Key Quality Aspects for a New Metallic Composite Pipe: Corrosion Testing, Welding, Weld Inspection and Manufacturing

2010 ◽  
Author(s):  
Robert J. Conder ◽  
Peter Felton ◽  
Richard Smith ◽  
Raymond Burke ◽  
Frits Dijkstra ◽  
...  
Keyword(s):  
Steel Strip ◽  
High Strength ◽  
Coarse Grained ◽  
Pipe Production ◽  
Metallic Composite ◽  
Quality Aspects ◽  
Composite Pipe ◽  
Ultrasonic Techniques ◽  
Weld Inspection ◽  
Robust Manufacturing

The composite pipe system, known as XPipe™, uses high-performance adhesives to manufacture a metallic composite pipe. Both technical development and a robust manufacturing quality system are required to ensure the safe use of such novel technology. Several aspects are discussed in this paper. Firstly, the use of ultra-high strength martensitic steels in a buried, cathodically protected environment requires an understanding of their susceptibility to hydrogen embrittlement. A series of slow strain rate and constant load tests was performed under polarised conditions to establish any reduction in ductility over samples tested in air. The results are presented and implications for their use in such a system are discussed. Secondly, although the technology to perform quality welds in thin walled austenitic materials using automated orbital techniques is well established, weld inspection by radiographic techniques is not preferred due to the continuous nature of the process and safety considerations. However, the inspection of such welds by ultrasonic techniques is challenging due to the coarse grained nature of the austenitic welds and the thinness of the liner, well below the 6mm normally considered the minimum for conventional weld inspection. Therefore, Automated Ultrasonic Testing (AUT) requires optimized ultrasonic techniques. AUT capabilities and recommendations towards an optimal inspection concept will be discussed in this paper. Thirdly, the manufacture of the liner, ultra-high strength steel strip and adhesive into the XPipe™ composite pipe requires a robust manufacturing control system, which maintains traceability of the incoming materials and controls and records all the essential parameters during pipe production. This is achieved using a sophisticated SCADA system, using feedback from a variety of sensors.

In-Field Production of a New Metallic Composite Pipeline

2010 ◽  
Author(s):  
Nicholas J. Venero ◽  
Tom Ody ◽  
Raymond N. Burke ◽  
David J. Miles
Keyword(s):  
High Performance ◽  
Steel Strip ◽  
High Strength ◽  
Pipe Production ◽  
Acceptance Test ◽  
Thin Wall ◽  
Pipe System ◽  
Metallic Composite ◽  
Integration Test ◽  
Composite Pipe

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. This paper describes the Factory Acceptance Test (FAT) and subsequent Site Integration Test (SIT) of the containerised pipe manufacturing facility. The FAT was performed in factory conditions in Rome, NY (December 2008) and demonstrated acceptable operation of the complete pipe production line. For the SIT, a site in Houston, TX was chosen which would be broadly representative of in-field conditions. The SIT was performed between April and June 2009 and demonstrated acceptable in-field operation of the pipe production system. The paper also describes the results of full-scale testing performed on pipe produced during the SIT and FAT, including burst, tension and cyclic pressure testing pipe sections.

Code Compliance of a New Metallic Composite Pipeline

2010 ◽  
Author(s):  
Colin McKinnon ◽  
David J. Miles ◽  
Raymond N. Burke
Keyword(s):  
Failure Modes ◽  
Continuous Process ◽  
High Strength ◽  
Specific Reference ◽  
Thin Wall ◽  
Metal Composite ◽  
Metallic Composite ◽  
Safety Margins ◽  
Composite Pipe ◽  
Qualification Testing

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.

Burst pressure of perforated-steel strip composite pipe

2021 ◽  
pp. 1-12
Author(s):  
Qiang Q. Shao ◽  
Peng Cheng ◽  
Wen S. Liu ◽  
Wen X. Cai ◽  
Zhi P. Han ◽  
...  
Keyword(s):  
Steel Strip ◽  
Burst Pressure ◽  
Composite Pipe

scholarly journals Manufacturing and development of a bolted GFRP flange joint for oil and gas applications

2021 ◽  
pp. 095440542198951
Author(s):  
Muhsin Aljuboury ◽  
Md Jahir Rizvi ◽  
Stephen Grove ◽  
Richard Cullen
Keyword(s):  
Pressure Vessel ◽  
Oil And Gas ◽  
Polyester Resin ◽  
High Strength ◽  
Adhesively Bonded ◽  
Acceptable Quality ◽  
Composite Pipe ◽  
And Performance ◽  
Composite Pipes

The goal of this experimental study is to manufacture a bolted GFRP flange connection for composite pipes with high strength and performance. A mould was designed and manufactured, which ensures the quality of the composite materials and controls its surface grade. Based on the ASME Boiler and Pressure Vessel Code, Section X, this GFRP flange was fabricated using biaxial glass fibre braid and polyester resin in a vacuum infusion process. In addition, many experiments were carried out using another mould made of glass to solve process-related issues. Moreover, an investigation was conducted to compare the drilling of the GFRP flange using two types of tools; an Erbauer diamond tile drill bit and a Brad & Spur K10 drill. Six GFRP flanges were manufactured to reach the final product with acceptable quality and performance. The flange was adhesively bonded to a composite pipe after chamfering the end of the pipe. Another type of commercially-available composite flange was used to close the other end of the pipe. Finally, blind flanges were used to close both ends, making the pressure vessel that will be tested under the range of the bolt load and internal pressure.

Effect of Microstructure on High-Strength Low-Alloy Steel Welded Joint Toughness with Simulation of Heat-Affected Zone Coarse-Grained Area

Metallurgist ◽  
2021 ◽  
Vol 64 (9-10) ◽  
pp. 875-884
Author(s):  
K. G. Vorkachev ◽  
P. P. Stepanov ◽  
L. I. Éfron ◽  
M. M. Kantor ◽  
A. V. Chastukhin ◽  
...  
Keyword(s):  
Alloy Steel ◽  
Heat Affected Zone ◽  
Welded Joint ◽  
High Strength ◽  
Coarse Grained ◽  
Low Alloy Steel ◽  
Effect Of Microstructure

Microstructural Refinement in a Commercial Aluminum Alloy Processed by ECAP Using a Die Channel Angle of 110 Degrees

2015 ◽  
Vol 1114 ◽  
pp. 3-8
Author(s):  
Nicolae Şerban ◽  
Doina Răducanu ◽  
Nicolae Ghiban ◽  
Vasile Dănuţ Cojocaru
Keyword(s):  
Grain Refinement ◽  
Cross Section ◽  
High Strength ◽  
Secondary Phase ◽  
Coarse Grained ◽  
Metallographic Analysis ◽  
Second Phase ◽  
Channel Angle ◽  
Ambient Temperatures ◽  
Fine Grained

The properties of ultra-fine grained materials are superior to those of corresponding conventional coarse grained materials, being significantly improved as a result of grain refinement. Equal channel angular pressing (ECAP) is an efficient method for modifying the microstructure by refining grain size via severe plastic deformation (SPD) in producing ultra-fine grained materials (UFG) and nanomaterials (NM). The grain sizes produced by ECAP processing are typically in the submicrometer range and this leads to high strength at ambient temperatures. ECAP is performed by pressing test samples through a die containing two channels, equal in cross-section and intersecting at a certain angle. The billet experiences simple shear deformation at the intersection, without any precipitous change in the cross-section area because the die prevents lateral expansion and therefore the billet can be pressed more than once and it can be rotated around its pressing axis during subsequent passes. After ECAP significant grain refinement occurs together with dislocation strengthening, resulting in a considerable enhancement in the strength of the alloys. A commercial AlMgSi alloy (AA6063) was investigated in this study. The specimens were processed for a number of passes up to nine, using a die channel angle of 110°, applying the ECAP route BC. After ECAP, samples were cut from each specimen and prepared for metallographic analysis. The microstructure of the ECAP-ed and as-received material was investigated using optical (OLYMPUS – BX60M) and SEM microscopy (TESCAN VEGA II – XMU). It was determined that for the as-received material the microstructure shows a rough appearance, with large grains of dendritic or seaweed aspect and with a secondary phase at grain boundaries (continuous casting structure). For the ECAP processed samples, the microstructure shows a finished aspect, with refined, elongated grains, also with crumbled and uniformly distributed second phase particles after a typical ECAP texture.

scholarly journals Heterogeneous lamella structure unites ultrafine-grain strength with coarse-grain ductility

2015 ◽  
Vol 112 (47) ◽  
pp. 14501-14505 ◽  
Author(s):  
Xiaolei Wu ◽  
Muxin Yang ◽  
Fuping Yuan ◽  
Guilin Wu ◽  
Yujie Wei ◽  
...  
Keyword(s):  
Large Scale ◽  
Low Cost ◽  
High Strength ◽  
Back Stress ◽  
Coarse Grained ◽  
Ultrafine Grain ◽  
Asymmetric Rolling ◽  
Dislocation Hardening ◽  
Ultrafine Grained ◽  
Lamella Structure

Grain refinement can make conventional metals several times stronger, but this comes at dramatic loss of ductility. Here we report a heterogeneous lamella structure in Ti produced by asymmetric rolling and partial recrystallization that can produce an unprecedented property combination: as strong as ultrafine-grained metal and at the same time as ductile as conventional coarse-grained metal. It also has higher strain hardening than coarse-grained Ti, which was hitherto believed impossible. The heterogeneous lamella structure is characterized with soft micrograined lamellae embedded in hard ultrafine-grained lamella matrix. The unusual high strength is obtained with the assistance of high back stress developed from heterogeneous yielding, whereas the high ductility is attributed to back-stress hardening and dislocation hardening. The process discovered here is amenable to large-scale industrial production at low cost, and might be applicable to other metal systems.

Mechanical Behaviors of Steel Strip Reinforced Flexible Pipes Under Bending

2018 ◽  
Author(s):  
Shan Jin ◽  
Shuai Yuan ◽  
Ting Liu ◽  
Peihua Han ◽  
Yong Bai
Keyword(s):  
Steel Strip ◽  
Practical Application ◽  
Pure Bending ◽  
Flexible Pipe ◽  
Four Point Bending ◽  
Offshore Engineering ◽  
Flexible Pipes ◽  
Proposed Model ◽  
Composite Pipe ◽  
Good Coincidence

Steel strip reinforced flexible pipe (SSRFP) is a kind of unbonded composite pipe, which has more application foreground in offshore engineering due to its excellent mechanics and the considerable flexibility. In practical application, SSRFP will inevitably experience bending during reeling process and installation. In this paper, the mechanical behavior of SSRFP subjected to pure bending are studied both experimentally and numerically. A four-point bending equipment is utilized to conduct the full-scale laboratorial tests of SSRFP. Furthermore, the commercial software ABAQUS is employed to simulate its ovalization instability. The results acquired from the ABAQUS simulation are compared with the ones from verification bending experiment, which are in good coincidence with each other. The proposed model and the relative results may be of interest to the manufacture factory engineers.

Effect of Welding Processes with High Heat Input on the Microstructure and Toughness of Coarse-Grained Heat-Affected Zone of a High-Strength High-Toughness Steel

2018 ◽  
Vol 937 ◽  
pp. 61-67
Author(s):  
Yu Jie Li ◽  
Jin Wei Lei ◽  
Xuan Wei Lei ◽  
Oleksandr Hress ◽  
Kai Ming Wu
Keyword(s):  
Low Temperature ◽  
Impact Toughness ◽  
Heat Affected Zone ◽  
Heat Input ◽  
High Strength ◽  
High Heat ◽  
Coarse Grained ◽  
Low Temperature Impact Toughness ◽  
The Impact ◽  
Welding Processes

Utilizing submerged arc welding under heat input 50 kJ/cm on 60 mm thick marine engineering structure plate F550, the effect of preheating and post welding heat treatment on the microstructure and impact toughness of coarse-grained heat-affected zone (CGHAZ) has been investigated. The original microstructure of the steel plate is tempered martensite. The yield and tensile strength is 610 and 660 MPa, respectively. The impact absorbed energy at low temperature (-60 °C) at transverse direction reaches about 230~270 J. Welding results show that the preheating at 100 °C did not have obvious influence on the microstructure and toughness; whereas the tempering at 600 °C for 2.5 h after welding could significantly reduce the amount of M-A components in the coarse-grained heat-affected zone and thus improved the low temperature impact toughness.

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