Presentation on theme: "Combining Engineering And New Technology"— Presentation transcript:
1 Combining Engineering And New Technology Pre-Installed User:Combining EngineeringAndNew TechnologyPeter Hatcher, P.Eng. Fluor Canada Ltd. March 3, 2004
2 Engineering & New Technology Opportunity UnboundedConventional Wisdom
3 E P CEngineering Procurement & Construction (EPC)
4 EPC – Process Industry Process Industry – Design Engineering ConservativeProcess Industry - ConstructionProven TechnologiesSignificant Capital InvestmentsNew Technology - NIMP!!!!
5 Engineering & New Technology The essence of science: ask an impertinent question, and you are on the way to a pertinent answerJacob Bronowski
6 Engineering & New Technology Examples of Combining Engineering & TechnologyMaterial of ConstructionFabricationMechanical Integrity
7 Impertinent Question #1 Does Material of Construction exist that allows refining of following crude conditions???High conventional corrosion ratesnaphthenic acidpolythionic acidHigh operating temperaturessensitization of stainless steels
8 Material Selection Conventional Approach Based on Code listed stainless steel materials:321/347v.g. resistance to sensitizationpoor resistance to naphthenic acid corrosion316L/317Lv.g. resistance to naphthenic acid corrosionpoor resistance to sensitizationAbove 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
14 Answer # 1 16Cr11Ni2.5MoCbResistance to naphthenic acid attack and sensitizationThin wall allows for optimal heat transfer and stress reductionEliminate need for post weld heat treatmentEliminate 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-SNo Backing Gas (NBG)
17 HistoryFluor previously investigated welding of stainless steels without a backing gas using GTAW processResulted in quality issues and the ability to reproduce acceptable Code welds
18 Process Optimization Optimized selected wire feed speeds High silicon filler metalsShielding gasWelder training
19 NBG Stainless Steel Welding Good appearanceNo NDE defectsGood mechanical characteristicsGood metallurgical structureGood Strauss Corrosion Test resultsGood Pitting Corrosion Test resultsMinimum oxidation on the ID
21 Answer #2 GMAW-s NBG Low repair rate Eliminates backing gas requirementWelder friendlySignificant 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 wallBent-strap test (ASTM D2657)Low probability of detection:
24 Current Practices (Continued…) Traditional UT pulse-echoIneffective for heavy wallHydro testingDerived from metallic systemsViscoelastic plasticsdeformation depends on time and temperaturedoes not ensure long-term performance
25 UT-TOFD Probes Fluor Ultrasonic Probes Patents are pending on this technology and its applicationProbesTransducerReceiverLateral WaveBack Wall EchoUpper TipLower TipOuter Diameter; Outside wallInner Diameter; Back wallFlawWeld
26 Development Work Stage 1 - Laboratory Stage 2 - Field Investigation Calibration blocksDouble-blind test spoolsindications correlated to defectslack of fusion (LOF) identifiedStage 2 - Field InvestigationOperating pipeline, analysis of field weldsStage 3 - Correlation UT-TOFD vs. Destructive TestingLab test spoolsField welds
27 Accurate Defect Identification Correlation ExampleAccurate Defect IdentificationField SampleTOFD Scan
28 Development Work Completed Summary of findingsVisual examinationpoor correlationBackwall echo - lateral wave losssevere lack of fusionMultiple point reflectorsnon-fusion and poor fusionForeign contaminationeasily detectable“Clear” UT-TOFD scanproperly fusedLab SampleBead Profile - High/Low
29 Answer #3 UT-TOFD Current Examination Practices Not equipped to detect heavy wall flaws and faulty weldsLimits thermoplastic: low pressure, non-criticalNew application for pipeline industryLeap in Quality of testingPlastics expansion into pipeline industryUT - TOFD MethodUltrasonic Time of Flight DiffractionReliable - quick - easy
30 Summary Engineering & New Technology Combining Engineering & Technology3 examplesConventional Approaches Not Necessarily OptimumOpportunities Abound