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ipeline Materials

Selection -An Overview

rasenjit Kayal

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INTRODUCTION TO PIPELINE DESIGN June 2009 2

Material OverviewMaterial Overview

IndexIndex

1. Linepipe

2. Clad pipe

3. Large Radius Bends

4. Anticorrosion Coatings

5. Concrete Coating

6. Sacrifcial Anodes

7. Field oint !aterial

". Flanges# $as%ets and Bolting

&. SS'( )Su*sea Sa+et, 'nsulated (al-e /-er-ie01. 'nsulating oints

11. tees and Conical Reducer )Butt0elded Fittings

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LinepipeLinepipe

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In the Oil & Gas Industry the pipe material selection depends on fluid conveyed

(Sweet i.e. without H2S or Sour service i.e. with H2S ). Typical pipe materials are

!ow "ar#on steel (Steel pipe)

"orrosion $esistant %lloy"$% ('uple Super duple Inconel *2+ %ISI ,-*!)

"$% "ladded!ined "ar#on Steel ("lad pipe "ar#on steel layer / "$% layer)

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Linepipe - Fabrication ProcessLinepipe - Fabrication Process

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Su#mer0ed %rc 1elded (S%1)

lectrical $esistance 1elded ($1)

Hi0h 3re4uency Induction (H3I) welded or Hi0h 3re4uency 1elded (H31)

Seamless (S5!S) i.e. without lon0itudinal (seam) weld

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5/87INTRODUCTION TO PIPELINE DESIGN June 2009 5


Submerged Arc Welded Pipe (SAW - !O"Submerged Arc Welded Pipe (SAW - !O"

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Submerged Arc Welded Pipe (SAW - !O"Submerged Arc Welded Pipe (SAW - !O"

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LSAW Pipe# Press $ending Met%odLSAW Pipe# Press $ending Met%od

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LSAW Pipe# Press $ending Met%odLSAW Pipe# Press $ending Met%od

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Spiral&'elical SAW PipeSpiral&'elical SAW Pipe

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Spiral&'elical SAW PipeSpiral&'elical SAW Pipe

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!inepipe 3a#rication 6rocesses!inepipe 3a#rication 6rocesses

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Medium-iameter ()*-inMedium-iameter ()*-in

"lectrical +esistance Welded Pipe ("+W"lectrical +esistance Welded Pipe ("+W

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!inepipe 3a#rication 6rocesses!inepipe 3a#rication 6rocesses

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Small-iameter (*-in 'FI PipeSmall-iameter (*-in 'FI Pipe

'ig% Fre,uenc Welded or Induction Welded Pipe ('FW&'FI'ig% Fre,uenc Welded or Induction Welded Pipe ('FW&'FI

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'FI PIP" . /oiler'FI PIP" . /oiler

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'FI PIP" . Welding'FI PIP" . Welding

M i l O iM t i l O i

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"+W Pipe vs0 'FI Pipe"+W Pipe vs0 'FI Pipe

M t i l O iM t i l O i

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TENARISTENARIS

M t i l O iM t i l O i

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Linepipe - Fabrication ProcessesLinepipe - Fabrication Processes

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M t i l O iMaterial Overview

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Plug +olling Mill (Medium iameter Seamless PipePlug +olling Mill (Medium iameter Seamless Pipe

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Mandrel Mill (Small iameter Seamless pipeMandrel Mill (Small iameter Seamless pipe


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TENARISTENARIS


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Pipe Production +angePipe Production +ange


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Pipelines usuall %ave diameters wit%in 123and 4530 Large diameter linepipes (6 correspond to

SAW longitudinal welded pipes t%at matc% more re,uirements 7or Oil 8 9as applications0

9enerall spea:ing; "+W and S"AML"SS pipes are respectivel less and more expensive t%anLSAW0

S"AML"SS&"+W

LSAW

SAW Spiral

7uantity of Supplier for 5ar8et

Se0ment

123 )23 453

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IndeInde

1. Linepipe

2. Clad pipe



5. Concrete Coating




&. SS'( )Su*sea Sa+et, 'nsulated (al-e /-er-ie0

1. 'nsulating oints


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Offshore 6ipeline for corrosive service (sour service i.e. with H2S) are fa#ricated in

"orrosion $esistant %lloy"$% ('uple Super duple Inconel *2+ %ISI ,-*!)

"$% "ladded!ined "ar#on Steel ("lad pipe "ar#on steel layer / "$% layer)

"lad pipelines are formed from a car#on man0anese steel outer pipe (#ase material or #ac8

steel) lined internally with a thin layer (2, mm thic8) of corrosion resistant material.

'efinition

!inepipe is denoted 9clad: if the #ond #etween #ase and claddin0 material is metallur0ical

!inepipe is denoted 9lined: if the #ond #etween #ase and claddin0 material is mechanical.

"lad 6ipe"$% 6ipe!ined 6ipe

/LA Pipe/LA Pipe


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/LA Pipe/LA Pipe


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/lad Steel Plate Fabrication Process - "xample/lad Steel Plate Fabrication Process - "xample


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Material Overviewate a O e e

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Welded /lad Steel Pipe - Fabrication Process "xampleWelded /lad Steel Pipe - Fabrication Process "xample


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%n eample of 5echanically ;onded (!ined) pipe

$!==I>9 $u$i?

In order to increase the advanta0es of a clad pipe ;pipe) at the #e0innin0 of the ?@A.

The ;u;i>pipe consists of a "$% pipe which is telescopically ali0ned inside a pipe in

car#onman0anese material (seamless or welded pipe).=%e tig%t bonding between t%e two pipes is ac%ieved b %draulic expansion0

The produci#le siBe ran0e comprises pipes in O'Cs from --D., mm (DE) up to **A mm (2*E)

and len0ths up to -2 m without circumferential weld.

"ompared with the metallur0ically clad pipe ;u;i>pipe offers a wide ran0e of material

com#inations for #oth the inner and outer pipe and price advanta0es.

6rice advanta0e is due to the use of low cost car#on steels in conFunction with corrosion

resistin0 steels and an economic production process.

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Lined PipeLined Pipe


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Lined Pipe#Lined Pipe# $!$!TTI=GTTI=G$i$imetalpipe (;u;i>pipe)metalpipe (;u;i>pipe)


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IndeInde

1. Linepipe

2. Clad pipe



5. Concrete Coating





1. 'nsulating oints


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INTRODUCTION TO PIPELINE DESIGN June 2009 3308/05/15

Offshore %pplication

pansion loop (Spool) construction (e.0. 0oose nec8 #end part).

$iser construction (e.0. #end part).

Top side 6ipin0

5ain "haracteristics

;end $adius + O' 6ipeline (i.e. pi00a#le)

Strai0ht len0th (e.0. A.+ -.A m) Same "hemical composition of mother pipe of

linepipe (e.0. "ar#on 4uivalent)

5ain 3a#rication 6rocesses

Hot #endin0 of the ori0inal pipe ($+-AO')

"old ;endin0 of the ori0inal pipe ($ADAO')

Large +adius $endsLarge +adius $ends


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$ends . 'ot $end Production$ends . 'ot $end Production


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$ends . 'ot induction $ending - "xample$ends . 'ot induction $ending - "xample


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$ending Mac%ine 'eating and /ooling +ing

$ends . 'ot induction $ending - "xample$ends . 'ot induction $ending - "xample


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$

=6S

'T%I!E%E

O'

THJ I'

S 'T%I!

E%E

T

T

=ote 2

=ote 2

I="M PIP" Wall Mot%er

Material9rade

Pipe =pe

alp%a + @ = @)=>AM" SIB" =%ic:ness Pipe W0=

(inc% CmmD CmmD (E (mm (mm (mm (mm

"xpansion Loops2E $ends

12 )2;* )G;5L41< H/

S"AML"SS2 1G*

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IndeInde

1. Linepipe2. Clad pipe



5. Concrete Coating





1. 'nsulating oints


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"oatin0

The li4uid li4uefia#le mastic powder or any composition and material thatafter application to a su#strate (e.0. pipes) is converted into a solidanticorrosion protective adherent films.


6ipeline and "omponents (;ends flan0e fittin0s etc.) ternal %nticorrosion

6rotection System. $iser ternal %nticorrosion and mechanical 6rotection System.

"oatin0 System Selection "riteria is #ased on

6roFect $e4uirements

nvironmental service eposure (seawater soil other)

Service temperature (depends on ma. conveyed fluid temperature)

Anticorrosion /oatingsAnticorrosion /oatings

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%nticorrosion coatin0s main type

6olyethylene (6) (e.0. ,.+mm K @+A 80m,L linepipe) "oal tar namel ("T) (e.0. pipeline)

6olypropylene (66) (e.0. ,mm K @AA 80m, linepipe ,.+mm 3lame Spray 66 L$iser and ;ends)

3usion ;onded poy (3;) (e.0. field Foint)

6olyurethane (6

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GLPP

F$"

GLP"

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The threelayerNs 6olyethylene coatin0 (,!6) is a multilayer coatin0 composed of three

functional components

3irst layer primer (li4uid or powdered fusion #onded epoy (3;)). "ontinuous thin layerresistant to the corrosive a0ents. Guarantee a suita#le adhesion of the coatin0 to the steel.

Second layer copolymer or modified polyethylene adhesive. Guarantee a suita#le adhesion#etween the upper polyethylene layer and the primer.

Third layer polyethylene. It provides 0ood mechanical stren0th mechanical protection andelectric insulation.

,!6 Systems provide ecellent pipeline protection for small and lar0e diameter

pipelines with service temperatures varyin0 from *A " to /P+ ".

%ccordin0 to the maimum service temperatures the polyethylene may #e

!ow 'ensity 6olyethylene (!'6) (@-P @,+ J0m,)

5ediumHi0h 'ensity 6olyethylene (5'6H'6) (@DA @+A 80m,)

5inimum 6 "oatin0 Thic8ness ,.+ mm

"ut #ac8 len0th re4uired for pipeline installation -+A mm /2AA mmM

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G-Laer Polet%lene (GLP"G-Laer Polet%lene (GLP"


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The threelayerNs 6olyethylene coatin0 (,!66) is a multilayer coatin0 composed of three

functional components

3irst layer primer (li4uid or powdered fusion #onded epoy (3;)). "ontinuous thin layerresistant to the corrosive a0ents. Guarantee a suita#le adhesion of the coatin0 to the steel.

Second layer copolymer adhesive. Guarantee a suita#le adhesion #etween the upperpolypropylene layer and the primer.

Third layer polypropylene. It provides very 0ood mechanical stren0th mechanical protectionand electric insulation.

,!66 Systems provide ecellent pipeline protection for small and

!ar0e diameter pipelines with service temperatures varyin0 from 2A " to /-DA ".5inimum 6olypropylene 'ensity @AA 80m,

5inimum 6 "oatin0 Thic8ness ,.+ mm

"ut #ac8 len0th re4uired for pipeline installation -+A mm /2AA mm.

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G-Laer Polproplene (GLPPG-Laer Polproplene (GLPP


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GLP" . Fabrication Process - "xampleGLP" . Fabrication Process - "xample

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GLPP . Fabrication Process - "xampleGLPP . Fabrication Process - "xample

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P/P . Fabrication Process - "xampleP/P . Fabrication Process - "xample

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F$" . Fabrication Process - "xampleF$" . Fabrication Process - "xample

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/oal =ar "namel (/=" . Fabrication Process - "xample/oal =ar "namel (/=" . Fabrication Process - "xample

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This linin0 is applied #y layerin0 one or several coats of paint or #y sprayin0 epoy powder.

-. The pipe is preheated to eliminate humidity

2. The interior surface is shot#lasted to remove mill scale and rust o#tainin0 a metal surfacewhich facilitates the adhesion

,. 1hen epoy powder is fused the pipe is preheated to 2,P" in order to 4uic8ly cure the epoy.

D. The pipe is rotated and the linin0 is sprayed from a set of noBBles which moves inside the pipe.

+. 1hen paint is used it is dried #y #lowin0 hot air throu0h the pipe.

"pox +esin Lining . Application "xample"pox +esin Lining . Application "xample


IndeInde

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IndeInde

1. Linepipe2. Clad pipe



5. Concrete Coating





1. 'nsulating oints


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/ t / ti

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$einforced "oncrete "oatin0 is made #y a ri0ht miture of cement a00re0ates and water

reinforced with steel ca0e or steel welded fa#ric .


6ipeline 1ei0htin0 (sta#iliBation of offshore pipeline su#Fected to Hydrodynamicforces)

5ain "haracteristics to #e re4uired

5in. "ompressive Stren0th at Q and 2P day "ore"u#e

5inimum %pplica#le Thic8ness

5inimum and 5aimum 'ensity

1ater %#sorption

"ut #ac8 len0th ('epends on 1eldin0 System used)

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/oncrete /oating/oncrete /oating


= i l / t t " l= i l / t t " l

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5inimum $ecommended %pplica#le "oncrete Thic8ness DA mmM

5aimum Standard %pplica#le "oncrete Thic8ness -+A mmM

5aimum Standard concrete coatin0 density (dry) ,.ADA tm,M

5inimum Standard concrete coatin0 density (dry) 2.2DA tm,M

"oncrete wei0ht increase in order to ta8e into account water a#sorption

on #ottom sta#ility analysis (minimum) 2R #y wei0htM

layin0 analysis (maimum) +R #y wei0ht."ut #ac8 len0th re4uired for pipeline installation

,QA mm /2AA mm (6resto & 6asso 1eldin0 System)M

,@A mm /2AA mm (1ermaat 1eldin0 System).

=pical /oncrete ata - "xample=pical /oncrete ata - "xample


IndeInde

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IndeInde

1. Linepipe

2. Clad pipe



5. Concrete Coating





1. 'nsulating oints11. tees and Conical Reducer )Butt0elded Fittings

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S i7i i l A dS i7i i l A d

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Sacrificial %node (Offshore 6ipeline) is made #y Indium activated aluminium alloy

or inc alloy.


6ipeline "athodic 6rotection (ternal %nticorrosion System)

%node Type

;racelet halfshell (s4uared and Tapered)

!on0 Slender Standoff (e.0. 6latform !e0 Su#sea Structure etc.) 3lushmounted (e.0. 6latform !e0 Su#sea Structure etc.)

Sacri7icial AnodesSacri7icial Anodes


A d = i l i / t / t d PiAnode =pical rawing /oncrete /oated Pipe

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Collega5ento a Rp32.e6e.ln%

Anode =pical rawing- /oncrete /oated PipeAnode =pical rawing- /oncrete /oated Pipe


Anode =pical rawing Anticorrosion /oated PipeAnode =pical rawing Anticorrosion /oated Pipe

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Anode =pical rawing - Anticorrosion /oated PipeAnode =pical rawing - Anticorrosion /oated Pipe


IndeInde

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IndeInde

1. Linepipe

2. Clad pipe



5. Concrete Coating





1. 'nsulating oints


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Field Koints /oatingsField Koints /oatings

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3" is the protective coatin0 applied on field weld Foints (circumferential weld).

The 3" ensure the suita#le corrosion protection and coatin0 continuity to the steelpipes surface left #are (uncoated) durin0 coatin0 application on shop.

3ield oint coatin0 System Selection "riteria is #ased on 6roFect $e4uirements nvironmental service eposure (seawater soil other) Service temperature (depends on ma. 3luid conveyed temperature)

"ompati#ility with the pipeline ternal %nticorrosion "oatin0




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3ield oint coatin0s main type

%nticorrosion "oated 6ipe Heat Shrin8a#le Sleeve (HSS)

6olymer plastic tapes (e.0. Spirally wrapped 66 tapes (6IH) & "i0arette wrapped 66 tapes (""SI))

3usion ;onded poy 6owder (3;)

!i4uid poy resin (Tar free)

!i4uid 6olyurethane (Tar free) (e.0. 5arin#loc8 trademar8)

InFection 5oulded 6olypropylene (66) and 6olyurethane (6

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GLPP

F$" PP

Flame-Spra

P! Foam

P! Mixture (e0g0 Marinbloc:'SS

Field Koints /oatings - "xamplesField Koints /oatings - "xamples

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Application O7 'eat S%rin:able Sleeve ('SSApplication O7 'eat S%rin:able Sleeve ('SS

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Application O7 'eat S%rin:able Sleeve ('SSApplication O7 'eat S%rin:able Sleeve ('SS

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PP Flame Spra . Application Process "xamplePP Flame Spra . Application Process "xample

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PP Flame Spra Application Process "xamplePP Flame Spra Application Process "xample

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IndeInde

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IndeInde

1. Linepipe

2. Clad pipe



5. Concrete Coating





1. 'nsulating oints


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FlangesFlanges

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3lan0es are hot or cold for0ed fittin0s

$e4uired 3lan0e $atin0 depends on the pipeline desi0n and hydrostatic test pressures


"ouplin0 flan0ed (e.0. 6ipelineSpool $iserSpool alvepipin0 etc.)

Typical 3lan0es 5aterials

"ar#on Steel !ow %lloyed Steel Stainless Steel.

3lan0e Type

1eldin0 =ec8 (1=) Swivel =ec8 (S1) ;lind (;!) 3lat 3ace (33) $aise 3ace ($3)

FlangesFlanges


Flanges =pesFlanges =pes

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Flanges =pesFlanges =pes


/arbon Steel Flanges +ating (ASM" $1*0

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/arbon Steel Flanges +ating (ASM" $1*0

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g g ( g g (


Stainless Steel Flanges +ating (ASM" $1*0

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g g ( g g (


Swivel Flange =pical rawing- 123 SW +=K "xampleSwivel Flange =pical rawing- 123 SW +=K "xample

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g p g pg p g p


Weld >ec: Flange =pical rawing- 123 W> +=KWeld >ec: Flange =pical rawing- 123 W> +=K

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g p g


$lind >ec: Flange =pical rawing- 123 $L +=K$lind >ec: Flange =pical rawing- 123 $L +=K

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9as:ets (O77s%ore Application9as:ets (O77s%ore Application

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$in0 Type oint ($T) Gas8ets are metallic sealin0 rin0s suita#le for hi0h pressure and hi0h

temperature applications (e.0. couplin0 flan0ed).

$T 0as8ets are desi0ned to seal #y Einitial line contactE or wed0in0 action #etween the matin0flan0e and the 0as8et.

;y applyin0 pressure on the seal interface throu0h #olt force the softer metal of the 0as8et flows

into the microfine structure of the harder flan0e material creatin0

very ti0ht and efficient seal.

Typical Gas8ets 5aterial Soft iron SS ,-* (and 6lastic 5etallic6lastic)

The rin0s shall have hardness lower than that of the flan0e in order to assure ti0ht Foint.

$in0 Gas8et 6rofiles used in offshore pipeline application are Oval 3lat Octa0onal.

$T 0as8ets are manufactured in accordance with %S5 ;-*.+

%S5 ;-*.DQ %S5 ;-*.2A and 5S S6 DD specifications.


+ing =pe Koint (+K= 8 FLA= (+F 9as:ets-"xamples+ing =pe Koint (+K= 8 FLA= (+F 9as:ets-"xamples

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Stud $olts and >utsStud $olts and >uts

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Stud ;olts are made #y alloy steel accordin0 to %ST5 % -@, Grade ;Q.

The len0th 9!: of stud #olts is measured from first thread to first maFor diameter thread.

The ;olt len0th has to #e suita#le for the 1=S1 couplin0 flan0ed included the etra len0th

for automatic #olt tensioner (hydra ti0ht Type)

;oth ends of stud#olt shall have a tip.

The threadin0 shall #e carried accordin0 %=SI code ;-.-.

=uts are machined hot or cold for0ed in "ar#on Steel accordin0 to %ST5 % -@D Grade 2

(teflon coated).


IndeInde

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Inde

1. Linepipe

2. Clad pipe



5. Concrete Coating





1. 'nsulating oints


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SSI@ (Subsea Sa7et Isolation @alveSSI@ (Subsea Sa7et Isolation @alve

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% Subsea Sa7et Isolation @alve (SSI@is re4uired in proimity (distance to #e defined #y dedicated

study) of a selected platform to provide the isolation in case of accident (e.0. fire) of the surface

facilities and the riser from the fluid (e.0. 5ethane) contained inside the sealine comin0 from another

6latform or from onshore 3acilities.

SSI@ Station Main /omponents#U OnOff ;all alveU %ctuatorU ;ase support / 6rotection "overU 6ipin0 (flan0es included)

U "ontrol

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6rotection "over

6ipin0OnOff ;all alve

%ctuator


IndeInde

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-. !inepipe

2. "lad pipe

,. !ar0e $adius ;ends

D. %nticorrosion "oatin0s

+. "oncrete "oatin0

*. Sacrificial %nodes

Q. 3ield oint 5aterial

P. 3lan0es Gas8ets and ;oltin0

@. SSI (Su#sea Safety Insulated alve) Overview

-A. Insulatin0 oints

--. T & V tees and "onical $educer (;uttwelded 3ittin0s)

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Insulation KointInsulation Koint

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%n Isolatin0 oint (I) is a hi0hresistance fittin0 used to electrically isolate sections of a

pipeline in order to avoid any electrical current to cross from one side of the Foint to the

other one and conse4uently to improve the effectiveness of the cathodic protectionsystem.

Weldedconnection

Flangedconnection



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Good insulation level #etween two sections of a pipeline is 0ranted when the isolatin0 Foint

is installed a#ove 0round or a#ove sea level or in inspection pits.

!o"nd #e$el

Sea #e$el

Sedi%ent #e$el

I&olating 'oint&

In&(ection )it


Insulation oints are typically made in one piece (5onolithic) or flan0ed and can #e


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Insulation oints are typically made in one piece (5onolithic) or flan0ed and can #e

desi0ned and manufactured for any pipeline siBe and pressure ratin0.

% 5onolithic dielectric oint (5I) are composed of two pieces of metallic pipe

assem#led #y weldin0 alon0 with interposition of insulatin0 material and sealin0

0as8ets so that the two piece at the same time come out each other mechanically

connected and electrically insulated.

5I is provided with etension nipples (pup piece) that must match the pipeline wall

and 0rade and are lon0 enou0h to eliminate any possi#ility of thermal dama0e to the5I durin0 field weldin0.

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IndeInde

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1. Linepipe

2. Clad pipe



5. Concrete Coating





1. 'nsulating oints11. tees and Conical Reducer )Butt0elded Fittings

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$uttwelded Fittings$uttwelded Fittings

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Tee piece is a special # tt elded fittin0 sed to reali e the connection #et een t o

=3 and 3 =ee=3 and 3 =ee

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Tee piece is a special #uttwelded fittin0 used to realiBe the connection #etween two

pipelines with different headin0s and same (Strai0ht tee) or different ($educin0 Tee)

Outsider diameters.Vway piece is a special #uttwelded fittin0 used to realiBe the connection #etween two

pipelines with different headin0s and same or different Outsider diameters.

ach Tee and yway can #e desi0ned and manufactured for any pipeline siBe and

6ressure ratin0.

Straig%t =ee +educing =ee


=3 and 3 =ee . Application "xample# Laing In Line=3 and 3 =ee . Application "xample# Laing In Line

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=3 and 3 =ee Welded on Spool - "xample=3 and 3 =ee Welded on Spool - "xample

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/onical +educer/onical +educer

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% conical reducer is a #uttwelded fittin0 used to connect two pipelines with different

Outsider diameter (e.0. ,*: O' offshore 6ipeline with ,D: O' eistin0 onshore pipeline).

"onical $educer can #e made from steel plates andor pipes and may #e manufactured #y

for0in0 pressin0 rollin0 weldin0 or #y a com#ination of these processes.

"onical reducers can #e desi0ned and manufactured for any pipeline siBe and

6ressure ratin0.

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