0.

72m NS&NNS Machined Demonstrator

Schedule

Future Net Shape Manufacture Technology For

Subsea Applications
Charley Carpenter
Net Shape Technology Manager
Manufacturing Technology Centre
*TTI HIP Vessel is currently broken.
0.72m NS&NNS Machined Demonstrator
HVM Catapult
Schedule

*TTI HIP Vessel is currently broken.

Taking Research into Production
0.72m NS&NNS Machined Demonstrator
Schedule

*TTI HIP Vessel is currently broken.

 Spun Demonstrators
Game Changing ….completely changing the way that
Technologies something is done, thought about or
made.

Hot Isostatic Pressing

An alternative to large castings and

forgings.
 Traditional Manufacturing Methods
Main methods of manufacturing components:

• Casting
Complexity

• Welding Potential for defect

development or
• Forging non-uniformity

• Extruding

• Inter-stage Heat treatments and post-processing Extra time/cost

Subsequent defect development
Main defects produced by these methods:
• Porosity • Distortion due to residual stresses
• Internal shrinkages • Anisotropic mechanical behaviour
• Interdendritic cracks • Chemical segregation
• Heat Affected Zone segregates • Microstructural variation
• Inclusions
• Hydrogen embrittlement in SS
Porosity

[3]
Grain structure

[4]
Stress Corrosion Cracking

[1] [2] [1]

 Repair Technologies & High Integrity
Manufacture Methods
All manufacture methods may cause defects to a greater or lesser extent…

Tolerate if… Repair If… Alternative Manufacture Method If…

• Defects do not significantly • Cost of repair is low vs • Component performance can be

impact component function
or life
• Defects are well understood
(NDE)
• Defects remain stable over
component life
replacement
• High lead time for replacement
• Repair does not reduce part
performance
increased
• Cost can be reduced (at
manufacture or in life)
• Greater or new functionality can
be attained
Hot Isostatic Pressing
Properties produced via HIP
• Isotropic grains structure

• Refined grain size

• No chemical composition variation

• 100% densification
[5]
HIP component properties
HIP produced near
net-shape part
• Isotropic mechanical behaviour
• Greater corrosion resistance/life
• High Ultrasonic inspectability
• Welds can be eliminated
Milling + heat treatment
• Near Net/Net shape – less machining

[6]
End component
Metso Materials Technology
Component Life…
Aging equipment is one of the biggest challenges facing the industry.
• The UK Health and Safety Executive's plant-aging initiative is centred on
an inspection programme
• HSE's plant-aging guide (RR509) states:
“Aging is not about how old the equipment is. It's about what is known about its
condition, and how that's changing over time.” 7
 Products
produced via HIP

• Manifolds [6]

• X-trees
Manifolds
• Well-heads
• First PHIP manifold in North Sea’s Jade Field
• Swivels
2000
• Barrel Casings and hubs
• Water injection manifold installed in Heidrun
• Wye Pieces field, decreasing the number of welds by 85%,
manufactured in just 4 HIPed parts8
 As forged piece As HIPed piece
Products
produced via HIP

• Manifolds
[7] [8]
• X-trees
Swivels (5-16 tons)
• Well-heads
• Multi-phase swivel containing complex
• Swivels
internal flow channels, used for Floating
• Barrel Casings and hubs Production Storage Offloading (FPSO)
• Wye Pieces • Claimed 10 week lead time & UT inspectable
• Just under 240 tons of HIP material for swivels
can be found around the world8
 Products
produced via HIP
Wye Pieces
• Produced for the East Spar
Project (Australia)
• Manifolds
• Due to a design stress of 25
• X-trees MPa, conventional methods
of production would require
• Well-heads a part of 3.5 tonnes, HIP
• Swivels only 2 tonnes9

• Barrel Casings and hubs [9]

• Wye Pieces
Timeline of HIP product manufacture
1987 Powdermet process introduced in 1987- solid and
hollow bars, ring and preforms with the size required by
the market10
Mid 1990s Production of Swivels by HIP processes starts10
1998 >4000 ton of HIPed pieces for offshore industry were
produced by Sandvik Powdermet –
2001 Six seabed manifold sections for BP’s Norge’s
Valhall Field installed11
2003 70 tons of HIPed pieces sent to Shah Deniz Field in
Azerbaijan13
Timeline of HIP product manufacture
2004 China National Offshore Oil Corp. (CNOOC) ordered
two barrel casings for Sulzer pumps from Metso
Powdermet12
2006 Framo Engineering provide a swivel in duplex
stainless steel for BHP Billiton’s Stybarrow FPSO13
2007 Aker Kvaerner Subsea for subsea hubs for the Dalia,
Gimboa, Tyrihans, Visund, Hild, and Kristin projects5
2015 Impregnated drill bit series from Varel international
includes cylindrical HIPed segments, 14
The Future of Powder HIP
Advances in HIP compaction modelling:

• More complex components possible

• Improved material efficiency
• Greater design functionality

[20]
Bodycote
New Materials & Multi Materials
• Advanced PM alloys and metal matrix composite materials
• Multi Material components

[20]
Kennametal Sandvik Powdermet
Powder HIP Development in The UK
 References
1: Kemplon Engineering (2014) Stress Corrosion Cracking (SCC): A Capriciously Insidious Material Killer, Available at:
http://kemplon.com/stress-corrosion-cracking-scc-a-capriciously-insidious-material-killer/ (Accessed: 12th November 2015).
2: Canadian Energy Pipeline Association (2007) Stress Corrosion Crack: Recommended Practices, 2nd Edition, Available at:
http://kemplon.com/wp-content/uploads/2015/08/Cracking.jpg (Accessed: 12th November 2015)
3: TWI Global (2015) Defects/imperfections in welds - porosity, Available at: ( http://www.twi-global.com/technical-knowledge/job-
knowledge/defects-imperfections-in-welds-porosity-042/ (Accessed: 12th November 2015).
4: Sandvik (2015) Advantages of HIP products, Available at: http://smt.sandvik.com/ja-jp/products/hot-isostatic-pressed-hip-
products/product-advantages/ (Accessed: 12th November 2015).
5: Altak-MHD (2014) Fan structure of wrought alloys ingots, Available at: http://www.altek-mhd.com/en/articles/fanstructure (Accessed:
12th November 2015).
6: Powder Metallurgy Review (12th June 2012) Recent trends in Hot Isostatic Pressing (HIP) technology: Part 2 - Powder based HIP
products, Available at: http://www.ipmd.net/articles/001756.html (Accessed: 12th November 2015).
7: Bridging the Energy Gap. Source: MWP. May 2014, Vol. 158 Issue 4, p50-55
8: Hjorth, C.G (03/01/1997) Hot isostatic pressing proves value on complex subsea components, Available at: http://www.offshore-
mag.com/articles/print/volume-57/issue-3/news/general-interest/powder-metallurgy-design-hot-isostatic-pressing-proves-value-on-
complex-subsea-components.html (Accessed: 6th October 2015).
 References
7: Fomas Group (2015) Oil and Gas, Available at: http://www.fomasgroup.com/portals/0/pdf/Oil_Gas_eng.pdf (Accessed: 12th
November 2015).
8: Crestana, L. H., and Camargo, F. C. (2010) Experience and reference of Powder Metallurgy parts produced by HIP (Hot Isostatic
Pressing), Available at: http://www.nucleoinox.org.br/inox-2010/downloads/trabalhos/M7-HIP(Sandvik).pdf (Accessed: 9th October
2015).
9: Terdre, N. (2007) 'Sandvik Powdermet to pursue further avenues for Hot Isostatic Processing', Offshore, March, p. 105.
10: Boyer, C.B (1992) 'Historical Review of HIP Equipment', in Koizsumi, M (ed.) Hot Isostatic Pressing - Theory and Applications.
Netherlands: Springer Netherlands, pp. 465-510.
11: Björman, G (03/01/2002) Hot isostatic pressing proves value on complex subsea components, Available at: http://www.offshore-
mag.com/articles/print/volume-62/issue-3/news/sweden-hip-manufacture-extending-from-subsea-to-downhole-applications.html
(Accessed: 6th October 2015).
12: Björman, G (07/01/2005) Demand up for HIP components, Available at: http://www.offshore-mag.com/articles/print/volume-
65/issue-7/sweden/demand-up-for-hip-components.html (Accessed: 6th October 2015).
13: Hjorth, C.G (03/01/2007) Sandvik Powdermet to pursue further avenues for hot isostatic processing, Available at:
http://www.offshore-mag.com/articles/print/volume-67/issue-3/sweden/sandvik-powdermet-to-pursue-further-avenues-for-hot-isostatic-
processing.html (Accessed: 6th October 2015).
 References
14: Ghiselin, D (05/06/2015) Advances in drill bits improve efficiency, performance, Available at: http://www.offshore-
mag.com/articles/print/volume-75/issue-5/drilling-and-completion/advances-in-drill-bits-improve-efficiency-performance.html
(Accessed: 6th October 2015).
15: Hjorth, C-G. (2007) HIPing of large Near Net shape components for industrial applications, Available at:
http://ventilsystemer.no/pdf/artikkel_1.pdf (Accessed: 9th October 2015).
16: Uehara, K; Ishii, T; Inoue, Y; Fujikawa, T (1993) 'Recent Advances in HIP Equipment Technology', in Tas, H; Delaey, L (ed.) Hot
Isostatic Pressing '93. Belgium: Elsevier Science, pp. 481.
17: Anderton, J; 'Hot Isostatic Pressing Expands 3D Printing Into Hot Section Jet Parts'. Engineering 2015. Web. 9 Oct. 2015.
18: Whittaker, D. (2012) 'A nuclear waste disposal system enabled by hot isostatic pressing technology', Powder Metallurgy Review,
1st August.
20: PM HIP Technology EPMA (30/11/2015) http://www.epma.com/hot-isostatic-pressing
Thank you for listening
Any Questions?