Subsea Pipeline and Risers

Dasharatha Achani
 MECHOCEAN
Eng. Solutions

Material,
fabrication
welding and ECA

6-Sep-18
6-Sep-18 Page 2 www.mechocean.com Dasharatha Achani
 MECHOCEAN
Eng. Solutions

When it goes wrong with wrong material

selection

 Local buckling
 Ovalising
 Ductile crack growth

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 MECHOCEAN
Eng. Solutions

Plastic deformation
R = 7.5m

Elastic deformation

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Rev: Achani
 MECHOCEAN
Material selection Eng. Solutions

Material is selected based on the following parameters:

– Yield and tensile strength
– Yield / tensile ratio
– Toughness (impact and fracture)
– Elongation and ductility
– Welding properties
– Corrosion properties
– Availability
– Cost

Materials selected for reel laid pipelines are the following

– Corrosion Resistance Alloys (Duplex stainless steel,13 % Cr,)
– Clad materials (C-Mn mother material, with internal CRA clad)
– C-Mn steel

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Rev: Achani
 MECHOCEAN
Rigid Pipeline Projects – Common Materials Eng. Solutions

X52 – SML 350

X60 – SML 415
X65 – SML 450
Martensitic 13% Cr
X60 or X65 pipe with clad

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 MECHOCEAN
Rigid Pipeline Projects – Coating, Design Input Eng. Solutions

Design Temperatures
Requirements to corrosion protection
Requirements to Insulation Properties
Installation Method

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Rev: Achani
 MECHOCEAN
Corrosion Eng. Solutions

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 MECHOCEAN
Corrosion Eng. Solutions

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 MECHOCEAN
Internal Corrosion Protection Eng. Solutions

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External Corrosion Protection Eng. Solutions

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External Corrosion Protection Eng. Solutions

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 MECHOCEAN
Cathodic Protection (CP) Eng. Solutions

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 MECHOCEAN
Cathodic Protection (CP): Anode Specification Eng. Solutions

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 MECHOCEAN
Why do we need coating? Eng. Solutions

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 MECHOCEAN
What is coated? Eng. Solutions

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 MECHOCEAN
Coating Types Eng. Solutions

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 MECHOCEAN
Example: 3 Layer Poly Propylene Coating Eng. Solutions

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 MECHOCEAN
Field Joint coating Eng. Solutions

Polypropylene field joint

coating is produced in
accordance with the
principles of 3LLP system:
1.FBE
2.PP Adhesive
3.Injection moulded PP

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Rev: Achani
 MECHOCEAN
Fabrication Eng. Solutions

Manufacturing Requirements-International Standards:

 Design requirements for offshore projects are reflected as

pipe's manufacturing requirements in the applicable
specifications

 Pipe for offshore applications are always required according

to international standards such as
 - API 5L
 - ISO 3183 (or the European EN 10208)
 - DNV OS-F101, 2000

 Though API specification is dated back to the 1920s, it is

the most widely used
6-Sep-18 www.mechocean.com Dasharatha Achani
 MECHOCEAN
Pipe Materials -Technical Requirements for Offshore MarketEng. Solutions

 X60/X65 materials for flowlines/risers

 High strength weldable materials for SCRs (X80 and

above)

 High grades for welded pipes (gas lines)

 Chemical composition (beyond standard requirements)

 Sour service steel even for non sour applications

 Higher mill hydrostatic test pressures

 Stringent requirements for surface quality and NDT

 Stringent dimensional tolerances for all products

 Non standard sizes

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes

Tubular forming process depends on manufacturing process

– Seamless pipe
• Fabricated from steel billets
• Pipe is pierced, rolled, heat treated and hydrotested
• Usually upto 16” OD
– Longitudinally seam welded pipe
• Fabricated from steel plate or strip
• Pipe is formed, welded, expanded and hydrotested
– SAW
– ERW HFI
• Usually for larger OD pipes above 16” (SAW)

– Standard nominal pipe joint length: 12.2 meters (40

feet)
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 MECHOCEAN
Fabrication -Manufacturing Methods Eng. Solutions

In offshore
pipeline installation Very
“cold“ forming / Process Medium Large
Small Large Pipe
piercing Pipe Pipe
Pipe
of the seamless
SEAMLESS

pipeline
PROCESS

is forbidden MANDRELL 1” to 6”
Rolling PLUG 6” to 16”
EXPANDER 18” to 28”

Submerged Arc 16” to 56”

UOE / JUOE
Welding SAW
WELDING PROCESS

Electric Resistance ERW HFI 1.3/4 to 6” 7” to 24 “

Welding ERW

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes -Seamless Pipe

Tubular without weld seam

A billet of hot steel is pierced by rollers around a mandrel to

form a hollow bloom

Then rolled or drawn over a mandrel to produce a length of

pipe.

Method may vary depending on pipe manufacturer

Production limit
– 16” OD
– up to 28” OD possible for few mills

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 MECHOCEAN
Pipe Manufacturing Processes -Seamless Pipe Eng. Solutions

2. Billet Preparation

1. Stock Yard

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 MECHOCEAN
Eng. Solutions

Pipe Manufacturing Processes -Seamless Pipe

3. Billet Heating 4. Billet Centering

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes -Seamless Pipe

5. Piercing

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes -Seamless Pipe

6. Mandrel Mill

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes -Seamless Pipe

8. Hydraulic Descaling 7. Re-Heating

Re-Heating
Hydraulic Descaling
Stretch Reducing

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes -Seamless Pipe

10. Cooling Bed

Cooling Table

9. Stretch Reducing

Stretch Reducer

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 MECHOCEAN
Eng. Solutions
Pipe Manufacturing Processes -Seamless Pipe

11. Finishing and Final Inspection

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 MECHOCEAN
Fabrication- Submerged Arc Welded (SAW) Pipe Eng. Solutions

Rolling process -UOE

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 MECHOCEAN
Fabrication -Submerged Arc Welded (SAW) Pipe Eng. Solutions

UOE size range

– OD 16 ~ 56 in
• WT 6.0 ~ 50.8 mm (0.236 ~ 2 in)
• Maximum length 60 ft (18.3 m)

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 Fabrication -Electrical Resistance Welded Pipe -High MECHOCEAN
Eng. Solutions
Frequency Induction (ERW / HFI)

Continuous forming process

Manufactured from metal sheets delivered in coils

Welding process by high frequency inductor surrounding

the tube without contact and pressing the edges

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 Fabrication -Electrical Resistance Welded Pipe -High MECHOCEAN
Eng. Solutions
Frequency Induction (ERW / HFI)

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 MECHOCEAN
Eng. Solutions
Pipeline Fabrication

Video

1. https://www.youtube.com/watch?v=XneFt2rvfgE

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 MECHOCEAN
WELDING Eng. Solutions

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 MECHOCEAN
Pipeline Fabrication -Welding Eng. Solutions

Shielded metal arc welding (SMAW) -”Stick” welding

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 MECHOCEAN
Pipeline Fabrication -Welding Eng. Solutions

Gas metal arc welding (GMAW) -”Mig” welding

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 MECHOCEAN
Pipeline Fabrication -Welding Eng. Solutions

Gas tungsten arc welding (GTAW) -”Tig” welding

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 Rigid Pipeline Projects – Welding Terminology MECHOCEAN
Eng. Solutions

pWPS Perform welding Non Destructive Perform Mechanical Perform Mechanical ECA
Record Parameters Testing testing of as-welded testing of Strain-
Aged

Parameter record NDE Reports Mechanical Mechanical ECA Report

Material cert. Properties Properties
Consumable cert.

NDE Accept
ECA: Engineering Criticality
Criteria
Assessment
pWPS: Proposed Welding WPQR
Procedure Specification
WPQR: Welding Procedure
Qualification Records.
WPS: Welding Procedure
Specification
NDE: Non Destructive
Examination
WPS WPS WPS

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 MECHOCEAN
NDT- Non Distructive Testing Eng. Solutions

MPI (Magnetic particle inspection)

– Used for Anode Pads
– Anchor & Recovery heads
Automated Ultrasonic Testing (AUT)
– Used as primary method on all types of pipelines
– Can be used offshore
– Requires ECA to verify accept criteria
– Fast, no restricted areas, expensive
Radiographic Testing
– Used as primary method on all types of pipelines
– Panorama and double wall techniques
– Slow, restricted areas due to radiation, relatively inexpensive
Manual Ultrasonic Testing
– Secondary method
– Sizing of defects
Dye Penetrant
– 13% Cr Anode Pads
– 13% Cr A&R Heads

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Rev: Achani
 Fabrication -Electrical Resistance Welded Pipe -High MECHOCEAN
Eng. Solutions
Frequency Induction (ERW / HFI)

Max OD 24”

Max thickness 20 mm

Most mills limited to 18” OD capability

ERW / HFI pipes

– Require much more stringent QC than others
– Can be up to 20-25% cheaper than the SAW pipes

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Eng. Solutions

Thank you

6-Sep-18 www.mechocean.com Dasharatha Achani