Advances In Pipeline Materials, Welding, and Inspection by Robin Gordon EWI, Columbus, Ohio, USA

2. �Advances In Pipeline Materials, Welding, and Inspection�byRobin GordonEWI, Columbus, Ohio, USA

3. Pipeline Design and Construction Many new major Oil and Gas reserves are in remote locations and will require the construction of long distance pipelines. Pipeline construction costs can exceed: $1M - $1.5M per mile for cross country pipelines $3M - $5M per mile for offshore pipelines In many cases the cost of pipeline construction dominates the economics of Oil and Gas recovery. In addition to the capital investment associated with new pipeline construction, there is a need to extend pipeline design methods to cover increasingly demanding operating requirements.

4. Pipeline Industry - Business Drivers Reduce the cost of new pipeline design, construction, and operation without compromising pipeline integrity. Extend existing pipeline design codes to cover increasingly demanding operating requirements including strain-based loading.

5. Presentation Outline Pipeline Cost Reduction High Strength Pipe Materials High Productivity Welding Advanced NDE Methods Pipeline Design Strain-Based Design

6. Pipeline Construction Costs

7. Pipeline Cost Reduction Technology Options include: High Strength Pipe Reduced Material Costs Higher Operating Pressures Higher Design Factors Higher Operating Pressures High Productivity Welding / Inspection Improved Construction Methods & Equipment

8. High Strength Pipelines - X80, X100, X120� Current Status X80 Pipeline Technology Proven methods for X80 pipe production Good material properties (including crack arrest) Proven construction methods Cross country X80 pipelines constructed in Europe and Canada Offshore X80 pipelines are becoming increasingly common (pipeline, flowlines, and risers) Summary X80 Pipeline Technology is Mature

9. High Strength Pipelines - X80, X100, X120� Current Status X100 Pipeline Technology X100 Pipeline Technology is at an advanced stage of development and demonstration. Crack arrest performance is still not fully proven, particularly for high pressure applications. TCPL constructed an X100 pipeline loop in the Fall of 2002 to gain experience with field construction. X120 and Beyond Major proprietary R&D program to develop and assess X120 and X120+ pipeline technology. Initial results are very encouraging.

10. High Strength Pipelines - CRLP Current Status Composite Reinforced Linepipe (CRLP) Technology CRLP is an alternative to high strength linepipe CRLP offers excellent crack arrest performance. Field Construction methods have been developed. Long term performance of composite wrap not fully proven. Composite wrap cannot be inspected or monitored using conventional in-line inspection methods. CRLP may not be suited to strain based design (i.e., pipelines that may experience high strains in service)

11. High Strength Pipeline - R&D Priorities Near Term Develop and Validate X100 Pipeline Technology Pipe Production and Pipe Properties Validate Construction Methods (Field Welding) Operational Integrity (Fitness for Service) Medium Term Develop and Validate CRLP Technology Long Term Structural Performance Long Term Corrosion Performance Strain Based Loading Monitoring and in-line inspection (embedded sensors) Long Term Develop and Assess X120 Pipeline Technology

12. High Productivity Pipeline Welding Higher pipeline welding productivity can be achieved through a combination of: High Speed Root Pass Welding High Productivity Fill Pass Welding High Speed Root Pass Welding Options include Laser / GMAW Hybrid Welding or advanced Automated GMAW Welding (VP-GMAW). High Productivity Fill Pass Welding Options include Laser / GMAW Hybrid Welding or Dual Tandem GMAW Welding (e.g., CAPS)

13. Schematic of Hybrid Process Used

14. CAPS Welding System

15. High Productivity Welding - Future R&D Near Term Continue to validate high productivity GMAW Welding for High Strength Pipelines Welding productivity and weldability Consumable development Weld joint characterization Develop process monitoring capabilities Medium Term Continue to monitor Laser Welding Developments Long Term Monitor and evaluate future developments with new high productivity and / or single shot welding methods.

16. Pipeline Girth Weld Inspection Current Status Automated Ultrasonic Testing (AUT) is now recognized as the preferred inspection method for new pipelines. AUT system performance is generally very good although there is uncertainty as to the actual performance (POD & Sizing Errors) of AUT. Phased Array AUT Technology has been introduced in the last few years for pipeline inspection and appears to offer improved performance. There is a need to determine the limits of AUT and Phased Array AUT (particularly for larger wall thickness pipes) to verify fitness-for-service design methods and ECAs

17. Pipeline Girth Weld Inspection - R&D Priorities Near Term Compare performance of AUT and Phased Array AUT NDE for pipeline girth weld inspection: Probability of Detection Sizing Errors Medium Term Assess Performance of AUT and Phased Array AUT for heavy wall high pressure pipelines. Long Term Extend and improve Phased Array AUT Technology

18. Pipeline Design Current Status The majority of pipeline design codes are based on stress based design methods. Although conventional stress based design covers most pipeline applications, it does not cover the design of pipelines that may experience high strains in service. High strains can occur in service due to ground movement, bending over an unsupported span and seismic loading. In such cases pipelines should be designed based on strain capacity. Girth welds can be source of strain localization and can be a limiting factor in strain based design.

19. Pipeline Design - R&D Priorities Near Term Develop and validate ECA and strain based design methods for cross country and offshore pipelines. Design Guidance (Material Selection, Welding Recommendations, Full Scale Validation) ECA Guidance (Material Property Characterization, FFS Models) Medium Term Incorporate strain based design methods with overall pipeline reliability methods.

20. Summary The cost of pipeline construction can be reduced through the adoption of next generation technologies. High Strength Pipe High Productivity Welding Advanced Inspection Methods Higher Design Factors and Operating Pressures Maximum benefit obtained by adopting multiple parallel technologies simultaneously. New Oil and Gas discoveries in remote geographically demanding regions will require the development of new improved design methods for pipelines.