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Challenges About Testing, Welding and NDT of CRA Pipelines in Brazilian Pre-
Salt

Conference Paper · July 2012

DOI: 10.1115/OMAE2012-83461

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 Proceedings of the 31st International Conference on Ocean, Offshore and Arctic
OMAE12
July 10-15, 2012, Rio de Janeiro, Brazil

OMAE2012-83461

CHALLENGES ABOUT TESTING, WELDING AND NDT OF CRA PIPELINES IN

BRAZILIAN PRE-SALT

Petrônio Zumpano Júnior Genaro Zanon

PETROBRAS/ENGINEERING PETROBRAS/ ENGINEERING
São José dos Campos, SP, Brazil São José dos Campos, SP, Brazil

Alexandre Galiani Garmbis Luciano Braga Alkmin Manfred Ronald Richter

PETROBRAS/ ENGINEERING PETROBRAS/ ENGINEERING PETROBRAS/ ENGINEERING
São José dos Campos, SP, São José dos Campos, SP, São José dos Campos, SP,
Brazil Brazil Brazil

Eduardo Valente Oazen Paulo Nunez Chaves Eduardo Hippert Júnior

PETROBRAS/E&P PETROBRAS/E&P PETROBRAS/CENPES
Macaé, RJ, Brazil Macaé, RJ, Brazil Rio de Janeiro, RJ, Brazil

ABSTRACT
Some new pre-salt fields at Santos Basin in Brazil are
located in water depths as deep as 2200m and about 300 km
away from the coast. There is variable level of contaminants in
the produced fluid, mainly CO2, that affects the material
selection of the infield flowlines and risers. Based on these
constraints, Petrobras has selected UNS N06625 clad or lined
steel linepipes to develop the first fields in Pre-Salt area and
also the module 3 of Roncador a post-salt field in Campos
Basin. Several challenges have arisen during design,
construction and installation of these facilities related to
pipeline welding procedures, NDT inspection and Engineering
Critical Assessment (ECA). Firstly weld overmatching
condition may not be fully achieved due to differences in
mechanical properties between UNS 06625 and API X65, and
concern increases when reel-lay installation method is chosen.
Another welding issue is the maximum interpass temperature of
nickel alloys (which DNV and PETROBRAS standards limit in
100ºC) and this impacts pipeline installation productivity.
Thirdly, back purging characteristics and number of passes
protected with purging gases affects the possibility of root
oxidation. Also, the inspection of the weld overlay in the pipe
end of lined linepipes is other point of great concern. As defect
sizing is mandatory for ECA, lined pipes have been designed
with a weld overlay length which allows the inspection of the
final girth weld by AUT. However, AUT solutions are normally
more efficient in laminated & extruded materials than in weld
overlaid ones. Additionally, the ECA methodology for both girth
welds and weld overlay has complexities that are not usually
addressed in a regular ECA for carbon steel pipelines (e.g.
internal misalignment of girth welds in risers has stringent
requirements because of its effects on fatigue performance and,
consequently, the ECA girth weld criteria). Also CRA clad/lined
pipelines and risers qualification program may include additional
testing when compared with usual carbon steel welding
qualification process (namely pitting and intergranular corrosion;
full scale fatigue; spooling trials of lined linepipes; segment
testing for ECA and others). Finally, the contribution of clad/lined
layer in pipeline design strength is also discussed. This work
presents challenges PETROBRAS has faced at design and
construction phases of on-going Guará and Lula-NE pre-salt
fields and Roncador Field Projects, as well as the solutions
proposed by the project team in order to overcome the issues
raised during project execution.
INTRODUCTION
So called “Brazilian pre-salt” is the offshore area close to the
Brazilian coast where hydrocarbon reservoirs exist below a
geological salt layer. PETROBRAS has given enough data to

1 Copyright © 2012 by ASME

Brazilian Federal Government and the Brazilian Petroleum
Regulatory Agency (ANP) that demonstrated the economic
potential of these areas. Since then, new challenges to exploit
oil and gas in these fields have been identified and strategy was
established to address them.
Linepipe material selection for both infield flowlines and
risers has raised a comprehensive discussion within
PETROBRAS. Indeed, due to the water depths (about 2200m)
and a variable level of contaminants in the produced fluid
(mainly CO2) a unique and definitive solution for the pre-salt
exploitation is hard to achieve and is still under development.
For Guará and Lula-NE pilots PETROBRAS has decided
to develop these areas by using rigid risers and flowlines. A
carbon steel production riser would not withstand the produced
fluid corrosivity, and their life would be diminished by the
general internal corrosion and corrosion fatigue. In this context,
corrosion resistant alloy UNS N06625 (alloy 625) clad or lined
carbon steel linepipe have been selected as the regular solution
for infield risers and flowlines in these pilot fields.
Once CRA material was considered, additional material
challenges should be considered regarding welding, NDT and
structural integrity issues. This paper discusses few points
about these issues.
NOMENCLATURE
AUT - Automatic Ultrasonic Testing
BSR - Riser Supporting Buoy
CRA – Corrosion Resistant Alloy
ECA – Engineering Critical Assessment
FCC – Face Centered Cubic
FEED - Front-end Engineering and Design
FPSO - Floating Production Storage and Offloading
GMAW – Gas Metal Arc Welding
GTAW – Gas Tungsten Arc Welding
HAZ – Heat Affected Zone
JIP- Joint Industry Project
NDT – Non Destructive Testing
PoD – Probability of Detection
PLET – Pipeline End Termination
SCF – Stress Concentration Factor
SCR – Steel Catenary Riser
SMYS – Specified Minimum Yield Strength
TDZ – Touch Down Zone
FIRST BRAZILIAN FLOWLINES AND RISERS WITH
UNS N06625 CLAD AND LINED LINEPIPES
Roncador Field is located in the northern area of the Post-
Salt in the Campos Basin, in a water depth ranging from 1300
m to 1900 m. Exploitation strategy of these resources was split
in 4 Modules – the P-55 Project corresponds to the
development of Module 3. P-55 subsea production system
comprises 11 production and 7 water injection wells in addition
to 4 spare (2 producers and 2 injectors) wells, connected to a
semi-submersible platform [1]. As risers’ top and TDZ sections
are the most critical areas in view of cyclic loading, extreme loads
and corrosion-fatigue during their operational life, these were
chosen to be fabricated with sections of alloy 625. This is the
first experience in Brazil to adopt alloy 625 in bimetallic pipes
for subsea application. SAIPEM is the installation contractor
for this challenge, and Figure 1 sketches the clad sections in
production risers of P-55 project [2].
Fig. 1: P-55 Project - General sketch of the production and
water injection SCR [2].
Guará and Lula-NE pilot projects consist of the
development of two pre-salt modules, in 2200 m water depth.
Each area will be developed with its own FPSO with uncoupled
risers design approach by using BSR buoys. The SCRs, flexible
service lines and umbilical risers will be supported in single
catenary configuration from the seabed to the BSR. Flexible
jumpers will connect the BSRs to the FPSO and flexible
flowlines will connect the SCR PLETs up to the well heads.
Figure 2 shows a sketch of the BSR components. The BSR
concept reduces the criticality of the cyclic stresses applied on
SCRs.
As P-55 project has been a pioneer experience with clad
material in Brazil, also Guará and Lula-NE consist of a
particular challenge in terms of linepipe material experience.
Guará and Lula-NE production and water injection risers will
be fabricated from metallurgically clad and lined pipe
installed by reeling.
These projects comprise 27 SCRs, being the risers’ critical
and non-critical sections built with alloy 625 clad and lined
linepipes, respectively. This is the first time that projects have
demanded such amount of alloy 625 clad and lined linepipe
material. This demand will be supplied by H. Butting GmbH &
Co from Germany and it represents huge volume of bimetallic
material to be fabricated in a heated market. In this context,
lined linepipes will be adopted in the non critical sections since
2 Copyright © 2012 by ASME
the lined linepipe is cheaper and the production is normally
faster than clad material. Clad linepipes will be only utilized in
risers´ critical sections. Subsea 7 is the contractor for both
Guará and Lula-NE projects and installation is expected to be
carried out in the first half of 2013.
Fig.2: Sketch with Guará and Lula-NE BSR system
components [3].
In the Guará and Lula-NE projects FEED phase, Subsea 7
has executed some pre-qualification tests in order to
demonstrate the feasibility of the lined linepipes utilization in
risers installed by reel-lay. As the main concern was the
wrinkling during reeling, Subsea 7 has proposed to pressurize
the risers system during spooling in order to allow the
utilization of reel-lay method. Full-scale pre-qualification
bending test (with internal pressurization) results showed that
the utilization of reel-lay method in lined linepipe sections were
possible. Full scale fatigue tests of lined linepipe girth welds
were also executed. The results indicates that lined linepipes
could be adopted at the non critical sections of those risers
Next sections describe the main issues referring to welding,
NDT and integrity of the clad and lined material sections.
NDT ISSUES
Due to the presence of two different materials and the
consequent differences in sonic energy propagation in both, it
would normally be expected to be a challenge to ultrasonically
inspect a bimetallic linepipe material. One would expect that
inspection in lined linepipe would be also more complicate, or
even unfeasible, since the ultrasonic beam could not be
transmitted through the interface between both materials.
Figure 3 presents a picture of the alloy 625 clad linepipe of P-
55 Project.
In fact, ultrasonic inspection in bimetallic linepipe is
naturally more complicated than in carbon steel linepipe. But
the metallurgical bond between clad and carbon steel within the
sandwich plate turns the ultrasonic inspection of clad linepipe
girth welds into an easier path. Since the interface of both
materials is flat in the clad linepipe, no great concern appears.
Fig.3: Sample of P-55 DNV MWP 450 SFD C UNS N06625
clad linepipe sample.
Inspection matters in clad sections actually begin in the
transition pieces between clad linepipes and regular carbon
steel linepipes. For P-55 Project, a transition joint has been
designed comprising a weld overlay in the end of the carbon
steel linepipe at one side of the joint and a clad linepipe in the
other side, both girth welded by means of nickel alloy weld
metal. The interface between the weld overlay and the carbon
steel is very irregular. Indeed, the effect of these interface on the
ultrasonic beam is of great concern for the ultrasonic inspection
in the girth weld of this transition pieces. Normally, geometric
solutions for ultrasonic inspection pass through the avoidance
of this interface.
Lined linepipes section have issues similar to the
transition joint of clad sections regarding girth weld inspection.
A seal welded linepipe would make it impossible to inspect the
girth welds by means of AUT. Also, in case of need to cut the
girth weld due to the presence of defects, the lined linepipe
sealing would be in risk. Due to those reasons, Guará and Lula-
NE design have adopted a minimum length of weld overlay in
the lined linepipe ends (50mm). Thus, here again, AUT design
should geometrically avoid the interface between the lined
linepipe weld overlay and the back steel.
Other NDT concern relates to the pipe end inspection by
the pipe supplier. As will be discussed further, Petrobras design
has required an ECA on the lined linepipe end. So far, AUT in
the weld overlay at the lined linepipe end and at the interface
between the liner extremity and the weld overlay is under
development. At moment, authors have not found any
evidences of any AUT configuration that has been approved
for all the requirements of appendix E of DNV OS-F101 [4]
and also provided a good probability of detection (PoD) for the
inspection of the weld overlay lined linepipe end. For this
reason, Guará and Lula-NE project supplier and installator are
adopting X-Ray inspection instead, and repairing any detected
discontinuity at this area, which is considered a conservative
approach. A demonstration of detectability of the X-Ray
3 Copyright © 2012 by ASME
inspection at the lined linepipe end has been carried out by
supplier with Petrobras’ follow up by making seeded defects in
this area, inspecting them with X-Ray and making comparisons
with macrographic examination (similar to AUT “salami test”).
Petrobras has now confidence that the employed NDT
technique assures that at least a discontinuity 1 mm high and 20
mm long will be easily detectable. It is difficult to make a
comparison with DNV required PoD (90:95) for AUT [4], but
it may be appropriate that such discontinuity size can be the
maximum ECA output size. Petrobras still expects that AUT
developments, especially with the phased array technique, will
make the ultrasonic inspection of the weld overlay feasible.
Recent developments in NDT area, like computerized X-ray
tomography with 3D discontinuity analysis, seem to promise
good results in the future for the bimetallic material inspection.
But such solutions are not ready so far for the application in the
offshore industry.
WELDING ISSUES
DNV OS-F101 [4] clearly requires weld metal
overmatching to ensure resistance against failure of the weld
metal during the transverse weld tensile tests. It should be
noted that this requirement refers to the ultimate tensile
strength of weld metal, HAZ and parent pipe. Regarding the
yield strength, this standard recommends the weld metal
properties to be at least 80 MPa above the linepipe SMYS in
case of S-Lay or J-Lay installation method. The
recommendation increases to at least 120 MPa in case of Reel-
Lay installation method. For Guará and Lula-NE fields and
Roncador field (P-55) projects the required clad and lined steel
pipe has been DNV SMLS/MWP 450 [4]. This is equivalent to
API 5L grade X65 linepipe material [5]. On the other hand,
internal corrosion protection by alloy 625 clad or lined linepipe
has been required in some flowline and riser sections, as
previously mentioned. Since a single side welded joint is
normally adopted in offshore industry, due to the flowline or
riser characteristics, weld metal filling is normally completely
done with alloy 625 weld metal, or otherwise the joint would
not be weldable, since dilution of nickel alloy cladding in
ferritic filler metal could cause weld cracking. When
comparing the yield strength properties of most of the suitable
welding consumables with DNV SMLS/MWP 450 [4] linepipe,
the linepipe upper yield strength limit (570 MPa) will not be
overmatched by the weld metal. This fact has also been
approached by recent multi-client sponsored project carried out
by DNV, where the concept of “partial overmatching” has been
described [6]. Although the full overmatching condition is not
achievable, since alloy 625 weld metal yield strength is
normally lower than a linepipe material equivalent to API 5L
grade X65, it is possible for the alloy 625 weld filler metal
stress-strain curve to cross DNV SMLS/MWP 450 stress-strain
curve before the tensile strength of the parent material is
reached and before 5% strain. On the other hand, welding
consumable properties varies with welding process, brand and
even batch. For J-Lay and S-Lay installation methods, and due
to alloy 625 stress-strain curve behavior, it is expected that
DNV’s recommendation of a welding consumable with 80 MPa
above linepipe SMYS could be reasonably relaxed for 50 or 60
MPa above DNV grade 450 linepipe SMYS. This corresponds
to 500 MPa as the minimum filler metal yield strength and this
value has been adopted within Petrobras for future projects in
the pre-salt fields, since it is feasible to find such consumables
commercially available. For reeling installation method this
approach is not applicable, and concerns are greater since gross
plastic deformations occur during installation. This will be better
discussed in the next section.
Preheating of nickel alloys is not required and it should
even be avoided. When applied, preheat is done just to remove
moisture in the parent material. Other welding concerns include
the maximum allowed interpass temperature for the nickel alloy
weld metal. DNV and Petrobras standards limit the maximum
interpass temperature in 100ºC when welding nickel alloys. But
it should be recognized that 100ºC as maximum interpass
temperature is too low since this negatively impacts the
installation productivity. API-RP582 [7], recommends
maximum interpass temperature between 150ºC and 175ºC
when welding nickel alloy. Specifically for alloy 625 this
standard recommends 175ºC as maximum interpass
temperature. For weld overlay one could assume that those
limits above are not applicable, and in fact most of the offshore
industry welding procedures utilize maximum interpass
temperature well above the mentioned values. It is usually
argued that it should be expected for the weld overlays to comply
with corrosion resistance requirements only and that the
properties of the steel pipe would not be affected by higher
interpass temperatures. The restrictions regarding maximum
interpass temperature in a welding procedure refers to alloy
625 and not to the back steel. The degradation of these nickel
alloys is also not sufficient to affect the corrosion resistance in
most environments [8]. Even a stabilized alloy 625, when held at
intermediate temperatures long time enough may suffer
degradation. The atomic structure of Ni-Cr-Mo alloys is
predominantly face-centered cubic (FCC). In this respect, they
are similar to austenitic stainless steel. Like them, alloy 625 are
not completely stable, and thus they are susceptible to second
phases formation when exposed to temperatures in the range
between 650ºC and 1100ºC [9]. In this aspect, the maximum
interpass temperature control is beneficial. Additionally, if the
maximum interpass temperature is controlled in the welding
procedure it will reduce probable grain growth in the parent
pipe HAZ and the risk of surface oxides on welds, as well.
Finally, these oxides may be retained in the weld pool, leading
to inclusion formation.
Referring to the contribution of CRA layer for the flowline
or riser strength design, this is normally not taken into account.
But if this is the case, and DNV OS-F101 [4] predicts this
design hypothesis, care should be taken with the degradation of
the CRA layer mechanical properties.
Back purging is required in the first weld beads to avoid
oxidation in the internal surface. Normally, at least 6 mm of
4 Copyright © 2012 by ASME
welded beads are necessary before removing the back purging.
Gases with improved purity are normally adopted for alloy 625,
and DNV OS-F101 [4] requires a maximum of 1000 PPM of
oxygen, and the presence of a gas analyzer to control that.
Formations of surface oxides on underlying weld beads should
be removed or cleaned since they may be added to weld pool
inclusions. Additional precautions shall also be taken for
cleaning and preparation of the joint to be welded in order to
avoid the presence of contaminants.
The welding procedure qualification of alloy 625 clad and
lined linepipe for flowlines and risers may include additional
tests not required for carbon steel welding procedures.
Regarding the corrosion properties, ASTM G-48 [10] test is
normally adopted to verify the resistance against pitting
corrosion. ASTM G-28 [11] may be required to verify
intergranular corrosion. Finally, since the risers should
withstand severe cyclic loads, fatigue full scale tests are
normally required in technical specifications.
A welding concern when dealing with risers, independent
from the utilization of CRA layers in the linepipe, is the
internal misalignment. Stringent hi-lo requirements are
normally adopted, since this may affect the design fatigue life.
Although fatigue full scale tests should be carried out, hi-lo
requirements between 0.5 and 0.8 mm are usually adopted by
Petrobras. Installator is required to check the internal hi-lo by
means of laser and camera devices after root and hot passes.
Such instruments may be fixed within the internal line up
clamps. Since most of the automatic welding procedures
utilized in the offshore industry are based in close gap “V”
bevel configuration, the hi-lo measurement during the girth
weld fit up is made indirectly, and the gauge tip is in contact Fig.4: Sketch of hi-lo measurement during girth welds fit up.
with the “top” of the root faces r1 and r2, as it may be seem in
Figure 4. Taken into account the stringency of a hi-lo
requirement lower than 0.5 mm, the influence of the root face
manufacture tolerance, and possible change in the internal
misalignment due to the weld shrinkage, the laser or camera hi-
lo measurement is done after the first passes have been
completed.
A good weld root profile is also important for the fatigue
behavior of welding procedures for risers. Thus, although they
give lower productivity than conventional or pulsed GMAW
process, GMAW with controlled short circuit transfer mode is Fig.5: Root profile of different welding process.
normally adopted in the root passes. Petrobras is requiring
automatic welding processes for the girth welds of risers
projects, and this is beneficial for the root profile. Also the
options are restricted to solid wire process, to increase ECA ISSUES
toughness and avoid discontinuities related to slag. Thus, Engineering Critical Assessment (ECA) of risers girth
automatic GTAW, hot wire or not, has been acceptable. It welds are expected to allow more strict defect criteria if
should be noted that copper shoes in the internal line up clamp compared with flowlines girth welds ECA, since the first is
largely used in GMAW roots of submarine pipeline projects more affected by cyclic loading during lifetime. DNV OS-F201
normally do not provide the same fatigue performance of [12] is adopted by Petrobras for risers design. Although this
GMAW with controlled short circuit transfer mode due to their standard refers to DNV OS-F101 [4] for welding the risers’
root profile. At figure 5, the root profile of different welding girth joints, the last one does not include risers in its appendix
processes, including controlled short circuit transfer GMAW A, which contains the ECA rules for flowlines. For carbon steel
and GMAW with copper shoes is compared. risers, Petrobras on the other hand, uses this appendix also as

5 Copyright © 2012 by ASME

 basis for the ECA rules, adding additional requirements for
fatigue, and for corrosion fatigue, as previously mentioned by
Zumpano et al [13].
There is a challenge and concern to carry out an ECA for
clad and lined linepipes, since there is no current guidance
for the ECA in bimetallic material. At moment Petrobras is
sponsoring in conjunction with other Companies phase 3 of
DNV’s JIP “Lined and Clad Pipeline Materials”, and the
guidance of this JIP has been adopted in the current risers’
projects [14]. Exception is made in the root area, where
Petrobras has preferred to carry out an ECA instead specifying
“zero defect” criteria. This decision was related to the argument
that any AUT system has a minimum probability of detection,
and in case the ECA allowable defect size is not detectable
there would not be confidence in the riser integrity during its
design life. The referred phase 3 of the DNV JIP is evaluating
the accuracy of the previously suggested JIP ECA procedure
based on one equivalent stress-strain curve [6].
An important issue at Guará and Lula-NE project, since the
reel-lay process is adopted (large deformation during
installation process), is that DNV OS-F101 requires to carry out
an Engineering Critical Assessment (ECA) on the girth
welds between lined linepipes. Due to that, due to fatigue
concerns and also to the possible existence of defects within the
linepipe weld overlay, Petrobras has also required an ECA on
the lined linepipe end in order to guarantee the risers and
flowlines integrity. On the other hand, the design of Guará and
Lula-NE project, based in BSR concept, is very beneficial to
fatigue life since top sections of the risers are not directly
coupled to the FPSO. As previously discussed in the previous
NDT section, ECA in the lined linepipe end will be based in a
minimum detectable size of a discontinuity by means of X-ray
inspection in the pipe end, in such a way there is enough
confidence to detect this minimum size.
The requirements related to maximum girth welds internal
hi-lo mentioned in the previous section also affect the final
ECA acceptance criteria, as per SCF equation stated in DNV-
OS-F101[4].
The overmatching condition is also a concern for the ECA.
As previously discussed, the assumptions made for J-Lay and
S-Lay should not been acceptable for Reel-lay installation
method. One could realize that for projects adopting linepipes
with nominal diameter equal or lower than 10”, weld metal
stress-strain curves will not cross over the parent pipe stress-
strain curves at the actual installation design strain. In fact, for
Guará and Lula-NE projects, installator has proposed to prove
by finite element analysis two distinct aspects. First, in case of
collapse, necking and rupture will be carried out within the
parent linepipe. Second, in case of conservative difference in
strengths between weld metal and parent material, maximum
allowable discontinuities size is safe in terms of fracture. It is
expected that upper strength linepipes will be utilized within
the segment testing required by DNV for ECA [4] in order to
have confidence in the partial overmatching condition
presented. It has been proposed to fatigue pre-crack the
segment test specimen since the standard notched specimen may
not be conservative if compared to a cracked reeled pipe.
CONCLUSIONS
New Brazilian pre-Salt fields in Santos Basin presented
new challenges in terms of material selection, welding, NDT,
integrity and regarding the respective specified qualification
tests. This paper presented Petrobras experiences in design and
construction of on-going risers projects as well as the solutions
proposed to overcome the issues related to the welding and
non-destructive inspection of risers composed by lined and clad
linepipes.
AUT to detect in the linepipe weld overlay discontinuities
that are orthogonal to pipe surface is still under development,
and it is an important issue as the AUT PoD 90%|95% is
required to be carried out to comply with DNV ECA
philosophy [4].
Alloy 625 has been the chosen CRA material for clad and
lined linepipes. Some issues related to the welding of those
CRA linepipes are oxides formation, limited interpass
temperature and overmatching condition. Some welding issues
related to fatigue performance in risers are the maximum
allowable internal hi-lo and improvements in the root profile.
Petrobras and their contractors are following recent DNV’s
JIP recommendations regarding ECA procedures for bimetallic
materials with additional and modified requirements.
ACKNOWLEDGMENTS
Acknowledges to Engineering Department, E&P and
CENPES from Petrobras for the permission to publish this paper.
Authors would like to thank also the partners BG E&P Brasil
LTDA, Repsol Sinopec Brasil S.A. and Petrogal Brasil for the
permission to publish this paper.
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6 Copyright © 2012 by ASME
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7 Copyright © 2012 by ASME

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