GEDİK TECHNOLOGY DAYS

Transcription

1 GEDİK TECHNOLOGY DAYS 10 th Feb Pendik Green Park Hotel,Istanbul ORBITAL WELDING TECHNOLOGY OF NATURAL GAS PIPELINES Dr. Didem GENÇKAN GEDİK Welding Business Development and Project Responsible

2 Demand to Natural Gas and Consumption Natural Gas Consumption in the world Estimated Europe Energy Need * Ekonomik İşbirliği ve Kalkınma Örgütü (OECD) Estimated natural gas consumption in the world %1,6 /year rising; ,4 trillion m trillion m 3 Estimated Europe natural gas need until 2030, %1,5-3 / year rising is expected. U.S International Energy Agency / International Energy Outlook 2013

3 Europe/ Natural Gas Import International Energy Agency

4 Turkey/ Natural Gas Import Country Based TURKEY is dependent to Russia for natural gas supply. Doğal gaz piyasası sektör raporu 2012, EPDK Natural Gas Market Report 2012, EPDK

5 Natural Gas Demand and Potential Transportation Route ARKET Europe BCM: bilion m 3 (2020) ENERGY ENERGY Enerji ve Tabii Kaynaklar Bakanlığı, 2013 TURKEY has an important energy corridor role intercontinental.

6 Trans Anatolian Natural Gas Pipeline Project (TANAP) Azerbaijan > Georgia > Turkey > Greece >Bulgaria Pipe diameter: 56, 48 inch X70 çelik borular /19 mm,23 mm,28 mm Pipeline length: 1850 km Quantity of transported gas: 2026, 31 billion m 3 /year Operating pressure: 95 bar Run-up time:

7 Trans Adriatic Natural Gas Pipeline Project (TAP) Greece > Albania > Adriatic Sea > Italy Pipe diameter: 48 inch (on-shore) ve 36 inch (off-shore) X70 steel pipes Pipe thickness: mm (on-shore), mm (off-shore) Pipeline length: 870 km Quantity of transported gas: 20 billion m 3 /year Operating pressure: 95 bar Run-up time:

8 Türk Akım Natural Gas Pipeline Project (South Stream) Rusia >Turkey> Bulgaria Pipe diameter: 32 inch, TMCP (SAWL) Pipe thickness: 39 mm Pipeline length: 650 km +250 km Quantity of transported gas: 63 billiom m 3 /year Operating pressure: 92 bar Run-up time:

9 Iran-Turkey-Europe Natural Gas Pipeline Project (ITE) İranian > Turkey > Greece > Germany Pipe diameter: 56 inch X70 çelik boru Pipeline length: 5000 km (1769 km Turkey) Quantity of transported gas: 35 billion m 3 /year Operating pressure: 92 bar Run-up time: 2016

10 Advantages of Pipelines Economic Eco-friendly Safer than road and rail Pipe diameter and grade effect the capacity. Route, outside the city Resistant to severe weather conditions

11 Development Pipeline Steels API Boru Hattı Çelik Kalitesi Akma Mukavemeti X100 X 80 X70 X65 X60 X52 Çelik Alaşımı Proses Mikroyapı % 0.20 C+V+ (Nb) N Ferrit + % 30 Perlit % 0.10 C +Nb (+V) TM Ferrit + % 10 Perlit % 0.07 C+Nb+Ti+Mo TM+ACC/DQ Beynit (+Martensit) % 0.08 C+Nb (+Ti) TM + ACC Ferrit + % 50 Beynit TOKLUK (N: Normalize haddeleme, TM: Termomekanik haddeleme, DQ: Doğrudan soğutma, ACC: Hızlı soğutma). H.G. Hillenbrand, A. Liessen, G. Knauf: Pipeline Technology, Elsevier,2000.

12 Advantages of High Strength Pipe Steels Pipe thickness decrease Low transportation costs Less welding consumables Grade of steel increased (X52 X80) DECREASE IN COSTS Reduction at welding time Better quality and mechanical properties Work under greater pressure efficiency on transport capacity

13 Demands for Weld Area Reliable, no defect: Pore, slag, crack free Carbon Equvalent: %C > 0.12 C eş < 0.42 at HAZ area, Toughness and Strength Cold cracking and brittleness Impact value: API 5L/ISO 3183; Steel pipe X80; Çap< 1422 mm, 0 C 27J Steel pipe X80; Çap 1422 mm, 0 C 40J %C 0.12 C eş < 0.22 Hardness : Weld and HAZ areas < 275 HV Yield and Tensile Strength: (σ Yweld > σ YBM ) Fracture: BM

14 Welding and Automation on Pipelines Manuel Metal Arc Welding Time Labor force Cost Contiunity on weld quality Weld conditions

15 Portable cabin used during the welding outside (Pipeline from Russia to Germany) DEMAND/TARGET: Fast and quality weld

16 Orbital Welding Technology Orbital welding systems will be used in TANAP Pipeline Construction Project.

17 Orbital Welding Technology Advantages to manuel welding; High speed, continuous and economic High quality root, hot, filler and final passes Welding parameters can be adjust before welding Minimum operator using Full penetration Suitable for position welding Available for almost all pipe sizes (DN 250 and larger) High quality in all wall thicknesses Ability to work with generator at construction site Setting of all welding parameters and functions electronically

18 Orbital Welding System Tractor Power source Stainless rail Wire feeder Control center Working panel Control panel

19 Working Principle of Orbital Welding System tractor Rail Steel pipe

20 Weld Direction and Welding Consumables ROOT PASS Solid Wire Metal Flux Cored Wire 12 clock pos. 6 clock pos. FILLER PASS Rutile Flux Cored Wire 6 clock pos. 12 clock pos.

21 Flux Cored Wire (FCW) arc stabilizer, slag formers,alloying elements, gasifiers, deoxidizers, denitrifiers etc.. Cu and Cu-Free Flux Cored Wires

22 Flux Cored Wire (FCW) Flux optimise the metallurgy and chemistry of weld metal Rutile, basic, stainless and metal flux cored wires Different configurations Higher metal deposition Position welding Continously, suitable for automation a: şerit sac b: öz Seamless Butt Lap Heart shape

23 Weld Groove Preparation WELD JOINT GEOMETRY MISALIGNMENT

24 Pipe Alignment System (Transco project) Internal Pneumatic Line Up Clamps

25 Preparations for Welding Preheating Boru et kalınlığı ve C eş değerine göre belirlenir. Çatlama problemi, nem alma vb. Cleaning of weld groove Yağ, kir, pas vb. istenmeyen birikintiler

26 Orbital Welding System Working Plan for Field Welding

27 Orbital Welding Application for X80 Grade Pipes API 5L X-80 Pipe 56 inch spirally welded pipe W:21,6 mm Ø: 1422 mm Consumables: Root: SG3 Ø: 1,2 mm Filler: Geka Elcor R 110 Rutile FCW Ø: 1,2 mm Shielding gas: %100 CO 2

28 Orbital Girth Welded X80 Pipe Steel Root pass is welded from outside the pipe with orbital welding machine. Root Hot 1. d a) 2. b) d 3. c) d 4. d 5. d Cap 28

29 Mechanical tests according to API 1104 Non-destructive Tests (Radiography) (EN 1435 standard) Destructive Tests Tensile Test Nick-break Test Face, Root and Side Bend Test Hardness Test Impact Test Macro sections (3,6,9,12 clock position) Greater than inch steel pipes

30 X80 Mechanical Test specimens Mechanical Tests Specimes are prepared according to API 1104 standard. 12 clock p. 3 clock p. 6 clock p. 3-6 clock pos clock pos. Mechanical test specimens extracted from 12-3 and 3-6 clock positions of welded pipe.

31 Macro Sections and Nick-break Test Specimens MACRO SECTIONS OF X80 WELDS 3-6 clock pos clock pos. No weld defects in both welds. NICK-BREAK SPECIMENS OF X80 WELDS 3-6 clock pos clock pos.

32 Tensile Test Results for X80 Orbital Girth Welds σ Y (MPa) (MPa) σ y / σ T Rupture Base material All weld Elcor R Weld area BM 12 3 clock pos BM Weld area BM 3-6 clock pos BM σ T 3-6 clock pos clock pos.

33 Charpy V-Notch (Joule) Charpy V-Notch Tests Results for X80 Orbital Girth Welds Ort saat poz. Ort. 3-6 saat poz Temperature ( C) X80 API 5L/ ISO 3183 Steel pipe X80; Çap 1422 mm, 0 C de 40J ~65 J

34 Bend Test Results for X80 Orbital Girth Welds Root bend Side bend Face bend 3-6 clock pos clock pos. No sign of cracking in both welds. Tested at RT.

35 Hardness Test Results for X80 Orbital Gith Weld Hardness (HV 0.2) TS EN ISO / 200 gr force 12-3 clock.p. 3-6 clock.p. Base material 245 Weld HAZ Root

36 FCW + ORBITAL WELDING SYSTEM SAFE AND CONTINUOUS PROCESS HIGH SPEED HIGH & CONSISTENT WELD QUALITY HIGH DEPOSITION RATE ECONOMIC

37 Thank you for your attention.

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