D-4: PIPE MATERIALS TABLE OF CONTENTS

1 INTRODUCTION 2 MANUFACTURING STANDARDS 3 PIPE MATERIAL STRENGTH 4 MATERIAL SUITABHJTY 5 MATERIAL COMPOSITION 5.1 5.2 5.3 5.4 Composition Alloying Element Effects Welding Considerations Pipe Toughness

6 PIPE MANUFACTURING TECHNIQUES 6.1 6.2 6.2.1 6.2.2 6.3 Seamless Pipe Longitudinally Seam Welded Pipe SUBMERGED ARCH WELDED (SAW) PIPE ELECTRICAL RESISTANCE WELDED (ERW) PIPE Spiral Welded Pipe

7 SOUR SERVICE PIPELINES 7.1 7.2 7.3 7.3.1 7.3.2 7.3.3 General Sour Product and its Effect Methods of Control PREVENTION OF SSC PREVENTION OF HIC TESTS FOR SOUR SERVICE PlPES

8 CORROSION RESISTANT ALLOYS (CRA) 9 CLADPHE 10 QUALITY ASSURANCE AND CONTROL

Ove-viav@csb)-rkj-23/08/00 Rev. A

D-4 PIPE MATERIALS

1 INTRODUCTION

A fundamentally important aspect of pipeline design is the selection of the pipe material. Most hydrocarbon pipeline systems have been constructed of carbon steel pipe. However, in some cases, exotic alloy steel materials such as stainless steel or Duplex stainless steel, or similar materials, have been used. The pipe material suitability depends on the product to be transported, pressures and temperatures, and strength requirements during operation, installation and testing. The pipe material chemistry is determined by consideration of product chemistry, vulnerability of the material to corrosion, etc. It is always advisable to seek advice from a material specialist in selecting the pipe material and equally important is to ensure adherence to specifications during pipe manufacture and testing. Quality control is very important to

avoid costly mistakes.

The purpose of this Chapter is to introduce the basics of material selection for pipelines.

MANUFACTURING STANDARDS

Line pipe used for pipeline systems is manufactured to internationally acceptable standards. These standards define acceptable manufacturing processes and methods, limits on chemical composition, quality controls, mechanical strength requirements, etc. The most commonly used standard for carbon steel pipe is API 5L: Specification for Line Pipe issued by the American Petroleum Institute (API). This standard also specifies standard pipe diameters and wall thicknesses, and allowable fabrication tolerances. New International Standards have been produced by the International Standards Organisation (ISO) and these are starting to replace the use of the API standards. DnV 2000 can also be used as a standard for line pipe. Since DnV 2000 is written specifically for subsea oil and gas pipelines, it specifies more stringent requirements than API 5L which is a general purpose standard.

Ove-view@csb)-rkj-23/08/00 Rev. A

It is pointed out that API 5L requirements are the minimum that a pipe used for oil and gas service must meet. It is a common practice to supplement API 5L requirements for the line pipe for subsea oil and gas pipelines.

PIPE MATERIAL STRENGTH

Pipe material strength is given in terms of its yield strength and ultimate tensile strength. Design is normally based on yield strength although some recent design criteria have also introduced the use of ultimate tensile strength. We shall limit our discussion to yield strength. The yield strength is the tensile stress required to produce permanent plastic deformation (API 5L defines this as a total elongation of 0.5 percent). Ultimate strength is the tensile stress required for the material to fail in tension. API requires that ratio of the yield strength and the ultimate tensile strength should not exceed 0.93. Test specimens are produced from samples of the test pipe. Samples are flattened in a specified manner subjected to tensile testing in accordance with the specifications. Similarly, ultimate tensile strength is also determined for the sample pipe. Pipes manufactured to API 5L standard are available in different grades of strength as defined by the pipe minimum yield strength, hence the term used is specified minimum yield strength (SMYS). The lowest yield strength of API range of pipes is Grade B with a yield strength 172MPa(25,000psi) and the highest is Grade X 80 with yield strength of 551MPa(80,000psi). Commonly used line pipes in offshore oil and gas industry are grades X52, X60 and X65 having yield strengths of 358 Mpa (52,OOOpsi), 413 Mpa (60,OOOpsi) and 448 MPa (65,OOOpsi), respectively. Generally, the finished pipe has yield strength in excess of the specified minimum value. 4 MATERIAL SUITABILITY

Carbon steel materials tend to corrode due to a combination of CO, and water (sweet corrosion), and due to H,S which can also initiate various forms of cracking (sour corrosion). Hence, pipelines in certain operational conditions may suffer a loss of material on the inside surface, generally due to the presence of CO, or H,S. The procedure for assessing the loss of wall thickness due to CO, corrosion is discussed in Chapter 10. The anticipated loss of wall thickness over the life span of the pipeline is normally compensated by increasing the thickness of the new pipe, i.e., by incorporating a corrosion
Ove-viav@csb)-rkj-23/08/00 Rev. A

allowance . The extent of sweet corrosion may be controlled in many cases by mixing the product with suitable corrosion inhibitors and by pipe manufacture techniques. Resistance to H,S cracking can be provided by attention to steel composition and manufacturing techniques. In certain cases, the levels of corrodants in the product may be such that these measures are either not suitable or are insufficient to limit the loss of pipe wall due to corrosion. In such cases, pipe made from corrosion resistant alloy (CRA) is used. Carbon steel pipes clad with CRA material are also used. Alloy or clad steel pipe material and construction cost can be several magnitudes greater than that for the carbon steel pipe but are generally maintenance free. 5 MATERIAL COMPOSITION

5.1 Composition Over a period of time, considerable effort work has gone into the improvements of composition of steel suitable for hydrocarbon transportation in different environment. API 5 L and Engineering Equipment and Materials Users Association (EEMUA) standards provide compositional requirements that specify the maximum levels of various components. API specify only a few of the major component elements whereas EEMUA has specified all component elements used in carbon steel pipe. Both give wide ranges for various elements to be used in the composition of steel. One of the considerations, apart from the product to be transported, is the weldability of the materials for a particular application. Manufacturers of steel and pipe can vary compositions within these limits to achieve the required mechanical properties and weldability. By varying the composition, steel materials of different strengths can be produced. Composition is modified in to take account to improve weldability of thick wall pipes. It is prudent to seek advice of a materials engineer to determine the optimum material composition of the pipe material. A typical composition for pipe material for sweet service is shown in the Table 1.

5.2

Alloying Element Effects

Different elements are added in varying amounts during steel manufacture to achieve the required mechanical properties and corrosion resistance. Table 4.2 outline the major effects

Ove-viav@csb)-rkj-23/08~00 Rev. A

of each of elements on the steel performance. It is noted that interaction of one element with the other will have further effects which are not discussed in Table 2. 5.3 Welding Considerations Welding of pipe is an important aspect of pipeline manufacture and construction. Inadequate welding methods and procedures will lead to mechanical and corrosion related failures of a pipeline. Traditional stick welding of thick pipes suffers from hydrogen cracking problems at the welds. Hydrogen that is created during welding dissolves more readily in the molten metal and when the dissolved hydrogen comes out of solution during solidification it can initiate cracking in the weld metal or the heat affected zone adjacent to the weld. Welding techniques have been refined over the period to overcome the problems of failure at the welds. Pipeline specifications that are prepared during detailed design as amendments to API 5L must specify weld and welder qualification requirements and tests that must be adhered to. Quality of welding materials and storage are equally important. Steel compositions and manufacturing techniques have also been modified to minimise weld failures. Two parameters which are used to control material composition for weldability both relate to carbon equivalentdefined as follows cE=c+Mn+(cr+A40+v)+(cu+Ni) 6 5 1.5 (IIW is the International Institute of Welding) IIW Formula: Pcm Formula: Pcm =
I Jh I fkb I v I 5B

cpM=c I si I Wn+Cu+Cr)

30

20

60

15

10

A low value of carbon equivalent means good weldability. Generally it is recommended that CE should be less than 0.45 and CPM to be less than 0.25. (Many manufacturers regularly achieve CE values well below 0.40, particularly in SAW and ERW/HFW pipe) 5.4 Pipe Toughness

Ove-viav@csb)-rkj-23/08/00 Rev. A

Hydrocarbon pipelines must have good toughness characteristics, particularly if subject. to low temperatures. Tough materials can withstand impact loads and failure is progressive. However, even tough materials can become brittle under certain conditions. Rupture of a high pressure gas/condensate pipeline can lead to a sudden release of product energy causing very rapid cooling of the steel pipe turning the material behaviour from a ductile to a brittle. In this state, the initial crack propagates along the pipeline at the speed of sound. This continues till the crack propagation energy drops below a critical level. The problem of brittle failure can be eliminated by careful design, operational procedures and material selection. Lowest temperature in a pipeline during a sudden depressurisation in an emergency is determined during process studies. Pipeline materials are selected to ensure that these do not lose ductility well below the lowest design temperature. This minimum temperature for the pipes steel material is generally 10 below the minimum calculated from process studies. Pipe material and welds are tested to ensure that these have good toughness properties. A number of tests have been developed in which samples are subjected to impact loading. The methods that are used are: Charpy test and drop weight tear test. It is not intended to discuss test methods/procedures and evaluation methods in detail here. API 5L discusses requirements for these tests. Charpy test is one of the most common tests used for offshore pipeline materials. It requires the steel to withstand a specified applied energy at a specified temperature. Test temperatures are generally between -10 C and -40 C, and the energy applied to the sample can ranges from 15 Joules to 50 Joules.
6

PIPE MANUFACTURING TECHNIQUES

Pipe manufacturing process primarily starts with the steel production since the quality control process starts from that moment. An adequately quality controlled pipe will have a high probability of failure during operation. For offshore oil and gas industry, the following pipe manufacturing techniques are considered suitable.
6.1 Seamless Pipe

The technique involves hot working of steel to form tubular without a weld seam. A billet of hot steel is extruded by rollers around a piercer to form a hollow bloom, which is then
Ove-viav@csb)-rkj-23/08/00 Rev. A

rolled or drawn over a mandrel to produce a length of pipe. Variations of the method are used by different pipe manufacturers. Seamless pipe manufacturing technique is normally limited to the production maximum 18 diameter pipe and of limited length. However, pipes upto 24 diameter can be produced by seamless technique. The constraining factors are the handling and working of billet. Due to the limitation on the billet size, thicker pipe may not be produced in the standard 12 m nominal length by this method, and double jointers or shorter lengths may have to be accepted. Furthermore, there is a wide variation of wall thickness in a seamless pipe. Normally, API 5Ls specified tolerances of + 15% and -12% are observed by the pipe manufacturers. Plus tolerance means that the pipe wall thickness along a joint can exceed the specified thickness by as much as 15 %; and the minus tolerance means that the thickness can be upto 12 % less than the specified thickness.

6.2

Longitudinally Seam Welded Pipe

In this method, pipe is rolled from a plate and manufactured by welding along the longitudinal direction. Plate is produced from the billet in a controlled manner so as to minimise inclusion size, shape and frequency. The plate is produced by a controlled rolled method to achieve the required mechanical properties. The plate is then rolled to a cylindrical shape, two longitudinal edges are butted together, i.e., brought together, and welded. The formed pipe goes through a shaping process to achieve roundness and required outside diameter. The two methods which are acceptable are submerged arc welding (SAW) and electrical resistance welding (ERW). The latter method has been accepted for offshore pipeline only in the recent years.

6.2.1

SUBMERGED ARCH WELDED (SAW) PIPE

The plate is cut to predetermined dimensions, bent first to U-shape followed by formation to an O-shape in a press so that the longitudinal edges butt together. The longitudinal weld is performed by submerged arc welding technique. The welded pipe is cold expanded to achieve the required shape. SAW pipe is used for large diameters and has smaller variations in wall thickness. Typical values for wall thickness tolerances are + 12 %, -10% but negative tolerance of 0.0% can be achieved.
Ove-view@csb)-rkj-23/08/00 Rev. A

6.2.2

ELECTRICAL RESISTANCE WELDED (ERW) PIPE

Plate is roiled into the shape of a pipe, the longitudinal seam weld is made by pressing the two longitudinal edges together and using electrical resistance welding which involves passing an electrical current across the interface to melt the steel and produce a weld. (Where high frequency current is used the process is termed High Frequency Welding or HFW). After trimming the weld flush, the pipe goes through sizing process. It is then passed through a barrel furnace to achieve required strength and to reduce weld hardness. ERW/HFW pipe has not been used much for offshore oil and gas pipelines since the welds tended to be unreliable through contamination by non-metallic inclusions in the steel plate. Weld area could also be vulnerable to corrosion. The availability of cleaner steels in recent years has improved the quality of the welds in ERW/HFW pipe and its use in subsea environment is now tending to increase. The maximum diameter of pipe produced is 24 but most mills are limited to 22 capability. ERW/HFW pipe requires much more stringent quality control. ERWIHFW pipe can be upto 20-25% cheaper than the SAW pipe.

6.3 Spiral Welded Pipe

Spiral welded pipe is produced by uncoiling a long strip of hot coiled strip and wound like a helical to form the pipe. The butting edges of the coiled strip are welded using submerged arch welding producing a continuous length of pipe. The pipe is not expanded and may have higher out of roundness and longitudinal tolerances compared with SAW and ERW pipe. Spiral welded pipe can be made in a wide range of sizes. Spiral welded pipe is not generally used for offshore oil and gas systems due to its greater susceptibility to corrosion compared to the longitudinally welded pipe. Spiral pipe is mostly used as external sleeve for bundle pipes or for water transportation.
7

SOUR SERVICE PIPELINES

7.1 General
Ove-view@csb)-rkj-23/08/00 Rev. A

Design of sour service pipeline is an important aspect for gas pipelines since a pipeline can fail during service if it is not manufactured and installed in a manner which minimises the failure rate. A pipeline system failed and had to be replaced at a tremendous both in terms of construction and product loss. The aim of the section is to give an overview of the problem. 7.2 Sour Product and its Effect

Hydrocarbons which contain hydrogen sulphide (H,S) are known as sour. The sulphide causes the following three types of corrosion related problem:
l

pitting sulphide stress cracking (SSC): causes embrittlement of high strength steels which crack under imposed loads. SSC can occur in weld areas due to (a) local hard spots, (b) hard zones in heat affected zone due to the parent plate composition or inadequate heat treatment, (c) hardness caused by incompatible consumables.

hydrogen induced cracking (HIC): hydrogen gas is formed within the steel which expands and causes cracking. HIC starts as isolated blisters in the steel. For SAW pipe, the vulnerable spots are inclusions in the plate with the longitudinal area opposite to the longitudinal weld most affected. The

blisters spread and finally lead to tearing of the steel.

Small quantities of H,S may not cause any problem. The type of corrosion caused by H,S depends on the level of H,S in the product.
l

Pitting corrosion can occur, in general, if the product contains 100 ppm of H,S.

Sulphide stress cracking (SSC) can occurs when the partial pressure of H,S exceeds 0.05 psia as defined by NACE MR017.5. (partial pressure is defined

as the mole % of H,S in the product multiplied by the design pressure)

l

Hydrogen induced cracking (HIC) can occur in steel if the partial pressure of H,S exceeds 0.1 psia but it also depends on the pH value for the fluid

Ove-view@csb)-rkj-23/08/00 Rev. A

which is largely dependent on the partial pressure of CO, in the product. Gas pipelines are more vulnerable compared with the oil pipelines, particularly where free water can be formed due to condensation. 7.3 Methods of Control

Pitting corrosion can be controlled by chemical inhibition. SSC and HIC can also be controlled by chemical inhibition but it is advisable to prevent these problems by modifying the chemical composition of steel; and by adopting pipe manufacturing, and welding techniques and procedures which eliminate/minimise susceptible spots. 7.3.1 PREVENTION OF SSC SSC is prevented by avoiding high residual tensile stresses and local hard spots and by keeping the maximum tensile strength of steel below 100,000 psi. Tensile tests are destructive so an indirect method is to measure steel and weld hardness by pressing a small sphere or cone with a fixed force and measure the indentation. Hardness is measured as Rockwell Hardness or Vickers Hardness values in accordance with the applicable standards and specifications. SSC is avoided if the hardness is below Rockwell hardness 22 or Vickers hardness 248 (110,000 psi or 758 Mpa) In addition NACE MR0175-96 provides the standard material requirements for the sulphide stress cracking resistant metallic materials for oilfield equipment. Suitable weld procedures conforming to the applicable code NACE MR0175 prevents problems at welds. 7.3.2 PREVENTION OF HIC HIC risk is reduced by a suitable composition of the steel and by using manufacturing techniques which minimise inclusions. 7.3.3 TESTS FOR SOUR SERVICE PIPES

Carbon steel pipes intended for sour service are tested in accordance with the following two standards:
l

NACE TM0177: Standard Test Method- Laboratory Testing of Metals for Resistance to Sulphide Stress Cracking in H,S Environment

NACE TM0284: Evaluation of pipeline Steels for Resistance to Stepwise Cracking

Ove-viav@csb)-rkj-23/08/00 Rev. A

NACE test are carried out on a sample cut from the pipe. A more rigorous test method has been developed by UMIST in the UK where a ring cut from the pipe which includes a girth weld also is tested. The later test is performed only once to confirm the material suitablity. During production, NACE test are carried out.
8

CORROSION RESISTANT ALLOYS (CRA)

In cases where the product composition or operations make carbon manganese steel unsuitable, corrosion resistant alloys (CRA) may have to be used. Most common case is that of highly corrosive hydrocarbons where chemical inhibition is either not effective or is un-economical. CRA has been used for a number of flowlines with subsea production facilities. CFL4 materials are several times the cost of carbon steel on per tonne basis, hence CRAs are used as a last resort. There are three forms in which CRA can be used; these are (a) pipe totally made from CPA, (b) carbon steel pipe lined or clad with CFLA, and (c) flexible pipe with a CRA liner. One of the problems with CRA is the increased time and cost of field. Hence, welding of CRAs can make a project uneconomical. The CRA materials tend to have low yields requiring thicker wall thicknesses. CRA strength can be improved by cold working and other methods but there are some side adverse effects. Under certain conditions, stainless steels can suffer pitting and crevice corrosion, and stress corrosion cracking. Most of the CRA pipelines to date have been fabricated from duplex stainless steel which have good mechanical properties compared with many other stainless steels and corrosion resistance. Welding of duplex pipe can be 4-6 times slower than the equivalent carbon steel pipeline which makes offshore welding prohibitively expensive. 9 CLAD PIPE

When carbon manganese steel pipe is lined internally with a layer of corrosion resistant alloy material, the process is called cladding. The liner thickness is of the order of 2-3 mm. The clad pipe provides strength coupled with corrosion resistance. The outer pipe can be of any API grade from X 65 to X 80.

Ove-view@csb)-r/+23/08/00 Rev. A

The clad pipe costs much more than the equivalent carbon steel pipe. The liner can be bonded or non-bonded. In non-bonded pipe may corrode.due to the buid up of hydrogen in the very small space between the outer and the liner. However, if the liner is fitted tightly, the risk of corrosion may be discounted. Bonded pipe can be manufactured in a variety of ways. Seamless pipe can be formed by extruding the carrier and the liner together. Seam welded pipe can be manufactured from plate to which the lining material has already been bonded. Non-bonded pipe is manufacture by heating the outer carbon manganese pipe and fitting the liner inside the heated pipe. The liner is expanded into the outer pipe by hydraulic pressure. Liner and the outer pipe are welded at the ends.
10 QUALITY ASSURANCE AND CONTROL

Of paramount importance in pipe manufacture is strict adherence to quality assurance and quality control systems. The process of quality control starts at the steel making mill and continues until the pipe is delivered to the designated site. QC personnel need to be located at each manufacturing site, i.e., steel making, pipe rolling, pipe manufacture and testing and at pipe delivery site. Traceability is equally important. The systems of logging must ensure that each pipes origins can be traced. Each pipe is given a unique identification number which can be used to determine which mill/heat the steel was made, where and when it was rolled into plate and finally into a pipe. All test records are supplied in the pipe data books. Apart from manufacturers quality control personnel, buyer should have his own inspectors. In many cases, third party independent inspectors are also employed. DnV 1996 gives strong emphasis on quality assurance/control. Several pipe mills can produce API pipe but that is not just sufficient for oil and gas applications. Our requirements are more stringent than API in general. Before selecting a mill, make sure that the mill has established quality assurance systems in accordance with IS0 9000 or its equivalent which are actually observed.

Ove-view@csb)-r&23/08/00 Rev. A

Pipe manufacturers sometimes offer cost reduction in lieu of relaxation on testing and inspection requirements. One should be wary of such offers.

Ove-view@csb)-rl+23/08/00 Rev. A

Table 1 CHEMICAL COMPOSITION OF CARBON STEEL Element Maximum Permitted Alloy Content (percentage weight) Maxi mum Variati on on Agreed Compositi on (see 6.1.3) 0.03 0.30 0.25 Notes

SAW C Mn Si P S V Nb Ti Cr MO Ni CU Al N B Ca CE Pcm
Notes: 1. 2. 3.

SMLS 0.16 1.60 0.45 0.025 0.01 0.08 0.05 0.04 0.20 0.25 0.30 0.25 0.06 0.012 0.0005 0.006 0.41 0.22

HFW 0.16 1.60 0.45 0.025 0.005 0.08 0.05 0.04 0.20 0.25 0.30 0.25 0.06 0.012 0.0005 0.006 0.39 0.21

0.16 1.70 0.45 0.025 0.01 0.08 0.05 0.04 0.20 0.10 0.30 0.25 0.05 0.012 0.0005 0.006 0.39 0.21

0.02 0.02 0.02 0.05 0.05 0.10 0.10 -

1 1 1 2 2 2 2 3 3

4 5

4.
5.

V+Nb*Ti shall not exceed 0.15 percent. Cr+Mo+Ni+Cu shall not exceed 0.6 percent. The total Al : N ratio shall not be less than 2 :I. CE = C + Mn16 + (Cr+Mo+V)/S + (Ni+Cu)/l5.0. Pcm = C + Si130 + (Mn + Cu +Cr)/20 + Ni160 + Moll5 + V/IO + 58.

he-view@csb)-rkj-23/08/00 Rev. A

Table 2 MAJOR EFFECTS OF VARIOUS COMPONENT ELEMENT Element Aluminium (Al) Calcium (Ca) Effect Refines grain size; increases toughness and hardness De-oxidiser and de-sulphuriser for steel; controls inclusion shape Increases tensile strengthand hardness; reduces toughness; high content reduces weldability and increases corrosion susceptibility. Increases tensile strength, corrosion resistance and hardness; decreases weldability. Improves cracking resistance for sour service; affects the corrosion of weld heat affected zone Increases tensile strength, toughness, abrasion resistance and hardness; decreases cracking and porosity. Increases tensile strength, hardness and wear resistance. Increases tensile strength, toughness and resistance to corrosion; improves weld strength and reduces susceptibility of the weld to corrosion. Increases tensile strength, hardness and wear resistance Increases brittleness and cracking Increases tensile strength, markedly reduces toughness; high levels used to reduce corrosion in acids. Increases inclusions, brittleness and cracking. Increases tensile strength, hardness and wear resistance. Increases tensile strength, hardness and wear resistance.

Carbon (C)

Chromium (Cr)

Copper (Cu)

Manganese (Mn) Molybdenum (MO) Nickel (Ni)

Niobium (Nb) Phosphorus (P) Silicon (Si)

Sulphur (S) Titanium (Ti) Vanadium (Vn)

Ove-view@&-&j-23/08/00 Rev. A

SUMMARY POINTS

PIPE MATERIAL SELECTION

. FUNDAMENTAL IMPORTANCE . STEEL PIPE USED:
l l l

Mostly Carbon Steel Corrosion Resistant Alloys (CRA)

SELECTION DEPENDS ON:

+ Product to be Transported + Operational Functions l Environment + Strength Requirements
l cost

PIPE MATE
l

MANUFACTURING STANDARDS
+ API 5 L - Specification for Line Pipe is universally used l API 5L Specifies Minimum Requirements l API 5L specifies: l standard diameters and wall thicknesses l fabrication tolerances: wall thickness, diameter, etc l manufacturing and testing requirements + Supplement with Additional Requirements l DnV 2000 for Subsea Application is More Stringent l New International Standards in Preparation

PIPE M4TERIAL SELECTION

. PIPE STRENGTH :
Strengths in terms of Minimum Specified Yield (SMYS) and Ultimate Tensile (UT) - psi or Mpa l SMYS: Tensile strength for plastic elongation of 0.5 % l Grades: B, X-52, X-60, X-65, X-70, X-SO + SMYSAJT < 0.93 l Finished pipe exceeds specified strength
l
l

MATERIAL SUITABILITY
+ Carbon steel suitable for most applications * Carbon steel corrodes due to CO, & water (sweet corrosion) l H,S causes cracking (sour corrosion) l Corrosion resistant alloys (CRA) for sour service

w.:.. .,.. .. .\..,% Y

.., .. .,<wx:* .>..>

. ..A.......... *

.% .%,%-,I

. ... . ...:. :

PIPE MATERIAL SELECTION

l

MORE ON CORROSION
+ + + + Pipe wall loss due to sweet corrosion Controlled by inhibitors and manufacturing techniques Corrosion allowance for wall thickness H,S cracking reistance by composition & manufacturing techniques

CHEMICAL COMPOSITIONS
+ API 5L & EEMIJA standards provide compositions + API identifies major components & maximum levels + EEMUA specifies all components for carbon steel pipes l Welding considerations + Prudent to seek material specialist advice

ALLOYING EFFECTS
+ Effects of various elements shown in Table

WELDING CONSIDERATIONS
+ + + + * Traditional stick welding: hydrogen cracking Weld metal & heat affected zone affected Welder & welding qualifications to be ensured Quality of welding materials and storage important API 5 L specifies different welding techniques

PIPE MATERIAL SELECTION

1 PARAMETERS FOR WELDING
Carbon equivalence for weldability of carbon steel + Internationai Institute of Welding Formula + Pcm Formula CE =C +++iCr + MO f v ) + ( cu + Ni
l

15

CPW

=c+x+ 30

(Ad..

ecu 20

+Cr)+E MO v i--+-+5B 60 15 io

+ Low value of carbon equivalent: Good Weldability + CE < 0.45; CPM < 0.25 recommended

PIPE MATERIAL SELECTION

PIPE TOUGHNESS
+ Pipe should have good toughness l Important for low temperatures + Impact load capability + Materials become brittle due to sudden release of energ + A small crack can propagate at speed of sound + Determine lowest temperature, T,i, during sudden depressurisation + Material not to lose ductility well below Tmin + Pipe material and welds tested for toughness + Tests are: drop weight tear test & Charpy test + Charpy test temperatures: (-10 C) to (- 40) + Applied energy levels: 15 -50 Joules

. ,.

.......~...~.~ _ >>.:.:<.::...:<.

*<.:.:.:ril

PIPE MATERIAL SELECTrON

. PIPE MANUFACTURE TECHN?QUES
*API 5L approves several techniques * For subsea pipelines, not all suitable + Suitable techniques: seam welded & seamless l Seam weld: longitudinal & spiral l Longitudinal welds: Submerged arch welding (SAW) Electrical resistance weld (ERW) l Spiral welded: greater susceptibility to corrosion l Seamless: limited to max. 18 diameter + Seamless pipe: wider variations in thickness l Welded pipe: close tolerances possible
l

PIPE MATERIAL SELECTION

l

SOUR SERVICE PIPELINES

+ Hydrocarbons containing H,S are sour l Sulphide causes following corrosion + Pitting: products containing 100 ppm of H,, + Sulphide stress cracking @SC): embrittlement in high strength steels; + SSC in weld area: local hard spot, HAZ, incompatible consumable + SSC occurs if partial pressure of H,S > 0.05 psia + Hyurogen induced cracking (HICK): due tb &&&&on of l BBB trapped hydrogen; isolated blisters + HIC occurs if partial pressure of H,S > 0.1 % l CCC

PIPE MATERIAL SELECTION

. CONTROL OF SSC :
+ Maintain tensile strength < 100,000 psi * Avoid hard spots + Measure hardness by indentation l Two scales used for hardness: Rockwell & Vickers + SSC is avoided if Rockwell hness <22, Vickers hness <248 + NACE MR0 175-96 provides material requirements

CONTROL OF HIC:
Testing to the following standards: + NACE TM0 177 7 Tests on pieces from pipe +NACE TM0284 1 &MIST test: on a ring including a girth weld + Tests on each pipes from each heat
l

CORROSION RESISTANT ALLOYS:

+ + + 4 + + Used if carbon manganese steel unsuitable Used for short small diameter flowline Several times costly than carbon steel Welding: difficult, 4-6 times slower Three types: austenitic, martensitic & Duplex Austenitic steels: lower yield; reduces with temperature; improved by hard working with side effects + Martenitic & Duplex steels: strength similar to carbon steel

 PIPE IMATERIAL SELECTION

l

CORROSION RESISTANT ALLOYS:

+ Martensitic Stainless Steel: + Carbon manganese steel with increased chromium + Chromium content: 12-13 % + Maximum temperature: 120 C + Susceptible to cracking due to chloride & sulphide + AUSTEMTIC STAINLESS STEEL: + Carbon manganese steel with 18 % chromium & 9 % nickel + Chromium oxide film protects the surface + May suffer from pitting, crevice corrosion & SSC + Chromium film may be broken by Oxygen & chlorides in seawater

CORROSION RESISTANT ALLOYS:

t Duplex Stainless Steel: + Contains 22-25 % chromium & 5-7% nickel + Good corrosion resistance + High strength, ductility & toughness
l

CLAD PIPE:
+ Carbon steel pipe lined internally with a thin layer of CRA l Provides strength and corrosion resistance + Outer pipe: API grades X 65 - X 80 l Liner can be bonded or non-bonded + Seam welded pipe made from plate with bonded line

1
PIPE MATERIAL SELECTION
. QUALITY CONTROL:
l

* + + *

Very important to avoid costly mistakes Insist on strict adherence to test requirements Full traceability from steel to pipe manufacturing Generally third party inspection Manufacturer with quality procedure to IS0 9000 approval should be preferred