GEDİK TECHNOLOGY DAYS
10th Feb. 2015
Pendik Green Park Hotel,Istanbul
ORBITAL WELDING TECHNOLOGY
OF NATURAL GAS PIPELINES
Dr. Didem GENÇKAN
GEDİK Welding
Business Development and Project Responsible
Demand to Natural Gas and Consumption
Natural Gas Consumption in the world
Estimated Europe Energy Need
* Ekonomik İşbirliği ve Kalkınma Örgütü (OECD)
 Estimated Europe natural gas need until
 Estimated natural gas consumption in the world
%1,6 /year rising;
2006
3,4 trillion m3
2030, %1,5-3 / year rising is expected.
2035
5 trillion m3
U.S International Energy Agency / International Energy Outlook 2013
Europe/ Natural Gas Import
International Energy Agency
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
Natural Gas Demand and Potential Transportation Route
(2020)
BCM: bilion m3
ENERGY
MARKET
Europe
ENERGY
Enerji ve Tabii Kaynaklar Bakanlığı, 2013
TURKEY has an important energy corridor role intercontinental.
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 m3/year
Operating pressure: 95 bar
Run-up time:2017-2018
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: 17.5-31 mm (on-shore), 21-34 mm (off-shore)
Pipeline length: 870 km
Quantity of transported gas: 20 billion m3/year
Operating pressure: 95 bar
Run-up time: 2017-2018
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 m3/year
Operating pressure: 92 bar Run-up time:2015-2018
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 m3/year
Operating pressure: 92 bar
Run-up time: 2016
Advantages of Pipelines
 Economic
 Eco-friendly
 Safer than road and rail
 Pipe diameter and grade effect
the capacity.
 Route, outside the city
 Resistant
conditions
to
severe
weather
API Boru Hattı Çelik Kalitesi
Akma Mukavemeti
Development Pipeline Steels
X100
Çelik Alaşımı
Proses
Mikroyapı
% 0.08 C+Nb (+Ti)
TM + ACC
Ferrit + % 50 Beynit
X 80
X70
% 0.10 C +Nb (+V)
TM
Ferrit + % 10 Perlit
X65
X60
X52
% 0.07 C+Nb+Ti+Mo
TM+ACC/DQ
Beynit (+Martensit)
% 0.20 C+V+ (Nb)
N
Ferrit + % 30 Perlit
TOKLUK
(N: Normalize haddeleme, TM: Termomekanik haddeleme, DQ: Doğrudan soğutma, ACC: Hızlı soğutma).
H.G. Hillenbrand, A. Liessen, G. Knauf: Pipeline Technology, Elsevier,2000.
Advantages of High Strength Pipe Steels
Pipe thickness decrease
Low transportation costs
Grade of steel
increased
(X52→ X80)
Less welding
consumables
Reduction at welding time
DECREASE
IN COSTS
Work under greater
pressure – efficiency
on transport capacity
Better quality and mechanical properties
Demands for Weld Area
 Reliable, no defect: Pore, slag, crack free
 Carbon Equvalent:
at HAZ area, Toughness and Strength
Cold cracking and brittleness
%C > 0.12 Ceş< 0.42
%C ≤ 0.12 Ceş< 0.22
 Impact value: API 5L/ISO 3183;
Steel pipe ≤ X80; Çap< 1422 mm, 0 °C 27J
Steel pipe ≤ X80; Çap≥ 1422 mm, 0 °C 40J
 Hardness : Weld and HAZ areas < 275 HV
 Yield and Tensile Strength: (σYweld > σYBM )
Fracture: BM
Welding and Automation on Pipelines
Manuel Metal Arc Welding
 Time
 Labor force
 Cost
 Contiunity on weld quality
 Weld conditions
Portable cabin used during the welding outside
(Pipeline from Russia to Germany)
DEMAND/TARGET:
Fast and quality weld
Orbital Welding Technology
Orbital welding systems will be used in TANAP Pipeline Construction Project.
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
Orbital Welding System
 Tractor
 Power source
 Stainless rail
 Wire feeder
 Control center
 Working panel
 Control panel
Working Principle of Orbital Welding System
tractor
Rail
Steel pipe
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.
Flux Cored Wire (FCW)
arc stabilizer, slag formers,alloying elements,
gasifiers, deoxidizers, denitrifiers etc..
Cu and Cu-Free Flux Cored Wires
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
Weld Groove Preparation
WELD JOINT GEOMETRY
MISALIGNMENT
Pipe Alignment System (Transco project)
Internal Pneumatic Line Up Clamps
Preparations for Welding
Preheating
Boru et kalınlığı ve Ceş değerine göre belirlenir.
Çatlama problemi, nem alma vb.
Cleaning of weld groove
Yağ, kir, pas vb. istenmeyen
birikintiler
Orbital Welding System Working Plan for Field Welding
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 CO2
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
Cap
5. d
28
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 12.75 inch steel pipes
Mechanical Tests
Specimes are prepared according to API 1104 standard.
12 clock p.
3 clock p.
X80 Mechanical
Test specimens
6 clock p.
3-6 clock pos.
12-3 clock pos.
Mechanical test specimens extracted from 12-3 and 3-6 clock positions of welded pipe.
Macro Sections and Nick-break Test Specimens
MACRO
SECTIONS OF
X80 WELDS
3-6 clock pos.
12-3 clock pos.
No weld defects in both welds.
NICK-BREAK
SPECIMENS
OF X80 WELDS
3-6 clock pos.
12-3 clock pos.
Tensile Test Results for X80 Orbital Girth Welds
Base material
All weld
Elcor R 110
Weld area
12–3 clock pos.
Weld area
3-6 clock pos.
σY
(MPa)
595
σT
(MPa)
696
706
634
634
638
641
σy / σ T
Rupture
0.85
-
787
0.89
-
691
685
673
684
0.91
0.92
0.93
0.93
BM
BM
BM
BM
3-6 clock pos.
12-3 clock pos.
Charpy V-Notch (Joule)
Charpy V-Notch Tests Results for
X80 Orbital Girth Welds
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
Ort. 12-3 saat poz.
-60
-50
X80
Ort. 3-6 saat poz.
-40
-30
-20
-10
0
20
Temperature (°C)
API 5L/ ISO 3183
Steel pipe ≤ X80; Çap≥ 1422 mm, 0°C’de 40J
~65 J
Bend Test Results for X80 Orbital Girth Welds
Root bend
Side bend
Face bend
3-6 clock pos.
12-3 clock pos.
Tested at RT.
No sign of cracking in both welds.
Hardness Test Results for X80 Orbital Gith Weld
Hardness (HV 0.2)
TS EN ISO 6507-1 / 200 gr force
12-3 clock.p.
Base material
3-6 clock.p.
245
Weld
280
285
HAZ
275
280
Root
250
248
 SAFE AND CONTINUOUS
FCW + ORBITAL WELDING SYSTEM
PROCESS
 HIGH SPEED
 HIGH & CONSISTENT
WELD QUALITY
 HIGH DEPOSITION RATE
 ECONOMIC
Thank you for your attention.