pre-installed user: combining engineering and and new technology new technology peter hatcher,...

Pre-Installed User:

Pre-Installed User:

Combining Engineering Combining Engineering

And And New TechnologyNew Technology

Peter Hatcher, P.Eng.Peter Hatcher, P.Eng.

Fluor Canada Ltd.Fluor Canada Ltd.

March 3, 2004March 3, 2004

C a l g a r y C e n t r efor Innovative Technology

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Engineering & New TechnologyEngineering & New Technology

Opportunity UnboundedOpportunity Unbounded

Conventional WisdomConventional Wisdom

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E P C E P C

Engineering Procurement & Construction (EPC)Engineering Procurement & Construction (EPC)

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EPC – Process IndustryEPC – Process Industry

Process Industry – Design Process Industry – Design EngineeringEngineering Conservative

Process Industry - ConstructionProcess Industry - Construction Proven Technologies

Significant Capital InvestmentsSignificant Capital Investments

New Technology - NIMP!!!!New Technology - NIMP!!!!

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Engineering & New TechnologyEngineering & New Technology

The essence of science: ask an impertinent question,

and you are on the way to a pertinent answer

Jacob BronowskiJacob Bronowski

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Engineering & New TechnologyEngineering & New Technology

Examples of Combining Engineering & Examples of Combining Engineering & TechnologyTechnology

Material of Construction Fabrication Mechanical Integrity

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Impertinent Question #1Impertinent Question #1

Does Material of Construction exist that Does Material of Construction exist that allows refining of following crude allows refining of following crude conditions???conditions???

High conventional corrosion rates naphthenic acid polythionic acid

High operating temperatures sensitization of stainless steels

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Material SelectionMaterial Selection

Conventional ApproachConventional Approach

Based on Code listed stainless steel materials: 321/347

v.g. resistance to sensitizationpoor resistance to naphthenic acid corrosion

316L/317Lv.g. resistance to naphthenic acid corrosionpoor resistance to sensitization

Above options do not provide Owner the capability to handle potentially highly corrosive process streams with long term reliability.

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Material Selection Material Selection

Selected MetallurgySelected Metallurgy

Unlisted Material:

16Cr11Ni2.5MoCb

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Strategy Strategy

Corrosion TestingCorrosion Testing

Mechanical PropertiesMechanical Properties

FormabilityFormability

WeldabilityWeldability

Aggressive Timeline / Complex ExecutionAggressive Timeline / Complex Execution

11Photograph showing a side view of an ASTM A262 method E (Strauss) specimen after exposure and bending.

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Weld MetalWeld Metal

Comparision of Yield Strength on welds between 16Cr 11Ni 2.5Mo Cb and 347 (API 530)

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100

1000

300 400 500 600 700 800 900 1000

Temperature (°C)

Str

es

s (

MP

a)

YIELD STRENGTH OF 347 (API 530)

YIELD STRENGTH OF 16Cr11Ni2.5MoCb

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Larson-Miller ParameterLarson-Miller Parameter

1

10

100

1000

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P - Larson-Miller Parameter

P = T(18.265 + log t) x 10-3

MPa

16Cr11Ni2.5MoCb

347SS (API 530)

Larson -Miller Parameter for 16Cr 11Ni 2.5Mo Cb & 347SS (API 530)

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Answer # 1Answer # 1 16Cr11Ni2.5MoCb 16Cr11Ni2.5MoCb

Resistance to naphthenic acid attack and Resistance to naphthenic acid attack and sensitizationsensitization

Thin wall allows for optimal heat transfer and Thin wall allows for optimal heat transfer and stress reductionstress reduction

Eliminate need for post weld heat treatmentEliminate need for post weld heat treatment

Eliminate requirement for soda ash wash Eliminate requirement for soda ash wash during shut downduring shut down

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Impertinent Question #2Impertinent Question #2

How can field pipe welding productivity be How can field pipe welding productivity be improved???improved???

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Welding Stainless Steel PipingWelding Stainless Steel Piping

GMAW-SGMAW-S No Backing Gas (NBG)

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HistoryHistory

Fluor previously investigated welding of Fluor previously investigated welding of stainless steels without a backing gas stainless steels without a backing gas using GTAW process using GTAW process

Resulted in quality issues and the ability to Resulted in quality issues and the ability to reproduce acceptable Code weldsreproduce acceptable Code welds

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Process OptimizationProcess Optimization

Optimized selected wire feed speedsOptimized selected wire feed speeds

High silicon filler metals High silicon filler metals

Shielding gas Shielding gas

Welder trainingWelder training

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NBG Stainless Steel WeldingNBG Stainless Steel Welding

Good appearanceGood appearance

No NDE defectsNo NDE defects

Good mechanical characteristicsGood mechanical characteristics

Good metallurgical structureGood metallurgical structure

Good Strauss Corrosion Test resultsGood Strauss Corrosion Test results

Good Pitting Corrosion Test resultsGood Pitting Corrosion Test results

Minimum oxidation on the IDMinimum oxidation on the ID

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Weld Root Weld Root

With Backing GasWith Backing Gas No Backing GasNo Backing Gas

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Answer #2Answer #2 GMAW-s NBG GMAW-s NBG

Low repair rateLow repair rate

Eliminates backing gas requirement Eliminates backing gas requirement

Welder friendlyWelder friendly

Significant cost savings over other Significant cost savings over other processesprocesses

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Impertinent Question #3Impertinent Question #3

How can we ensure integrity of high pressure How can we ensure integrity of high pressure high density polyethylene (HDPE) high density polyethylene (HDPE) pipeline???pipeline???

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Current PracticesCurrent Practices

Visual examVisual exam Poor correlation to weld quality for heavy wall

Bent-strap testBent-strap test (ASTM D2657)(ASTM D2657) Low probability of detection:

t

1-1/2 t(25mm min)

15 t(150mm min)

15 t(150mm min)

TEST STRAP

BUTT FUSION

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Current Practices Current Practices (Continued…)(Continued…)

Traditional UT pulse-echoTraditional UT pulse-echo Ineffective for heavy wall

Hydro testingHydro testing Derived from metallic systems Viscoelastic plastics

deformation depends on time and temperaturedoes not ensure long-term performance

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x

UT-TOFD ProbesUT-TOFD Probes

Fluor Ultrasonic Probes Fluor Ultrasonic Probes Patents are pending on this technology and its application

Transducer ReceiverLateral Wave

Back Wall Echo

Upper Tip

Lower Tip

Outer Diameter; Outside wall

Inner Diameter; Back wall

Flaw

ProbesProbes

WeldWeld

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Stage 1 - LaboratoryStage 1 - Laboratory Calibration blocks Double-blind test spools

indications correlated to defectslack of fusion (LOF) identified

Stage 2 - Field InvestigationStage 2 - Field Investigation Operating pipeline, analysis of field welds

Stage 3 - CorrelationStage 3 - Correlation UT-TOFD vs. UT-TOFD vs. Destructive TestingDestructive Testing Lab test spools Field welds

Development WorkDevelopment Work

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Correlation ExampleCorrelation Example

Accurate Accurate Defect Defect

IdentificationIdentification

Field SampleField Sample

TOFD ScanTOFD Scan

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Summary of findingsSummary of findings Visual examinationVisual examination

poor correlation Backwall echo - lateral wave lossBackwall echo - lateral wave loss

severe lack of fusion Multiple point reflectorsMultiple point reflectors

non-fusion and poor fusion Foreign contaminationForeign contamination

easily detectable ““Clear” UT-TOFD scanClear” UT-TOFD scan

properly fused

Bead Profile - Bead Profile - High/LowHigh/Low

Isolated Defects

Development Work Completed Development Work Completed

Lab Lab SampleSample

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Answer #3 UT-TOFDAnswer #3 UT-TOFD

Current Examination PracticesCurrent Examination Practices Not equipped to detect heavy wall flaws and faulty

welds Limits thermoplastic: low pressure, non-critical

New application for pipeline industryNew application for pipeline industry Leap in Quality of testing Plastics expansion into pipeline industry

UT - TOFD MethodUT - TOFD Method Ultrasonic Time of Flight Diffraction Reliable - quick - easy

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Summary Engineering & New Summary Engineering & New TechnologyTechnology

Combining Engineering & TechnologyCombining Engineering & Technology 3 examples

Conventional Approaches Not Necessarily Conventional Approaches Not Necessarily Optimum Optimum

Opportunities AboundOpportunities Abound