Upload
trankiet
View
231
Download
0
Embed Size (px)
Citation preview
1Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Material design for
high strain linepipe
Confidential
Doc. No. FK15-06
Feb 10th, 2015
Steel Research Laboratory
T. YOKOTA
2Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Aim of HIPER®
to increase critical buckling strain
without an increase in wall thickness
controlling microstructure
accordingly, it leads to
reduce material and construction cost
High strain linepipe: HIPER ®
3Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Material Development Flow
ab
MicroStructureControl
StructuralAnalysis
Nano-microstructure
Mechanical propertiesMicro Mechanics
Acceleratedcooling
0
200
400
600
800
0 5 10 15 20Strain (%)
Stre
ss (
MPa
) Conventional(Q-T)
New Process(Bainite+MA)
Rapidheating
Structure performance
Process development & control
Super-OLAC®-A HOP®
BainiteBainite--MAMA
4Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
� Deformation of buried linepipes
� Critical event of the linepipe
Fault movement
Deformation and Fracture of Linepipe
Frost heave
Thaw settlement
Bending
①Local buckling
Bending
Girth weld portion is most critical
②Tensile rupture (Weld fracture)
Seismic area
Permafrost area
5Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Strain Capacity and Controlling Factors
・・Pipe body strain hardenabilityPipe body strain hardenability
(nn--value,value, Y/T, stress ratioY/T, stress ratio)
・weld over-matching
・misalignment
・flaw size, flaw location
・・Pipe body strain hardenabilityPipe body strain hardenability
(nn--value,value, Y/T, stress ratioY/T, stress ratio)
・D/t (diameter/thickness ratio)
・Internal pressure
Controlling factors
Tension / Weld fracture
Compression / Buckling
Mode / Critical event
6Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Effect of SS curve on Buckling Strain
Buckling strain and n-value Stress-strain curves
σ = Aεn
n :n-value
Strain, ε
Round-house type
Str
ess
, σ
Luderselongation type
n-value (Strain hardenability)
Crit
ical
com
pres
sive
stra
in (
%)
0
0.4
0.8
1.2
1.6
0 0.05 0.10 0.15 0.20
D/t= 40-44
Round-house type
Luderselongation type
• Round-house S-S curve• High n -value
• Round-house S-S curve• High n -value
Higher buckling resistance
7Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Material Development Flow
ab
MicroStructureControl
StructuralAnalysis
Nano-microstructure
Mechanical propertiesMicro Mechanics
Acceleratedcooling
0
200
400
600
800
0 5 10 15 20Strain (%)
Stre
ss (
MPa
) Conventional(Q-T)
New Process(Bainite+MA)
Rapidheating
Structure performance
Process development & control
Super-OLAC®-A HOP®
BainiteBainite--MAMA
8Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
How to Control Stress-Strain Curve?
� Experimentation
� Analytical study
σ
ε
Roundhouse
High n-value
� Microscopic behavior and Macroscopic behavior
� Optimization of Microstructure
Requires a lot of work and time
PP PP
“Unit Cell Model”
“Micromechanics”
by
9Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Analysis by Unit Cell Model� Unit cell model
(Voronoi cell)
FEM meshes
Ra=1.0 Ra=4.0
6020 60 80 1000
70
80
90
0
0.1
0.2
40
Y/T
(%
)
n-va
lue
Bainite ratio (%)
n-value (cal.)Y/T (cal.)
n-value (exp.)Y/T (exp.)
� Example of analysis
Ferrite-Bainite steel
10Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Effect of Bainite Morphology
200
300
400
500
600
700
800
0 5 10 15
Exp. (n=0.21)Ra=1.0 (n=0.03)Ra=1.5 (n=0.04)Ra=2.0 (n=0.08)Ra=4.0 (n=0.12)
Nom
inal
str
ess
(MP
a)
Nominal strain (%)
Experimental
FEM(V-BCC model)
Bainite volume fraction : 30%
� Effect of Bainite aspect ratio
• Bainite vol. fraction ~ around 30% over• Elongated bainite morphology
Round-house
High n -value
� Effect of Bainite vol. fraction
200
300
400
500
600
700
800
0 5 10 15
10%20%30%
Nom
inal
str
ess
(MP
a)
Nominal strain (%)
Bainite FEM(V-BCC model)
FerriteBainite volumefraction
Bainite aspect ratio=2.0
Ferrite-BainiteFerrite-Bainite
11Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Analysis by Micromechanics
� Dual-phase microstructure
Harder 2nd phase
400370 980
0.30
0.25
0.20
0.15
0.10
0.05
n-v
alu
e
TS(hard phase)-TS(soft phase), ∆TS (MPa)
2nd phase ratio =50%
40%
30%
20%
10%
bainite
pearlite
martensite
Soft phase:Ferrite
Hard phase:
- Pearlite
- Bainite
- Martensite
ΔΔΔΔTS up
Higher n-valuematrix
inclusion
Plastic relaxation
Two phase
εt2
εP1
True strain
Tru
e st
ress
εP
εP2
εt
εt1
internal stress
stage 3
stage 2
stage 1
Hard phase
Soft phase
Micromechanics
12Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Material Development Flow
ab
StructuralAnalysis
Mechanical propertiesMicro Mechanics
Acceleratedcooling
BainiteBainite--MAMA
0
200
400
600
800
0 5 10 15 20Strain (%)
Stre
ss (
MPa
) Conventional(Q-T)
New Process(Bainite+MA)
Rapidheating
Structure performance
MicroStructureControl
Nano-microstructure
Process development & control
Super-OLAC®-A HOP®
13Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Hot leveler
Cooling bed
Furnace
slab
plate
Plate Production Line
Super-OLAC®-AHOP®
On-Line Accelerated CoolingHeat treatment On-line Process
UOE pipe forming
14Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Plate Production ProcessT
em
pe
ratu
re
Re-crystall.temp.
CR- γ ACC
Ar3
Bainite
CR- (α+γ) ACC
Ferrite-Bainite
Accelerated cooling (ACC)
Controlled rolling (CR)
CR- ACC -HOP
Bainite-MA
Heat treatment on-line process (HOP)
MAMA
Time
15Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
MA formation
5µm
MA
Bainite
� Microstructure change
un-transformed γ
(a) after ACC
(b) HOP heating
(c) air cooling
Bainite(tempered)
ACC
HOP
Bainite
Bainite(tempered)
� SEM microstructure
Dual phase microstructure of Bainite - MA
C diffusion
Microstructure Control by HOP
16Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
TEM images of bainite-MA
2µµµµm
100nm
500nm
MA MA
MA phaseBainite-MA microstructure
Bainite (Bainitic ferrite) phase
(Nb,Mo,V)C
MA
5µµµµm
17Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Size and Grade Availability
WT(mm)
Grade
15
20
25
30
35
X52X52 X60 X65 X70 X80 X100 X120X52
Mass produced Developed(F-B design)
Developed(B-MA design)
18Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Supply Record of HIPER®
Total 88,137 metric ton
Chita Pipeline Project (2001)Onshore, Seismic regionX65 30”OD X 20.5mmWT 106 ton
#2 West-East Gas Pipeline Project (2008)Onshore, Seismic regionX80 48”OD X 22.0mmWT 7,500 tonX80 48”OD X 26.4mmWT 5,500 tonTotal 13,000 ton
Sakhalin 1 Project (Phase 1, 2003-2004)Onshore & Offshore, Seismic regionX60 24”OD X 15.6mmWT 6,940 tonX60 24”OD X 20.8mmWT 770 tonX60 24”OD X 30.2mmWT 5,305 tonX60 36”OD X 26.0mmWT 6,970 tonX60 48”OD X 30.0mmWT 5,360 tonTotal 25,345 ton
No.2 Suruga Pipeline Project (2001-2004)Onshore, Seismic regionX65 24”OD X 14.3mmWT 2,273 ton
Sakhalin 2 Phase 2 Project (2005)Onshore, Seismic regionX60 20”OD X 19.1mmWT 65 tonX60 48”OD X 31.8mmWT 2,825 tonTotal 2,890 ton
Sakhalin 2 Phase 2 Project (2003 - 2004)Offshore, Ice gouging regionX52 30”OD X 23.8mmWT 2,635 tonX52 30”OD X 30.2mmWT 16,575 tonTotal 19,210 ton
North Central Corridor Project (2008-2009)Onshore, Frost region X80 42”OD X 12.7mmWT 3,000 ton
Chiba-Kashima Pipeline Project (2009)Onshore, Seismic regionX80 24”OD X 14.5mmWT 281 ton
PNG Project (2010)Onshore, Seismic regionX60 32”OD X 25.2mmWT 1,850 ton
Sakhalin 1 Project (Phase 4, 2010)Offshore, Seismic regionX60 20”OD X 22.2mmWT 7,252 ton
Isewan Crossing Pipeline Project (2010-2011)Onshore, Seismic regionX65 24”OD X 15.6mmWT 4,280 tonX65 28”OD X 18.1mmWT 4,150 tonTotal 8,430 ton
#3 West-East Gas Pipeline Project (2012)Onshore, Seismic regionX80 48”OD X 26.4mmWT 4,500 ton
19Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
X120 Mill Trial (2007)
70
90
800 900 1000 1100
Y/T
rat
io (
%)
Tensile strength (MPa)
80
Round bar specimenLongitudinal direction
Bainite (B added)
Ferrite-Bainite (B-free)
Bainite (B added)
Ferrite-Bainite (B-free)
150
200
250
300
800 900 1000 1100
Cha
rpy
abso
rbed
ene
rgy
at -
30o C
(J)
Tensile strength (MPa)
ACC
ACC+HOP
Ferrite-Bainite
150
200
250
300
800 900 1000 1100
Cha
rpy
abso
rbed
ene
rgy
at -
30o C
(J)
Tensile strength (MPa)
ACC
ACC+HOP
ACC
ACC+HOP
Ferrite-Bainite
� First trial production test of X120�36”OD x 19mmWT�Design temp. –20oC
� Material design�B free-Dual phase microstructure�Online heating for Charpy energy improvement 10µµµµm10µµµµm
Ferrite
Bainite10µµµµm10µµµµm
Ferrite
Bainite
� Mech. properties
� Microstructure
OMAE2007-29561
20Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
JFE Steel’s high performance linepipe “HIPER®”won 2013 R&D100 Awards.
JFE Steel’s high performance linepipe “HIPERHIPER®®”won 2013 R&D100 AwardsR&D100 Awards.
Called the “Oscars of Innovation”, the R&D 100 Awards recognizes and celebrates the top 100 technology products of the year.
HIPERHIPER®® : High deformable linepipe for gas transmission pipeline
2013 Award ceremony2013 Award ceremony7th Nov. 2013, Orland, USA
21Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
JFE’s cutting edge linepipe products
� Martensite SS 12Cr� High efficiency stainless steel making
� Largest stainless seamless supplier
SMLS
� Large OD/ Heavy WT
� MightySeam
� Max. 26 inches OD – World largest
� High forming capability
ERW
� HIPER
(High strain capacity pipe)
� High grade (- X100)
� Sour Gas line pipe
� Heavy wall pipe
� Advanced TMCP
Super-OLAC :
Super On-Line Accelerated Cooling
HOP: Heat treatment On-Line Process
� Hybrid Forming Line of UO &
NEO PressTM
SAWL
Products Production TechnologyMill
22Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory
Conclusions
914mm, 18.3mm
JFE Steel developed high strength linepipe for strain based design “HIPERHIPERTMTM” with dual-phase microstructure by applying Super-OLAC and HOPin the plate manufacturing process.
Material design for high performance linepipeinvolves not only plate products for UOE, but also hot-rolled coil products for ERW & SMLS.
23Copyright © 2015 JFE Steel Corporation. All Rights Reserved. Steel Research Laboratory 914mm, 18.3mm
İlginiz için çok teşekkür ederim
鞆の浦(福山)鞆の浦(福山)鞆の浦(福山)鞆の浦(福山)
Tomonoura (Fukuyama city)
24
Copyright © 2015 JFE Steel Corporation. All Rights Reserved.
Any reproduction, modification, translation, distribution, transmission, uploading of the contents of the document, in whole or in part, is strictly prohibited