This document discusses a new solution for creating corrosion resistant alloy (CRA) lined pipes using a full length pipe expander. There is a growing demand for CRA lined pipes that can withstand corrosive conditions over long distances and high pressures. Current options like solid stainless steel pipes or pipes with metallurgical bonding are expensive. The proposed solution uses an expander head with flexible dies to incrementally expand a carbon steel pipe outward to precisely bond it to a CRA liner. Research shows this method creates a more uniform bond with minimal air gaps compared to existing hydrostatic expansion processes. It allows for diameter control, pre-expansion of materials, no oversized liner, and a strong gripping force over 150N/mm2

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Fontijne Grotnes
New solution for CRA Lined Pipes

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Market Overview
Growing demand for corrosion resistant pipes
• Corrosive conditions will increase in the future, higher concentrations of H2S
and CO2
• About 43% of the world’s natural gas reserves are sour (IEA)
• More offshore applications, which requires a higher collapse pressure
• Transport is needed over longer distance and with higher pressures
• There is a need for a good economical alternative, compared to solid stainless
tubes and CRA Clad Pipes
> Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
Results Research
Conclusions

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> Fontijne Grotnes
> Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
Results Research
Conclusions
Corrosion Resistant Pipes
1. Solid Stainless Steel Pipe: Cost intensive and require specific heat treatments
after forming and welding. Lower yield and ductility properties compared to
carbon steel pipes.
2. Metallurgical Bond: Expensive manufacturing process for metallurgical bonding
of plate material; roll bonding (hot rolling) or explosion bonding. There are only
a limited amount of suppliers.
3. Mechanical Bond: Good economic alternative: different bonding processes on
the market, but currently no optimal process available
Different solutions to deal with growing demand for Corrosion resistant pipes:

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> Fontijne Grotnes
FLPE for Creating Mechanical Bonding
Fontijne Grotnes Full Length Pipe Expander
• Radial expansion to precise diameters and improving straightness
• Increase material yield
• Weld strength test
Introduction
> Pipe Expander
Process
CRA Standards
Bonding Principle
Results Research
Conclusions

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> Fontijne Grotnes
FLPE for Creating Mechanical Bonding
Features
• The diametrical tool movement is controlled by a Diameter Control System
which enables more control over the process.
• The complete pipe is not expanded in one step but incrementally
---) reduces the force required for expansion.
• The expanded pipe end moves into a tunnel beam assembly, which also
straightens the pipe.
Introduction
> Pipe Expander
Process
CRA Standards
Bonding Principle
Results Research
Conclusions

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> Fontijne Grotnes
API 5L 45th edition, December 2012
Outer Carbon Steel backing Pipe, API Grades X42 – X80
API 5LC 3rd edition, July 1998
Inner CRA line pipe, Stainless steel 316L / Inconel 825 / others
API 5LD 3rd edition, March 2009
Combined CRA lined pipe
• Mechanical bonding
• Guidelines (everything subject to agreement):
• Max 2% plastic strain of outer tube (total)
• Test of bonding quality:
• Gripping force
Other tests may be proposed and agreed upon between the purchaser and manufacturer:
• Push out force
API Standard – Final Pipe
Introduction
Pipe Expander
Process
> CRA Standards
Bonding Principle
Results Research
Conclusions

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> General Knowledge
Mechanical Bonding Principle
CRA Liner
Outer Pipe
Stress[N/mm2]
Strain [%]
Initial gap
Intersection point:
Equal springback
Residual strain
Introduction
Pipe Expander
Process
CRA Standards
> Bonding Principle
Results Research
Conclusions

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> General Knowledge
Influence of Hardening curve
CRA Liner
Outer Pipe
Stress[N/mm2]
Strain [%]
+ Residual strain
Introduction
Pipe Expander
Process
CRA Standards
> Bonding Principle
Results Research
Conclusions

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> General Knowledge
Influence of Initial Gap
CRA Liner
Outer Pipe
Stress[N/mm2]
Strain [%]
Initial gap + Residual strain
Introduction
Pipe Expander
Process
CRA Standards
> Bonding Principle
Results Research
Conclusions

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> General Knowledge
Influence of Amount of Expansion
Outer Pipe
Stress[N/mm2]
Strain [%]
CRA Liner
- Residual strain
Introduction
Pipe Expander
Process
CRA Standards
> Bonding Principle
Results Research
Conclusions

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CRA Lined Pipe Research
CRA lined pipes are currently manufactured in different ways however the
main production process is hydrostatic bonding.
There is one patented process from Cladtek, which is based on
incremental expansion.
Discussions with major players in the market learned that current bonding
processes has multiple disadvantages:
• No Diameter Control
• No Possible Pre-Expansion
• No Control on Material Flow
• Large Air Pockets End of Pipe
• Necessary Over Length CRA Liner
• Moisture
• High Force Required
Introduction
Pipe Expander
Process
CRA Standards
> Bonding Principle
Results Research
Conclusions

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Intensive Research
• Existing Expander Head is not suitable for mechanical bonding
• Studies in the form of tests and simulations are performed to investigate
our solution.
• Use of Flexible Dies (Patent Pending) to increase the uniformity of the
bonding
FLPE for Creating Mechanical Bonding
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
> Results Research
Conclusions

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CRA Lined Pipe Results - Uniformity
Air gap distribution at the interface of inner and outer pipe:
Hydrostatic: 20 - 30 μm Expander Head with Flexible Dies: 7 μm
Minor air gaps which are less than 0,007 mm (7 μm), in the range
of roughness for shot blasted surfaces.
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
> Results Research
Conclusions

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CRA Lined Pipe Results
Advantages compared to existing processes:
• Diameter position can be controlled -> optimum mechanical bond
Hydrostatic Expander Head with Flexible Dies
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
> Results Research
Conclusions

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CRA Lined Pipe Results
Advantages compared to existing processes:
• Possibility to Pre-Expand starting materials to decrease Initial Gap
Hydrostatic Expander Head with Flexible Dies
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
> Results Research
Conclusions

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CRA Lined Pipe Results
Advantages compared to existing processes:
• Control on material flow
• No large air pockets end of pipe
• End of pipe equal to rest of pipe body (7 μm)
• No necessary over length CRA Liner (no sealing required)
• No risk of moisture
• No high force equipment required (incremental steps), only compared
to hydrostatic bonding
• Production output, only compared to Cladtek
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
> Results Research
Conclusions

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Test Results Gripping Force:
• Accepted market value: 40 – 160 N/mm2 for 18”Pipe
• Expander Head with Flexible Dies: > 150 N/mm2
Test Results
Test set-up push out test
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
> Results Research
Conclusions

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Conclusions
Expander Head with Flexible Dies Hydrostatic Expander
Diameter Control No Diameter Control
Possible Pre-Expansion of Starting
Materials
No Possible Pre-Expansion of Starting
Materials
Control on Material Flow No Control on Material Flow
No Large Air Pockets End of Pipe Large Air Pockets End of Pipe
No Necessary Over Length CRA Liner Necessary Over Length CRA Liner
No Risk of Entrapped Moisture Risk of Entrapped Moisture
No High Force Equipment Required High Force Equipment Required
Low investment costs High investment costs
Introduction
Pipe Expander
Process
CRA Standards
Bonding Principle
Results Research
> Conclusions
Validation of this process is not necessary as it already exists in a different
process from one of the key players (Cladtek)

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Questions
Questions?

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