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

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Presentation on theme: "Pre-Installed User: Combining Engineering And And New Technology New Technology Peter Hatcher, P.Eng. Fluor Canada Ltd. March 3, 2004."— Presentation transcript:

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

2 2 Engineering & New Technology u Opportunity Unbounded u Conventional Wisdom

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

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

5 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 6 Engineering & New Technology u Examples of Combining Engineering & Technology l Material of Construction l Fabrication l Mechanical Integrity

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

8 8 Material Selection u Conventional Approach Based on Code listed stainless steel materials: l 321/347 v.g. resistance to sensitization poor resistance to naphthenic acid corrosion l 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 9 Material Selection u Selected Metallurgy Unlisted Material: l 16Cr11Ni2.5MoCb

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

11 11

12 12 Weld Metal

13 13 Larson-Miller Parameter

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

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

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

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

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

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

20 20 Weld Root u With Backing Gas u No Backing Gas

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

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

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

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

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

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

27 27 Correlation Example Accurate Defect Identification Field Sample TOFD Scan

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

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

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

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