Technical (and other) challenges associated with welding and - - PowerPoint PPT Presentation

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technical and other challenges associated with welding
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Technical (and other) challenges associated with welding and - - PowerPoint PPT Presentation

Dec 18, 2023 42 likes •365 views

Technical (and other) challenges associated with welding and inspection of CRA pipelines Matt Lancien , Materials & Welding Engineer, SPEC Pty Ltd We Welding in in the the indus ndustr try We Welding in in our our indus ndustr try DNV AWS

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Technical (and other) challenges associated with welding and inspection of CRA pipelines

Matt Lancien, Materials & Welding Engineer, SPEC Pty Ltd

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We Welding in in the the indus ndustr try

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SLIDE 3

We Welding in in our

  • ur indus

ndustr try

ASME DNV AWS D1.1

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SLIDE 4

We Welding of

  • f CRA

CRA HP HP/HT /HT Pi Pipeli pelines nes

DNV‐OS‐F101 + DNV JIP + Company specification

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ND NDT of

  • f CRA

CRA Pi Pipel pelines es

Carbon Steel Pipelines: same/similar material for pipe & weld

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ND NDT of

  • f CRA

CRA Pi Pipel pelines es

CRA pipelines: dissimilar materials for pipe & weld & CRA layer

  • High anisotropy (grain orientation)
  • Scatter of ultrasound
  • Varying speed of sound transmission
  • Specific calibration block & qualification program
  • Training of operators
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SLIDE 7

Desi Design gn

Specify an achievable & consistent flaw acceptance criteria

Planned buckles over ZRBs / DIs Unplanned buckles

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CRA CRA Li Linepipe nepipe Procur

  • curem

emen ent

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Qualific alificatio ions ns & Te Testing

2: Inherent welding flaws 1: WPS & Welders qualifcation 3: NDT procedure qualification

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We Welding Pre Preparat ation

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SLIDE 11

Ma Main Line Line We Welding Process

  • cess
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We Welding Qualific alificatio ions

2: Manual welding (GTAW) for repairs & tie‐ins 1: Automatic welding (GMAW) for main line

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We Welding & Pu Purge rge Mo Monito toring

Strict control on welding parameters

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CRA CRA Root

  • ot Pa

Pass Inspection Inspection

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CRA CRA Root

  • ot Pa

Pass Inspection Inspection

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CRA CRA Root

  • ot Pa

Pass Inspection Inspection

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AU AUT Qualific alificatio ion

Comprehensive program to demonstrate sizing/detection capability of the AUT system:

  • Significant number of defects (minimum of 122 flaws seeded across the weld volume)
  • All flaws need to be representative of production inherent flaws and actual ECA criteria
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AU AUT Qualific alificatio ion

Comprehensive program to demonstrate sizing/detection capability of the AUT system:

  • Comparing AUT predicted flaw sizes with actual flaw sizes (oversizing and undersizing)
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Qualifie alified Pe Pers rsonnel

  • Welding Engineer ‐ Operator and Contractor
  • NDT Level 3 in RT & UT (PA & TOFD) ‐ Operator and

Contractor

  • Experienced QC Welding & NDT Inspectors (surveillance)
  • Trained and familiarised welder and operators (training

school and pipe cycling) CONTINUITY is the key ! The same people involved at qualification will follow on offshore pipeline production

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The The Lucky Lucky Coun Country

Engineers – 8 on / 4 off WA & NT – 3 on / 3 off Welders – 13 on / 3 off Bass Strait – 2 on / 2 off Changes are needed to ensure consistent pipeline production

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Less Less Of Offshor hore Weld lding ing

Most of the pipeline production removed from critical path and performed outside Australia (South East Asia, etc.)

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EPCI EPCI Con Contr tracti acting ng

  • EPCI procure his pipes according to the agreed project

specification therefore they have to weld it together

  • Only 3 pipe mills in the world (Japan & Germany)
  • SMEs and Company reps to work as an integrated team with

the installation contractors

  • It’s done this way for complex SURF projects overseas
  • “You’re building my house but not living in it later on” so

managing risks can’t be left to Contractor only who doesn’t share the same risks as the Operator

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In In‐house house ex expertise

Installation contractors and specialised subcontractors have their own welding center of excellence with permanent R&D projects to improve the productivity and quality of pipeline welding and inspection.

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Surf Surface ace Te Tension Tr Transfer (S (STT)

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Re Recent we welding technol chnology gy

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Pre Previous ND NDT technology chnology

“Old School” Radiography Technology, everybody can “see”

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Re Recent ND NDT te technology

Ultrasonic Technology, not everybody can “see” and interpret

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Re Recent ND NDT te technology

More NDT companies = competition drives to innovation

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The The ne next fr fron

  • ntier

tier in in WA WA?

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The The “T “Terrace”

  • Talking and knowledge sharing
  • We have laid more CRA flowlines in WA in the last 5 years

than any other country so by now we should know how do to get it right

  • But there is no silver bullet, every project is different and

when technical issues arise we work together to solve it and sometimes learn to give up on specs or design !!