XI-929-09

THE PIPELINE-STEELS X100 AND X120

S. Felber, Institute for Building Construction and Technology (E 206), Vienna University of Technology, Karlsplatz 13, A-1040 Vienna, Austria, Tel ++43 1 58801 20640, Fax ++43 1 58801 20694, email sfelber@mail.zserv.tuwien.ac.at F. Loibnegger, Institute for Materials Research and Testing (TVFA - TU Wien), Vienna University of Technology, Karlsplatz 13, A-1040 Vienna, Austria, Tel ++43 1 58801 43061, Fax ++43 1 58801 43099, email friedrich.loibnegger@tvfa.tuwien.ac.at

ABSTRACT Nowadays already a few sections of pipelines are constructed of the pipeline-steels X100 or X120. These pipeline-steels are discussed in detail as well as the projects performed. A complete change from the steels X65 and X70 to the steels X80, X100, and X120 for pipelines has not happened until now. The paper deals with the development of the high strength pipeline-steels X100 and X120 with different approaches with respect to the chemical composition and the process parameters for the thermomechanical rolling process. The corresponding welding processes with welding parameters, the used consumable types, and heat-inputs of the joining process, preheating and interpass temperatures, and so on, are discussed, as well as the sensitiveness of different welding processes to hydrogen induced cracking and heat treatment. Furthermore, it deals with the chemical composition of the tested materials and the mechanical properties, as yield strength, tensile strength, hardness, and impact energy, as well as metallographic examinations. A big saving potential is in material costs and improved construction methods & equipment. Project cost reduction may result from various benefits that can be derived from using highstrength steels, even when the price per ton of the pipe increases as the material grade increases. The benefits include lower pipe transportation costs, and lower pipe laying costs. On the other hand the reduction in the manufacturing cost per ton of the pipe at a given transport capacity of a pipeline is amplified not only by an increase in the material grade of the steel but also by a reduction in the wall thickness of the pipe. Not only the pipe costs but also the pipe laying costs have an important influence. Larger pipes also result in faster and safer pipe lying with reduced costs for welding, testing, and site coating.

BENEFITS Pipeline-steels X100 and X120, welding parameters, consumable types, preheating and interpass temperatures for different projects. Determination of the mechanical technological properties, as yield strength, tensile strength, hardness, and impact energy. Comparison of the values.

KEY WORDS Pipes, pipelines, pipeline projects, thermomechanical rolling process, pipeline-steels, X100, X120, different welding processes, manual metal arc welding, mechanized welding, CAPS, mechanical properties, yield strength, tensile strength, hardness, impact energy.

XI-929-09

1 INTRODUCTION In former times construction steels with low yield strength, then normalized and microalloyed C-Mn-steels were used for natural gas pipelines [1]. The development with regard to different strength levels is shown in Figure 1 [1] to [4]. The next important step started in 1970 with the use of the thermomechanical treatment [5] and [6] for the steel production for pipes. According to this procedure since about 1973 the steel X60 and since 1977 the steel X70 were produced as the dominant pipeline-steel types [1]. An improved processing method, consisting of thermomechanical rolling plus subsequent accelerated cooling, emerged in the eighties. By this method, it has become possible to produce even higher strength materials like X80, having further reduced carbon content and thereby excellent welding properties in the field. Additions of molybdenum, copper, and nickel enable the strength level to be raised to that of grade X100, when the steel is processed to plates by thermomechanical rolling plus modified accelerated cooling [7]. Unlike the development and introduction of the grades up to X70, the introduction of the grade X80 takes longer time and is still going on [8] and [9]. Nowadays some pipeline projects are already performed using the steel X80. Also, in some long distance lines, where an increase of the capacity is not required, a reduction of the wall thickness (no change of diameter and pressure) can be an economic impulse to use pipes out of X80. This is going to be more and more implemented in Australia using HFI (ERW) pipes and in Canada using spiral pipes of the grade X80 [10].
130 120 110
yield strength [ksi]

TM = thermomechanically treated N = normalized DSAW X120 TM accelerating rate of development DSAW X100 TM DSAW X80 TM X70 TM X60 N X56 N X52 N X52 TM X65 HIC 1970 1980 1990 year 2000 2010 X60 TM SMLS X65 TM

100 90 80 70 60 50

X42/46 40 1950 1960

Figure 1. Developmental periods for high strength line pipes [3] and [4] A complete change from the steels X65 and X70 to the steels X80, X100, and X120 for pipelines has not happened until now. For some parts of longer pipeline projects in Northern Canada pipes made of X100 are already in use since 2002 [11] and [12]. The installation of X100 has been performed on the TransCanada system in Alberta by evaluating at the same time the summer and winter construction aspects of this pipeline-steel [11], [13], and [14]. Exxon Mobil and TransCanada PipeLines Ltd. claim that they have successfully demonstrated the field installation of the worlds strongest line pipe, X120. One mile (1.6 km) of X120 line pipe was installed as part of a longer pipeline looping operation in Northern Alberta in February 2004, using the CRC-Evans welding process. The steel was jointly developed under an agreement among ExxonMobil, Nippon Steel Corporation (NSC), and Mitsui & Co. Ltd. (Mitsui). The yield strength is supposed to be 50 % higher than for X80 and is expected to substantially reduce pipeline project costs. The companies showed that X120 was compatible with standard pipeline construction practices, even under severe Canadian winter conditions. The construction rate was comparable to rates expected for winter installation, and the weld defect rate was lower than rates commonly reported for major pipeline projects [15] and [16]. The pipeline-steels X80, X100, and X120 are also planned to be used in the Sakhalin-Janan Subsea [12] and [17].

XI-929-09

2 THE PIPELINE-STEELS X100 AND X120 EUROPIPE started the development of X100 already in 1995. The use of materials with even higher yield strength, such as grade X120, is the challenging next step. In the current line pipe standards a grade X100 and X120 is not specified, the chemical compositions and mechanical properties of these steels are shown in Supplement 1 the comparison of designations according to different standards in Supplement 2. In regard to producers of the pipelinesteel X100 see Supplement 3. In regard to a further development from X70 to X80 it could be assumed that an increase of the strength properties (tensile strength and yield strength) is possible without any difficulties by just a small increase of the additional alloying elements, which however unfortunately is not the case. Figure 2 shows the occuring minimum yield strength values dependent on the carbon equivalents [18]. According to [19] there are two processes of different cooling capacity: (I) water cooling after rolling to intermediate temperature (600 ~ 500 C) followed by air cooling (DAC I) and (II) water cooling to ambient temperature after rolling (DAC II). DAC I is applied to X80 and DAC II to X100. For further information about thermomechanical treatments see [20] to [26].
1 100
developments

1 000

TM-DQ +A TM-DQ +A

minimum upper yield strength [N/mm ]

900
special steels

lo ci t y

800

TM-BA +A TM-BA +A TM-BA TM-BA V

700

600

standardized steels

co ol in g

ve

500

TM

TM

+alloying elements +micro-alloying elements C-Mn

400 WBB 300 wall thickness 0.2 0.3

C eq IIW = C +
N V TM BA DQ A WBB

N heavy plate

0.4

0.5

0.6

0.7

Mn Cr + Mo + V Cu + Ni + + 6 5 15
normalized water quenched and tempered thermomechanical rolling accelerated cooling direct quenching annealed hot rolled wide strip

Figure 2. Yield strength versus carbon equivalent for different TM-rolling treatments [18]

XI-929-09

As can be seen in Figure 3 three different approaches have been developed for grade X100 with respect to the chemical composition and the process parameters for the thermomechanical rolling process. Approach A is characterized by a relatively high carbon content and carbon equivalent of 0.49 as well as a low cooling rate and a relatively high cooling stop temperature. Approach B with a carbon equivalent of only 0.43 has been used in combination with fast cooling rates down to a very low cooling stop temperature. Approach C enables the desired property profile to be achieved through an optimized two-stage rolling process in combination with medium carbon content, a medium carbon equivalent and optimized cooling conditions. This approach ensures excellent toughness as well as fully satisfactory field welding ability of the pipes. It combines a medium alloying content right between the first two approaches. For further information see [27] and [28].
C-content 0.08 % 0.06 % A 0.05 % 0.43 C steel chemistry 0.49 0.48 Ceq IIW

l ow

hi g

h hig cooling rate (AcC)

B cooling parameters

l ow
cooling stop temperature (AcC)

Figure 3. Three different approaches to reach API grade X100 [28] In regard to the development of the steel grade X120 the greatest challenge has been to develop a micro-structure with high strength and toughness, which is additionally weldable. For that purpose the following three possibilities of a development of the micro-structure have been investigated: - mainly lower bainite, - dual phase, and - tempered lamellar martensite. The chemical composition of the tested three micro-structures are shown in Table 1.
micro-structure lower bainite dual phase tempered lamellar martensite min max min max min C 0.03 0.09 0.05 0.09 0.06 Mn 1.0 2.5 0.5 2.0 0.2 Ni 0.0 2.0 0.0 2.0 0.5 Mo 0.2 0.5 0.2 0.8 0.2 Cr 0.0 0.5 0.0 0.5 0.0 Cu 0.0 0.5 0.0 0.5 0.5 Nb 0.01 0.04 0.01 0.08 0.02 V 0.02 0.08 0.02 0.10 0.03

max 0.09 2.0 2.0 0.8 0.5 2.0 0.12 Table 1. Chemical composition of the three micro-structures [29]

0.15

Some of the tested steels contain boron and others not. Boron accelerates the hardening of steels with low carbon content and little alloying elements. It also supports the development stages, which are dominated by grain degeneration, like the forming of ferrite, granular bainite, and upper bainite. Therefore, the addition of boron makes the austenite transformation possible, as much as the forming of lower bainite and lamellar martensite. The steels containing boron shall be melt carefully and handled with care to contain boron in permanent solution. Boron has to be protected of a combination with oxygen, nitrogen, and carbon.

XI-929-09

Recrystallization rolling produces fine and homogeneous austenitic grain. The plates are heated to temperatures between 1 000 and 1 200 C to heat the main part of the alloy to a durable solution. The mechanical properties of the three X120 micro-structures are shown in Table 2.
micro-structure lower bainite dual phase tempered lamellar martensite YS [N/mm] 690 - 900 620 - 860 960 - 1 030 TS [N/mm] 931 - 1 100 960 - 1 140 1 000 - 1 070 YS / TS [-] 0.75 - 0.85 0.65 - 0.75 0.94 - 0.99 DBTT [C] -60 - -90 -80 - -90 -90 - -105 CVN [J] at -40 C 230 - 300 250 - 300 100 - 240

Table 2. Mechanical technological properties of the three tested micro-structures of X120 (DBTT Ductile-to-Brittle Transition Temperature, CVN absorbed impact energy tested with Charpy-V specimens) [29] The production of the pipes made of X120 is reduced presently to a wall thickness of 12 mm to 20 mm. This range can be enlarged by improved processing procedures [29]. For further information see [27], [28], and [30] to [38]. Pipeline-Steel X100 This high strength material has a specified yield strength of 690 N/mm2 minimum and a tensile strength of 865 N/mm minimum, which allows high operation pressure with small wall thickness. The chemical composition and the mechanical properties are shown in Table 3.
C 0.070 Ni 0.300 Si 0.030 Mo Mn 1.900 V P Cr Al Ti S 0.020 Nb Cu N Ca YS 0.050 0.200 0.005 690 N/mm2 absorbed impact energy 180 J at 0 C B TS 865 N/mm2

- details not available Table 3. Chemical composition (values in mass-%) and strength values of the tested steel X100 [6] and [39] to [41] For X100 no technological breakthroughs in TM rolling and accelerated cooling were necessary, just an optimization of the existing technology. Since 1995 six small mill production trials have been completed in a wall thickness range from 12.7 mm up to 25.4 mm and diameters between 30 (768 mm) and 56 (1 434 mm) [42]. As a result, the production window becomes narrower but a heat treatment of the plates or pipes is obviously not necessary. Some investigations performed with this steel are described in [43]. For further information see [3], [35], [41], [42], and [44] to [58]. Pipeline-Steel X120 This steel has a specified yield strength of 830 N/mm minimum and a tensile strength of 931 N/mm minimum. The chemical composition of the test material used can be seen in Table 4, where also the specified mechanical properties are shown.
C 0.05 Si Mn P S Al 0.3 1.9 0.01 0.0006 0.04 Nb + V + Ti B N PS < 0.06 0.001 0.004 890 N/mm YS / TS 86 %, absorbed impact enery 280 J at -40 C Cr + Ni + Mo < 0.5 TS 1 035 N/mm

-1... details not available Table 4. Chemical composition (values in mass-%) and mechanical properties of the tested steel X120 [59]

XI-929-09

The required properties of a steel in grade X120 are only attainable with a mainly bainitic micro-structure that predominantly consists of lower bainite. Due to the combination of a high dislocation density and a very fine scale substructure, so-called domains, this lower bainitic micro-structure is a reasonable option for an ultra-high-strength level along with sufficient toughness properties. The basic alloying system contains Cu, Ni, Cr, Mo, and the microalloying elements V, Nb, Ti, and B. There is a very narrow production window in terms of chemistry and rolling and cooling conditions. One of the special challenges is the pipe forming, especially the U-forming step is affected by spring back. It can lead to shells that cannot be inserted into the O-press [42]. For further information see [42] to [44], [58], and [60] to [63].

3 WELDING OF PIPES For pipelines the welding processes Manual Metal Arc Welding (MMAW), Gas Metal Arc Welding (GMAW), Tungsten Inert Gas (TIG) Welding, and Submerged Arc Welding are in general used. In regard to more details on the welding processes see [64] and [65]. MMAW: Supplement 4 shows a welding procedure specification for X100 and Supplement 5 one for X120. GMAW: In regards to the gas metal arc processes just the CAPS-process should be explained more in detail, because it was tested for welding in the field for X100. The CAPS-Process: The CAPS-process, the "Cranfield Automated Pipewelding System-process, is a special gas metal arc welding process on the basis of the tandem-technology, which was developed by Cranfield University for pipeline engineering. The CAPS process makes pipeline welding faster and more economic, even under hard environmental conditions, as extreme cold climate [66]. Although the potential of multi-wire GMAW was first explored as early as the 1950s, it has not become commercially viable as the power source technology in the process was unstable. Tandem GMAW differs from conventional GMAW as two welding wires are passed through the same welding torch. A single torch with two contacts is used to feed both wires into a single weld pool. This tandem GMAW torch is specifically developed for the use of narrow gap weld preparations utilized in pipeline welding. Further development led to the use of two tandem torches on a single carriage, called therefore dual tandem welding. The high speed of tandem GMAW is retained and two passes are deposited simultaneously [67] to [70]. The weld metal micro-structure and metallurgical properties are also similar to conventional mechanized pipeline welds. CAPS is therefore suitable for the use on all line pipe materials including X100 steels. The system can be fitted to any welding head using dual oscillation capabilities. It is important that each torch has a separate oscillator to allow the last fill and cap passes to be completed simultaneously. Because of the high travel speed, an oscillation rate of more than 400 beats per minute is required to avoid a saw-tooth effect. Travel speeds of 1 m/min can be used for all filler layers and speeds of 1.5 m/min can be used in the position 2G. This compares with speeds of approximately 50 cm/min for the mechanized GMAW process currently used for pipelines. Surprisingly, it was found that the cap pass could also be welded at 1 m/min. The cap pass is normally the slowest pass with travel speeds of approximately 30 cm/min. The girth welds were satisfying X80 mechanical tests requirements [67]. The chemical compositions of these welding rods are given in Supplement 6. For detailed information on the root pass and the filler layer technique see [71]. The mentioned Alaska gas pipeline made of X100 will be built with a diameter of 1 321 mm and a wall thickness of 22.9 mm. The yield strength of the weld metal will be 810 N/mm2. These requirements were simulated in field tests with the pipeline-steel X80 with a pipe diameter of 1 016 mm and a wall thickness of 19.1 mm from March 3 to 13, 2003 with the

XI-929-09

CAPS-process in Edmonton, Alberta, Canada. The preparation of the joint was similar to the one for the CRC-Evans-process, see Figure 4 [66] and [72].
- 52
2.3

45

4.0 - 5.0

37. 5

Figure 4. Preparation of the joint for the CAPS-process and macroscopic picture of a circumferential joint with a wall thickness of 14.9 mm made of the pipeline-steel X100 [73] The pipes were preheated to 100 C before the internal layer was welded. The welding wire was GSNi1Mo (1 % Ni, 0.3 % Mo). All layers were protected with a mixed Ar gas with 5 % He, 12.5 % CO2. The internal welding device had 4 welding heads using the wire ER480S-6. After the root pass, the welding tents were built up and the external layers were welded with the CAPS dual-tandem-process with the wire ER690S-G. The welding velocity was double the one of the root pass for the filler layers and twice as large as common in pipeline engineering. For the top layer single-tandem-gas metal arc welding was used [66]. In regard to further information and the mechanical technological properties see [66], [68], [69], [71], and [74] to [88]. At the beginning of January 2002 the work started in Canada with single-tandem-devices on a pipe with a diameter of 610 mm made of X80 and with dual-tandem-devices on a pipe with a diameter of 914 mm made of X100, and in September 2002 the first pipeline was laid made of X100 by TransCanada Pipelines [73]. The pipes can only be laid in winter, when the ground is frozen enough to hold the weight of the construction equipment and the snow and ice protects the tundra form permanent damage by vehicles. The 24 m long pipes must be welded inside a special shelter. This protective enclosure is transported from weld-seam to weld-seam suspended from a side-boom tractor. Each welding shelter needs to be selfsufficient, carrying all equipment and consumables for the welding operation and powering the welding power sources from a diesel generator. To obtain the largest welding speeds, welding has to be performed vertical down with one machine on each side of the pipe. The welding passes shall be made by using the RMS Internal Welding Machine. This equipment acts as an internal alignment clamp for the pipe to align the pipe bevels and incorporates 4 GMAW welding heads that travel around the inside of the pipe at a speed of 762 mm/min. Once the root is completed, the welding shelter shall be set over the weld and the external passes shall be completed using the CAPS dual-tandem process. Each welding machine carries two tandem welding torches spaced 70 mm apart, so two weld passes can be deposited simultaneously. Three weld runs shall be performed with dual-tandem GMAW, before the final cap pass is made with single tandem GMAW. All filler layers shall be welded at a travel speed of 1 300 mm/min, which is more than twice the speed of the current welding technology used for pipeline construction. The Alaska Gas Pipeline is being designed using a X100 line pipe. However, X100 has never been used in a long-distance pipeline before and the 690 N/mm of the pipe must be overmatched by the strength of the weld metal. BP requires a minimum weld metal yield strength of 810 N/mm for X100 [72]. The completed weld has a very similar profile to conventional mechanized pipeline welds so conventional radiography and automated ultrasonic testing can be used for welding inspection. The weld metal

1.5

XI-929-09

micro-structure and metallurgical properties are also similar to conventional mechanized pipeline welds [67]. Supplement 7 shows the welding parameters for the CAPS-process. Recommendations of consumables for different pipeline-steel grades according to Boehler can be found in Supplement 8. Figure 5 shows the sensitiveness of different welding processes to hydrogen induced cracking.
40

ml of diffusible hydrogen

111-C

unacceptable

100 g steel

acceptable 5 111-B and 136 2 135 and 136 X65 X60 X100 X120 sensitivity for hydrogen induced cracks

Figure 5. Sensitiveness of different welding processes to hydrogen induced cracking (111 ... manual metal arc welding, C ... cellulosic electrodes, B ... basic electrodes, 135 ... MAG-welding with solid wire, 136 ... MAG-welding with filler wire) [89] and [90]

4 HEAT TREATMENT OF PIPES According to [91] with the Taper test the maximum hardness is identified depending on the cooling time t8/5 and two different wall thicknesses, see Figure 6. It shows clearly that the influence of the cooling time and hardening is very small for this steel. With the Tekken-test it was found, see Figure 7, that the preheating temperature should be at least 125 C. It should be mentioned that for X100 cracks in the weld metal are more likely than interpass cracks [91].
ignition spot 30 mm

70 mm
thickness mm kJ/cm

200 mm thickness of the wedge [mm]

64 133 17 9.5

22 18 16 14 18 16 14 12 10

12

10

maximum hardness HV 10

450

400

350

300 0.5 2 5 cooling time t8/5 [s] 10 20

Figure 6. Taper test at X100 [91]

XI-929-09

200 A 150

60

60 100 number of cracks [%] 80 60 40 20 0 0

80

A'

60 A - A'
thickness 64 mm 133 mm surface tr. microgr. root pass

50 100 150 200 preheating temperature [C]

Figure 7. Tekken test on X100 (tr. microgr. transverse micrograph) [91] In Supplement 9 the preheating and interpass temperatures, as specified by the manufacturers or used in welding, are collected.

5 WELDING TECHNOLOGICAL EXAMINATIONS AND MECHANICAL TECHNOLOGICAL PROPERTIES Pipeline-Steel X100 The impact energy values of the test plate of the pipeline-steel X100 are shown in Figure 8. In regard to combined welding of this steel with cellulosic and basic electrodes of this steel see the welding procedure specification Supplement 4, in regard to GMAW with a single or dual torch see [92], in regard to MMAW and SAW see [90], in regard to mechanized rolled welds see [85], and in regard to results of different laser and laser hybrid welds on X100 see [93].
300 X100-longitudinal specimen X100-transverse specimen X120-longitudinal specimen X120-transverse specimen

250

impact energy [J]

200

150

100

50

0 -200 -160 -120 -80 temperature [C] -40

Figure 8. Impact energy values over the temperature for the pipeline-steels X100 and X120

XI-929-09

Pipeline-Steel X120 The impact energy values of the test plate of the pipeline-steel X120 are shown in Figure 8. In regard to manual metal arc welding of this steel see the welding procedure specification Supplement 5. In regard to further results see [42].

6 METALLOGRAPHIC EXAMINATIONS After taking of the specimens, marking, and the first grinding or flattening of the surfaces of the specimens, the surfaces have been fine-ground in steps up to a granulation of 4 000 m. After grinding, the surface of the specimens has been polished in steps down to 1 m. Unfortunately, not all the materials react in the same way to the etching, which led to strong contrasts and coloring on the light microscopic pictures. The alcoholic nitric acid (HNO3 (nital etching fluid)) used for the etching process is a grain boundary etching fluid. The etching with nitric acid is especially useful for unalloyed and low alloyed structural steels, so also for the ferritic-pearlitic and bainitic steels. It results into a sufficient etching already after a few seconds, depending on the material and the concentration of the etching fluid [94] and [95]. etching fluid: 1 to 5 cm nitric acid (HNO3), 100 cm ethyl alcohol (methanol, ethanol) [96]. The grain boundary etching has been performed with nital. The pearlite and the grain boundaries stand out dark against the ferrite. In case of the tested ferritic-pearlitic pipelinesteels X70 etching times of approximately 10 to 15 seconds were appropriate. In case of the tested bainitic pipeline-steels X80 and X120 the etching times have been slightly longer to achieve a good contrast of the grain boundaries. For the light microscopic examinations, see also [97] and [98], a longitudinal, a transverse, and a surface micrograph, see Figure 9, have been performed.
microscopic pictures of the pipeline-steels (etched with nital 2 %) X70 (L) X70 (S) X80 (B) X80 (N) X120

Figure 9. Structure of the pipeline-steels X70, X80, and X120 (magnification

In case of the pipeline-steel X120, the arithmetic averages of the determined microhardness values have been HV 330 / 0.1 for the longitudinal cross-section, HV 338 / 0.1 for the transverse cross-section, and HV 323 / 0.1 for the flat cross-section. In comparison to that the normal Vickers hardness tests resulted in average hardness values of 320 HV10 for the longitudinal cross-section, of 320 HV10 for the transverse cross-section, and 325 HV10 of the flat cross-section.

7 DESIGN, SAFETY, ECOLOGICAL, AND ECONOMICAL ASPECTS FOR PIPELINES For information about design factors, design codes, and safety factors see [99] to [107], in regard to fatigue design and fatigue assessment see [99], [100], [103], and [108] to [112]. More information on Good-Workmanship or Fitness-for Purpose can be found in [99] and [113]

10

XI-929-09

to [120], on construction in [121]. Since 1964 also safety requirements against earthquakes have been taken into consideration in most of the countries [113], [122], and [123]. Often over- or undermatching is discussed in case of welding procedure qualifications. Overmatching means that the ultimate strength of the weld metal is larger than the strength of the base material: YS weld
metal

> YS base

material

(1)

If this requirement is accepted for the area construction of the pipeline, the following effects have to be considered: - the steel manufacturers have to meet the specifications and - the consumable manufacturers have to produce suitable consumables [2]. For further information, especially in regard to pipeline-steels with higher strength than X70, see [102] and [124] to [127]. Undermatching means that the yield strength of the base material is higher than the one of the weld metal. YS weld
metal

< YS base

material

(2)

For more details see [102] and [128] to [131]. For information on mismatching see [132]. In Figure 10 the entire project costs for the building of a pipeline are spread in percentage of the main cost causes. It can be clearly seen that the main costs are building and material costs. A big saving potential is therefore just in case of these costs [133] and [134], but in general the following considerations lead to cost savings: high strength pipe o reduced material costs o higher operating pressures higher design factors o higher operating pressures high productivity welding / inspection improved construction methods & equipment Also according to [135] half of the entire pipeline costs are building costs, and so the welded joints per day. This amount is mainly influenced by the welding velocity and especially by the welding velocity for performing the root pass.
engineering and design 7% communication 2% material 34 % operator 3%

construction 54 %

Figure 10. Typical distribution of costs for the building of an onshore natural gas pipeline [133] and [134] A major cost factor are fitness for purpose-considerations, which are especially influenced by the repair rates. For European pipelines the repair rates are 5 of 100 welded joints and the cut out-rates (e.g. because of cracks) 0.3 of 100 welded joints. A repair rate of 3 to 5 % percent is often seen as the best compromise solution between maximum welding velocity and optimum quality, see also [136]. The mainly occurring defects in case of welding of onshore pipelines are slag inclusions, followed in general by defects in the root pass. The repair costs could be reduced substantially, if the acceptance criteria for slag inclusions and other

11

XI-929-09

voluminous defects were less strict, and the welding of the root pass were inspected and checked more accurately. Mechanized welding processes cannot be found very often in Europe, with the exception of Russia. The repair rates for these processes are certainly already below the ones of 17 to 23 %, known from older publications from Russia [137]. [138] reports on the 50 km field trial at the RUHRGAS project, performed with the CRC process, that only 4 % of the welds had to be repaired. Also the CAPS process as field trial in Canada, performed by Cranfield University and Fronius, showed repair rates of 3.9 %. In this field trial, a grade X80 pipeline with a length of 3 km including 182 welds has been performed under arctic conditions of -50 C. This field trial is one of the primary parts to the big project of the Alaska Gas Pipeline planned with the pipeline-steel X100, with a total length of approximately 5 700 km. Further projects using the CAPS process in Indonesia, Korea, and Canada are planned [139]. In case of the TIG hot wire welding process used on a pressure pipe made of X100, the defect rate of 0.3 % at the beginning could be reduced to below 0.1 % [140]. Project cost reduction may result from various benefits that can be derived from using highstrength steels, even when the price per ton of the pipe increases as the material grade increases. The benefits include: - reduced quantity of steel required, - lower pipe transportation costs, and - lower pipe laying costs. The use of grade X80 line pipes in the construction of the first RUHRGAS X80 pipeline led to a material saving of approximately 20 000 t to the total amount of approximately 145 000 t, compared with grade X70 pipes through a reduction of the wall thickness from 20.8 mm for X70 to 18.3 mm for X80. This resulted also in a reduction of the pipe laying costs, because of reduced pipe transportation costs and reduced welding costs due to reduced welding times needed for the thinner walls [40]. According to [113] a total cost reduction of approximately 5 % is expected by upgrading from X65 to X80 and approximately 8 % by upgrading to X100, and, according to [141], the use of X80 pipe should provide an overall cost saving, compared to X70 pipe, equivalent to 8 - 12 % of the total pipe supply cost or 3 - 5 % of total project cost. The use of materials with still higher strength, such as grade X100 or grade X120 could lead to further material cost savings, as illustrated in Figure 11.
3 500 3 000 2 500

costs [USD/m]

2 000 1 500 1 000 500 0 API 5L X70 API 5L X80 API 5L X100 common costs welding laying materials not identified

Figure 11. Estimated costs per meter pipelines [56] A preliminary economic evaluation as feasibility study on X100 has been performed in 1997. Costs have been evaluated for several hypotheses: - Steel costs have been estimated according extrapolations from lower grades. - Costs of fittings and valves have been considered as a constant portion of the total steel costs. - Transportation costs have been evaluated as dependent on the steel weight.

12

XI-929-09

- Laying costs have been analyzed completely: trenching and field bending have been considered constant for both solutions, and welding costs have been divided in two parts, one constant and the other proportional to the thickness. Moreover, the possibly higher costs of consumables and the possibly greater difficulties for welders has been taken into consideration. - The other costs, like costs for coating and cathodic protection, have been considered to be equal for both solutions. On the other hand the reduction in the manufacturing cost per ton of the pipe at a given transport capacity of a pipeline is amplified not only by an increase in the material grade of the steel but also by a reduction in the wall thickness of the pipe. A reduction of the diameter of the pipe with the same wall thickness and a simultaneous increase in the pipeline operating pressure would represent a more favorable solution to the problem [27]. Not only the pipe costs but also the pipe laying costs have an important influence. The use of pipes with a length of 18 m results in a reduction of the number of girth welds required in the construction by approximately 33 % compared with the use of pipes with a length of 12 m. Larger pipes also result in faster and safer pipe lying with reduced costs for welding, testing, and site coating. Of course, also the use of intermediate lengths between 18 m and 12 m leads to reduced pipe laying costs, should the pipe lengths be restricted for transport reasons [47]. Of great importance are the same internal pipe diameters and out of roundness tolerances. To make the pipe more stable and, thereby, simplifying handling, it is necessary that the diameter to wall thickness ratio should be less than 100. Since thin-wall pipes are aligned by means of an internal alignment clamp in the field, out-of roundness of the pipe ends is not as important as the same internal diameter. The same diameter can be achieved particularly with expanded pipes. Large pipe diameters require more care in handling above the ditch. If the pipe laying requires a large number of field-bent pipes, contractors prefer submerged-arc welded pipes with lengths of 16 to 18 m [47].

8 DISCUSSION OF THE RESULTS For X100 no technological breakthroughs in TM rolling and accelerated cooling were necessary, just an optimization of the existing technology. The production window becomes narrower but a heat treatment of the plates or pipes is obviously not necessary. The required properties of a steel in grade X120 are only attainable with a mainly bainitic micro-structure that predominantly consists of lower bainite. Due to the combination of a high dislocation density and a very fine scale substructure, so-called domains, this lower bainitic micro-structure is a reasonable option for an ultra-high-strength level along with sufficient toughness properties. Unfortunately there were no values for fracture toughness investigations of the pipelinesteels X100 and X120. Further investigations for evaluation of these pipeline-steels should be done. Perhaps it is a benefit to make some experiences on investigations in the laboratory, the subjects are: examinations on the pipeline-steel X100 and X120, o CTOD, o hardness, repair rates, and repair procedures, high productivity inspection, and improved construction methods & equipment.

9 ACKNOWLEDGMENTS The authors thank the staff of the Institute for Testing and Research in Materials Technology (TVFA GmbH) of the Vienna University of Technology, of OMV-EEB-TS, of Boehler Welding, and of VOEST Alpine Steel Linz for their help.

13

XI-929-09

10 REFERENCES
[1] [2] Aigmueller, G., Schuetz, H.: Die Entwicklung und das Schweissen hochfester Roehrenstaehle. Schweisstechnik (1985) H. 1, S. 2-7. Perteneder, E., Koenigshofer, H., Mlekusch, J.: On the Present State of Field Welding of Pipelines by Means of Covered Electrodes. Pipeline Technology Conference, Oostende, Belgium, October 15 - 18, 1990. Gray, J.M.: Niobium Bearing Steels in Pipeline Projects. Microalloying International, Inc., Mannesmannroehren-Werke AG, Muehlheim, Deutschland. Andrews, R.M., Batte, A.D.: Developments in Fracture Control Technology for Gas Pipelines Utilising High Strength Steels. Advantica, Loughborough, UK. Kneissl, A., Ortner, B., Kleemaier, R., Windhager, M., Kuehlein, W.: Thermomechanisch behandelte Staehle. BHM, 135 (1990) H. 5, S. 147-154. Hillenbrand, H.-G., Kalwa, Ch.: Production and service behaviour of high-strength large-diameter pipe. Pipes and Pipelines International (2002) December, pp. 21-24. Hillenbrand, H.G., Kalwa, C.: High-strength line pipe for project cost reduction. Europipe GmbH, Ratingen, 2002. Graef, M.K., Hillenbrand, H.G., Niederhoff, K.A.: Production of large-diameter line pipe and bends for the world's first longe-range pipeline in grade X80 (GRS 550). Europipe GmbH, Ratingen, 1993. Caudhari, C., Ritzmann, H.P., Wellnitz, G., Hillenbrand, H.G., Willings, V.: German gas pipeline first to use new generation line pipe. Europipe GmbH, Ratingen, 1995. Hillenbrand, H.G., Heckmann, C.J., Niederhoff, K.A.: X80 line pipe for large-diameter high strength pipelines. Europipe GmbH, Ratingen, 2002. N.N.: Lowering Pipeline Costs Through Applied Technology. TransCanada. N.N.: Oil and gas pipelines in 2003: An overview. Pipes & Pipelines International, vol. 48 (2003) no. 6, November / December, pp. 23-27. Palmer, T.: Alaska Gas Pipeline Construction Cost Risks. TransCanada, Anchorage, Canada, June 16 - 17, 2004. Glover, A., Horsley, D., Dorling, D., Takehara, J., Savigny, K.W., Bruce, I.: Construction and Installation of X100 Pipelines. TransCanada Pipelines Ltd. Calgary, JFE Steel Corporation, BGC Engineering Inc.. N.N.: Turkey plans two oil lines. Pipe Line and Gas Technology (2004) June, p. 6. N.N.: CRC-Evans Welding Technology Puts Final Touch on Major Field Test Of X-120 and X-100 Pipe. TransCanada Pipeline Ltd., Houston, May 18, 2004. Egawa, T.: Outline of Sakhalin Pipeline Project. Norway-Japan Seminar "Milestones in onshore/offshore pipeline research", Tokyo, Japan, May 27, 2003. Wallner, F., Schimboeck, R., Rauch, R.: Verbesserte und neue TM-Staehle fuer geschweisste Konstruktionen. Internationale Schweiss- und Fertigungstechnische Tagung, Wien, Oesterreich, 25. - 26. Mai, 2000. Komizo, Y., Fukada, Y.: Weldability of large diameter grade X-80 and X-100 line pipe. Sumitomo metal Industries, LTD., Japan, July 1988. Engelmann, H., Engel, A., Peters, P.A., Dueren, C., Muesch, H.: First use of large-diameter pipes of the steel GRS 550 TM (X80) in a high-pressure gas pipeline. 3R International, 25 (1986) H. 4, April, S. 182-193. Heckmann, C.J., Ormston, D., Grimpe, F., Hillenbrand, H.G., Jansen, J.P.: Development of low carbon NbTiB nd micro-alloyed steels for high high-strength large large-diameter linepipe. 2 International Conference on Thermomechanical Processing of Steels, Liege, Belgium, June 15 - 17, 2004. nd Honeycombe, R., Bhadeshia, H.K.D.H.: Steels, Microstructure and properties. 2 Edition, Edward Arnold, London, New York, Sydney, Auckland, 1995. Afaganis, A.J., Barnes, K.R., Hanson, G.E., Lessard, R.G.: Development and Production of Large Diameter, High Toughness Gr. 550 (X80) Line Pipe at Stelco. I&SM (1998) June, pp. 49-56. Mayrhofer, M.: Thermomechanisch behandelte Staehle. EWE-Ergaenzungskurs, SZA, Maerz 1992. Streisselberger, A., Hanus, F., Schuetz, W., Hubo, R.: Erweiterte Nutzungsmoeglichkeiten der thermomechanischen Behandlung von Grobblechen. Stahl und Eisen, 117 (1997) Nr. 4, S. 49-57. Grimpe, F., Meimeth, S., Meuser, H., Liessem, A.: Entwicklung, Produktion und Anwendung thermomechanisch gewalzter hoch- und ultrahochfester Grobbleche. Stahl (2007) 4, S. 2-4. Graef, M.K., Hillenbrand, H.-G., Heckmann, C.J., Niederhoff, K.A.: High-strength large-diameter pipe for longdistance high pressure gas pipelines. ISOPE 2003, Honolulu, USA, May 26 - 30, 2003, Europipe GmbH, Ratingen, 2003. Grimpe, F., Meimeth, St., Heckmann, C.J., Liessem, A., Hehrke, A.: Development, Production and Application st of Heavy Plates in Grades up to X120. 1 International Conference Super-High Strength Steels, Rome, Italy, November 2 - 4, 2005. Petersen, C.W., Corbet, K.T., Fairchild, D.P., Papka, S., Macia, M.L.: Improving long-distance gas transmission th economics: X120 development overview. 4 International Pipeline Technology Conference, Ostend, Belgium, May 9 - 13, 2004. Kostic, M.M., Gedeon, S.A., Bowker, J.T., Dorling, D.: Development and Production of X80 (550 MPa) Gas Transmission Linepipe. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 2, pp. 399-409. Takeuchi, I., Fujino, J., Yamamoto, A., Okaguchi, S.: The prospects for high-grade steel pipes for gas pipelines. Pipes and Pipelines International, vol. 48 (2003) no. 1, January / February, pp. 33-43.

[3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21]

[22] [23] [24] [25] [26] [27]

[28]

[29]

[30]

[31]

14

XI-929-09

[32]

[33]

[34] [35]

[36] [37] [38]

[39] [40] [41] [42] [43]

[44] [45] [46] [47] [48]

[49]

[50] [51] [52] [53] [54] [55] [56] [57] [58] [59] [60] [61]

[62]

Asahi, H., Tsuru, E., Ohikita, S., Maruyama, N., Koyama, K., Akasaki, H., Murata, M., Miyazaki, H., Hara, T., Morimoto, H., Sugiyama, M., Shinada, K., Terada, Y., Ayukawa, N., Doi, N., Yoshida, T.: Development of UltraHigh-Strength Linepipe, X120. Nippon Steel Technical Report (2004) no. 90, July, pp. 82-87. st Kostic, M.M.: Manufacture, Properties, and Installation of X80 (550 MPa) Gas Transmission Linepipe. 1 International Pipeline Conference (IPC), ASME, Calgary, Alberta, Canada, June 9 - 14, 1996, vol. 1, Regulations, Codes, and Standards, Current Issues, Materials, Corrosion and Integrity, pp. 203-207. Asahi, H., Fujii, H., Sato, N.: Heavy Wall X80 Seamless Linepipe. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 2, pp. 253-262. Hillenbrand, H.-G., Amoris, E., Niederhoff, K.A., Perdrix, C., Streisselberger, A., Zeislmair, U.: Manufacturability of Linepipe in Grades up to X 100 from TM Processed Plate. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 2, pp. 273-285. Torvela, N., Porter, D.: Manufacture and Properties of Spiral-Welded X80 Pipes. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 2, pp. 411-420. Terada, Y., Tamehiro, H., Kojima, A., Ogata, Y., Katayama, K.: Development of X80 UOE Line Pipe for Sour Service. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 2, pp. 421-434. de Vito, A., Heisterkamp, F., Hulka, K., Pagone, N., Rizzi, L.: From standard production X 70 towards the development of X 80. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 2, pp. 565579. Hillenbrand, H.-G., Graef, M.K., Kalwa, Ch.: Development and production of high-strength pipeline steels. Niobium 2001, Orlando, Florida, USA, December 2 - 5, 2001, Europipe GmbH, Ratingen, 2001. Kalwa, Ch., Hillenbrand, H.-G., Graef, M.: High Strength Steel Pipes: New Developments and Applications. Onshore Pipeline Conference, Houston, Texas, USA, June 10 - 11, 2002, Europipe GmbH, Ratingen, 2002. Barsanti, L., Pozzoli, G., Hillenbrand, H.G.: Production and field weldability evaluation of X100 line pipe. Europipe GmbH, Ratingen, 2001. st Hillenbrand, H.-G., Kalwa, Ch., Liessem, A.: Technological solutions for ultra-high strength gas pipelines. 1 International Conference on Super-High Strength Steels, Rom, Italy, November 2 - 4, 2005. Hillenbrand, H.-G., Liessem, A., Biermann, K., Heckmann, C.J., Schwinn, V.: Development and production of linepipe steels in grade X100 and X120. Seminar of X120 grade high performance pipe steels, Technical Conference, Bejing, China, July 28 - 29, 2005. N.N.: Pipes and Tubes of Nippon Steels. Nippon Steel News (2005) no. 326, February, http://www.nsc.co.jp. Demofonti, G., Mannucci, G., Spinelli, C.M., Barsanti., L., Hillenbrand, H.G.: Large-diameter X100 gas line pipes: Fracture propagation evaluation by full-scale burst test. Europipe GmbH, Ratingen, 2000. Mannucci, G., Demofonti, G., Hillenbrand, H.-G.: Fracture properties of API X100 gas pipeline steels. Europipe GmbH, Ratingen, 2001. Graef, M.K., Hillenbrand, H.-G.: High quality line pipe a prerequisite for project cost reduction. Europipe GmbH, Ratingen, 1999. Demofonti, G., Mannucci, G., Hillenbrand, H.-G., Harris, D.: Evaluation of the suitability of X100 steel pipes for high pressure gas transportation pipelines by full scale tests. International Pipeline Conference, IPC, 2004, Calgary, Alberta, Canada, October 4 - 8, 2004. Hillenbrand, H.-G., Liessem, A., Biermann, K., Heckmann, C.J., Schwinn, V.: Development and production of linepipe steels in grade X100 and X120. Seminar of X120 grade high performance pipe steels, Technical Conference, Bejing, China, July 28 - 29, 2005. Graef, M.K., Hillenbrand, H.G.: Production of large-diameter line pipe - state of the art and future development trends. Europipe GmbH, Ratingen, 1995. Murakami, M.: Frontier Technology of Linepipe Production and Application. Norway-Japan Seminar "Milestones in onshore/offshore pipeline research", Tokyo, Japan, May 27, 2003. N.N.: High Strength Large Diameter Pipe Plate from Standard Production to X80 / X100. Streisselberger, A., Bauer, J., Fluess, P., Hillenbrand, H.G., Cordon, P.: High strength steel plates for line pipes in grade up to X100. Europipe GmbH, Ratingen, 1998. Mannucci, G., Demofonti, G., Barsanti., L., Spinelli, C.M., Hillenbrand, H.G.: Fracture behaviour and defect evaluation of large-diameter, HSLA steels, very high-pressure line pipes. Europipe GmbH, Ratingen, 2000. Hillenbrand, H.-G, Liessem, A., Knauf, G., Niederhoff, K., Bauer, J.: Development of large-diameter pipe in grade X100. Europipe GmbH, Ratingen, 2000. Barsanti, L., Hillenbrand, H.G.: Possible use of new material for high pressure line pipe constructions: The experience of SNAM RETE GAS and EUROPIPE on X100 grade steel. Europipe GmbH, Ratingen, 2002. Terada, Y., Tamehiro, H., Yamashity, M., Ayukawa, N., Hara, T.: Development of API X100 UOE Line Pipe. Nippon Steel Technical Report (1997) no. 72, pp. 47-52. N.N.: Research and Development of Class X100 and X120 Ultra-High-Strength, Large-Diameter Welded Steel Pipe. Sumimoto Metal Industries, Ltd., October 20, 2006. voestalpine Grobblech: Test plate out of X120. Material properties of a test plate out of X120 of voestalpine Grobblech GmbH, 5. Maerz 2008. N.N.: Integrated Mass Production of High-Strength X120-Grade Linepipe and other High-Strength Grades with Combined Properties. Nippon Steel Corporation, October 30, 2006. Hillenbrand, H.-G., Liessem, A., Biermann, K., Heckmann, C.J., Schwinn, V.: Development of high strength material and pipe production technology for grade X120 line pipe. International Pipeline Conference, IPC, 2004, Calgary, Alberta, Canada, October 4 - 8, 2004. Hillenbrand, H.-G., Liessem, A., Biermann, K., Heckmann, C.J., Schwinn, V.: Development of grade X120 pipe th material for high pressure gas transportation lines. 4 International Conference on Pipeline Technology, Ostend, Belgium, May 9 - 12, 2004, Europipe GmbH, Ratingen, 2004.

15

XI-929-09

[63] [64] [65] [66] [67] [68] [69] [70] [71] [72] [73] [74] [75] [76] [77] [78] [79] [80] [81] [82]

[83] [84] [85] [86] [87] [88] [89] [90]

[91]

[92] [93] [94] [95] [96] [97] [98]

[99]

Fujiwara, et al.: High-toughness, high-tensile-strength steel and method of manufacturing the same. United States Patent 6,183,573 (2001) February 6. Felber, S.: Pipeline Engineering. GS, 2009, ISBN 978-3-9501528-2-1. nd Felber, S.: Development of steels and welding processes for pipelines. 62 Annual Assembly and International Conference of the International Institute of Welding, Singapore, July 12 - 18, 2009, IIW XI-2009. Howard, R., Kepplinger, M., Schmidt, K.-P.: Automatisiertes Pipeline-Schweissen mit CAPS. DVS-Berichte, Band 235, 2005, S. 61-65. Blackman, S.A., Dorling, D.V., Howard, R.: High-speed tandem GMAW for pipeline welding. 4th Internat. Pipeline Conf., Calgary, Alberta, Canada, September 29 - October 3, 2002, pp. 517-523. N.N.: Schweissen im Doppeltakt. Schweiss- & Prueftechnik (2003) H. 8, S. 121. Hermann, Th.: Doppeltakt mal vier. Schweiss- & Prueftechnik (2004) H. 02, S. 28. Juhn, M.: Fronius Pipeline Edition. ASMET- Vortrag, OMV, Wien, Austria, 5. Dezember, 2005. Yapp, D., Blackman, S.A.: Recent Developments in High Productivity Pipeline Welding. Journal of the Brazil Society of Mechanical Science and Engineering, vol. XXVI (2004) no. 1, January - March, pp. 89-97. N.N.: How to melt a welders heart when the mercury plummets way below zero .... Case Study, C.A.P.S., Cranfield University of Technology, UK, Fronius, Austria. Perteneder, E., Koenigshoffer, H., Bischof, R.: Korszeru hozaganyagok tulajdonsgaia foeldbe fektetett csovezetkek hegesztsnl. Gp, vol. 51 (2000) no. 6, pp. 16-21. Wendelspiess, R.: IIW Subcommission XI-E, Transmission Pipelines. Report of the Meeting in Lausanne, France, June 28, 2006 at the Intermediate Meeting, Vienna, Austria, March 16, 2007. IIW XI-E-1009/05. Yapp, D.: Review of Activities of IIW Subcommission XI-E Transmission Pipelines. IIW XI-847/06. Blackman, S.: Developments forecast to reduce pipeline construction costs. Welding and Metal Fabrication (2001) September, pp. 7-10. Yapp, D.: Review of Activities of Subcommission XI-E Transmission Pipelines 2006/07. IIW XI-873/07. Norrish, N., Blackman, S.: High Integrity Welding Process for Pipeline Girth Welding. International Conference Pipeline Repairs and In-Service Welding, Wollongong, Australia, March 24 - 26, 2003, paper 4. Harwig, D, Blackman, S., Norrish, J.: Proposal for a Joint Industry Project on: Novel Arc Welding Processes for Improved Pipeline Welding. EWI, Welding Engineering Research Centre, October 15, 2002. N.N.: EWI The Materials Joining Experts. EWI. Yapp, D.: Welcome to Cranfield University. Intermediate Meeting der IIW SC XI-A und XI-E, Cranfield, UK, November 29 - 30, 2007. Yapp, D.: Effect of Shielding Gas Mixtures on Bead Geometry and Mechanical Properties of High Strength Pipeline Welds. Intermediate Meeting der IIW SC XI-A und XI-E, Cranfield, UK, November 29 - 30, 2007, IIW XI-E-1028/07. Norrish, J., Blackman, S., Harwig, D.: Novel Girth Welding Developments for Transmission Pipelines. WTIA International Pipeline Integrity Repairs Conference, Sydney, Australia, March 9, 2004, paper 7. Yapp, D.: Application of Tandem Gas Metal Arc Welding to X80 and X100 Pipelines. IIW SC XI-E meeting, Vienna, Austria, March 16, 2007. Gianetto, J.A., Bowker, J.T., Bouchard, R., Dorling, D.V., Horsley, D.: Tensile and Toughness Properties of Pipeline Girth Welds. IIW XI-853/06, IPC 2006, Calgary, Alberta, Canada, September 25 - 29, 2006. Yapp, D., Liratzis, H.: Mechanical Properties of Pipe Girth Welds in High Strength Pipeline Steels. IIW XI875/07. N.N.: Cold metal transfer digital GMA welding. Australasian Welding Journal, vol. 50 (2005) First Quarter, pp. 14-15. Kepplinger, M., Weigerstorfer, C.: Pipelineschweissen unter arktischen Bedingungen. Schweiss- & Prueftechnik (2004) 12, S. 167-169. Quintana, M.A.: Development of welding consumables: A historical review. Pipeline World (2005) no. 7, February, pp. 20-23, 27. van der Mee, V.J.H.M., Jansen, H., Kalfsbeck, B., van Ettger, P.: Consumables and practices for welding high th strength steels. 60 Annual Assembly and International Conference, Proceedings of the IIW International Conference Welding & Materials, Technical, Economical and Ecological Aspects, Dubrovnik & Cavtat, Croatia, July 1 - 8, 2007, pp. 271-281. Krammer, W., Starnberger, R., Ornig, H., Schuetz, H., Dittrich, S., Perteneder, E.: Fertigung und Montage von Druckrohrleitungen aus StE 690 fuer ein 1600-MW-Pumpspeicherwerk in Taiwan. DVS-Berichte, Band 146, 1992, S. 28-34. Gianetto, J.A., Bowker, J.T., Dorling, D.V.: Assessment of properties and microstructure of X100 pipeline girth welds. Welding in the World, vol. 49 (2005) no. 11 - 12, November / December, pp. 77-89. Gordon, R., Holdren, R., Johnson, M., Lozev, M.: Reducing pipeline construction costs: New technologies. Welding in the World, Le Soudage Dans Le Monde, vol. 47 (2003) no. 5 - 6, May / June, pp. 7-12. N.N.: Testing. Heat Treating Progress (2005) November / December, pp. 62-73. Schumann, H.: Metallographie. 12. Auflage, VEB Deutscher Verlag fuer Grundstoffindustrie, Leipzig, 1989. Schumann, H.: Metallographie. 13. Auflage, Deutscher Verlag fuer Grundstoffindustrie, Leipzig, 1990. Liepert, G.: Metallo- und fraktographische Untersuchungen an Pipelinestaehlen. Diplomarbeit, TU-Wien, Oktober 1999. Liepert, G., Felber, S., Varga, T.: Werkstoffphysikalische Untersuchungen an Staehlen fuer Erdgasleitungen. Schriftenreihe der Technischen Universitaet Wien: Schweisstechnik und verwandte Verfahren, Internationale Konferenz Schweisstechnik, Werkstoffe und Werkstoffpruefung, Bruchmechanik und Qualitaetsmanagement, Wien, Oesterreich, 25. - 27. September 2000, S. 169-180. Hopkins, Ph.: Introduction to Basic Pipeline Engineering Principles. Penspen Integrity, UK, 2003.

16

XI-929-09

[100] Hopkins, Ph.: Defect Assessment in Pipelines, Course, vol. 1. Penspen Integrity, UK, 2004. [101] Bjornsen, T.: Experiences with new DNV pipeline codes. Milestones of Offshore/Onshore Pipeline Research, Japan-Norwegian Seminar, Tokyo, Japan, 2003, May 27. [102] Hopkins, Ph.: Defect Assessment in Pipelines, Course, vol. 2. Penspen Integrity, UK. [103] Mohr, W.: Strain-Based Design of Pipelines. EWI Report, Project No. 45892GTH, October 8, 2003. [104] Yatabe, H., Masuda, T., Toyoda, M.: Effects of the Design Factor on the Large Deformation Behavior of X80 Straight Pipes Subjected to Bending. JGA Paper Awards for Outstanding Research and Development, 2004. [105] Andrews, R.M., Jandu, C.S., McCallum, M., Bramley, D.N., Cousens, P.S.: Uprating of Pipeline System Beyond 72% Design Factor - an Integrated Risk-Based Approach. WTIA International Pipeline Integrity Conference, Wollongong, Australia, March 7 - 9, 2005, paper 5. [106] Hopkins, P.: High Design Factor Pipelines: Integrity Issues. WTIA International Pipeline Integrity Conference, Wollongong, Australia, March 7 - 9, 2005, paper 1. [107] Blackman, S.A.: An economic assessment of mechanized welding of high-strength linepipe for the Australian pipeline industry. Pipes and Pipelines International, vol. 48 (2003) no. 2, March / April, pp. 27-37. [108] Zhang, Y.H., Maddox, S.J., Razmjoo, G.R.: Experimental study and prediction of fatigue crack growth in girth welded pipes. OMAE:2002 Offshore Mechanics and Arctic Engineering Conference, Oslo, Norway, June 23 28, 2002. [109] Erdelen-Peppler, M., Knauf, G., Marewski, U., Reepmeyer, O.: Longitudinal welded pipes with enhanced th fatigue strength (Hifa pipe). 4 International Conference on Pipeline Technology, Ostend, Belgium, May 9 12, 2004, Europipe GmbH, Ratingen, 2004. [110] Macdonald, K.A., Maddox, S.J.: New guidance for fatigue design of pipeline girth welds. Engineering Failure Analysis, vol. 10 (2003) no. 2, April, pp. 177-197. [111] Chapetti, M.D., Otegui, J.L., Motylicki, J.: Fatigue assessment of an electrical resistance welded oil pipeline. International Journal of Fatigue, vol. 24 (2002) no. 1, January, pp. 21-28. [112] Bai, Y., Knauf, G., Hillenbrand, H.-G.: Materials and design of high strength pipelines. Europipe GmbH, Ratingen, 2000. [113] Nagahama, Y., Yamamoto, S.: High Performance Steel Pipes and Tubes. NKK Technical Review (2003) no. 88, pp. 81-87. [114] Barbaro, F.J.: Requirements for Welding X80 Grade Linepipe. WTIA International Pipeline Integrity Conference, Wollongong, Australia, March 7 - 9, 2005, paper 17. [115] Bilston, K., Dietsch, A., Fletcher, L.: Performance requirements for onshore pipeline girth welds in Australia a discussion paper. WTIA/APIA Panel 7 Research Seminar, Wollongong, Australia, October 26, 1995, paper 8. [116] Shuanlu, L., Yong, H., Changyi, Q., Pengbin, Y., Xinwei, Z., Jinheng, L.: Crack and fitness-for-service assessment of ERW crude oil pipeline. Engineering Failure Analysis, vol. 13 (2006) no. 4, June 2006, pp. 565-571. [117] Denys, R.M.: Weld-defect acceptance models need more validated inputs, Part 2: Using good mechanical, toughness and defect-size data could reduce unneeded repairs. Pipe Line & Gas Industry (1999) October, pp. 59-64. th [118] Hopkins, P.: Limitation of fitness-for-purpose assessments of pipeline girth welds. 7 NG-18/EPRG, Joint Biennial Technical Meeting on Line Pipe Research, Calgary, Alberta, Canada, August 29 - September 1, 1988, paper 22. [119] Roodbergen, A.H., Denys, R.M.: Limitations of fitness for purpose assessments of pipeline girthwelds. Pipe Technology, International Conference, Rome, Italy, November 17 - 19, 1987. [120] Fazzini, P.G.,Cisilino, A.P., Otegui, J.L.: Experimental validation of the influence of lamination defects in electrical resistance seam welded pipelines. International Journal of Pressure Vessels and Piping, vol. 82 (2005) no. 12, December, pp. 896-904. [121] Nayyar, M.L.: Piping Handbook. Sixth Edition, McGraw-Hill Inc., New York, St. Louis, San Francisco, Auckland, Bogot, Caracas, Lisbon, London, Madrid, Mexico, Milan, Montreal, New Delhi, Paris, San Juan, So Paulo, Singapore, Sydney, Tokyo, Toronto, 1992. [122] Akiyoshi,T., Fuchida, K., Shirinashihama, S., Tsutsumi, T.: Effectiveness of Anit-Liquefaction Techniques for Buried Pipelines. Transactions of ASME, Journal of Pressure Vessel Technology 116 (1994) August, pp. 261266. [123] Ozaki, H.: Gas Industry and Technical Activities of the Japan Gas Association. Norway-Japan Seminar "Milestones in onshore/offshore pipeline research", Tokyo, Japan, May 27, 2003. [124] Denys, R.M.: Methods for the assessment of girth weld strength. WTIA/APIA Panel 7 Research Seminar, Wollongong, Australia, October 26, 1995, paper 7. [125] Graef, M.K., Niederhoff, K.A.: Overmatching Criterion and Manual Welding of Linepipes in Grades X 70. Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 1, pp. 487-504. [126] Schwalbe, K.-H.: Welded joints with non-matching weld metal-crack driving force considerations on the basis of the Engineering Treatment Model (ETM). International Journal of Fracture, 62 (1993) pp. 1-24. [127] Chuanjing, Z.: Study for West-East gas pipeline shows safety benefits of overmatched girth welds. Oil and Gas Journal, vol. 101 (2003) March 10, pp. 62-65. [128] Boothby, P.J.: Pipeline-Schweissen in der Gasindustrie in Grossbritannien. Schweiss- und Prueftechnik, 53 (1999) H. 12, S. 178-181. [129] Koenigshofer, H., Bischof, R. Perteneder, E.: Schweisszusaetze fuer das Schweissen von Rohrrundnaehten im Pipelinebau. Schweiss- & Prueftechnik (2000) 3, S. 34-40. [130] Denys, R.: Provisional definitive statement on the significance of over and undermatching weld metal strength. IIW X-1222/91. [131] Denys, R.M.: Is the Transverse Weld Tensile Test a Reliable Test? Pipeline Technology Conference, Ostend,

17

XI-929-09

Belgium, September 11 - 14, 1995, vol. 2, pp. 581-590. [132] Pisarski, H.G., Tkach, Y., Quintana, M.: Evaluation of weld metal strength mismatch in X100 pipeline girth welds. IPC 2004, International Pipeline Conference, Calgary, Alberta, Canada, October 4 - 8, 2004. [133] Graef, M.K., Hillenbrand, H.G.: High quality line pipe a prerequisite for project cost reduction. Europipe GmbH, Ratingen, 1999. [134] Venton, P.: Pipeline construction costs in Australia. WTIA/APIA Panel 7 Research Seminar, Wollongong, Australia, October 26, 1995, paper 21. [135] Kwiatkowski, J.: Barriers and aids to cost efficient cellulosic MMA welding of pipelines. WTIA/APIA Panel 7 Research Seminar, Wollongong, Australia, October 26, 1995, paper 18. [136] Norrish, J.: Mechanised and automatic girth welding methods current options and future trends in Australia. First International Conference on Weld Metal Hydrogen Cracking in Pipeline Girth Welds, Wollongong, Australia, March 1 - 2, 1999. [137] Prosser, K.: Fitness-For-Purpose Assessments of Pipeline Girth Welds - Economic Considerations. IIW XI-E4/89. [138] Jansen, J.P., Mullie, J.P., Amoris, E., Jalty, P.: Present status, development and qualification of "TSE 550"th grade steel for large-diameter pipelines. 113 Gas Congress, Paris, France, September 10 - 13, 1996, Europipe GmbH, Ratingen, 1997. [139] Woodward, N.: Offshore Hyperbaric Welding. Intermediate Meeting der IIW SC. XI-A und XI-E, Cranfield, UK, November 29 - 30, 2007. [140] Auberger, G., Friedl, H., Klug, P., Rauch, R., Zimmerl, E.: Einfuehrung leistungsfaehiger Schweisstechnologien bei der Montage von Druckrohrleitungen aus hochfesten Feinkornbaustaehlen. Schweiss- & Prueftechnik (2001) 3, S. 38-41. [141] Robinson, R.: Value improvement through the use of X-80 pipe. Version for Pipeliner 161202. [142] OENORM EN 10 208 - 2: Stahlrohre fuer Rohrleitungen fuer brennbare Medien, Technische Lieferbedingungen, Rohre der Anforderungsklasse B (enthaelt auch Berichtigung AC:1996). Ausg. 1. April 1997. [143] DIN 17 172: Stahlrohre fuer Fernleitungen fuer brennbare Fluessigkeiten und Gase, Technische Lieferbedingungen. Ausg. Mai 1978. [144] API Spec 5L: Specification for Line Pipe. Ed. April 1995. [145] Sommer, B., et al.: Stahlrohr Handbuch. 12. Auflage, Vulkan-Verlag, Essen, 1995. [146] Drehsen, H.: Werkstoffschluessel der Schweisstechnik, Grundwerkstoffe - Schweisszusaetze, Erzeugnisformen. DVS-Berichte, Band 3, 1992. [147] Wegst, C.W.: Stahlschluessel. 17. Auflage, Verlag Stahlschluessel, Wegst GMBH, Marbach, 1995. [148] N.N.: Linepipe Plates. http://www.voestalpine.com/grobblech/en/products/heavy_plates/linepipe_plates.html. [149] N.N.: Line Pipe Tables. Pipeline & Gas Journal (2003) September, pipelineandgasjournalonline.com. [150] Widgery, D.: Pipeline welding - back to the future. IIW XI-E-1011/07. [151] N.N.: Pipeline catalogue. Esab. [152] N.N.: Pipelines Welding Handbook. Esab. [153] N.N.: Boehler Welding: Welding Consumables for Pipeline Construction. Boehler Welding. [154] Ornig, H., Starnberger, R.: Schweissen von Druckrohrleitungen aus StE 690. Stahl (1993) H. 3, S. 69-71. [155] N.N.: Pipeline welding consumables. Boehler Schweisstechnik GmbH, Maerz 2000. [156] Mlekusch, J.: Fallnahtschweissen mit basischen Stabelektroden im Rohrleitungsbau. Boehler Schweisstechnik Austria GmbH, Kapfenberg, 1997. [157] Knoche, E.: Selbstschuetzende Fuelldrahtelektroden fuer das Schweissen von Grossrohrleitungen. Der Praktiker (1995) Nr. 2, S. 52-57. [158] Muesch, H., Chaudhari, V., Hess, H., Wellnitz, G.: Feldschweissungen von Pipelines im Sauergaseinsatz. 3R international 29 (1990) H. 6, S. 332-338.

18

XI-929-09

steel grades according to material chemical composition maximum values [mass-%] API EN 10 208 DIN 17 172 number C1) Si Mn1) P S V Nb Ti Al2) N Cu Ni Cr Mo steels for seamless and welded pipes B L 245NB StE 240.7 1.0457 0.16 0.40 1.1 0.025 0.02 -1 -1 -1 0.06 0.012 0.25 0.30 0.30 0.10 X42 L 290NB StE 290.7 1.0484 0.17 0.40 1.2 0.025 0.02 0.05 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10 X52 L 360NB StE 360.7 1.0582 0.20 0.45 1.6 0.025 0.02 0.10 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10 X60 L 415NB StE 415.7 1.8972 0.21 0.45 1.6 0.025 0.02 0.15 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.35 steels for seamless pipes 1 X52 L 360QB 1.8948 0.16 0.45 1.4 0.025 0.02 0.05 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10 X60 L 415QB -1 1.8947 0.16 0.45 1.6 0.025 0.02 0.08 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.35 X65 L 450QB -1 1.8952 0.16 0.45 1.6 0.025 0.02 0.09 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35 X70 L 485QB -1 1.8955 0.16 0.45 1.7 0.025 0.02 0.10 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35 X80 L 555QB -1 1.8957 0.16 0.45 1.8 0.025 0.02 0.10 0.06 0.06 0.06 0.012 0.25 0.60 0.50 0.35 steels for welded pipes B L 245MB -1 1.0418 0.16 0.45 1.5 0.025 0.02 0.04 0.04 -1 0.06 0.012 0.25 0.30 0.30 0.10 X42 L 290MB StE 290.73) 1.0429 0.16 0.45 1.5 0.025 0.02 0.04 0.04 -1 0.06 0.012 0.25 0.30 0.30 0.10 X52 L 360MB StE 360.73) 1.0578 0.16 0.45 1.6 0.025 0.02 0.05 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10 X60 L 415MB StE 415.73) 1.8973 0.16 0.45 1.6 0.025 0.02 0.08 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35 X65 L 450MB StE 445.73) 1.8975 0.16 0.45 1.6 0.025 0.02 0.10 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35 X70 L 485MB StE 480.73) 1.8977 0.16 0.45 1.7 0.025 0.02 0.10 0.06 0.06 0.06 0.012 0.25 0.30 0.30 0.35 X80 L 555MB -1 1.8978 0.16 0.45 1.8 0.025 0.02 0.10 0.06 0.06 0.06 0.012 0.25 0.30 0.30 0.35 X100 L 690MB -1 -1 0.07 0.30 1.9 -1 -1 -1 0.05 0.02 -1 0.005 0.20 0.30 -1 -1 1 1 1 1 1 1 1 1 1 X120 L 830MB 0.06 0.23 1.9 - 0.04 0.02 0.004 - 0.20 1 ) ... for every decrease of 0.01 % under the maximum carbon content an increase of the manganese content 0.05 % over the adjusted highest level is allowed, whereas the increase is limited by 0.2 % 2 ) ... 0.015 < Al < 0.060 3 ) ... thermomechanical treatment steel grades according to material YS TS A4) YS / TS CVNmin5) API EN 10 208 DIN 17 172 number [N/mm] [N/mm] [%] [-] [J] L 245NB StE 240.7 1.0457 max 0.80 B 245 to 440 min 415 min 22 40 1 1.0418 L 245MB max 0.85 L 290NB StE 290.7 1.0484 X42 290 to 440 min 415 min 21 max 0.85 40 to 42 L 290MB StE 290.73) 1.0429 L 360NB StE 360.7 1.0582 max 0.85 1 X52 L 360QB 1.8948 360 to 510 min 460 min 20 max 0.88 40 to 42 L 360MB StE 360.73) 1.0578 max 0.85 L 415NB StE 415.7 1.8972 max 0.85 1 X60 L 415QB 1.8947 415 to 565 min 520 min 18 max 0.88 40 to 51 L 415MB StE 415.73) 1.8973 max 0.85 1 1.8952 L 450QB max 0.90 X65 450 to 570 min 535 min 18 40 to 57 3) L 450MB StE 445.7 1.8975 max 0.87 1 1.8955 L 485QB X70 485 to 605 min 570 min 18 max 0.90 40 to 77 L 485MB StE 480.73) 1.8977 1 1.8957 L 555QB X80 555 to 675 625 to 827 min 18 max 0.90 48 to 120 1 1.8978 L 555MB 1 1 1 X100 L 690MB 690 to 825 760 to 970 0.95 180 to 240 X120 L 830MB -1 -1 min 827 min 931 min 14 0.88 min 231 3 ) ... thermomechanical treatment 4 ) ... for transverse specimens taken out of the pipe body, L0 = 5.65 . S0 5 ) ... for transverse specimens at 0 C dependent on the external diameter of the pipe and a safety factor

-1 ... details not available Supplement 1. Chemical composition and mechanical properties of pipeline-steels according to OENORM EN 10 208 - 2 [142], DIN 17 172 [143], and API-standard [144] and the pipelinesteels X100 and X120 [6], [39], [40], [41], [43], [48], and [61]

19

XI-929-09

API 5L B X42 X52

designations according to OENORM EN DIN 17 172 10 208 - 2 L 245NB L 245MB L 290NB L 290MB L 360NB L 360QB L 360MB L 415NB L 415QB L 415MB L 450QB L 450MB L 485QB L 485MB L 555QB L 555MB L 690MB L 830MB StE 240.7 StE 240.7 TM StE 290.7 StE 290.7 TM StE 360.7 -1 StE 360.7 TM StE 415.7 -1 StE 415.7 TM -1 StE 445.7 TM -1 StE 480.7 TM -1 -1 -1 -1

ASME / UNS -1 K 03005 / K 03006 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 K 12700 / K 12709 -1 -1

material numbers according to OENORM EN 10 027 - 2 1.0457 1.0418 1.0484 1.0429 1.0582 1.8948 1.0578 1.8972 1.8947 1.8973 1.8952 1.8975 1.8955 1.8977 1.8957 1.8978 -1 -1

X60

X65 X70 X80 X100 X120

-1 ... details not available Supplement 2. Comparison of designations of pipeline-steels according to different standards [142] to [147]

country, town company name

AUSTRIA VOEST Grobblech FRANCE, Boulogne VALLOUREC & MANNESMANN GERMANY, Siegen BERGROHR GmbH GERMANY, Hilchenbach EISENBAU KREMER GERMANY, Salzgitter SALZGITTER JAPAN, Chiyoda-Ku Tokyo NIPON KOKAN JAPAN, Tokyo SUMITOMO METAL INDUSTRIES INC.
1

process

highest grade
X100 X100 X100 X100 X100 X100 X100

outside diameter [mm]

plates, b = 2 600 - 3 950 25 - 711

wall thickness [mm]

5.0 - 50.0 3.2 - 101.6

max length [m]

18.7 16.2 12.0 13.4 18.3 18.4 18.4

-1
SMLS DSAW DSAW DSAW DSAW SAW

-1
406 - 1 524 508 - 1 676 406 - 1 422 609 - 1 625

-1
6.3 - 203.0 6.3 - 20.6 6.0 - 44.0 6.4 - 38.0

- details not available Supplement 3. Suppliers for the pipeline-steel X100 [148] and [149] (DSAW double submerged arc welding, SMLS seamless, SAW submerged arc welding)

20

XI-929-09

X100SP1 layers cellulosic electrodes R H F T

electrode AWS [mm] E 6010 E 7010-A1 E 9010-G E 7010-A1 E 10018-G E 11018-G E 10018-G E 11018-G 4.0 5.0 4.0 4.5 4.0

amperage [A] 120-160 180-200 190-210 230-250 190-210

voltage [V] 24 24 20 20 20

basic electrodes

Supplement 4. Welding procedure specification for X100 (X100SP1) combined welding with cellulosic and basic electrodes (R root pass, H hot-pass, F filler layer, T top layer, SP welding specimen) [48] and [55]
material grade X120 wall thickness 20 mm welding consumable EXX 26 and EXX 27 welding process manual metal arc welding preheating temperature min 150 C interpass temperature max 200 C run process 1 111 2 111 3-8 111 9 111 10 111 11-29 111 PS [N/mm] 941, 953 consumable EXX 26 EXX 27 EXX 27 EXX 27 EXX 27 EXX 27 TS [N/mm] 950, 962 size current voltage [mm] [A] [V] 3.0 120 19 4.0 215 22 4.0 215 22 4.0 210 21 4.0 210 21 4.0 210 21 A [%] R of A [%] 21.2, 21.2 63, 63

A
1

travel speed heat-input [m/min] [kJ/mm] 0.20 0.68 0.36 0.79 0.57 - 0.39 0.50-0.73 1.50 0.18 0.88 0.30 0.39 - 0.58 0.46-0.68 CVN at -40 C [J] 61, 65, 63, 72, 70, 68

Supplement 5. Welding procedure specification for X120 (X120SP1) manual metal arc welding in vertical down position with basic electrodes (SP welding specimen) [150]

21

XI-929-09

AWS specification

rod designation -1 -1 -1 -1 -1

chemical composition of the weld metal C Si Mn Mo Ni -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1

3

according to -1 ER 100S-G -2 ER 120S-G GSNi1Mo ER480S-6 ER690S-G

0.3 0.6 -1 -1 -1 0.3 0.3 0.3

1.0 2.5 -1 -1 -1 1.0 1.0 1.0

-1 G3Ni1Mo according to PHILIPS ER 100S-G -3 according to THYSSEN WIRE ER 100S-G -4 -1

1 2

CVN at T [N/mm] [N/mm] [%] [J] -40 C 804 -1 19.5 182 964 990 16,5 133 -1 -1 -1 -1 1 1 1 -1 -1 -1 -1 -1 -20 C 753 810 23 206 -40 C 841 888 20.5 188 -40 C 753 810 23 -1 YS TS A

- ... details not available, - tandem GMAW, - single torch GMAW, -4CAPS dual tandem Supplement 6. Chemical composition (in mass-%) and mechanical properties of welding rods used for the CAPS-process [67], [71], and [72]

root pass filler layers electrode type ER480S-6 ER690S-G ER690S-G ER690S-G diameter [mm] 0.9 1.0 1.0 1.0 amperage [A] 185 - 210 200 - 220 140 - 170 190 - 210 voltage [V] 20 - 22 20 - 23 19 - 22 19 - 22 wire feed 12 200/ 12 9 200/ 11 500/ 11 9 652 [mm/min] 200 9 200 500 welding velocity 1 270 760 1 270 1 270 [mm/min] +/- 10 % heat-input [kJ/mm] 0.32 - 0.38 0.30 - 0.40 0.30 - 0.40 0.30 - 0.40 head velocity [mm] N/A 2.0 - 3.0 2.5 - 3.5 3.0 - 4.0 frequence [cpm] N/A 350 350 350 welding head 5 - 7 -2 to +2 -2 to +2 -2 to +2 angle []

top layers ER690S-G ER690S-G ER690S-G 1.0 1.0 1.0 140 - 160 110 - 140 110 - 140 18 - 21 18 - 20 18 - 20 8 500/ 7 000/ 7 000/ 8 500 7 000 7 000 1 270 1 270 1 270 +/- 10 % +/- 20 % +/- 20 % 0.30 - 0.40 0.20 -0.30 0.20 -0.30 3.5 - 4.5 1.5 - 2.5 1.5 - 2.5 350 300 300 -2 to +2 -2 to +2 -2 to +2

Supplement 7. Welding parameters for the CAPS-process [66]

22

XI-929-09

steel grade ESAB X56

111 111-C-PG PIPEWELD 6010(1) PIPEWELD 7010 111-C-PF PIPEWELD 6010(1) 111-B-PG FILARC 27P 111-B-PF OK 48.00 OK 53.70

135 OK Autrod 12.66-

136

12

-1

X60 ESAB

FOX CEL(1) FOX BVD(1) FOX EV Pipe FOX CEL S(1) FOX BVD FOX EV 60 FOX CEL MO FOX CEL S(1) (1) RP Pipe FOX CEL 75(2) FOX BVD 85 85 PIPEWELD (1) 6010 PIPEWELD 8010 PIPEWELD (1) 6010 FILARC 27P OK 48.00 OK 53.70(1) OK 74.70 FOX EV (1) Pipe FOX EV 60 Pipe FOX EV 70 Pipe OK 53.70 OK 74.70
(1)

Boehler

SG-3-P K-Nova Ni

-1

-1

OK Autrod 12.66-

-1

-1

X65 ESAB

FOX CEL(1) FOX BVD(1) (1) FOX CEL S FOX BVD FOX CEL 75(1) FOX CEL S(1) (1) RP FOX CEL 85(2) FOX BVD 85 90 PIPEWELD 6010(1) PIPEWELD 8010 PIPEWELD 6010(1)

Boehler

SG-3-P K-Nova Ni

-1

FILARC 27P

OK Autrod 12.66-

OK Tubrod 15.17

OK Tubrod 15.00 S

X70 ESAB

FOX CEL(1) FOX BVD(1) FOX CEL S(1) FOX BVD FOX CEL 75(1) FOX CEL S(1) RP(1) FOX CEL 85FOX BVD 90(2) 90 PIPEWELD (1) 6010 PIPEWELD 9010 PIPEWELD (1) 6010 FILARC 27P FOX BVD FOX BVD RP(1) (2) FOX BVD 90 FOX BVD (2) 100 FILARC 37P FILARC 108MP FOX BVD(1) FOX BVD (1) RP FOX BVD 110(2) 1 (1)

FOX EV Pipe(1) FOX EV 70 Pipe OK 53.70(1) OK 74.70

Boehler

K-Nova Ni NiMo1-IG

-1

-1

OK Autrod 12.66-

OK Tubrod 15.17

-1

Boehler

FOX CEL(1) (1) (1) FOX CEL S FOX CEL S FOX CEL 90

X80 ESAB PIPEWELD 9010

1

FOX EV (1) Pipe FOX EV 70 Pipe

NiMo1-IG

-1

-1

OK 53.70

(1)

OK Autrod 12.66 OK Autrod 13.13-

OK Tubrod 15.07 OK Tubrod 15.09

-1

Boehler

-1

-1

-1

-1

-1

X100 ESAB 1

OK Autrod 13.13-

OK Tubrod 15.09 Coreshield 8Ni1

-1

-1 ... details not available, (1) only for root pass, (2) only for filler and top layers Supplement 8. Recommendations of consumables for different pipeline-steel grades according to Boehler (2) (111 manual metal arc welding, C cellulosic electrodes, B basic electrodes, PG ... vertical down position, PF ... vertical up position, 135 ... MAG-welding with solid wire, 136 ... MAG-welding with filler wire, 12 ... submerged arc welding) [151] to [153]

23

XI-929-09

process

cover, wire

designation Boehler FOX CEL FOX CEL Mo FOX CEL 75 FOX CEL 85 FOX CEL S Boehler FOX CEL 90 Boehler FOX BVD RP FOX EV Pipe FOX BVD 85 FOX BVD 90 FOX BVD 100 FOX EV 50-W Boehler FOX EV 50 Boehler FOX EV 85 -1

wall thickness [mm] < 20

PT [C] 50-100 150

IT [C]

comment -1 for steels with a higher C content -1 -1 -1

100 30

20 < 20 20 < 20 20

~ 200 50 - 150 150 30 ~ 200 not required 100 30 50 - 100

111

outside temp. > 5 C, at steels tending to hardening: PT ~ 100 C

31, 230

150

135 136

solid wire filler wire

50 25 -1

single wire 12 double wire

-1 wire: S3 NiMoCr powder: UV 421 TT-LH 31, 230

130

120 designation acc. to EN 758: T563 1NiYn1H5

X100, fixing and root pass X100, assembly 250 welding, post weld heat treatment: 250300 C, 2 - 4 h welding in the field at 120 a pipe made of X65, outer diameter: 70 - 180 914 mm X100, prefabrication (longitudinal-, 180 circumferential- and fillet welding), post weld heat 170 treatment: 250 - 300 C, 2 - 4 h 150 X80

114

filler wire

< 25

120

-1 ... details not available Supplement 9. Heat guidance for welding pipeline-steels (111 ... manual metal arc welding, 135 ... MAG-welding with solid wire, 136 ... MAG-welding with filler wire, 12 ... submerged arc welding, 114 ... metal arc welding with filler wire, C ... cellulosic covered, B ... basic covered, PT ... preheating temperature, IT ...interpass temperature) [154] to [158]

24