2013 CHA Seminar Presentation DR Franz Martin Knoop

PRODUCTI ON OF HELI CAL TWO STEP PI PE USE OF MI CROALLOYI NG
ELEMENTS TO I MPROVE STRENGTH FOR GRADES UP TO X70 WI TH

SOUR SERVI CE RESI STANCE
Franz Martin Knoop
Salzgitter Mannesmann Grossrohr GmbH
Djordje Mirkovic, Volker Flaxa Djordje Mirkovic, Volker Flaxa
Salzgitter Mannesmann Forschung GmbH
Introduction
Contents
Introduction
History
Contents
Development programme
Manufacturing issues relevant for sour service resistance
steel production steel production
hot rolling
pipe production
Dr. Knoop July 2013, London
2.
Mechanical and corrosion test results
Summary and outlook
Introduction
Salzgitter's research and development activities for HSAW-pipe
extending pipe/coil wall thickness up to 25.4 mm for grades X70 and X80
steel grades with high strength and excellent low temperature toughness
Salzgitter s research and development activities for HSAW pipe
sour service resistant steel and pipe
enhancement of collapse resistance for shallow water off-shore applications
use of FEM for simulation of pipe forming and welding use of FEM for simulation of pipe forming and welding
reducing residual stresses in pipe and weld seam
improving the strain capacity of pipes for strain based design requirements
3.
reduction of geometrical tolerances on steel and pipe
History
Failures of helical welded pipe p p
4.
History
Cooking recipe for sour service material g p
Malcolm Gray Full Scale Testing of Linepipe for Severe H
2
S
Service; NACE Canadian Regional Western Conference,
A h Al k F b 19 22 1996 Anchorage, Alaska, February 1922. 1996
5.
Targeted pipe properties R&D and commercial projects
Quantity
Grade /
w th
OD
YS TS CVN
DWTT
HIC (base + weld) NACE
TM248
SSC
(base+weld)
g p p p p p j
Project
Quantity
(t)
Grade /
Standard
w.th.
(mm)
OD
(mm)
YS
(MPa)
TS
(MPa)
CVN
(J/cm
2
)
DWTT
(% shear
area)
TM248 (base+weld)
(4 point
bend.) CAR CLR CTR CSR
X60MS 250; 0C 85 @at 80%SMYS
SZ X60 200
X60MS
API 5L/ISO3183
14.0 1067 420 520
250; 0C
(base)
85 @ at
-40C
5 -
80% SMYS
No crack
SZ X65 200
X65MS
14 1 813 450 535
300; 0C 85 @ at
5 -
80% SMYS
SZ X65 200
API 5L/ISO3183
14.1 813 450 535
(base) -40C
5
No crack
SZ X70 200
X70MS
API 5L/ISO3183
16.0 1016 485 570
300; 0C
(base)
85 @ at
-40C
5 -
80% SMYS
No crack ( )
Grade
1000
GR241
15 9
762
and 241 414
50; not
15 5 2
80% AYS
241
1000
CSA_Z245.1-07
15.9 and
914
241 414
0C required
- 15 5 2
No crack
Grade
448
800
GR448
CSA Z245.1-07
13.7 1372 448 531
50;
-18C
60 @ at
-18C
- 15 5 2
not
required
6.
448
CSA_Z245.1 07 18 C 18 C required
(mechanical properties in hoop direction)
Chemical composition for R&D and commercial projects
Project Purpose
C
wt %
Si
wt %
Mn
wt %
P
ppmw
S
ppmw
Al
wt %
Cu + Cr + Ni
wt %
Mo
wt %
Nb
wt %
CEV (IIW)
wt %
CEV (Pcm)
wt %
p p j
wt.% wt.% wt.% ppmw ppmw wt.% wt.% wt.% wt.% wt.% wt.%
SZ X60 R&D 0.035 0.30 1.46 70 5 0.04 0.44 0.07 0.05 0.33 0.14
SZ X65 R&D 0.038 0.28 1.37 80 7 0.04 0.86 0.04 0.05 0.36 0.14
SZ X70 R&D 0.038 0.33 1.33 90 6 0.04 0.84 0.32 0.05 0.43 0.15
Grade Grade
241
Commercial 0.041 0.23 1.14 95 4 0.04 0.23 0.004 0.02 0.25 0.11
Grade
448
Commercial 0.060 0.32 1.55 150 8 0.04 0.36 0.005 0.05 0.35 0.16
7.
Production: Metallurgical process up to slab casting
Production: Metallurgical process up to slab casting
1
2
3
1. Blast furnace
3
4
1. Blast furnace
2. Hot-metal mixer
3. Desulphurization facility
5
p y
4. BOF shop
5. Secondary metallurgy facilities y gy
6. Continuous slab caster
6
High automatization level including close
integration of steel plant control and supervision system
with technical planning
6
8.
slab thickness: 250 mm
Steel plant: quality issues and measures
Steel plant: quality issues and measures
Desired quality issues Consistently applied Salzgitters measures to attain them
Narrow steel composition tolerances
High steel cleanliness
lowering non-metal inclusions
Continuous composition control and adjustment
Secondary metallurgy and appropriate casting procedure
ti i t ith ti l ti
lowering non-metal inclusions
( low [O]
total
)
inclusion shape and size control
gas stirring + caster with vertical section
Ca treatment for inclusion shape control
vacuumdegassing
low tramp element steel contents
( especially P and S )
low H content
vacuum degassing
High slab centerline quality
avoiding centerline segregation
Soft reduction at continuous slab caster
(C, Mn, P)
9.
Steel cleanliness: non-metallic inclusions as HIC initiating sites
Example: insufficient ladle rinsing and unsuitable degassing
Steel cleanliness: non-metallic inclusions as HIC initiating sites
top view of US scan
Rolling direction
top view of US scan
side view of US scan
HIC fracture
surface
Al
consistent application of LM refining measures to remove inclusions
from the steel melt, such as:
bottom stirring with N
2
and Ar
f t h l lid t f i i i d l
O
use of tap hole slide gates for minimized slag carry over
optimized Ca-treatment with Ca-wire injection; high Ca recovery
optimized ladle rinsing procedure
use of argon shielded tundish for optimized flow pattern / inclusion removal
10.
HIC cracks primarily initiated at Al-
O inclusions and are traced back
to slab upper half
use of argon shielded tundish for optimized flow pattern / inclusion removal
application of caster with 2.6 m long vertical section instead of bow casters
Slab centerline quality: segregation effects
Slab centerline quality: segregation effects
Example: casting without dynamic soft reduction
Martensite
HIC crack at strip
mid thickness
top view of US scan
side view of US scan
consistent slab centerline quality optimization by application of Dynamic Soft Reduction consistent slab centerline quality optimization by application of Dynamic Soft Reduction
dynamic segment regulation (soft reduction), particularly at the point of final solidification
11.
Production: layout of Salzgitters hot strip mill
Production: layout of Salzgitter s hot strip mill
Reheating furnaces (4)
Slab sizing
press
Slab sizing
press
R hi ill R hi ill
Descaler
Roughingmill Roughingmill
C h C h
Finishing train
Crop shear Crop shear
Run-out table:
Laminar cooling unit
descaler
Slab thickness = 250 mm
St i thi k 1 5 25 Strip thickness = 1.5 - 25 mm
Strip width = 900 - 2.000 mm
Strip length = 100 - 2.000 m
3 Down coilers
12.
One of the worlds most modern
high performance hot strip mills
Hot strip mill: quality issues and measures
Consistently applied Salzgitters measures to attain them
Hot strip mill: quality issues and measures
Desired quality issues
Continuous control and adjustment of rolling parameters
highly planar
strip profile
n
e
s
s
m
]
Narrow strip dimension tolerances
lowering of residual stresses in the
pipe bodies and welds strip profile
S
t
r
i
p

t
h
i
c
k
n
v
a
r
i
a
t
i
o
n
[
pipe bodies and welds

High strip surface quality
prevention of surface defects e.g.
Thickness 60 m
Precise temperature monitoring from furnace to coiler
Strip width[mm] slivers, roll-ins
Homogeneous strip temperature
distribution
highly desirable acicular ferrite microstructure along the
strip length and across the strip width
Precise strip temperature prediction and control
distribution
prevention of transformation
during the finishing
p p p
based on run-out table simulation
strip microstructure adjustment
without undesirable phases
13.
Hot strip mill: strip profile and temperature distribution
Hot strip mill: strip profile and temperature distribution
Temperature scan after finishing train
Example: two-phase finish rolling / undesirable phases at strip edge area
Rolling direction
Temperature scan after finishing train
i
a
t
i
o
n
undercooled strip edges
T
e
m
p
.

d
e
v
strongly elongated -grains,
Martensite also observed
precise temperature monitoring and control in every process phase and section
to obtain fine-grain structure across the strip width to obtain fine grain structure across the strip width
indispensable to prevent transformation already during the finishing
to prevent undesirable phases, such as martensite
Rolling direction
14.
properly cooled strip edges
NO HIC cracks observed !
Pipe production: Helical seam Two Step (HTS) technology
Pipe production: Helical seam Two Step (HTS) technology
B = 1200 - 1500 mm
= 20 - 40
D = f (B, ) ( , )
D = 610 - 1676 mm
Second step: inside and outside
Fi i f i i h i k ldi
Second step: inside and outside
submerged arc welding
15.
First step: pipe forming with continuous tack welding
Pipe mill: quality issues and measures
Consistently applied SZ measures to attain them
Pipe mill: quality issues and measures
Desired quality issues
Quality controls and R&D
use of FEM simulation methods
consistent quality controls and recording of forming
controlled cold working
during coil straightening and pipe
forming consistent quality controls and recording of forming
parameters
continuous control of pipe geometry using a patented in-situ
l di t t l
forming
minimized springback
optimized pre-bending of coil edges to
id ki d d i l l laser diameter control
peaking below 0.8mm
avoid peaking and reducing local
stress which might affect sour gas
resistivity at weld area (SOHIC)
separating forming and welding by using the HTS process
no forming stresses during welding
Material selection and welding process controls
qualification and careful selection of coil material and
welding consumables
maximum hardness of 248 HV
16.
g
continuous recording and documentation of all essential
welding parameters
Pipe mill: reduction of residual stresses
Pipe mill: reduction of residual stresses
640
720
800
240
320
400
480
560
S
t
r
e
s
s

,

M
P
a
0
0
80
160
240
0 2,5 5 7,5 10 12,5 15 17,5 20
Strain %
0
30
45
60
90
Strain , %
2 0
2.5
3.0

[
-
]
Maximum value over wall thickness
Inner surface
Outer surface
Stress strain curves at different angles
Simulation of different forming strategies
0.0
0.5
1.0
1.5
2.0
o
o
p

s
t
r
e
s
s

h

/

h
(
N
F
)

2 5
-2.0
-1.5
-1.0
-0.5

R
e
l
a
t
i
v
e

r
e
s
i
d
u
a
l

h
o
negative spring-back positive spring-back
17.
-3.0
-2.5
1.8E-03 1.9E-03 2.0E-03 2.1E-03 2.2E-03 2.3E-03 2.4E-03 2.5E-03 2.6E-03 2.7E-03
Curvature under load [1/mm]
Relative residual hoop stress as function of the curvature under load
R&D sour service trials: SZ X65
Coil
Pipe
Type of
samples &
direction
R
t0.5
[MPa]
R
m
[MPa]
R
t0.5
/R
m
A
DIN
[%]
A
API
[%]
DWTT @
[% shear area];
- 60C
CVN @
[J/cm
2
]
- 80C
p
direction
[ ] [ ]
- 60 C - 80 C
Strip 30 [rect.] 528 581 0.91 24 39 93 382
Pipe hoop [rect.] 483 575 0.84 24 38 75 379
HIC 24 HIC i t t d
Targeted API X65 grade reached reliably; excellent low temperature toughness
HIC: 24 HIC specimens were tested
Result: mean CAR value ~0.1 %
SSC (4-point-bending test): 9 specimens were
tested at 85% of SMYS (383 MPa)
R lt SSC k b d Result: no SSC cracks were observed
Full ring test: 72% of SMYS (323 MPa) for 720h in
18.
NACE TM0177 solution A
Result: No indications above threshold were found by
ultrasonic examinations prior to and after the test
Very good sour gas resistivity
R&D sour service trials: SZ X70
680
700
720
R
m
90
100
%
]
580
600
620
640
660
API Samples
DIN Samples
R
t0.5
,

R
m

[
M
P
a
]

70
80
90
DWTT transition
Coil 686056 a
c
t
u
r
e

a
r
e
a

[
%
500
520
540
560
580
Coil center
Rectangular samples
Hoop direction
R
t
0
.
5

40
50
60
Coil 686056
Coil 686057
Coil 686059
S
h
e
a
r

f
r
a
Test temperature: -50C
100% shear area
6
8
6
0
5
6
6
8
6
0
5
7
6
8
6
0
5
8
6
8
6
0
5
9
6
8
6
0
6
0
500
Coil
-60 -50 -40 -30 -20
40
Test temperature [C]
Targeted API X70 grade reached reliably; excellent low temperature toughness
HIC: 112 HIC specimens (base and weld) tested
Result: mean CAR value of 2.82 % (max. 13.1 %);
mean average CAR value base material: 3.62%, mean CAR value for weld specimens: 1.16%
V d i ti it f API X70 d
19.
Very good sour gas resistivity, even for API X70 grade
Commercial projects: GR448
p j
620
640
660
R
t0.5
R
m
A

38
39
40
400
540
560
580
600
620
A

[
%
]
5

,

R
m

[
M
P
a
]

34
35
36
37
38

350
375

V
N

a
K

[
J
/
c
m
2
]
2
0
9
1
8
8
1
9
8
2
0
3
460
480
500
520
DIN rect. sample; hoop direction
Coil
R
t
0
.
30
31
32
33
4
1
8
8
4
1
9
8
4
2
0
3
4
2
0
9
300
325
Mean value
Test temperature -18C
C
V
360 357 383 344
Coil
LOM Microstructure thick width
Targeted GR448 grade reached reliably
9
5
7
4

/

9
8
4
2
0
9
5
7
1

/

9
8
4
1
8
9
5
7
2

/

9
8
4
1
9
9
5
7
3

/

9
8
4
2
0
Coil
Heat
9
5
7
1

/

9
8
4
1
8
9
5
7
2

/

9
8
4
1
9
9
5
7
3

/

9
8
4
2
0
9
5
7
4

/

9
8
4
2
0
Heat
Coil
LOM Microstructure thick., width
50 % Ferrite; 40 % Bainite; 10 % Pearlite
HIC: 1 set for both base material and weld per heat were tested.
Result: mean CLR and CSR values of all samples 3.5 , 0.7 and 0.3 %, respectively
G d i ti it ! (d it f l ti l hi h C d M t t )
Pipe
DWTT [% shear area]; average of 2 specimens
0C C 10C 20C 40C 60C
E ll l DWTT l
Good sour gas resistivity! (despite of relatively high C and Mn contents)
20.
0C -5C -10C -20C -40C -60C
100 100 100 100 100 93
100 100 100 100 95 83
Excellent low temperature DWTT results
Summary
Summary and outlook
y
Large diameter helical line pipe for sour service up to X70 has been successfully
d l d d d d developed and produced
Critical parameters in steel production and hot rolling have been shown and their
influence has been explained by means of examples.
Well balanced microalloying and steel cleanness has been achieved in industrial trials
and commercial projects
All relevant process parameters during continuous casting and hot rolling were All relevant process parameters during continuous casting and hot rolling were
effectively controlled and adjusted to the used chemistry an microalloying
All necessary measures for the improvement of HIC and SSC resistance have been
optimized and managed during spiral pipe forming and welding optimized and managed during spiral pipe forming and welding
Excellent mechanical properties (incl. low temperature toughness) and corrosion
resistance have been achieved
21.
Outlook
Summary and outlook
Next milestones are defined on basis of actual and future market needs
Growing interest for sour service resistant line pipe with heavy wall thickness up to 1
and grades up to X70 is expected
Technical solutions require further development q p
- on chemical composition of the base material,
- on welding consumables
- on further production parameters at each stage of production
- and on suitable equipment at each stage of production
Pi ith ll di t i th f 26 d hi h ll thi k (hi h ld Pipes with smaller diameters in the range of 26 and higher wall thickness (high cold
forming degree) need further development
22.

2013 CHA Seminar Presentation DR Franz Martin Knoop

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PRODUCTI ON OF HELI CAL TWO STEP PI PE USE OF MI CROALLOYI NG

ELEMENTS TO I MPROVE STRENGTH FOR GRADES UP TO X70 WI TH

pipe bodies and welds

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