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Pre-Installed User:

Pre-Installed User:. Combining Engineering And New Technology. Peter Hatcher, P.Eng. Fluor Canada Ltd. March 3, 2004. Engineering & New Technology. Opportunity Unbounded Conventional Wisdom. E P C . Engineering Procurement & Construction (EPC). EPC – Process Industry.

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  1. Pre-Installed User: Combining Engineering And New Technology Peter Hatcher, P.Eng.Fluor Canada Ltd.March 3, 2004

  2. Engineering & New Technology • Opportunity Unbounded • Conventional Wisdom

  3. E P C • Engineering Procurement & Construction (EPC)

  4. EPC – Process Industry • Process Industry – Design Engineering • Conservative • Process Industry - Construction • Proven Technologies • Significant Capital Investments • New Technology - NIMP!!!!

  5. Engineering & New Technology The essence of science: ask an impertinent question, and you are on the way to a pertinent answer Jacob Bronowski

  6. Engineering & New Technology • Examples of Combining Engineering & Technology • Material of Construction • Fabrication • Mechanical Integrity

  7. Impertinent Question #1 • Does Material of Construction exist that allows refining of following crude conditions??? • High conventional corrosion rates • naphthenic acid • polythionic acid • High operating temperatures • sensitization of stainless steels

  8. Material Selection • Conventional Approach Based on Code listed stainless steel materials: • 321/347 • v.g. resistance to sensitization • poor resistance to naphthenic acid corrosion • 316L/317L • v.g. resistance to naphthenic acid corrosion • poor resistance to sensitization Above options do not provide Owner the capability to handle potentially highly corrosive process streams with long term reliability.

  9. Material Selection • Selected Metallurgy Unlisted Material: • 16Cr11Ni2.5MoCb

  10. Strategy • Corrosion Testing • Mechanical Properties • Formability • Weldability • Aggressive Timeline / Complex Execution

  11. Weld Metal

  12. Larson-Miller Parameter

  13. Answer # 1 16Cr11Ni2.5MoCb • Resistance to naphthenic acid attack and sensitization • Thin wall allows for optimal heat transfer and stress reduction • Eliminate need for post weld heat treatment • Eliminate requirement for soda ash wash during shut down

  14. Impertinent Question #2 • How can field pipe welding productivity be improved???

  15. Welding Stainless Steel Piping • GMAW-S • No Backing Gas (NBG)

  16. History • Fluor previously investigated welding of stainless steels without a backing gas using GTAW process • Resulted in quality issues and the ability to reproduce acceptable Code welds

  17. Process Optimization • Optimized selected wire feed speeds • High silicon filler metals • Shielding gas • Welder training

  18. NBG Stainless Steel Welding • Good appearance • No NDE defects • Good mechanical characteristics • Good metallurgical structure • Good Strauss Corrosion Test results • Good Pitting Corrosion Test results • Minimum oxidation on the ID

  19. Weld Root • With Backing Gas • No Backing Gas

  20. Answer #2 GMAW-s NBG • Low repair rate • Eliminates backing gas requirement • Welder friendly • Significant cost savings over other processes

  21. Impertinent Question #3 • How can we ensure integrity of high pressure high density polyethylene (HDPE) pipeline???

  22. Current Practices • Visual exam • Poor correlation to weld quality for heavy wall • Bent-strap test(ASTM D2657) • Low probability of detection:

  23. Current Practices (Continued…) • Traditional UT pulse-echo • Ineffective for heavy wall • Hydro testing • Derived from metallic systems • Viscoelastic plastics • deformation depends on time and temperature • does not ensure long-term performance

  24. UT-TOFD Probes Outer Diameter; Outside wall Lateral Wave Transducer Receiver Upper Tip Lower Tip Flaw Back Wall Echo Inner Diameter; Back wall • Fluor Ultrasonic Probes • Patents are pending on this technology and its application Probes Weld

  25. Development Work • Stage 1 - Laboratory • Calibration blocks • Double-blind test spools • indications correlated to defects • lack of fusion (LOF) identified • Stage 2 - Field Investigation • Operating pipeline, analysis of field welds • Stage 3 - CorrelationUT-TOFD vs. Destructive Testing • Lab test spools • Field welds

  26. Correlation Example Accurate Defect Identification Field Sample TOFD Scan

  27. Development Work Completed • Summary of findings • Visual examination • poor correlation • Backwall echo - lateral wave loss • severe lack of fusion • Multiple point reflectors • non-fusion and poor fusion • Foreign contamination • easily detectable • “Clear” UT-TOFD scan • properly fused Lab Sample Bead Profile - High/Low

  28. Answer #3 UT-TOFD • Current Examination Practices • Not equipped to detect heavy wall flaws and faulty welds • Limits thermoplastic: low pressure, non-critical • New application for pipeline industry • Leap in Quality of testing • Plastics expansion into pipeline industry • UT - TOFD Method • Ultrasonic Time of Flight Diffraction • Reliable - quick - easy

  29. Combining Engineering & Technology 3 examples Conventional Approaches Not Necessarily Optimum Opportunities Abound Summary Engineering & New Technology

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