1. Combining Engineering And New Technology
Pre-Installed User:
Combining Engineering
And
New Technology
Peter Hatcher, P.Eng. Fluor Canada Ltd. March 3, 2004

2. Engineering & New Technology
Opportunity Unbounded
Conventional Wisdom

3. E P C
Engineering Procurement & Construction (EPC)

4. EPC – Process Industry Process Industry – Design Engineering
Conservative
Process Industry - Construction
Proven Technologies
Significant Capital Investments
New Technology - NIMP!!!!

5. Engineering & New Technology
The essence of science: ask an impertinent question, and you are on the way to a pertinent answer
Jacob Bronowski

6. Engineering & New Technology
Examples of Combining Engineering & Technology
Material of Construction
Fabrication
Mechanical Integrity

7. Impertinent Question #1
Does Material of Construction exist that allows refining of following crude conditions???
High conventional corrosion rates
naphthenic acid
polythionic acid
High operating temperatures
sensitization of stainless steels

8. Material Selection Conventional Approach
Based on Code listed stainless steel materials:
321/347
v.g. resistance to sensitization
poor resistance to naphthenic acid corrosion
316L/317L
v.g. resistance to naphthenic acid corrosion
poor resistance to sensitization
Above options do not provide Owner the capability to handle potentially highly corrosive process streams with long term reliability.

9. Material Selection Selected Metallurgy Unlisted Material:
16Cr11Ni2.5MoCb

10. Strategy Corrosion Testing Mechanical Properties Formability
Weldability
Aggressive Timeline / Complex Execution

12. Weld Metal

13. Larson-Miller Parameter

14. Answer # 1 16Cr11Ni2.5MoCb
Resistance to naphthenic acid attack and sensitization
Thin wall allows for optimal heat transfer and stress reduction
Eliminate need for post weld heat treatment
Eliminate requirement for soda ash wash during shut down

15. Impertinent Question #2
How can field pipe welding productivity be improved???

16. Welding Stainless Steel Piping
GMAW-S
No Backing Gas (NBG)

17. History
Fluor previously investigated welding of stainless steels without a backing gas using GTAW process
Resulted in quality issues and the ability to reproduce acceptable Code welds

18. Process Optimization Optimized selected wire feed speeds
High silicon filler metals
Shielding gas
Welder training

19. NBG Stainless Steel Welding
Good appearance
No NDE defects
Good mechanical characteristics
Good metallurgical structure
Good Strauss Corrosion Test results
Good Pitting Corrosion Test results
Minimum oxidation on the ID

20. Weld Root
With Backing Gas
No Backing Gas

21. Answer #2 GMAW-s NBG Low repair rate
Eliminates backing gas requirement
Welder friendly
Significant cost savings over other processes

22. Impertinent Question #3
How can we ensure integrity of high pressure high density polyethylene (HDPE) pipeline???

23. Current Practices Visual exam Bent-strap test (ASTM D2657)
Poor correlation to weld quality for heavy wall
Bent-strap test (ASTM D2657)
Low probability of detection:

24. Current Practices (Continued…)
Traditional UT pulse-echo
Ineffective for heavy wall
Hydro testing
Derived from metallic systems
Viscoelastic plastics
deformation depends on time and temperature
does not ensure long-term performance

25. UT-TOFD Probes Fluor Ultrasonic Probes
Patents are pending on this technology and its application
Probes
Transducer
Receiver
Lateral Wave
Back Wall Echo
Upper Tip
Lower Tip
Outer Diameter; Outside wall
Inner Diameter; Back wall
Flaw
Weld

26. Development Work Stage 1 - Laboratory Stage 2 - Field Investigation
Calibration blocks
Double-blind test spools
indications correlated to defects
lack of fusion (LOF) identified
Stage 2 - Field Investigation
Operating pipeline, analysis of field welds
Stage 3 - Correlation UT-TOFD vs. Destructive Testing
Lab test spools
Field welds

27. Accurate Defect Identification
Correlation Example
Accurate Defect Identification
Field Sample
TOFD Scan

28. Development Work Completed
Summary of findings
Visual examination
poor correlation
Backwall echo - lateral wave loss
severe lack of fusion
Multiple point reflectors
non-fusion and poor fusion
Foreign contamination
easily detectable
“Clear” UT-TOFD scan
properly fused
Lab Sample
Bead Profile - High/Low

29. Answer #3 UT-TOFD Current Examination Practices
Not equipped to detect heavy wall flaws and faulty welds
Limits thermoplastic: low pressure, non-critical
New application for pipeline industry
Leap in Quality of testing
Plastics expansion into pipeline industry
UT - TOFD Method
Ultrasonic Time of Flight Diffraction
Reliable - quick - easy

30. Summary Engineering & New Technology
Combining Engineering & Technology
3 examples
Conventional Approaches Not Necessarily Optimum
Opportunities Abound