US20100147047A1 - Method of Making an Udersea Pipe, the Method Including Peening Assembly Welds Inside the Pipe - Google Patents
Method of Making an Udersea Pipe, the Method Including Peening Assembly Welds Inside the Pipe Download PDFInfo
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- US20100147047A1 US20100147047A1 US12/595,376 US59537608A US2010147047A1 US 20100147047 A1 US20100147047 A1 US 20100147047A1 US 59537608 A US59537608 A US 59537608A US 2010147047 A1 US2010147047 A1 US 2010147047A1
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- pipe
- peening
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L1/00—Laying or reclaiming pipes; Repairing or joining pipes on or under water
- F16L1/26—Repairing or joining pipes on or under water
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
- B23K9/282—Electrode holders not supplying shielding means to the electrode
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B39/00—Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor
- B24B39/02—Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor designed for working internal surfaces of revolution
- B24B39/026—Impact burnishing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25D—PERCUSSIVE TOOLS
- B25D11/00—Portable percussive tools with electromotor or other motor drive
- B25D11/06—Means for driving the impulse member
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D7/00—Modifying the physical properties of iron or steel by deformation
- C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
- C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
- C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/08—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/01—Risers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L13/00—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints
- F16L13/02—Welded joints
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
- F16L55/26—Pigs or moles, i.e. devices movable in a pipe or conduit with or without self-contained propulsion means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/10—Pipe-lines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25D—PERCUSSIVE TOOLS
- B25D2250/00—General details of portable percussive tools; Components used in portable percussive tools
- B25D2250/275—Tools having at least two similar components
- B25D2250/285—Tools having three or more similar components, e.g. three motors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25D—PERCUSSIVE TOOLS
- B25D2250/00—General details of portable percussive tools; Components used in portable percussive tools
- B25D2250/275—Tools having at least two similar components
- B25D2250/285—Tools having three or more similar components, e.g. three motors
- B25D2250/291—Tools having three or more parallel bits, e.g. needle guns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25D—PERCUSSIVE TOOLS
- B25D2250/00—General details of portable percussive tools; Components used in portable percussive tools
- B25D2250/311—Ultrasonic percussion means
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
Definitions
- the present invention relates to a method of making undersea pipes for conveying corrosive fluids, and in particular water, the method comprising assembling unit pipe elements together by welding.
- the present invention relates more particularly to a subsurface connection installation between a floating support and an oil loading buoy.
- the present invention relates more particularly to a bottom-surface connection installation comprising at least one undersea pipe providing a connection between a floating support and the bottom of the sea, in particular at great depth.
- undersea pipes are referred to as “risers” and they are made up of unit tubular elements made of steel that are welded together end-to-end.
- the present invention provides a riser type undersea pipe for making a connection between a floating support and the bottom of the sea, said riser being constituted by a rigid, catenary-type pipe that extends from said floating support to a point of contact with the sea bottom.
- the technical field of the invention is thus the field of fabricating and installing undersea pipes and more particularly production bottom-surface connections for offshore extraction of oil, gas, or other soluble or phase-change material, or a suspension of mineral material, from an undersea well head in order to develop production fields located at sea or off-shore.
- the main and immediate application of the invention lies in the field of oil production, and also in reinjecting water and producing or reinjecting gas.
- a floating support in general, includes anchor means enabling it to remain in position in spite of the effects of currents, winds, and swell. It also generally includes means for drilling, storing, and processing oil, and means for off-loading to off-loading tankers that call at regular intervals to remove production.
- Such floating supports are referred to as floating production storage off-loading (FPSO) vessels or as “floating drilling and production units” (FPDU) when the floating support is also used for performing drilling operations with wells being deflected in the depth of the water.
- FPSO floating production storage off-loading
- FPDU floating drilling and production units
- An undersea pipe or “riser” of the invention may constitute either a “production pipe” for crude oil or gas, or a water injection pipe providing a connection with an undersea well head at the sea bottom, or indeed a “drilling riser” providing the connection between the floating support and a well head located on the sea bottom.
- a multiplicity of lines are generally installed on FPSOs and it is necessary to implement either hybrid-tower type bottom-surface connections or else catenary type connections, i.e. connections that follow a catenary curve.
- the bottom-surface connection pipe When the bottom-surface connection pipe is of the catenary type, it provides a direct connection between a floating support and a point of contact with the sea bottom that is offset from the axis of said support, said pipe taking up a so-called “catenary” configuration under the effect of its own weight, i.e. a curve having a radius of curvature that decreases from the surface down to the point of contact with the sea bottom, with the axis of said pipe forming an angle ⁇ relative to the vertical that varies in general from 10° to 20° at the level of the floating support up to, theoretically, 90° at the sea bottom corresponding to a theoretical position that is substantially tangential to the horizontal, as explained below.
- substantially vertical risers have been developed so as to bring the catenary-configuration flexible connection closer to the surface near the floating support, thus making it possible to minimize the length of said flexible pipe, and also to minimize the forces that are applied thereto, thereby considerably reducing its cost.
- SCRs steel catenary risers
- curvature varies along the catenary from the surface where its radius of curvature has a maximum value R max down to the point of contact where its radius of curvature has a minimum value R min (or R 0 in the above formula).
- the pipe presents a radius of curvature that is greatest at the top of the catenary, and in generally at least 1500 m, and in particular lies in the range 1500 m to 5000 m, i.e. at the point where it suspended from the FPSO, with said radius of curvature decreasing down to the point of contact with the bottom.
- the radius of curvature is at a minimum in the portion that is suspended.
- said pipe in the adjacent portion that is resting on the sea bottom, said pipe is theoretically in a straight line so its radius of curvature is theoretically infinite. In fact, since some residual curvature remains, said radius is not infinite, but it is extremely large.
- the radius of curvature passes in succession from a minimum value R min to a value that is extremely large, or even infinite in a theoretical configuration where the undersea pipe rests on the sea bottom substantially in a straight line.
- These pipes are made by welding unit pipe elements together end-to-end.
- the unit pipe elements are themselves assembled to form strings, in general strings of two to four unit elements welded end-to-end, which strings are then taken to sea.
- these strings are assembled by being welded to one another at sea from a pipe-laying ship, in particular in a J-lay tower.
- the assembly welds are made preferably and for the most part from the outside of the pipe.
- the most critical portion of a riser is situated at the assembly welds between unit pipe elements, in particular in the portion of the riser that is closest to the point of contact, and the major fraction of the forces in this low portion of the catenary are generated by the movements of the floating support and by the excitations that are applied to the top portion of the catenary, which is subjected to current and swell, with all of these excitations then propagating mechanically along the entire length of the pipe to the foot of the catenary.
- the steels from which pipes are made are selected to withstand fatigue throughout the lifetime of installations, however, the welds between pipe elements, in this catenary foot region constitute weak points when said pipe conveys water or fluid that includes water, and more particularly salt water. In the presence of water, said welds are subjected to fatigue and corrosion phenomena that give rise over time, and under varying bending stresses, to cracks that lead to said pipes being destroyed.
- Anti-corrosion alloys are well known to the person skilled in the art, and are constituted mainly by nickel-based alloys, in particular of the Inconel type, preferably of a specific grade, and in particular Inconel 625 or 825.
- Such Inconels also present excellent resistance to fatigue as a result of their high elastic limits, thereby making it possible to achieve lifetimes of 20 to 30 years.
- Such a lining of stainless steel or anti-corrosion alloy, in particular of the Inconel type, is provided using an expensive arc method referred to as “cladding”, and generally performed using a tungsten inert gas (TIG) method or a plasma method, associated with a filler wire or with a powder of stainless steel or of corrosion-resistant alloy.
- TOG tungsten inert gas
- the object of the present invention is to provide a novel method of fabricating and installing undersea pipes for conveying corrosive fluids and in particular water, the method comprising welding together undersea pipe strings at sea on board a ship for laying undersea pipes, which method should:
- incipient cracks are located on the inside of the pipe in the vicinity of the small projection of the weld bead that extends towards the inside of the pipe, and not on the outside face comprising the main bulk of the weld bead on the outside of the pipe. More precisely, and as explained in the detailed description below given with reference to FIGS. 3E and 3F , the inventors have discovered that the origin of weld destruction lies in the transition region between the welds and the inside surface made of the base steel of the adjacent pipe, in which region traction stresses associated with thermal shocks during welding can give rise to physical defects, and in particular to incipient cracks located in said zone.
- the present invention provides a method of making steel undersea pipes for conveying corrosive fluids and in particular water, the method comprising assembling unit pipe elements together end-to-end, the weld beads of steel or metal alloy of said welds being located on the outside of the pipe, the method being characterized in that localized peening is performed inside the pipe to increase the level of compression stress in the steel or the metal in the vicinity of said welds and in the adjacent peripheral inside surface of the pipe on either side of the welds so as to create a peened surface swath that is peened over a distance L that is limited in the axial longitudinal direction XX of said pipe, i.e. over a fraction only of the length of each of the two pipe elements that are assembled together by said welds, and as measured from their respective abutting ends.
- said peened swath extends over a distance L that is not less than half the thickness of the pipe wall, and more preferably over a distance L that is less than twice the thickness of the pipe.
- the weld comprises a main weld bead on the outside of the pipe and a projection or seam on the inside that is of smaller thickness and that projects into the inside of the pipe.
- This internal projection or seam results from the partial melting of the ends of the unit elements that are assembled together by welding, said melting taking place during the welding heat treatment.
- said peened swath extends over a distance L corresponding to the width of the weld on the inside of the pipe, in particular the width of said internal seam, which seam presents a width lying in practice in the range 3 millimeters (mm) to 5 mm, plus a width on either side lying in the range 1 mm to 10 mm, so as to give a distance L lying in the range 5 mm to 25 mm.
- peeling is used herein to mean surface treatment by multiple impacts using one or more projectiles so as to increase the level of compression stress in a region of the surface under treatment.
- the present invention is the entire surface of said swath, i.e. the cylindrical inside surface section on either side of the weld, overlapping the weld, that is subjected to these impacts, with no region of the surface outside said swath being subjected to such an impact.
- the projectiles may be in the form of balls or the tips of pointed spindles, the projectiles striking the surface for treatment at their ends and, during impacts, the kinetic energy of the projectiles is transformed into plastic and elastic deformation energy in the surface being treated, thereby having the effect of increasing the compression stress in the material where it is treated, and as a result eliminating residual regions of traction stress.
- Peening tools that can be used in the present invention are described in FR 2 791 293 in the name of one of the Applicants, however more rudimentary peening tools as described for example in U.S. Pat. No. 3,937,055 could also be used.
- Peening in the present invention consists, so to speak, in cold forging to eliminate residual traction stresses by deforming the material in the peened surface. It should be observed that it is not desired to eliminate any extra thickness associated with an inside seam or projection of the weld bead, but only to apply compression in substantially uniform manner to the surface of the welding region and of the adjacent regions, using sufficient energy to plasticize and deform the metal so as to eliminate any residual traction stresses due to the welding operation.
- said ends of the unit pipe elements for welding together comprise, in longitudinal axial section, a straight end beside the inside of the pipe forming a root face that preferably occupies at least one-fourth of the thickness of the main portion of the pipe and that is extended towards the outside of the pipe by a sloping chamfer.
- the inside projection or seam of the weld that stands proud is a made up molten metal from said root face and of the filler metal.
- said chamfer faces towards the outside of the pipe so that it can receive a weld bead deposited between the two chamfers at the ends of two abutting pipe elements, thereby substantially forming a V-shape at the end of the two pipe elements for butt welding together.
- material is removed by prior machining, preferably by grinding or by milling, from the inside surface of the pipe and from the weld bead over the surface that is to be peened, prior to said peening.
- said peening is performed at least in the transition region between the inside surface of the weld bead and the adjacent inside surface of the pipe.
- said peening is performed in such a manner as to establish compression or to increase compression over a thickness of 0.2 mm to 2 mm of said inside surface of the pipe and of said weld.
- the limited distance L represents one to three times the thickness of the pipe.
- peening is performed in such a manner as to obtain compression stress that is greater than 5 megapascals (MPa), preferably greater than 50 MPa, in particular lying in the range 50 MPa to 1000 MPa, over the entire peened surface.
- MPa megapascals
- said peening is performed with a peening device that is moved inside said pipe in translation and in rotation in the vicinity of said weld, the peening device comprising:
- said peening tool comprises a vibratory surface that preferably extends over said limited distance L in the axial longitudinal direction XX, and a plurality of projectiles of rounded or pointed type suitable for being projected towards the inside surface for treatment by said vibrating surface in order to create a plurality of impacts.
- the method of the invention is characterized in that said first carriage includes means for moving said peening tool in translation relative to said first carriage in said longitudinal axial direction XX.
- said means for imparting relative movement in longitudinal translation to the peening tool are suitable for moving said projectiles over at least a distance corresponding to the spacing between two successive projectiles so that the entire treated surface can be peened completely in substantially uniform manner.
- the method of the invention is characterized in that it includes the following steps:
- the longitudinal movement of the peening tool in translation relative to said first carriage may be performed either continuously, or else essentially between two of said rotations of said peening tool. This makes it possible to avoid leaving any non-peened area between two impact regions of said successive projectiles, and thus to reach the most critical regions that are situated at the interface between the seam of the weld bead and the base metal of the pipe.
- said peening tool has a plurality of projectiles, in particular of the rounded or pointed type that are projected from a vibrating surface of said peening tool against said surface for peening, in particular in a radial direction, where appropriate.
- said peening tool is mounted to pivot relative to said second carriage, thus enabling the angle of inclination 3 of the projection direction Y 1 Y 1 of said projectiles to be varied relative to said direction YY of movement in radial translation of said second carriage.
- This embodiment makes it possible to optimize peening of the transition regions between the inside weld seam and the adjacent pipe wall, in particular when there is no prior machining of said inside weld seam.
- the prior grinding of the surface for peening is performed with a grinder tool having a rotary grindwheel mounted in the place of or together with a said peening tool on a said first carriage.
- said welding is performed using carbon steel, stainless steel, or a corrosion-resisting alloy of the Inconel type having high elasticity, and good fatigue resistance, and preferably Inconel of grade 625 or 825.
- the method of the invention comprises the following successive steps:
- the present invention also provides a bottom-surface connection undersea pipe having at least a portion including regions of said assembly welds between unit pipe elements that have been put into compression by a method of the invention.
- the present invention provides a bottom-surface connection undersea pipe of the invention that is characterized in that it is a catenary pipe of the SCR type with at least a portion thereof, including the region that comes into contact with the bottom and extending from the bottom over at least 100 m, and preferably 200 m, being assembled by a pipe-making method of the invention.
- the present invention provides a peening device comprising at least a said peening tool mounted on a said first carriage suitable for moving in translation inside a pipe, the device comprising a said peening tool suitable for moving in longitudinal translation XX relative to said first carriage and in rotation about said axial longitudinal axis XX of the pipe in the vicinity of said welds, as defined above.
- FIG. 1 is a side view of a pipe in a simple catenary configuration 1 , suspended from a floating support 10 of the FPSO type, having its bottom end resting on the sea bottom 13 , and shown in three different positions 1 a , 1 b , and 1 c;
- FIG. 1A is a side view in section showing in detail the trench 12 that is dug by the foot 11 of the catenary during movements in which the pipe is lifted off and rested on the sea bottom;
- FIG. 2 is a longitudinal section of a pipe and a side view of a peening robot 3 inside the pipe while it is being assembled, shown during peening treatment of the weld 6 between the ends of two pipe elements 2 a and 2 b , the weld being shown in the bottom half only of the section;
- FIG. 2A is a section view of the pipe showing the peening robot 3 inside the pipe;
- FIG. 3 is a longitudinal section view of one end of a pipe element showing a straight portion (root face) and an inclined portion (chamfer);
- FIGS. 3A , 3 B, 3 C, and 3 D are side views in section showing all or part of the respective ends of two pipe elements to be assembled together, respectively during an approach and positioning stage ( 3 A), a welding stage ( 3 B), an internal grinding stage ( 3 C), and a peening stage ( 3 D).
- FIGS. 3C and 3D show only a bottom portion of the weld so as to show more clearly the inside surface 6 3 of the weld bead 6 after it has been ground;
- FIG. 3 A′ shows a variant of FIG. 3A in the event of a small offset between the end root faces of two pipe elements for assembling together;
- FIGS. 3 B′ and 3 C′ are fragmentary longitudinal sections corresponding to FIGS. 3B and 3C and showing only the bottom portion of the weld and of the pipe;
- FIGS. 3E and 3F show variants of FIGS. 3 B′ in the event that the pipe ends are offset, as in FIG. 3 A′, with a incipient crack from the inside being shown at 2 k in FIG. 3F ;
- FIG. 4A shows a pipe-laying ship fitted with a J-lay tower
- FIG. 4B is a side view of a pipe 2 P being lowered down to the sea bottom and held under tension within said J-lay tower, and a string 2 N held in the top portion of said J—lay tower, said string being approached to said suspended pipe 2 P for the purpose of being assembled thereto by welding;
- FIG. 4C is a side view in section showing the two ends of the pipe elements, in the bottom portion of the figure peening has not yet been performed at 7 2 , while said peening is taking place in the top half-portion at 7 1 ;
- FIG. 4D is a side view showing a string 2 made up of four pipe elements 2 a - 2 d assembled to one another and ready for transferring to the J-lay ship of FIG. 4A ;
- FIG. 5 is a detail view of the peening tool 5 ;
- FIG. 5A is a side view of a tiltable peening tool having a single row of projectiles.
- FIG. 6 is a detail view of a grinder tool 19 mounted on a said second carriage 4 c , taking the place of the peening tool 5 .
- FIG. 1 there can be seen a side view of a bottom-surface connection 1 , 1 a , 1 b , and 1 c of the SCR type, that is suspended from a floating support 10 of the FPSO type anchored at 15 , the pipe resting on the sea bottom 13 at its point of contact 14 a , 14 b , 14 c.
- Curvature varies along the catenary from the surface, where the radius of curvature has a maximum value, to the point of contact where the radius of curvature has a minimum value R 0 , R 1 , R 2 .
- the floating support 10 moves, e.g. from left to right as shown in the figure, thereby having the effect of lifting or lowering the catenary-shaped pipe off or onto the sea bottom.
- the floating support In position 10 c , the floating support is away from its normal position 10 a , thereby having the effect of tensioning the catenary 1 c and raising it, thereby moving the point of contact 14 towards the right from 14 a to 14 c ; the radius of curvature at the foot of the catenary increases from R 0 to R 2 , and the horizontal tension in the pipe generated at said point of contact also increases, and consequently the tension increases in the pipe and said floating support.
- the movement to the right of the floating support has the effect of relaxing the catenary 1 b and of resting a portion of pipe on the sea bottom.
- the radius R 0 at the point of contact 14 a decreases to a value R 1 , and similarly the horizontal tension in the pipe at the same time also decreases, as does the tension in the pipe at said floating support.
- This reduction in the radius of curvature at 14 b gives rise to considerable internal stresses with the structure of the pipe, thereby generating fatigue phenomena that are cumulative and that can lead to the bottom-surface connection being destroyed.
- the pipe presents a radius of curvature that is at its greatest at the top of the catenary, i.e. the point where it is suspended from the FPSO, and that decreases down to the point of contact 14 with the bottom 13 .
- the radius of curvature at the suspended portion is at its smallest, however in the adjacent portion that is resting on the sea bottom, and assuming that said pipe is extending in a straight line, its radius of curvature becomes theoretically infinite.
- said radius of curvature is not infinite but is very large, since, as a general rule, some residual curvature persists.
- the radius of curvature passes successively from a minimum value R min to a value that is extremely large, or even infinite, in a configuration that extends substantially in a straight line.
- FIG. 4D shows a string 2 comprising four unit pipe elements 2 a - 2 d that are assembled together by welds 2 2 , 2 3 , and 2 4 made in a workshop.
- the first end 2 1 of said string is for welding to the end 2 5 of already-assembled pipe that is being laid, with the end 2 5 of the string then constituting the new end 2 5 of the pipe being laid and being ready for assembly with the end 2 1 of the next string, assembly taking place on board the laying ship 8 shown in FIG. 4A , which ship is fitted with a J-lay tower 9 .
- the strings are stored horizontally on deck, and then they are raised one after another by a pivoting ramp 18 from a horizontal position to a position in which they can be inserted in the J-lay tower 9 .
- the already-laid portion of pipe 2 P (not shown in FIG. 4A but visible in FIG. 43 ) is held under tension within the tower by means of a clamp.
- a new string 2 N is lowered towards said pipe 2 P that is held under tension, as shown in detail in FIG. 4B , and is finally welded thereto, and then subjected to the peening treatment of the invention, as shown in detail in FIG. 4C .
- FIG. 2 is a section in side view showing two pipe elements 2 a and 2 b assembled end-to-end by welding 6 in a workshop, the top half-portion being shown in the approach stage prior to welding.
- a remotely-controlled device or robot 3 is inserted from the right-hand end of the right pipe 2 b , said robot carrying a peening tool 5 of the invention and serving to position said peening tool astride said weld 6 , substantially on the axis thereof.
- the robot 3 serves to enable the inside wall and the weld to be subjected automatically to peening treatment over a swath 7 of width L, e.g. having a total width of 2 centimeters (cm) to 6 cm, i.e. substantially 1 cm to 3 cm on either side of the weld bead 6 .
- FIG. 3 is a section showing the face of a pipe element that has machined in order to enable it to be assembled to the following element by welding.
- the face is machined in the plane perpendicular to the axis XX of the pipe and, towards the inside of the pipe, it presents a root face 16 occupying a few millimeters, generally 2 mm to 4 mm, followed by a chamber 17 , e.g. a straight and conical chamfer as shown, or a curved and parabolic chamfer (not shown).
- FIG. 3A two pipe elements have been positioned face to face, ready for welding.
- the pipe elements present an extremely high level of quality, or when they have been made so as to present a diameter that is perfectly circular, the inside wall surfaces of said pipe element are substantially continuous.
- this gives rise to a small internal projection 6 2 that is substantially uniform to the right ( 2 k ) and to the left ( 2 h ) and all around the periphery, as shown in detail in FIG. 3 B′.
- FIGS. 3E and 3F show the above-described unwanted phenomenon for this type of pipe that is to be subjected to fatigue over a period that may exceed 25 to 30 years.
- the first pass needs to merge perfectly with the respective root faces 16 of the two ends of the two pipe elements 2 a and 2 b .
- the chamfers 17 are prepared as shown in FIGS. 3 and 3A . It is the melting of said root faces that gives rise to a small amount of extra thickness in the form of a narrow seam or projection 6 2 ( FIG.
- the pipe elements do not have an internal cross-section that is perfectly circular, with the section being slightly ovalized.
- wall thickness may vary around the periphery.
- connection angle ⁇ 1 is small
- connection angle ⁇ 2 is larger and may result in a sharp angle.
- the welding process involves the use of heating and melting powers, and thus of considerable amounts of energy, since it is desirable to minimize cycle time, particularly for the welding that is performed on board the laying ship 8 , as explained above with reference to FIG. 4A to 4D .
- Such pipe-installing ships have extremely high hourly operating costs, with welding and preparation operations constituting critical busy times. It is desirable to have welding process cycle times of the order of 10 minutes (min) to 12 min for pipes having a diameter of 300 mm and a thickness of 20 mm.
- the localized thermal shocks created by the power of the welding equipment are considerable and they give rise to residual regions of stress concentration that cannot be treated in conventional manner, in particular by thermal annealing, in order to obtain acceptable relaxation of stresses within a lapse of time that is compatible with the desired rates of laying.
- Said residual stresses may be compression stresses or traction stresses with traction stresses being more dangerous in terms of fatigue behavior over the lifetime of installations that may exceed 25 to 30 years or more.
- the device of the invention is constituted by a first carriage 3 having wheels 3 e driven by a motor 3 a and powered by an umbilical cord 3 d .
- the wheels are connected to an axial main body 3 1 of the first carriage via a system of arms 3 b mounted as a hinged parallelogram, preferably three parallelogram structures 3 b , each carrying two wheels in alignment on the direction XX.
- the three parallelogram structures 3 b are preferably uniformly distributed at 120° from one another, as shown in the cross-section of FIG. 2A , and they are actuated synchronously by springs or actuators 3 c so that the main body 3 1 of the robot remains substantially on the axis XX of said pipe.
- the first carriage or robot 3 carries at its front end an axial shaft 4 that is movable in translation along the axis XX in a guide barrel 4 a that is secured to the main body 3 1 , passing axially therethrough, and movable in translation along said axis XX by an actuator (not shown) that may be a hydraulic cylinder or an electric motor, and that is preferably servo-controlled and operated by a computer via the umbilical cord 3 d . Furthermore, said shaft 4 is capable of rotating about the same axis XX within said guide barrel 4 a . Said rotation of the shaft 4 is actuated by an electric motor (not shown) incorporated in the main body 3 1 , and preferably controlled and operated by said computer.
- a guide support 4 b secured to said shaft serves to support a second carriage 4 c and guided in a direction perpendicular to the axis XX and to the inside wall 2 i of the pipe 2 .
- Said second carriage 4 c carries a peening tool 5 that is secured thereto.
- Said peening tool is held in intimate contact with the inside wall 2 i of the pipe 2 , preferably with a constant bearing force, e.g. by means of a pneumatic actuator 4 d , with said second carriage 4 c being moved in a transverse direction.
- said robot 3 is inserted from the right-hand end of the pipe 2 b , carrying the second carriage 4 c that in turn carries the peening tool 5 in a retracted position, thus ensuring that the peening tool does not interfere with the inside surface of the pipe wall.
- the robot Under drive from the motor 3 a , the robot is moved to the weld 6 for treatment, under monitoring via a video camera 4 e carried by the carriage 4 c .
- the carriage is then locked in longitudinal position by locking its motor drive 3 a and by increasing the pressure in the actuators 3 c so as to cause the hinged arm 3 b to pivot and jam the wheels 3 a against the inside surface 2 i of the wall of the pipes.
- the main body is then substantially on the axis XX of the pipe, and the position of the peening tool 5 is adjusted by acting on the position of the shaft 4 that is movable in translation along the axis XX, still under monitoring via the video camera 4 e .
- the actuator 4 d is then actuated so as to deploy the peening tool in a transverse direction in order to press it against the surface 2 i of the wall of said pipe.
- the peening tool is then actuated while also driving the shaft 4 in rotation about its axis XX in order to apply said peening tool to the entire periphery of the inner weld bead together with the adjacent internal surfaces 2 i of each of the pipe elements so as to form a peened swath 7 of width corresponding to the active width of said peening tool.
- the peening process is advantageously improved by performing successive circular passes of the peening tool that are slightly offset in longitudinal translation towards the left or towards the right, by modifying the longitudinal position of the shaft 4 that is movable in translation along the axis XX in the guide barrel 4 a secured to the carriage 3 .
- a peening tool 5 is used that is of the kind described in FIGS. 6 and 7 of FR 2 791 293. More particularly, its vibratory surface is constituted by the end of a sonotrode.
- the metallic sonotrode is secured to a piezoelectric emitter via one or more acoustic amplifiers that, in known manner, present a profile that is adapted to amplify the amplitude of the oscillations of the sonotrode.
- the projectiles may be in the form of balls or in the form of spindles, or in the form of spikes. The ends of the projectiles strike the surface for treatment, and on impact their kinetic energy is transformed into plastic and elastic deformation energy, thereby creating or increasing the level of compression stress in the material at the point of impact.
- FIG. 5 shows in greater detail a carriage 4 c fitted with its peening tool 5 that is remotely controlled via an umbilical connection 5 3 , the tool having a surface that vibrates under the effect of an ultrasound wave 5 2 in a transverse direction YY perpendicular to the longitudinal direction XX, thereby projecting the elongate projectiles 5 1 from a retracted position 5 1 a to a deployed position 5 1 b, with two successive such projectiles being spaced apart by a distance e lying in the range 2 mm to 5 mm.
- FIG. 5A shows a peening tool 5 having a single row of projectiles 5 1 in the direction XX.
- Said peening tool pivots about the axis 4 f of the support 4 g that is secured to the carriage 4 c .
- the axis Y 1 Y 1 of the projectiles 5 1 which also corresponds to the direction in which said projectiles 5 1 are projected against the surface for peening, is inclined at an angle ⁇ relative to said direction (YY) of radial movement in translation of the carriage 4 c so as to arrive under the best conditions in the transition region 2 h - 2 k as described above with reference to FIGS. 3 B′ and 3 F, i.e.
- a first peening tool as described with reference to FIG. 5 is used advantageously to perform general peening. Thereafter, peening is performed with insistence on each of the transition regions 2 h - 2 k by means of said peening tool having a single row of projectiles, with both peening tools advantageously being installed on a common carriage 4 c or on carriages that are independent and both secured to the same axial shaft 4 .
- This peening serves to provide local deformation over a controlled thickness as a function of the energy transmitted by the sonotrode to said needles, the metal of the weld, and the base metal at the end of each of the pipe elements.
- This plastic deformation of the metal makes it possible to establish a generalized and substantially uniform compression stress state throughout the treated region 7 , thereby having the effect of absorbing any residual localized traction stress state that might result from the welding process and the above-described undesirable localized quenching phenomena.
- Achieving compression depends on the power and the accuracy of the peening process, and it is generally performed over a thickness lying in the range 0.2 mm to 2 mm, thereby advantageously preventing unwanted incipient cracks from appearing.
- the quality of the pipe in the welding region is advantageously improved by internally grinding 6 3 the weld prior to peening so as to eliminate geometrical surface defects, thereby enabling peening to be performed over an inside surface of the pipe and the welding that is substantially cylindrical where it is peened.
- Grinding is advantageously performed using a grinder tool 19 as shown in FIG. 6 , which tool is mounted on a device similar to said above-described peening tool, but in which the peening tool is replaced with a grinder tool 19 .
- the grinder tool 19 comprises a rotary grindwheel 19 1 that is mounted an a said second carriage 4 c and that can therefore be moved in translation in the transverse direction YY such that the rotary grindwheel 19 1 comes to bear against the inside surface of the pipe and of the weld for grinding.
- At least one guide wheel 20 is securely mounted to the grinder tool 19 on one side thereof to serve as a guide to ensure that the rotary grindwheel 19 1 is held in position when it comes to bear against said inside surface of the pipe, i.e. so as to ensure that said rotary grindwheel 19 1 does indeed remain tangential to the bore of the pipe, and thus removes only the necessary quantity of the projection 6 2 of the weld bead 6 , as shown in FIGS. 3 C- 3 C′.
- FIG. 6 shows a rotary grindwheel 19 1 of cylindrical shape and having an axis of rotation X 1 X 1 , which axis extends in a longitudinal direction parallel to the axial longitudinal direction XX of the pipe, the abrasive surface of the grindwheel corresponding to its cylindrical outer surface.
- the cylindrical rotary grindwheel may extend in the direction X 1 X 1 over a said distance L.
- the guide wheel 20 presents an axis of rotation X 2 X 2 in the longitudinal direction parallel to the axes XX and X 1 X 1 , such that the guide wheel 20 and the rotary grindwheel 19 1 present a common tangent X 3 X 3 beside the inside surface 2 i of the pipe, thus enabling the guide wheel 20 to guide the grinder tool by maintaining its axis X 1 X 1 tangential to the bore 2 i of the pipe, as described above.
- FIG. 3D shows the state of the inside surface of the pipe in the peened region 7 of the inside surface of the weld over a width L that corresponds substantially to the width of the vibrating surface of the peening tool 5 .
- the length of the unit elements 2 a to 2 d lies in the range about 6 m to 12 m, thereby making it necessary to insert the peening robot from the end that is closest to the weld for treatment, i.e. at a distance of about 6 m to 12 m depending on circumstances, and then cause the robot to travel along said distance in order to take up an accurate position astride said weld for treatment.
- the prefabricated strings generally have a length of about 50 m, as shown in FIG. 4D , or under certain circumstances of 25 m or of 100 m, and it is then necessary to make the robot travel over that distance in order to reach the welding region for treatment.
- FIGS. 4A to 4C show two strings being assembled together together with the welding region being treated by peening, during on-site installation as performed on board a laying ship 8 that is fitted with a J-lay tower 9 , as shown in FIG. 4A .
- the already-laid pipe element 2 P is held securely in suspension from the foot of the tower, and a new pipe element 2 N is transferred by means of a pivoting ramp 18 and in known manner from the horizontal position to the oblique position that corresponds to the inclination of the tower, after which it is positioned on the axis of the terminal suspended pipe element.
- Said pipe element 2 N that is to be assembled is subsequently moved axially along the direction XX towards the suspended terminal pipe element 2 P, as shown in FIG.
- the peening robot 3 is inserted into the pipe and lowered to the welding region that is situated 50 m below when using 50 m string, as shown in FIG. 4C , after which a swath 7 is peened in a manner similar to the treatment performed in a workshop and as described in detail with reference to FIGS. 2-2A .
- the peening robot is raised back to the top of the tower 9 and then the top end of the pipe is grasped and lowered towards the bottom of the tower so as to be ready to perform a new cycle of assembling and treating a new pipe string.
- the most appropriate inspection technique is the X-ray method that makes it possible to measure the inter-atomic distances within the surface of the material, and thus to characterize very accurately the stress state and level, regardless of whether stress is in traction, at rest, or in compression.
- Such means are available from the Applicant and are implemented using a robot similar to that described above, the peening tool 5 being replaced by the X-ray source and the associated sensors that are available from the supplier Stresstech (Finland).
- the signals recovered by the sensors are then sent to a signal processor unit, e.g. a computer, which deduces therefrom the real stress level that exists after and possibly also before the peening treatment of said welding region.
- the present invention is described mainly for solving the problem associated with bottom-surface connections and more particularly in the region of the point of contact with the sea bottom in an SCR type connection. Nevertheless, the invention applies to any type of undersea pipe, whether it rests on the sea bottom, whether it is incorporated in a vertical tower, or indeed whether it constitutes a subsurface connection between two FPSOs, or between an FPSO and an unloading buoy.
- subsurface connection The various types of subsurface connection are described in patent FR 05/04848 in the name of one of the Applicants, and more particularly in FIGS. 1A-1D and 2 A. Said subsurface connections are particularly subject to fatigue phenomena when they are subjected to swell and to currents and above all to the movements of the floating supports, FPSO or loading buoy, which generates alternating stresses, particularly in the regions close to said floating supports.
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Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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FR0754425A FR2914979B1 (fr) | 2007-04-12 | 2007-04-12 | Procede de realisation de conduite sous-marine comprenant le martelage de soudures d'assemblage a l'interieur de la conduite |
FR0754425 | 2007-04-12 | ||
PCT/FR2008/050625 WO2008139116A1 (fr) | 2007-04-12 | 2008-04-09 | Procede de realisation de conduite sous-marine comprenant le martelage de soudures d'assemblage a l'interieur de la conduite |
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US20100147047A1 true US20100147047A1 (en) | 2010-06-17 |
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US12/595,376 Abandoned US20100147047A1 (en) | 2007-04-12 | 2008-04-09 | Method of Making an Udersea Pipe, the Method Including Peening Assembly Welds Inside the Pipe |
Country Status (7)
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US (1) | US20100147047A1 (de) |
EP (1) | EP2132474B1 (de) |
AT (1) | ATE502241T1 (de) |
BR (1) | BRPI0810164A2 (de) |
DE (1) | DE602008005564D1 (de) |
FR (1) | FR2914979B1 (de) |
WO (1) | WO2008139116A1 (de) |
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US20110107571A1 (en) * | 2007-08-21 | 2011-05-12 | Saipem S.A. | Peening Device for Peening Welds Inside Steel Submarine Pipes, Process for Producing Steel Submarine Pipes Using Such a Device, and Submarine Connection Pipe |
US20120298628A1 (en) * | 2009-12-01 | 2012-11-29 | Saipem S.P.A | Method of and a welding station for laying a pipeline, with pipe section welded together by internal and external welding |
US9339886B2 (en) * | 2009-12-01 | 2016-05-17 | Saipem S.P.A. | Method of and a welding station for laying a pipeline, with pipe section welded together by internal and external welding |
US20110137616A1 (en) * | 2009-12-07 | 2011-06-09 | Nuovo Pignone S.P.A. | Design Method for Subsea Equipment Subject to Hydrogen Induced Stress Cracking |
US8386221B2 (en) * | 2009-12-07 | 2013-02-26 | Nuovo Pignone S.P.A. | Method for subsea equipment subject to hydrogen induced stress cracking |
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US10220444B2 (en) | 2015-11-20 | 2019-03-05 | United Technologies Corporation | Additive manufactured conglomerated powder removal from internal passages |
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US20190084066A1 (en) * | 2017-09-18 | 2019-03-21 | Raul Cardona | Cylinder Welding System |
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Also Published As
Publication number | Publication date |
---|---|
ATE502241T1 (de) | 2011-04-15 |
EP2132474A1 (de) | 2009-12-16 |
DE602008005564D1 (de) | 2011-04-28 |
EP2132474B1 (de) | 2011-03-16 |
WO2008139116A1 (fr) | 2008-11-20 |
BRPI0810164A2 (pt) | 2014-12-30 |
FR2914979A1 (fr) | 2008-10-17 |
FR2914979B1 (fr) | 2009-07-10 |
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