Pipeline Installation, Manufacturing, Welding and NDT

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: lamha@statoil.com
1 - 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
2011-09-09
Welding, Materials and Fabrication Department
Pipelines and laying techniques
2011-09-09
Pipeline transport system

in North Sea
Snhvit
Melkya
Export pipelines to Germany,

Belgium, France and the UK
High regularity and
great flexibility
Statoil is technical
operator for 7,000km
of pipeline
Norne
sgard
Kristin
Heidrun
TS
Ormen Lange
Statfjord
Frigg
Vesterled
Sleipner
St Fergus
Ekofisk
Haltenpipe
Nyhamna
Troll
Kollsnes
Krst
Europipe II
Europipe I
Langeled
Teesside
Norpipe
Zeepipe I
Franpipe
Emden
Easington
Zeebrugge
Dunkerque
2011-09-09
Infield pipelines
2011-09-09
Future for Norwegian

oil exploration?
2011-09-09
Subsea pipeline installation techniques

NO plastic deformation of pipeline
S-lay
J-lay
PLASTIC deformation of pipeline
Reel Lay
Others
Flex Lay
Bundles
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
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
2011-09-09
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
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
2011-09-09
Videos
S-lay offshore fabrication S-lay welding
Reel lay site fabrication Spoolbase welding
2011-09-09
Steel manufacturing and material refining

techniques
2011-09-09
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
2011-09-09
Casting
Casting
Continuous casting
Ingot casting
2011-09-09
Seamless linepipe
Piercing
Elongation
Reducing/stretching
Cutting to 12-13 m
lengths
Heat treatment
Straightening
NDT
2011-09-09
Longitudinal welded pipes

Long welded pipes
UOE process
Submerge Arc Welded
(SAW)
Electric Resistance
welded (ERW)
High Frequency Induction
welded (HFI
2011-09-09
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)
2011-09-09
Lined mechanical bonding principles
2011-09-09
- 16 -
Lined pipe end sealing /Cladding
3mm
Up to 2008, not good for AUT and

repair
2011-09-09
From 2008, repair and NDT

properties improved
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
2011-09-09
Metallurgical bonded clad pipes
2011-09-09
What is clad pipes; Manufacturing principles
2011-09-09
What is clad pipes; Manufacturing principals
2011-09-09
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
2011-09-09
Principals for refining of mechanical properties in steel by heat

treatment
2011-09-09
Heat treatment; principles

Quench and tempering
2011-09-09
Heat treatment; quenching results
Feritt + perlitt
2011-09-09
Refining of mechanical properties in steel,

tempering vs. mech. properties
1900.0
140.0
1800.0
130.0
1600.0
120.0
1500.0
110.0
1400.0
100.0
1300.0
1200.0
90.0
1100.0
80.0
1000.0
70.0
900.0
800.0
60.0
700.0
50.0
600.0
40.0
500.0
400.0
30.0
300.0
20.0
200.0
10.0
100.0
0.0
0
200
250
300
350
400
anl.temp. (grader celsius)
2011-09-09
450
500
0.0
550
Charpy V (joule), A 5(%), Z(%)
Rm (Mpa), Rp 0,2 (Mpa), HV
1700.0
Rm (Mpa)
Rp0,2(Mpa)
HV
Charpy V
A5 (%)
Z (%)
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
Load
Feritt + perlitt
Heat treated steel

Mild steel
1000 kg
Tempered martensite/ainite
2011-09-09
Strain
Refining of mechanical properties in steel by

quench and tempering
Heat treated steel
Mild steel
Permanent deformation
No permanent
deformation
2011-09-09
Wall Thickness [ Inch]
Linepipe dimensions and ranges
Outer Diameter (OD) [ Inch]
2011-09-09
Corrosion and material selection
2011-09-09
Corrosion
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.
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
2011-09-09
Internal corrosion protection

Material selection
Corrosion Resistant Alloys, CRA(Duplex stl, 13%Cr steel)
Very good resistance against CO2 corrosion
Good resistance against H2S corrosion
Some of the CRAs 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 Stl

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
2011-09-09
External corrosion protection

Material selection
Cathodic protection
Single anodes with equidistance distribution (200300m)
Evenly distributed electro- potential

Difficult to get water tight at the contact point
(Crevice problems)
Surface protection (coating)
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
2011-09-09
Cathodic protection; Pourbaix diagram
2011-09-09
Protection potential for steel in seawater
2011-09-09
Potential distribution
2011-09-09
Potential distribution
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)
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.
2011-09-09
Coating and insulation
2011-09-09
Production chemistry the problems
2011-09-09
2010-11-07
How to keep the hydrocarbons hot during

transport?
Insulation
2011-09-09
2010-11-07
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
05.10.2012
What is coated?
Pipeline
Line pipe
Field joint
Spools
Line pipe
Field joint
Bend
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)
2011-09-09
3 layer Polypropylene (3LPP)
2011-09-09
Multi-layer Polypropylene
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
2011-09-09
Qualification of coating - Bending test
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
2011-09-09
Welding and Non Destructive Examination
2011-09-09
Content
Welding
Definition of welding
Pipeline Welding Techniques
Welding Procedure qualification
Testing
Documentation, Welding procedure Specifications
None Destructive Examination
Examination methods
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.
2011-09-09
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) grainrefined (normalized) section, (III) partially grainrefined section, (IV) recrystallized section, (V)
aging section
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)
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%)
2011-09-09
SMAW welding of pipelines
2011-09-09
Submerged Arc welding; SAW
2011-09-09
Submerged Arc welding; SAW
2011-09-09
Gas Metal Arc Welding; GMAW; MIG/MAG
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 0,6 2,4mm
2011-09-09
Gas Tungsten Arc Welding, principle
2011-09-09
Flux Cored Arc Welding; FCAW
2011-09-09
Flux Cored Arc Welding; FCAW, cont.
2011-09-09
Welding positions
Welding Position
2011-09-09
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
Bevelling
I-bevel
V-bevel
X-bevel
J-bevel
2011-09-09
Welding procedure qualification

pWPS
Perform welding
Record Parameters
Parameter record
Material cert.
Consumable cert.
Non Destructive
Testing
Perform Mechanical
testing of as-welded
Perform Mechanical
testing of StrainAged
NDE Reports
Mechanical
Properties
Mechanical
Properties
WPQR
WPS
2011-09-09
ECA
ECA Report
NDE Accept
Criteria
Welding Procedure
Specification
2011-09-09
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:
Fabrication Aspects
Weld indications and defects from typical project pipe
Fabrication Aspects
Weld defect locations from typical project pipe
None Destructive Testing
2011-09-09
NDT- Non-Destructive Testing

Definition of NDT
Overview of methods relevant to pipelines
AUT
Definition of NDT
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.
Methods of NDT
Visual
Five Most Common NDT Methods

Visual
Liquid Penetrant
Magnetic
Ultrasonic
X-ray
2011-09-09
Visual Inspection
Most basic and common
inspection method.
Tools include fiberscopes,
borescopes, magnifying
glasses and mirrors.
Liquid Penetrant Inspection

A liquid with high surface wetting
characteristics is applied
The excess liquid is removed
A developer (powder) is applied.
Visual inspection.
Liquid Penetrant Inspection
2011-09-09
Magnetic Particle Inspection

Magnetic Ink applied.
The part is magnetized
.
2011-09-09
Magnetic Particle flux

Flux leakage is formed
2011-09-09
Magnetic Particle inspection
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
+
Radiation
Penetrate
the Sample
Exposure Recording Device
2011-09-09
Film Radiography
Cluster porosity
2011-09-09
Film Radiography
Cracks.
2011-09-09
Film Radiography
Lack of Penetration
2011-09-09
Ultrasonic inspection
2011-09-09
Ultrasonic wave forms
Surface wave
Longitudinal wave
Shear wave
2011-09-09
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.
initial
pulse
crack
echo
back surface
echo
crack
0
2011-09-09
10
plate
Scanning
angle beam
2011-09-09
Ultrasonic Inspection
Size Evaluation
2011-09-09
AUT- Automatic Ultrasound Inspection
2011-09-09
AUT- Automated Ultrasonic Inspection

TOFD -Time of Flight Differaction
Not amplitude base method

Diffracted signals
Matched angle probes
Longitudinal wave
2011-09-09

PE-Pulse Echo
Weld is divided into zones

Each zone is scanned separately
2011-09-09

TOFD and PE
2011-09-09

Pipeline Installation, Manufacturing, Welding and NDT

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Pipeline Installation, Manufacturing, Welding and NDT

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Formate disponibile

Offshore flow- and pipelines,

manufacturing, material selection

Corrosion Resistant Alloys (Stainless steels)

Welding, Materials and Fabrication Department

Pipelines and laying techniques

Pipeline transport system

Export pipelines to Germany,

Future for Norwegian

Subsea pipeline installation techniques

Laying speed, 50 150 m/hr

Laying speed, 600 1000 m/hr

Pipeline fabrication; onshore

Reel-lay fabrication yards

Steel manufacturing and material refining

Longitudinal welded pipes

Clad pipes; Manufacturing principles

1. Internal cladding by welding (Proclad,

2. Lined clad pipe; Mechanical expanded

Lined mechanical bonding principles

Lined pipe end sealing /Cladding

Up to 2008, not good for AUT and

From 2008, repair and NDT

Pros and cons, lined clad pipes

Air gap, mix. off materials, etc

Metallurgical bonded clad pipes

What is clad pipes; Manufacturing principles

What is clad pipes; Manufacturing principals

Manufacturing principles; Nickel layer (adhesion)

3. Reduces the risk of cracking under

4. Reduces the penetration rate of pitting

Principals for refining of mechanical properties in steel by heat

Heat treatment; principles

Heat treatment; quenching results

Refining of mechanical properties in steel,

anl.temp. (grader celsius)

Charpy V (joule), A 5(%), Z(%)

Rm (Mpa), Rp 0,2 (Mpa), HV

Refining of mechanical properties in steel

Heat treated steel

Refining of mechanical properties in steel by

Wall Thickness [ Inch]

Linepipe dimensions and ranges

Outer Diameter (OD) [ Inch]

Corrosion and material selection

Internal corrosion protection

Good corrosion control

Fig. from Kawasakis patent increase Cr- in C-Mn Stl

External corrosion protection

Hydrogen induced cracking, crevice and pitting

External corrosion protection

Evenly distributed electro- potential

Cathodic Protection (CP)

Cathodic protection; Pourbaix diagram

Protection potential for steel in seawater

Cathodic Protection; Anode specification

Coating and insulation

Production chemistry the problems

How to keep the hydrocarbons hot during

3 layer Polypropylene (3LPP)

Coating qualification tests

Qualification of coating - Bending test

Field Joint coating

Welding and Non Destructive Examination

Origin of Electrical Arc Welding