construction:
The experience of SNAM RETE GAS and EUROPIPE on
X 100 grade steel
L.Barsanti, SNAM RETE GAS SpA
H.G. Hillenbrand, EUROPIPE GmbH
Proceedings of IPC:
The International Pipeline Conference
September , 2002, Calgary, Alberta, Canada
ABSTRACT
The increasing needs of natural gas, foreseen for the
next years, makes more and more important the type of
transportation chosen, both from strategic and economic
point of view. The most important gas markets will be
Northern America, Europe, Asia and Russia but the
demand shall be fulfilled also by emerging producers as
Kazakhstan, Turkmenistan and Eastern Siberia that at the
moment are developing their resources in order to be
competitive on Gas market.
In this way producers and customers will be placed
at greater and greater distances implying realization of
complex gas transportation pipeline network, when use
of LNG tankers is impossible or uneconomic.
On the base of these considerations Eni group
sponsored in 1997 a feasibility study on X100 steel, given
that, comparing different design approaches, it has been
observed that consistent savings could be obtained by
means of using high grade steel and high pressure
linepipes. In this project, involving CSM and Corus
group for the laboratory and full-scale pipes testing,
played an important part also Europipe: the pipes
producer.
No technical breakthrough, but only improvements
in the existing expertise were involved in the X100
production; consequently, the production window is very
narrow.
However optimized steelmaking practices and
processes enabled the material to reach the desired
properties: strength, toughness and weldability.
This paper is intended to present the general results
arising from this project, in terms of steel properties
(chemical composition, mechanical properties), ductile
and brittle fracture resistance (results of full scale burst
tests, West Jefferson tests) and field weldability, but
above all the know-how stored till now on high grade
H.G. Hillenbrand
EUROPIPE GmbH
Formerstrasse 49, 40878 Ratingen,
Germany
steel and its possible use from a Gas company and a Pipe
maker point of view.
INTERNATIONAL SCENARIO
The energetic scenario has been changing quickly
in these last years. International studies foresaw an
increasing demand of natural gas till doubling in 2030.
This statement is based on several issues:
The availability of natural gas fields is greater than
that of verified oil fields.
The exploitation of these reserves is yet limited.
The need of substituting polluting fuels according
Kyoto agreement with the consequent increasing use
of natural gas for electric energy production with
combined cycles.
This increasing demand will be satisfied not only by
major producers (Russia, Norway, Northern America
etc.) but also by emerging countries like Kazakhstan,
Turkmenistan and Eastern Siberia, that at the moment are
developing their resources in order to be competitive on
Gas market.
Also for this reason, producers and customers will be
placed at greater and greater distances implying
construction of complex gas transportation pipeline
network, when use of LNG tankers is impossible or
uneconomic.
This makes high pressure natural gas
transportation via pipelines more and more interesting
for gas companies.
On the base of these considerations Eni group
sponsored in 1997 a feasibility study on X100 steel grade
because this high strength steel could give consistent
savings in terms of CAPEX comparing it to an X80 high
pressure solution. Also other gas companies tried to
Mn
Mo
Ni
yield to
yield strength tensile strength
tensile ratio
Rt0.5 *
Rm *
R t0.5 / R m *
739 MPa
792 MPa
Cu
Ti
CEIIW PC M
Elongation
A5 *
CVN
(20C)
DWTTtransition
temperature
18.4%
235
- 15 C
0.93
Heat
II
pipe size
OD X WT
Mn
Si
Mo
Ni
Cu
-
Nb
755 MPa
820 MPa
0.92
17.1 %
Ti
CEIIW PC M
yield to
yield strength tensile strength
Elongation
tensile ratio
Rt0.5 *
Rm *
A5 *
R t0.5 / R m *
Nb
MATERIALS
To cope with market requirements for enhancing
strength Europipe put its effort to the development of
grade X100. No technological breakthroughs, such as TM
rolling and accelerated cooling which increased the
strength and toughness respectively, but only
improvements in the existing technology were involved
in the production of grade X100 plate. As a result, the
production window is quite narrow. Heat treatment of
plate or pipe is obviously not advisable.
Si
30" x 19.1 mm 0.08 1.95 0.26 0.26 0.23 0.22 0.05 0.018 0.003 0.49 0.22
Heat
I
pipe size
OD X WT
CVN
(20C)
DWTTtransition
temperature
240
- 25 C
pipe size
OD X WT
Mn
Si
Mo
Ni
Cu
Nb
Ti
CEIIW PCM
III
56" x 19.1 mm 0.07 1.90 0.30 0.17 0.33 0.20 0.05 0.018 0.005 0.46 0.20
IV
Heat
III
IV
V
yield to
yield strength tensile strength
Elongation CVN
tensile ratio
Rt0.5 *
Rm *
A5 *
(20C)
Rt0.5 / Rm *
737 MPa
800 MPa
752 MPa
816 MPa
0.92
DWTTtransition
temperature
18 %
200 J
- 20 C
0.92
18 %
~0.94
15-18 %
270 J
- 50 C
200~-60 - -10C**
270 J
Nominal diameter
Nominal thickness
Pressurizing medium
Test pressure
Usage Factor
1 test
56
19.1 mm
air
126 bar
68%
2 test
36
16 mm
air
181 bar
75%
2 test
In this case two propagations and two clear arrests
were observed.
West side: the crack, after initiation, propagated with
a maximum speed of about 310 m/s and arrested
eventually in the last pipe (297 J of Charpy V energy)
after about 1.5 2 meters.
East side: the crack, after the initiation, propagated
with a maximum speed of about 300 m/s and entered in
the following pipe (259 J of Charpy V energy) where it
arrested after about 5 meters.
On the base of these results, especially for the
second burst test, where we had two valid arrests, it can
be said a toughness level of about 260 J is sufficient to
arrest a long ductile propagating fracture in the tests
conditions chosen.
To tell the truth, on the west side, it arrested in a pipe
characterised by 297 J, but considering that in the
previous pipe (252 J ) we had a lower DWTT energy and
that fracture arrested at the very beginning of the last
pipe, we can subscribe previous statement.
This result is in agreement with previous tests
performed on high grade/high hoop stress pipelines.
Therefore in order to use the conventional Battelle Two
Curves Approach, based on CharpyV values, several
correction factors according the tests should be used: 1.5
for the first test and 1.7 for the second one (see Fig. 7).
FIELD WELDABILITY
One of the most important issue in gas transportation
industry is not only development of the steel but also
appropriate welding procedures.
So in the present paper will be presented results obtained
by means of laboratory and full scale concerning three
main items:
Review on commercial availability of consumables
with suitable chemical composition and mechanical
properties in terms of tensile strength and hardness
to fulfil overmatching criterion ;
Definition of minimum welding requirements with
reference to pre-heating temperatures in order to
IMPLANT
TEKKEN
200C
100C
Basic el. E10018
200C
Cellulosic el. E9010 250C
150C
Cellulosic el. E6010 n. d.
Table 1: Minimum Preheating Temperatures established
from laboratory tests
Once chosen pre-heating temperatures two field welding
trials have been performed on two pipes (56"x19mm and
36"x16mm) investigating on both most spread
techniques: GMAW (PASSO system) and SMAW.
In the tables 2-3 can be observed the welding procedures
followed for each geometry.
Both techniques gave good results even if GMAW
resulted less problematic because of its lower impact on
welders skill and training, in Fig.8-9 the appearance of
welds can be observed for each technique.
CONCLUSIONS
On the base of last previsions, gas quantities to
be transported will increase significantly making more
and more attractive natural gas transportation by means
of long distance high pressure pipelines.
X100 steel could be a material suitable for this
type of construction: it could combines high pressure and
reduced thickness of the pipe in order to minimize
CAPEX. But it will be necessary to reassess and redefine
some of the material requirements
ACKNOWLEDGMENTS
This research was performed also with the help
of Esab and Bohler for the consumables supplying and
with the collaboration of Bonatti and Sicim for pipe
welding.
REFERENCES
APPENDIX
3000
2500
Costs [USD/m]
2000
Common costs
1500
Welding
Laying
1000
Materials
500
API 5L X80
API 5L X100
Fig.1:
Comparison between costs associated to X80 and X100 options for the same project construction.
Fig.2:
100
90
10
80
20
30
DWTT
60
40
Charpy V
50
50
WJ Results
40
60
30
70
20
80
Battelle Criterium
10
0
-160
70
90
100
-140
-120
-100
-80
-60
-40
-20
20
40
Temperature (C)
Fig.3:
100
10
90
DWTT
20
80
Charpy V
Brittle fracture (%)
WJ Results
60
40
50
50
40
60
30
70
20
80
Battelle Criterium
90
10
0
-160
100
-140
-120
-100
-80
-60
-40
-20
20
40
Temperature (C)
Fig.4:
30
70
EAST
Severance
Reservoir
Reservoir
Initiation pipe
Pipe number
Tensile and
toughness
properties
YS (MPa)
TS (MPa)
Y/T ratio
CharpyV (Joule)
846020
707
766
0.92
271
846038
719
766
0.94
245
846129
780
832
0.94
200
846113
773
858
0.90
151
846058
755
829
0.91
170
846157
663
762
0.87
263
846061
722
778
0.93
284
Fracture
Path
Arrest predicted CharpyV toughness values with P=126 bar (hoop stress=469 MPa)
Battelle simpl. formula
188 J
176 J
Fig.5:
WEST
Reservoir
Reservoir
Initiation pipe
Pipe number
Tensile and
toughness
properties
YS (MPa)
TS (MPa)
Y/T ratio
CharpyV (Joule)
99447
724
780
0.93
297
99458
750
819
0.92
252
99460
711
797
0.89
202
99461
709
802
0.88
165
99456
761
844
0.90
259
99457
740
811
0.91
253
99446
766
826
0.93
274
Fracture
Path
Arrest predicted CharpyV toughness values with P=181 bar (hoop stress=517 MPa)
Battelle simpl. formula
186 J
154 J
Fig.6:
350
Database Arrest
1:1.7
1:1.5
Database Propagation
300
1:1.43
250
1:1
200
150
100
50
0
0
50
100
150
200
Fig.7:
Actual vs. Predicted CharpyV energy (Battelle Two Curve Approach) for high-grade steel linepipes (CSM
database)
Fig.8:
Appearance of a weld (test n.3 SMAW 36x16mm, mixed weld joint, vertical up welding)
10
Fig.9:
Appearance of a weld (test n.10 GMAW 36x16mm, wire A 5.28 ER 100 S-G)
Snam specifications
Sal
2:
SMAW
Joining
welding
(es: tie in)
Sal
1:
GMAW
(PASSO type)
Table 2:
Test
N.
Root pass
(AWS)
Hot pass
(AWS)
Filler
(AWS)
E6010
E9010
E10018-G
E8018-G
E10018-G
E10018-G
E6010
E10018
E10018
E7016
E10018
E10018-G
E6010
E10018-G
E10018-G
E6010
E9010
E10018-G
ER 100 S-G
ER 90 S-G
ER 100 S-G
Types of welding procedures, wires and electrodes used for 56x19mm pipe.
11
S n a m specification
Sal
2:
SMAW
(linking w e l d i n g )
Sal
1:
GMAW
( P A S S O type)
Table 3:
Test
N.
Root pass
(AWS)
Second
pass
(AWS)
Filling
(AWS)
E6010
E11018-G
E11018-G
E8018-G
E10018-G
E10018-G
E6010
E10018
E10018
E6010
E10018-G
E10018-G
E6010
E10018-G
E10018-G
E7016
E10018
E10018-G
ER 90 S-G
10
ER 100 S-G
Types of welding procedures, wires and electrodes used for 36x16mm pipe.
12