PRODUCTION OF HELICAL TWO STEP PIPE – USE OF MICROALLOYING

ELEMENTS TO IMPROVE STRENGTH FOR GRADES UP TO X70 WITH

SOUR SERVICE RESISTANCE

Franz Martin Knoop

Salzgitter Mannesmann Grossrohr GmbH
Djordje Mirkovic, Volker Flaxa
Salzgitter Mannesmann Forschung GmbH
 Introduction

Contents
• Introduction
• History
• Development programme
• Manufacturing issues relevant for sour service resistance
• steel production
• hot rolling
• pipe production
• Mechanical and corrosion test results
• Summary and outlook
Dr. Knoop July 2013, London 2.
 Introduction

Salzgitter's
Salzgitter s research and development activities for HSAW-pipe
HSAW pipe
• extending pipe/coil wall thickness up to 25.4 mm for grades X70 and X80
• steel grades with high strength and excellent low temperature toughness
• sour service resistant steel and pipe
• enhancement of collapse resistance for shallow water off-shore applications
• use of FEM for simulation of pipe forming and welding
• reducing residual stresses in pipe and weld seam
• improving the strain capacity of pipes for strain based design requirements
• reduction of geometrical tolerances on steel and pipe

Dr. Knoop July 2013, London 3.

 History

Failures of helical welded pipe

pp

Dr. Knoop July 2013, London 4.

 History

Cooking
g recipe
p for sour service material

Malcolm Gray „Full Scale Testing of Linepipe for Severe H2S

Service“; NACE Canadian Regional Western Conference,
A h
Anchorage, Al
Alaska,
k February
F b 19
19—22.
22 1996

Dr. Knoop July 2013, London 5.

 Development programme

Targeted
g pipe
p p properties
p p R&D and commercial p
projects
j

HIC (base + weld) NACE SSC

Quantity Grade / w th
w.th. OD YS TS CVN DWTT (base+weld)
TM248
Project (% shear
(t) Standard (mm) (mm) (MPa) (MPa) (J/cm2) area) (4 point
CAR CLR CTR CSR bend.)

X60MS ≥ 250; 0°C 85 @ at 80% SMYS

SZ X60 200 14.0 1067 ≥ 420 ≥ 520 ≤5 -
API 5L/ISO3183 (base) -40°C No crack

X65MS ≥ 300; 0°C 85 @ at 80% SMYS

SZ X65 200 14 1
14.1 813 ≥ 450 ≥ 535 ≤5 -
API 5L/ISO3183 (base) -40°C No crack

X70MS ≥ 300; 0°C 85 @ at 80% SMYS

SZ X70 200 16.0 1016 ≥ 485 ≥ 570 ≤5 -
API 5L/ISO3183 ((base)) -40°C No crack

Grade 762
GR241 ≥ 50; not 80% AYS
1000 15 9
15.9 and ≥ 241 ≥ 414 - ≤ 15 ≤5 ≤2
241 CSA_Z245.1-07 0°C required No crack
914

Grade GR448 ≥ 50; 60 @ at not

800 13.7 1372 ≥ 448 ≥ 531 - ≤ 15 ≤5 ≤2
448 CSA Z245.1-07
CSA_Z245.1 07 18 C
-18°C 18 C
-18°C required

(mechanical properties in hoop direction)

Dr. Knoop July 2013, London 6.
 Development programme

Chemical composition
p for R&D and commercial p
projects
j

C Si Mn P S Al Cu + Cr + Ni Mo Nb CEV (IIW) CEV (Pcm)

Project Purpose
wt %
wt.% wt %
wt.% wt % ppmw ppmw wt
wt.% wt.%
% wt.%
wt % wt.%
wt % wt %
wt.% wt %
wt.% wt %
wt.%
SZ X60 R&D 0.035 0.30 1.46 70 5 0.04 0.44 0.07 0.05 0.33 0.14

SZ X65 R&D 0.038 0.28 1.37 80 7 0.04 0.86 0.04 0.05 0.36 0.14

SZ X70 R&D 0.038 0.33 1.33 90 6 0.04 0.84 0.32 0.05 0.43 0.15

Grade
Commercial 0.041 0.23 1.14 95 4 0.04 0.23 0.004 0.02 0.25 0.11
241
Grade
Commercial 0.060 0.32 1.55 150 8 0.04 0.36 0.005 0.05 0.35 0.16
448

Dr. Knoop July 2013, London 7.

 Manufacturing issues relevant for sour service resistance

Production: Metallurgical process up to slab casting

1
1. Blast furnace 2
3
2. Hot-metal mixer 4

p
3. Desulphurization facility
y

4. BOF shop

y metallurgy
5. Secondary gy facilities 5

6. Continuous slab caster

High automatization level including close

integration of steel plant control and supervision system
with technical planning 6

slab thickness: 250 mm

Dr. Knoop July 2013, London 8.

 Manufacturing issues relevant for sour service resistance

Steel plant: quality issues and measures

Desired quality issues Consistently applied Salzgitter’s measures to attain them

Narrow steel composition tolerances Continuous composition control and adjustment

High steel cleanliness Secondary metallurgy and appropriate casting procedure

• lowering non-metal inclusions • gas stirring
ti i + caster
t with
ith vertical
ti l section
ti
( low [O] total)
• Ca – treatment for inclusion shape control
• inclusion shape and size control
• vacuum degassing
• low tramp element steel contents
( especially P and S )
• low H content

High slab centerline quality Soft reduction at continuous slab caster

• avoiding centerline segregation

(C, Mn, P)

Dr. Knoop July 2013, London 9.

 Manufacturing issues relevant for sour service resistance

Steel cleanliness: non-metallic inclusions as HIC initiating sites

Example: insufficient ladle rinsing and unsuitable degassing
top view of US scan

Rolling direction

side view of US scan

HIC fracture
surface

consistent application of LM refining measures to remove inclusions

from the steel melt, such as:
֜ bottom stirring with N2 and Ar Al
֜ use off tap
t hole
h l slide
lid gates
t ffor minimized
i i i d slag
l carry over
O
֜ optimized Ca-treatment with Ca-wire injection; high Ca recovery
֜ optimized ladle rinsing procedure
֜ use of argon shielded tundish for optimized flow pattern / inclusion removal
HIC cracks primarily initiated at Al-
֜ application of caster with 2.6 m long vertical section instead of bow casters
O inclusions and are traced back
to slab upper half
Dr. Knoop July 2013, London 10.
 Manufacturing issues relevant for sour service resistance

Slab centerline quality: segregation effects

Example: casting without dynamic soft reduction

top view of US scan

HIC crack at strip

mid thickness Martensite

side view of US scan

consistent slab centerline quality optimization by application of Dynamic Soft Reduction

֜ dynamic segment regulation (soft reduction), particularly at the point of final solidification

Dr. Knoop July 2013, London 11.

 Manufacturing issues relevant for sour service resistance

Production: layout of Salzgitter

Salzgitter’s
s hot strip mill

Reheating furnaces (4)

Slab sizing
press
R
Roughing
hi mill
ill
Descaler
Finishing train

C
Crop shear
h
descaler Run-out table:
Laminar cooling unit
Slab thickness = 250 mm
St i thickness
Strip thi k = 1.5
1 5 - 25 mm
Strip width = 900 - 2.000 mm
Strip length = 100 - 2.000 m
3 Down coilers

One of the world’s most modern

high performance hot strip mills
Dr. Knoop July 2013, London 12.
 Manufacturing issues relevant for sour service resistance

Hot strip mill: quality issues and measures

Desired quality issues Consistently applied Salzgitter’s measures to attain them

Narrow strip dimension tolerances Continuous control and adjustment of rolling parameters
• lowering of residual stresses in the • highly planar

ness
µm]
pipe bodies and welds strip profile

Strip thickn
variation [µ
Thickness ± 60 µm
High strip surface quality
• prevention of surface defects e.g.
slivers, roll-ins Strip width [mm]

Homogeneous strip temperature Precise temperature monitoring from furnace to coiler

distribution
• highly desirable acicular ferrite microstructure along the
• prevention of γ→α transformation strip length and across the strip width
during the finishing
p temperature
• Precise strip p prediction
p and control
• strip microstructure adjustment based on run-out table simulation
without undesirable phases

Dr. Knoop July 2013, London 13.

 Manufacturing issues relevant for sour service resistance

Hot strip mill: strip profile and temperature distribution

Example: two-phase finish rolling / undesirable phases at strip edge area
Temperature scan after finishing train

Rolling direction
Temp. deviation

undercooled strip edges

strongly elongated α-grains,
Martensite also observed
precise temperature monitoring and control in every process phase and section
֜ to obtain fine
fine-grain
grain structure across the strip width
֜ indispensable to prevent γ→α transformation already during the finishing
֜ to prevent undesirable phases, such as martensite

Rolling direction

properly cooled strip edges

NO HIC cracks observed !
Dr. Knoop July 2013, London 14.
 Manufacturing issues relevant for sour service resistance

Pipe production: Helical seam Two Step (HTS) technology

B = 1200 - 1500 mm
α = 20 - 40°
D = f ((B,, α)
D = 610 - 1676 mm

Second step: inside and outside

submerged arc welding

Fi step: pipe
First i fforming
i with
i h continuous
i tack
k welding
ldi

Dr. Knoop July 2013, London 15.

 Manufacturing issues relevant for sour service resistance

Pipe mill: quality issues and measures

Desired quality issues Consistently applied SZ’ measures to attain them

controlled cold working Quality controls and R&D
• during coil straightening and pipe • use of FEM simulation methods
forming • consistent quality controls and recording of forming
• minimized springback parameters
• optimized pre-bending of coil edges to • continuous control of pipe geometry using a patented in-situ
avoid
id peaking
ki and
d reducing
d i local
l l l
laser diameter
di t control
t l
stress which might affect sour gas • peaking below 0.8mm
resistivity at weld area (SOHIC)

no forming stresses during welding separating forming and welding by using the HTS –process

maximum hardness of 248 HV Material selection and welding process controls

• qualification and careful selection of coil material and
g consumables
welding
• continuous recording and documentation of all essential
welding parameters
Dr. Knoop July 2013, London 16.
 Manufacturing issues relevant for sour service resistance

Pipe mill: reduction of residual stresses

800

720

640

560
Stress , MPa

480

400

320

240 0°
0
30°
160 45°
60°
80
90°
0
0 2,5 5 7,5 10 12,5 15 17,5 20

Strain ,
 %

Stress strain curves at different angles

Simulation of different forming strategies
3.0
Maximum value over wall thickness
2.5
Inner surface
oop stressh / h(NF) [-]

Outer surface
20
2.0

1.5

1.0

0.5

0.0
Relative residual ho

-0.5

-1.0

-1.5
positive spring-back negative spring-back
-2.0

25
-2.5

-3.0
1.8E-03 1.9E-03 2.0E-03 2.1E-03 2.2E-03 2.3E-03 2.4E-03 2.5E-03 2.6E-03 2.7E-03
Curvature under load [1/mm]

Relative residual hoop stress as function of the curvature under load

Dr. Knoop July 2013, London 17.
 Mechanical and corrosion test results

R&D sour service trials: SZ X65

Coil Type of Rt0.5 Rm DWTT @ CVN @

ADIN AAPI
samples & Rt0.5/Rm [% shear area]; [J/cm2]
Pipe
p [MPa]
[ ] [MPa]
[ ] [%] [%]
direction - 60°C
60 C - 80°C
80 C
Strip 30° [rect.] 528 581 0.91 24 39 93 382
Pipe hoop [rect.] 483 575 0.84 24 38 75 379

Targeted API X65 grade reached reliably; excellent low temperature toughness

HIC:
HIC 24 HIC specimens
i were tested
t t d
Result: mean CAR value ~0.1 %

SSC (4-point-bending test): 9 specimens were

tested at 85% of SMYS (383 MPa)
R
Result:
lt no SSC cracks
k were observed
b d

Full ring test: 72% of SMYS (323 MPa) for 720h in

NACE TM0177 solution A
Result: No indications above threshold were found by Very good sour gas resistivity
ultrasonic examinations prior to and after the test
Dr. Knoop July 2013, London 18.
 Mechanical and corrosion test results

R&D sour service trials: SZ X70

720
700 Rm 100
680

%]
acture area [%
660 90
Rt0.5 , Rm [MPa]

640
API Samples 80
620 DIN Samples DWTT transition
600 Rt0.5 70
Coil 686056

Shear fra
580
60 Test temperature:
Coil 686057 -50°C
560
100% shear area
Coil 686059
540 Coil center 50
Rectangular samples
520
Hoop direction
500 40
-60 -50 -40 -30 -20
56

57

58

59

60
60

60

60

60

60
68

68

68

68

68

Coil Test temperature [°C]

Targeted API X70 grade reached reliably; excellent low temperature toughness

HIC: 112 HIC specimens (base and weld) tested

Result: mean CAR value of 2.82 % (max. 13.1 %);
mean average CAR value base material: 3.62%, mean CAR value for weld specimens: 1.16%

V
Very good
d sour gas resistivity,
i ti it even ffor API X70 grade
d

Dr. Knoop July 2013, London 19.

 Mechanical and corrosion test results

Commercial p
projects:
j GR448

660 Rt0.5 40 400

Rm
640 39
A
620 38
375
600 37
Rt0.5 , Rm [MPa]

VN aK [J/cm ]
2
580 36

A [%]
560 35 350
540 34

CV
520 33
325 360 357 383 344
500 32
480 31
DIN rect. sample; hoop direction Test temperature -18°C Mean value
460 30 300
thick., ½ width Coil
LOM Microstructure ¼ thick

9
Coil
9

18

19

20

20
20

18

19

20

84

84

84

84
84

84

84

84

50 % Ferrite; 40 % Bainite; 10 % Pearlite

/9

/9

/9

/9
/9

/9

/9

/9

Heat

71

73
72

74
Heat
4

3
7

95

95

95

95
95

95

95

95

Targeted GR448 grade reached reliably

HIC: 1 set for both base material and weld per heat were tested.
Result: mean CLR and CSR values of all samples 3.5 , 0.7 and 0.3 %, respectively

G d sour gas resistivity!

Good i ti it ! (d
(despite
it off relatively
l ti l hihigh
h C and
dMMn contents)
t t )

DWTT [% shear area]; average of 2 specimens

Pipe
0°C -5°C
°C -10°C
10°C -20°C
20°C -40°C
40°C -60°C
60°C Excellent
E ll low
l temperature DWTT results
l
100 100 100 100 100 93
100 100 100 100 95 83
Dr. Knoop July 2013, London 20.
 Summary and outlook

Summary
y

Large diameter helical line pipe for sour service up to X70 has been successfully
developed
d l d and
d produced
d d
Critical parameters in steel production and hot rolling have been shown and their
influence has been explained by means of examples.
Well balanced microalloying and steel cleanness has been achieved in industrial trials
and commercial projects
All relevant process parameters during continuous casting and hot rolling were
effectively controlled and adjusted to the used chemistry an microalloying
All necessary measures for the improvement of HIC and SSC resistance have been
optimized and managed during spiral pipe forming and welding
Excellent mechanical properties (incl. low temperature toughness) and corrosion
resistance have been achieved

Dr. Knoop July 2013, London 21.

 Summary and outlook

Outlook

Next milestones are defined on basis of actual and future market needs
Growing interest for sour service resistant line pipe with heavy wall thickness up to 1’’
and grades up to X70 is expected
Technical solutions require
q further development
p
- on chemical composition of the base material,
- on welding consumables
- on further production parameters at each stage of production
- and on suitable equipment at each stage of production
Pi
Pipes ith smaller
with ll di t
diameters iin th
the range off 26’’ and
d higher
hi h wall
ll thickness
thi k (hi h cold
(high ld
forming degree) need further development

Dr. Knoop July 2013, London 22.