Pipeline Manufacturing Research Articles

A cradle-to-gate life cycle assessment for clean hydrogen gas production pathway using the CeO2/Ce2O3-based redox thermochemical cycle

The present study is conducted to develop a two-steps redox thermochemical cycle based on combined ceria reduction and methane reforming through the CeO2/Ce2O3 redox pair. This cycle incorporates simultaneous water splitting for hydrogen production. To enhance the accuracy and reliability of the inventory data, the system is simulated using the Aspen Plus software package. Also, the goal of this work is to evaluate the carbon footprint of thermochemical based hydrogen production under different scenarios and to compare it with traditional technologies like steam methane reforming (SMR). The analysis takes into account both the plant manufacturing line (reactors), fuel processing (H2 production), redox particles oxygen carrier manufacturing (OC), H2 compression (power consumption) and H2 storage (pipeline manufacturing). The openLCA software with the European database environmental footprint is employed to compute the total carbon emissions of this thermochemical cycle during its overall life cycle. The study concludes that the base case scenario of this system has an overall GWP of 1751.14 g CO2 eq./kg H2 respectively. In the overall GWP, the share of plant construction and OC production was found to be around 1.67%, and 15.78% respectively. The conventional steam methane reforming is loaded with an overall GWP of 4472.83 g CO2 eq./kg H2. In terms of renewable energy input, the base case scenario of this hydrogen production system results in 1465.73 g CO2 eq./kg H2 with thermal energy produced from renewable sources. Comparative life cycle assessment (LCA) demonstrates that base case of CeO2/Ce2O3 has an 85.41% lower GWP emphasizing its environmental advantages over the SMR and Fe3O4/FeO redox pair carries an 84.06% lower GWP as compared to the conventional SMR with 1483.55 g CO2 eq./kg H2. The present study concludes that the combined ceria reduction and methane reforming chemical looping process with simultaneous water splitting may be a more promising option to produce hydrogen using renewable energy.

DEVELOPMENT OF LOADING MODELS AND ANALYSIS OF THE STRESS-STRAIN STATE OF THE MAIN GAS PIPELINE WITH COMPOSITE LININGS

The operation of sections of main gas pipelines that are on the verge of developing a design resource is associated with a number of problems in ensuring industrial safety. One of the most acute problems is the occurrence of local defects. The main material for the manufacture of main gas pipelines is steel. During the operation of the pipeline, local defects occur due to metal corrosion or mechanical damage to the gas pipe. Such concentrators with high internal pressure in the gas pipeline can lead to the destruction of the entire structure. In this case, the situation of destruction is especially critical, since it can cause a man-made disaster. To increase the shelf life of damaged sections of main pipelines in places where defects are located, banding with composite linings is used. The article contains part of a comprehensive study, which consisted in the development of methods for modeling the main gas pipeline for oil and petroleum products under seismic loads, dynamic stress-strain state under the influence of seismic loads and stress-strain state of a damaged gas pipeline reinforced with composite linings under the action of internal pressure. The technology of manufacturing linings from composite material is also described in detail. At the same time, a geometric model of the section of the main gas pipeline with composite linings was developed and an analysis of the loading of the section of the main gas pipeline in ANSYS was carried out, provided that the lining is mounted without tension on the pipeline and provided that the lining is mounted with tension, where a comparative analysis showed that the installation condition of composite linings does not significantly affect the static stress state.

Fatigue fracture mechanisms and life prediction of welded S310 - S321 joints at high temperature

Austenitic stainless steel is prevalent in the manufacturing of aircraft structural components and chemical pipelines, which are frequently subjected to high temperatures. To investigate the high cycle fatigue strength of welds involving two stainless steel materials S310 and S321, a series of high cycle fatigue tests were conducted at 550 °C, 650 °C, 750 °C, and 850 °C, respectively. Scanning electron microscopy (SEM) was used to observe the fracture surfaces in the base metal zone (BM), fusion zone (FZ), and heat affected zone (HAZ). The microstructure characteristics near the fusion line of the specimens were analyzed by the electron backscatter diffraction (EBSD). Results reveal a negative relavance between the presence of inclined coherent twin boundaries (CTBs) and material's fatigue performance. The initiation of cracks from the surface is caused by machining defects, welding voids, and high temperature oxidation of certain grains near the surface. For specimens that fracture in the FZ, the fatigue life show the divergence trend with temperature increases. Meanwhile, a fatigue life prediction model based on XGboost algorithm is developed with axial stress amplitude (σa), temperature (T), average grain size (Dmean), twin boundary density in the FZ (ρtb), and fracture location (Lf) as crucial analytical parameters. This model demonstrates better accuracy in predicting fatigue life with a mean absolute percentage error (MAPE) of 39.58 % compared with Basqin model's 46.81 %.

Study of the effectiveness of inhibiting corrosion processes in mineralized water-oil environments

Corrosion is a phenomenon that strongly affects many industries. Everything related to metallurgy, shipbuilding, or the oil industry is negatively affected by corrosion processes. This is a big problem, because the number of industrial accidents due to corrosion reaches more than 75%. Therefore, in this work, the effectiveness of inhibition of corrosion processes in mineralized water-oil environments was investigated in detail. The main goal of the article is to study the regularity of corrosion processes in water-oil media of different composition and at different temperature regimes for effective selection of the inhibition mechanism and type of corrosion inhibitor.
 An effective method of reducing the impact of corrosion processes today is the use of inhibitors. This is expedient not only from the point of view of the effectiveness of the action, but also from the point of view of economic expediency. Inhibitors are added to corrosive environments in order to stop or reduce corrosion processes. They can be used as protective barriers that form a protective layer, and as absorbers that prevent oxidation processes. In the future, the type of inhibitor is selected depending on the type of metal and the conditions of the reactions responsible for the occurrence and course of corrosion.
 Currently, the use of corrosion inhibitors is recognized as the most effective way to reduce the intensity of corrosion destruction of metal structures. At the same time, it is impossible to obtain a universal inhibitor that meets the requirements of high efficiency, manufacturability, toxicological safety, and at the same time is obtained in an economically feasible way. Among various corrosion inhibitors, organic ones have shown their effectiveness in protecting low-alloy steels of oil industry equipment.
 Metal samples of St20 steel, the most widely used for the manufacture of oil pipelines and oil production equipment, were used as corroding materials in the study. The pH was changed by adding a solution of acetic acid. The degree of corrosion was determined by the massometric method. The volume of the test solution was 150 cm3, the pH of the solution was adjusted with a 5% acetic acid solution. Alkylimidozoline was used as an inhibitor.
 Judging by the research results, the mineral composition of the aqueous solution largely affects the rate of corrosion. The presence of oil significantly reduces the rate of corrosion due to both blocking the access of oxygen to the system by the oil film and due to the corrosion inertness of the chemical components of the oil. However, it was also found that with an increase in the content of carboxylic acids, the presence of oil does not affect the corrosion rate in any way. Arguably, the alkylamidazoline inhibitor showed a high degree of protection at room temperature, in contrast to studies at high temperatures.

CO2 corrosion prediction on 20# steel under the influence of corrosion product film

Based on corrosion thermodynamics and kinetics, considering the multi-field coupling effects of fluid flow, electrochemical reaction and mass transfer process, a new corrosion prediction mechanistic model was proposed by introducing the influence factor of corrosion product film on diffusion coefficient of ion mass transfer, which is based on the CO 2 corrosion prediction model proposed by Nesic et al. The influence of temperature, flow rate and pH value on CO 2 corrosion behavior on 20# steel was studied by orthogonal tests. Scanning electron microscopy (SEM) and energy spectrum analysis (EDS) was used to analyze the surface and cross section morphology of the corrosion product film, and the thickness of the corrosion product film was measured. The results show that the introduced influence factor can simplify the ion mass transfer calculation in the presence of corrosion product film, and the relative error between the predicted value of the modified model and the experimental results is satisfactorily controlled less than 10%. Compared with the prediction model without considering the influence of corrosion product film, the influence factor can effectively correct the high prediction value of the mechanistic model under the influence of corrosion product film, improve the accuracy and applicability of corrosion prediction, and provide important theoretical guidance for the design, manufacturing, operation and maintenance of oil and gas production pipelines and related facilities.

Проблема изготовления труб по проектной информации

The article considers the problem of increasing the efficiency of shipbuilding production on the basis 
 of pipe manufacturing technologies by design information. The reasons that prevent the manufacture of pipes by design information and possible ways to eliminate them are analyzed. Great attention to the manufacture of pipelines is explained by the significant amount of pipeline work, which makes 10-12% of the total labor intensity of building 
 a ship, and on some projects - up to 14-17%. At the same time, the share of pipes manufactured in advance does not exceed 40%. The solution of the problem is considered in a historical retrospective taking into account modern realities, because the development and improvement of the technology of pipe production is one of the main important directions in the development of shipbuilding not only in Russia, but also in the world. Significant changes in the technology are associated with the widespread use of computing devices to improve the computer-aided design, technological preparation of production and the manufacture of pipelines according to design information. There has been carried out comparative analysis of pipe production efficiency using pipe bending machines, bent segments and straight sections. To form the pipe configuration, it is proposed to retain the traditional technology of pipe bending using pipe bending machines. Directions for further research in this area are identified and solutions are proposed, the implementation of which will help reduce construction time, reduce labor intensity and increase the productivity of pipeline work when fulfilling shipbuilding orders. Ensuring the reliability of design information is aimed at increasing the proportion of pipes manufactured in advance, regardless of the functional purpose of pipelines.

Абразивная износостойкость и ресурс эксплуатации труб из стеклокомпозита

This article presents studies of the abrasive wear resistance of fiber-glass composite pipes inner surface, which are laid us-ing microtunneling technology under construction of drinking water pipes, irrigation and sewerage systems. Due to a very smooth inner surface, the pipes have a high coefficient of fluid flow speed transmission through the pipe and a low coeffi-cient of roughness. When in long-term operation, the movement of water and solid particles through the pipeline eventually causes wear of inner walls of the pipe. The study of data on abrasive wear and abrasive resistance of fiber-glass composite pipes allows calculating the pipeline's operability under controlled conditions, predicting the period of trouble-free opera-tion of pipelines and making a reasonable choice of material for pipeline manufacturing. The objects of the study of glass composite pipes samples were selected, manufactured by LLC «New Pipe Technologies» using the method of continuous winding with an inner layer based on: orthophthalic polyester, isophthalic polyester and vinyl ester resins. The assessment of the overall wear resistance of the inner surface of the pipes was fulfilled using test equipment according to the Darmstadt method (GOST R 55877-2013, method B). This method allows simulating the abrasion and wear of linings and pipes that may occur in real operating conditions. Crushed quartz was used as an abrasive material. According to the results of the research, the arithmetic mean values of wear and safety coefficients of fiber-glass composite pipes were deter-mined depending on the number of test cycles. The data were used to select the most promising material as a polymer matrix for the production of fiberglass pipes both for water supply and sewerage.

Technical, economic, and environmental performance assessment of manufacturing systems: the multi-layer enterprise input-output formalization method

In the production planning and control field, assessing the performance of a manufacturing system is a multi-dimensional problem in which neglected dimensions may lead to hidden inefficiencies and missed opportunities for gaining a competitive advantage. In this paper, a new data formalization method is proposed to model a manufacturing system by simultaneously considering value creation and technical, economic, and environmental performance. The proposed method combines the principles of Material Flow Analysis and a new data structure that exploits some characteristics of the Multi-layer Stream Mapping and the Enterprise Input-Output methods to obtain a data-driven approach, typical of Industry 4.0. The proposed method can deal with complex systems and allows to consider also non-value-added activities such as transport and inventories. The implementation of the method and its advantages are shown through a numerical example based on a recycled plastic pipeline manufacturing system. The method shows positive synergies and mutual benefits between sustainable production, lean principles, and data-driven approaches and technologies of Industry 4.0. The method improves the alignment of environmental, technical, economic, and value creation information between operational and strategical levels, removing redundancies in data collection, conditioning, and processing activities, thus reducing partial information, hidden risks and opportunities, and inconsistencies.

Ultra-Compact Eddy Current Transducer for Corrosion Defect Search in Steel Pipes

This research is devoted to the application of non-destructive testing methods for detecting defects of the internal structure of the material in steel pipelines. Despite the use of modern approaches to the design and manufacture of pipelines, which make it possible to lay a significant margin of safety in the created system, the task of developing new approaches to measuring the technical and operational characteristics and parameters of steel parts using software and hardware complexes for non-destructive testing does not lose its relevance. The paper presents the results of the development of defect detection system aimed at detecting damage of the structure of the material with a diameter of 0.2 mm and located at a depth of up to 2 mm. The proposed system is based on the physical principles of the influence of the existing defect on the value of the transformer voltage, which is induced in the measurement circuit of the sensor built on eddy current effects. The focus of the research is the relationship between the linear dimensions of the defect, its location and the generated voltage indications of the developed sensor. Also, within the framework of the study, the results of processing and analysis of the data collected by the defect detection system are presented, the result of which was the determination of the parameters of the detected defects.

Effect of temperature and specimen orientation on Charpy impact toughness

Steel grade 14MoV6 3 is used for manufacturing of boilers and steam pipelines designed for steam temperatures up to 560°C. This paper presents the experimental analysis which included impact toughness test. The analysis resulted in impact energy values, and their respective components, crack initiation and crack propagation energy, and represents the initial stage of extensive research involving the behavior of 14MoV6 3 steel. The aim was to determine the effects of temperature (room vs. operated), as well as the effects of specimen orientation with regards to the rolling direction, on the impact toughness and the relation between its components.

Numerical simulation of 14Mov6-3 steel CT-specimen Fracture Behavior

Steel grade 14MoV6 3 is used for manufacturing of boilers and steam pipelines designed for steam temperatures up to 560°C. This paper presents the numerical simulation of a CT-specimen, using the finite element method. The analysis was performed using Ansys Workbench R21, and represents the initial stage of extensive research involving the behaviour of 14MoV6 3 steel. The goal was to simulate the real experimental conditions, including boundary conditions and loads, which were defined in accordance with relevant standards, and to obtain representative results. The temperature dependent mechanical properties needed for the simulation of plastic behaviour of such specimens under tensile loads were obtained from the experimental data and the literature.

Application Of Integrated FTA And 5x5 Matrix for the Comprehensive Risk Evaluation of a Project-Based Enterprise

Risk management play an important role on preventing failures of any enterprise as it ensures an effective planning and control. Not managing such failures including political, geographical, project, environmental, monetary, human, supply chain risks of the enterprises cause irreparable results. Therefore, there is a need for a comprehensive risk assessment approach regarding qualitative and quantitative risk factors. This paper tackles this need and Fishbone Diagram (FD) as a qualitative method and integrated 5x5 Matrix and Fault Tree Analysis (FTA) methods are used as quantitative methods. The root causes of the risks are examined by taking a project-based enterprise into consideration and evaluated by applying an integrated risk analysis method. Taking into account the risk analysis results obtained, measures are recommended. An improvement of approximately 24% has been achieved as a result of the application of measures. The efficiency of the proposed methods is illustrated in the real world data of a project-based pipeline manufacturing system and the obtained results demonstrate that practitioners and researchers can easily use these methods to prevent the risks.

Effects of Ternary Shielding Gas on Weld Characteristics of All-Position Welding for Pipelines

As an efficient welding method, Gas Metal Arc Welding (GMAW) has the advantages of low thermal energy input and stable mechanical properties of ring weld joints. GMAW has now become the main welding method for large-diameter oil and gas pipelines. Narrow gap welding is widely needed in pipeline manufacturing, yet lack of fusion on side walls is often produced in this process when conventional binary shielding gas (Ar–CO2) is used. Here, we use a ternary shielding gas (Ar–CO2–O2) to improve the weld formation of all-position narrow gap welding of pipelines. The weld formation and weld penetration depth of the pipe welding at 0 o’clock (flat welding), 3 o’clock (vertical welding), 6 o’clock (overhead welding) are investigated. Macroscopic metallographic analysis on the melt width are carried out, and feasibility of the ternary shielding gas is illustrated. Comparing to the binary shielding gas, the ternary shielding gas leads to better weld formation, weld width and weld penetration. Especially, the weld penetration depth can increase by 20%, which helps to reduce the lack of fusion.

Estimation of the Influence of Compressed Hydrogen on the Mechanical Properties of Pipeline Steels

Consideration of the possibility of transporting compressed hydrogen through existing gas pipelines leads to the need to study the regularities of the effect of hydrogen on the mechanical properties of steels in relation to the conditions of their operation in pipelines (operating pressure range, stress state of the pipe metal, etc.). This article provides an overview of the types of influence of hydrogen on the mechanical properties of steels, including those used for the manufacture of pipelines. The effect of elastic and plastic deformations on the intensity of hydrogen saturation of steels and changes in their strength and plastic deformations is analyzed. An assessment of the potential losses of transported hydrogen through the pipeline wall as a result of diffusion has been made. The main issues that need to be solved for the development of a scientifically grounded conclusion on the possibility of using existing gas pipelines for the transportation of compressed hydrogen are outlined.

INVESTIGATION OF THE CORROSION RESISTANCE OF STEEL SS330 (СТ3 in Russ.) IN THE FREE AND ANNEALED STATES

For the manufacture of field pipelines, low-carbon of steel SS330 is often used. It is well welded, almost does not harden and therefore is very convenient for operation in structural elements. Studies of samples made of steel grade SS330 were carried out for the initial and heat-treated states by the following methods: 1) investigation of mechanical properties: - tensile test; - hardness test; 2) microstructural analysis. At the beginning of the research, annealing was performed to obtain an equilibrium structure. According to the results of the experiment, it was noted that after annealing, the structure of SS330 steel acquired low strength and hardness with high plasticity. After annealing, tensile tests of the steel samples of SS330 steel were carried out. Tensile tests make it possible to determine the strength and ductility characteristics of metals under static uniaxial loading. Tensile tests of metal were carried out to determine the main indicators of mechanical properties and to compare these properties in the initial and heat-treated states. Hardness measurements were performed using the Rockwell method. Microanalysis is an indispensable tool for assessing structural changes in the size, shape and orientation of grains, individual structural and phase components. The microstructure of samples of steel SS330 was studied using an optical microscope «Metam RV-21-1Ц», with which it is possible to study the microstructure at a magnification of 200 times. It is shown that the structure of steel is ferrite-perlite. In the initial state, there is a small scribbling and a liquation band. This section has a large chemical heterogeneity, is contaminated with impurities (oxides, nitrides, sulfides, silicides), differs in the values of the characteristics of mechanical properties from the base metal of the pipe. The structure of SS330 steel in its initial state is fine-grained. After annealing, it becomes more uniform, the deformation texture disappears.

The effects of back-up on drilling machinability of filament wound GFRP composite pipes: Mechanical characterization and drilling tests

Composite structures used in many engineering fields are produced using different production methods according to the design characteristic. The filament winding (FW) method, one of the most important of these production techniques, is preferred in the manufacturing of high-pressure vessels, pressure pipelines, and construction components. Composite pipes produced by the FW method are assembled using various processing methods depending on their usage. Drilling is one of the most used method among these processing techniques. The drilling-induced damages negatively affect the mechanical properties of the composite pipes during service. Therefore, it is important to determine the optimum cutting parameters and a suitable back-up material so that minimal damage occurs during the drilling process. In this study, firstly, mechanical properties of the glass fiber reinforced polymer (GFRP) produced by the FW method at ± 55° configuration were determined and damage characteristic based on ring tensile test was analyzed. Then, the effects of back-up use on the drilling machinability of FW GFRP pipes were investigated. Results showed that back-up use in drilling composite pipes plays a key role in reducing delamination, borehole damages, and surface roughness although it leads to occur higher thrust forces. Also, it helps prevent the propagation of interlaminar cracks around the hole. • Back-up use slightly increase the thrust force in drilling of FW GFRP pipes. • In drilling without using back-up, more severe delamination damages occur in the area close to the hole edges owing to intralaminar and interlaminar cracks. • Damage modes were intralaminar cracks, fiber breakages, uncut fibers, and debonding. • Back-up use improves surface quality in drilling FW GFRP pipes.

Comparison of characteristics of St3 in a free and annealed state

For the manufacture of field pipelines, low-carbon steel grade St3 is often used. It welds well, almost never hardens, and therefore is very convenient for working in structural elements. Studies of samples from this steel grade were carried out for the initial and heat-treated state by the following methods: study of mechanical properties (tensile test, hardness test); microstructural analysis. At the beginning of research, annealing was carried out in the work to obtain an equilibrium structure. According to the results of the experiment, it was noted that after annealing, the steel structure acquired low strength and hardness with high plasticity. After annealing, tensile tests were carried out on steel samples. Tensile tests of the metal were carried out in order to determine the main indicators of mechanical properties and to compare these properties in the initial and heat-treated state. Hardness measurements were carried out according to the Rockwell method. The microstructure of steel samples was studied using an optical microscope “Metam RV-21-1”, which made it possible to study the microstructure at a magnification of 200 times. It is shown that the structure of steel is ferritic-pearlite. In the initial state, there is a segregation banding and segregation streamer. The structure of the steel under study in the initial state is fine-grained. After annealing, it becomes more homogeneous, and the deformation texture disappears.

Effect of heat treatment on the microstructure and mechanical properties of a low-carbon X80 pipeline steel

Abstract In this work, the effect of heat treatment conditions on the microstructure and mechanical properties of an American Petroleum Institute (API) X80 steel with a low carbon content of ~0.02% wt., destined for the manufacture of pipelines and pipeline transmission systems by welding, was investigated. Samples were heat treated under different conditions and then were characterized by scanning electron microscopy (SEM), orientation image microscopy (OIM), and electron backscattered diffraction (EBSD). The results showed that when the steel is fastly cooled from the austenitic field (990°C), the mechanical properties increase significantly [ultimate tensile strength (UTS) >1,100 MPa, yield strength (YS) 900 MPa, and elongation 27%] due to the high percentage of martensite (M) present in the microstructure (95%). In contrast, when the cooling rate decreases and the treatment conditions remain at/or above the bainitic/martensitic transformation (from 990°C to 600°C and 450°C), the mechanical properties are decreased by almost 50% because of the decrease in the percentage of martensite (18%). However, the percentage of elongation increases significantly (38%) due to the presence of other micro-constituents resulting from the phase transformation. On the other hand, the best combination of mechanical properties (UTS above 800 MPa and YS between 610 MPa and 720 MPa) was obtained when the steel acquired a dual-phase microstructure [(martensite/austenite)-(ferrite/martensite)] since the amount of martensite is conserved between 45% and 82%, in combination with the other micro-constituent present in the steel that allows us to achieve elongation percentages close to 30%.

A review of onshore and offshore pipeline construction and decommissioning cost in the USA - part 1: specifications, cost estimation and onshore construction

The cost to construct and decommission oil and gas pipelines varies widely between onshore and offshore regions as well as within each area, depending on numerous factors. The purpose of this review is to evaluate publicly available data sources for onshore and offshore pipeline installation and decommissioning activities in the USA. The activities and processes involved, factors that impact cost, cost statistics and limitations of analysis are presented for onshore and offshore pipeline installation and decommissioning. Similarities and differences between construction and decommissioning processes and the tradeoffs involved in design are described to better understand the cost differences that arise between projects. In the first part of a two-part review, an overview of pipeline manufacturing and API 5L specifications introduce relevant terminology and basic pipeline requirements, and a description of cost estimation procedures, normalisation, and data sources provides the evaluation framework. A description of onshore pipeline construction cost data and analysis concludes the paper. [Received: May 4, 2020; Accepted: June 3, 2020]

A review of onshore and offshore pipeline construction and decommissioning cost in the USA - part 1: specifications, cost estimation and onshore construction

The cost to construct and decommission oil and gas pipelines varies widely between onshore and offshore regions as well as within each area, depending on numerous factors. The purpose of this review is to evaluate publicly available data sources for onshore and offshore pipeline installation and decommissioning activities in the USA. The activities and processes involved, factors that impact cost, cost statistics and limitations of analysis are presented for onshore and offshore pipeline installation and decommissioning. Similarities and differences between construction and decommissioning processes and the tradeoffs involved in design are described to better understand the cost differences that arise between projects. In the first part of a two-part review, an overview of pipeline manufacturing and API 5L specifications introduce relevant terminology and basic pipeline requirements, and a description of cost estimation procedures, normalisation, and data sources provides the evaluation framework. A description of onshore pipeline construction cost data and analysis concludes the paper. [Received: May 4, 2020; Accepted: June 3, 2020]