Materials and Materials and JoiningJoining

March 2005 R&D ForumMarch 2005 R&D Forum

David HorsleyDavid Horsley

TransCanada Pipelines TransCanada Pipelines LimitedLimited

OutlineOutline

BackgroundBackground Links to DesignLinks to Design Links to Construction Links to Construction Links to OperationLinks to Operation

Materials and Joining IssuesMaterials and Joining Issues List and PrioritizeList and Prioritize

Overriding PrinciplesOverriding Principles

Protection of Persons, Property Protection of Persons, Property and the Environmentand the Environment

Compliance with Laws and Compliance with Laws and Regulations Regulations

Develop and Utilize Technologies Develop and Utilize Technologies to enhance 1 and 2, and improve to enhance 1 and 2, and improve Cost Effectiveness of pipeline Cost Effectiveness of pipeline systems systems

Life Cycle CostsLife Cycle Costs

Design – Construct – OperateDesign – Construct – Operate

Links to DesignLinks to Design Reliability Based Design and Assessment (RBDA)Reliability Based Design and Assessment (RBDA)

Quantifies reliability for all relevant limit statesQuantifies reliability for all relevant limit states Reliability Optimized over life cycle Reliability Optimized over life cycle Higher Design FactorsHigher Design Factors

Loading ConditionsLoading Conditions SeismicSeismic Slope InstabilitySlope Instability Frost Heave and Thaw SettlementFrost Heave and Thaw Settlement

Load EffectsLoad Effects Stress based designStress based design Strain based design (Tensile and Compressive Limit Strain based design (Tensile and Compressive Limit

States)States) High-Strength PipelinesHigh-Strength Pipelines High-Pressure/ Low Temperature/ Rich Gas High-Pressure/ Low Temperature/ Rich Gas

PipelinesPipelines

Links to ConstructionLinks to Construction

High Productivity WeldingHigh Productivity Welding MaterialsMaterials Inspection and ECAInspection and ECA Alternatives to HydrotestAlternatives to Hydrotest

Links to OperationLinks to Operation

RBDARBDA Materials Properties databaseMaterials Properties database CorrosionCorrosion

Materials and JoiningMaterials and Joining

Materials account for up to 50% of Materials account for up to 50% of installed costinstalled cost Reduce steel requirements - use higher Reduce steel requirements - use higher

gradegrade Welding is the often the pace-Welding is the often the pace-

limiting processlimiting process Improve productivity by advanced Improve productivity by advanced

automated welding systemsautomated welding systems

MaterialsMaterials

Materials OutlineMaterials Outline

High Strength Materials High Strength Materials Fracture Propagation and ArrestFracture Propagation and Arrest Inspection and ECAInspection and ECA CorrosionCorrosion

High Strength MaterialsHigh Strength Materials

Increased strength → reduced WT → Increased strength → reduced WT → lower cost (for steel and construction)lower cost (for steel and construction)

Fracture propagation and arrestFracture propagation and arrest JoiningJoining Stress-strain properties Stress-strain properties Damage Tolerance Damage Tolerance Response to external loads – tensile Response to external loads – tensile

and compressiveand compressive

Fracture Propagation Fracture Propagation and Arrestand Arrest

Validated Fracture Control Methodology for Validated Fracture Control Methodology for new pipelines of high-strength steel, new pipelines of high-strength steel, operating at higher pressure, lower operating at higher pressure, lower temperature, richer gas.temperature, richer gas.

Driving force (equation of state)Driving force (equation of state) Material resistance – appropriate small scale Material resistance – appropriate small scale

teststests Other resistance – backfill coefficientsOther resistance – backfill coefficients Experimental data to validate predictive modelsExperimental data to validate predictive models

Inspection and Inspection and Engineering Critical Engineering Critical

AssessmentAssessmentDefine uncertainties in and suggest refinements to weld Define uncertainties in and suggest refinements to weld inspection and assessment methods in order to increase inspection and assessment methods in order to increase the level of confidence associated with their use and the level of confidence associated with their use and expand applicability to higher strength materials and other expand applicability to higher strength materials and other joint configurations.joint configurations.

AUT AUT Sizing precision and accuracySizing precision and accuracy Design toolsDesign tools

ECAECA Strain based design methodologiesStrain based design methodologies

Experimental data for a wider range of materials and D and WTExperimental data for a wider range of materials and D and WT Interaction of flawsInteraction of flaws Applicability to high strength pipe materialsApplicability to high strength pipe materials Realistic small scale fracture tests (low constraint)Realistic small scale fracture tests (low constraint) Old and existing pipelinesOld and existing pipelines Risk/reliability/probabilistic methodsRisk/reliability/probabilistic methods Codes and StandardsCodes and Standards

CorrosionCorrosion

Comprehensive Models to predict Comprehensive Models to predict susceptibility and rates for both susceptibility and rates for both General Corrossion and SCCGeneral Corrossion and SCC Soil typeSoil type Moisture contentMoisture content pH pH Aerobic/AnaerobicAerobic/Anaerobic Coating typeCoating type Pipe grade / manufacturer/ processPipe grade / manufacturer/ process

Effectiveness of CP in PermafrostEffectiveness of CP in Permafrost

JoiningJoining

Joining OutlineJoining Outline

Joining of Higher Strength MaterialsJoining of Higher Strength Materials Welding on Pressurized LinesWelding on Pressurized Lines New and Improved Welding New and Improved Welding

ProcessesProcesses

Joining of Higher Strength Joining of Higher Strength MaterialsMaterials

Identify factors critical to successful joining of high Identify factors critical to successful joining of high strength materials and develop welding strength materials and develop welding procedures and techniques which demonstrate procedures and techniques which demonstrate sufficient reliability and can be practically sufficient reliability and can be practically implemented.implemented.

Consumable development for X-80 and X100 pipe Consumable development for X-80 and X100 pipe in strain based loading design -to ensure in strain based loading design -to ensure overmatching and sufficient toughnessovermatching and sufficient toughness MainlineMainline Tie-insTie-ins Double joints and fabrication weldsDouble joints and fabrication welds

Effects of repairs on metallurgical propertiesEffects of repairs on metallurgical properties Hydrogen cracking susceptibilityHydrogen cracking susceptibility High productivity welding systemsHigh productivity welding systems

New and Improved Joining New and Improved Joining ProcessesProcesses

Adapt new joining processes and improve or refine existing processes Adapt new joining processes and improve or refine existing processes which show sufficient increases in productivity, efficiency or which show sufficient increases in productivity, efficiency or reliability.reliability.

Enhancements to mechanized GMAW processesEnhancements to mechanized GMAW processes TandemTandem Dual tandemDual tandem Laser assistedLaser assisted

Optimization of pipeline spread, e.g. appropriate number of shacks Optimization of pipeline spread, e.g. appropriate number of shacks and welding process/equipmentand welding process/equipment

Optimization of welding procedures to reduce number and size of Optimization of welding procedures to reduce number and size of flaws to meet strict requirements for strain based design flaws to meet strict requirements for strain based design

Semi-automatic process for tie-ins and repairsSemi-automatic process for tie-ins and repairs One-shot welding processes, e.g. MIABOne-shot welding processes, e.g. MIAB Automated processes for in-service welding (full pressure and flow Automated processes for in-service welding (full pressure and flow

if possible)if possible) Hot taps and stopples (design codes w.r.t structure analysis needs work Hot taps and stopples (design codes w.r.t structure analysis needs work

too)too) Repair sleevesRepair sleeves Direct deposition repairsDirect deposition repairs

Welding on Pressurized Welding on Pressurized LinesLines

Increase accuracy in predicting base and weld metal Increase accuracy in predicting base and weld metal response when welding in-service pipelines and response when welding in-service pipelines and develop welding techniques which demonstrate develop welding techniques which demonstrate sufficient safety, reliability and economy. sufficient safety, reliability and economy.

Cooling rate models to account for various WT, Cooling rate models to account for various WT, products, flow rates, etc.products, flow rates, etc.

Microstructure/hardness prediction to assess Microstructure/hardness prediction to assess hydrogen cracking susceptibilityhydrogen cracking susceptibility

Structural integrity assessment for repair sleeves Structural integrity assessment for repair sleeves and large-diameter large-ratio hot tap tees and and large-diameter large-ratio hot tap tees and stopplesstopples

Special issues applicable to thin wall pipeSpecial issues applicable to thin wall pipe Direct deposition repair methods.Direct deposition repair methods.

Other Materials and Joining Other Materials and Joining Issues (from 2003 lists)Issues (from 2003 lists)

Inspection of CRA clad pipesInspection of CRA clad pipes Composite materialsComposite materials Composite Reinforced Steel Composite Reinforced Steel

(Leal/Rupture)(Leal/Rupture) Deep Water technologyDeep Water technology Design of SCR systemsDesign of SCR systems Plastic PipePlastic Pipe High pressure linersHigh pressure liners LNG/ CNGLNG/ CNG

New Issues from New Issues from Alternative Pipeline Alternative Pipeline

ProductsProducts High CO2 contentHigh CO2 content Hydrogen contentHydrogen content Hydrogen conversionHydrogen conversion Others?Others?

Top 5 Needs Top 5 Needs RBDARBDA

Tools / Techniques / StandardsTools / Techniques / Standards Strain Based DesignStrain Based Design

Experimental data – compressive and tensileExperimental data – compressive and tensile AUTAUT

Improved precision and accuracyImproved precision and accuracy Optimization of Welding ProcessesOptimization of Welding Processes

Reduced flaw size to meet strain based design Reduced flaw size to meet strain based design Consumables for overmatching M/L, tie-in, dbl-jointConsumables for overmatching M/L, tie-in, dbl-joint Appropriate equipment on right-of-wayAppropriate equipment on right-of-way

Corrosion/SCCCorrosion/SCC Improved models to predict growth ratesImproved models to predict growth rates

Issues and Issues and OpportunitiesOpportunities

Identified at 2003 R&D Identified at 2003 R&D ForumForum