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Line Pipe Manufacturing Processes & Materials

Tony Walker & Derek Bish

Manufacturing Facilities
Hartlepool UOE SAW Pipe Mill HFI Pipe Mill 3 Roll Bend SAW Mill BSR Pipelines Services Pipe in Pipe Fabrication Facility

Corby Commercial Office Corby 6 HFI Mill

Linepipe Applications

Linepipe manufacture 3RB Forming

Three Roll Bending Process Flow

3RB Process Roll Bending

3RB Process Hot Forming

Three Roll Bending


Observations

Advantages Flexible process Small quantities available

Disadvantages

Low forming power Quick changeovers Three Roll Bending Uniform strain distribution Dependent on welding capability Heat treatment capability SAW welding single/multipass Compressive strength de-rated by 7%

Linepipe manufacture - UOE

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UOE Process - Crimp

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UOE Importance of Crimp Press

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UOE Process U Press

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UOE Process O Press

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UOE Process - Expander

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UOE Observations

Advantages Grades up to X80 available Consistent dimensional properties

Disadvantages

Minimum quantity required UOE High throughput rate Compressive strength de-rated by 15% High wall thickness available SAW High Production Weld

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High Frequency Induction Welding

Linear Forming
Process Flow

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HFI - Accumulator

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HFI Pipe Forming

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HFI Weld line Annealing

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HFI Process Full Body Heat Treatment

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Linear Forming Process


Observations

Advantages High throughput rate Minimal HAZ Linear Forming Reduced testing Consistent dimensional properties High Production HFI Weld

Disadvantages

Mechanical properties limited by strip supply Restricted wall thickness Limited mechanical properties in the weld

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Linepipe Properties - Dimensions

Dimensions
Typical Offshore Requirements Typical Tolerances Cold Formed Products Seamless Reason for Requirement

Wall Thickness

1.0 mm

12.5 % W.T.

Minimum to guarantee strength & corrosion allowance Maximum to calculate weight and cost of material Ease pipe fit-up Ease pipe fit-up and resistance to collapse Ease pipe fit-up Ensure girth welds are within range of lay barge stations.
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Diameter Ovality Straightness Length

1.6 mm

2.0 mm

0.5 - 1.0 % O.D. 0.15 % Length Average 100 mm

Ancillary Operations - Coating

Flow Coating

Picture Courtesy of Bredero Shaw Ltd. 27

Anti-Corrosion Coating - FBE

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Anti Corrosion Coating 3LPP/3LPE

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Coatings
Process Flow

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Weight Coating

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The Finished Product

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Insulation coatings at BSR

Polypropylene Foam process route

Layer thicknesses
FBE thickness 250350m by spray gun Adhesive thickness 250350m by spray gun PP foam thickness up to 40mm by extrusion PP topcoat 2.53mm by extrusion

Polypropylene foam micrograph

Bubble size is 250-500 microns Bubbles are near spherical when viewed either longitudinally or transversely Slightly smaller bubble size near surface

BSR Capability

6 to 20 OD Up to 40mm PP foam per layer Multi-layer capability U values in the range of 3-7 (excluding burial)

Pipe in Pipe Systems

Tata Steel Pipe-in-Pipe systems

Design suited to S-lay Options of Polyurethane, Aerogel or Hybrid (PU/Aerogel) Pipe joints and field joints engineered to aid offshore fabrication Qualification of materials and thermal efficiency Full procurement & project management of all materials Additional project activity - bend in bends - bulkheads and flanges welded to straights/bends - outer pipe coatings

Insulation systems

Polyurethane Foam

Polymer (Polyol), Isocyanate Bubbles in Polymer matrix Injected, Cast or Sprayed Thermal Ageing OHTC <1.0W/m2K Work Horse for Industry

PU Pipe-in-pipe process flow

PU Foam Pipe in pipe

Engineered Assembly Tolerance

Half Shell Connection


Pre-assembled joints with accurate stick-out
Simple Construction Half-shells made from outer pipe with accurate tolerances Field joint insulation Mechanical continuity Thermal integrity

Hybrid Pipe-in-Pipe system


Combines Aerogel and PU foam Improved thermal efficiency High temperature Maintain bond between inner and outer pipe

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Thermal advantages

Aerogel temperature resistant to 200C and above High insulation with thin layer Protects PU foam from accelerated ageing and degredation
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15mm Aeroogel 35mm PU Foam

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Hybrid Pipe in pipe

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Straight PiP Joint Insulation

Aerogel Wrap

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Pipe-in-pipe bend integration

POSSIBLE SOLUTION Concerns over long split of outer and weld cost Structural integrity issues

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Pipe-in-pipe bend integration

POSSIBLE SOLUTION Concerns over long split of outer and weld cost Structural integrity issues

OPTIMUM SOLUTION Integrate inner bends with short stick-out length. Max practical stick-out 150mm 90 degree bend (300mm tangent inner, 150mm outer)
one end can have longer inner tangent

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Fixed Outer

Inner Driven on Rollers

Establish stick-outs
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Final Bend Assembly

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Pipe in Pipe bend integration Video clip

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