material for swivels can be found around the world8

[8]

As forged piece As HIPed piece

[7]

Products produced via HIP

Manifolds X-trees Well-heads Swivels Barrel Casings and hubs Wye Pieces

Wye Pieces Produced for the East Spar

Project (Australia)

Due to a design stress of 25 MPa, conventional methods of production would require a part of 3.5 tonnes, HIP only 2 tonnes9

[9]

Timeline of HIP product manufacture 1987 Powdermet process introduced in 1987- solid and hollow bars, ring and preforms with the size required by the market10

Mid 1990s Production of Swivels by HIP processes starts10 1998 >4000 ton of HIPed pieces for offshore industry were produced by Sandvik Powdermet

2001 Six seabed manifold sections for BPs Norges Valhall Field installed11

2003 70 tons of HIPed pieces sent to Shah Deniz Field in Azerbaijan13

Timeline of HIP product manufacture 2004 China National Offshore Oil Corp. (CNOOC) ordered two barrel casings for Sulzer pumps from Metso Powdermet12

2006 Framo Engineering provide a swivel in duplex stainless steel for BHP Billitons Stybarrow FPSO13

2007 Aker Kvaerner Subsea for subsea hubs for the Dalia, Gimboa, Tyrihans, Visund, Hild, and Kristin projects5

2015 Impregnated drill bit series from Varel international includes cylindrical HIPed segments, 14

The Future of Powder HIP Advances in HIP compaction modelling:

More complex components possible

Improved material efficiency

Greater design functionality

[20] Bodycote

New Materials & Multi Materials Advanced PM alloys and metal matrix composite materials Multi Material components

Kennametal Sandvik Powdermet [20]

Powder HIP Development in The UK

References 1: Kemplon Engineering (2014) Stress Corrosion Cracking (SCC): A Capriciously Insidious Material Killer, Available at: http://kemplon.com/stress-corrosion-cracking-scc-a-capriciously-insidious-material-killer/ (Accessed: 12th November 2015).

2: Canadian Energy Pipeline Association (2007) Stress Corrosion Crack: Recommended Practices, 2nd Edition, Available at: http://kemplon.com/wp-content/uploads/2015/08/Cracking.jpg (Accessed: 12th November 2015)

3: TWI Global (2015) Defects/imperfections in welds - porosity, Available at: ( http://www.twi-global.com/technical-knowledge/job-knowledge/defects-imperfections-in-welds-porosity-042/ (Accessed: 12th November 2015).

4: Sandvik (2015) Advantages of HIP products, Available at: http://smt.sandvik.com/ja-jp/products/hot-isostatic-pressed-hip-products/product-advantages/ (Accessed: 12th November 2015).

5: Altak-MHD (2014) Fan structure of wrought alloys ingots, Available at: http://www.altek-mhd.com/en/articles/fanstructure (Accessed: 12th November 2015).

6: Powder Metallurgy Review (12th June 2012) Recent trends in Hot Isostatic Pressing (HIP) technology: Part 2 - Powder based HIP products, Available at: http://www.ipmd.net/articles/001756.html (Accessed: 12th November 2015).

7: Bridging the Energy Gap. Source: MWP. May 2014, Vol. 158 Issue 4, p50-55

8: Hjorth, C.G (03/01/1997) Hot isostatic pressing proves value on complex subsea components, Available at: http://www.offshore-mag.com/articles/print/volume-57/issue-3/news/general-interest/powder-metallurgy-design-hot-isostatic-pressing-proves-value-on-complex-subsea-components.html (Accessed: 6th October 2015).

References 7: Fomas Group (2015) Oil and Gas, Available at: http://www.fomasgroup.com/portals/0/pdf/Oil_Gas_eng.pdf (Accessed: 12th November 2015).

8: Crestana, L. H., and Camargo, F. C. (2010) Experience and reference of Powder Metallurgy parts produced by HIP (Hot Isostatic Pressing), Available at: http://www.nucleoinox.org.br/inox-2010/downloads/trabalhos/M7-HIP(Sandvik).pdf (Accessed: 9th October 2015).

9: Terdre, N. (2007) 'Sandvik Powdermet to pursue further avenues for Hot Isostatic Processing', Offshore, March, p. 105.

10: Boyer, C.B (1992) 'Historical Review of HIP Equipment', in Koizsumi, M (ed.) Hot Isostatic Pressing - Theory and Applications. Netherlands: Springer Netherlands, pp. 465-510.

11: Bjrman, G (03/01/2002) Hot isostatic pressing proves value on complex subsea components, Available at: http://www.offshore-mag.com/articles/print/volume-62/issue-3/news/sweden-hip-manufacture-extending-from-subsea-to-downhole-applications.html (Accessed: 6th October 2015).

12: Bjrman, G (07/01/2005) Demand up for HIP components, Available at: http://www.offshore-mag.com/articles/print/volume-65/issue-7/sweden/demand-up-for-hip-components.html (Accessed: 6th October 2015).

13: Hjorth, C.G (03/01/2007) Sandvik Powdermet to pursue further avenues for hot isostatic processing, Available at: http://www.offshore-mag.com/articles/print/volume-67/issue-3/sweden/sandvik-powdermet-to-pursue-further-avenues-for-hot-isostatic-processing.html (Accessed: 6th October 2015).

References 14: Ghiselin, D (05/06/2015) Advances in drill bits improve efficiency, performance, Available at: http://www.offshore-mag.com/articles/print/volume-75/issue-5/drilling-and-completion/advances-in-drill-bits-improve-efficiency-performance.html (Accessed: 6th October 2015).

15: Hjorth, C-G. (2007) HIPing of large Near Net shape components for industrial applications, Available at: http://ventilsystemer.no/pdf/artikkel_1.pdf (Accessed: 9th October 2015).

16: Uehara, K; Ishii, T; Inoue, Y; Fujikawa, T (1993) 'Recent Advances in HIP Equipment Technology', in Tas, H; Delaey, L (ed.) Hot Isostatic Pressing '93. Belgium: Elsevier Science, pp. 481.

17: Anderton, J; 'Hot Isostatic Pressing Expands 3D Printing Into Hot Section Jet Parts'. Engineering 2015. Web. 9 Oct. 2015.