manufacturing process of welded tubes ...raiselife.eu/dissemination/docs/2nd_workshop/14...
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Raiselife seminar
Dusseldorf, November 28th 2019
MANUFACTURING PROCESS OF WELDED TUBES
SOLAR TOWER RECEIVER APPLICATION
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Umbilicals market for Oil & Gas:
• Super Duplex 2507 tubes
• ID ½’’ to 1½’’ → 2’’
• WT 1.0 to 3.4 → 4.5 mm
• Laser seam welded tubes
• AYS0.2>750MPa , UTS>900MPa
• One plant located at Venarey-les-Laumes
• Qualified by IOC and BV
New generation of superduplex stainless steel premium tubes
VALLOUREC UMBILICALS
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TUBES FOR UMBILICALS CHARACTERISTICS
► High quality grade 2507 (UNS S32750 / EN 1.4410) strip
• PREN 42.5
• Suitable pitting and crevice corrosion resistance
• Excellent resistance to SSC and HISC tests
► Control:
• NDT performed over the entire length of the finished tubes
(100%).
• Hydrostatic test performed internal hydrostatic pressure
► Tight dimensional tolerances
• No internal and external weld bead
• Wall Thickness (WT): +/- 5%
• Outside Diameter (OD): +/- 0.1mm (including ovalisation)
► Excellent tube mechanical properties
• Optimised strength
» YS0,2 > 750MPa
» UTS > 900MPa
• Elongation ≥ 25%
• Excellent fatigue properties
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Renewable energies with
first focus on tubes for CSP
DIVERSIFICATION PROGRAM
Capacity and capability
increase
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1.00 2.00 3.393.00 4.500.85
12.70
No
min
al In
tern
al D
iam
ete
r
15.88
19.05
22.23
25.40
28.58
31.75
38.10
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
16.10 x 1.00
12.90 x 1.15
25.6 x 1.45
25.4 x 1.53
19.05 x 1.82
31.75 x 2.95
mm
mminch
12.70 x 1.00
19.05 x 1.06 19.05 x 1.25
38.10 x 2.12
50.802VU2 range
VU1 range
12.70 x 1.14
19.05 x 1.70
19.30 x 1.73
16.00 x 1.4315.88 x 1.00
5.00
76.23
6.00
Wall Thickness
4.002.50 3.60
38.10 x 3.39
25,4x 3.59
31.75 x 4.49
50.8 x 4.52
31.75 x 2.27
ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
TUBES FOR RECEIVERS
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Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
TUBES FOR RECEIVERS
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Material : Ni based alloy (Haynes 230)
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Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
TUBES FOR RECEIVERS
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Material : Ni based alloy (Haynes 230)
Strip Preparation
& FormingLaser welding
Weld beads
finishingHeat treatment
Sizing &
polishing
NDT control &
marking
Strip
inspection &
decoiling
Coiled strip Intermediate reel
Laser longitudinal welding line
• Forming rollers give
progressively a round
shape to the strip
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Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
TUBES FOR RECEIVERS
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- Material : Ni based alloy (Haynes 230)
Strip Preparation
& FormingLaser welding
Weld beads
finishingHeat treatment
Sizing &
polishing
NDT control &
marking
Strip
inspection &
decoiling
Coiled strip Intermediate reel
Laser longitudinal welding line
• CO2 laser is used
• Energy can reach
8KW
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Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
TUBES FOR RECEIVERS
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- External and internal weld bead shall be properly removed
- Material : Ni based alloy (Haynes 230)
Strip Preparation
& FormingLaser welding
Weld beads
finishingHeat treatment
Sizing &
polishing
NDT control &
marking
Strip
inspection &
decoiling
Coiled strip Intermediate reel
Laser longitudinal welding line
• Bead are internally and
externally rolled
• External surface is brushed
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Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
TUBES FOR RECEIVERS
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- External and internal weld bead shall be properly removed
- Solution annealed (1177°C - 1245°C)
- Material : Ni based alloy (Haynes 230)
Strip Preparation
& FormingLaser welding
Weld beads
finishingHeat treatment
Sizing &
polishing
NDT control &
marking
Strip
inspection &
decoiling
Coiled strip Intermediate reel
Laser longitudinal welding line
• Heating then cooling inside
10 m long tunnel in a
controlled atmosphere
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Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
TUBES FOR RECEIVERS
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- External and internal weld bead shall be properly removed
- Solution annealed (1177°C - 1245°C)
- NDT tests (Eddy Current) of the whole tube
- Material : Ni based alloy (Haynes 230)
Strip Preparation
& FormingLaser welding
Weld beads
finishingHeat treatment
Sizing &
polishing
NDT control &
marking
Strip
inspection &
decoiling
Coiled strip Intermediate reel
Laser longitudinal welding line
• US: 100% of the tube is controlled
• EC: 100% of the tube is controlled
• OD and WT control
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TUBES FOR RECEIVERS
Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- External and internal weld bead shall be properly removed
- Solution annealed (1177°C - 1245°C)
- NDT tests (Eddy Current) of the whole tube
- Tubes with plain ends cut and deburred
- Material : Ni based alloy (Haynes 230)
Sizing &
straighteningCutting
Ends
preparation
Tube preparation line
Intermediate reel
Laboratory
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TUBES FOR RECEIVERS
Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- External and internal weld bead shall be properly removed
- Solution annealed (1177°C - 1245°C)
- NDT tests (Eddy Current) of the whole tube
- Tubes with plain ends cut and deburred
- Material : Ni based alloy (Haynes 230)
Sizing &
straighteningCutting
Ends
preparation
Tube preparation line
Intermediate reel
• Straight tube preparation
Laboratory
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TUBES FOR RECEIVERS
Solar
Welded rolled
tube for molten
salt application in
solar tower
technology
Tubes for Receivers
Specification
- Dimensions : ID 47.8 mm x WT 1.5 mm
ID 46.8 mm x WT 2 mm
- Cold worked
- Laser welded
- External and internal weld bead shall be properly removed
- Solution annealed (1177°C - 1245°C)
- NDT tests (Eddy Current) of the whole tube
- Tubes with plain ends cut and deburred
- Hydrostatic tests up to 6.9 MPa
- Material : Ni based alloy (Haynes 230)
Sizing &
straighteningCutting
Ends
preparation
Tube preparation line
Customer tubesIntermediate reel
• Hydrostatic test
Cleaning Drying PackingPressure test
Laboratory
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➢Receiver (straight) tubes: Grades 625 or Haynes 230
➢ In accordance to VU dimension range
➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:
TUBES FOR RECEIVERS
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➢Receiver (straight) tubes: Grades 625 or Haynes 230
➢ In accordance to VU dimension range
➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:
➢ Forming
TUBES FOR RECEIVERS
Finite Element Modelling
Numerical simulation of strip forming using :
• Roller shape
• Mechanical properties of strips
• Strips dimensions
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➢Receiver (straight) tubes: Grades 625 or Haynes 230
➢ In accordance to VU dimension range
➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:
➢ Forming
➢ Laser welding
TUBES FOR RECEIVERS
Finite Element Modelling
Numerical simulation of strip forming using :
• Roller shape
• Mechanical properties of strips
• Strips dimensions
Laser Welding tests
Laser welding tests on Haynes 230 strip using :
• CO2 laser
• Welding energy, focal distance..
• Dimensional check (tolerances)
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➢Receiver (straight) tubes: Grades 625 or Haynes 230
➢ In accordance to VU dimension range
➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:
➢ Forming
➢ Laser welding
➢ Heat treatment
TUBES FOR RECEIVERS
Finite Element Modelling
Numerical simulation of strip forming using :
• Roller shape
• Mechanical properties of strips
• Strips dimensions
Laser Welding tests
Laser welding tests on Haynes 230 strip using :
• CO2 laser
• Welding energy, focal distance..
• Dimensional check (tolerances)
Heat treatment tests
Heat treatment tests on Haynes 230 strip using :
• Dilatometer control
• Chemical etching
• SEM observations
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➢Receiver (straight) tubes: Grades 625 or Haynes 230
➢ In accordance to VU dimension range
➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:
➢ Forming
➢ Laser welding
➢ Heat treatment
➢ Microstructure
TUBES FOR RECEIVERS
Finite Element Modelling
Numerical simulation of strip forming using :
• Roller shape
• Mechanical properties of strips
• Strips dimensions
Laser Welding tests
Laser welding tests on Haynes 230 strip using :
• CO2 laser
• Welding energy, focal distance..
• Dimensional check (tolerances)
Heat treatment tests
Heat treatment tests on Haynes 230 strip using :
• Dilatometer control
• Chemical etching
• SEM observations
Metallurgical investigation
Microstructure investigation on Haynes 230 strip :
• Carbides
• Intermetallic phases
• Grain growth
• Precipitation ’/’’
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➢Receiver (straight) tubes: Grades 625 or Haynes 230
➢ In accordance to VU dimension range
➢ Industrialization study on Haynes 230 in Vallourec Umbilicals:
➢ Forming
➢ Laser welding
➢ Heat treatment
➢ Microstructure
➢ Mechanical properties
TUBES FOR RECEIVERS
Finite Element Modelling
Numerical simulation of strip forming using :
• Roller shape
• Mechanical properties of strips
• Strips dimensions
Laser Welding tests
Laser welding tests on Haynes 230 strip using :
• CO2 laser
• Welding energy, focal distance..
• Dimensional check (tolerances)
Heat treatment tests
Heat treatment tests on Haynes 230 strip using :
• Dilatometer control
• Chemical etching
• SEM observations
Metallurgical investigation
Microstructure investigation on Haynes 230 strip :
• Carbides
• Intermetallic phases
• Grain growth
• Precipitation ’/’’
Tensile tests
Tensile tests on Haynes 230 strip :
• Mechanical propertiers at room temperature
• Tensile specimens (1.6 mm and 2 mm)