IBP2090_12 HIGH TOUGHNESS API 5L X70MS PIPE GRADE DEVELOPMENT FOR DEEP AND ULTRADEEP WATER APPLICATION.

Marcos Ponciano1, Luis C. Chad2, Marcelo Jose B. Teixeira 3, Vinicius R. de Abreu Lima 4, Helder Heleno Ferreira 5, Monica C. Riccio Ribeiro6

Copyright 2012, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Oil & Gas Expo and Conference 2012, held between September, 17-20, 2012, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical Committee of the event according to the information contained in the final paper submitted by the author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute opinion, or that of its Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Oil & Gas Expo and Conference 2012 Proceedings.

Abstract: The Pres-salt offshore explorations at distant points from the Brazilian coast bring to national industry important technological challenges. Considering the need to produce and transport large volumes of gas in a safe condition the use of large diameter steel pipes produced by UOE-SAWL process is a confident alternative and already applied for some important projects. However, due to the hostile environment in which the new fields are placed it is necessary to develop new products in order to meet the rigorous mechanical and corrosion properties requirements as toughness and corrosion resistance in the H2S presence. Other important issue is the water deep where these fields are placed. Some fields are placed at 2500 meters deep but it is forecast to be up to 3000meters, where the pipe resistance becomes an important challenging for the present installation methods due to the considerable load caused by the pipe wall thickness necessary to comply with the external collapse pressure. Considering the scenery above exposed and the fact that now a days the maximum pipe grade available to comply with the pre-salt gas pipeline requirements are the X65, so higher pipe grade need to be study and developed in order to reduce the wall thickness without final gas pipeline resistance capability reduction.

1. Introduction In the previous work[1] it was presented the evaluation of mechanical properties and corrosion resistance in presence of H2S for OD 20 inches, WT 25,4 mm APL 5L X-70MS pipe considering the pipe body, longitudinal and girth welding in as welded conditions. In that work it will be presented the evaluation of the girth welding performed for the same pipe dimensional, but considering the plastic deformation possibly suffered by the pipes during the installation processes. In that paper the results of the mechanical and corrosion properties evaluation regarding the girth weld performed with Low and High heat inputs using for OD 20 x 1,00 wt X70MS pipe grade followed by some cycle of plastic deformation and ageing will be presented. Very good toughness (Charpy and CTOD values) were achieved down to -40C and -20C respectively, additionally the pipes presented good Stress Corrosion Cracking Resistance (SSC), even for girth welding produced with low and high heat inputs.

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Welding Metallurgy & Technology Department Manager Tenaris Confab R&D 2 Product Engineering Manager Tenaris Confab 3 Gerente Setorial de Projetos de Dutos e Instalaes Martimas - Petrobras 4 Equipment Engineer - Petrobras 5 Equipments Engineer - Petrobras 6 Engenheira de Materiais, D.Sc - Intecsea do Brasil
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2. Experimental Program

2.1 Girth welding production Considering the need to evaluate the girth welding heat affected zone characteristics with as minimum as possible influence of the base and weld metal, the API RP2Z bevel design was applied for all welding production in order to guarantee the uniform heat affected zone (HAZ) shape and consequently homogenous microstructure distribution in the straight joint side where the HAZ toughness evaluation was performed. A schematic sketch about the joint preparation is presented in the figure 1:

Figure 1: Join preparation

In order to perform the characterization of the girth welding HAZ and determine the pipe properties considering the welding heat input work window typically applied for offshore application welding processes, two different heat inputs representing typically the minimum and the maximum heat inputs were applied. The Low heat input (LHI) chosen was between 0.7 and 0.8 KJ/mm and the High heat input (HHI) chosen was between 1.2 and 1.3 KJ/mm. Several rings of pipes were welded in order to prepare the samples for testing. The table 1 summarizes the testing performed considering each heat input. Table 1 Welding conditions and samples for each condition Amount of Samples Macrograph TT 1 1 3 3 Hardness 1 1 CVN 75 75 CTOD 6 6 FPBT 3 3

Welding condition LHI HHI

2.2 Girth welding characteristics - Macrograph After weld conclusion the joints were inspected by radiography and macro sections were taken from each joint in order to know about the welding alignment in the region of interesting. Figure 2a and 2b shown the macrograph obtained in the girth weld for low and high heat inputs:

Figure 2a Macro section low heat input Magnification: 1x

Figure 2b Macro section high heat input Magnification: 1x

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2.3 Plastic Deformation application According to the client specification four cycle of plastic deformation were applied on the bars with the welding in the center in order to carry out the girth welded joints characterization considering the plastic deformation suffered during the pipe installation process. The cycling was performed following the client requirements consisting of: - 1st cycle: compression to 2,5 % and Elongation to 0.0%; - 2nd cycle: compression to 2,5 % and Elongation to 0.0%; - 3nd cycle: compression to 2,5 % and Elongation to 0.0%; - 4rd cycle: compression to 2,5 % and Elongation to 0.0%; The figure 3 shows the deformation cycles applied on the bar before ageing application:

Figure 3 Load cycle application After the described cycling, the bars were submitted to accelerate aging thermal treatment at 250 C for one hour. Finally the bars were machined to achieve the final samples: longitudinal tensile (TT), hardness, Charpy VNotch Test (CVN), CTOD and SSC (FPBT) specimens. 3. Results Evaluation 3.1 Tensile Test After plastic deformation cycles and ageing application tensile test were carried out on samples taken transversal to the girth weld. The results are presented in the table 2. Table 1 Transversal Tensile tests results Welding Condition LHI Sample 1 2 3 1 2 3 Heat Input L Results Accepted Accepted Accepted Accepted Accepted Accepted Remarks Failure at Patent Metal Failure at Patent Metal Failure at Patent Metal Failure at Patent Metal Failure at Patent Metal Failure at Patent Metal

HHI

All samples failure at parent metal with ultimate tensile stain above the minimum specified for X70MS pipe grade, making it possible to assert that the weld and the heat affected zone present properly tensile resistance.

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3.2 Charpy V-Notch Test After deformation cycles and ageing application, Charpy V-Notch test taken transversal to the girth weld were carried out considering the following regions of the HAZ: Fusion Line (FL), FL+2mm, FL+5mm. One set of five specimens each one was carried out at the following temperatures: 27C, 0C, -20C, -40C and -60C. The Charpy V-Notch tests were performed in accordance with ASTM A370. Specimens dimensions applied were (10 X 10 x 55mm). The results for low and high heat inputs are presented in the charts 1a and 1 b.
Charpy Test Results - Low Heat Input
500 450 400 350 300 250 200 150 100 50 0
-80 -60 LHI - FL -40 -20 0 20 40 LHI - FL + 2 mm LHI - FL + 5 mm

Charpy Test Results - High Heat Input

500 450 400 350 300 250 200 150 100 50 0
-80 -60 HHI - FL -40 -20 0 20 40 HHI - FL + 2 mm HHI - FL + 5 mm

Chart 1a Charpy V-Notch results Low Heat input

Chart 1b Charpy V-Notch results Low Heat input

Except for the fusion line very good Charpy V-Notch test values were obtained down to -60C. Considering the fusion line the values could comply with the minimum requirement value down to -40C showing very good toughness for both heat inputs applied. It is important to state that, from 5 specimens tested in each condition, the minimum and the maximum values were eliminated, presenting thus three out of five values for each temperature and location.

3.3 CTOD Test after Deformation Cycles The CTOD testing after deformation cycles and ageing was carried out for each heat input applied. The testing were carried out at -20C with specimens geometry Bx2B according to BS 7448 Part 2 using as higher thickness as possible. The notch was located in the fusion line with T-T orientation and crack plane orientation NP. One set of 5 was carried out at -20C for each welding condition. The results are shown at the tables 3 and 4. Table 3 CTOD test results for Low Heat Input CTOD Fracture Cracking (%) mm Mode CGHAZ +F/IHAZ 1,07 1,07 0,88 M M M 90 100 100

Location Temperature Geometry Orientation Bx2B HAZ -20C Bx2B Bx2B T-T T-T T-T

Table 4 CTOD test results for High Heat Input CTOD Fracture Cracking (%) mm Mode CGHAZ + F/IHAZ 1,00 0,99 0,98 M M M 100 88 100

Location Temperature Geometry Orientation Bx2B HAZ -20C Bx2B Bx2B T-T T-T T-T

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The minimum value established for CTOD after test validation was 0,15mm. According to the values presented in tables 3 and 4 the CTOD values obtained could comply very well with the minimum established for both heat input applied at -20C.

3.4 Hardness Test after Cycles of Deformation For hardness tests after cycles of deformation and ageing application, one test specimen from each Girth Welding condition were tested. Hardness tests were performed in conformance with ASTM E384 standard. The location of points examined is shown at the figure 4.

Figure 4 Hardness Location for Deformed Samples. Test hardness results are presented in the charts 2a and 2b.
Hardness - LHI
300

Hardness - HHI
300

Base Metal
Hardness HV10

HAZ

Weld

HAZ

Base Metal
Hardness (HV10)

Base Metal
250

HAZ

Weld

HAZ

Base Metal

250

200

200

150

150
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Internal

10 11 12 13 14 15 16 17 18 Internal

External

Middle

External

Middle

Chart 2a Hardness test results for low heat input

Chart 2b Charpy V-Notch results High Heat input

From the results presented above, it is possible to observe that all base metal and heat affected zone results were below 250 HV10 at welding root and smooth higher at middle and capping region considering the last nearest point of the fusion line (condition where the weld metal can be affecting the results). Therefore, the results are approved according to DNV-OS-F101 for sour service application. 3. 5 Corrosion Test after Cycles of Deformation 3.5.1 Testing conditions The SSC exposure was conducted according to the procedures given in NACE TM0177, Method B, ASTM G39 and incorporates the amendments in ANNEX A of EFC Publications No. 16 or EFC No. 17. The Testing duration was 720 hours and the stress applied during testing was 100% of the minimum value of yield stress obtained during the tensile tests for base material evaluation (520 MPa). A set of 3 specimens was tested for each heat input. Specimens were taken as close as possible of the internal surface of the line pipe. Prior to testing, the specimens were measured and degreased with toluene and acetone. Eight (8) liters of synthetic sea (Solution B per NACE TM0284) was prepared (initial pH was adjusted to 8.2) and deaerated overnight. The stressed specimens were placed in a glass tank and deaerated with nitrogen. The solution was transferred to the tank and further deareated for additional two hours with nitrogen at a flow rate of 100 ml/min to
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avoid oxygen contamination during the solution transfer. After final deaeration, the solution was saturated with 100% H2S at ambient temperature and pressure and kept at a positive pressure thereafter for the duration of the test. The initial pH of the solution was 8.2 and the pH at the end of the exposure was 5.3 No indication of environmental cracking on the surfaces was observed on any specimen after testing. Table 5 and 6 presents the results for the SSC testing. Table 5 SSC (FPBT) results - Low Heat Input Identification Sample LHI Specimens 54245-1 54245-2 54245-3 Length (in) Width (in) 4.51 4.53 4.54 0.587 0.591 0.588 Thick (in) 0.194 0.194 0.195 Stress Applied (psi) 75,420 Test Results No Cracks No Cracks No Cracks

Table 6 SSC (FPBT) results - Low Heat Input Identification Sample HHI Specimens 54244-1 54244-2 54244-3 Length (in) Width (in) 457 454 457 587 589 588 Thick (in) 0.193 0.195 0.195 Stress Applied (psi) 75,420 Test Results No Cracks No Cracks No Cracks

Upon completion of the exposures, the pH of the solution was measured; the specimens were removed, cleaned, and visually examined for cracking according to the NACE TM0177, Method B and ASTM G39 at 10x magnification. Photographs of the specimens after testing are presented in Figures 5a and 5b.

Figure 5a SSC specimens after test Low Heat Input 4. Conclusions

Figure 5b SSC specimens after test High Heat Input

The X70MS pipe OD 20 x wt 1,000 HAZ characterization has produced good overall results for both heat input conditions (LHI & HHI) applied: Tensile test: presented values higher than the minimum specified for the grade complying with the requirement of DNV-OS-F101; Hardness: values achieved at HAZ (at root) both heat inputs comply with the maximum hardness specified by DNV-OSF-101 for root and capping, Charpy: High CVN values were achieved at -40C. Minimum value founded was 81 J at Fusion Line. It means that the material presents very good toughness and also complying with DNV-OS-F101 requirements down to -40C; CTOD: Very good results obtained at -20C at HAZ with minimum value of 0,88 mm, complying with the minimum specified by DNV-OS-F101 (0,20 mm);
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Corrosion testing: the SSC presents satisfactory results after 720 hours exposed to H2S (solution B NACE TM 284) and according to NACE TM0177, Method B, ASTM G39.

5. Acknowledgements The support of Tenaris for this research program is gratefully acknowledged.

6. References 1. Ponciano M., Chad L., Teixeira M. J. B., Ferreira H. and Lima V. 2011. High toughness API 5L X70MS Pipe Grade Development for Deep and Ultra Deep Water Application. Rio Pipeline Conference & Exposition 2011. IBP_1333, Rio de Janeiro, Brasil, Sep, 20-22, 2011. DNV. 2010. Submarine Pipeline Systems. Det Norske Veritas, DNV OS-F101. AMERICAM PETROLEUM INSTITUTE, ANSI/API Specification 5L/ISO 3183:2007 44th Edition, October 1, 2008: Petroleum and natural gas industries Steel pipe for pipeline transportation system. DET NORSKE VERITAS, Offshore Standard DNV-OS-F101 Submarine Pipeline Systems, October 2007. NACE MR 0175/ISO 15156-1:2001: Petroleum and natural gas industries Materials for use in H2S containing environments in oil and gas production part 1: General principles for selection of cracking-resistant materials. NACE MR 0175/ISO 15156-2:2001: Petroleum and natural gas industries Materials for use in H2S containing environments in oil and gas production part 2: Cracking-resistant carbon and low alloy steel, and the use of cast irons. NACE Standard TM0177-2005: Standard Method Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments. NACE Standard TM0284-2003: Standard Test Method Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking.

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