IIW White Paper

9 Needs and challenges of major industry sectors for future applications

state welding technologies are being developed, however, that may begin to displace arc welding. Some emerging opportunities include field deployable techniques like friction stir welding, spinduction welding or magnetic pulse welding. This prediction is not made lightly; it is based on the fact that AUT has continued to develop since its industrial deployment in the late 80s and early 90s. In 2007, technology advancements have been made which enable AUT technology to be utilised for solid state welding techniques. Combine the fact that solid state welding has continued to become a more controllable process and that it is now inspectable using techniques accepted by industry and one can begin to envision what the future might look like. The reality that cannot be overlooked is that pipelines will continue to be fabricated using SMAW (“stick”) welding. Manual welding will remain a key component of the pipeline infrastructure for the foreseeable future. As long as manual welding exists in the pipeline industry, there will always be applications that require automation of the manual process. Thus, the expansion into GMAW (MIG) and orbital GMAW is normal. The potential use of hydrogen as an energy source presents an opportunity for the pipeline sector. The use of hydrogen will require the development of a hydrogen distribution network, of which pipelines will play a significant part. Although there are currently several hydrogen pipelines in service in the US, there are technological challenges associated with the transportation of hydrogen by pipeline. Hydrogen pipelines of the future will either be ‘new builds’ or conversions from existing pipelines. The pipeline industry is fighting the same labour constraints as every industry and constantly trying to developwelding techniques that overcome these constraints. So as inspection tools continue to be developed and optimised and new welding techniques are discovered, they will be deployed. Since it will take time to overcome the prevailing perception and opinions of these processes, the time for this deployment is unknown. Until then we will continue to see manual SMAW and Orbital GMAW predominate. gas pipelines There is an increasing need to replace coal and oil as the primary energy sources world-wide. This has resulted in an increase of the exploitation of the natural gas resources, often located in remote and difficult to reach fields. It has a strategic value to transfer these sources to the market in a cost-effective and safe manner. These large gas reservoirs around the world could provide global economic growth if industry could deliver the gas in an efficient and economic way. The long distance pipeline transportation of natural gas can be more economical than the LNG (liquidified natural gas) and compressed natural gas (CNG) transportation methods. This, however, require significant developments in high strength steels (HSS), advanced welding technologies, higher strength and toughness welding consumables and in fitness-for-service (FFS) methodologies for safe operation. Development of these technologies to use higher strength (beyond X80: up to X100 and X120 grade steels with minimum yield strength of 825 MPa (120 ksi)) linepipe steels to reduce the cost of gas transmission pipeline is considered to be a strategic target for industries. Significant amounts of research and development work are still needed in the fields of HS steels and consumables as well as in pipeline design and fitness- for-service assessment. It is obvious that the challenge will be to use increased yield strength (of 827 Mpa for X120 steel) with sufficient fracture toughness, adequate weldability, weldment (longitudinal and girth) integrity in terms of dynamic (running) ductile fracture and crack arrest while maintaining cost effectiveness. Here, a particular need will be focused on the improvements of weld joint properties, setting the design requirements and structural integrity assessment rules including crack arrest for these new generation line pipe systems. 9.4.3 Natural and CO 2

Transmission of dense, high pressure (liquid or supercritical) CO 2 in onshore and offshore pipelines is a new and challenging area for various industrial sectors. There is a need to develop new welded pipeline

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Through Optimum Use and Innovation of Welding and Joining Technologies

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