Download - 13. Statoil, Lars Magne Haldorsen.pdf
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
1/50
1 - Classification: Internal 2010-04-23
Trends in welding of offshore
flow-
and pipelinesLars M. Haldorsen Ph.D, IWELeading Engineer, Material Technology
Statoil
Mobile: +47 90091669E-mail: [email protected]
mailto:[email protected]:[email protected] -
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
2/50
2 - Classification: Internal 2010-04-23
Trends
Transport in pipelines
Pipelay
techniques
More efficient, modernised vessel fleet
New material and pipeline configurations
CRA Cladded
and lined carbon pipes
13% Chromium
Pipe in pipe
Long. high frequency induction welded HFW-Pipes
New welding and NDT trends for new
materials
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
3/50
3 - Classification: Internal 2010-04-23
Content
Introduction
Statoil operated pipelines
Pipelay
techniques
Linepipe manufacturing and ranges
New linepipe materials and challenges
CRA cladded
and lined pipelines
13% Chromium pipelines
Welding and NDT trends for new
materials
Summary and conclusions
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
4/50
4 - Classification: Internal 2010-04-23
Pipeline transport system
in North Sea
Export pipelines to Germany,Belgium, France and the UK
High regularity and
great flexibility
Statoil is technicaloperator for 6,000km
of pipelineNyhamna
Europipe II
Europipe I
Norpipe
Emden
Teesside
TS
Norne
sgard
Haltenpipe
Heidrun
Franpipe
Zeebrugge
Zeepipe I
St Fergus
Vesterled
Frigg
Statfjord
Krst
Kollsnes
Melkya
Snhvit
Ormen Lange
Easington
Langeled
Ekofisk
Sleipner
Troll
Dunkerque
Kristin
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
5/50
5 - Classification: Internal 2010-04-23
Where is the future for Norwegian oil exploration?
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
6/50
6 - Classification: Internal 2010-04-23
Subsea pipeline installation techniques
NO plastic deformation of pipeline
S-lay
J-lay
PLASTIC deformation of pipeline
Reel Lay
Others
Flex Lay
Bundles
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
7/50
7 - Classification: Internal 2010-04-23
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
Positions
Double jointing; PA (1G) spinning
Main line; PF, PG (3G)
Consumables; SAW (Double jointing), FCAW,GMAW, GTAW
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
8/50
8 - Classification: Internal 2010-04-23
J-lay principles
Key data:
Diameter: 8 -
30
Welding onboard
Mainly longitudinal weldedpipes
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
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
9/50
9 - Classification: Internal 2010-04-23
J-lay welding
Welding
Working stations; 2, one forwelding and one for FJC
Welding techniques
Manual and semi-automatic
Positions
Double jointing; PA (1Gspinning)
Main line; PC (2G)
Bevelling; API and narrow groove
Consumables; SAW (Doublejointing, FCAW, GMAW, GTAW
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
10/50
10 - Classification: Internal 2010-04-23
Reel-lay principles
Diameter: 4 -18
Mainly seamless pipes, (long. welded for clad
and HFW)
Accumulated plast ic 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
Positions: Double jointing; PA
(1G) spinning Main line; PF, PG(3G)
Consumables; SAW (Double
joint ing), FCAW, GMAW, GTAW
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
11/50
11 - Classification: Internal 2010-04-23
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 offincluding 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
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
12/50
12 - Classification: Internal 2010-04-23
Videos
S-lay
offshore fabrication S-lay
welding
and coating_final.wmv
Reel lay
site fabrication S7-
Reeling
revised_final.wmv
http://s-lay%20welding%20and%20coating_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s-lay%20welding%20and%20coating_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s-lay%20welding%20and%20coating_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s7-%20reeling%20revised_final.wmv/http://s-lay%20welding%20and%20coating_final.wmv/ -
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
13/50
13 - Classification: Internal 2010-04-23
Seamless linepipe manufacturing
Piercing
Elongation
Reducing/stretching
Cutting to 12-13 mlengths
Heat treatment
Straightening
NDT
http://images.google.com/imgres?imgurl=http://www.mannesmann-archiv.de/englisch/images/faq_schraegwalzen_l.jpg&imgrefurl=http://www.mannesmann-archiv.de/englisch/faq_01.html&usg=__JBuUOHs2OlUzR3MWigVEU1hMvlI=&h=357&w=340&sz=13&hl=no&start=14&um=1&tbnid=YK9hM0sVSQECiM:&tbnh=121&tbnw=115&prev=/images%3Fq%3Dmannesmann%2Bseamless%26hl%3Dno%26lr%3D%26sa%3DG%26um%3D1 -
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
14/50
14 - Classification: Internal 2010-04-23
Longitudinal welded pipes
UOE process
Submerged Arc Welded(SAW, GMAW, PAW)
Electric Resistance welded(ERW)
High Frequency Inductionwelded (HFI
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
15/50
15 - Classification: Internal 2010-04-23
Linepipe dimensions and ranges
W
allThickness[Inch]
Outer Diameter (OD) [ Inch]
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
16/50
16 - Classification: Internal 2010-04-23
What is clad pipes; Manufacturing principles
Manufactured by different productiontechniques:
1.
Internal cladding by welding(Proclad, IODS, etc)
2.
Lined clad pipe; Mechanical
expanded CRA pipe in backingpipe (Butting, Cladtek)
3.
Clad pipe; Metallurgical bondedclad to backing material (JSW,
Butting)
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
17/50
17 - Classification: Internal 2010-04-23
- 16 -
Lined mechanical bonding principles
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
18/50
18 - Classification: Internal 2010-04-23
Lined pipe end sealing /Cladding
3mm
Up to 2008, not good for AUT and
repair
From 2008, repair and NDT
properties improved
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
19/50
19 - Classification: Internal 2010-04-23
Pros and cons, lined clad pipes
Less expensive compared tometallurgically 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
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
20/50
20 - Classification: Internal 2010-04-23
Metallurgical bonded clad pipes
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
21/50
21 - Classification: Internal 2010-04-23
What is clad pipes; Manufacturing principles
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
22/50
22 - Classification: Internal 2010-04-23
What is clad pipes; Manufacturing principals
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
23/50
23 - Classification: Internal 2010-04-23
Manufacturing principles; Nickel layer (adhesion)
The nickel layer applied between the backingmaterial and CRA has the following functions:
1.
Increases homogeneity and reliability ofbonding (clue).
2.
Prevents carbon diffusion from the backingsteel to CRA and Chromium diffusion fromCRA to the Carbon material, which in turnprevents:
High hardness at the boundary due tobainite
/martensite
formation.
Reduce sensitivity of boundary cracking.
3.
Reduces the risk of cracking under
hydrogen service4.
Reduces the penetration rate of pittingand/or stress corrosion cracking, if initiatedat the cladding surface
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
24/50
24 - Classification: Internal 2010-04-23
Manufacturing principles; Pipe forming methodology
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
25/50
25 - Classification: Internal 2010-04-23
Manufacturing principles; Pipe forming effect
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
26/50
26 - Classification: Internal 2010-04-23
Hardness difference between outer surface, mid surface andinner surface
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
27/50
27 - Classification: Internal 2010-04-23
Yield strength distribution between outer and inner surface
One compression side, reducedyield strength (Bauchinger
effect)
On the tensile side, increased yield
strength (strain hardening)
Conclusion: heat treatment afterforming would give an evenlystrength distribution
Compression
side
Tension
side
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
28/50
28 - Classification: Internal 2010-04-23
Tensile test challenges for Clad material
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
29/50
29 - Classification: Internal 2010-04-23
Super Martensittic Stainless
Steel (SMSS)
Statoil Projects using SMSSFlowlines (predominantly use of12Cr-6Ni-2.0/2.5Mo Grade)
Project Diameter Length
Gullfaks satelite
F1 6,8 & 10 80 900m
Gullfaks satelite
F2 8 & 12 43 000m
Sleipner -
Loke 10 8 900m
sgard
phase
1 10 85 150m
sgard
phase
2 10 58 900m
Huldra 8 17 500m
Sigyn 10 27 100mMikkel 10 600m
Nam Con
Son 16 5 000m
Kristin 10 36 000 m
Snhvit 14 17 000 m
Sleipner vest Alfanord
14 18 000 m
Totally installed ca. 400 kmMartensitic
structure in austenite matrix
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
30/50
30 - Classification: Internal 2010-04-23
Why chose SMSS
Cost savings potential
~100 million
saving estimated for the sgard
and Gullfaks
projects compared with conventionalduplex stainless steel
Environmental potential
avoid use of polluting chemicals; CS case
High strength potential
SMYS of 550 MPa
X80; nominal 600-700 MPa
Retained strength (no de-rating) up to 150C
Good weldability
Carbon content typically below 0.01% C
Focus on hydrogen sensitivity (treated later)
Adequate weld mechanical properties both in the as-welded and short term PWHT condition
Conventional duplex/superduplex
weld consumable
High toughness in martensitic
HAZ
High CO2
corrosion resistance
Fitness-for-purpose corrosion testing (both Formation-
and Condensed Water)
Qualified for mildly sour service conditions : 4-40 mbar H2
S, 23500-94000 ppm
chlorides, CO2
partialpressures up to 20 bar, temperatures up to 140-160C
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
31/50
31 - Classification: Internal 2010-04-23
STATOIL S13Cr Challenges
:Spring 1998 -
Girth
weld
fracture
during reeling
due to conumable
containing
hydrogen
The soft martensitic 13% chromium stainless steels havebeenselectedandqualified for use in flowlines. Thegirthwelding is performed using a mechanised MIG processwith superduplex wire. Prior to reeling of thepipeonthelaybarge vessel, a tie-in procedure with manual TIGtechnique is used to connect the premade 900m longpipe.Occasionally, this tie-in weld is subjected to fractureduring reeling, and detailed examination of fracturesurfaces suggested thecause tobehydrogen inducedcracking. An example of such fracture, with the
corresponding surface and fracture profile, is shownbelow.
3 onshore tie-in girth welds (manual TIG) fractured on
the reel during spring 1998
Crack initiation at weld toe and propagation through
13Cr HAZ and base metal
Transgranular and intergranular fracture mode with
secondary cracking and crack branching
Hydrogen assisted fracture with the superduplex solid
filler wire as a major hydrogen source (10-12 ppm H)
Measures: Use of degassed/solution annealed filler wire
STATOIL S13C h ll ( ti )
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
32/50
32 - Classification: Internal 2010-04-23
Initi
ation
area
12
oclock9
oclock
General fracturedirection
Through thickness
fracture areas
Weld side
fracture half
Fracture
initiatio
n profile
Brittle intergranular
mode
Brittle transgranular
mode
STATOIL S13Cr challenges (continue):May 2003 -
Gullfaks
C2 Towhead Incident; HISC due to welding with consumablecontaining hydrogen
During ROV survey a gas
leakage was identified the 6th of
May 2003 from a 12 gooseneck
pipe of the C2 towhead connected
to the North bundle from GullfaksC to Gullfaks South from L and M
wellframes
The actual leakage turned out to
be located at the weld toe transition
of the supermartensitic stainlesssteel (S13Cr) pipe of the
Superduplex stainless steel girth
weld made against a Superduplex
transition pipe piece close to the
inboard Hub.
No hydrogen charging from CP
evident, but TIG filler rods with
hydrogen were originally used
during fabrication. Cracks was also
found in the superduplex cap weld
metal.
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
33/50
33 - Classification: Internal 2010-04-23
STATOIL S13Cr Challenges (continue):2002 -
Leakages K101 & J102 flowlines; HISC due to CP influenced hydrogendevelopment
Weld toe
initiation
Macro fracture
IC fracture
Crackdetection
K-101
J-102
Crack
branching
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
34/50
34 - Classification: Internal 2010-04-23
Welding
Material considered:
Clad / Lined
13% Cr
Weld Consumables
Joint Configurations
Mechanical properties
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
35/50
35 - Classification: Internal 2010-04-23
Welding consumables
Requirements
Welding consumable with sufficient corrosion properties
Welding consumable with over matching or partly over matching strength compared toparent material
Welding consumable with good facture mechanical properties
Welding consumable suitable for the welding processes
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
36/50
36 - Classification: Internal 2010-04-23
Welding consumables
Clad:
Duplex / Super duplex
+ Good corrosion properties
+
Overmatching mechanical properties
+ Good welding properties
-
Yield stress de-rating at higher temperature-
HISC sensitive
Inconel 625 all through the weld
+
Good corrosion properties
+ Good welding properties
+ Good facture mechanical properties
-
GMAW narrow groove, poor welding properties
-
Partly overmatching
Inconel 625 in root and hot-pass and Inconel 686 for fi ll and cap
+
Good corrosion properties+ Good welding properties
+ Less good facture mechanical properties (686)
-
Partly overmatching
-
GMAW narrow groove, poor welding properties
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
37/50
37 - Classification: Internal 2010-04-23
Welding consumables
13 % Cr
Super duplex
+ Good corrosion properties
+
Overmatching mechanical properties
+ Good welding properties
-
Yield stress de-rating at higher temperatures
-
HISC sensitive
-
PWHT needed
13% Cr
+
Matching / Overmatching+
Good corrosion properties
+ Adequate fracture mechanical properties
-
HISC sensitive
-
PWHT needed-
Limited availability
-
Qualification to be performed
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
38/50
38 - Classification: Internal 2010-04-23
Joint Configuration
6+/-1
Clad layer 1.6mm
1.7mm
3.5
-3.6mm
3.2mm
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
39/50
39 - Classification: Internal 2010-04-23
Mechanical
testing
Weld consumable; ECA requires overmatching or partly
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
40/50
40 - Classification: Internal 2010-04-23
Weld consumable; ECA requires overmatching or partlyovermatching tensil
properties
Clad JIP Design Guideline App A no 2007-0220 rev 02
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
41/50
41 - Classification: Internal 2010-04-23
Fracture mechanical properties (SENT)
Fracture Toughness (SENT) Results of 625 & 625 / 686 Girth Welds
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
42/50
42 - Classification: Internal 2010-04-23
NDT; Automatic
Ultrasound
Testing
(AUT)
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
43/50
43 - Classification: Internal 2010-04-23
Integrated internal inspection, clamp and purging system
Rema
Cut Internal Line up Clamp
Inflatable dams
Purge system
Onboard purge analyser
Video Camera
Laser Measuring Device
Camera
Insp.MPG
Drive Mechanism
Laser Light on Root
Graph Showing alignment and cap height
Control Module
http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/ -
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
44/50
44 - Classification: Internal 2010-04-23
Internal defect criteria
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
45/50
45 - Classification: Internal 2010-04-23
Examples
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
46/50
46 - Classification: Internal 2010-04-23
Examples
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
47/50
47 - Classification: Internal 2010-04-23
Examples
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
48/50
48 - Classification: Internal 2010-04-23
Examples
-
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
49/50
49 - Classification: Internal 2010-04-23
Video Internal inspection
Camera
Insp.MPG
http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/ -
8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf
50/50
Summary and conclusions
Clad and lined linepipes
future materials for corrosion resistant materials
Less expensive compared to solid CRAs
Resistant to internal corrosion
External corrosion is taken care of by CP and corrosion coating
HFW future for longitudinal welded pipelines
13% Chromium
Need for knowledge and experience transfer
Welding consumable
Superduplex
13% Cr (in combination with experience and knowledge)
Sensitive to HISC