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Sonja FelberPIPELINE ENGINEERINGISBN 978-3-9501528-2-1

Sonja FelberPIPELINE ENGINEERING

Ao.Univ.Prof. Dipl.-Ing. Dr.techn. Sonja FelberVienna University of TechnologyInstitute for Building Construction and Technology (E 206)Karlsplatz 13A-1040 Vienna, AustriaPIPELINE ENGINEERINGFirst Edition 2009ISBN 978-3-9501528-2-1Editor and Distribution:Oesterreichische Gesellschaft fuer Schweisstechnik (OEGS)Arsenal Objekt 207A-1030 Wien1 - (2009) ISBN 978-3-9501528-2-1This work is protected under copyright.Single photocopies of single subchapters may be made for personal use as allowed by national copyrightlaws. Permission of the Publisher and payment of a fee is required for all other photocopying, includingmultiple or systematic copying, copying for advertising or promotional purpose, resale, and all forms of document delivery. Special rates are available for educational institutions that wish to make photocopies fornon-profit educational classroom use. Permission may be sought directly from OEGS. In the USA, usersmay clear permission and make payments through the Copyright Clearance Centre. Other countries mayhave a local rights agency for payments.Tables of contents may be reproduced for internal circulation, but permission of OEGS is required for external resale or distribution of such material. Permission of the Publisher is required for all other derivativeworks, including compilations and translations. Permission of the Publisher is required to store or useelectronically any material contained in this work, including any chapter or part of a chapter. Except asoutlined above, no part of this work may be reproduced, stored in a retrieval system or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior writtenpermission of the Publisher. Address permission requests to OEGS.No responsibility is assumed by the Publisher and Author for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the work, because of rapid advances in science.Copyright OEGS 2009. All rights reserved.Printed in AustriaCover: Concept & design, Sonja Felber

PIPELINE ENGINEERINGKEYWORDSPipeline engineering, ferritic-pearlitic and bainitic steels (pipeline-steels), duplexsteels, pipeline failures, natural gas pipelines, crack-arrestors, pipeline corrosion, corrosion protection of pipelines, pipelines in Austria, in Europe, world wide, pipelinewelding, heat treatment of pipelines, fracture mechanical investigations, CTOD tests,crack-arrest tests, tensile tests, impact tests, hardness tests, heat-input, alloying elements of thermomechanically treated steels and duplex-steels, metallography, fractography, pipeline design, operation of pipelines, radiographic testing, ultrasonic testing, visual testing, quality management in pipeline engineering, pigging, analysis offailures in pipeline engineering.SCHLAGWOERTERPipelinebau, ferritisch-perlitische und bainitische Staehle (Pipeline-Staehle), DuplexStaehle, Schadenfaelle an Pipelines, Erdgasleitungen, Rissarrestoren, Korrosion anPipelines, Korrosionsschutz von Pipelines, Pipelines in Oesterreich, in Europa, weltweit, Schweissen von Pipelines, Waermebehandlungen an Pipelines, bruchmechanische Untersuchungen, CTOD-Untersuchungen, Rissauffang-Untersuchungen, Zugversuche, Kerbschlagbiegeversuche, Haertepruefungen, Streckenenergie, Legierungselemente von thermomechanisch behandelten Staehlen und Duplex-Staehlen,Metallographie, Fraktographie, Projektierung von Pipelines, Betrieb von Pipelines,radiographische Untersuchungen, Ultraschallpruefung, visuelle Kontrolle, Qualitaetsmanagement im Pipelinebau, Molchungen, Fehlerauswertungen beim Bau von Pipelines.Sonja Felber0.1

PIPELINE ENGINEERINGABSTRACTPipelines offer an economically and ecologically reliable, good solution for the transport of liquids and gases worldwide. Even in a small country like Austria they are analmost indispensable means of transport, especially for natural gas.THEORETICAL PART:This work addresses the most important questions industrial engineers and scientistsare confronted with, when working in the fields of project planning, construction, andoperation of pipelines.Starting from a description of the situation in Austria and a comparison with worldwide solutions, the following fields are examined: Damage caused by cracks and corrosion, as well as countermeasures; materials used in pipeline construction (ferriticpearlitic, bainitic, and duplex-steels) and their processing properties (especially concerning welding technology); aspects of materials testing and quality management.EXPERIMENTAL PART:Based on numerous welding-technological and fracture-mechanical examinations,the influencing parameters and limits, essential for a problem-free construction andreliable operation of pipelines, are discussed and limits established.MATHEMATICAL PART:This part offers mathematical approaches for the predetermination of welding-technological and fracture-mechanical parameters, to be considered during the construction and the subsequent testing of pipelines.0.2Sonja Felber

PIPELINE ENGINEERINGKURZREFERATRohrleitungen stellen weltweit eine oekonomisch und oekologisch zuverlaessige undgute Loesung zum Transport fluessiger und gasfoermiger Stoffe dar. Auch in einemkleinen Land wie Oesterreich sind sie kaum zu ersetzende Transportmittel, vor allemfuer Erdgas.THEORETISCHER TEIL:Diese Arbeit ist eine Zusammenstellung der wichtigsten Details, mit denen Ingenieure im industriellen Einsatz und Wissenschafter konfrontiert werden, wenn sie im Bereich Projektierung, Bau und Betrieb von Rohrleitungen arbeiten.Ausgehend von einer Beschreibung der Situation in Oesterreich und einer Gegenueberstellung zu weltweiten Loesungen, sollen die Bereiche: Schadensfaelle durchRisse und Korrosion und Gegenmassnahmen, verwendete Werkstoffe (ferritisch-perlitische, bainitische und Duplex-Staehle) und ihre Verarbeitungseigenschaften (besonders schweisstechnische), prueftechnische Aspekte und Qualitaetssicherung behandelt werden.EXPERIMENTELLER TEIL:Anhand von zahlreichen schweisstechnischen und bruchmechanischen Untersuchungen werden die Einflussgroessen fuer eine problemlose Fertigung und einenzuverlaessigen Betrieb von Pipelines bestimmt und ihre Grenzen festgelegt.RECHNERISCHER TEIL:Weiters werden rechnerische Ansaetze fuer die Vorherbestimmung der schweisstechnischen und bruchmechanischen Parameter, die sich bei der Fertigung undeiner anschliessenden Pruefung ergeben, geliefert.Sonja Felber0.3

PIPELINE ENGINEERINGPREFACEThe first German edition of this book has been written as a habilitation at ViennaUniversity of Technology. The author is thankfull for suggestions to this book.The individual introductions to the various subjects are intended also to open thisbook to interested experts with different knowledge and background, and not justonly to scientifically qualified readers.Hopefully the variaty of information by the dissemination of this book will be suppliedto an interested and attentive circle of readers, to lead to a better understanding ofthe problems possibly occurring with ferritic-pearlitic steels, bainitic steels, or duplexsteels, especially with regard to the properties of the used materials, their processsing (especially welding technology), the following testing (e.g. destructive and nondestructive testing, fracture mechanical, metallographical, and fractographical methods), the quality management, the ecology, and the economy.Ao.Univ.Prof. Dipl.-Ing. Dr.techn. Sonja Felber0.4Sonja Felber

PIPELINE ENGINEERING0 CONTENTpage1Introduction1.11.1Development and Use of Pipeline-Steels1.51.1.1Development of Pipeline-Steels1.51.1.2Use of Pipeline-Steels1.111.1.2.1Natural Gas and Oil Pipelines in Austria1.121.1.2.2Natural Gas and Oil Pipelines in Europe1.191.1.2.3Natural Gas and Oil Pipelines in America1.261.1.2.4Natural Gas and Oil Pipelines in Australia and New Zealand1.311.1.2.5Natural Gas and Oil Pipelines Worldwide1.331.2Development and Use of Duplex-Steels1.361.2.1Development of Duplex-Steels1.361.2.2Use of Duplex-Steels1.381.3Failures, Causes, and Avoidance1.401.3.1Failures of Pipelines1.401.3.2Crack-Arrestors for Pipelines1.53Crack-Arrestors Causing the Crack to Run Into a PipeSection of Reduced Hoop StressCrack-Arrestors Using Application of a Pre-StressedBandage to Certain Sections of the PipelineCrack-Arrestors Using Inserting Pipe Sections with HighFracture ToughnessCrack-Arrestors Causing the Crack to Run Into a Row ofSlotsCrack-Arrestors Preventing the Flap OpeningCrack-Arrestors Preventing the Flap Opening by Means ofLarge Masses Along the Pipe Length, Which Must n of Pipelines1.591.3.4Corrosion Protection Against External Corrosion1.601.3.4.1Coating of Pipes1.60Temporary CoatingPlant-Applied CoatingSonja Felber1.611.620.5

PIPELINE ENGINEERINGCoating in the FieldCoatings for Extreme Service Requirements1.641.651.3.4.2Cathodic Corrosion Protection (CCS)1.671.3.5Corrosion Protection Against Internal Corrosion1.711.3.6Standards, Rules, and Regulations1.751.3.7Determination and Evaluation of a Defect Analysis1.842Materials for Pipelines2.12.1Pipeline-Steels2.32.1.1Chemical Composition2.32.1.1.1Standards and Designations2.32.1.1.2Alloying Elements2.92.1.1.3Effect of Alloying rVanadium, Niobium, pper, Nickel, sical Properties2.272.1.2.1Phase Diagrams, Transformation Behavior2.272.1.2.2Precipitation Behavior2.34Carbides, NitridesV-Nitride(Si, Corrosion Behavior2.372.372.372.382.382.382.38Sonja Felber

PIPELINE ENGINEERING2.1.3Mechanical 522.1.4.2Forming2.54Thermomechanical Rolling2.1.4.3Pipe ManufactureProduction of Longitudinal Welded Pipes (U-O-Process)Production of Spiral Welded Pipes2.552.662.682.702.1.5Manufacturing Properties2.722.1.6Standards and Technical Terms of Delivery2.722.1.7Tested Pipeline-Steels2.802.1.7.1Pipeline-Steel X702.80Longitudinal Welded Pipes Made of X70Spiral Welded Pipes Made of X702.822.822.1.7.2Pipeline-Steel X802.832.1.7.3Joined Spiral Pipes Made of X70 and X802.872.1.7.4Comparison of Pipeline-Steels X70 and X802.872.1.7.5Pipeline-Steel X1002.892.1.7.6Pipeline-Steel X1202.902.2Duplex-Steels2.912.2.1Chemical Composition2.912.2.1.1Standards and Designations2.912.2.1.2Alloying Elements2.982.2.1.3Effect of Alloying urNitrogenChromiumCopperMolybdenumNickelSonja 62.1170.7

PIPELINE ENGINEERINGTungsten2.1192.2.2Physical Properties2.1192.2.2.1Phase Diagrams, Transformation Behavior2.1202.2.2.2Precipitation Behavior2.124α (Alpha )- or δ (Delta )- and G-Phaseγ2-Phaseσ(Sigma)-Phaseχ(Chi)- and η(Eta)-Phaseχ(Chi)-Phaseη(Eta)-, R- or .1362.1382.1392.1392.1402.2.2.3Corrosion Behavior2.1422.2.3Mechanical 2.1492.2.4.2Forming2.1502.2.4.3Pipe Manufacture2.1542.2.5Manufacturing Properties2.1552.2.6Standards and Technical Terms of Delivery2.1552.2.7Tested Duplex-Steels2.1572.2.7.1Duplex-Steel 1.4462 (Rolled)2.1582.2.7.2Duplex-Steel 1.4462 (Forged)2.1592.3Comparison of Pipeline-Steels and Duplex-Steels2.1603Weldability and Heat Treatment3.13.1Weldability and Heat Treatment of Pipelines Made of PipelineSteels3.3WeldabilityHeat Treatment3.1.1Welding AbilityCarbon Equivalent (Ceq) and Hardness0.83.33.33.43.4Sonja Felber