pipeline installation, manufacturing, welding and ndt
DESCRIPTION
Pipeline Installation, Manufacturing, Welding and NDTTRANSCRIPT
1 - Classification: Internal 2011-09-09
Offshore flow- and pipelines,
manufacturing, material selection
installation, welding and NDT
Lars M. Haldorsen Ph.D,
Leader Material Technology
Statoil
Mobile: +47 90091669
E-mail: [email protected]
2 - Classification: Internal 2011-09-09
Content
• Introduction
• Statoil operated pipelines
• Pipelay techniques
• Steel manufacturing and refining mechanisms
• Corrosion and material selection
• Cathodic protection
• Corrosion coating and insulation
• Corrosion Resistant Alloys (Stainless steels)
• Challenges with stainless steels
• Welding
• Engineering Critical Assessment
• None Destructive Examination
Welding, Materials and Fabrication Department
3 - Classification: Internal 2011-09-09
Pipelines and laying techniques
4 - Classification: Internal 2011-09-09
Pipeline transport system
in North Sea
• Export pipelines to Germany,
Belgium, France and the UK
• High regularity and
great flexibility
• Statoil is technical
operator for 7,000km
of pipeline Nyhamna
Europipe II
Europipe I
Norpipe
Emden
Teesside
ÅTS
Norne
Åsgard
Haltenpipe
Heidrun
Franpipe
Zeebrugge
Zeepipe I
St Fergus
Vesterled
Frigg
Statfjord
Kårstø
Kollsnes
Melkøya
Snøhvit
Ormen Lange
Easington
Langeled
Ekofisk
Sleipner
Troll
Dunkerque
Kristin
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Infield pipelines
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Future for Norwegian
oil exploration?
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Subsea pipeline installation techniques
• NO plastic deformation of pipeline
− S-lay
− J-lay
• PLASTIC deformation of pipeline
− Reel Lay
• Others
− Flex Lay
− Bundles
8 - Classification: Internal 2011-09-09
S-lay principles
• Diameter: 8 - 40”
• Mainly longitudinal welded pipes,
• Laying speed, 100 -500 m/hr
• Normally long transport lines with large dimensions
• Main actors; Saipem, Acergy, Heerema,
• Welding
− Welding onboard (video)
− Working stations; 10 including FJC
− Welding techniques
• Manual and semi-automatic
9 - Classification: Internal 2011-09-09
J-lay principles
• Key data:
− Diameter: 8 - 30”
− Welding onboard
− Mainly longitudinal welded
pipes
− Deformations within elastic
limit of the material
− Laying speed, 50 – 150 m/hr
− Normally short lines (risers)
− Challenges: Top tension
− Main actors; Saipem, Acergy,
Heerema, Subsea 7
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Reel-lay principles
• Diameter: 4 -18”
• Mainly seamless pipes, (long. welded for clad
and HFW)
• Accumulated plastic deformation, 10-20%
• Laying speed, 600 – 1000 m/hr
• Reel capacity, 2200 -3500 tonnes (10 -15 km)
• Main actors; Subsea 7 and Technip
• Pipeline fabrication; onshore
(Video)
− Up to 24 working stations
including FJC
− Welding techniques;
• Manual and semi-automatic
11 - Classification: Internal 2011-09-09
Reel-lay fabrication yards
• Fabrication yards
− Norway 2 off
− UK 2 off
− Africa 2 off
− Brazil 2 off
− USA 2 off
• Typical stalk lengths: 900 – 1500m
• Number of working stations 15- 24 off
including field joint coating
• Double jointing 12,2m 24,4m
• Welds per shift (12 hrs) 60 – 150 off (1400 –
3600 m for double joints)
• NDT; Automatic Ultrasonic Testing (AUT),
Visual inspection
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Videos
• S-lay – offshore fabrication S-lay welding
• Reel lay – site fabrication Spoolbase welding
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Steel manufacturing and material refining
techniques
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Steel manufacturing
• Raw material ; Scrap and iron ore (pig iron)
− Scrap content varies from 20 – 90%
• Melted in an electric furnace where 90 % of the alloying elements are supplied.
− Remove most of the impurities (phosphorus and ore leftovers by slag (CaMgO)
• Refining in vacuum or inert atmosphere furnaces
− Final chemistry (alloying)
− De-oxidation ( Si, Al)
− Removal of rest impurities (sulphur by slag optimisation and Argon blow through)
− Spectrographic analysis
• Tapping onto continuous casting furnace
Pictures from Tenaris Dalmine
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Casting
• Casting
− Continuous casting
− Ingot casting
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Seamless linepipe
• Piercing
• Elongation
• Reducing/stretching
• Cutting to 12-13 m lengths
• Heat treatment
• Straightening
• NDT
17 - Classification: Internal 2011-09-09
Longitudinal welded pipes
• Long welded pipes
− UOE process
− Submerge Arc Welded
(SAW)
− Electric Resistance
welded (ERW)
− High Frequency Induction
welded (HFI
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Clad pipes; Manufacturing principles
• Manufactured by different production
techniques:
1. Internal cladding by welding (Proclad,
IODS, etc)
2. Lined clad pipe; Mechanical expanded
CRA pipe in backing pipe (Butting,
Cladtek)
3. Clad pipe; Metallurgical bonded clad to
backing material (JSW, Butting)
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- 16 -
Lined mechanical bonding principles
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Lined pipe end sealing /Cladding
3mm
Up to 2008, not good for AUT and
repair
From 2008, repair and NDT
properties improved
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Pros and cons, lined clad pipes
• Less expensive compared to
metallurgically bonded clad
• Good tolerances
• Challenges during NDT (AUT)
− Air gap, mix. off materials, etc
• Not reelable, yet
− Techniques under development
(internal pressure, etc)
• Well suited for S-lay and J-lay
3mm
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Metallurgical bonded clad pipes
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What is clad pipes; Manufacturing principles
24 - Classification: Internal 2011-09-09
What is clad pipes; Manufacturing principals
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Manufacturing principles; Nickel layer (adhesion)
• The nickel layer applied between the backing
material and CRA has the following functions:
1. Increases homogeneity and reliability of
bonding (clue).
2. Prevents carbon diffusion from the backing
steel to CRA and Chromium diffusion from
CRA to the Carbon material, which in turn
prevents:
• High hardness at the boundary due to
bainite /martensite formation.
• Reduce sensitivity of boundary cracking.
3. Reduces the risk of cracking under
hydrogen service
4. Reduces the penetration rate of pitting
and/or stress corrosion cracking, if initiated
at the cladding surface
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Principals for refining of mechanical properties in steel by heat
treatment
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Heat treatment; principles • Quench and tempering
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Heat treatment; quenching results
Feritt + perlitt
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Refining of mechanical properties in steel,
tempering vs. mech. properties
0.0
100.0
200.0
300.0
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500.0
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700.0
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900.0
1000.0
1100.0
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1300.0
1400.0
1500.0
1600.0
1700.0
1800.0
1900.0
0 200 250 300 350 400 450 500 550
anl.temp. (grader celsius)
Rm
(M
pa),
Rp
0,2
(M
pa),
HV
0.0
10.0
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Ch
arp
y V
(jo
ule
), A
5(%
), Z
(%)
Rm (Mpa)
Rp0,2(Mpa)
HV
Charpy V
A5 (%)
Z (%)
30 - Classification: Internal 2011-09-09
Refining of mechanical properties in steel
by quench and tempering
• Austenitisation temp. 920 0C
• Cooling 1.75 0C/sec. in water + 10 % NaOH.
• Tempered at 590-670 0C
Feritt + perlitt
Tempered martensite/ainite
Heat treated steel
Strain
Lo
ad
1000 kg
Mild steel
31 - Classification: Internal 2011-09-09
Refining of mechanical properties in steel by
quench and tempering
No permanent
deformation
Permanent deformation
Heat treated steel Mild steel
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Linepipe dimensions and ranges W
all
Thic
kness [ Inch]
Outer Diameter (OD) [ Inch]
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Corrosion and material selection
35 - Classification: Internal 2011-09-09
Corrosion
36 - Classification: Internal 2011-09-09
Corrosion
• Corrosion is deterioration of essential properties in a material due to reactions with its surroundings. In the most common use of the word, this means a loss of an electron of metals reacting with water and oxygen.
37 - Classification: Internal 2011-09-09
Corrosion
• Corrosion of pipelines is divided into two
categories:
− Internal corrosion
− External corrosion
• Internal corrosion (main categories)
− CO2 corrosion (dominating)
− H2S corrosion
• External corrosion (main categories)
− General corrosion
− Pitting corrosion
− Crevice / Hydrogen induced cracking
38 - Classification: Internal 2011-09-09
Internal corrosion protection
Material selection
• Corrosion Resistant Alloys, CRA(Duplex stål, 13%Cr steel)
− Very good resistance against CO2 corrosion
− Good resistance against H2S corrosion
− Some of the CRA’s are sensitive to contact with
sea water
• C-Mn steel
− Low resistance against CO2 corrosion
• Inhibitors
• Corrosion allowance
• Increase Cr-content
− Acceptable resistance against H2S corrosion
• Internal coating (organic)
− FBE +polymers
• Good corrosion control
• Sensitive to sand production
• Technology in start phase
Fig. from Kawasakis patent increase Cr- in C-Mn Stål
39 - Classification: Internal 2011-09-09
External corrosion protection
Material selection
• CRA materials
− Sensitive to contact with seawater in combination
with Cathodic protection.
• Hydrogen induced cracking, crevice and pitting
corrosion
− Cathodic protection
− Corrosion protection and isolation need to be water
tight
• C-Mn steel
− Good corrosion resistance when protected by:
• Cathodic protection
• Properly applied corrosion coating
• Clad pipes
− Good corrosion resistance when protected by:
• Cathodic protection
• Properly applied corrosion coating
40 - Classification: Internal 2011-09-09
External corrosion protection
Material selection
• Cathodic protection
− Single anodes with equidistance distribution (200-
300m)
• Evenly distributed electro- potential
• Difficult to get water tight at the contact point
(Crevice problems)
• Surface protection (coating)
41 - Classification: Internal 2011-09-09
Cathodic Protection (CP)
From Wikipedia:
• Cathodic protection (CP) is a technique to control the corrosion of a metal surface by making that surface the cathode of an electrochemical cell.
• It is a method used to protect metal structures from corrosion. Cathodic protection systems are most commonly used to protect steel, water/petroleum pipelines and storage tanks; steel pier piles, ships, offshore oil platforms and onshore oil well casings.
• A side effect of improperly performed cathodic protection may be production of molecular hydrogen, leading to its absorption in the protected metal and subsequent hydrogen embrittlement
42 - Classification: Internal 2011-09-09
Cathodic protection; Pourbaix diagram
43 - Classification: Internal 2011-09-09
Protection potential for steel in seawater
44 - Classification: Internal 2011-09-09
Potential distribution
45 - Classification: Internal 2011-09-09
Potential distribution
46 - Classification: Internal 2011-09-09
Cathodic Protection; Anode specification
• Anodes are typically made of
aluminium (Al-Zn-In material).
• Anodes are typically mounted every
200-300 m along the pipeline.
• Typical anode weight is 30-40kg (10”
pipeline)
47 - Classification: Internal 2011-09-09
Anode types
Stand off Flush mounted Bracelet
Indium and zinc are added to reduce the passivation effect of the oxide
film and to avoid pitting. The electrochemical efficiency (Ah/kg) and the
anode potential (V) are improved with In and Zn alloy
elements.
48 - Classification: Internal 2011-09-09
Coating and insulation
49 - Classification: Internal 2011-09-09
Production chemistry – the problems
49 - Classification: Internal 2010-11-07
50 - Classification: Internal 2011-09-09
How to keep the hydrocarbons hot during
transport?
50 - Classification: Internal 2010-11-07
Insulation
05.10.2012
Why coating? • Corrosion protection
− Reduce amount of anodes by 90%
− Avoid reduction of hydrogen at the steel surface (13%Cr, Duplex)
• Insulation of pipeline
− Avoid formation of hydrates, wax etc (flow assurance)
• Mechanical protection, e.g. trawl impact
52 - Classification: Internal 2011-09-09
What is coated? • Pipeline
− Line pipe
− Field joint
• Spools
− Line pipe
− Field joint
− Bend
53 - Classification: Internal 2011-09-09
Coating types • Fusion Bonded Epoxy (FBE)
• Polypropylene (PP) Crystallin thermo plastic
• Polyurethane (PU) Thermoset plastic
• Pipe in pipe (Typical PU)
• Polyethylene (PE) Crystallin thermo plastic
• Polychloroprene (neoprene rubber)
54 - Classification: Internal 2011-09-09
3 layer Polypropylene (3LPP)
55 - Classification: Internal 2011-09-09
Multi-layer Polypropylene
56 - Classification: Internal 2011-09-09
Coating qualification tests • Bend test
• Impact resistance
• Cathodic disbondment
• Hardness
• Adhesion
• Abrasion
• Heat transfere test
• Ageing test
• Shear strength test
• Fungal & Bacterial Growth test
• UV test
57 - Classification: Internal 2011-09-09
Qualification of coating - Bending test
58 - Classification: Internal 2011-09-09
Field Joint coating
• Polypropylene field joint coating is produced in
accordance with the principles of 3LLP system:
1. FBE
2. PP Adhesive
3. Injection moulded PP
59 - Classification: Internal 2011-09-09
Welding and Non Destructive Examination
60 - Classification: Internal 2011-09-09
Content
• Welding
− Definition of welding
− Pipeline Welding Techniques
− Welding Procedure qualification
− Testing
− Documentation, Welding procedure Specifications
• None Destructive Examination
− Examination methods
61 - Classification: Internal 2011-09-09
Origin of Electrical Arc Welding
In 1885, Nikolai Benardos and Stanislav
Olszewski were granted a patent for an
electric arc welder with a carbon electrode
called the Electrogefest. Nikolai Benardos
(Russia) and Stanislav Olszewski (Poland)
are considered the inventors of modern
welding apparatus.
Effects of Welding
• Fusion Zone
− Mixture of welding consumable and molten
origin metal
• Welding consumable is made for the
purpose and ends up with good properties
• The fusion line ends up with material
properties resulting from the mixture and
these have to be evaluated carefully
(Schaeffler)
• Heat-affected zone (HAZ) is the area of base
material which has had its microstructure and
properties altered by welding
− (1) weld metal, (2) fusion zone
− (I) overheated section, grain growth (II) grain-
refined (normalized) section, (III) partially grain-
refined section, (IV) recrystallized section, (V)
aging section
62 - Classification: Internal 2011-09-09
63 - Classification: Internal 2011-09-09
Arc welding processes
Arc welding
12 Submerged Arc Welding (SAW)
111 Metal-arc welding with covered electrode (SMAW) 114 Flux cored wire metal-arc welding (FCAW) 131 MIG welding: metal-arc inert gas welding (GMAWi) 135 MAG welding: metal-arc active gas welding (GMAWa) 136 Flux-cored wire metal-arc welding with active gas shield (G-FCAW)
141 TIG welding: tungsten inert gas arc welding (GTAW)
64 - Classification: Internal 2011-09-09
Shield Metal Arc Welding; SMAW
• Shield tasks
− Protection gas (CO2, CO, H2)
− Protection slag (cooling and
oxidation)
− Alloying elements
− Arc stabilising
− Utilisation (120%)
SMAW welding of pipelines
65 - Classification: Internal 2011-09-09
66 - Classification: Internal 2011-09-09
Submerged Arc welding; SAW
67 - Classification: Internal 2011-09-09
Submerged Arc welding; SAW
68 - Classification: Internal 2011-09-09
Gas Metal Arc Welding; GMAW; MIG/MAG
69 - Classification: Internal 2011-09-09
Gas Metal Arc Welding; GMAW; MIG/MAG
Gasses:
• Metal inert gas, MIG welding
• MIG welding uses an inert gas (Argon and /or Helium). For this process the gas do not actively react with the welding process. The purpose of the gas is to protect the liquid smelt for reactions with the surrounding environment
• Metal Active Gas, MAG
• MAG uses an active gas (CO2, Hydrogen Argon and mixture of these), meaning that the gas react with the smelt and contribute to the heating process. In addition the gas protect the smelt from the surrounding environment
• Welding consumable
− Solid metal electrode Ø 0,6 – 2,4mm
70 - Classification: Internal 2011-09-09
Gas Tungsten Arc Welding, principle
71 - Classification: Internal 2011-09-09
Flux Cored Arc Welding; FCAW
72 - Classification: Internal 2011-09-09
Flux Cored Arc Welding; FCAW, cont.
Welding positions
73 - Classification: Internal 2011-09-09
Welding Position Test Position ISO and EN
Flat 1G PA
Horizontal 2G PC
Vertical Upwards Progression 3G PF
Vertical Downwards Progression 3G PG
Overhead 4G PE
Pipe Fixed Horizontal 5G PF
Pipe Fixed @ 45 degrees Upwards 6G HL045
Pipe Fixed @ 45 degrees Downwards 6G JL045
74 - Classification: Internal 2011-09-09
Bevelling
I-bevel V-bevel X-bevel
J-bevel
75 - Classification: Internal 2011-09-09
pWPS
Perform welding
Record Parameters
Parameter record
Material cert.
Consumable cert.
Perform Mechanical
testing of as-welded
Perform Mechanical
testing of Strain-
Aged
Non Destructive
Testing
NDE Reports
Mechanical
Properties
Mechanical
Properties
ECA
ECA Report
NDE Accept
Criteria WPQR
WPS
Welding procedure qualification
76 - Classification: Internal 2011-09-09
Welding Procedure
Specification
Fabrication Challenges
• Different weld types and location:
o Mainline girth weld
o Tie-in girth weld
o Repair welds
o Seal weld/weld overlay.
• Defect locations:
• Defect detection and interaction.
Fabrication Aspects
• Weld indications and defects from typical project pipe
• Weld defect locations from typical project pipe
Fabrication Aspects
80 - Classification: Internal 2011-09-09
None Destructive Testing
NDT- Non-Destructive Testing • Definition of NDT
• Overview of methods relevant to pipelines
• AUT
The use of noninvasive
techniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure without doing harm.
Definition of NDT
Methods of NDT
Visual
84 - Classification: Internal 2011-09-09
Five Most Common NDT Methods
• Visual
• Liquid Penetrant
• Magnetic
• Ultrasonic
• X-ray
Most basic and common
inspection method.
Tools include fiberscopes,
borescopes, magnifying
glasses and mirrors.
Visual Inspection
Liquid Penetrant Inspection
• A liquid with high surface wetting
characteristics is applied
• The excess liquid is removed
• A developer (powder) is applied.
• Visual inspection.
87 - Classification: Internal 2011-09-09
Liquid Penetrant Inspection
88 - Classification: Internal 2011-09-09
Magnetic Particle Inspection
• Magnetic Ink applied.
• The part is magnetized
.
89 - Classification: Internal 2011-09-09
Magnetic Particle flux
• Flux leakage is formed
90 - Classification: Internal 2011-09-09
Magnetic Particle inspection
91 - Classification: Internal 2011-09-09
Radiography
The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential
Electrons - +
Exposure Recording Device
Radiation
Penetrate
the Sample
92 - Classification: Internal 2011-09-09
Cluster porosity
Film Radiography
93 - Classification: Internal 2011-09-09
Cracks.
Film Radiography
94 - Classification: Internal 2011-09-09
Film Radiography
Lack of Penetration
95 - Classification: Internal 2011-09-09
Ultrasonic inspection
96 - Classification: Internal 2011-09-09
Ultrasonic inspection
Ultrasonic wave forms
Longitudinal wave
Shear wave
Surface wave
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Ultrasonic inspection
High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound.
plate
crack
0 2 4 6 8 10
initial
pulse
crack
echo
back surface
echo
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Ultrasonic inspection
Scanning
angle beam
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Ultrasonic Inspection
• Size Evaluation
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AUT- Automatic Ultrasound Inspection
101 - Classification: Internal 2011-09-09
AUT- Automated Ultrasonic Inspection
TOFD -Time of Flight Differaction
• Not amplitude base method
• Diffracted signals
• Matched angle probes
• Longitudinal wave
102 - Classification: Internal 2011-09-09
AUT- Automated Ultrasonic Inspection
• PE-Pulse Echo
• Weld is divided into zones
• Each zone is scanned separately
103 - Classification: Internal 2011-09-09
AUT- Automated Ultrasonic Inspection
• TOFD and PE