Designing CO2 Transmission Pipelines Without Crack Arrestors

Masdar is developing several carbon capture projects from power plants, smelters, steel works, industrial facilities and oil and gas processing plants in Abu Dhabi in a phased series of projects. Captured CO2 will be transported in a new national CO2 pipeline network with a nominal capacity of 20×106 T/y to oil reservoirs where it will be injected for reservoir management and sequestration. Design of the pipeline network considered three primary factors in the selection of wall thickness and toughness, (a) steady and transient operating conditions, (b) prevention of longitudinal ductile fractures and (c) optimization of total project owning and operating costs. The paper explains how the three factors affect wall thickness and toughness. It sets out code requirements that must be satisfied when choosing wall thickness and gives details of how to calculate toughness to prevent propagation of long ductile fracture in CO2 pipelines. It then uses cost optimization to resolve contention between the different requirements and arrive at a safe and economical pipeline design. The design work selected a design pressure of 24.5 MPa, well above the critical point for CO2 and much higher than is normally seen in conventional oil and gas pipelines. Despite its high operating pressure, the proposed network will be one of the safest pipeline systems in the world today.

Crystallographic Texture Control Helps Improve Pipeline Steel Resistance to Hydrogen-Induced Cracking

Low-carbon steel specimens, all within API (American Petroleum Institute) specifications, were produced following different thermomechanical paths. After austenization, the samples were rolled and recrystallized. The rolling process was carried out using different reduction-in-thickness degrees and finishing temperatures. The investigated steels showed similar microstructural features but differed considerably in their crystallographic textures and grain boundary distributions. After cathodic hydrogen charging, hydrogen-induced cracking (HIC) was detected in the hot-rolled recrystallized steels, whereas the cold and warm-rolled recrystallized steels proved resistant to this damage. Among the investigated specimens, the HIC-stricken show either the strongest {001}ND texture fiber, the smallest fraction of low-angle grain boundaries, or the weakest {111}ND (γ) texture fiber ({hkl}ND representing crystallographic orientations with {hkl} planes parallel to the steel rolling plane). In contrast, the HIC-resistant steels show the weakest {001}ND texture fiber, the largest fraction of low-angle grain boundaries, and the strongest γ fiber. These results support the hypothesis of this and previous works, that crystallographic texture control, through warm rolling schedules, helps improve pipeline steel resistance to hydrogen-induced cracking.

Challenges in Joining Thermoset Composite Piping

The aim of this paper is to examine solutions and challenges related to joining thermoset composite piping. Fiber reinforced polymers (FRP) have been used in piping systems for more than 40 years. Higher specific mechanical properties and corrosion resistance of FRP make them a potential candidate for replacing metallic piping structures. Despite the advantages associated with FRP, their application is still limited due to, in part, unsatisfactory methods for joining composite subcomponents and inadequate knowledge of failure mechanism under different loading conditions. Adhesively bonded joints are attractive for many applications since they offer integrated sealing, minimal part count and do not require pipe extremities with complex geometries such as threads or bell and spigot configurations. So far, the majority of work reported in the technical literature on adhesively bonded pipe joints is concerned with lap joints employing wrapping techniques to produce overlap sleeve connections. More recently, a joining technique was proposed that replaces the wrapping technique with filament-wound overlap sleeve couplers that are adhesively bonded to the pipe extremities. In the present article, various joining techniques for FRP piping through adhesive bonding are discussed, and damage mechanisms under different loading conditions are examined.

Study on Tensile Property and Strain Ageing Behavior of X100 Linepipe

A series research programs and industrial trials of X100 linepipe have been launched by CNPC so as to build an X100 trial in China for long-distance gas pipeline in the coming years. In present paper, tests have been conducted on 20.6mm×1016mm diameter Grade X100 linepipe. The microstructures, tension properties will be presented. In order to investigate the influence of anti-corrosion coating process on the performance of pipe, strain aging tests in lab have been carried out as well. It is found that testing method, tensile specimen size and sampling location had a noticeable effect on the testing results. The difference is also observed between the flattened strap specimen and round bar. The influence of time, temperature and pre-strain amount of aging tests on the shape of S-S (stress-strain) curve, tension tests results, yield ratio of pipes are presented as well.

Guidelines for Production of API Pipelines Steels Suitable for Hydrogen Induced Cracking (HIC) Service Applications

Worldwide oil and natural gas reserves can be classified as either sweet or sour service. The sour service classified oil and natural gas reserves contain some level of H2S making the product flowing through a steel pipeline corrosive. Due to this, the majority of the oil and natural gas reserves that have been drilled are of the sweet service nature. However as demand continues and supplies change, many of the remaining oil and natural gas reserves contain the H2S component and are of a sour service nature. These oil and natural gas reserves containing the H2S component through a corrosion mechanism will allow for diatomic hydrogen — in the presence of moisture — to disseminate to monatomic hydrogen and diffuse into the pipeline steel microstructure. Depending on the microstructure and level of cleanliness the monatomic hydrogen can become trapped at areas of high residual stress, recollect to diatomic hydrogen and creating partial pressures that exceed the tensile strength of the steel resulting in cracking. Therefore transmission pipelines are being built to transport sour service oil or natural gas requires steels with hydrogen induced cracking (HIC) resistance. Alloy designs, steel making processing, continuous casting, plate or strip rolling, pipe forming, and last not least corrosion testing are all key components in producing pipeline steels that are resistant to HIC applications and meeting the NACE TM0284 specifications. However, producing steels that have good HIC performance do not necessarily meet other mechanical property requirements such as strength and YT ratios. Balance has to be achieved to meet not only the HIC requirements but the other required mechanical properties. Mastering this complex HIC process poses a serious challenge to pipe producers and their primary material suppliers. The capability of producing HIC steel grades according to critical specifications and/or standards clearly distinguishes excellent steel producers from good steel makers. This paper will discuss the basics of the hydrogen induced cracking phenomenon, the requirements of the NACE TM0284 specification and give guidelines for steel production of API pipeline steels that not only can meet the specification requirements the NACE testing but also fulfill the other mechanical property requirements.

A Study on the Residual Stress and Fracture Behavior of Pipeline Girth Welds Joining Pipes of Different Strength

The following cases of girth welded region between pipelines having different base strength were considered. The pipeline shows different fracture behavior from girth welded pipeline between similar materials due to strength mismatch and residual stress distribution. Investigation about the residual stress distribution and fracture behavior of pipeline having girth welds of the differnet base metals (X70/X65 and X70/X42) with different material property has performed using finite element analysis. The effect of mismatched material property on girth weld region is negligible when shape of pipeline is similar. The assessment for occurance of crack on girth weld region with pipes with material property mismatched can be replaced by that of the similar pipes with low strength on the point view of conservation.

Predictions of Cleavage Fracture in Welded Components Incorporating Strength Mismatch Effects: A Weibull Stress Based Approach

This work describes the development of a toughness scaling methodology incorporating the effects of weld strength mismatch on crack-tip driving forces. The approach adopts a nondimensional Weibull stress, σ¯w, as a the near-tip driving force to correlate cleavage fracture across cracked weld configurations with different mismatch conditions even though the loading parameter (measured by the J-integral) may vary widely due to mismatch and constraint variations. Application of the procedure to predict the failure strain for an overmatch girth weld made of an API X80 pipeline steel demonstrates the effectiveness of the micromechanics approach. Overall, the results lend strong support to use a Weibull stress based procedure in defect assessments of structural welds.

Code Compliance of a New Metallic Composite Pipeline

The composite pipe system, known as XPipe™, is a steel strip laminate technology which uses high-performance adhesives to manufacture a metallic composite pipe. It offers a new method of low cost pipeline construction suitable for onshore gas and oil pipelines in a variety of configurations. The pipe is based on a thin wall liner that provides the fluid containment, the material of which will vary according to service requirements. Fusion bonded epoxy (FBE) coated martensitic ultra-high strength steel strips are then pre-formed and helically wound around the liner to form a laminated high strength reinforcing layer providing the pipe’s hoop strength. These are bonded using an adhesive. Unlike conventional linepipe that is manufactured in a pipe mill away from the construction site, this lightweight composite pipe can be produced at the construction facility using a portable manufacturing line. All components of the manufacturing process fit within standard ISO containers, each weighing between 5 and 15 tonnes. This allows for easy transportation via truck, and handling or shipping. Existing regulations and codes make no specific reference to metal composite pipes. They are mainly written for steel pipe lines with some mention of plastic pipe. The paper presents a comprehensive review of the following US onshore design codes (ASME B31.4/B31.8) and relevant regulations (CFR (DOT) 49 P192 / P195) in order to establish the applicability of these codes for use on XPipe. The paper describes how XPipe meets the code and regulation requirements with regard to safety, design, material, construction, inspection, testing, operation and maintenance. The paper will identify any areas where XPipe does not meet code and regulation requirements and describe the testing and /or design changes that have been made in order to meet the code requirements. The paper will focus on the how the XPipe can meet the practical requirements of these codes. The paper will describe how the qualification testing is being performed in accordance with DNV-RP-A203 Qualification Procedures for New Technology. The qualification testing focuses on how the XPipe meets or exceeds pipeline safety margins with regard to typical failure modes such as yield, burst, facture, fatigue, collapse, etc. This is a continuous process and is being updated after each step using the available knowledge on the status of the qualification.

Reality Check on Girth Weld Defect Acceptance Criteria

This paper examines the inherent conservatisms of alternative girth weld defect acceptance criteria from the 2007 API 1104 Appendix A, CSA Z662 Appendix K, and the proposed EPRG Tier 2 criteria. The API and CSA codes have the same empirical limit-load criteria, where it has previously been shown that the conservatism on the failure stress is ∼30 to 50 percent compared to pipe test data prior to applying any safety factors. In terms of flaw length, it was found that the API/CSA limit-load equation might allow a flaw of 5% of the pipe circumference, where the properly validated limit-load equation would allow a flaw of 75% of the circumference, i.e., a safety factor of 30 percent on load corresponded to a safety factor of 15 on flaw length for that example case. Similarly there are conservatisms in a proposed EPRG Tier 2 girth weld defect acceptance criterion. This proposed criterion was directly based on curved-wide-plate data to assure that toughness was sufficient to meet limit-load conditions for a curved-wide plate. However, the curved-wide plates are really an intermediate-scale test, and still require proper scaling to pipes of different diameters. The proposed Tier 2 EPRG allowable flaw length is 7T from a large database of curved-wide-plate tests with the a/t value of less than 0.5 (or a < 3mm), and the failure stress being equal to the yield strength of the base metal (also requires the weld metal overmatch the base metal strength, and the Charpy energy at the defect location have a minimum > 30 J and average > 40 J). However, the widths of those curved-wide-plate tests are typically a factor 5 to 12 times less than typical large-diameter pipes. The proper limit-load/fracture mechanics scaling solution would have the flaw length proportioned to the plate width, not the specimen thickness. Additionally, the proper limit-load solution for a pipe in bending gives a much larger tolerable flaw size at the yield stress loading than a plate or pipe under pure tension. Example calculations showed that the EPRG Tier 2 approach is conservative on the flaw lengths by approximately 9 for pure axial tension loading, and between 34 to 79 for a pipe under bending. Suggestions are presented for an improved procedure that accounts for proper limit-load solutions for pipe tests, effects of pipe diameter, effects of internal pressure, and also a much simpler approach to incorporate the material toughness than the 2007 API 1104 Appendix A Option 2 FAD-curve approach. The fracture analyses could evoke SENB, SENT testing, or have relatively simple Charpy test data to assess the transition temperatures to ensure ductile initiation will occur.

Weld Metal Hydrogen Cracking in Transmission Pipelines Construction

Developments of high strength steels for natural gas pipelines have been in the forefront of steelmaking and rolling technology in the past decades. However, parallel to such developments in steel industry, the welding technology especially with regards to SMAW process which is still widely used in many projects has not evolved accordingly. Decreasing carbon equivalent has shifted the tendency of hydrogen cracking from the HAZ to the weld metal. Hydrogen cracking due to its complex mechanism is affected by a range of interactive parameters. Experience and data gained from field welding of pipeline construction projects indicated that weld metal hydrogen cracking is related to welding position as it occurs more in the 6 o’clock position of pipeline girth welds. In this research an attempt is made to open up the above observation in order to investigate the contributory factors such as welding position and welding progression in terms of diffusible hydrogen and possibly residual stress considerations. It was observed that transverse cracks produced in laboratory condition may not be detected by radiography. But, the higher tendency for cracking at 6 o’clock position was confirmed through bend test. It is shown that more hydrogen can be absorbed by the weld metal in the overhead position. It is shown that welding progression may also have a significant effect on cracking susceptibility and it is proposed that to be due to the way that weld residual stresses are developed. The observations can have an important impact on planning for welding procedure approval regarding prevention of transverse cracking in pipeline girth welds.