Metallurgically bonded UOE

clad (DSAW) linepipe

- Process route capable of large scale production
- Available in sizes from 16” to 42” outside diameter
- Quality plate feedstock sourced from specialist manufacturers
- World’s strongest crimp and ‘O’ press combination enables
production of thick walled pipe, even in smaller diameters
- Flexible production route to accommodate smaller quantities
e.g. risers
- Increased resistance to liner collapse

Introduction 45
Oil and gas reserves in shallow and sweet conditions are
becoming increasingly scarce, requiring the development of
40
products able to withstand extremely corrosive oil and gas
(sour service).
35
Pipe Thickness (mm) including CRA layer

In early developments, the management of corrosive oil and

gas reserves was accomplished by the use of sour service
30
steels and the introduction of chemical inhibitors into the line.
As developments have increased in complexity so have the
solutions being considered and the recent trend is towards the 25
use of more exotic alloys. However, the availability and cost
of these solutions still presents difficulties that can restrict the 20
development of the most challenging resources.

Clad linepipe, carbon steel with a corrosion resistant alloy 15

(CRA) lining, is a material technology that delivers corrosion
resistance, pipe strength and an economical use of these 10
costly and scarce alloys. The recognition of the benefits of
this mix of materials is resulting in increased demand for
longer lengths of clad pipelines. Previous methods for the 5
manufacture of clad linepipe have been slow and more suited
to small quantity requirements rather than the larger project 0
quantities now required by the industry. With these factors in
0 15 20 25 30 35 40 45
mind, Corus Tubes is now offering large scale production of
clad pipes. Outside Diameter (inches)
Please refer to sales team for specific size and grade information.
Clad pipe manufacture
Corus Tubes UOE double submerged arc welded (DSAW) pipe
mill is the only mill capable of manufacturing metallurgically
bonded clad linepipe by the UOE method specifically for use
in regions of sour service oil and gas. By using our linepipe
expertise and UOE process route, we are able to produce
high quality clad linepipe ranging in outside diameters from 16
inches to 42 inches. The mill is also capable of supplying very
thick wall pipes, even at smaller diameters, due to the power of
its crimp and ‘O’ presses. These products are ideally suited to
high pressure, high temperature applications as well as deep
water and riser applications.
Feedstock manufacture
Our clad linepipe is formed from carbon steel and corrosion-
resistant alloy (CRA) metallurgically bonded plate providing a
highly corrosion-resistant pipe surface. This high quality steel
plate feedstock is sourced from a select number of assured
manufacturers throughout Europe. This ability to purchase
plate on the open market enables us to ensure we provide the
best technical solution to meet customers’ bespoke project
requirements and to take advantage of technological advances
in clad plate manufacture.
Pipe manufacture
A detailed manufacturing process route for UOE DSAW clad
linepipe can be found on page 5.
Plate receipt and preparation
Plate is transported by road from receipt at the deepwater
port in Hartlepool in accordance with the project schedule. All
plates are assigned a unique identification code that is entered
into the pipe tracking system to ensure complete traceability.
Carbon steel welding tabs are attached to the four corners
of the plate before being passed through the edge milling
machine. This shapes the plate edges into the optimum profile
for welding. The configuration of this preparation is unique to
each pipe size and thickness.
After edge milling the plate moves onto the crimping press.
This machine bends the edges of the plate so that when the
pipe is formed, optimum shape and roundness is achieved
around the circumference at the point where the plate edges
come together.
CRA clad layer

Figure 1 below demonstrates a typical manufacturing

process for clad plate. Through a controlled process of heat
treatment and hot rolling a finished clad plate is produced and
despatched to Corus Tubes’ facility in Hartlepool.

Plate can be supplied with a carbon steel backing plate in a

range of linepipe grades, API X65 or equivalent being the most
commonly requested. The corrosion-resistant alloy layer can be
supplied in either 316L or 825, covering the majority of linepipe Figure 2: Plate edges are milled to create the
applications. Prior to despatch to the pipe mill in Hartlepool, all optimum profile for welding
Figure 1: Typical clad plate manufacturing route
plates are ultrasonically tested and fully inspected.

Sandwich assembly Sandwich welding Heating

Backing material
linepipe steel

Clad layer high alloyed

Separating agent

Plasma torch cutting Heat treatment Hot rolling

Separation and ultrasonic testing

Surface finishing
and final
inspection

Figure 1: Typical clad plate manufacturing route

Pipe forming
There are two key stages in the transformation of the flat plate
profile to the round pipe shape – the ‘U’ press and the ‘O’
press.

The ‘U’ press pushes a bulb shaped head onto the middle of
the steel plate and rollers move in from the sides to form a ‘U’
shaped steel plate, from this point on referred to as a skelp.

The skelp then moves through to the ‘O’ press. With a total
pressing weight of 50,000 tonnes, Corus Tubes’ ‘O’ press is
the strongest in the world over a 12 metre pipe length. This
controlled power enables the mill to press clad plates up to
40mm thick.

As the top of the ‘O’ press descends down onto the ‘U’ shaped
skelp, the steel is moulded to fit into the size bespoke dies
lining the mill. By controlling the speed and power of this
press the mill can optimise the shape and configuration of the
resultant skelp.

Pipe welding
Once the clad plate has been formed into a round pipe shape
it is passed through to the welding operations of the mill. An
initial tack weld is applied to the root of the weld preparation
on the carbon steel outer surface of the pipe. This maintains
the pipe shape as it passes into the internal welding process.

Preliminary non-destructive testing (NDT) of both the internal

and external welds is completed prior to the pipe being
transferred to the offline welder. This has been specifically
designed for the welding of the CRA layer of clad pipes.

The CRA layer of the clad plate is restored by the electro-slag

method of welding. Electro-slag welding allows for optimised
welding speed, minimal dilution (less than 10%), an excellent
bead shape, no spatter, a ferrite level of less than 10% in the
weld bead and good corrosion resistance of the overlay weld.
This Page:
Corus has worked closely with Air Liquide Welding to develop The controlled power of the ‘U’ and ‘O’ presses enables the manufacture of clad linepipe
consumables for this process, and can offer matching and to precise dimensional tolerances.

overmatching welds for 316L and 825 claddings.

MIG welding

Multi-wire
CRA clad layer double SAW

Electro-slag
welding

Figure 3: After forming, pipe manufacture is completed with a four stage welding process
This overlay weld is then subjected to NDT to prove the
integrity of the weld before the pipe is transported to the
mechanical expander.
Figure 4: The clad pipe is expanded to achieve its
final dimensions
The expander moves along inside the length of the welded
pipe, exerting uniform pressure to ensure consistent
dimensional properties around the circumference and along
the length of the pipe. Clad pipe from Corus is supplied to the
same world-leading dimensional tolerances as our carbon steel
pipes, allowing excellent fit up and weldability.
Pipe finishing
Once the pipe has been expanded it passes through to the
finishing mill. Within this part of the manufacturing facility, each
pipe can be hydrotested and finished in accordance with the
client’s project requirements. End faces of the pipes can be
bevelled and prepared to the configuration required by the lay
contractor.
During the forming process there will have been contact
between the carbon steel tooling and the CRA layer. Carbon
steel contamination of the CRA surface of clad linepipe can
have a detrimental effect to the corrosion resistance of the CRA
layer. Following the carbon steel contact during the forming
process, in accordance with DNV-OS-F101, Corus cleans the
bore with the application of a pickling solution.
Firstly the pipe ends are sealed before feeding a spray nozzle
along its entire length, ensuring complete coverage of the CRA
with an HF/HNO3 solution while avoiding contamination of
the outer carbon steel. After a short time, the acidic solution
is rinsed away with deionised water and the pipe is left to
dry completely. Ferroxyl tests prove complete removal of
carbon steel contamination using this method, and corrosion
performance is guaranteed by the passivation resulting after
the pickling process.
Following final inspection of the bore, protective caps are fitted
to the pipe ends in order to protect the CRA surface whilst the
pipes are despatched to their delivery point.
Non-destructive testing
Conventional ultra-sonic and radiographic techniques are not
guaranteed to identify all defects in the complex weld structure
of a clad pipe. To address this issue, Corus has developed
specialist techniques to enable the inspection of all areas of the
weld.
Ultra-sonics
Conventional ultra-sonic testing uses shear waves to detect
defects in the carbon steel weld. Shear waves are formed when
the energy is transmitted tangentially to the direction of the
wave propagation. Waves of this form become diffused when
they cross the boundary between the fine-grained structure of
the main weld and body, and into the coarse grained austenitic
weld of the CRA overlay. This diffusion causes excessive noise,
obscuring any defects in the clad weld.
Inspection of the entire weld can be achieved by the use of
compression waves. These waves transmit the energy from
particle to particle in-line with the direction of travel by a
compressive action. These waves can be used to penetrate the
CRA weld area, crossing the boundary without diffusion.
A combination of shear and compression probes is the
best option to inspect the whole weld in sequence. Shear
waves are used to check the majority of the weld and the
junction between the CRA layer and the main body and weld.
Compression waves are included to inspect the coarse grain
overlay weld structure. These probes are mounted within
Corus’ existing test equipment.
Single crystal (pulse echo and cross reflect) shear wave
probes, for carbon steel and
boundary defects
Twin crystal (send and receive) compression wave
angle beam probes, for austenitic clad
weld defects
Clad pipe process route

Plate stock Edge preparation milling Edge crimping

Mechanical
unload

Internal & external DSAW “O” press “U” press

01-02-03 01-02-03
01-02-03

Weld seam ultrasonic Electro-slag overlay welding Mechanical expander

testing or X-ray

01-02-03 01-02-03
Off-line On-line

End-facing and bevelling Hydrostatic testing Weld seam ultrasonic

Pickling/
testing or X-ray
Passivation
01-02-03
Customer 01-02-03 01-02-03

Acceptance

Quality management Corrosion testing

During pipe manufacture, as part of Corus Tubes quality
management philosophy, production tests are taken to
comply with the customer’s specification. Corus Tubes has
a dedicated materials testing laboratory, which completes all
mechanical and toughness testing prior to product release.
For more intricate fracture toughness and sour service testing,
the facilities at Corus Research, Development and Technology
are also available. Examples of clad specific tests available are
tests for bond strength between the CRA and carbon steel,
corrosion testing of the CRA to ASTM G48 or ASTM A262 and
ferroxyl testing for cleanliness of the CRA layer.
A key challenge for materials producers and specifiers is how
to test and guarantee the corrosion resistance of the CRA layer.
There are a number of test methods available which each have
their own advantages, however a common drawback among
all is that none of the laboratory tests can mimic accurately
the service conditions of the pipe. The principal international
standards deal with this question in various ways.
DNV-OS-F101
This standard recognises that the corrosion resistance of the
CRA is primarily defined by chemical composition: and states,
“Unless otherwise agreed, corrosion testing of roll bonded clad
pipes or any longitudinal weld seams is not required.” Where
this testing is required DNV references ASTM G48 “Standard
Test Methods for Pitting and Crevice Corrosion Resistance
of Stainless steels and Related Alloys by the Use of Ferric
Chloride solutions,” Method A.
API 5LD
The current (1998) version of API 5LD recommends the
intergranular corrosion test as per ASTM A262 Practise
E. The proposed new edition of API 5LD recognises that:
“The purpose of this [corrosion] test is to assure proper
manufacturing procedures for austenitic steel and Ni-base
alloys. It is not a test to determine susceptibility for use
with a particular environment.” It also states that corrosion
testing should be carried out as part of the MPQ: “The testing
procedure shall conform to the requirements of the latest
edition of ASTM A262, Practice E, Practice B or ASTM G28 or
The following histograms depict tolerances achieved on typical
projects for carbon steel linepipe. Reference to carbon steel
pipe manufacture allows us access to a greater body of data
than clad projects alone; the forming process being identical
and material responses being essentially the same.
Diameter
6000
5000
4000

Frequency
ASTM G48, Method A (Section 8) whichever is suitable for the
cladding or liner material and as agreed between the purchaser 3000
and manufacturer.”
2000

Referenced in both DNV-OS-F101 and API 5LD, the ASTM 1000

G48 test has become the industry standard reference
0
for determining corrosion integrity. When using this test,
0 546.0 546.5 547.0 547.5 548.0 548.5 549.0
acceptance criteria is not specified and must be agreed
Diameter
between the purchaser and manufacturer for each project. The
test itself involves removing the CRA layer from the carbon The distributions achieved on projects demonstrate that the
steel base then machining a test coupon from this CRA. This measurements taken, for the vast majority of the pipe, are
test coupon is then immersed in a ferric chloride solution at within a range of +/-0.5mm around a mean. However, the
a specified temperature for a set period of time. Acceptance normal distribution imposed on the histograms shows that
criteria of the test are normally based on the presence or there is potential for some pipes to lie outside this range, which
absence of pitting, or degree of weight loss measured during would need to be accounted for either in pipe yield or identified
the test. The nature of this test means that the end result is and accepted for a project.
highly dependent on the initial condition and machining of the
test coupon. Ovality (pipe ends and pipe body)
2300
It should be noted that with all tests for corrosion, it is
2000
extremely difficult to simulate infield service conditions in the
Frequency

laboratory environment. 1300

In summary, Corus Tubes offers the following corrosion testing 1000

on 316L cladding
300

• ASTM G48 testing with no pitting on ID surface at 15 0

deg. C 0.0 0.3 0.6 1.0 1.2 1.5 1.8 2.1
• ASTM A262 Method E tested with no cracking visible Ovality
after sensitisation
• Ferroxyl tests prove no carbon steel contamination on The control of ovality in pipe ends is high within the Corus
final CRA surface layer Tubes production process with the majority of values lying
within the region of 1mm. The infrequent, wider ranging results
Dimensional control take the limits out to 2mm.
Dimensional control of clad linepipe is of utmost importance to
ensure that the material can be efficiently welded in the field. Measurements of pipe body ovality are difficult to take during
This facilitates repeatability and quality in field girth welds, the manufacturing process, however the UOE process has
thereby reducing timely and costly fit up delays. been proven to give equal control at both pipe end and pipe
body.
Through its extensive experience of manufacturing carbon
steel linepipe for projects all over the world, Corus Tubes has Peaking
developed the capability to produce linepipe with superior During the UOE forming process the edges of the plate have
tolerances and is able to apply this technology to the to be preformed by the crimp press. This ensures that the
manufacture of metallurgically bonded clad linepipe. curvature of the pipe body is consistent even at the weld area.
By careful control of this part of the forming process Corus is
able to produce linepipe with minimal out of roundess in this
key region of the pipe.
Mechanical properties

Tensile results

Mean Rt0.5 / MPa Mean Rm / MPa Mean Elongation % Mean Rt0.5/Rm Ratio
/ 50mm
Tranverse 485 558 44 0.87
Longitudinal 506 558 42 0.91
All Weld Tensile (ID) 555 633 15 0.88
All Weld Tensile (OD) 602 671 25 0.89
Transverse Weld Tensile 579

Example charpy results

Position Temp °C Average Energy Average Shear

Weld Centre Line Mid-Thickness -30 166 98
Weld Centre Line Outside Diameter -30 170 100
Weld Centre Line Inside Diameter -30 169 100
Fusion Line 50/50 Mid-Thickness -30 193 83
Fusion Line 50/50 Outside Diameter -30 240 73
Fusion Line 50/50 Inside Diameter -30 253 95
Body Mid-Thickness -30 446 100
Body Outside Diameter -30 432 100
Body Inside Diameter -30 445 100

Drop weight tear testing: example transition data

Temperature Shear 1 Shear 2 Shear Av.

-10 100 100 100
-40 100 100 100
-50 100 100 100
-60 95 0 48
-65 10 0 5
-70 0 0 0

Tensile, charpy and drop weight tear testing (DWTT) results

show the same excellent performance as Corus carbon steel
pipes. We can guarantee X65 tensile performance and our
combination of world leading plate suppliers and welding
know how allows us to offer upper shelf charpy and DWTT
performance at –30°C, despite the reheating effect of our
electroslag overlay weld.
Bond Shear Strength
Our average shear strength of the bond between CRA and
carbon steel is >400MPa.
Hv10 Hardness (316L cladding)
Body Haz Weld CRA
Minimum hardness (actual) 180 160 200 180
Maximum hardness (actual) 198 211 228 253
Mean hardness (actual) 186 182 213 207
Hardness is controlled allowing us to comply fully with
customer specification requirements.

Corus Tubes can supply metallurgically

bonded CRA clad linepipe in a wide
range of diameter and wall thickness
combinations. The UOE process enables
Corus to meet project demands for large
volumes of pipe to precise dimensional
tolerances.