13. Statoil, Lars Magne Haldorsen.pdf

8/10/2019 13. Statoil, Lars Magne Haldorsen.pdf

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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]


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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


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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


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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


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Where is the 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


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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


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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


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J-lay welding

Welding

Working stations; 2, one forwelding and one for FJC

Welding techniques


Positions

Double jointing; PA (1Gspinning)

Main line; PC (2G)

Bevelling; API and narrow groove

Consumables; SAW (Doublejointing, FCAW, GMAW, GTAW


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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;


Positions: Double jointing; PA

(1G) spinning Main line; PF, PG(3G)

Consumables; SAW (Double

joint ing), FCAW, GMAW, GTAW


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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


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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/


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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


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Longitudinal welded pipes

UOE process

Submerged Arc Welded(SAW, GMAW, PAW)

Electric Resistance welded(ERW)

High Frequency Inductionwelded (HFI


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Linepipe dimensions and ranges

W

allThickness[Inch]

Outer Diameter (OD) [ Inch]


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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)


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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 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


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Metallurgical bonded clad pipes


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What is clad pipes; Manufacturing principles


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What is clad pipes; Manufacturing principals


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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


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Manufacturing principles; Pipe forming methodology


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Manufacturing principles; Pipe forming effect


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Hardness difference between outer surface, mid surface andinner surface


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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


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Tensile test challenges for Clad material


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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


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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


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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 )


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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.


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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


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Welding

Material considered:

Clad / Lined

13% Cr

Weld Consumables

Joint Configurations

Mechanical properties


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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


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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 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


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Welding consumables

13 % Cr

Super duplex

+ Good corrosion properties

+

Overmatching mechanical 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


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Joint Configuration

6+/-1

Clad layer 1.6mm

1.7mm

3.5

-3.6mm

3.2mm


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Mechanical

testing

Weld consumable; ECA requires overmatching or partly


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Weld consumable; ECA requires overmatching or partlyovermatching tensil

properties

Clad JIP Design Guideline App A no 2007-0220 rev 02


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Fracture mechanical properties (SENT)

Fracture Toughness (SENT) Results of 625 & 625 / 686 Girth Welds


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NDT; Automatic

Ultrasound

Testing

(AUT)


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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/


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Internal defect criteria


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Examples


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Examples


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Examples


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Examples


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Video Internal inspection

Camera

Insp.MPG
http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/http://camera%20insp.mpg/


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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

13. Statoil, Lars Magne Haldorsen.pdf

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