manufacturing process of welded tubes ...raiselife.eu/dissemination/docs/2nd_workshop/14...

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Raiselife seminar

Dusseldorf, November 28th 2019

MANUFACTURING PROCESS OF WELDED TUBES

SOLAR TOWER RECEIVER APPLICATION

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Umbilicals market for Oil & Gas:

• Super Duplex 2507 tubes

• ID ½’’ to 1½’’ → 2’’

• WT 1.0 to 3.4 → 4.5 mm

• Laser seam welded tubes

• AYS0.2>750MPa , UTS>900MPa

• One plant located at Venarey-les-Laumes

• Qualified by IOC and BV

New generation of superduplex stainless steel premium tubes

VALLOUREC UMBILICALS

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TUBES FOR UMBILICALS CHARACTERISTICS

► High quality grade 2507 (UNS S32750 / EN 1.4410) strip

• PREN 42.5

• Suitable pitting and crevice corrosion resistance

• Excellent resistance to SSC and HISC tests

► Control:

• NDT performed over the entire length of the finished tubes

(100%).

• Hydrostatic test performed internal hydrostatic pressure

► Tight dimensional tolerances

• No internal and external weld bead

• Wall Thickness (WT): +/- 5%

• Outside Diameter (OD): +/- 0.1mm (including ovalisation)

► Excellent tube mechanical properties

• Optimised strength

» YS0,2 > 750MPa

» UTS > 900MPa

• Elongation ≥ 25%

• Excellent fatigue properties

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Renewable energies with

first focus on tubes for CSP

DIVERSIFICATION PROGRAM

Capacity and capability

increase

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1.00 2.00 3.393.00 4.500.85

12.70

No

min

al In

tern

al D

iam

ete

r

15.88

19.05

22.23

25.40

28.58

31.75

38.10

1/2

5/8

3/4

7/8

1

1 1/8

1 1/4

1 1/2

16.10 x 1.00

12.90 x 1.15

25.6 x 1.45

25.4 x 1.53

19.05 x 1.82

31.75 x 2.95

mm

mminch

12.70 x 1.00

19.05 x 1.06 19.05 x 1.25

38.10 x 2.12

50.802VU2 range

VU1 range

12.70 x 1.14

19.05 x 1.70

19.30 x 1.73

16.00 x 1.4315.88 x 1.00

5.00

76.23

6.00

Wall Thickness

4.002.50 3.60

38.10 x 3.39

25,4x 3.59

31.75 x 4.49

50.8 x 4.52

31.75 x 2.27

ID 47.8 mm x WT 1.5 mm

ID 46.8 mm x WT 2 mm

TUBES FOR RECEIVERS

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Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

TUBES FOR RECEIVERS

Tubes for Receivers

Specification

- Dimensions : ID 47.8 mm x WT 1.5 mm


- Material : Ni based alloy (Haynes 230)

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Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

TUBES FOR RECEIVERS

Tubes for Receivers

Specification



- Cold worked


Strip Preparation

& FormingLaser welding

Weld beads

finishingHeat treatment

Sizing &

polishing

NDT control &

marking

Strip

inspection &

decoiling

Coiled strip Intermediate reel

Laser longitudinal welding line

• Forming rollers give

progressively a round

shape to the strip

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Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

TUBES FOR RECEIVERS

Tubes for Receivers

Specification



- Cold worked

- Laser welded


Strip Preparation


Weld beads


Sizing &

polishing

NDT control &

marking

Strip

inspection &

decoiling



• CO2 laser is used

• Energy can reach

8KW

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Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

TUBES FOR RECEIVERS

Tubes for Receivers

Specification



- Cold worked

- Laser welded

- External and internal weld bead shall be properly removed


Strip Preparation


Weld beads


Sizing &

polishing

NDT control &

marking

Strip

inspection &

decoiling



• Bead are internally and

externally rolled

• External surface is brushed

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Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

TUBES FOR RECEIVERS

Tubes for Receivers

Specification



- Cold worked

- Laser welded


- Solution annealed (1177°C - 1245°C)


Strip Preparation


Weld beads


Sizing &

polishing

NDT control &

marking

Strip

inspection &

decoiling



• Heating then cooling inside

10 m long tunnel in a

controlled atmosphere

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Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

TUBES FOR RECEIVERS

Tubes for Receivers

Specification



- Cold worked

- Laser welded



- NDT tests (Eddy Current) of the whole tube


Strip Preparation


Weld beads


Sizing &

polishing

NDT control &

marking

Strip

inspection &

decoiling



• US: 100% of the tube is controlled

• EC: 100% of the tube is controlled

• OD and WT control

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TUBES FOR RECEIVERS

Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

Tubes for Receivers

Specification



- Cold worked

- Laser welded




- Tubes with plain ends cut and deburred


Sizing &

straighteningCutting

Ends

preparation

Tube preparation line

Intermediate reel

Laboratory

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TUBES FOR RECEIVERS

Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

Tubes for Receivers

Specification



- Cold worked

- Laser welded






Sizing &


Ends

preparation


Intermediate reel

• Straight tube preparation

Laboratory

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TUBES FOR RECEIVERS

Solar

Welded rolled

tube for molten

salt application in

solar tower

technology

Tubes for Receivers

Specification



- Cold worked

- Laser welded





- Hydrostatic tests up to 6.9 MPa


Sizing &


Ends

preparation


Customer tubesIntermediate reel

• Hydrostatic test

Cleaning Drying PackingPressure test

Laboratory

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➢Receiver (straight) tubes: Grades 625 or Haynes 230

➢ In accordance to VU dimension range

➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:

TUBES FOR RECEIVERS

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➢ Forming

TUBES FOR RECEIVERS

Finite Element Modelling

Numerical simulation of strip forming using :

• Roller shape

• Mechanical properties of strips

• Strips dimensions

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➢ Forming

➢ Laser welding

TUBES FOR RECEIVERS



• Roller shape



Laser Welding tests

Laser welding tests on Haynes 230 strip using :

• CO2 laser

• Welding energy, focal distance..

• Dimensional check (tolerances)

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➢ Forming

➢ Laser welding

➢ Heat treatment

TUBES FOR RECEIVERS



• Roller shape



Laser Welding tests


• CO2 laser



Heat treatment tests

Heat treatment tests on Haynes 230 strip using :

• Dilatometer control

• Chemical etching

• SEM observations

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➢ Forming

➢ Laser welding

➢ Heat treatment

➢ Microstructure

TUBES FOR RECEIVERS



• Roller shape



Laser Welding tests


• CO2 laser








Metallurgical investigation

Microstructure investigation on Haynes 230 strip :

• Carbides

• Intermetallic phases

• Grain growth

• Precipitation ’/’’

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➢ Forming

➢ Laser welding

➢ Heat treatment

➢ Microstructure

➢ Mechanical properties

TUBES FOR RECEIVERS



• Roller shape



Laser Welding tests


• CO2 laser








Metallurgical investigation

Microstructure investigation on Haynes 230 strip :

• Carbides

• Intermetallic phases

• Grain growth

• Precipitation ’/’’

Tensile tests

Tensile tests on Haynes 230 strip :

• Mechanical propertiers at room temperature

• Tensile specimens (1.6 mm and 2 mm)

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THANKS FOR YOUR ATTENTION

manufacturing process of welded tubes ...raiselife.eu/dissemination/docs/2nd_workshop/14...

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