TheSuitabilityofCRALinedPipesforFlowlines SusceptibletoLateralBuckling

SUTGlobalPipelineBucklingSymposium,2324February2011
DuncanWilmot,TechnicalManager,CladtekInternational,Australia PaulMontague,ManagingDirector,CladtekInternational,Australia

Abstract
CRA lined pipes are a proven and economical solution, widely used for pipelines operating at moderate temperatures. However, increasingly, CRA lined pipes are being considered for HPHT fieldswheretheflowlinesoperateathightemperaturesandaresusceptibletolateralbuckling. This paper presents results of testing performed on 24 CRA lined pipe under typical HPHT conditionsincludinghightemperature,highaxialcompressivestrainandlowinternalpressure. Testing confirmed that strains exceeding DNV design guidelines could be applied without incurringlocalisedwrinklingoftheCRAliner. TheresultsvalidatetheuseofCRAlinedpipeforHPHTpipelinesystems

1.Introduction
CorrosionResistantAlloy(CRA)linedsteelpipesareanestablishedandeconomicalsolutionto the problem of transporting corrosive multiphase fluids between well heads and processing facilitiesforonshoreandoffshoreoilandgasfields. Foroffshorefields,theuseofCRAlinedpipehaslargelybeenlimitedtopipelinesthatoperate at moderate temperatures or to pipelines that operate at elevated temperatures and that are highlyconstrainedinordertopreventlateralpipelinebuckling.However,withtheincreasing developmentofHighPressureHighTemperature(HPHT)fields,thereisagrowingdemandto utiliseCRAlinedpipesforflowlinesthataredesignedtooperateathightemperaturesandin conditionswherethepipelinewillbesubjectedtolateralbuckling. ThedemandtouseCRAlinedpipefortheseflowlinesisdrivenbythesignificantcommercial benefitsthatcanberealised:CAPEXissubstantiallyreducedasCRAlinedpipecancost3060% less than comparable CRA clad pipe and project schedule is improved as the market for CRA linepipeisopeneduptomoremanufacturers. However,inthecaseofCRAlinedpipe,asthebondingoftheCRAlinertothebackingsteelis mechanical,thepipelinedesignneedstoconsiderlimitstatesfortheonsetoflinerwrinkling, particularlyforflowlineswheretherewillbehighlevelsofaxialcompressivestrain.Inorderto addressthis,CladtekinitiatedaprogrammeoftestingonNPS24diameterCRAlinedpipe. The aim of the test programme was to validate the proposal that NPS 24 CRA lined pipe was suitableforuseinhightemperatureflowlinessusceptibletolateralbuckling. Thispaperoutlinesthetestmethodologyandpresentsresultsderivedfromthetesting.

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

2.TestProgramme
A detailed test programme with representative test parameters was developed after consultation with engineering and operator companies. The test programme takes account of offshoreHPHTflowlinedesignconditionsandhassomekeyfeatures: NPS24(609.6mmOD)SAWLCSOuterPipe TestPipewith2GirthWelds SimulationofPipelineCoating InstallationConditionTesting PipelineSystemPressureTest OperatingConditionTesting StartUp/ShutDownConditionTesting The test pipes were manufactured by Cladtek using 24 x 24.3mm SAWL carbon API 5LX65 steelpipethatwaslinedwith4mmthick316LUNSS31603linerpipe(Table1).Thematerials used(CSSAWLpipeand12m316Lsheet)werenotmanufacturedwithpropertiesandfinish optimised for CRA lined pipe but were standard materials sourced from stockists. The test pipesweremanufacturedinlinewithDNVOSF101[1]usingcontrolledhydraulicexpansion.
TestPipe CSpipeOD(nominal) CSpipeWT(nominal) CSmaterialgrade CRAthickness(nominal) CRAmaterialgrade Requirement NPS24(609.6mm) 24.3mm API5LX65SAWL 4.0mm 316L(UNSS31603)

Table1:TestPipeMaterials

ThemechanicalpropertiesofthematerialsareshowninTable2.
MaterialProperty CarbonSteelPipe(BaseMetalTransverse) YieldStrengthRt0.5 TensileStrengthRm Elongation CarbonSteelPipe(CrossWeldSeam) TensileStrengthRm CRALiner(BaseMetalTransverse) YieldStrengthRt0.5 TensileStrengthRm Elongation CRALiner(CrossWeldSeam) TensileStrengthRm SampleTestResult 520MPa 620MPa 45% 668MPa 319MPa 640MPa 55% 629MPa

Table2:TestPipeMechanicalProperties

The pipe ends were sealed using 75mm of 309LMo weld overlay cladding with the inside diametermachined(tolerance0.5mm)aftercladding.HotwireGTAW(TIG)wasspecifiedfor theweldoverlaycladdingasthisprocessproducesanoverlayweldwithanarrowfusionline, minimalpenetrationoftheCSbase,reducedirondilution,fewerlackoffusiondefectsandthe reducedheatinputresultsinlowerresidualstressandreducedthermaldistortion.

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling
The test pipe assembly (Figure 1) included two pipeline girth welds, 2m apart, in the middle 3.5m pipe section that was subject to constant bending moment. The girth welds were made withInconel625usingaqualifiedGTAW(TIG)buttweldprocedure.TheCSseamweldinthe 2mpipesectionbetweenthegirthweldswaslocatedatthe180position(bottom),whilethe CSweldsintheadjacentlinedpipesectionswereoffsetfromthis(at135and225).Alloysteel loadpinswereweldedtotheoutsideofthetestpipealongthebendneutralaxis. Testing was performed at Cladteks dedicated test facility in Batam using a 4point bend test rig,equippedwith4x100tonnetwowayverticalhydraulicactuators,abletobendfullscale 1112m long test pipes using programmable controlled displacement loading (Figure 2). The rig was configured to have the central 3.5m pipe section under constant bending moment. Althoughtherigwasfittedwithhorizontalactuatorsabletoexertupto250tonnesloadateach end, to apply axial tension or compression loading during bending, the application of end loadingduringinstallationandservicebendtestingwasexcludedbythespecification. Heatingwasachievedusingelectricceramicpadheatersstrappedtotheexternaldiameterand compressedairwasusedasthepressurisingmedium(withappropriatesafeguards). Instrumentationusedtomonitorthebendtestingincluded:12straingaugesmountedonthe external surfaces at 0 and at 180 positions to measure local axial strain; 5 displacement transducers to measure the deflection of the pipe and calculate global bending strain, 1 dial typepressuregauge,1electronicpressuretransducer,4thermocouplesand2networkedHD digital video cameras with light sources. The cameras were fixed inside the pipe, one either end, to view the central 3.5m section during bending. On account of the low angle back lightingeffect,thecameraswereabletodetectverysmalllinerdeformations.Theoutputfrom theinstrumentationwascapturedbyadataacquisitionsystemandrecordeddigitally.

3.TestParametersandResults
Representative test parameters were developed taking due account of design conditions and limits appropriate for a subsea flowline of size NPS 24 operating at high temperatures and thereforebeingsusceptibletolateralbuckling.Thereferencestandardusedasthebasisofthe pipelinedesignwasDNVOSF101SubmarinePipelineSystems[1].
TestParameter PipelineCoating InstallationSimulation(Slay): Temperature Pressure AxialStrain PipelineSystemTestPressure HPHTFlowlineSimulation: Temperature Pressure AxialStrain StartUp/ShutDownSimulation: Temperature Pressure Strain TestRequirement 240250C Ambient Ambient 0.25%,0.30%,0.35%,0.40% 320barg 110C 20,15,10,5,0barg 0.40%,0.50%,0.60% 110C 10barg 500cycles0.2%to0.5%

Table3:SummaryofTestParameters

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

3.1CoatingSimulation
The application of anticorrosion pipeline coating is known to cause the gripping force to decreasesubstantiallyfromtheoriginalgrippingforcemeasuredinthepipemill. The extent of the reduction is illustrated by Figure 4, which compares the exmill average gripping force for two different expansion pressures (lower bound and mid range) with the averagegrippingforcemeasuredaftercoatingsimulation.Theaveragelinergrippingforcehas dropped from 260kN to 7kN after coating simulation. This is a known effect due to the CRA liner having a larger coefficient of thermal expansion than the backing steel. The thermal expansioncoefficientfor316LandCSare16.5x106mm/mm/Cand13.0x106mm/mm/C respectively. Increasing the temperature increases the grip force until the point is reached whentheCRAlinerundergoescompressiveyielding,atwhichpointthegripforceisreduced. The temperature used during pipeline coating (240250C) is sufficient to cause compressive yieldingofthelinerwiththeresultthatthegripforceissubstantiallyreducedaftercoating. CladtekperformedthecoatingsimulationbyfeedingtheNPS24linedpipethroughan800kW inductionfurnacewithwaterquench.Therewasnodataavailablefromcoatersfortheinternal temperatureduringcoatingsotheinductionfurnacewasconservativelyconfiguredtoheatthe inner CRA liner surface to 240250C. Figure 5 shows the timetemperature profile achieved, measuredusingthermocouplesattachedtointernalCRAandexternalCSsurfaces.

3.2PostCoatingHydrostaticPressureTest
Liner gripping force can restored (at least partially) by performing a pressure test after pipelinecoating.Thepressuretesthastocausethelinertoyieldandincreasethelinercontact pressure.Howeverifthetestpressureislowerthantheoriginalexpansionliningpressure,the restoredlevelofgripwillbelowerthantheoriginallevelofgrip(Figure4). Thereisacaseforperforminghydrostaticpressuretestafterpipelinecoating,particularlyfor largediameterCRAlinedpipes,toensurethegrippingforceisoptimisedpriortoinstallation. Forthetestprogramme,apostcoatinghydrotestat320bargwasperformedononepipe.

3.3InstallationBendTesting
The test pipe was subjected to the following bending cycles in order to replicate the strain experienced by the pipe during Slay pipeline installation. The testing is conservative as the strains specified are in excess of the maximum allowable installation strain, which would be limited to 0.250% per DNV OSF101 guidelines for grade X65 steel pipe without concrete weightcoating(thisfigureisbasedonDNVOSF101SimplifiedCriteria,Overbend,CriterionI, staticloadingandincludestheeffectsofbending,axialforceandlocalrollerloads). Bendtestingwasperformedatambientconditions(i.e.noheating,nointernaloverpressure). 3cyclesbetween+0.25%and0.25%strain 3cyclesbetween+0.30%and0.30%strain 3cyclesbetween+0.35%and0.35%strain 3cyclesbetween+0.40%and0.40%strain A few minor ripplelike features with height less than 1mm did appear at 0.4% strain in the area above the CS seam weld at the 180 position but they subsequently flattened and then disappearedwhentheaxialbendloadingwaschangedfromcompressiontotension.
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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling
Thetestpipewasinspectedoncompletionoftheinstallationbendtesting.Nolinerwrinklesor buckleswereapparentinthepipeaftercompletionofinstallationbendtestingat+/0.4%.

3.4PipelineSystemPressureTest
Forthereasonsoutlinedearlierinthediscussiononpostcoatinghydrostaticpressuretesting, if the liner gripping force has been reduced by coating, or if pipeline installation has caused someminorseparationbetweentheCRAlinerandbackingsteel,thepipelinesystempressure testwillincreasethelinercontactpressureandrestoregrippingforceintheCRAlinedpipe. Postinstallationfieldhydrotesthasnotbeenincludedinpreviousbendtestprogrammes,even thoughitisnecessarytoperformbeforethepipelinecanbeputintoservice.Accordinglythe pipelinesystempressuretestwasreplicatedinthistestprogramme. Forthetestprogramme,atestpressureof320bargwasspecified.Thisismarginallybelowthe calculatedsystemtestpressurebasedonDNVOSF101(350barg).

3.5OperatingCondition:BendTesting
Aftercompletingtheinstallationbendingandthepipelinesystempressuretest,thetestpipes were subjected to bending that replicated the pipeline design maximum strain. The test pipe was heated to 110C and internal pressure was introduced. The initial pressure was 20 barg butthiswasprogressivelyreducedin5barincrementsdownto0barg(ambientpressure)to testthesensitivityofthelinedpipetointernalpressure. Foreachdifferentinternalpressure,thetestpipewassubjectedto: 1cyclebetween0%(straight)and0.40%strainat110Cand[020]barg 1cyclebetween0%(straight)and0.50%strainat110Cand[020]barg 1cyclebetween0%(straight)and0.60%strainat110Cand[020]barg Figure7illustratesthecyclesofstrainandinternalpressureintheordertheywereapplied. Thelinerdidnotcollapseanddidnotformanyripplesorwrinklesduringthedecompression stageswhenthepressurewassuddenlydroppedwiththepipeheldatmaximumstrain. The service condition strain bend tests were satisfactorily performed and completed with no linerwrinklesorbuckles,evenat0.60%strainwithzerooverpressure(ambientpressure).

3.6OperatingCondition:LimitStateA(20bargPressure)
Theinservicebendtestingwasextendedtoincludehigherstrainsinordertoexplorethelimit statestrainforlinerwrinklingattheoperatingconditionservice. One test pipe was repressurised to 20 barg and while still at 110C, was strained to 0.73% and then 0.80%. Figure 8 is a still that shows this pipe without wrinkling when the axial compressivestrainwas0.80%,temperaturewas110Candinternalpressurewas20barg. As Figure 8 shows, there were no signs of any ripples or wrinkles in the liner at an axial compressivestrainof0.80%at110Cwith20bargoverpressure.

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling
Asthistestpipewasshowingnosignsofwrinkleinitiationwith20barginternalpressure,the bendtestingwasstoppedtopreservethetestpipeforothertests. Thisresultwasnotunexpected.Previousbendtestprogrammes,performedusingNPS12and NPS20linedpipes,havedemonstratedthatthepresenceofarelativelylowinternalpressure (6 bar) can be sufficient to prevent liner wrinkling. In the case of the pipes mentioned, there wasnolinerwrinklingatstrainsintheorderof1.9%,thephysicallimitofthetestequipment. This particular test programme with NPS 24 lined pipe specified that the internal pressure shouldbe20bargasthispressurewastheminimumdesignpressure.Theresultsconfirmthat nowrinklingoccursunderhighaxialcompressivestrainattheminimumdesignpressure. Theresultsverifiedthat20barginternalpressurewassufficienttodelaytheonsetofanyliner wrinkling. The testing was stopped at 0.8% strain but, in light of previous test results, the expectedlimitstatewith20barginternalpressurewouldbefargreaterthanthis. Neverthelessthetestresultexceedsthespecifieddesignrequirements

3.7OperatingCondition:LimitStateB(ZERObargPressure)
Usingthesametestpipeasabove,theinternalpressurewasreducedtoambient(0barg)and thebendingstrainprogressivelyincreaseduntillinerwrinklingwasobserved.Thistestingwas notrequiredby,butwasperformedinadditionto,thespecifiedtestprogramme. Thetestpipewasstrainedto0.75%,0.80%,0.90%andfinally1.0%with0bargpressure Linerwrinklingwasclearlyvisibleat1.0%strainalthoughtheonsetofwrinklingwasjudged to occur at about 0.83% strain with 0 barg pressure. Figure 9 is a still frame that shows wrinklinginthelineratanaxialcompressivestrainof1.0%at110Cand0bargpressure. After straining to 1.0%, the test pipe was removed and the wrinkles examined further. The wrinkleheightwasfoundtovarybetween0.5mmand1.0mm,withaseparationorspacingof about100mmbetweenadjacentwrinkles.Therewerenoindicationsofsurfacedefects. ThelinerwrinklinghadinitiatedinthelinerabovetheCSseamweld,whichisconsistentwith expectationsgiventhattheCSseamweldpresentsageometricalimperfection. Thesewrinklesweresmoothinprofile,relativelysmallandlowinheight.Astheywere,itisnot cleartherewouldhavebeenanyimpactonflowassuranceorpiggingperformanceinservice. Therealsoremainsthepossibilitythatifthepipewasrepressurised,tothepressureexpected innormalflowlineservice,thenthesewrinkleswouldflattenanddisappear.Howeverforthe purposeoftesting,theonsetofwrinklingwasdeterminedtobe0.83%at0bargpressure.

3.8OperatingCondition:StartUp/ShutDown
OverthelifeofanHPHTpipelinesystem,theinstalledflowlinewillexperienceperiodiccycles ofstartupandshutdownandthesewillimposecyclicstresses(highstrain,lowcyclefatigue) onthepipelineasitissubjectedtochangesinpressureandtemperature. Inordertosimulatestartupandshutdowncyclicconditions,onetestpipewassubjectedtoan additional500straincyclesasnotedbelow(aftercompletingthebendtestingoutlinedabove) overaperiodofabout24hours,duringwhichthetestpipewascontinuouslymonitored.
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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling
500cyclesbetween0.2%and0.5%strainat110Cand10barg Oncompletionofthe500cyclesbetween0.2%and0.5%strain,thetestpipewasexamined (visuallyandwithsurfaceNDE)forfatiguedefects.Particularattentionwasgiventotheliner tooverlayinterfacebutnodefectswerefoundinthelinerorattheinterface.Alsotherewere nolinerwrinklesorbucklesvisibleafterthe500cyclesofstartup/shutdownstrain.

4.Discussion
Liner wrinkling or buckling can occur under conditions of high axial compressive strain becausethelinerisonlymechanicallybondedtothecarbonsteelouterpipe. Theacceptedmechanismfortheformationofalinerwrinkleorbuckleis: 1) The contact pressure between the liner and pipe in the bending compression region reducestowardszeroasthebendingstrainisincreased.Thisiscausedbytheovalising effects of the bending on the liner and the yielding of the liner material. When the contactpressurereacheszero,athingapisopenedbetweenthelinerandthepipe 2) Small scale rippling can then be initiated, which leads to a localised variation in the longitudinalstressandstrain. 3) Thesmallscaleripplesgrowinsizeasthebendingstrainincreases. 4) Asthestrainsincreasefurther,oneormorerippleswillgrowandbecomelargerthan the rest. Several smaller wrinkles may coalesce and plastically localise to form fewer butlargerpermanentwrinklesorbuckles. Wrinkleformationisthereforesensitivetointernalpressureastheinternalpressureinhibits linerripplingandwrinkleinitiationbymaintainingacontactorinterfacepressurebetweenthe liner and the backing steel. These test results confirm this: the presence of 20 barg internal pressurewasenoughtosuppresslinerwrinkling. Wrinkleinitiationissensitivetothepresenceofmaterialandgeometricimperfections.Inthe case of SAWL outer pipe, the internal weld reinforcement resulting from the longitudinal carbonsteelseamweldisapotentiallysignificantgeometricimperfection.Thiswasconfirmed by the testing as, where liner wrinkling did occur, the wrinkling initiated in areas where the linerwasfittedoverthecarbonsteellongitudinalseamweld. DNVhasestablishedasetofdesignguidelinesthatincludeastraincriterionforCRAlinedpipe basedontheonsetoflinerwrinkling.ThisworkispartoftheDNVJointIndustryProjectLined andCladPipelineMaterials[2],Thecriterionfortheonsetoflinerwrinklingisintheformof anequation,whichisbasedonasetoftestresults. Forthepipesusedinthistestprogramme,NPS24x24.3+4mmlinedpipe,thecalculatedlimit statefortheonsetofwrinklingusingtheDNVformulawouldbe0.61%strain. Under the service conditions used for this test programme, liner wrinkling was observed at levels of strain that were much higher than predicted by the DNV formula. For NPS 24 lined pipe at 110C with ZERO overpressure, liner wrinkling appeared to initiate at about 0.83% straincomparedtotheDNVpredicted0.61%strain(Table4).

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling
ONSETOFLINERWRINKLING NPS24x24.3+4mmX65/316LLINEDPIPE ServiceCondition:Temperature110CandPressure020Barg Strainlimit(DNV DesignGuidelines) 0.61% WrinklingStrain (ZERObargpressure) 0.83% Table4:BendTestResults Wrinklingstrain (20bargpressure) (NoWrinkling)

The DNV limit state strain criterion for the onset of liner wrinkling appears to be relatively conservativewhencomparedtothetestresultachievedwith0barginternalpressure. Pipeline system pressure testing (which ensures adequate gripping force is restored after coatingandinstallation)andelevatedservicetemperature(whichincreasesthegrippingforce) arenotconsideredbytheDNVformulaandthesemayhavecontributedtotheresultachieved. NeverthelessthetestresultforNPS24linedpipeexceedstheDNVdesigncriterion.

5.Conclusions
The installation bend testing verified that NPS 24 lined pipe is suitable for installationbyoffshorelaybarge.Therewerenopermanentwrinklesorbucklesin the liner after testing at strains of up to +/0.40%. The strain used for the testing exceedstheDNVOSF101guidelines,whichlimitthemaximumstrainto0.25%. The operating condition bend testing verified that NPS 24 lined pipe meets the specified pipeline design parameters. There were no wrinkles or buckles in the lineraftertestingatgreaterthan0.60%strainat110Cwithorwithoutpressure. Therewerenolinerwrinkles,orlinertooverlayinterfacedefects,after500cycles ofstrainbetween0.2%and0.5%at110Cwith10bargpressure.Thismeetsthe pipelinedesigncriteriaforstartupandshutdownconditions. The results obtained during the secondary operating condition testing exceed the DNVstraincriterion.Wrinkleinitiationwasjudgedtooccurat0.83%strain,which exceeds the DNV predicted onset criterion of 0.61% strain. The DNV design criterioncanbeconsideredconservativecomparedtothetestresult. NPS 24 x 24.3+4mm X65/316L lined pipe meets (or exceeds) the pipeline design criteriaand,onthatbasis,NPS24CRAlinedpipeisconsideredsuitableforusein hightemperatureflowlinesthatwillbepronetolateralbucklingduringservice. Gripping force trials demonstrated that performing hydrostatic pressure testing afterpipelinecoatingisaneffectivewaytorestoresomelinergrippingforce. Grippingforcetrialsverifiedthattheheatingprocessusedduringpipelinecoating cancauseasignificantandsubstantialreductioninthelinergrippingforce.

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

6.References
[1]DNVOSF101October2010SubmarinePipelineSystems [2]DNVTechnicalReport20070220rev2JIPLinedandCladPipelineMaterials:Guidelines forDesignandConstructionofCladandLinedPipelines

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

FIGURE1:DrawingofNPS24CRALinedTestPipeConfiguration

FIGURE2:DiagramIllustratingTestRigin4PointBendTestConfiguration
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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

FIGURE3:PhotographofTestPipeonTestRigwithHeatingandInstrumentation

FIGURE4ChartshowingVariationofGrippingForcewithPipeCondition

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

FIGURE5SimulationofCoatingThermalCycle(TemperaturevTime)

FIGURE6NPS24LinedPipeNoWrinklesafter+/0.4%Strain(Ambient)

FIGURE7:OperatingConditionBendTestingAppliedStrainvsInternalPressure

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TheSuitabilityofCRALinedPipesforFlowlinesSusceptibletoLateralBuckling

FIGURE8:NPS24LinedPipeNowrinklesat0.80%strain,110Cand20barg

FIGURE9:NPS24LinedPipeWrinklesat1.0%strain110CwithZEROoverpressure

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