1. Unique Characteristics of Hydraulically Expanded Long Seam Pipe
Jason Norris
Dura-Bond Pipe, LLC
Steelton, PA
Dura-Bond Pipe, LLC
March 22, 2010

2. Content Introduction Mill Configuration Topic Background Information
Discussion Topic
Conclusion
March 22, 2010
Dura-Bond Pipe, LLC

3. Introduction Dura-Bond Pipe, LLC was founded in 2003
Purchased former Bethlehem Steel Corp., Steelton, PA
UOE Mill facilities on the location of Dura-Bond’s Fusion Bond Coating Plant.
Completely refurbished the forming, welding and finishing equipment. Extensively modified welders. Installed laser controlled seam tracking on the ID welders.
Upgraded Ultrasonic Equipment and Radiographic Equipment
Installed a complete destructive testing laboratory and sample preparation machine shop
Achieved API Q1 licensure October 2004
Produced over 240,000 Tons 2006 through 2009
March 22, 2010
Dura-Bond Pipe, LLC

4. Mill Configuration Manufacturing Process Forming and Welding Equipment
UOE Double Submerged Arc Welded Long Seam Pipe
Forming and Welding Equipment
Double Sided Single Pass Planer
End Planer
Long Seam Double Sided Edge Crimper
U press – 7,000 tons
O press – 20,000 Tons
ID/OD Welders
3 - ID Berkeley Welder 2-Wire Continuous Feed Machines
Lincoln Power-Wave Welder System
Laser guided wire feeder heads
3 - OD AC/AC 2- Wire Continuous Feed Welder
Longitudinal seam welding is a “Continuous Welding System” and does not require tacking and run-on or run-off tabs.
March 22, 2010
Dura-Bond Pipe, LLC

5. Mill Configuration Finishing Equipment
Hydraulic Expansion and Hydrostatic Testing
5,000 psi capacity
Double Ended End Beveling Machine
Hydraulic Expansion is the point of today’s discussion
March 22, 2010
Dura-Bond Pipe, LLC

6. Evaluation Systems NDT
Weld seam 100% Fluoroscopic inspection prior to expansion
Ultrasonic Inspection
Long seam system is an 11 channel machine with 7 probes and provides 100% inspection of the weld
Considering replacement with phased array system in 2011
Pipe Body UT system has 4 wheel probes with a 4 channel transducer array in each wheel which provides helical inspection of 100% of the pipe surface.
Weld Radiographic
X-ray of pipe ends with up to 17” of film
Capable of 100% long seam weld x-ray
March 22, 2010
Dura-Bond Pipe, LLC

7. Evaluation Systems Destructive Testing Lab Tensile Testing
Charpy Testing
Drop Weight Tear Testing
Vickers and Rockwell Hardness Testing
Machining facilities for sample preparation
Spectrographic analysis is performed off-site
March 22, 2010
Dura-Bond Pipe, LLC

8. Product Capability Size and Grade Capability Low Strength pipe
A252, API 5LB, API 5L X42
24” OD to 42” OD
thickness to 1.000”
High Strength Pipe 24” OD to 42” OD
API 5L X52 – thickness to 0.850”
API 5L X60 – thickness to 0.825”
API 5L X65 – thickness to 0.800”
API 5L X70 – thickness to 0.775”
API 5L X80 – thickness to 0.750”
Wall thicknesses beyond listed max may be considered.
March 22, 2010
Dura-Bond Pipe, LLC

9. Project Participation
Energy Transfer, 42” & 36” X70
Exco Energy/Regency Gas, 36” X70
Dominion 30” & 36” X70
Northern Natural Gas 30” & 36” X70
El Paso Energy 30” X70
Kern River Gas Transmission 36 “ X70 & X65
Colonial Pipeline 30” X52
Texas Gas 26” & 30” X70
Williams Gas 42” X70
March 22, 2010
Dura-Bond Pipe, LLC

10. Topic Background
Energy needs for North America have been increasing over the past 10 years
Many new pipeline projects, primarily natural gas, have been built especially in the past 3-4 years
Economics of gas transportation have resulted in a desire for increased operating pressures of natural gas lines.
The increased operating pressure goal has resulted in more stringent requirements being placed on the pipeline builders by regulators to assure pipeline safety.
Field hydrostatic testing of in-service pipelines can determine if the line can operate at increased pressures.
After field hydrostatic testing , an inspection pig can be run through the line to determine if deformation (bulging) took place as a result of the test.
If too much deformation has occurred, the situation must be addressed by the operator before approval is granted to operate at a higher pressure.
March 22, 2010
Dura-Bond Pipe, LLC

11. Topic Background
It has been reported that in the process of field testing of pipe, that pipe with lower than expected yield strength has been discovered.
The Question is … How can the owner be sure of the yield strength of every foot of pipe in the line? Plate/coil mills and pipe mills utilize the required sample testing methodology to ascertain compliance with the production specification standard (API 5L).
March 22, 2010
Dura-Bond Pipe, LLC

12. Discussion Topic
The problem of deformed pipe being discovered after field hydrostatic testing revolves around strength issues.
API 5L strength testing is a single random tensile test per 50 or 100 pipe test unit (lot) size. A tensile test unit requires 1 test per 100 pipes in the test unit. Typically a test unit is a “Heat” if it meets the test unit criteria.
Other API 5L required tests have different test unit sizes i.e. weld tensile, guided bend, weld charpy etc.
March 22, 2010
Dura-Bond Pipe, LLC

13. Discussion Topic
The result of tensile test unit sampling is a statistical representation of skelp and pipe results assuming that the processing of the skelp for pipe applications has good process control and the changes in properties from forming are considered.
However, statistically, it is possible that pipe with lower yield strength could “slip” through the system undetected. This possible “slip” could result from a low tensile testing sample frequency of 1-4% depending on test unit size.
Is there a way to detect such an event in production without destructive testing?
March 22, 2010
Dura-Bond Pipe, LLC

14. Discussion Topic
All JCO and UO long seam mills have expansion capabilities for dimensional control.
The two types of expansion methods are:
Hydraulic expansion – pressurized water is used to expand the entire pipe length at once. A set of sizing clamps contains the pipe during the expansion process and helps give the finished pipe its dimensional properties.
Mechanical expansion – uses mechanical “shoes” to expand the pipe. The sizing mandrel expands the pipe incrementally along the length.
March 22, 2010
Dura-Bond Pipe, LLC

15. Discussion Topic Mechanical Expansion Hydraulic Expansion
March 22, 2010
Dura-Bond Pipe, LLC

16. Expansion
March 22, 2010
Dura-Bond Pipe, LLC

17. Expansion Video
March 22, 2010
Dura-Bond Pipe, LLC

18. Discussion Topic
For hydraulic expansion, the pressure system is set up based on the product’s specified minimum yield strength, the diameter and wall thickness.
A unique characteristic of hydraulic expansion is that to fulfill the pressure requirement in this single step process (versus other multi-step systems), the yielding behavior of the entire pipe is monitored with a graphic recording display. This cannot be replicated with a multi-step expansion process.
March 22, 2010
Dura-Bond Pipe, LLC

19. Expander Charts
March 22, 2010
Dura-Bond Pipe, LLC

20. Discussion Topic
What hydraulic expansion means to customer confidence is that the yielding behavior (yield stress) of EVERY pipe can be seen, recorded and documented.
This means that every pipe has a “tensile test” and graphic records can show variations in yield strength from pipe to pipe.
March 22, 2010
Dura-Bond Pipe, LLC

21. Discussion Topic
If a pipe yields lower than the minimum or higher than the maximum values allowed, it can be detected at the hydraulic expander.
An added benefit is that data from expansion records can be used to reveal the Bauschinger Effect on the end product.
March 22, 2010
Dura-Bond Pipe, LLC

22. Setting Up Test Pipe
March 22, 2010
Dura-Bond Pipe, LLC

23. Expander Graphic Normal and Low Yield
March 22, 2010
Dura-Bond Pipe, LLC

24. Other Characteristics
Dimension and Shape
Properly installed and maintained expander dies make exceptionally straight pipe with uniform dimensions along the length of each pipe segment.
Possible field cuts along the pipe length will offer excellent fit to mill finished ends.
Uniform dimensions and shape provide efficient and productive double jointing and fusion bond coating processes.
March 22, 2010
Dura-Bond Pipe, LLC

25. Conclusion
Hydraulic expansion shows the yielding behavior of every pipe expanded.
Strength variations from pipe to pipe can be seen in the hydraulic expander process.
In a sense, every pipe has a “tensile test” performed and documented.
Bauschinger Effect can be evaluated for different chemical compositions and skelp/plate rolling practices.
March 22, 2010
Dura-Bond Pipe, LLC

26. Conclusion
More work needs to be done to study expander yielding behavior and actual pipe strengths to develop correlations.
Potentially, hydraulically expanded pipe can act as a screening mechanism for low strength pipe.
March 22, 2010
Dura-Bond Pipe, LLC

27. Thank you for your attention.
March 22, 2010
Dura-Bond Pipe, LLC