WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, OCTOBER 2016
Sponsored by the American Welding Society and the Welding Research Council
G. Z. BATISTA is a metallurgical engineer and L. DA P. CARVALHO is a mechanical engineer with Petrobras, Rio de Janeiro, Brazil. M. S. DA SILVA
is a metallurgical engineer with ATNAS, Rio de Janeiro, Brazil. M. P. SOUZA is a mechanical engineer with Tenaris, Rio de Janeiro, Brazil.
WELDING RESEARCH
Fig. 1— Bevel dimensions (ASME B31.8, Ref. 12). Fig. 2 — X70 pipe welding.
ness can increase to values above the tle phases, including the formation of steel welding are easily found in the
limits for sour service application. martensite-austenite (MA), which ac- literature, the same cannot be said
Another fact that needs to be stud- cording to Babu et al. (Ref. 9) may de- about high-strength steel for sour
ied in the HAZ is the possibility of em- teriorate or improve the properties de- service, especially for heavy wall thick-
brittlement due to either grain coars- pending on its morphology or concen- ness pipes. This investigation shows
ening or brittle phase formation. Pep- tration of carbon. For weld metal, it is how the girth welding of API 5L X70
pler et al. (Ref. 7) commented that a important to evaluate if the high and X80 pipes developed for use in
low toughness can be expected in the strength levels required do not impair sour environments affects weld metal
coarse-grain HAZ due to grain growth. the toughness or increase the hard- and HAZ properties. The test method-
Furthermore, Terada et al. (Ref. 8) ness above the limits for sour service ology included tensile, nick-break, side
commented that the HAZ toughness application. bend, Charpy, crack tip opening dis-
can be reduced by the presence of brit- Although studies on high-strength placement (CTOD), hardness, and
stress corrosion tests. The results pro-
vide technical information to support
the application of these materials for
Table 1 — Chemical Composition
onshore gas pipelines from presalt
fields.
C Mn Si Nb V Ti Cr Cu Mo
X70 0.04 1.23 0.237 0.048 0.002 0.010 0.32 0.007 0.09
X80 0.05 1.62 0.270 0.033 0.005 0.013 0.17 0.011 0.11 Material and Experimental
Ca Al N P S Ni B CE Procedure
IIW Pcm
X70 0.0016 0.03 0.009 0.007 0.002 0.366 0.0002 0.35 0.14 Pipe Material
X80 0.0018 0.03 0.007 0.009 0.003 0.032 0.0003 0.38 0.16
CEIIW = C + (Mn/6) + [(Cr + Mo + V)/5] + [(Ni + Cu)/15] (Ref. 1). The plates for pipe manufacture
CEPcm = C + (Si/30) + (Mn/20) + (Cu/20) + (Ni/60) + (Cr/20) + (Mo/15) + (V/10) + 5B (Ref. 1). were produced by a thermomechani-
WELDING RESEARCH
WELDING RESEARCH
cates issued by the manufacturers and ing the welding conditions found in Mechanical Tests and
correspond to the chemical analysis of onshore pipeline construction. Weld- Metallographic Analysis
the same heat of the consumable used ing parameters are seen in Table 4. A
in the tests. For each consumable, the preheating of 100°C and interpass Specimens were taken from the
chemical analysis was performed ac- temperature of 175°C were also weld coupons to perform metallo-
cording to the requirements of the ap- applied. graphic analysis and mechanical tests
plicable AWS standard. After welding, the coupons were in- of tensile, nick break, and bending, re-
Figure 2 shows the API 5L X70 pipe spected by radiographic examination quired by API 1104 (Ref. 14), and also
during welding. The pipe girth welding and ultrasonic tested, and they met the Charpy, hardness, CTOD, and stress
was done with two welders represent- requirements of API 1104 (Ref. 14). corrosion testing.
X70 E81T1Ni1C 0.046 1.47 0.41 0.010 0.013 0.820 0.030 0.020 — 0.02
FCAW
X80 E101T1G 0.050 1.57 0.38 0.010 0.020 0.900 0.040 0.170 — 0.02
WELDING RESEARCH
Samples for metallographic analysis bottom pipe quadrant. Three full-size 15156-2 (Ref. 15) to test an opera-
were etched with nital 2%, and the im- specimens of 10 ¥ 10 ¥ 55 mm were tional condition similar to the presalt
ages were taken with magnification of tested according to ASTM A370 (Ref. gas characteristics. The girth weld root
500¥ by optical microscopy. 16) for each position. The test was car- was placed in the tensioned area of the
The test methods and samples for ried out at 0ºC, which is below the mini- specimen and was not machined to
tensile, nick break, and bending tests mum design temperature for onshore test the real weld profile found in cir-
of the girth welds were done according pipelines. Figure 4, based on DNV-OS- cumferential weld roots.
to API 1104 (Ref. 14) requirements. F101 (Ref. 17), shows the notch posi- For CTOD tests, single-edge,
A Vickers hardness test was per- tions for the girth weld Charpy test. notched bend specimens were used ac-
formed with a load of 10 kgf. The spec- The stress corrosion test of three cording to BS 7448 (Ref. 20). The weld
imen, removed from the 6 o’clock posi- specimens was performed according to metal test was conducted on a through
tion, was prepared according to Fig. 3 ISO 7539-2 (Ref. 18) standard using thickness specimen of rectangular sec-
extracted from ISO 15156-2 (Ref. 15) the four-point loading method — Fig. tions (Bx2B) with crack plane orienta-
that defines the hardness require- 5. During the test, a stress level corre- tion correspondent to NP, where N
ments for sour service. sponding to 80% of the actual yield means normal to weld direction and P
Charpy impact test specimens were strength of the pipe was applied. The means crack propagation parallel to
sampled at 2 mm from the inner surface stressed samples were exposed to the weld direction, in accordance with BS
(close to the root pass) and at 2 mm test solution B of NACE TM 0284 7448 (Ref. 20). The HAZ test was con-
from the outside surface (close to the standard (Ref. 19) for 30 days with ducted on surface-notched specimens
cap pass) of the pipe for both weld met- continuous bubbling of H2S. This solu- of square sections (BxB) with crack
al and HAZ. The specimens were re- tion was chosen because its severity is plane orientation corresponding to
moved from both one upper and one closer to that recommended by ISO NQ, where N means normal to weld
direction and Q means crack propaga-
tion in the weld thickness direction ac-
Table 4 — Process Parameters cording to BS 7448 (Ref. 20), to place
the fatigue precrack at the grain
Pipe Pass Number Polarity Voltage Current Speed Heat Input growth region of the HAZ — Fig. 6.
of Passes (V) (A) (mm/s) (kJ/mm) Nine specimens were tested for
Root 1 CC + 15–16 140–190 1.6–2.1 0.9–1.8 both the weld metal and HAZ, three
X70 Fill 22 CC + 20–23 180–220 1.8–4.6 0.7–2.3 from the 12 o’clock position, three
Cap 5 CC + 21–23 180–200 3.0–5.5 0.8–1.0 from the 6 o’clock position, and three
Root 1 CC + 15–17 120–140 1.6–2.1 0.8–1.5 from the 3 o’clock position. The test
X80 Fill 25 CC + 21–23 190–220 2.1–5.5 0.9–2.1 temperature was –10°C for X70 and
Cap 5 CC + 21–23 190–210 3.3–4.7 0.9–1.2 0°C for X80. In fact, the test tempera-
ture depends on the minimum tem-
perature of the environment where
Table 5 — Stress Corrosion Cracking Testing Results the pipe will be applied. During the
X80 CTOD tests, the minimum tem-
Pipe Grade pH before H2S Saturation / Result perature had been set to 0°C, later on,
pH at End of Test it was decided to adopt a more conser-
vative condition for the X70 pipe, and
X70 8.14/5.25 No cracks the test temperature was reset
X80 8.17/5.23 No cracks
to –10°C.
WELDING RESEARCH
Fig. 12 — X70 weld metal CTOD. Fig. 13 — Weld metal microstructure of X70 welded with 100%
CO2.
Fig. 14 — Charpy absorbed energy of weld metal. Fig. 15 — Charpy absorbed energy for HAZ.
Results and Discussion Considering the results of tensile, possibilities from the engineering
bending, and nick-break tests, the point of view to deal with situations
The weld metal microstructure of welding procedure was considered where specific analysis is necessary,
X70 and X80 can be seen in Figs. 7 and qualified according to API 1104 (Ref. such as defects found during in-
8, respectively. The X70 microstruc- 14). However, to meet the specific re- service inspection and to avoid unnec-
ture presented acicular ferrite, grain quirements for presalt gas pipelines essary repairs (Ref. 21).
boundary ferrite, and polygonal fer- and perform a deep evaluation, other Figure 10 shows that one X80 spec-
rite, while the X80 presented a higher tests such as Charpy, CTOD, hardness, imen presented a CTOD value below
amount of acicular ferrite and also and stress corrosion were necessary. 0.15 mm for the HAZ. Barnes (Ref. 22)
some polygonal ferrite. Charpy and CTOD tests were car- commented that local brittle zones ex-
The results of the weld tensile test ried out to verify the weld metal and ist within the HAZ, especially within
for each quadrant are shown in Fig. 9. HAZ toughness. Figure 10 presents those regions of the grain-coarsened
The horizontal dashed line expresses the CTOD results of the HAZ and Fig. HAZ, reheated into the intercritical
the minimum acceptable values of 570 11 the CTOD of the weld metal. Only regime by subsequent weld passes.
MPa for X70 and 625 MPa for X80. the CTOD valid specimens were plot- These brittle zones are formed due to
Eight side bending specimens for ted so that less than three results may the formation of MA constituent.
each joint were tested. No one speci- appear for some positions. The hori- According to Barnes (Ref. 23), the
men presented a crack or other discon- zontal dashed line represents the min- scatter observed in the test data can be
tinuity greater than 3 mm, so that all imum acceptable value of 0.15 mm explained by the inhomogeneity of the
specimens of both materials met the recommended by Hopkins and Denys microstructure and by the fact that the
requirements for the bending test. For (Ref. 21) to allow the use of a fitness- local brittle zones are small so that the
the nick-break test, four specimens for-purpose criteria. This minimum crack tip can be, or not, at these regions.
from each joint were tested, one for value is required to ensure that plastic Barnes (Ref. 23) suggested that the
each quadrant, and all of them met the collapse equations can predict defect thermal simulation techniques can re-
API 1104 (Ref. 14) acceptance criteria. failure stresses. This provides more duce the inherent variability and allow
WELDING RESEARCH
WELDING RESEARCH
GMAW process for the root pass and of these recently developed materials. Sour Service. São Paulo, Brazil.
the FCAW process for fill passes were The authors wish to acknowledge 12. ASME B31.8. 2010. Gas Transmis-
evaluated for both X70 and X80 sour Petrobras and Tenaris for the financial sion and Distribution Piping Systems. The
service pipes. According to API 1104 and technical support, and Senai-CTS American Society of Mechanical Engineers.
13. Procario, J. R., and Melfi, T. 2011.
requirements, the welding procedures for the welding of test joints. The au-
Weld metal alloy systems for seam welding
can be considered approved. thors also would like to thank Richard of niobium micro-alloyed pipe steels. Weld-
The X80 HAZ presented low Bravo and Harold Leon, Tenaris, Mar- ing of High Strength Pipeline Steels Interna-
toughness according to one specimen cy Saturno de Menezes, Petrobras, and tional Seminar.
evaluated by CTOD tests. In fact, the Suelen Navarro, Consulpri for their 14. API 1104. 2010. Welding of Pipelines
CTOD test is not required to meet the contributions, technical guidance, and and Related Facilities. American Petroleum
workmanship criteria of API 1104. support provided during this research. Institute. 20th Edition.
However, a low toughness can restrict 15. ISO 15156-2. 2009. Petroleum and
a fitness- for-purpose analysis to Natural Gas Industries — Materials for Use
avoid unnecessary repairs of defects in H2S-Containing Environments in Oil and
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The Charpy impact test presented crostructure modeling of HAZ softening in guidelines on acceptable girth weld defects
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This paper presented the results of dard and non-standard HIC conditions. In-
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a weldability study applied in X70 and Sour Service. São Paulo, Brazil.
X80 pipes developed for sour service. 11. Nieto, J. et al. 2012. Process and
The results obtained can be used for quality controls for production of line pipe
field girth welding of these materials slabs for sour service applications at
and provides information that leads to ArcelorMittal Lazaro Cardenas, Mexico. In-
a better comprehension of the welding ternational Seminar Microalloyed Steels for