Unique Characteristics of Hydraulically Expanded Long Seam Pipe

1. Unique Characteristics of Hydraulically Expanded Long Seam Pipe Jason Norris Dura-Bond Pipe, LLC Steelton, PA Dura-Bond Pipe, LLC

2. Content • Introduction • Mill Configuration • Topic Background Information • Discussion Topic • Conclusion Dura-Bond Pipe, LLC

3. Introduction • Dura-Bond Pipe, LLC was founded in 2003 • Purchased former Bethlehem Steel Corp., Steelton, PA • UOE Mill facilities on the location of Dura-Bond’s Fusion Bond Coating Plant. • Completely refurbished the forming, welding and finishing equipment. Extensively modified welders. Installed laser controlled seam tracking on the ID welders. • Upgraded Ultrasonic Equipment and Radiographic Equipment • Installed a complete destructive testing laboratory and sample preparation machine shop • Achieved API Q1 licensure October 2004 • Produced over 240,000 Tons 2006 through 2009 Dura-Bond Pipe, LLC

4. Mill Configuration • Manufacturing Process • UOE Double Submerged Arc Welded Long Seam Pipe • Forming and Welding Equipment • Double Sided Single Pass Planer • End Planer • Long Seam Double Sided Edge Crimper • U press – 7,000 tons • O press – 20,000 Tons • ID/OD Welders • 3 - ID Berkeley Welder 2-Wire Continuous Feed Machines • Lincoln Power-Wave Welder System • Laser guided wire feeder heads • 3 - OD AC/AC 2- Wire Continuous Feed Welder • Longitudinal seam welding is a “Continuous Welding System” and does not require tacking and run-on or run-off tabs. Dura-Bond Pipe, LLC

5. Mill Configuration • Finishing Equipment • Hydraulic Expansion and Hydrostatic Testing • 5,000 psi capacity • Double Ended End Beveling Machine • Hydraulic Expansion is the point of today’s discussion Dura-Bond Pipe, LLC

6. Evaluation Systems • NDT • Weld seam 100% Fluoroscopic inspection prior to expansion • Ultrasonic Inspection • Long seam system is an 11 channel machine with 7 probes and provides 100% inspection of the weld • Considering replacement with phased array system in 2011 • Pipe Body UT system has 4 wheel probes with a 4 channel transducer array in each wheel which provides helical inspection of 100% of the pipe surface. • Weld Radiographic • X-ray of pipe ends with up to 17” of film • Capable of 100% long seam weld x-ray Dura-Bond Pipe, LLC

7. Evaluation Systems • Destructive Testing Lab • Tensile Testing • Charpy Testing • Drop Weight Tear Testing • Vickers and Rockwell Hardness Testing • Machining facilities for sample preparation • Spectrographic analysis is performed off-site Dura-Bond Pipe, LLC

8. Product Capability • Size and Grade Capability • Low Strength pipe • A252, API 5LB, API 5L X42 • 24” OD to 42” OD • thickness to 1.000” • High Strength Pipe 24” OD to 42” OD • API 5L X52 – thickness to 0.850” • API 5L X60 – thickness to 0.825” • API 5L X65 – thickness to 0.800” • API 5L X70 – thickness to 0.775” • API 5L X80 – thickness to 0.750” • Wall thicknesses beyond listed max may be considered. Dura-Bond Pipe, LLC

9. Project Participation • Energy Transfer, 42” & 36” X70 • Exco Energy/Regency Gas, 36” X70 • Dominion 30” & 36” X70 • Northern Natural Gas 30” & 36” X70 • El Paso Energy 30” X70 • Kern River Gas Transmission 36 “ X70 & X65 • Colonial Pipeline 30” X52 • Texas Gas 26” & 30” X70 • Williams Gas 42” X70 Dura-Bond Pipe, LLC

10. Topic Background • Energy needs for North America have been increasing over the past 10 years • Many new pipeline projects, primarily natural gas, have been built especially in the past 3-4 years • Economics of gas transportation have resulted in a desire for increased operating pressures of natural gas lines. • The increased operating pressure goal has resulted in more stringent requirements being placed on the pipeline builders by regulators to assure pipeline safety. • Field hydrostatic testing of in-service pipelines can determine if the line can operate at increased pressures. • After field hydrostatic testing , an inspection pig can be run through the line to determine if deformation (bulging) took place as a result of the test. • If too much deformation has occurred, the situation must be addressed by the operator before approval is granted to operate at a higher pressure. Dura-Bond Pipe, LLC

11. Topic Background • It has been reported that in the process of field testing of pipe, that pipe with lower than expected yield strength has been discovered. • The Question is … How can the owner be sure of the yield strength of every foot of pipe in the line? Plate/coil mills and pipe mills utilize the required sample testing methodology to ascertain compliance with the production specification standard (API 5L). Dura-Bond Pipe, LLC

12. Discussion Topic • The problem of deformed pipe being discovered after field hydrostatic testing revolves around strength issues. • API 5L strength testing is a single random tensile test per 50 or 100 pipe test unit (lot) size. A tensile test unit requires 1 test per 100 pipes in the test unit. Typically a test unit is a “Heat” if it meets the test unit criteria. • Other API 5L required tests have different test unit sizes i.e. weld tensile, guided bend, weld charpy etc. Dura-Bond Pipe, LLC

13. Discussion Topic • The result of tensile test unit sampling is a statistical representation of skelp and pipe results assuming that the processing of the skelp for pipe applications has good process control and the changes in properties from forming are considered. • However, statistically, it is possible that pipe with lower yield strength could “slip” through the system undetected. This possible “slip” could result from a low tensile testing sample frequency of 1-4% depending on test unit size. • Is there a way to detect such an event in production without destructive testing? Dura-Bond Pipe, LLC

14. Discussion Topic • All JCO and UO long seam mills have expansion capabilities for dimensional control. • The two types of expansion methods are: • Hydraulic expansion – pressurized water is used to expand the entire pipe length at once. A set of sizing clamps contains the pipe during the expansion process and helps give the finished pipe its dimensional properties. • Mechanical expansion – uses mechanical “shoes” to expand the pipe. The sizing mandrel expands the pipe incrementally along the length. Dura-Bond Pipe, LLC

15. Discussion Topic Mechanical Expansion Hydraulic Expansion Dura-Bond Pipe, LLC

16. Expansion Dura-Bond Pipe, LLC

17. Expansion Video Dura-Bond Pipe, LLC

18. Discussion Topic • For hydraulic expansion, the pressure system is set up based on the product’s specified minimum yield strength, the diameter and wall thickness. • A unique characteristic of hydraulic expansion is that to fulfill the pressure requirement in this single step process (versus other multi-step systems), the yielding behavior of the entire pipe is monitored with a graphic recording display. This cannot be replicated with a multi-step expansion process. Dura-Bond Pipe, LLC

19. Expander Charts Dura-Bond Pipe, LLC

20. Discussion Topic • What hydraulic expansion means to customer confidence is that the yielding behavior (yield stress) of EVERY pipe can be seen, recorded and documented. • This means that every pipe has a “tensile test” and graphic records can show variations in yield strength from pipe to pipe. Dura-Bond Pipe, LLC

21. Discussion Topic • If a pipe yields lower than the minimum or higher than the maximum values allowed, it can be detected at the hydraulic expander. • An added benefit is that data from expansion records can be used to reveal the Bauschinger Effect on the end product. Dura-Bond Pipe, LLC

22. Setting Up Test Pipe Dura-Bond Pipe, LLC

23. Expander Graphic Normal and Low Yield Dura-Bond Pipe, LLC

24. Other Characteristics • Dimension and Shape • Properly installed and maintained expander dies make exceptionally straight pipe with uniform dimensions along the length of each pipe segment. • Possible field cuts along the pipe length will offer excellent fit to mill finished ends. • Uniform dimensions and shape provide efficient and productive double jointing and fusion bond coating processes. Dura-Bond Pipe, LLC

25. Conclusion • Hydraulic expansion shows the yielding behavior of every pipe expanded. • Strength variations from pipe to pipe can be seen in the hydraulic expander process. • In a sense, every pipe has a “tensile test” performed and documented. • Bauschinger Effect can be evaluated for different chemical compositions and skelp/plate rolling practices. Dura-Bond Pipe, LLC

26. Conclusion • More work needs to be done to study expander yielding behavior and actual pipe strengths to develop correlations. • Potentially, hydraulically expanded pipe can act as a screening mechanism for low strength pipe. Dura-Bond Pipe, LLC

27. Thank you for your attention. Dura-Bond Pipe, LLC