The Design and Construction of High Pressure Pipelines Alan Murray ASME Pipeline System Division ASME INDIA

OIL & GAS PIPELINE CONFERENCE Goa February 4th February 2011

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Demand for Clean Energy is Growing

World gas consumption has grown 435% since 1965. EIA forecast to 2030: World energy demand will grow by 55% Gas consumption will grow at an annual rate of 2.4%, (100 trillion cubic feet (tcf) to 163 tcf) compared to 1.4% for oil (83 million barrels of oil per day (mb/d)to 118 mb/d ) Gas will account for 26% of global energy use by 2030.

Energy Supply Energy Infrastructure

Energy Demand

Some Current Pipeline Trends

Reducing capital and operating costs Lowering pressure losses Reducing Pumping Power needs Higher operating pressures circa 160bar + Larger diameters 1.2 to 1.4m Use of higher strength steels X80,X100, X120 Limit States Design Methods (probabilistic rather than deterministic) better utilisation of material Challenge cannot compromise safety and reliability improving current pipe manufacturing and construction techniques
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Increasing Transmission Efficiency

3-Materials - High Strength Steels - Pipe Manufacture 2 - Design - Fracture control - Composite Materials - Higher Utilisation -Non ferrous -Working Stress Design 80% SMYS materials - Strain Based design - Post yield response I Route - Limit States Design - Weldability Selection - Satellite Imagery Reliability Methods - Defect Assessment - Coatings -Immersive Video - Improved Geo technics - GIS Optimisation -Dense Phase Flow -Public consultation

4 Construction Methods
Semi-Fully Automatic Welding Improved Inspection Installation Methods Crossings Trenchless construction Buoyancy control Hydrotesting and Commissioning

5 Operations
- SCADA - Automation and Control - Ultrasonic metering - Pipe cleaning -Use of drag reducing additives -Intelligent Pigging - Risk & Integrity management

Route Selection
Satellite Imagery/Google Earth /GIS have transformed Routing processes

Hydraulic profiles, cut & fill, crossings are identified and Optimised in GIS driven software packages

 Immersive video here

Current/Proposed World High Pressure Transmission Lines

Name Zee Pipe Sable Island Souris Valley FLAGS Ruhrgas Iroquois PGUP Alliance GasAndes Gas Del Pacif ico Enron PNG Aust rialia BSL Pipeline
*Proposed

Locat ion Norw ay/ Belgium Canada Canada/ USA Scot land Germany Canada/ USA M alaysia Canada/ USA Argent ina/ Chile Argent ina/ Chile Boliva/ Brazil Paupa New Guina/ Aust ralia* Germany

M AOP (PSIG) 2200 2200 2200 2000 1480 1440 1000 1780 1440 1405 2200 2200 1480

Product Transport ed Nat ural Gas Nat ural Gas CO2 Nat ural Gas Nat ural Gas Nat ural Gas Nat ural Gas Nat ural Gas Nat ural Gas Nat ural Gas Nat ural Gas Nat ural Gas M ult i Product s
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Consider the Steady Flow Energy Equation

Dense phase can obviate the need for a separate liquids line

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Pipe roughness and types of flow

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Evolution of Compression

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J curves used to optimise pipe size

320 1 - 8690 kPa (1260 psi) MOP 300 280 260 240 220 200 180 160 2 140 120 1 2 - 12410 kPa (1800 psi) MOP (With Higher Pipe Cost)

10 000

30 000

50 000

70 000

90 000

110 000

130 000

150 000

170 000

Pipeline Design Day Flow (103 m3/d)

Cost of Service vs. Design Day Flow

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for 1219 mm (NPS 48) Diameter Pipe

Codes, Standards and Methodologies

(Working Stress Design)

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Partial Factors in LSD

Shift Due to

Resistance Distribution Shift Due to Load Distribution

Load or Resistance Characteristic Mean Load Mean or Characteristic Resistance

Probability of Failure

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Above ground Supports in earthquake zone

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Extrados Tensile strains - Parameters

McLamb 2003
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Technological Advances in Pipe Production

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Controlled Rolling of Steel Plate

Source: Kevin Prosser: Macaw Engineering

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Non Destructive Testing

Evolution of Pipeline grade and its effect on Installed Cost

(NPS 16, design pressure 10200 kPa) 110 1000
Price per kilometre

100

900
Price per ton

90

800 80

700 Grade (API) WT (mm)

70 5L GRB 14.3 5X-X42 12.7 X56 9.5 X65 8.7 X70 7.1

Need to balance strength with toughness, ductility Practical considerations such as forming, welding, field bending and joining
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Pipe price ($/km)

Price ($/ton)

Economics of High Strength Steel Pipelines Desk Study

For transportation of 3.0 Bcfd of natural gas a distance of 1,000 miles:
X70 X120 X70*

Operating pressure, psi Pipe OD, inches Number of Compressors CAPEX, $M

1450 58 9 6,770

2800 46 7 6,010

2800 46 8 6,670

Summary of CAPEX Cost Comparison

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Alloys to reduce Carbon

Carbon increases strength Interstitial atoms frictional resistance to dislocations
140 120 100 80 60 40 20 0

700 600

Strength MPa

500 400 300 200 100 0 Carbon Content

Too much carbon Reduces toughness Strain aging Hardness, weldability

Carbon Content

Glover 2004

Toughness J

High strength steels- At what cost to ductility?

Higher the strength the less post yield strain capacity 15% decrease in strain at ultimate Y/T ratio approaching 0.95 in transverse round bar tests May impact strain based designs (Pipe body strains >> weld matl) Matching /overmatching weld metal issues (toughness) High fracture initiation energies
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Pipe & Weld Metal Tensile Testing

How do we establish a reliable measure of strength?
2.5 .31 3 .602 .630 2.0 .1 57

Round Bar Tensile

.75 3.0 1 .50 .75 .360 .1 80

.602

Weld sampling

Modified Strip Tensile

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Fracture Toughness Testing

Drop Weight Tear Test Specimen

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Mechanical Properties of High Strength Steel Pipe

Tensile Properties

Toughness & Fracture Ductility Properties

Bauschinger Effect round tensile bars Charpy measure of toughness DWTT measure of fracture ductility A compromise is required between strength & toughness for HSS pipe Crack arrestors are being proposed for fracture control for HSS pipe

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Weldability
Pipes must be able to welded in the field:
rapidly in all weathers with minimum of pipe heating

Weldability is affected by:

Parent

HAZ

Weld

pipeline chemistry higher chemistry pipe more susceptible to hydrogen cracking thickness thicker pipe has poorer weldability diameter greater cooling occurs between weld runs increasing risk of cracking
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Metal Inert Gas Welding

Advantages: Higher speed than MMA due to ; Continuous feed of filler metal Absence of slag Higher deposition rates Weld metal has a low hydrogen content, which can be important, especially in welding hardenable steels Deeper penetration allows the use of smaller fillet welds Applicable in semiautomatic and fully automated welding systems. Case study pipe example available of benefits of MIG over MMA http://www.weldreality.com/pipeweldAlberta.ht m

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Metal Inert Gas Welding

Limitations: Equipment is more costly and less portable than MMA welding equipment Less adaptable for welding in areas of limited access In hardenable steels, more susceptible to weld metal cracking - no slag cover to reduce the rate of cooling Requires positive protection from strong drafts, which blow the stream of shielding gas away from the weld; therefore less practical than the shielded metal arc welding outdoors

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Mechanized or Manual Welding ?

For 36 x 0.622 w.t. Line Pipe

Mechanized Welding 17 to 19
minutes per weld

Manual Welding 47 to 68 minutes per

weld

Mechanized or Manual Welding ?

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Conventional & Phased Array Mechanized Ultrasonics

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Girth Weld Critical Assessment

Girth Weld Straining

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Pipe Coating Protection

FBE Coating Process

Improved Trenching and Lowering Techniques

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Buoyancy control

Sack Weights Concrete Weights

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Screw Anchors

Directional Drilling Profile

History & Purpose of Hydrostatic Testing

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Safety Margins given by the System Pressure Test & Mill Pressure Test
Failure stress of defect free pipeline System Pressure Test Mill Pressure Test

Safety Margin On Test

Design Pressure

Safety Margin on Failure

The system pressure test is considered to be the final test of the integrity of a new pipeline.
OPERATION COMMISSIONING MILL

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Hydro-Test Ruptures

Defects that Remain in Pipe

125 % MOP
Defects removed Hydro-test

100 % MOP
Normal Operating
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Full Scale Rupture tests

Fracture arrest occurs when brittle crack enters ductile pipe BUT Cracks can propagate in the fully ductile mode In-service fractures have propagated up to 300m Full-scale studies conducted to derive requirements for fracture arrest Correlated to a convenient small scale test Charpy /DWTT
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Crack arrest options for high strength, high pressure systems

Composite Reinforced Linepipe

Steel Grouted Sleeve

20.6 mm
1346 mm (53") ID 1320 mm (52") OD

20.6 mm

X100

X80

X100

Epoxy grout (SBD - DG38)

3000 mm

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Full Scale Tests (Bending)

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Intrados compressive Prelim results (FEA plots)

Limit Point

Softening Point

Post Buckling #1

Post Buckling #2

Thank you for your Attention! Any Questions?

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