Pipeline welding,

inspection
and field joint
coating
Technology
product
overview

Subsea 7 is developing and implementing leading-edge

pipeline production technologies, including a diversity of
linepipe materials, in order to satisfy evolving and increasing
market demand, and also to meet progressively more stringent
pipeline fabrication codes and operator specifications.
Since 2006, Subsea 7 has operated an in-house central technical authority for pipeline
welding, NDT and field-joint coating for rigid pipelines globally. Underpinning this philosophy,
Subsea 7 has committed to the following strategies in applied pipeline welding technology
development:
Recently expanded Global Pipeline Welding Development Centre with the capacity
to provide leading edge welding and inspection solutions for the full range of pipeline
fabrication needs
combining all R-Lay, S-Lay, J-Lay and bundle, welding, inspection and field joint coating
capability within a single entity i.e. Pipeline Production Team
access to state of the art automatic pipeline welding equipment provided by leading
suppliers including CRC-Evans, Serimax and Vermaat
strategic technology relationships with key process technology suppliers including
welding, inspection and field-joint coating
commitment to an on-going comprehensive pipeline fabrication technology
development programme to meet future industry demands seabed-to-surface
High-strength steel weld detail Welding enhancements in the pipeline By-Pass Purge enclosure in place AUT System in operation

Welding qualification for reelable Welding advances for clad/lined and First deployment of unique By-Pass AUT system for Pipe-in-Pipe (PIP)
high-strength steels solid CRA pipe Purge welding system swaged weld
There is increasing demand for pipeline Subsea 7 continues to further develop and The Skuld project offshore pipelay operation for In deepwater fields, one of the technical
installation, including SCRs, in deeper water, deploy its advanced Pulsed Gas Metal Arc Statoil offshore Norway using Seven Oceans challenges is the pipeline insulation to ensure
coupled with a requirement for higher operating Welding (PGMAW) technology for technically presented the first opportunity to implement the flow assurance of the oil at 100oC to 150oC
pressures and temperatures and the need to demanding linepipe materials including CRA the Subsea 7 Aquasol By-Pass Purge system when the outside environment is between 0oC
transport corrosive constituents. For such clad/lined and solid CRA pipe. A key part of for execution of the offshore tie-in welds. to 4oC. For this purpose Subsea 7 and ITP have
applications, the use of high-strength steel,
the welding solution is the use of the Cold Performance of these critical welds is made developed high-performance PIP.
Grade X80, offers significant benefits including a
Metal Transfer (CMT) process for root welding. difficult by the suck and blow conditions
reduction in pipeline weight and savings At the end of double joints, the outer pipe is
in fabrication and installation costs. This is an advanced Gas Metal Arc Welding within the pipeline which cause difficulties in
swaged
(GMAW) technique which allows the weld root creating an inert purge atmosphere needed to
Subsea 7, in collaboration with Vallourec, has down to its inner pipe and welded. The swage
to be deposited very precisely, with minimum ensure the soundness of the girth weld.
performed a qualification programme for reelable weld is a key point of the PIP integrity, so its
heat input, giving good control of the root-bead
X80 linepipe. Vallourec manufactured seamless The unique design feature of the By-Pass quality is subject to special attention. Subsea 7,
quality and profile. These are essential features
X80 pipe of 323.9mm OD x 18mm WT pipe in Purge includes a fully sealed enclosure to in collaboration with ApplusRTD, has developed
accordance with DNV OS-F101, supplementary to maintain the corrosion performance of the
maintain the integrity of the purge gas together an automatic ultrasonic testing (AUT) system to
P requirements. Subsea 7 developed and pipeline. Assurance of the weld root quality is
with a central vent which allows the draughts to conduct 100% inspection.
qualified a mechanised girth weld procedure achieved by internal inspection using state-of-
pass through the pipeline without disturbing the
based on the CMT/PGMAW welding process. the-art camera and laser equipment. The swaged weld is inspected by a multi-UT-
internal purge gas.
Procedure qualification was successfully technique combining conventional pulse-echo,
Following initial deployment for clad fabrication
performed in compliance with DNV OS-F101, The entire system is made uniquely of fully phased-array linear and sectorial scans and
in the Vigra spoolbase in 2012, this welding
including mechanical, fracture toughness and water-soluble materials, which enables the TOFD. The method allows a perfect mapping
sour service testing. solution has been utilised in Subsea 7's Ubu
system to be flushed out on completion, and of the weld in order to determine if the level of
spoolbase for riser fabrication in both clad
In order to address the need to transport more its design and materials are sufficiently robust imperfection is acceptable, thus ensuring the
and lined pipe for the Guar-Lula NE project
corrosive constituents, BUTTING manufactured to withstand the rigours of offshore operations. integrity of the high-performance PIP system.
in Brazil during 2013. To date, in excess of
Alloy 625 and 316L mechanically lined or BuBi This innovative system significantly increases
120km clad/lined pipe has been successfully
pipe (323.9 x 17.5 + 3.0mm) using the X80 pipe the reliability of offshore welding operations
welded to high-quality standards using the
supplied by Vallourec. Subsea 7 developed a with better assurance of weld quality and
novel girth welding procedure utilising internal advanced CMT/PGMAW solution.
minimal risk of extended vessel time.
welding of the CRA lining and external welding 2013 saw the first-time application of this
using conventional C-Mn filler wire. The latter advanced CMT/PGMAW solution for the
facilitated the achievement of overmatching weld fabrication of 13Cr linepipe. This enabled
metal strength which is necessary for reeled
the use of conventional copper back-
pipe. Girth weld procedure qualification was
up shoes to be eliminated, resulting in
successfully performed in accordance with DNV
OS-F101 including a full-scale reeling trial. a significant improvement in weld root
corrosion performance. Continued successful
The development of linepipe material and deployment of the CMT/PGMAW solution is a
welding solutions for reelable high-strength testament to its reliability.
carbon steel and CRA-lined pipe are considered
to be key enabling technologies for the
exploitation of deepwater oil and gas
reserves in the future.
 Global Pipeline Welding
Development Centre
2013 saw the completion in Glasgow, UK, of Subsea 7s new Global Pipeline
Welding Development Centre, managed by the companys Pipeline Production
Group (PPG). This new facility considerably enhances our capacity to provide
leading-edge welding solutions for the full range of pipeline fabrication
requirements. Global Pipeline Welding
Development Centre
The new centre incorporates 18 welding bays and supporting cutting and
bevelling facilities to perform pipeline welding and testing for spoolbase welding
and vessel tie-ins, as well as simulations for our S-lay and J-lay vessels.
The existing development centre has been re-configured to provide advanced
NDT capabilities, including full pipe length radiographic testing facilities as well Luanda spoolbase,
Angola
as dedicated R&D facilities. A major advantage of the new centre will be its
capability to simulate the production firing line. This will allow PPG to perform
realistic pre-production welding trials and operator training, which will facilitate
the efficient transfer of technology to our fabrication sites worldwide.

MILESTONES
Port Isabel spoolbase, Texas,
2005 First J-lay welding using the GMAW process for high-fatigue performance clad USA
steel catenary riser (SCR) in 10 and 12inch dia pipe for Exxon Erha project,
Nigeria.
2006/7 First reel-lay SCR system for Chevrons Blind Faith, Gulf of Mexico, project.
Welding of the 12km of 7-inch line was carried out using an in-house developed
hot-wire GTAW mechanised welding system.
Ubu spoolbase, Brazil
2007 First S-lay welding single and dual torch GMAW process for high-fatigue
performance - 18-inch carbon steel pipe for BP Greater Plutonio project, Angola.
2008/9 First lazy-wave SCR system fabricated by Subsea 7 at its Ubu spoolbase, Brazil,
and installed by reel-lay for Shells BC10 project.
2009/10 First reeled clad pipe fabrication for Subsea 7, for BPs Skarv project, at Vigra.
This included double-jointing, and the use of a camera and laser inspection of the
root for the first time. Vigra spoolbase, Norway

2010 First use of the Phased Array system for AUT inspection of carbon steel pipelines
on Totals K5CU project at Vigra spoolbase.
2010 First use of Real-Time Digital Radiography on the Apache Bacchus Bundled
pipeline project at Wester fabrication site.
2011 First use of mechanised Cold Metal Transfer root-welding process on Danas
Triton 10-inch pipeline, then lined with plastic pipe using the swagelining method. Wick bundle fabrication site,
Weldlink connectors were NDTd using Real-Time Digital Radiography. UK

2011 First use of Real-Time Digital Radiography on the Centrica Ensign project - the
2-inch pipeline scope at Vigra spoolbase.
2012 Deployment of Subsea 7 advanced CMT/PGMAW welding technology for clad
pipe at Vigra.
2013 First-time use of CMT/PGMAW for fabrication of 13 Cr pipe.
2013 Opening of the Global Pipeline Welding Development Centre.
2013 Deployment of CMT/PGMAW welding solution for reelable risers in carbon steel,
clad and lined pipe for Guar-Lula NE.
2013 J-lay installation of heavy PIP production lines for Total's CLOV using the Seven
Borealis.

For further information contact

Richard Jones, Welding Technology Manager
[email protected]

www.subsea7.com
Subsea 7, 2015. Information correct at time of going to press. seabed-to-surface