Metallurgically Clad Pipes

Name des Referenten von BUTTING | 08.03.2017

Metallurgically clad pipes

Production of metallurgically clad pipes

• Pipes are generally

produced in dimensions
from 4“ - 48“ in lengths of
6 or 12 m (additional sizes
and pipe length upon
agreement)

A wall thickness / diameter ratio of approx. 1 / 10 can be realized

 Metallurgically clad pipes

Selection of typical material grades for carbon steel

and cladding

C-Mn Steel YS [MPa] TS [MPa] Cladding YS [MPa] TS [MPa]

API X52 360 460 Alloy 825 241 586
API X60 415 520 Alloy 625 (Gr 2) 276 690
API X65 450 535 904L 220 490
API X70 485 570 316L 170 485
Comparable grades in accordance with ISO, DNV, etc. are
also used
Metallurgically clad pipes

Production of metallurgically clad plates

Different manufacturing methods of metallurgically clad plates:

• Roll-bonded

• Explosive clad

• Weld-clad
Data Source: Voest Alpine Stahl Linz
 Metallurgically clad pipes

Production of roll-bonded plates for the manufacturing

of metallurgically clad pipes

Rolling of base Package Evacuation Re-heating

material and assembly
cladding
 Metallurgically clad pipes

Production of roll-bonded plates for the manufacturing

of metallurgically clad pipes

Plates are TM + ACC rolled or

quenched and tempered

• Rolling • Heat treatment • Plasma

cutting
 Metallurgically clad pipes

Production of roll-bonded plates for the manufacturing

of metallurgically clad pipes

Plate inspection in accordance with

ASTM A578 Level C and ASTM A265
Quality Class1 or in accordance with
client requirement

• Ultrasonic • Levelling • Grinding

testing
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Production of metallurgically clad pipes

Goods inwards inspections of the raw material

is carried out according to standardized and
individually agreed quality criteria, e. g.
• Control of material and marking
• Dimensional control
• Control of delivery note and certificate Visual inspection of plates

Thickness of cladding Total thickness PMI of plates

Metallurgically clad pipes

Production of metallurgically clad pipes

• Pre-bending and plasma cutting of the plates

Pre-bending of the plates Pre-bended plate Plasma cutting of the plates

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Production of metallurgically clad pipes

• Milling of plate edges in order to prepare for longitudinal welding

Milling machine Plate edge after milling

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Production of metallurgically clad pipes

• On a 3 000 t or 10 000 t press brake the plates are bent into open seam
pipes (distance between forming steps 10 – 30 mm)

Pipe forming by
JCO Process
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Production of metallurgically clad pipes

• Cleaning of the plate edges and continous tack-welding (GTAW)

Continous tack-welding line Tack welded pipe

GTAW
Metallurgically clad pipes

Production of metallurgically clad pipes

• For welding the longitudinal weld, different welding methods are used,
e. g. GMAW, SAW, GTAW, ESW

Longitudinal welding carbon steel Longitudinal welding CRA Macro of a longitudinal weld

2-n SAW

1 GMAW
3 GTAW

Tack weld 4 ESW

PTA
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Production of metallurgically clad pipes

• To optimize the calibration process and the following UT, the

longitudinal weld is ground from the outside

Outside surface contour grinding

Metallurgically clad pipes

Production of metallurgically clad pipes

• Depending on the customer‘s specification, the material combination

and pipe size, a post-weld heat treatment is carried out

Quenching and tempering of clad pipes Tempering of clad pipes

Typical temperatures (depending on the material):
Quenching: 980°C ± 10° water cooling
Tempering: 630°C ± 10° air cooling
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Production of metallurgically clad pipes

• Calibration at the 2 000 ton or 6 000 ton press in full die

Calibration of pipe Calibration machine

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Production of metallurgically clad pipes

• Additional ID calibration for improvement of pipe end tolerances

Additional calibration from the pipe inside if required

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Production of metallurgically clad pipes

• Hydrostatic pressure testing

Hydrostatic pressure testing up to 1 000 bar

Metallurgically clad pipes

Production of metallurgically clad pipes

• X-ray of the longitudinal weld using digital or film technique

X-ray up to a wall thickness of max. 90 mm

Metallurgically clad pipes

Production of metallurgically clad pipes

• Ultrasonic examination of the longitudinal weld

Phased Array UT examination

Automatic UT examination unit

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Production of metallurgically clad pipes

• The pipe ends are bevelled according to project requirements in order to

enable further treatment

Pipe end bevelling Typical V-bevel

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Production of metallurgically clad pipes

• Special treatment:
Pipe end ID machining for fatigue resistant
SCR pipes to achieve best possible
tolerances of ± 0,25 mm incl. out of
roundness

w1
**

r
s

f
t

*
b
c

a
Ø

max. ID high low = 0.5 mm

ID machined pipe end
Metallurgically clad pipes

Production of metallurcigally clad pipes

• MPI of the longitudinal weld

MPI testing
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Production of metallurgically clad pipes

• 100 % dye penetrant inspection of the pipe ends

DPI of bevel and pipe end inside

Metallurgically clad pipes

Production of metallurgically clad pipes

• Pipe lenghts up to 24 m by circumferential welding

Girth weld, 5G, GTAW hot wire Typical filler wire Alloy 625

1. GTAW 2. GTAW
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Production of metallurgically clad pipes

• 100 % pickling of the pipe inside surface

Inside spray pickling

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Production of metallurgically clad pipes

• 100 % visual inspection

Pipe inside video inspection View of inside video inspection

Metallurgically clad pipes

Production of metallurgically clad pipes

• 100 % dimensional control

Typical Tolerances for a 16" metallurgically clad pipe

OD Pipe Body
OOR Pipe Body
ID Pipe Ends (100 mm)
OOR Pipe Ends (100 mm)
Straightness
Wall thickness Carbon Steel
Wall thickness CRA
Pipe length
Pipe End Squareness
Improved tolerances can be agreed
- 0,25 % / + 0.75 %
< 0.75 %
± 1.0 mm incl. OOR
incl. in ID tolerance Laser measurement (ID & OoR)
< 0.1% of Pipe length
- 0.5 mm / + 2.0 mm
- 0 / + 1.0 mm
12.0 m ± 0.2 m (with girth welds)
< 1.0 mm

Weld area
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Production of metallurgically clad pipes

• Mechanical and corrosion test

Corrosion testing Micro / Macro examination Mechanical testing

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Production of metallurgically clad pipes

• Packing and storage

Special packaging for individual transportation Intermediate storage

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Production of metallurgically clad pipes

• Dispatch
• Transporatation by truck, train and vessel
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Production of metallurgically clad pipes

• High-quality prefabrication of metallurgically clad spools for a refinery

Metallurgically clad pipes

Metallurgically clad pipes

• Produced out of clad plates

• From OD 114.3 mm (4″) to OD 1 219 mm (48″)

• Wall thicknesses up to 70 mm

• Maximum wall thickness to outer diameter ratio

approx. 1:10

• 6-m or 12-m lengths without circumferential welds,

up to 24-m lengths with circumferential welds

• Used e.g. as riser pipes, SCR pipes, process pipes

and line pipes according to API 5LD and DNV OS-
F101
Metallurgically clad pipes

Metallurgically clad pipes – Your benefit:

 Reduction in wall thickness

 Cost benefits compared to full wall pipes

by savings in materials and weight

 A wide range of material combinations

 BUTTING skills: our facilities enable the

production of up to 10 km of metallurgically
clad pipes each month

 Market leader for Clad SCR Pipes

 Metallurgically clad pipes

References
Year Project Operator Tons Material
MWP 415 & 450 /
2016 Bahr Essalam Mellitah Oil & Gas 7 300
Alloy 625 & 825
2016 Zohr Petrobel 5 000 X65 / Alloy 625
2016 Arbi & Karan Saudi Aramco Oil Company 1 300 X65 / Alloy 625
2015 Maria Wintershall 500 MWP 450 / Alloy 625
2015 C26 & PRP4 ONGC 2 200 X60 / Alloy 825
2014 Kashagan NCOC 47 000 MWP 415 / Alloy 625
2013 Kraken EnQuest 4 800 X65 / TP316L
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Kashagan Project

Sector Offshore & Onshore

Operator NCOC

130 km metallurgically clad pipes

Total amount
(47 000 tons)

ID 679,2 x 15,9 + 3 mm
Dimensions
ID 413,0 x 22,2 + 3 mm

Material MWP 415 / Alloy 625

Difficult climatic conditions

Peculiarity
+40 °C to -40 °C external temperature
Metallurgically clad pipes
Metallurgically clad pipes