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In thisedition >

2 Introduction to the Technical Journal &important dates ahead

3 Mechanically Lined Pipe: Installation byReel-Lay by Grégory Toguyeni

4 Illuminating UV CIPP at its cutting edgeby Julian Britton

5 Insulated Pipe-In-Pipe Riser and SpoolBends by Derek Bish

6 Optimising pipefit-up and logistics

to improve weldproductivity byHugh Davies

Journal

Technical

 August 2012 | www.pipeguild.com

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One of the key objectives of the Guild is to share knowledge andexpertise between our members, ensuring that innovations, newdevelopments and technical excellence on specific projects within thepipeline industry are highlighted and used as learning experiences forus all.

 The Technical Journal will be published twice-yearly, and I would encourage each and every

one of you to submit any articles that you feel would be suitable to share with your fellowmembers.

 The Guild are certain that this Journal will be a highly effective method of communicating

technical skills, capabilities and information for our members.

Disclaimer:

• The information, opinions and views presented in the Pipeline Industries Guild Technical

Journal reect the views of the authors and contributors of the articles and not of the Pipeline

Industries Guild or its publishers.

• Publication of articles, advertisements or product information does not constitute endorsement

or approval by the journal and/or i ts publisher.

• The Pipeline Industries Guild and/or its publisher cannot be held responsible for any errors or

for any consequences arising from the use of the information contained in this journal.

• Although all reasonable efforts are made by the editorial board and the publishers to see

that no inaccurate or misleading data, opinion or statement appear in this journal, the data

and opinions appearing in the articles including editorials herein are the responsibility of the

contributors concerned.

• The publishers and the editorial board accept no liability whatsoever for the consequences of

any such inaccurate or misleading data, information, opinion or statement.

Please do feel free to contact them if you

have any news, require any information

or have any issues that you would like to

discuss.

Offshore Panel

Contact: Robbie Williamson

Email: robbie.williamson@wgim.com

Onshore Panel

Contact: Ian Harrison

Email: ian.v.harrison@uk.ngrid.com

Utilities Panel

Contact: Phillip Clisham

Email: philip.clisham@mouchel.com

International Panel

Contact: Keith Mole

Email: kmole@mcelroy.com

 Young Professionals Panel

Contact: Gavin Ware

Email: gavinware@rheadgroup.com

Below you will find contact details and

photographs of each of the panel chairs.

UpcomingEvents: 

27 September: Carron Trophy,

 Aberdeen

2 – 4 October: No-Dig Live, Stoneleigh

8 – 11 October: Gastech Conference &

Exhibition, Excel, London

16 October: Innovation Day, Warrington

7 December: SPIM: Subsea Pipeline

Integrity Management Conference,

London

For more information:

www.pipeguild.com/events

If you would like to submit

an article to be considered

for inclusion in the Technical

Journal, please email

pr@smartideasdesign.co.uk.

 Articles should be around 700

words, and up to 2 images can

be included. All information

should be technically soundalthough will be proofread for

grammar and spelling.

It is my great pleasure as this year’s National

Chairman, to introduce the first Pipeline IndustriesGuild Technical Journal to you.

Panel Information

 Technical Journal

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 The exploration

and production

of deeper and

more corrosive

subsea reservoirs

demands from

the industry to

design more

of its subsea

infrastructures

and pipelinesto cope with

increasing amounts of carbon dioxide and/ 

or hydrogen sulfide within the hydrocarbon

medium throughout the life of eld. A cost

effective solution to transporting corrosive

fluids is the combination of BUTTING

Mechanically Lined Pipe (BuBi® lined

pipe) and the reel lay installation technique.

BUTTING lined pipe has been successfully

used in towed pipeline bundle projects by

Subsea 7 over many years and has been

demonstrated to be a viable cost-effective

alternative to more expensive optionssuch as solid corrosion resistant alloys or

metallurgically clad pipe.

 The main challenge behind the installation of

this type of pipe by the reel lay method was

to demonstrate that the liner pipe does not

suffer from local buckling inside the outer

carbon steel pipe during the reeling process,

phenomenon also called wrinkling. Another

challenge was to ensure the integrity of the

weld joining the liner pipe to the outer pipe

at the ends of each joint (or seal weld), as a

failure at this location in service would expose

the outer pipe to the corrosive medium.

 A comprehensive development program

was conducted in order to demonstrate the

viability of this technology. It included:

• Manufacture of 15 test strings made of

carbon steel grade X65 for the outer pipe

and 316L stainless steel, alloy 825 and

alloy 625 for the liner. The test strings

were made up of BuBi® pipe sections

welded together using the mechanized

Hot Wire Pulsed Gas Tungsten Arc

Welding (PGTAW) process with alloy 625

filler metal.

• A detailed laser metrology examination

and mapping of the full internal surface of

the pipe at manufacturing stage and prior

and after reeling simulation.

 This innovative technique

allowed a close monitoring

of the behavior of the liner

pipe surface throughout the

reeling process down to an

accuracy of 50μm on any

surface feature.

• A conservative cyclic

bending test or reelingsimulation, using a radius

of curvature of 7.5m. This

allowed testing the specific

Subsea 7 reeling technique

using internal pressurization

of the pipe.

• Full scale resonance fatigue testing of the

string post reeling simulation. In order to

determine the fatigue resistance of the

welded joint in the strained condition,

several test pipes, each containing two

test girth welds and four seal welds, weresubjected to resonance fatigue at The

Welding Institute, Cambridge, UK. Four

progressively higher fatigue classes were

selected for the test. Each specimen was

fully inspected after reaching each fatigue

class in order to confirm the absence of

any failure initiation on the carbon steel

outer pipe but also on the corrosion

resistant liner and at the seal welds. The

endurance of the pipe and its welds was

thus confirmed to achieve the target level

of DNV fatigue class C (DNV-RP-C203).

• Finite Element Analysis was performed

using ABAQUS to model the behavior

of the pipe in several installation and

service conditions. This detailed analysis

proved itself very efficient to interpret and

predict the complex process of wrinkles

formation. Excellent correlation was

found with reeling tests and confirmed

that no wrinkling occurs during the

installation sequence.

• Mechanical and non destructive tests

were done post reeling and fatigue,

including tensile tests, Hardness,toughness tests, corrosion tests (G48,

G28, ASTM A262), radiography,

ultrasonic and dye-penetrant

examination.

• An extensive Non Destructive

Examination (NDE) validation program

was conducted between Subsea 7 andBUTTING to demonstrate the capacity

to detect flaws in the pipe ends overlay

welds and seal welds at the transition

between liner and overlay.

 The full program was performed in

accordance with DNV (DNV-RP-A203) and

was awarded the certificate for ‘fitness for

service’.

 This successful qualification contributed to

the award of the Guará-Lula NE contract

by Petrobras in 2011. This project includes

the world’s first reel-lay installation of several

BuBi® pipe Steel Catenary Risers (SCR) andis the largest contract award of its type to

date in Brazil.

 The development program is currently

expended to higher pipe diameters (up to

14 - 16” OD) and high strength carbon steel

outer pipe to further the applicability of the

technology to even greater water depth and

challenging design criteria.

 As a result of the qualication of the reelable

mechanically lined pipe, Subsea 7, a global

leader in seabed-to-surface engineering,construction and services was proud to

receive the Pipeline Industries Guild’s 2012

award for significant contribution to subsea

pipeline technology.

 Article submitted by  Grégory Toguyeni

Senior Welding & Materials Engineer,

Subsea 7

Website: www.subsea7.com 

Email: gregory.toguyeni@subsea7.com

Mechanically Lined Pipe:

Installation by Reel-Lay 

 Technical Journal

Grégory Toguyeni, Senior

Welding & Materials

Engineer, Subsea 7

S-N curves showing the number of

fatigue cycles reached on three test

strings (RF1, RF2, RF3). No failure of

the pipe or liner seal welds has been

recorded at the DNV class C

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 A small village car park in the Swedish town

of Vihelmina is identified as the location of the

rst UV catalysed ‘Cured in Place Pipeline’

(CIPP) in 1985 by ‘Inpipe AB’, and yet after

27 years, very few are installed in the UK

compared to hot water cured Polyester

liners.

From the perspective of Wessex Water,

the reason is that the adoption of UV cure

is a balance of cost, availability, transport,physical installation limitations and fitness for

purpose. However, the last year has seen

Wessex Water’s Sewer Rehabilitation Team

based near Weston–Super-Mare, exploit the

benefits of the system to line sewers over

railway lines, to act as bridges.

UV catalysed high glass content (HGC)

linings have an increased strength and

stiffness or Long Term Flexural Modulus

(LTFM), and this is a great attribute, with

corresponding reduced liner thickness.

 Along with this comes greater constructionalbenefits of safety, reduced environmental

impacts of noise, energy consumption and

the lack of Styrene impregnated boil water

upon completion.

The Exeter to Waterloo Line

 The construction of first time sewerage

schemes in rural Somerset in the 1950’s

took advantage of masonry railway bridges

to cross cuttings on numerous occasions.

 These sewers were bolted to the bridge

on hangers and constructed from cast iron

pipes.

Survey of these sewers had identified

tuberculation which was interfering with

laminar flow and causing blockages. The

ultimate aim of lining these pipes was to

prevent further corrosion of the internal pipe,

re-establish smooth hydraulic conductivity

and provide a support mechanism upon

catastrophic failure, that would allow an

early warning allowing time to take action in

conjunction with Network Rail.

 The Rehabilitation Team instigated the designof the liner to consider the axial bending

moments of the cured liner acting as a

bridge, rather than the usual hoop stresses

that would be considered when the pipe

is buried. Senior engineers recognised the

design would aim to utilise and enhance the

orientation of the axial rovings or longitudinal

glass, which are usually incorporated to cater

for drag in forces without overstressing the

liner due to self weight, rather than the hoop

tress which caters for the normal ground

loading.

It was never intended that the lining carrythe long term uniformly distributed load

represented by a complete circumferential

fracture of the host cast iron pipe, which

would eventually be exacerbated by a full

bore hydraulic load trapped in the excessive

deformation of the UV liner, but to allow for a

gradual deterioration of the liner which would

be observed on a planned annual inspection.

 The final design called for a Reline Europe

 Alphaliner 500 UV liner with a 5.1mm

thickness encapsulated within a 0.6mm

heavy duty PVC pre liner which would limitthe expansion of the UV liner on curing and

maintain a 1-2mm annulus between the

outside of the preliner and the inside of the CI

pipe. With the liner anchored independently

within the manholes at each end, it would

allow the two structures to thermally

expand and contract independently as the

exposed CI pipe could experience thermal

temperatures of -10c and 40c.

 The first liner was completed by Onsite Ltd at

Union Drove,

Somerset in

the summerof 2011, and

the lessons

learned and

the ongoing

better

understanding

of the declared

values of the

 Alphaliner 500

lead to the

lining of the

Bridge Cottage

sewer crossingin early 2012.

 This second

design pushed

the limits of design to cater for a 10.4m span

across the arch of the bridge as can be seen

in the photograph. This innovative use of UV

liners allows comparable solutions that the

lower LTFM of Polyester would never allow.

The future of UV CIPP?

 The Rehabilitation Team believe that UV

HGC liners will only become more frequently

used in the UK when the cost is closer to

that of traditional Polyester liners. This may

occur when the German and Scandinaviandominance of the market gives way to a

home grown British liner as transport costs

are a major element. Equally, for those

occasions when the high stiffness/strength

of the glass is not required, a UV photo-

catalysed Pe felt liner would bring speed to

curing that would be equally as attractive,

this along with HGC pressure liners is a vision

of the future.

 Article submitted by  Julian Britton

Critical Sewers Manager, Wessex Water

Website: www.wessexwater.co.uk 

Email:  julian.britton@wessexwater.

co.uk

Illuminating UV CIPP at

its cutting edge

 Technical Journal

Bridge Cottage extended span

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Introduction

Increasing demand for energy, matched with

the high commodity price and advances in

technology, is driving operators to extract

whatever reserves remain in the challenging

UKCS. That said, the requirement to transfer

these multi-phase products, from often high

pressure/high temperature (HPHT) wells

back onshore, is an even more demanding

prospect.

Up until now, the common belief in the

industry was that pipe-in-pipe systems able

to withstand environmental challenges such

as corrosion, structural integrity and thermal

management, would be too costly and

complex to apply to riser and spool systems.

 Tata Steel worked closely with supply

partners to engineer, procure and construct

these assemblies to further develop this

innovative technology as a cost-effective

solution to flow assurance issues.

Why insulate risers and spool bends?

HPHT elds are technically more complex

to develop because of the inherently higher

energy in the well fluid and its multi-phase

composition. Managing the extreme pressure

and operating temperature must be based

and evaluated on criteria such as corrosion,

maintaining structural integrity and thermal

management.

One particular challenge is the management

of pipeline shutdown. Less expensive

solutions for managing the insulation of

bends such as wet coatings compromise

overall shutdown times due to reduced

thermal efficiency. Solutions, such as ‘self-draining’ spools, present a significant design

challenge that can be mitigated by the

inclusion of pipe in pipe risers and spools,

including bends, enabling the same thermal

integrity to be maintained in the whole line.

 The main challenge with the construction of

pipe in pipe bends is how to pass the inner

flowline bend into the outer casing pipe. It

is important that pipe bends have a straight

portion on the end to enable efficient welding

to the next pipe section and this can present

the insertion of one bend into the other.

 The second construction challenge is efficient

insulation. Wrapping or sheathing is simply

not practical here as the insulation would

occupy the annulus of the assembly and

prevent the integration.

Insulation

 The system

developed by Tata

Steel overcomes

these problems by

deploying granular

 Aerogel insulationinto the annulus

of the pipe in pipe

system. Aerogel

is made by first

forming a silica

gel, then expelling

the water from the

silica matrix. The

resulting material

is granular with

trapped nanopores

of air, inhibiting

heat transfer

by conduction,

convection and

radiation.

 The deployment of a novel polymeric

bulkhead, cast directly into the annulus,

provides a solid barrier to retain the

insulation, allowing for the relative movement

of the inner and outer bends. The polymer

is a ‘syntactic’ material, silicone rubber

with glass microspheres dispersed through

the matrix with high strength, flexibility and

thermal efficiency. The tangent ends of

the inner and outer bends are held rigidly,

ensuring that the assembly tolerancesachieved at manufacture are retained

when the unit is transferred to the welding

contractor for incorporation into the pipeline

spool or riser.

In order for the insulation to be effectively

deployed, providing the consistent thermal

performance, the annular gap throughout the

assembly must be uniform. In this instance it

is important the manufacturing tolerances of

the pipe and bends are closely controlled.

 Tata Steel has developed a series of controls,

including a process and measurement

system, to ensure all bend dimensions are

closely controlled and mating bends can be

produced, matched and paired to ensure the

most accurate assembly is produced.

In most pipeline applications the critical

dimensions are the positions and attitudes

of the ends of the bends (centre-to-end

dimension) maintaining the overall geometry

of the pipeline. However, with pipe in pipe

bends it is important that the bend radius

is also accurately controlled ensuring the

two bends can be integrated. The precise

dimensions after bending need to also bemaintained following heat treatment.

Conclusion

 Tata Steel has expanded capabilities further

with the design and creation of cost-effective

insulated pipe in pipe bends for risers and

spools – an accomplishment previously

considered too difficult.

Pipe in Pipe bends, while challenging

technologically, can lead to simplification of

overall pipeline design and can give better

pipeline performance in times of operation

and shutdown.

 Article submitted by  Derek Bish

Sales and Applications Engineer, Tata Steel

Website: www.tatasteel.com 

Email: derek.bish@tatasteel.com

Insulated Pipe-In-Pipe

Riser and Spool Bends

 Technical Journal

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In oil and gas pipeline projects, the welding

of fatigue-sensitive SCR and flowline

pipes to tight specifications is critical.

Counterboring the pipes might not be a

viable method of controlling pipe geometry

due to cost considerations or to limitations

on pipe wall thickness. So how can pipeline

contractors ensure that pipe fit-up, weldingand pipelaying processes run smoothly with

minimal interruptions?

In order to prevent bottlenecks during

welding and to minimise project delays and

risks, oil industry owners, pipelay contractors

and welders need to capture, record and

analyse pipe end geometry quickly and

accurately. This measurement data, if used

correctly, can help to ensure that pipes

delivered into the bead stall will fit together

within the welding specification requirements.

 Typically, end dimensioning and fit-up

involves two steps: measuring and fit-up.

Measuring involves actually collecting pipe

measurement data. Automatic, laser-based

measurement tools can be used to measure

geometrical features of pipe ends, normally

performed onshore, although this process

sometimes needs to occur on a cargo barge.

Laser-based measurement tools can be used

to measure the IDs and WTs of pipe ends

in rapid time. Typically, several thousand IDs

of a pipe can be measured in less than 30

seconds, enabling hundreds of pipe ends to

be measured in one shift. This means less

time on site, minimal delays and costs for the

pipelay contractor. Laser measurement tools

are also very accurate (typically to 0.05mm).

Being able to measure up to 400 pipe

ends in a single day is at least three times

faster than using regular, conventional

measurement tools (e.g. caliper gauges),

which only measure at a few discrete

locations around the pipe. Pipelay

contractors are therefore able to keep their

project schedules on track and because

some projects involve measuring more than

2,500 pipes, the time and cost savings are

significant.

Data from laser measurement tools can be

made available to pipe optimisation software,

which will include some sort of simulation

or sequencing software. OMS’ ownSmartFit software, for example, uses pipe

measurement data to predict and control the

fit-up, before the pipes are brought into the

bead stall for welding. This averts production

issues relating to poor fit-up and manages

the assembly of problem pipes in order to

maximise welding productivity.

Measure, mark and fit-up

Each pipe end is measured, identified and

entered into the software. The

software analyses the fit-up ofpipes and allows the operator to

mark the best rotational position

on each pipe end. In the bead

stall, these marks are aligned

to immediately achieve the

best rotational position so that

misalignment is minimised.

 Any problem pipes that won’t

fit at a specified HiLo are also

indicated and are re-sequenced

or removed completely so that

fit-up problems do not occur in

the bead stall. Production delays

due to mismatched pipes are

avoided.

Experience shows that with typical flowline

HiLo limits and using typical seamless line

pipe that has not been counterbored, fit-up

issues can occur regularly depending on

the HiLo requirement. For a HiLo of around

1.0 to 1.2mm, problems are likely to occur

every 10 to 20 pipes (this varies according

to the exact project and the type of pipe).Using pipe optimisation & simulation software

enables the required HiLo’s to be achieved

in the bead stall without trial and error. But

when pipes will not fit, this will be indicated

and the problem pipe can be taken out of

sequence, therefore avoiding any problems

in the bead stall. For a HiLo of 0.8 to 1.0mm,

problem ts will occur in 20 to 50% of the

cases.

Many pipelay contractors are benefiting

from working closely with experienced,

independent measurement specialists such

as OMS, helping them to avoid a range

of potential issues such as wall thickness

problems in SCR and flowline pipe,

counterboring of SCR pipes and poor fit up

on board ‘J-lay’ vessels. OMS has already

completed more than 30 major projects with

customers using SmartFit, which optimises

pipe t-up and HiLo. SmartFit comprises a

laptop computer system used prior to the

pipe firing line, for example, in a ‘ready rack’

on the pipelaying vessel.

 Article submitted by  Hugh Davies

Director of Client Solutions, Optical

Metrology Services LtdWebsite: www.omsmeasure.com 

Email: hugh.davies@omsmeasure.com

Optimising pipe fit-up

and logistics to improveweld productivity 

 Technical Journal

OMS engineer on a cargo

barge, sequencing pipe

ends ready for welding

In the bead stall, datum marks are

aligned to immediately achieve best

rotational position so that pipe end

misalignment is minimised.