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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
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2011-09-09
3 - Classification: Internal
2011-09-09
Snhvit
Melkya
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
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2011-09-09
Infield pipelines
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6 - Classification: Internal
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7 - Classification: Internal
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
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J-lay principles
Key data:
Diameter: 8 - 30
Welding onboard
Mainly longitudinal welded
pipes
Deformations within elastic
limit of the material
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Reel-lay principles
Diameter: 4 -18
Mainly seamless pipes, (long. welded for clad
and HFW)
Accumulated plastic deformation, 10-20%
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2011-09-09
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
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2011-09-09
Videos
S-lay offshore fabrication S-lay welding
Reel lay site fabrication Spoolbase welding
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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
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2011-09-09
Casting
Casting
Continuous casting
Ingot casting
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2011-09-09
Seamless linepipe
Piercing
Elongation
Reducing/stretching
Cutting to 12-13 m
lengths
Heat treatment
Straightening
NDT
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- 16 -
3mm
2011-09-09
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Feritt + perlitt
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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
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450
500
0.0
550
1700.0
Rm (Mpa)
Rp0,2(Mpa)
HV
Charpy V
A5 (%)
Z (%)
Load
Feritt + perlitt
Tempered martensite/ainite
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Strain
Mild steel
Permanent deformation
No permanent
deformation
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Corrosion
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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.
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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
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2011-09-09
2011-09-09
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
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Potential distribution
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Potential distribution
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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.
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2010-11-07
Insulation
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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
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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)
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Multi-layer Polypropylene
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Impact resistance
Cathodic disbondment
Hardness
Adhesion
Abrasion
Heat transfere test
Ageing test
Shear strength test
Fungal & Bacterial Growth test
UV test
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3. Injection moulded PP
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Content
Welding
Definition of welding
Pipeline Welding Techniques
Welding Procedure qualification
Testing
Documentation, Welding procedure Specifications
None Destructive Examination
Examination methods
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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)
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Shield tasks
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Welding positions
Welding Position
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Test Position
ISO and EN
Flat
1G
PA
Horizontal
2G
PC
3G
PF
3G
PG
Overhead
4G
PE
5G
PF
6G
HL045
6G
JL045
Bevelling
I-bevel
V-bevel
X-bevel
J-bevel
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2011-09-09
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
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ECA
ECA Report
NDE Accept
Criteria
Welding Procedure
Specification
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Fabrication Challenges
Different weld types and location:
o Mainline girth weld
o Tie-in girth weld
o Repair welds
Defect locations:
Fabrication Aspects
Weld indications and defects from typical project pipe
Fabrication Aspects
Weld defect locations from typical project pipe
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2011-09-09
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.
Methods of NDT
Visual
Liquid Penetrant
Magnetic
Ultrasonic
X-ray
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2011-09-09
Visual Inspection
Most basic and common
inspection method.
Tools include fiberscopes,
borescopes, magnifying
glasses and mirrors.
Visual inspection.
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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.
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Film Radiography
Cluster porosity
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Film Radiography
Cracks.
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Film Radiography
Lack of Penetration
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Ultrasonic inspection
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Ultrasonic inspection
Ultrasonic wave forms
Surface wave
Longitudinal wave
Shear wave
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2011-09-09
Ultrasonic inspection
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
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10
plate
Ultrasonic inspection
Scanning
angle beam
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Ultrasonic Inspection
Size Evaluation
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