2. pipeline materials overview

Pipeline Materials
Selection -An Overview
Prasenjit Kayal

INTRODUCTION TO PIPELINE DESIGN – June 2009 2
Material OverviewMaterial Overview
IndexIndex
1. Linepipe
2. Clad pipe
3. Large Radius Bends
4. Anticorrosion Coatings
5. Concrete Coating
6. Sacrificial Anodes
7. Field Joint Material
8. Flanges, Gaskets and Bolting
9. SSIV (Subsea Safety Insulated Valve) Overview
10. Insulating Joints
11. T & Y tees and Conical Reducer (Buttwelded Fittings)
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LinepipeLinepipe
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In the Oil & Gas Industry the pipe material selection depends on fluid conveyed
(Sweet i.e. without H2S or Sour service i.e. with H2S ). Typical pipe materials are:
 Low Carbon steel (Steel pipe)
 Corrosion Resistant Alloy-CRA (Duplex, Super duplex, Inconel 625, AISI 316L)
 CRA Cladded/Lined Carbon Steel (Clad pipe: Carbon steel layer + CRA layer)

Linepipe - Fabrication ProcessLinepipe - Fabrication Process
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 Submerged Arc Welded (SAW)
 Electrical Resistance Welded (ERW)
 High Frequency Induction (HFI) welded or High Frequency Welded (HFW)
 Seamless (SMLS), i.e. without longitudinal (seam) weld

Submerged Arc Welded Pipe (SAW) - UOESubmerged Arc Welded Pipe (SAW) - UOE

Submerged Arc Welded Pipe (SAW) - UOESubmerged Arc Welded Pipe (SAW) - UOE
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LSAW Pipe: Press Bending MethodLSAW Pipe: Press Bending Method
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LSAW Pipe: Press Bending MethodLSAW Pipe: Press Bending Method

Spiral/Helical SAW PipeSpiral/Helical SAW Pipe
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Linepipe - Fabrication ProcessesLinepipe - Fabrication Processes
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Medium-Diameter (26-in)Medium-Diameter (26-in)
Electrical Resistance Welded Pipe (ERW)Electrical Resistance Welded Pipe (ERW)

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Small-Diameter (6-in) HFI PipeSmall-Diameter (6-in) HFI Pipe
High Frequency Welded or Induction Welded Pipe (HFW/HFI)High Frequency Welded or Induction Welded Pipe (HFW/HFI)

HFI PIPE – CoilerHFI PIPE – Coiler

HFI PIPE – WeldingHFI PIPE – Welding

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ERW Pipe vs. HFI PipeERW Pipe vs. HFI Pipe

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TENARISTENARIS

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Plug Rolling Mill (Medium Diameter Seamless Pipe)Plug Rolling Mill (Medium Diameter Seamless Pipe)
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Mandrel Mill (Small Diameter Seamless pipe)Mandrel Mill (Small Diameter Seamless pipe)

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TENARISTENARIS

Pipe Production RangePipe Production Range

Pipelines usually have diameters within 10”and 48”. Large diameter linepipes (*) correspond to
SAW longitudinal welded pipes that match more requirements for Oil & Gas applications.
Generally speaking, ERW and SEAMLESS pipes are respectively less and more expensive than
LSAW.
SEAMLESS/ERW
LSAW
SAW Spiral
Quantity of Supplier for Market
Segment
10” 20” 48” 56” 64”
DIAMETER
(inch) 24”
Typical Pipelines Range
Offshore Pipeline Market
LD
(*)
Pipe – Market SegmentPipe – Market Segment
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IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
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Offshore Pipeline for corrosive service (sour service i.e. with H2S) are fabricated in:
 Corrosion Resistant Alloy-CRA (Duplex, Super duplex, Inconel 625, AISI 316L)
 CRA Cladded/Lined Carbon Steel (Clad pipe: Carbon steel layer + CRA layer)
Clad pipelines are formed from a carbon manganese steel outer pipe (base material or back
steel) lined internally with a thin layer (2-3 mm thick) of corrosion resistant material.
Definition:
 Linepipe is denoted “clad” if the bond between base and cladding material is metallurgical.
 Linepipe is denoted “lined” if the bond between base and cladding material is mechanical.
Clad PipeCRA PipeLined Pipe
CLAD PipeCLAD Pipe

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CLAD PipeCLAD Pipe

Clad Steel Plate Fabrication Process - ExampleClad Steel Plate Fabrication Process - Example

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Welded Clad Steel Pipe - Fabrication Process ExampleWelded Clad Steel Pipe - Fabrication Process Example

An example of Mechanically Bonded (Lined) pipe:
BUTTING BuBi®
In order to increase the advantages of a clad pipe, BUTTING developed a mechanically
bonded BUTTING-Bimetal-pipe ( BuBi®-pipe) at the beginning of the ‘90.
The BuBi®-pipe consists of a CRA pipe which is telescopically aligned inside a pipe in
carbon-manganese material (seamless or welded pipe).
The tight bonding between the two pipes is achieved by hydraulic expansion.
The producible size range comprises pipes in OD's from 114.3 mm (4") up to 660 mm (26")
and lengths up to 12 m without circumferential weld.
Compared with the metallurgically clad pipe, BuBi®-pipe offers a wide range of material
combinations - for both the inner and outer pipe - and price advantages.
Price advantage is due to the use of low cost carbon steels in conjunction with corrosion
resisting steels and an economic production process.
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Lined PipeLined Pipe

Lined Pipe:Lined Pipe: BUBUTTING-TTING-BiBimetal-pipe (BuBi®-pipe)metal-pipe (BuBi®-pipe)

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
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Offshore Application:
 Expansion loop (Spool) construction (e.g. goose neck, bend part).
 Riser construction (e.g. bend part).
 Top side Piping
Main Characteristics:
 Bend Radius ≥ 5 x OD Pipeline (i.e. piggable)
 Straight length (e.g. 0.5 -1.0 m)
 Same Chemical composition of mother pipe of
linepipe (e.g. Carbon Equivalent)
Main Fabrication Processes:
 Hot bending of the original pipe (R≈5-10OD)
 Cold Bending of the original pipe (R≈0-40OD)
Large Radius BendsLarge Radius Bends

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Bends – Hot Bend ProductionBends – Hot Bend Production

Bends – Hot induction Bending - ExampleBends – Hot induction Bending - Example

Bending Machine Heating and Cooling Ring
Bends – Hot induction Bending - ExampleBends – Hot induction Bending - Example

R
NPS
V
DETAIL"A"
OD
THK ID
SEE DETAIL
"A"
T
T
Note 2
Note 2
α
ITEM PIPE Wall Mother
Material
Grade
Pipe Type
alpha R V T V+2T
NAME SIZE Thickness Pipe W.T
(inch) [mm] [mm] (°) (mm) (mm) (mm) (mm)
Expansion Loops
90° Bends
10 20,6 23,8
L415 QC
SEAMLESS
90 1365,5 2145 500 3145
Goose Neck
20° Bends
10 20,6 23,8
L415 QC
SEAMLESS
20 1365,5 477 500 1477
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Typical Bend Dimensions - ExampleTypical Bend Dimensions - Example

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
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Coating:
 The liquid, liquefiable, mastic, powder or any composition and material that
after application to a substrate (e.g. pipes), is converted into a solid
anticorrosion protective adherent films.
 Pipeline and Components (Bends, flange, fittings, etc.) External Anticorrosion
Protection System.
 Riser External Anticorrosion and mechanical Protection System.
Coating System Selection Criteria is based on:
 Project Requirements
 Environmental service exposure (seawater, soil, other)
 Service temperature (depends on max. conveyed fluid temperature)
Anticorrosion CoatingsAnticorrosion Coatings
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Anticorrosion coatings main type:
 Polyethylene (PE) (e.g. 3.5mm @ 950 kg/m3
– linepipe)
 Coal tar Enamel (CTE) (e.g. pipeline)
 Polypropylene (PP) (e.g. 3mm @ 900 kg/m3
linepipe, 3.5mm Flame Spray PP –
Riser and Bends)
 Fusion Bonded Epoxy (FBE) (e.g. field joint)
 Polyurethane (PU) (e.g. 15mm@1500kg/m3
-Solid PU Risers, 1.5mm @ 1600 kg/m3
PU tar free-Bends)
 Polychloroprene (PCP) (e.g. 15mm @ 1450 kg/m3
– Risers)
 High solid Epoxy (e.g. Bends, 1.5mm @ 1600 kg/m3
Flanges)
Main Characteristics to be required:
 Minimum Thickness; Minimum Density. and Min. and Max. Service Temperature.
 Cut back length (Depends on Welding System used)
Anticorrosion CoatingsAnticorrosion Coatings
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3LPP
FBE
3LPE
5LPP
PU Mixture (e.g. Marinplast)
15mm@1200kg/m3
PU
Solid
CTE
Anticorrosion Coatings - ExamplesAnticorrosion Coatings - Examples

The three-layer’s Polyethylene coating (3LPE) is a multilayer coating composed of three
functional components:
 First layer: primer (liquid or powdered fusion bonded epoxy (FBE)). Continuous thin layer
resistant to the corrosive agents. Guarantee a suitable adhesion of the coating to the steel.
 Second layer: co-polymer or modified polyethylene adhesive. Guarantee a suitable adhesion
between the upper polyethylene layer and the primer.
 Third layer: polyethylene. It provides good mechanical strength, mechanical protection and
electric insulation.
3LPE Systems provide excellent pipeline protection for small and large diameter
pipelines with service temperatures varying from -60° C to +85 °C.
According to the maximum service temperatures the polyethylene may be:
 Low Density Polyethylene (LDPE) (918 - 935 Kg/m3)
 Medium/High Density Polyethylene (MDPE/HDPE) (940 - 950 kg/m3)
Minimum PE Coating Thickness: 3.5 mm
Cut back length required for pipeline installation: 150 mm +20/-0 mm;
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3-Layer Polyethylene (3LPE)3-Layer Polyethylene (3LPE)

The three-layer’s Polyethylene coating (3LPP) is a multilayer coating composed of three
functional components:
 First layer: primer (liquid or powdered fusion bonded epoxy (FBE)). Continuous thin layer
resistant to the corrosive agents. Guarantee a suitable adhesion of the coating to the steel.
 Second layer: co-polymer adhesive. Guarantee a suitable adhesion between the upper
polypropylene layer and the primer.
 Third layer: polypropylene. It provides very good mechanical strength, mechanical protection
and electric insulation.
3LPP Systems provide excellent pipeline protection for small and
Large diameter pipelines with service temperatures varying from -20° C to +140 °C.
Minimum Polypropylene Density 900 kg/m3
Minimum PE Coating Thickness: 3.5 mm
Cut back length required for pipeline installation: 150 mm +20/-0 mm.
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3-Layer Polypropylene (3LPP)3-Layer Polypropylene (3LPP)

3
3LPE – Fabrication Process - Example3LPE – Fabrication Process - Example
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3
3LPP – Fabrication Process - Example3LPP – Fabrication Process - Example
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3
PCP – Fabrication Process - ExamplePCP – Fabrication Process - Example
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3
FBE – Fabrication Process - ExampleFBE – Fabrication Process - Example
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3
Coal Tar Enamel (CTE) – Fabrication Process - ExampleCoal Tar Enamel (CTE) – Fabrication Process - Example
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This lining is applied by layering one or several coats of paint or by spraying epoxy powder.
1. The pipe is preheated to eliminate humidity
2. The interior surface is shot-blasted to remove mill scale and rust, obtaining a metal surface
which facilitates the adhesion
3. When epoxy powder is fused, the pipe is preheated to 238°C, in order to quickly cure the epoxy.
4. The pipe is rotated and the lining is sprayed from a set of nozzles which moves inside the pipe.
5. When paint is used, it is dried by blowing hot air through the pipe.
Epoxy Resin Lining – Application ExampleEpoxy Resin Lining – Application Example

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
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Reinforced Concrete Coating is made by a right mixture of cement, aggregates and water
reinforced with steel cage or steel welded fabric .
 Pipeline Weighting (stabilization of offshore pipeline subjected to Hydrodynamic
forces)
Main Characteristics to be required:
 Min. Compressive Strength at 7 and 28 day Core/Cube
 Minimum Applicable Thickness
 Minimum and Maximum Density
 Water Absorption
 Cut back length (Depends on Welding System used)
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Concrete CoatingConcrete Coating

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Minimum Recommended Applicable Concrete Thickness: 40 mm;
Maximum Standard Applicable Concrete Thickness: 150 mm;
Maximum Standard concrete coating density (dry): 3.040 t/m3
;
Minimum Standard concrete coating density (dry): 2.240 t/m3
;
Concrete weight increase in order to take into account water absorption:
 on bottom stability analysis (minimum) 2% by weight;
 laying analysis (maximum) 5% by weight.
Cut back length required for pipeline installation:
 370 mm +20/-0 mm (Presto & Passo Welding System);
 390 mm +20/-0 mm (Wermaat Welding System).
Typical Concrete Data - ExampleTypical Concrete Data - Example

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
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Sacrificial Anode (Offshore Pipeline) is made by Indium activated aluminium alloy
or Zinc alloy.
 Pipeline Cathodic Protection (External Anticorrosion System)
Anode Type:
 Bracelet, half-shell (squared and Tapered)
 Long Slender Stand-off (e.g. Platform Leg, Subsea Structure, etc.)
 Flush-mounted (e.g. Platform Leg, Subsea Structure, etc.)
Sacrificial AnodesSacrificial Anodes

Collegamento a Rp32.exe.lnk
Anode Typical Drawing- Concrete Coated PipeAnode Typical Drawing- Concrete Coated Pipe

Anode Typical Drawing - Anticorrosion Coated PipeAnode Typical Drawing - Anticorrosion Coated Pipe

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
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FJC is the protective coating applied on field weld joints (circumferential weld).
The FJC ensure the suitable corrosion protection and coating continuity to the steel
pipes surface left bare (uncoated) during coating application on shop.
Field Joint coating System Selection Criteria is based on:
 Project Requirements
 Environmental service exposure (seawater, soil, other)
 Service temperature (depends on max. Fluid conveyed temperature)
 Compatibility with the pipeline External Anticorrosion Coating
Field Joints CoatingsField Joints Coatings

Field Joint coatings main type:
Anticorrosion Coated Pipe
 Heat Shrinkable Sleeve (HSS)
 Polymer plastic tapes (e.g. Spirally wrapped PP tapes (PIH) & Cigarette wrapped PP tapes (CCSI))
 Fusion Bonded Epoxy Powder (FBE)
 Liquid Epoxy resin (Tar free)
 Liquid Polyurethane (Tar free) (e.g. Marinblock trademark)
 Injection Moulded Polypropylene (PP) and Polyurethane (PU)
Concrete Coated Pipe
 Polyurethane mixture with anticorrosion properties (PU) (e.g. 1500kg/m3
) with or w/o Gravel
 Polyurethane Foam with anticorrosion properties (PU) (e.g. 125kg/m3
) with or w/o Gravel
 Heat Shrinkable Sleeve (HSS) + Polyurethane (PU) mixture Infill material (e.g. 1100 -1150kg/m3
)
 Flame Spray Polypropylene + Polyurethane (PU) mixture Infill material (e.g. 900Kg/m3
PP+1400-
1600kg/m3
PU)
Field Joints CoatingsField Joints Coatings
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3
3LPP
FBE PP
Flame-Spray
PU Foam
PU Mixture (e.g. Marinblock)HSS
Field Joints Coatings - ExamplesField Joints Coatings - Examples
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1. 2. 3.
4. 5. 6.
1. and 2.All weld areas shall be grit or sand blasted to remove all frayed or
loosened coating at edges of the mill cutback and slightly abrade the
coating sections to be covered by the heat shrinkable sleeve (HSS).
3. and 4.Heating the weld joint up to the specified heating application
temperature.
5. Before sleeve application, the primer, when required, shall be applied to
bare steel and adjacent abraided mill coating using supplied applicator
(i.e. spatula).
Then wrapping the sleeve centrally around the weld joint. Sleeve overlap
onto itself should be not less than 150 mm.
6. Installation of the closure patch and pressing in position centering over
the exsposed sheet end.
Application Of Heat Shrinkable Sleeve (HSS)Application Of Heat Shrinkable Sleeve (HSS)
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PP Flame Spray – Application Process ExamplePP Flame Spray – Application Process Example
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IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
07/16/14

Flanges are hot or cold forged fittings
Required Flange Rating depends on the pipeline design and hydrostatic test pressures
Coupling flanged (e.g. Pipeline-Spool, Riser-Spool, Valve-piping, etc.)
Typical Flanges Materials:
Carbon Steel, Low Alloyed Steel, Stainless Steel.
Flange Type:
Welding Neck (WN) - Swivel Neck (SW) - Blind (BL) - Flat Face (FF) - Raise Face (RF)
FlangesFlanges

Flanges TypesFlanges Types

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Carbon Steel Flanges Rating (ASME B16.5)Carbon Steel Flanges Rating (ASME B16.5)

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Low Alloyed Steel Flanges Rating (ASME B16.5)Low Alloyed Steel Flanges Rating (ASME B16.5)

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Stainless Steel Flanges Rating (ASME B16.5)Stainless Steel Flanges Rating (ASME B16.5)

Swivel Flange Typical Drawing- 10” SW RTJ ExampleSwivel Flange Typical Drawing- 10” SW RTJ Example

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Weld Neck Flange Typical Drawing- 10” WN RTJWeld Neck Flange Typical Drawing- 10” WN RTJ

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Blind Neck Flange Typical Drawing- 10” BL RTJBlind Neck Flange Typical Drawing- 10” BL RTJ

Ring Type Joint (RTJ) Gaskets are metallic sealing rings suitable for high pressure and high
temperature applications (e.g. coupling flanged).
RTJ gaskets are designed to seal by "initial line contact" or wedging action between the mating
flange and the gasket.
By applying pressure on the seal interface through bolt force, the softer metal of the gasket flows
into the micro-fine structure of the harder flange material, creating
very tight and efficient seal.
Typical Gaskets Material: Soft iron, SS 316 (and Plastic, Metallic-Plastic)
The rings shall have hardness lower than that of the flange in order to assure tight joint.
Ring Gasket Profiles used in offshore pipeline application are:
 Oval
 Flat
 Octagonal.
RTJ gaskets are manufactured in accordance with ASME B16.5,
ASME B16.47, ASME B16.20 and MS SP 44 specifications.
Gaskets (Offshore Application)Gaskets (Offshore Application)

Ring Type Joint (RJT) & FLAT (RF) Gaskets-ExamplesRing Type Joint (RJT) & FLAT (RF) Gaskets-Examples

Stud Bolts are made by alloy steel according to ASTM A 193 Grade B7.
The length “L” of stud bolts is measured from first thread to first major diameter thread.
The Bolt length has to be suitable for the WN/SW coupling flanged included the extra length
for automatic bolt tensioner (hydra tight Type)
Both ends of stud-bolt shall have a tip.
The threading shall be carried according ANSI code B1.1.
Nuts are machined, hot or cold forged, in Carbon Steel according to ASTM A 194 Grade 2
(teflon coated).
Stud Bolts and NutsStud Bolts and Nuts

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
07/16/14

A Subsea Safety Isolation Valve (SSIV) is required in proximity (distance to be defined by dedicated
study) of a selected platform to provide the isolation, in case of accident (e.g. fire), of the surface
facilities and the riser from the fluid (e.g. Methane) contained inside the sealine coming from another
Platform or from onshore Facilities.
SSIV Station Main Components:
• On-Off Ball Valve
• Actuator
• Base support + Protection Cover
• Piping (flanges included)
• Control Umbilical
• Control system
• J-tube and its top flange for the umbilical hang-off
SSIV (Subsea Safety Isolation Valve)SSIV (Subsea Safety Isolation Valve)

SSIV Genaral Arrangement - ExampleSSIV Genaral Arrangement - Example
Protection Cover
Piping
On-Off Ball Valve
Actuator

IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
07/16/14

An Isolating Joint (IJ) is a high-resistance fitting used to electrically isolate sections of a
pipeline in order to avoid any electrical current to cross from one side of the joint to the
other one and consequently to improve the effectiveness of the cathodic protection
system.
Welded
connection
Flanged
connection
Insulation JointInsulation Joint

Good insulation level between two sections of a pipeline is granted when the isolating joint
is installed above ground or above sea level or in inspection pits.
Ground Level
Sea Level
Sediment Level
Isolating Joints
Inspection Pit

Insulation Joints are typically made in one piece (Monolithic) or flanged and can be
designed and manufactured for any pipeline size and pressure rating.
A Monolithic dielectric Joint (MIJ) are composed of two pieces of metallic pipe,
assembled by welding along with interposition of insulating material and sealing
gaskets so that the two piece at the same time come out each other mechanically
connected and electrically insulated.
MIJ is provided with extension nipples (pup piece) that must match the pipeline wall
and grade and are long enough to eliminate any possibility of thermal damage to the
MIJ during field welding.
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IndexIndex
1. Linepipe
2. Clad pipe
5. Concrete Coating
07/16/14

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Buttwelded FittingsButtwelded Fittings

Tee piece is a special buttwelded fitting used to realize the connection between two
pipelines with different headings and same (Straight tee) or different (Reducing Tee)
Outsider diameters.
Y-way piece is a special buttwelded fitting used to realize the connection between two
pipelines with different headings and same or different Outsider diameters.
Each Tee and y-way can be designed and manufactured for any pipeline size and
Pressure rating.
Straight Tee Reducing Tee
““T” and “Y” TeeT” and “Y” Tee

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““T” and “Y” Tee – Application Example: Laying In LineT” and “Y” Tee – Application Example: Laying In Line

““T” and “Y” Tee Welded on Spool - ExampleT” and “Y” Tee Welded on Spool - Example

A conical reducer is a buttwelded fitting used to connect two pipelines with different
Outsider diameter (e.g. 36” OD offshore Pipeline with 34” OD existing onshore pipeline).
Conical Reducer can be made from steel plates and/or pipes and may be manufactured by
forging, pressing, rolling, welding or by a combination of these processes.
Conical reducers can be designed and manufactured for any pipeline size and
Pressure rating.
Conical ReducerConical Reducer

2. pipeline materials overview

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