1. Materials and Joining March 2005 R&D Forum David Horsley TransCanada Pipelines Limited

2. Outline Background Background Links to Design Links to Design Links to Construction Links to Construction Links to Operation Links to Operation Materials and Joining Issues Materials and Joining Issues List and Prioritize List and Prioritize

3. Overriding Principles Protection of Persons, Property and the Environment Protection of Persons, Property and the Environment Compliance with Laws and Regulations Compliance with Laws and Regulations Develop and Utilize Technologies to enhance 1 and 2, and improve Cost Effectiveness of pipeline systems Develop and Utilize Technologies to enhance 1 and 2, and improve Cost Effectiveness of pipeline systems

4. Life Cycle Costs Design – Construct – Operate Design – Construct – Operate

5. Links to Design Reliability Based Design and Assessment (RBDA) Reliability Based Design and Assessment (RBDA) Quantifies reliability for all relevant limit states Quantifies reliability for all relevant limit states Reliability Optimized over life cycle Reliability Optimized over life cycle Higher Design Factors Higher Design Factors Loading Conditions Loading Conditions Seismic Seismic Slope Instability Slope Instability Frost Heave and Thaw Settlement Frost Heave and Thaw Settlement Load Effects Load Effects Stress based design Stress based design Strain based design (Tensile and Compressive Limit States) Strain based design (Tensile and Compressive Limit States) High-Strength Pipelines High-Strength Pipelines High-Pressure/ Low Temperature/ Rich Gas Pipelines High-Pressure/ Low Temperature/ Rich Gas Pipelines

6. Links to Construction High Productivity Welding High Productivity Welding Materials Materials Inspection and ECA Inspection and ECA Alternatives to Hydrotest Alternatives to Hydrotest

7. Links to Operation RBDA RBDA Materials Properties database Materials Properties database Corrosion Corrosion

8. Materials and Joining Materials account for up to 50% of installed cost Materials account for up to 50% of installed cost Reduce steel requirements - use higher grade Reduce steel requirements - use higher grade Welding is the often the pace-limiting process Welding is the often the pace-limiting process Improve productivity by advanced automated welding systems Improve productivity by advanced automated welding systems

9. Materials

10. Materials Outline High Strength Materials High Strength Materials Fracture Propagation and Arrest Fracture Propagation and Arrest Inspection and ECA Inspection and ECA Corrosion Corrosion

11. High Strength Materials Increased strength → reduced WT → lower cost (for steel and construction) Fracture propagation and arrest Fracture propagation and arrest Joining Joining Stress-strain properties Stress-strain properties Damage Tolerance Damage Tolerance Response to external loads – tensile and compressive Response to external loads – tensile and compressive

12. Fracture Propagation and Arrest Validated Fracture Control Methodology for new pipelines of high-strength steel, operating at higher pressure, lower temperature, richer gas. Driving force (equation of state) Driving force (equation of state) Material resistance – appropriate small scale tests Material resistance – appropriate small scale tests Other resistance – backfill coefficients Other resistance – backfill coefficients Experimental data to validate predictive models Experimental data to validate predictive models

13. Inspection and Engineering Critical Assessment Define uncertainties in and suggest refinements to weld inspection and assessment methods in order to increase the level of confidence associated with their use and expand applicability to higher strength materials and other joint configurations. AUT AUT Sizing precision and accuracy Sizing precision and accuracy Design tools Design tools ECA ECA Strain based design methodologies Strain based design methodologies Experimental data for a wider range of materials and D and WT Experimental data for a wider range of materials and D and WT Interaction of flaws Interaction of flaws Applicability to high strength pipe materials Applicability to high strength pipe materials Realistic small scale fracture tests (low constraint) Realistic small scale fracture tests (low constraint) Old and existing pipelines Old and existing pipelines Risk/reliability/probabilistic methods Risk/reliability/probabilistic methods Codes and Standards Codes and Standards

14. Corrosion Comprehensive Models to predict susceptibility and rates for both General Corrossion and SCC Comprehensive Models to predict susceptibility and rates for both General Corrossion and SCC Soil type Soil type Moisture content Moisture content pH pH Aerobic/Anaerobic Aerobic/Anaerobic Coating type Coating type Pipe grade / manufacturer/ process Pipe grade / manufacturer/ process Effectiveness of CP in Permafrost Effectiveness of CP in Permafrost

15. Joining

16. Joining Outline Joining of Higher Strength Materials Joining of Higher Strength Materials Welding on Pressurized Lines Welding on Pressurized Lines New and Improved Welding Processes New and Improved Welding Processes

17. Joining of Higher Strength Materials Identify factors critical to successful joining of high strength materials and develop welding procedures and techniques which demonstrate sufficient reliability and can be practically implemented. Consumable development for X-80 and X100 pipe in strain based loading design -to ensure overmatching and sufficient toughness Consumable development for X-80 and X100 pipe in strain based loading design -to ensure overmatching and sufficient toughness Mainline Mainline Tie-ins Tie-ins Double joints and fabrication welds Double joints and fabrication welds Effects of repairs on metallurgical properties Effects of repairs on metallurgical properties Hydrogen cracking susceptibility Hydrogen cracking susceptibility High productivity welding systems High productivity welding systems

18. New and Improved Joining Processes Adapt new joining processes and improve or refine existing processes which show sufficient increases in productivity, efficiency or reliability. Enhancements to mechanized GMAW processes Enhancements to mechanized GMAW processes Tandem Tandem Dual tandem Dual tandem Laser assisted Laser assisted Optimization of pipeline spread, e.g. appropriate number of shacks and welding process/equipment Optimization of pipeline spread, e.g. appropriate number of shacks and welding process/equipment Optimization of welding procedures to reduce number and size of flaws to meet strict requirements for strain based design Optimization of welding procedures to reduce number and size of flaws to meet strict requirements for strain based design Semi-automatic process for tie-ins and repairs Semi-automatic process for tie-ins and repairs One-shot welding processes, e.g. MIAB One-shot welding processes, e.g. MIAB Automated processes for in-service welding (full pressure and flow if possible) Automated processes for in-service welding (full pressure and flow if possible) Hot taps and stopples (design codes w.r.t structure analysis needs work too) Hot taps and stopples (design codes w.r.t structure analysis needs work too) Repair sleeves Repair sleeves Direct deposition repairs Direct deposition repairs

19. Welding on Pressurized Lines Increase accuracy in predicting base and weld metal response when welding in-service pipelines and develop welding techniques which demonstrate sufficient safety, reliability and economy. Cooling rate models to account for various WT, products, flow rates, etc. Cooling rate models to account for various WT, products, flow rates, etc. Microstructure/hardness prediction to assess hydrogen cracking susceptibility Microstructure/hardness prediction to assess hydrogen cracking susceptibility Structural integrity assessment for repair sleeves and large- diameter large-ratio hot tap tees and stopples Structural integrity assessment for repair sleeves and large- diameter large-ratio hot tap tees and stopples Special issues applicable to thin wall pipe Special issues applicable to thin wall pipe Direct deposition repair methods. Direct deposition repair methods.

20. Other Materials and Joining Issues (from 2003 lists) Inspection of CRA clad pipes Inspection of CRA clad pipes Composite materials Composite materials Composite Reinforced Steel (Leal/Rupture) Composite Reinforced Steel (Leal/Rupture) Deep Water technology Deep Water technology Design of SCR systems Design of SCR systems Plastic Pipe Plastic Pipe High pressure liners High pressure liners LNG/ CNG LNG/ CNG

21. New Issues from Alternative Pipeline Products High CO2 content High CO2 content Hydrogen content Hydrogen content Hydrogen conversion Hydrogen conversion Others? Others?

22. Top 5 Needs RBDA RBDA Tools / Techniques / Standards Tools / Techniques / Standards Strain Based Design Strain Based Design Experimental data – compressive and tensile Experimental data – compressive and tensile AUT AUT Improved precision and accuracy Improved precision and accuracy Optimization of Welding Processes Optimization of Welding Processes Reduced flaw size to meet strain based design Reduced flaw size to meet strain based design Consumables for overmatching M/L, tie-in, dbl-joint Consumables for overmatching M/L, tie-in, dbl-joint Appropriate equipment on right-of-way Appropriate equipment on right-of-way Corrosion/SCC Corrosion/SCC Improved models to predict growth rates Improved models to predict growth rates

23. Issues and Opportunities Identified at 2003 R&D Forum