Fusion Bonded Joint: An innovative technology for cost...

Fusion Bonded Joint: An innovative technology for cost efficient plastic-lined pipe installation and operation Qualification Campaign

MCE Deepwater Development 2015, London

SAIPEM SA Proprietary Information Fusion Bonded Joint: An innovative technology for cost efficient plastic-lined pipe installation and operation

Introduction

Corrosion: key issues for subsea flowlines Current solutions

Corrosion allowance Internal cladding with Corrosion Resistant

Alloy Internal plastic liner

Internal plastic liner technology limited to

reeling so far… The FBJ offers a cost effective method for

J-laying

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Corroded Water Injection Flowline (COREL JIP)


Agenda

Requirements of the technology Overview of the Fusion Bonded Joint technology

Fabrication and Installation

Overview of the qualification tests

Conclusion

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Overview of the FBJ

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Overview of a Plastic lined pipe for J-lay Onshore

Quad Joint are assembled Plastic liner is inserted

Offshore

Plastic liner is going to be damaged during offshore welding Cut back length on liner is created Taylor designed sleeve in inserted to ensure continuity of liner

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Requirements of the technology

Excellent sealing

properties

No impact on Flow

Assurance / Piggability

Low marginal

cost

Limited impact on offshore

operations

Conventional carbon steel

weld

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Overview of the FBJ

HDPE sleeve is inserted at the weld location Electro-fusion weld between sleeve and liner

Based on technology applied for over 20 years

onshore Smooth constant ID: Preserves piggability

Fully controllable through AUT

Fully repairable

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FBJ before first application of pressure

FBJ under pressure


Overview of the FBJ

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Overview of the FBJ – Electro-fusion welding Development of dedicated tool

ICS: Inflatable Clamping System

Functions Maintain FBJ in position Ensure good face mating Power supply for EF Support AUT probes

Two versions

Horizontal Vertical

Controlled using a graphical interface

Light Equipment ~5 kg

No lifting equipment needed

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Clamping System

Welding Contactor

Pull Back System

AUT Probe

Clamping System

ICS installed on FBJ


Fabrication and Installation

Onshore Joints are assembled into quadjoints

(~50 m) HDPE liner is inserted in the quad

joints Liner extremities are machined to

specified tolerances -5 to 10 mm

Offshore Carbon steel pipe is beveled HDPE final machining is performed FBJ is installed in the firing line QJ is transferred to the tower Final assembly in the J-lay tower

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Pipe face mating prior to welding (Offshore)


The FBJ Technology: Development steps Step 1

• FBJ fabrication in HDPE • Complete electrical design test

Step 2 • Fusion Bonding tests with pipeline • Pulling Destructive testing without pipeline • Design and fabrication of ICS

Step 3 • Design and fabrication of Machining tool • Carbon Steel Welding testing on lined samples

Step 4 • Resonant Fatigue testing under pressure

Development steps

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Completed in 2012

Completed in 2013

Completed in 12/2014

Planned for 04/2015


Step 2 – Electro-fusion process qualification

Goals of the step Design and Fabrication of the ICS

Qualify Electro-Fusion Process

Findings

Electrofusion is a very sturdy process

All welds successfully pressure tested

Strength of HDPE unaffected by welding process

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Step 2 – Electro-fusion process qualification

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Step 3 – Complete process qualification

Goals of the step Fabricate the liner machining tool Qualify the use of the ICS and FBJ

In a totally enclosed environment In an environment as representative as

possible of the one of the FDS Qualify the carbon steel weld in the presence

of the FBJ

Performed tests Standard welding of the CS pipe with

temperature monitoring Shrinkage effect Temperature gradient in FBJ pipe Verification of the root pass quality

Fabrication of 5 fatigue strings

Electro-Fusion NDT

Carbon Steel Welding


Liner Machining Tool 2 Steps Machining

Cylindrical head – Remove most of the liner Conical head – Adjust dimension for fit up

15 minutes for complete machining

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Conical Machine Head

Cylindrical Machine Head

Machining Tool


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VIDEO QUALIFICATION CAMPAIGN



Carbon Steel Welds Standard Welding parameters Continuous Welding process All welds were found acceptable under MUT and RT

Electro-Fusion Welds

Vertical and horizontal ICS fully functional NDT of plastic welds didn’t show any issue in the welds

Interaction between FBJ and CS weld

No impact on line-up No impact on Carbon Steel weld No impact on FBJ sleeve (Temperature below 120°C at

all time)

Liner Machining Tools Over 50 machined pipe ends without any issue Improvement of associated tools

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Root Pass Examination

HDPE Sleeve after welding


Targets Confirm quality of carbon steel welds

(Class D Curve) Demonstrate HDPE fatigue life >

Carbon steel fatigue life

Program 2 Stress levels: 200 & 150 MPa 4 Welds per level 1 Spare string Stress level monitored both in

Carbon Steel and Plastic Welds

Specificities Specific End Piece design to detect

origin of leak Prevent water ingress outside of weld

location

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Step 4 – Fatigue testing

Fatigue Testing Bench @ SAIPEM

Fatigue Strings ready for expediting


Conclusion

FBJ is nearing full qualification Sleeve manufacturing process validated Electro-fusion welding paramters validated Carbion Steel welding process qualified Fatigue performance of the weld assessed within 2 weeks

FBJ appears as a sturdy technology

Plastic welding process very tolerant to parameters Carbon Steel welding process unaffected by sleeve presence Sleeve unimpacted by Carbon Steel welding process

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