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2. Advances In Pipeline Materials, Welding, and InspectionbyRobin 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.