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Collaborating Authors
Fonzo, Andrea
Hydrogen Offshore Pipelines for Net Zero: Testing Pipeline Material, Welds and Coating for a Complete System Qualification
Gargano, Giovanna (Saipem S.p.A.) | Santicchia, Angelo (Saipem S.p.A.) | Torselletti, Enrico (Saipem S.p.A.) | Scarsciafratte, Daniele (Saipem S.p.A.) | Aloigi, Elvira (Saipem S.p.A.) | Arcangeletti, Giorgio (Saipem S.p.A.) | Iob, Francesco (RINA Consulting - CSM S.p.A.) | Di Vito, Luigi Francesco (RINA Consulting - CSM S.p.A.) | Fonzo, Andrea (RINA Consulting - CSM S.p.A.)
Abstract Energy transition from the current fossil fuel-based economy to the renewable and sustainable technology era is one of the most important challenges of the future. Different promising options are being investigated, with particular attention to carbon capture & storage and hydrogen-based energy systems. Onshore and offshore pipelines have been identified as the primary mean for H2 transport and need to be investigated under different aspects. Many studies and experimental tests on metals are available in literature, however the call to advance the technology and close the gaps to make hydrogen transport offshore a viable option has matured in the last years. Scope of the paper is to present the activities carried out by SAIPEM (EPCI Contractor) to investigate and assess the behaviour of materials and coatings used for subsea pipelines transporting hydrogen. In literature, there are several studies and test results, however there are knowledge gaps for the offshore application. In addition, there are no comprehensive standards including detailed coating requirements specific for hydrogen or hydrogen/natural gas mixtures. Therefore, a dedicated testing program based on offshore pipeline materials and coatings has been prepared. Main target of the testing programs is the assessment of pipeline materials, circumferential welds and internal coatings for H2 transport. The paper explains the rationale behind the weld testing and in particular the girth welds. The selection process of tests conditions included the analysis of the most interesting hydrogen blending options in offshore transport operating scenarios to achieve a final partial pressure of H2 for testing that could be representative of the future offshore hydrogen transport development. The test methodology, samples preparation and procedures along with the status of tests are discussed, and the following steps foreseen to complete the test campaign are presented.
- Health, Safety, Environment & Sustainability > Sustainability/Social Responsibility > Sustainable development (1.00)
- Health, Safety, Environment & Sustainability > Environment > Climate change (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Offshore pipelines (1.00)
A Case Study for Repurposing Existing Sealines to CO2 Transport Offshore
Marchesani, Furio (Saipem S.p.A.) | Leporini, Mariella (Saipem S.p.A.) | Torselletti, Enrico (Saipem S.p.A.) | Orselli, Benedetto (Saipem S.p.A.) | Scarsciafratte, Daniele (Saipem S.p.A.) | Mercuri, Andrea (Saipem S.p.A.) | Aloigi, Elvira (Saipem S.p.A.) | Di Biagio, Massimo (RINA Consulting - CSM S.p.A.) | Fonzo, Andrea (RINA Consulting - CSM S.p.A.)
Abstract Depleted offshore fields envisaged for re-use as CO2 storage sites are also associated to pipelines which in the past carried out hydrocarbons. The possibility of repurposing such existing infrastructures to transport anthropogenic CO2 captured onshore or even offshore represents a key factor to reduce costs, risks and environmental impacts of Carbon Capture Storage (CCS) projects. The very limited number of such offshore applications, due to the relatively new need to reuse existing O&G sealines for CO2 transport, carries the uncertainty that not all design areas are fully covered. The paper presents the conceptual steps performed to allow a safe transport through an existing pipeline system retrofitted to CO2 transportation or a new designed pipeline: what is required for the reutilization of the existing pipeline, how the wall thickness considered for the assessment has been chosen (in presence of important metal loss features due to corrosion), how a new pipeline has been designed, the selected design and operating conditions, recommendations for further investigations. A risk assessment allowed to determine areas to be further investigated and developed to accurately determine the risk for health and environment in the worst scenarios. Finally, the application of the principal guidelines available for CO2 sealines design is presented, particularly about the ductile fracture arrest that confirmed to be a demanding requirement. In this case, the guidelines application revealed important differences, which are discussed together with full-scale tests, model uncertainties and safety factors to be used for the Battelle Two-Curve Method (BTCM), as modified by the guidelines or according to the original formulation.
Offshore Hydrogen Pipeline System Qualification: Design and Materials/Welds Testing in Hydrogen Environment
Santicchia, Angelo (Saipem SpA) | Aloigi, Elvira (Saipem SpA) | Terracina, Salvatore (Saipem SpA) | Torselletti, Enrico (Saipem SpA) | Scarsciafratte, Daniele (Saipem SpA) | Girault, Etienne (Saipem SpA) | Arcangeletti, Giorgio (Saipem SpA) | Di Vito, Luigi Francesco (RINA Consulting โ CSM SpA) | Iob, Francesco (RINA Consulting โ CSM SpA) | Fonzo, Andrea (RINA Consulting โ CSM SpA)
Abstract The qualification of a pipeline system for hydrogen transport, even if strictly related to offshore pipelines, is a broad field that requires a systematic approach from basic material knowledge to complex physical models, fracture, and fatigue assessments. The combination of embrittlement with the severe loads of an offshore pipeline calls for a comprehensive awareness of material performance under such conditions. To achieve that, the first step has been the classification of failure modes by type of installation condition and selection of the tests required to characterize materials against them. A second step was to strengthen the state-of-the-art knowledge on data and tests availability for such failure modes. A third step was to set up and conduct a dedicated testing campaign focusing on girth welds and develop a pipeline system qualification procedure. The technological and standardizations gaps, identified in the design, construction and installation process chain are described, along with the actions taken by an offshore EPCI contractor to overcome and fix them. The analysis of qualification requirements, including available test types and testing protocols, led to a matrix of potential tests to be done in hydrogen and air environment for the steel base material, seam weld and girth weld of offshore pipelines. The final design of the test campaign included the minimum number of key tests necessary to assess the effect of atomic hydrogen inside the steel matrix and the related changes in mechanical properties, including the evaluation of tensile behavior and ductility, impact properties, fracture toughness (through KIH and rising load tests) and the critical soaking time in H2 environment. The tests were performed in different concentrations of hydrogen (i.e., different blending scenarios) at a given pressure which was considered potentially representative of the future main operating conditions in offshore hydrogen transportation systems. The main findings of the R&D work presented in the paper confirm that the qualification approach should include material properties testing under various conditions to support and provide a strong and sound scientific basis for the standardization process of the offshore EPCI pipeline system. The new tests and test conditions concur to complete the knowledge on the materials suitability for transporting hydrogen and hydrogen blends in offshore pipelines.
- Europe (0.47)
- North America > United States (0.28)
Low-Cycle Tearing in a Deep-Water Buckle-Arrestor Assembly Girth Weld During S-Lay Installation
Selker, Ruud (INTECSEA) | Liu, Ping (INTECSEA) | Jurdik, Erich (South Stream Transport BV) | Chaudhuri, Jay (South Stream Transport BV) | Fonzo, Andrea (RINA Consulting-Centro Sviluppo Materiali) | di Biagio, Massimo (RINA Consulting-Centro Sviluppo Materiali)
S-Lay installation of inline buckle arrestors in deep water can introduce plastic strain to girth welds. The welds are repeatedly loaded by large-strain cycles when traversing the stinger. A material-testing program was launched to assess the impact of this load sequence on the welds' integrity. It is essential to establish the correct mechanism of crack growth caused by a limited number of sequential large-strain cycles. Segment specimens with increased specimen โdaylightโ length were tested. Fracture morphologies of ductile tearing and fatigue growth were distinguished; ductile tearing was identified only for the first load cycle, whereas subsequent cycles were dominated by fatigue crack growth. Introduction The TurkStream Offshore Pipeline was developed by South Stream Transport BV (SSTTBV). It is a major gas-transmission system that currently comprises two pipeline strings installed in up to 2,200 m water depth, connecting large gas reservoirs in Russia to the Turkish gas-transportation network through the Black Sea. The system currently has a capacity to transport 31.5 bcm of natural gas annually over a distance of more than 900 km. The pipeline's outer diameter (D) is 32 inches, and its wall thickness (t) is 39 mm. Material grade is DNV SAWL (submerged arc-welded longitudinal) 450 with supplementary requirement F, D, U, and (light) S according to offshore standard DNV-OSF101 (Det Norske Veritas, 2010) plus project-specific modifications. Pipe joints are produced by UOE (U-ing, O-ing and expansion) and JCOE (J-ing, C-ing, O-ing and expansion) pipe-forming methods. Ultra-deep water in combination with the large pipeline diameter makes this project one of the most challenging pipeline projects ever, pushing the boundaries of the industry. The first portion of the pipeline was installed in 2017โ2018.
- Europe (1.00)
- North America > United States > California > San Francisco County > San Francisco (0.28)
Industrial Application of SENT and Segment Testing on Deepwater Buckle Arrestor Assembly Installed by S-Lay
Fonzo, Andrea (Centro Sviluppo Materiali) | Porta, Riccardo (Centro Sviluppo Materiali) | Selker, Ruud (INTECSEA) | Liu, Ping (INTECSEA) | Jurdik, Erich (South Stream Transport BV) | Chaudhuri, Jay (South Stream Transport BV)
ABSTRACT For a major deepwater pipeline project in the Black Sea, Buckle Arrestors will be deployed to prevent catastrophic buckle propagation in the event of collapse. Buckle Arrestor Assemblies (BAAs) will be installed using the S-lay pipeline installation method, then introducing cyclic plastic strain on the BAAs' girth welds during their passage over stinger's rollers. Fracture during installation is one of the potential failure modes for the girth weld. A material testing and assessment program has been launched at Centro Sviluppo Materiali (Italy) aimed at evaluating the impact of in-field strain sequence on a defected girth weld. The program was articulated in the evaluation of toughness by using single-specimen method with compliance technique on large thickness SENT samples. Then cyclic tearing sequence has been applied on Segment specimens with increased daylight length, aimed at reproducing the real pipe remote strain conditions by small-to-medium scale testing. Accompanying the testing program, a series of ECA calculations has been performed to investigate the robustness of the segment testing methodology used to evaluate the resistance of flawed pipes when subjected to tearing plus cycling loading scenario. As a main conclusion, the segment with increased daylight methodology has been found robust. It has been confirmed by comparison of experimental results and ECA pipe solutions provided by both BS 7910 and API 579. INTRODUCTION South Stream Transport BV (SSTTBV) is developing a major gas transmission system comprising up to four (4) pipeline strings to be installed in water depths up to 2200 m. The full system will have a massive capacity to transport 63 billion cubic metres (bcm) of natural gas per annum, over a distance of more than 900 km through the Black Sea. The pipeline outside diameter (D) will be 32-inch and its wall thickness (t) 39 mm. The material grade of the line pipe is DNV SAWL 450 SFDU and, depending on the supplier, is manufactured using either UOE or JCOE method. This project can be considered as one of the most challenging pipeline projects ever, stretching the limits of present-day industry. In order to prevent catastrophic propagation of a buckle in the unlikely event of pipeline collapse, inline structures (Buckle Arrestors, BAs) are deployed at certain spatial intervals when the water depth exceeds that equivalent to the buckle propagation pressure for the pipeline. The BAs were designed and sized according to offshore design standard DNV-OS-F101 (2010). The BAA consists of three parts, i.e. one machined thick (BA) section girth welded between two pup pieces manufactured from line pipe sections of nominal dimensions. Material grade is the same for the BA section and the adjacent pup pieces, i.e. DNV SAWL 450 SFDU. However, BA and pup pieces were subjected to different thermal history. Fig. 1 schematically presents the inline Buckle Arrestor Assembly (BAA) that will be deployed in the pipeline project.
- Europe (1.00)
- North America > United States (0.68)
Low Cycle Tearing in a Deepwater Buckle Arrestor Assembly Girth Weld During S-Lay Installation
Selker, Ruud (INTECSEA) | Chaudhuri, Jay (South Stream Transport BV) | Liu, Ping (INTECSEA) | Fonzo, Andrea (Centro Sviluppo Materiali) | Jurdik, Erich (South Stream Transport BV) | di Biagio, Massimo (Centro Sviluppo Materiali)
ABSTRACT For a major deepwater pipeline project in the Black Sea, buckle arrestors will be deployed to prevent catastrophic buckle propagation in the unlikely event of collapse. If large diameter pipe is installed in deepwater using S-lay, plastic strain will develop when the pipe travels over the stinger. Presence of a relatively stiff feature will enhance straining locally. The thick buckle arrestor is girth-welded to thinner pipe sections. Consequently, strain concentration will occur in the girth weld. When traversing the stinger, tens of sequential loading-unloading cycles are introduced. The girth weld is loaded when the buckle arrestor is on top of a roller box and unloaded when located in between two roller boxes. To support assessing the impact of such load sequence on the integrity of the girth weld, a material testing program is launched. Fracture behaviour is investigated both qualitatively and quantitatively. It is essential to confirm the correct mechanism of crack growth under repetitive cycles of large strain. To establish the correct mechanism, segment tests with increased specimen "daylight" length are performed. After testing, the fracture surface is examined, measured and classified using a Scanning Electron Microscope (SEM). Fracture morphologies of ductile tearing, fatigue growth and brittle fracture can be distinguished. Ductile tearing is observed in the first loading cycle. Subsequent cycles are dominated by fatigue crack growth, which can be quantified using Paris Law. INTRODUCTION South Stream Transport BV (SSTTBV) is developing a major gas transmission system that comprises up to four (4) pipeline strings to be installed in water depths up to 2200 m. The system will have a massive capacity to transport 63 billion cubic metres of natural gas per year over a distance of more than 900 km through the Black Sea. The pipeline steel outside diameter (D) will be 812.8 mm (32-inch) and its wall thickness (t) 39 mm. Material grade of the linepipe is DNV SAWL 450 SFDU and, depending on the supplier, it is manufactured using either UOE or JCOE method. This project can be considered as one of the most challenging pipeline projects ever, stretching the limits of present-day industry.
- Europe (1.00)
- North America > United States (0.68)
Onshore Pipeline High-Grade Steel for Challenge Utilization
Ferino, Jan (Centro Sviluppo Materiali SpA) | Fonzo, Andrea (Centro Sviluppo Materiali SpA) | Di Biagio, Massimo (Centro Sviluppo Materiali SpA) | Demofonti, Giuseppe (Centro Sviluppo Materiali SpA) | Spinelli, Carlo Maria (Eni SpA) | Karamanos, Spyros A. (University of Thessaly)
High-pressure pipeline transportation is one of the key technologies to connect remote gas fields and deliver gas at competitive prices to consumer markets. Arctic regions will become more attractive in the near future as large gas resources are located there. Long onshore pipeline systems, characterized by high-strength steels (above API 5L grade X80, i.e., exceeding 555 MPa yield strength) operated at high internal gas pressure (more than 10โ12 MPa) in many cases appear to be the most convenient transportation option. This paper highlights the latest follow-up from a long-lasting R&D program launched by Eni, together with industrial/technical partners, on the exploitation of commercially available options with high-grade steels for onshore applications even in harsh environments. The results obtained in this R&D program can be useful even for applications in Arctic onshore or offshore scenarios. Introduction Natural gas has the chance to be one of the most important and strategic fuel sources in the years to come, even if the growth of the renewable source will play a fundamental role in the โnext green power energy,โ being the โgreenestโ among fossil fuels. Natural gas represents a continuous and reliable energy source on an economically viable base and a long-term span. Energy industries have analyzed several potential routes for gas exportation from giant midcontinental fields to final โend-user marketsโ via either pipeline or liquefied natural gas (LNG) ships. To be economically viable, these analyses include constructability and environmental impact evaluations, route optimization, proper material selection, and optimum hydraulic diameter and wall thickness selection, as well as sizing of intermediate gas-compression stations. High-pressure pipeline transportation is one of the key technologies to connect remote gas fields and to deliver gas at competitive prices to consumer markets. Several independent technical and economical evaluations have shown how natural gas pipeline transportation systems based on:traditional construction techniques, low-alloy high-strength C-steel (above API 5L grade X80), operating gas pressure higher than 10 MPa, and pipeline length of more than 1,000 km are the only solutions to exploit โstranded gas fields.โ This solution allows pipeline projects to meet all the requirements and compete on the โgas to marketโ for distances greater than 1,000 km, even for large-volume transportation. The main economic advantage of high-pressure gas transportation consists of reduced capital expenditure (CAPEX), saving in construction costs, and operational expenditure (OPEX), as a result of a reduced number of intermediate compression stations. This paper highlights the latest follow-up from a long-lasting R&D program launched by Eni, together with industrial/technical partners, on the exploitation of commercially available options with high-grade steels for onshore application even in harsh environments. The idea was to fill existing gaps in several fields dealing with pipeline integrity, based on an advanced design approach mixed together with โin fieldโ practical requirements.
- North America > United States (1.00)
- Europe (1.00)
- Geology > Geological Subdiscipline > Geomechanics (0.46)
- Geology > Structural Geology (0.46)
- Energy > Oil & Gas > Midstream (1.00)
- Government > Regional Government > North America Government > United States Government (0.68)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Piping design and simulation (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Offshore pipelines (1.00)
- Facilities Design, Construction and Operation > Natural Gas Conversion and Storage > Liquified natural gas (LNG) (1.00)
Offshore In-Service Resistance of Double Joints Under Strain-Based Conditions
Melis, Giorgio (Centro Sviluppo Materiali) | Fonzo, Andrea (Centro Sviluppo Materiali) | Ferino, Jan (Centro Sviluppo Materiali) | Quintanilla, Hector (TenarisTamsa) | Marines-Garcia, Israel (TenarisTamsa) | Darcis, Philippe (Tenaris) | Marchesani, Furio (Saipem) | Vitali, Luigino (Saipem)
Tenaris, Centro Sviluppo Materiali, and Saipem launched a cooperative program aimed at evaluating the in-service flaw tolerability of girth welded seamless pipes for offshore applications. Full-scale testing was conducted considering severe biaxial loading scenarios replicating actual offshore in-service conditions. Tearing by an occasional high axial strain was taken into account in order to consider suitability for strain-based conditions. Different notch sizes and sampling positions were also taken into account, thus improving the experimental database, which may assist the designer to evaluate the pipeline residual resistance when it is subjected to specific installation and in-service loading conditions. Introduction Girth welded seamless line pipes for offshore applications may undergo high plastic deformation during their whole life and be subjected to cyclic loading that may lead to unstable fracture occurrence. In general, different loading conditions may be envisaged, associated with internal pressure, cyclic loads occurring during line shutdown, and possible high occasional strains (e.g., due to ground movement). A strain-based approach is mandatory for the correct evaluation of weld flaw tolerability in the design, installation, and operation phases. Once the possible loading conditions have been identified, the evaluation of material behavior is necessary through tensile and toughness testing (both involving standard and nonconventional tests). The real girth weld linepipe behavior can be evaluated by full-scale testing as well as numerical finite element (FE) analyses and defect assessment procedures, when applicable. In this regard, Tenaris, Centro Sviluppo Materiali (CSM), and Saipem launched a cooperative program through different projects aimed at evaluating the in-service flaw tolerability of girth welded seamless pipes for offshore applications. First, a joint industry project (JIP), named โHeavy-Wall SEVere ENvironmentโ (HWSEVEN), was conducted to study heavy-wall offshore pipelines under severe loading scenarios (Di Vito et al., 2010). Both numerical and experimental activities performed in the framework of the HWSEVEN project led to relevant results that have been applied in subsequent strain-based design (SBD)-related projects. Although in HWSEVEN the interest was focused on the ratcheting of high-walled pipes (53 mm pipe wall thickness (WT)), the next activity focused on the performance of seamless double joints in terms of weld defect tolerability. To this purpose, linepipe geometry of 296.5 mm outer diameter (OD) X 21.2 mm WT was considered. Three full-scale tests (FSTs) were executed on flawed girth welded specimens, with notches artificially introduced by electrical discharge machining (EDM), in order to evaluate their tolerability under demanding in-service conditions.
- Europe (0.68)
- North America (0.47)
- Asia (0.46)
Abstract Applications of onshore pipelines in challenging areas need that the pipeline design, in addition to the traditional stress-based criteria, should also account for the strain which the line may occasionally be subjected to and which could be responsible of the final failure. A new plasticity model has been developed by CSM (Iob et Al, 2015) aimed at improving the prediction capability of FE codes, especially for simulating the behavior of high strength steel anisotropic materials. In this paper, the model has been calibrated, implemented into a commercial finite element code and then validated through experimental full-scale tests involving large diameter linepipes. Pipe hydraulic burst and bending tests have been reproduced by finite element analysis up to final failure.
- North America (0.46)
- Europe > Italy (0.28)
- Well Completion > Hydraulic Fracturing (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (0.93)
- Data Science & Engineering Analytics (0.88)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (0.68)
Updates on Flaw Tolerability and Life of Offshore Double Joints in Strain-Based Loading Conditions
Melis, Giorgio (Centro Sviluppo Materiali) | Ferino, Jan (Centro Sviluppo Materiali) | Fonzo, Andrea (Centro Sviluppo Materiali) | Darcis, Philippe (Tenaris) | Marines-Garcia, Israel (Tenaris Tamsa) | Marchesani, Furio (Saipem) | Vitali, Luigino (Saipem)
Abstract Tenaris, CSM and Saipem launched a long lasting cooperative research program aimed at evaluating the in-service flaw acceptability of girth welded seamless pipes produced by Tenaris for offshore applications. The project has been focused on experimental activities involving different test scales with the support of finite element analysis and assessment tools. Typical offshore pipelines in-service scenarios have been specifically selected and consist in an initial axial tensile straining followed by axial cyclic loading in combination with constant internal pressure, thus reproducing bi-axial loading. Different conditions, in terms of pipe geometry, notch size and sampling location, and straining scenario, have been considered to better represent the actual displacement controlled loading conditions occurring on offshore pipeline in-service.