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Pre-Installed User:
Pre-Installed User:
Combining Engineering Combining Engineering
And And New TechnologyNew Technology
Peter Hatcher, P.Eng.Peter Hatcher, P.Eng.
Fluor Canada Ltd.Fluor Canada Ltd.
March 3, 2004March 3, 2004
C a l g a r y C e n t r efor Innovative Technology
2
Engineering & New TechnologyEngineering & New Technology
Opportunity UnboundedOpportunity Unbounded
Conventional WisdomConventional Wisdom
3
E P C E P C
Engineering Procurement & Construction (EPC)Engineering Procurement & Construction (EPC)
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EPC – Process IndustryEPC – Process Industry
Process Industry – Design Process Industry – Design EngineeringEngineering Conservative
Process Industry - ConstructionProcess Industry - Construction Proven Technologies
Significant Capital InvestmentsSignificant Capital Investments
New Technology - NIMP!!!!New Technology - NIMP!!!!
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Engineering & New TechnologyEngineering & New Technology
The essence of science: ask an impertinent question,
and you are on the way to a pertinent answer
Jacob BronowskiJacob Bronowski
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Engineering & New TechnologyEngineering & New Technology
Examples of Combining Engineering & Examples of Combining Engineering & TechnologyTechnology
Material of Construction Fabrication Mechanical Integrity
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Impertinent Question #1Impertinent Question #1
Does Material of Construction exist that Does Material of Construction exist that allows refining of following crude allows refining of following crude conditions???conditions???
High conventional corrosion rates naphthenic acid polythionic acid
High operating temperatures sensitization of stainless steels
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Material SelectionMaterial Selection
Conventional ApproachConventional Approach
Based on Code listed stainless steel materials: 321/347
v.g. resistance to sensitizationpoor resistance to naphthenic acid corrosion
316L/317Lv.g. resistance to naphthenic acid corrosionpoor resistance to sensitization
Above options do not provide Owner the capability to handle potentially highly corrosive process streams with long term reliability.
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Material Selection Material Selection
Selected MetallurgySelected Metallurgy
Unlisted Material:
16Cr11Ni2.5MoCb
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Strategy Strategy
Corrosion TestingCorrosion Testing
Mechanical PropertiesMechanical Properties
FormabilityFormability
WeldabilityWeldability
Aggressive Timeline / Complex ExecutionAggressive Timeline / Complex Execution
11Photograph showing a side view of an ASTM A262 method E (Strauss) specimen after exposure and bending.
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Weld MetalWeld Metal
Comparision of Yield Strength on welds between 16Cr 11Ni 2.5Mo Cb and 347 (API 530)
10
100
1000
300 400 500 600 700 800 900 1000
Temperature (°C)
Str
es
s (
MP
a)
YIELD STRENGTH OF 347 (API 530)
YIELD STRENGTH OF 16Cr11Ni2.5MoCb
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Larson-Miller ParameterLarson-Miller Parameter
1
10
100
1000
14 16 18 20 22 24 26
P - Larson-Miller Parameter
P = T(18.265 + log t) x 10-3
MPa
16Cr11Ni2.5MoCb
347SS (API 530)
Larson -Miller Parameter for 16Cr 11Ni 2.5Mo Cb & 347SS (API 530)
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Answer # 1Answer # 1 16Cr11Ni2.5MoCb 16Cr11Ni2.5MoCb
Resistance to naphthenic acid attack and Resistance to naphthenic acid attack and sensitizationsensitization
Thin wall allows for optimal heat transfer and Thin wall allows for optimal heat transfer and stress reductionstress reduction
Eliminate need for post weld heat treatmentEliminate need for post weld heat treatment
Eliminate requirement for soda ash wash Eliminate requirement for soda ash wash during shut downduring shut down
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Impertinent Question #2Impertinent Question #2
How can field pipe welding productivity be How can field pipe welding productivity be improved???improved???
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Welding Stainless Steel PipingWelding Stainless Steel Piping
GMAW-SGMAW-S No Backing Gas (NBG)
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HistoryHistory
Fluor previously investigated welding of Fluor previously investigated welding of stainless steels without a backing gas stainless steels without a backing gas using GTAW process using GTAW process
Resulted in quality issues and the ability to Resulted in quality issues and the ability to reproduce acceptable Code weldsreproduce acceptable Code welds
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Process OptimizationProcess Optimization
Optimized selected wire feed speedsOptimized selected wire feed speeds
High silicon filler metals High silicon filler metals
Shielding gas Shielding gas
Welder trainingWelder training
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NBG Stainless Steel WeldingNBG Stainless Steel Welding
Good appearanceGood appearance
No NDE defectsNo NDE defects
Good mechanical characteristicsGood mechanical characteristics
Good metallurgical structureGood metallurgical structure
Good Strauss Corrosion Test resultsGood Strauss Corrosion Test results
Good Pitting Corrosion Test resultsGood Pitting Corrosion Test results
Minimum oxidation on the IDMinimum oxidation on the ID
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Weld Root Weld Root
With Backing GasWith Backing Gas No Backing GasNo Backing Gas
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Answer #2Answer #2 GMAW-s NBG GMAW-s NBG
Low repair rateLow repair rate
Eliminates backing gas requirement Eliminates backing gas requirement
Welder friendlyWelder friendly
Significant cost savings over other Significant cost savings over other processesprocesses
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Impertinent Question #3Impertinent Question #3
How can we ensure integrity of high pressure How can we ensure integrity of high pressure high density polyethylene (HDPE) high density polyethylene (HDPE) pipeline???pipeline???
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Current PracticesCurrent Practices
Visual examVisual exam Poor correlation to weld quality for heavy wall
Bent-strap testBent-strap test (ASTM D2657)(ASTM D2657) Low probability of detection:
t
1-1/2 t(25mm min)
15 t(150mm min)
15 t(150mm min)
TEST STRAP
BUTT FUSION
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Current Practices Current Practices (Continued…)(Continued…)
Traditional UT pulse-echoTraditional UT pulse-echo Ineffective for heavy wall
Hydro testingHydro testing Derived from metallic systems Viscoelastic plastics
deformation depends on time and temperaturedoes not ensure long-term performance
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x
UT-TOFD ProbesUT-TOFD Probes
Fluor Ultrasonic Probes Fluor Ultrasonic Probes Patents are pending on this technology and its application
Transducer ReceiverLateral Wave
Back Wall Echo
Upper Tip
Lower Tip
Outer Diameter; Outside wall
Inner Diameter; Back wall
Flaw
ProbesProbes
WeldWeld
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Stage 1 - LaboratoryStage 1 - Laboratory Calibration blocks Double-blind test spools
indications correlated to defectslack of fusion (LOF) identified
Stage 2 - Field InvestigationStage 2 - Field Investigation Operating pipeline, analysis of field welds
Stage 3 - CorrelationStage 3 - Correlation UT-TOFD vs. UT-TOFD vs. Destructive TestingDestructive Testing Lab test spools Field welds
Development WorkDevelopment Work
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Correlation ExampleCorrelation Example
Accurate Accurate Defect Defect
IdentificationIdentification
Field SampleField Sample
TOFD ScanTOFD Scan
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Summary of findingsSummary of findings Visual examinationVisual examination
poor correlation Backwall echo - lateral wave lossBackwall echo - lateral wave loss
severe lack of fusion Multiple point reflectorsMultiple point reflectors
non-fusion and poor fusion Foreign contaminationForeign contamination
easily detectable ““Clear” UT-TOFD scanClear” UT-TOFD scan
properly fused
Bead Profile - Bead Profile - High/LowHigh/Low
Isolated Defects
Development Work Completed Development Work Completed
Lab Lab SampleSample
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Answer #3 UT-TOFDAnswer #3 UT-TOFD
Current Examination PracticesCurrent Examination Practices Not equipped to detect heavy wall flaws and faulty
welds Limits thermoplastic: low pressure, non-critical
New application for pipeline industryNew application for pipeline industry Leap in Quality of testing Plastics expansion into pipeline industry
UT - TOFD MethodUT - TOFD Method Ultrasonic Time of Flight Diffraction Reliable - quick - easy
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Summary Engineering & New Summary Engineering & New TechnologyTechnology
Combining Engineering & TechnologyCombining Engineering & Technology 3 examples
Conventional Approaches Not Necessarily Conventional Approaches Not Necessarily Optimum Optimum
Opportunities AboundOpportunities Abound