PRECISION WELDED TUBING. Stainless Steel Duplex Nickel Alloys Titanium

Transcription

1 PRECISION WELDED TUBING Stainless Steel Duplex Nickel Alloys Titanium

2 Gibson Tube Products Gibson Tube, Inc. has set the standard for precision welded tubing in several different materials including: Stainless Steel Duplex Stainless Steels Nickel Alloys Commercially Pure Titanium Sizes range from 1/16" through 1-1/2" outside diameter and wall thicknesses from.010" through.125". Tubing is available in straight lengths to 68 feet or coils up to 90,000 feet

3 Gibson Tube Markets Gibson Tube, Inc. is a key provider of precision welded tubing to such diverse industries as: Power Generation Oil & Gas Beverage Chemical Processing Desalination Automotive Medical Gibson Tube s diverse customer base has extended beyond North America to include international customers in Asia, Africa, Europe and South America. 3

4 Table 1 PRODUCT INFORMATION PRODUCTS SIZES (Inches) LENGTHS GRADES STANDARD TOLERANCES O.D. WALL O.D. WALL LENGTHS WELDED AUSTENITIC STEEL BOILER, SUPER HEATER, HEAT-EXCHANGERS & CONDENSER TUBES Specifications ASTM-A 249, ASME-SA 249, ASTM 789 and ASTM-A 688 3/ Random or cut lengths up to 304/304L, Under 1" ±10% (avg) Randoms to to 68' and coils 316/316L, ±.004" +18% - 0% +1" or +2" 1-1/ /317L, (min) Cuts +1/8"-0" 321 1" to 1-1/2" ±.006" Duplex 2205 PRESSURE & CORROSION TUBING Meets or exceeds requirements for welded ASTM-A 269, ASTM-A 450, ASTM-A 632, ASTM 789 and ASTM-B 704 BEVERAGE TUBING For low pressure applications. Fully annealed. 1/ Random or cut lengths up to 304/304L, ±.005" ±10% Randoms to to 40' and coils 316/316L, +1" or +2" 1-1/ ,825 Cuts +1/8"-0" 625, G-31 Plus, Duplex /4.020 Random or cut lengths up to 304/304L ±.005" ±10% Randoms 5/16 to 40' and coils in excess of +1" or +2" 3/ ,000' Cuts +1/8"-0" 1/ SUBSEA UMBILICAL TUBING ASTM A 789 ASTM A 269 GRADE 2 TITANIUM Specification ASTM B338 and ASME SB338; Condenser and Chemical Process Applications 3/8.039 Cut lengths to 60 ; 316L, Zinc ±.005" ±10% Coils to to coils to 90,000 Clad Lean to 1-1/2.125 Duplex (19D, 90, , 2003); Super Duplex (2507, Zeron 100 ) 1/2.016 Cut lengths to 60 Grade 2 Under 1 ±10% Randoms to to and coils ±.004" +1 or 2 1-1/2.083 Cuts + 1/8-0 1 to 1-1/2 ±.005" NOTE: 1) Metric sizes available Gibson Tube, Inc. Control Line Tubing

5 Table 2 COMPOSITION (%) OF VARIOUS STAINLESS STEELS, NICKEL ALLOYS, & TITANIUM LEAN LEAN SUPER ALLOY DUPLEX DUPLEX DUPLEX DUPLEX TITANIUM GRADE L L 825 G-31 Plus D** 2101** 2507 Grade 2 UNS Designation S30400 S30403 S31600 S31603 N08825 NO8031 NO6625 S32205 S32001 S32101 S32750 R50400 Carbon (C) max * * max. Manganese (Mn) max to to Phosphorus (P) max Sulphur (S) max Silicon (Si) max Chromium (Cr) 18.0 to 18.0 to 16.0 to 16.0 to 19.5 to 27.0 to 20.0 to 22.0 to 19.5 to 21.0 to 24.0 to Nickel (Ni) 8.0 to 8.0 to 10.0 to 10.0 to 38.0 to 31.0 to to 1.0 to 1.35 to 6.0 to min Molybdenum (Mo) 2.0 to to to to 8.0 to 3.0 to to 3.0 to Nitrogen (N) to 0.14 to 0.05 to 0.20 to 0.24 to N= max Other Elements Fe=Bal Cu=1.5 to 3.0 Al=0.2 max. Ti=0.6 to 1.2 Cu = 1.0 to 1.4 Cu=.50 max H=.015 max Fe=.30 max Ti= Balance *Maximum carbon content of 0.04% acceptable for drawn tubes. **Also available as a Zinc Clad product (refer to page 6). Gibson Tube, Inc. Weld Mills 5

6 Oil andgas Gibson Tube has been a key supplier to the oil and gas industry for three decades. The unique ability to produce pressure coils up to 90,000 feet in length while minimizing the number of girth welds, has made Gibson Tube an important supplier to oil and gas customers around the world. Having developed an excellent reputation in this industry, Gibson Tube is able to develop specific process plans for both downhole and umbilical customers. As deepwater exploration and installations continue to escalate, Gibson Tube is developing cost effective, quality alternatives to seamless product offerings. Zinc Clad, Lean Duplex coiled tubing produced by Gibson Tube, which combines the high strength characteristics of Lean Duplex stainless steel with the anodic corrosion protection provided by zinc, continues to gain favor in the subsea umbilical market. Downhole Applications Include: Control Lines Chemical Injection Lines Hydraulic Lines Capillary Tubing Electrical Lines Existing Shallow Water Platform Seabed depth 600 feet Oil and gas export pipelines Downhole Product Options Include: L G-31 Plus Super Duplex 2507 Umbilical Applications Include: Control Lines Flying Leads Electrical Lines Chemical Injection Lines Hydraulic Lines Umbilical Product Options Include: Zinc Clad Lean Duplex 316L Super Duplex 2507 Zinc Rod By employing multiple non-destructive testing techniques, Gibson Tube is able to offer the ultimate in quality assurance to its oil and gas customers: Film Based X-ray Digital Radiography Ultrasonic Testing Dual Frequency Eddy Current Hydrostatic Testing Air Underwater Testing Metallographic Examination 2 Miles Seabed depth 5,000 feet Distance from platform miles Clustered wells Satellite Subsea System Manifold

7 Power Generation What are the key components of Gibson Tube s success in the power generation market (as well as other markets)? 99% On Time Delivery Performance Solid Quality Program Strong Technical Team Advanced Multiple Testing Procedures Gibson Tube s product offerings for heat exchangers, steam condensers, and desalination installations include 304L, 316L, duplex stainless steel alloys and titanium. Titanium Over the past 40 years, titanium has gained worldwide acceptance for numerous heat exchanger and condenser applications. Titanium tubing, which exhibits a very high strength to density ratio, has proven to be a cost effective solution for many installations. Gibson Tube Titanium Size Range Wall Thickness.016" through.083" Outside Diameter.500" through 1.500" Length To 60' Note: 1) See Table 6, page 9 for titanium tubing pounds per foot. 2) Coiled titanium tubing available upon request. 3) Metric sizes available. 7

8 Table 3 AUSTENITIC STAINLESS STEEL TUBING IN POUNDS PER FOOT WALL THICKNESS (Gauges & Inches) TUBE O.D. (Inches) / / / / / / / / / / / / / / / / / / The formula used to calculate the weights shown in Table 3 is: Pounds per foot = (D-t) t Where: D = Outside diameter, inches t = Wall Thickness, inches Table 4 CONVERSION FACTORS TO DETERMINE TUBING WEIGHTS FOR OTHER ALLOYS To determine weights of tubing made of other alloys, multiply weight per foot shown in Table 3 by the applicable conversion factor shown below. MATERIAL FACTOR ALLOY G-31 Plus ALLOY ALLOY DUPLEX SUPER DUPLEX LEAN DUPLEX

9 Table 5 PHYSICAL PROPERTIES OF STAINLESS STEEL, NICKEL ALLOYS AND TITANIUM IN THE ANNEALED CONDITION AT AMBIENT TEMPERATURE UNLESS NOTED COEFFICIENT OF *TENSILE STRENGTH *YIELD STRENGTH ELONGATION IN TWO MODULUS OF ALLOYS THERMAL EXPANSION (psi).2% OFFSET (psi) INCHES (%) ELASTICITY (x10 6 psi) (in./in./ F x 10-6 ) ,000 30, L 70,000 25, ,000 30, L 70,000 25, ,000 30, ALLOY G-31 Plus 115,000 65, (200 F) ALLOY ,000 35, (200 F) ALLOY ,000 60, (200 F) DUPLEX ,000 70, TITANIUM Grade 2 50,000 40,000 to 65, * Tensile and yield strengths are minimums. Table 6 TITANIUM TUBING IN POUNDS PER FOOT - GRADE 2 BWG/Avg. Wall TUBE O.D. (Inches) /2 (.500) /8 (.625) /4 (.750) /8 (.875) (1.000) /8 (1.125) /4 (1.250) /8 (1.375) /2 (1.500) For weight of minimum wall tube: Multiply the above weight by 1.1 The formula used to calculate the weights in Table 6 is: Pounds per foot = (D-t) t Where: D = Outside diameter, inches t = Wall Thickness, inches Gibson Tube laboratory. 9

10 Table 7 ESTIMATED INTERNAL BURST PRESSURE For Types 304 & 316 Stainless Steel Tubing at ambient temperature O.D. SIZE (Inches) WALL GAUGE NO. BURST PRESSURE (psi) O.D. SIZE (Inches) WALL GAUGE NO. BURST PRESSURE (psi) ,000 1/ , , ,950 3/ , , , , ,800 1/ , , , , , ,410 5/ , , , , , ,200 3/ , , , , , ,400 1/2 5/ , , , , , ,400 INTERNAL BURST PRESSURE Barlow s Formula can be used to estimate the theoretical internal bursting and working pressure of tubing. Simply stated, Barlow s Formula is: P = 2 St D Where: P = Burst pressure, psi S = Tensile strength of material, psi (75,000 psi for types 304 & 316) t = Wall thickness, inches D = Outside diameter, inches ,760 5/ , , , ,000 3/ , , , , ,000 7/ , , , , , , , , , , / , , , , /8 1-1/ , , , , , , , , ,300 Using this formula, reasonable estimated burst pressures can be calculated. Yield pressures can be estimated as well by substituting Y (yield strength of material, psi) for S in the formula. Note that actual burst values may vary from the theoretical values listed in Table 7 due to variations such as actual wall thickness, diameter to wall ratios, material properties and installation conditions. These theoretical values, however, are adequate for estimating required tubing sizes. EXTERNAL COLLAPSE PRESSURE Contact your Technical Representative for information concerning collapse pressure. API (American Petroleum Institute) bulletin 5C3 provides formulas to estimate external collapse pressure

11 Table 8 TABLE OF SPECIFICATIONS ASTM/ASME-SA 249 ASTM-A 269 ASTM/ASME-SB 338 ASTM-A 450 ASTM-A 632 ASTM-A 688 ASTM-B 704 ASTM-A 789 Specification titled Welded Austenitic Steel Boiler, Superheater, Heat Exchanger and Condenser Tubes. This specification covers pressure tubes made from a variety of austenitic steels. Specification titled Seamless and Welded Austenitic Stainless Steel Tubing for General Service. This specification covers a variety of grades of austenitic stainless steel tubing. Standard specifications for Seamless and Welded Titanium and Titanium Alloy Tubes for Condensers and Heat Exchangers. Specification titled General Requirements for Carbon, Ferritic and Austenitic Alloy Steel Tubes. This covers common requirements for ASTM tubular product specifications. Specification titled Seamless and Welded Austenitic Stainless Steel Tubing (Small Diameter) for General Service. This specification covers a variety of grades of austenitic stainless steel tubing in sizes under 1/2" down to.050" outer diameter wall thickness less than.065" down to.005". Specification titled Welded Austenitic Stainless Steel Feedwater Heater Tubes. This specification covers welded austenitic stainless steel tubes used in feedwater applications. Size range is 5/8" to 1" outside diameter inclusive and walls of.028" and heavier. Specification also covers U-bends. Specification titled Nickel-Alloy (UNS NO 6625 & NO8825) Welded Tube. This specification covers welded tubing of both alloy 625 and 825 in an annealed condition. Standard specification for seamless and welded ferretic/austenitic stainless steel tubing for general service. This specification covers various grades of duplex stainless steels. Rockwell Hardness Testing Pressure Tubing Production 11

12 Gibson Tube Quality Gibson Tube is committed to exceeding the requirements and expectations of our customers. Continuous improvement is the driving force of our quality program. Some of the destructive test procedures routinely performed at Gibson Tube to ensure quality control and compliance to specifications. This statement truly summarizes the Gibson Tube philosophy. In fact, it is a way of life with each and every employee. The entire process of fulfilling an order, from administration through production and shipment, is designed to exceed our customer s expectations. The extensive education, training and empowerment which all employees experience results in a passion for service. One visit to our facility will confirm the Gibson Tube corporate philosophy. ADDITIONAL TESTS PERFORMED BY GIBSON TUBE Film Based X-ray Digital Radiography Ultrasonic Testing Dual Frequency Eddy Current Hydrostatic Testing Metallographic Examination Air Underwater Test Corrosion Testing Manufacturer Size/Type

13 Quality Assurance is integrated into every step of our manufacturing process. Standards have been established for all product lines to assure consistency in our production and to support a delivery track record of 99% on-time. For large projects such as subsea umbilical systems, downhole oil and gas control lines, or steam condenser projects, Gibson Tube develops specific process plans. High Profile Project (HPP) designation provides the ultimate in quality assurance for complex projects. In addition to being ISO compliant, Gibson Tube recognizes the value of being on the leading edge of developing advanced film-based X-ray, digital radiography and ultrasonic testing techniques. Specification Country of Origin Shop Order Number Tray Number Test Operator Number Heat Number Time & Date in Military Time (ABOVE) Line marking is an important key to maintaining quality control and traceability. Complete product description, specifications, manufacturing and testing information are included. 13

14 Gibson Foundations The Gibson Tube story begins in 1962, when Glenn J. Gibson, founder, set up shop with a revolutionary small diameter tubing mill which he designed and built. From this humble beginning, Glenn s company grew through the next 4 decades and became recognized as the world leader in small diameter stainless steel tubing. In the 80 s, Glenn s son Jim assumed leadership of the company, growing the company while retaining his father s philosophy of exceeding customers expectations through continuous improvement. Despite Jim s retirement in 2003, this philosophy remains instilled in each employee. What sets Gibson Tube apart from other tubing manufacturers? A customer focus philosophy shared by every employee. Growth through product diversification. Gibson Tube is now providing not only Stainless Steel Tubing, but Nickel, Duplex Stainless Steel and Titanium as well. Unique capabilities such as specialty coiled tubing up to 90,000 feet in length. Technical leadership, ranging from state of the art production techniques to leading edge testing procedures. The ability to encapsulate electrical wire or fiberoptics in coiled tubing. Solid alliances with select raw material vendors which help feed our growth. A solid Quality System built to satisfy even the most demanding requirements. Through four decades, Gibson Tube has built a loyal customer base which includes select service centers, power companies, oil and gas corporations as well as oil and gas service companies. On-going capital investment fuels our growth. In 2002, we added an additional 55,000 square feet to our facility; the Gibson Tube complex now exceeds 255,000 square feet including administrative offices and manufacturing. Twenty-eight gas tungsten arc and laser weld mills are housed in the facility. 14 We extend an invitation to you to visit us in North Branch, New Jersey; we are located approximately one hour from New York City

15 Glossary of Terms ANNEALING The process of controlled heating and cooling a metal to achieve a reduction in hardness, remove stress, and to homogenize the material. ASME American Society of Mechanical Engineers. ASTM American Society for Testing Materials. AUSTENITIC The family of chromium-nickel stainless steels often referred to as the 300 series of 18-8 group. These steels can only be hardened by cold working. In the annealed condition they are nonmagnetic. In general, they have good corrosion resistance, good formability and are readily weldable. BRIGHT ANNEALING An annealing process which employs a reducing gas atmosphere. Stainless steel tubing annealed in this manner has a bright, clean appearance and is free from any oxides or scale. The process eliminates the need for the old fashioned acid bath pickling operations. BURST PRESSURE The internal pressure that will cause a piece of tubing to fail by exceeding the plastic limit and tensile strength of the material from which the tube is fabricated. COLD SINKING The process of pulling a tube through a carbide die to reduce the diameter of the tube. Small tubes with very high thickness-to-diameter ratios are commonly produced this way in long lengths. The sinking of the tube is done at room temperature, i.e., Cold. CONCENTRICITY Used to describe tubing where the center of its inside diameter is consistent with the center of its outside diameter resulting in no variation of wall thickness. By virtue of the fact that welded tubing is fabricated from precision rolled flat stock, concentricity is inherent with a roll-formed, welded tube. DESTRUCTIVE TESTING Any of the mechanical tests performed on an expendable sample of tubing to check physical properties. These tests include: tensile, yield, elongation, hardness, flare, flattening, bend and burst. ECCENTRICITY Opposite of concentricity, resulting in variations of wall thickness. This is a problem associated with seamless tubular products. EDDY CURRENT TESTING A nondestructive testing procedure which is a continuous process performed on the tubular products during fabrication and in final inspection. It is by nature an electrical test which checks tubing (against a calibrated standard) for possible defects such as holes, cracks, gouges, etc. on both inside and outside surfaces of the tube. All eddy current testing at Gibson Tube is done in accordance with ASTM-E 426. GAS TUNGSTEN ARC WELDING (GTAW) An arc welding process that uses an arc between a tungsten electrode (nonconsumable) and the weld pool (base metal of strip). A high quality full fusion weld is achieved. The process can be performed with or without the addition of filler metal. The GTAW process is also commonly referred to as Tungsten Inert Gas (TIG). HARDNESS Resistance to penetration by an indentor which may be a ball, cone or pyramid shape. The indentor is forced into the surface by application of a known load. The relationship of load to area or the depth of indentation is the measure of hardness. Gibson Tube uses Rockwell and Vickers hardness tests. Hardness generally correlates to the ultimate tensile strength of the material. HYDROSTATIC TESTING A nondestructive test procedure that checks for holes, cracks or porosity. Tubing is pressurized internally with water to a high pressure, but does not exceed material yield strength. I.D. Inside diameter of a tubular product. LASER BEAM WELDING (LBW) A fusion joining process that produces coalescence of materials with the heat obtained from a concentrated beam of coherent, monochromatic light impinging on the joint to be welded. Generally an autogenous weld with no filler metal added. LINE MARKING A continuous strip of information that is printed with an inert ink along the longitudinal surface of the tube after final inspection. This data includes ASTM spec number, material identification, size and wall thickness, as well as a heat number identity. Full traceability is possible with any line marked product. MEAN COEFFICIENT OF THERMAL EXPANSION This is the amount that a material will grow in size when subjected to a temperature rise. It is measured in inches/inch/ F. This number multiplied by the length of the tubing (in inches) and by the temperature rise (in F) indicates how much the tube length will expand (in inches). If the temperature decreases, the tube will shrink by a similar amount. MODULUS OF ELASTICITY A ratio of stress to strain. Used in engineering calculations to determine rigidity and deflections. The higher the number, the more rigid the item will be for a given load. The units are in pounds per square inch (psi). NONDESTRUCTIVE TESTING See Eddy Current Testing or Hydrostatic Testing. O.D. Outside diameter of a tubular product. ORBITAL WELD A circumferential, full fusion butt or girth weld used to join together two lengths of tubing. It is a GTAW welding process similar in nature to the longitudinal weld seam of a welded tubular product. OVALITY A quantitative measurement of how round a tube is by comparing width to height. Limits are specified on the appropriate ASTM specification of a product. PASSIVATION A protective layer of oxides on the surface of a metal which resists corrosion. This passive oxide layer is the chief reason why stainless steels have such good corrosion resistant properties. It is a natural phenomenon, but can be accelerated by special passivating solutions that can be applied to tubular products by an optional process. psi Common engineering abbreviation for pounds per square inch. A measurement of stress in a material. TENSILE STRENGTH The maximum load per unit area that a material is capable of withstanding before it fails (pulls apart). Units are in psi. ULTRASONIC TESTING The scanning of material with an ultrasonic beam, during which reflections from faults in the material can be detected: a powerful nondestructive test method. WELDED TUBING Tubular products which are roll formed and then joined continuously along a longitudinal seam by a material fusion process. The process employed at Gibson Tube is Gas Tungsten Arc Welding (GTAW). See Gas Tungsten Arc Welding and Laser Beam Welding, (LBW). YIELD STRENGTH The load per unit area that a material can withstand before permanent deformation (nonelastic) occurs. It is conventionally determined by a.2% offset from the modulus slope on a stress/strain diagram. Units are in psi and referenced to.2% offset in most literature. 15

16 PRECISION WELDED TUBING Stainless Steel Duplex Nickel Alloys Titanium Gibson Tube, Inc. 100 Aspen Hill Road P.O. Box 5399 North Branch, NJ USA TEL: FAX: TOLL FREE Copyright 2004, Gibson Tube, Inc. all rights reserved. Printed in the USA. The material provided herein reflects typical or average values. It is not a guarantee of maximum or minimum values. Suggested applications in this material are used solely for purposes of illustration, and are not intended in any form to be either expressed or implied warranties of fitness for any particular uses.