XI-929-09

THE PIPELINE-STEELS X100 AND X120

S. Felber, Institute for Building Construction and Technology (E 206),

Vienna University of Technology, Karlsplatz 13, A-1040 Vienna, Austria,
Tel ++43 1 58801 20640, Fax ++43 1 58801 20694,
email sfelber@mail.zserv.tuwien.ac.at
F. Loibnegger, Institute for Materials Research and Testing (TVFA - TU Wien),
Vienna University of Technology, Karlsplatz 13, A-1040 Vienna, Austria,
Tel ++43 1 58801 43061, Fax ++43 1 58801 43099,
email friedrich.loibnegger@tvfa.tuwien.ac.at

ABSTRACT

Nowadays already a few sections of pipelines are constructed of the pipeline-steels X100 or
X120. These pipeline-steels are discussed in detail as well as the projects performed. A com-
plete change from the steels X65 and X70 to the steels X80, X100, and X120 for pipelines has
not happened until now.

The paper deals with the development of the high strength pipeline-steels X100 and X120
with different approaches with respect to the chemical composition and the process parame-
ters for the thermomechanical rolling process. The corresponding welding processes with
welding parameters, the used consumable types, and heat-inputs of the joining process, pre-
heating and interpass temperatures, and so on, are discussed, as well as the sensitiveness
of different welding processes to hydrogen induced cracking and heat treatment.

Furthermore, it deals with the chemical composition of the tested materials and the mecha-
nical properties, as yield strength, tensile strength, hardness, and impact energy, as well as
metallographic examinations.

A big saving potential is in material costs and improved construction methods & equipment.
Project cost reduction may result from various benefits that can be derived from using high-
strength steels, even when the price per ton of the pipe increases as the material grade in-
creases. The benefits include lower pipe transportation costs, and lower pipe laying costs.
On the other hand the reduction in the manufacturing cost per ton of the pipe at a given
transport capacity of a pipeline is amplified not only by an increase in the material grade of
the steel but also by a reduction in the wall thickness of the pipe. Not only the pipe costs but
also the pipe laying costs have an important influence. Larger pipes also result in faster and
safer pipe lying with reduced costs for welding, testing, and site coating.

BENEFITS

Pipeline-steels X100 and X120, welding parameters, consumable types, preheating and in-
terpass temperatures for different projects. Determination of the mechanical technological pro-
perties, as yield strength, tensile strength, hardness, and impact energy. Comparison of the
values.

KEY WORDS

Pipes, pipelines, pipeline projects, thermomechanical rolling process, pipeline-steels, X100,

X120, different welding processes, manual metal arc welding, mechanized welding, CAPS,
mechanical properties, yield strength, tensile strength, hardness, impact energy.

1
 XI-929-09

1 INTRODUCTION

In former times construction steels with low yield strength, then normalized and microalloyed
C-Mn-steels were used for natural gas pipelines [1]. The development with regard to different
strength levels is shown in Figure 1 [1] to [4]. The next important step started in 1970 with the
use of the thermomechanical treatment [5] and [6] for the steel production for pipes. According
to this procedure since about 1973 the steel X60 and since 1977 the steel X70 were produced
as the dominant pipeline-steel types [1]. An improved processing method, consisting of ther-
momechanical rolling plus subsequent accelerated cooling, emerged in the eighties. By this
method, it has become possible to produce even higher strength materials like X80, having
further reduced carbon content and thereby excellent welding properties in the field. Addi-
tions of molybdenum, copper, and nickel enable the strength level to be raised to that of gra-
de X100, when the steel is processed to plates by thermomechanical rolling plus modified
accelerated cooling [7]. Unlike the development and introduction of the grades up to X70, the
introduction of the grade X80 takes longer time and is still going on [8] and [9]. Nowadays
some pipeline projects are already performed using the steel X80. Also, in some long distance
lines, where an increase of the capacity is not required, a reduction of the wall thickness (no
change of diameter and pressure) can be an economic impulse to use pipes out of X80. This
is going to be more and more implemented in Australia using HFI (ERW) pipes and in Cana-
da using spiral pipes of the grade X80 [10].

130 TM = thermomechanically treated

N = normalized DSAW
120
X120 TM
110
accelerating rate DSAW
yield strength [ksi]

100 of development
X100 TM
90
DSAW SMLS
80 X80 TM
70 X70 TM X65
60 X60 N TM
X56 N X60 TM
50 X52 N X52 TM
X42/46 X65 HIC
40
1950 1960 1970 1980 1990 2000 2010
year

Figure 1. Developmental periods for high strength line pipes [3] and [4]

A complete change from the steels X65 and X70 to the steels X80, X100, and X120 for pipeli-
nes has not happened until now. For some parts of longer pipeline projects in Northern Canada
pipes made of X100 are already in use since 2002 [11] and [12]. The installation of X100 has
been performed on the TransCanada system in Alberta by evaluating at the same time the
summer and winter construction aspects of this pipeline-steel [11], [13], and [14]. Exxon Mobil
and TransCanada PipeLines Ltd. claim that they have successfully demonstrated the field
installation of the world’s strongest line pipe, X120. One mile (1.6 km) of X120 line pipe was
installed as part of a longer pipeline looping operation in Northern Alberta in February 2004,
using the CRC-Evans welding process. The steel was jointly developed under an agreement
among ExxonMobil, Nippon Steel Corporation (NSC), and Mitsui & Co. Ltd. (Mitsui). The
yield strength is supposed to be 50 % higher than for X80 and is expected to substantially
reduce pipeline project costs. The companies showed that X120 was compatible with
standard pipeline construction practices, even under severe Canadian winter conditions. The
construction rate was comparable to rates expected for winter installation, and the weld
defect rate was lower than rates commonly reported for major pipeline projects [15] and [16].
The pipeline-steels X80, X100, and X120 are also planned to be used in the Sakhalin-Janan
Subsea [12] and [17].

2
 XI-929-09

2 THE PIPELINE-STEELS X100 AND X120

EUROPIPE started the development of X100 already in 1995. The use of materials with even
higher yield strength, such as grade X120, is the challenging next step. In the current line
pipe standards a grade X100 and X120 is not specified, the chemical compositions and me-
chanical properties of these steels are shown in Supplement 1 the comparison of designa-
tions according to different standards in Supplement 2. In regard to producers of the pipeline-
steel X100 see Supplement 3.
In regard to a further development from X70 to X80 it could be assumed that an increase of the
strength properties (tensile strength and yield strength) is possible without any difficulties by just
a small increase of the additional alloying elements, which however unfortunately is not the ca-
se. Figure 2 shows the occuring minimum yield strength values dependent on the carbon
equivalents [18]. According to [19] there are two processes of different cooling capacity: (I)
water cooling after rolling to intermediate temperature (600 ~ 500 °C) followed by air cooling
(DAC I) and (II) water cooling to ambient temperature after rolling (DAC II). DAC I is applied
to X80 and DAC II to X100. For further information about thermomechanical treatments see
[20] to [26].

1 100
developments

1 000 TM-DQ
+A TM-DQ
+A
minimum upper yield strength [N/mm ]

900
2

special steels

TM-BA
800 +A
y
ci t

TM-BA
lo
ve

+A
g
in

700 TM-BA
ol
co

TM-BA
standardized steels

600
V
+alloying
500 TM TM elements
+micro-alloying
elements
N
400 C-Mn

WBB heavy plate

300
wall thickness
0.2 0.3 0.4 0.5 0.6 0.7

Mn Cr + Mo + V Cu + Ni
C eq IIW = C + + +
6 5 15

N normalized
V water quenched and tempered
TM thermomechanical rolling
BA accelerated cooling
DQ direct quenching
A annealed
WBB hot rolled wide strip

Figure 2. Yield strength versus carbon equivalent for different TM-rolling treatments [18]

3
 XI-929-09

As can be seen in Figure 3 three different approaches have been developed for grade X100
with respect to the chemical composition and the process parameters for the thermomecha-
nical rolling process. Approach A is characterized by a relatively high carbon content and
carbon equivalent of 0.49 as well as a low cooling rate and a relatively high cooling stop tem-
perature. Approach B with a carbon equivalent of only 0.43 has been used in combination
with fast cooling rates down to a very low cooling stop temperature. Approach C enables the
desired property profile to be achieved through an optimized two-stage rolling process in
combination with medium carbon content, a medium carbon equivalent and optimized coo-
ling conditions. This approach ensures excellent toughness as well as fully satisfactory field
welding ability of the pipes. It combines a medium alloying content right between the first two
approaches. For further information see [27] and [28].

steel Ceq IIW

C-content
chemistry
0.49
0.08 % 0.48

0.06 %
0.05 % 0.43
A C

hi g
l ow h

h l ow
hig B
cooling rate cooling cooling stop
(AcC) parameters temperature (AcC)

Figure 3. Three different approaches to reach API grade X100 [28]

In regard to the development of the steel grade X120 the greatest challenge has been to de-
velop a micro-structure with high strength and toughness, which is additionally weldable. For
that purpose the following three possibilities of a development of the micro-structure have
been investigated:
- mainly lower bainite,
- dual phase, and
- tempered lamellar martensite.
The chemical composition of the tested three micro-structures are shown in Table 1.

micro-structure C Mn Ni Mo Cr Cu Nb V
min 0.03 1.0 0.0 0.2 0.0 0.0 0.01 0.02
lower bainite
max 0.09 2.5 2.0 0.5 0.5 0.5 0.04 0.08
min 0.05 0.5 0.0 0.2 0.0 0.0 0.01 0.02
dual phase
max 0.09 2.0 2.0 0.8 0.5 0.5 0.08 0.10
tempered lamellar min 0.06 0.2 0.5 0.2 0.0 0.5 0.02 0.03
martensite max 0.09 2.0 2.0 0.8 0.5 2.0 0.12 0.15
Table 1. Chemical composition of the three micro-structures [29]

Some of the tested steels contain boron and others not. Boron accelerates the hardening of
steels with low carbon content and little alloying elements. It also supports the development
stages, which are dominated by grain degeneration, like the forming of ferrite, granular baini-
te, and upper bainite. Therefore, the addition of boron makes the austenite transformation
possible, as much as the forming of lower bainite and lamellar martensite. The steels con-
taining boron shall be melt carefully and handled with care to contain boron in permanent
solution. Boron has to be protected of a combination with oxygen, nitrogen, and carbon.

4
 XI-929-09

Recrystallization rolling produces fine and homogeneous austenitic grain. The plates are
heated to temperatures between 1 000 and 1 200 °C to heat the main part of the alloy to a
durable solution. The mechanical properties of the three X120 micro-structures are shown in
Table 2.

YS TS YS / TS DBTT CVN [J] at

micro-structure [N/mm²] [N/mm²] [-] [°C] -40 °C
lower bainite 690 - 900 931 - 1 100 0.75 - 0.85 -60 - -90 230 - 300
dual phase 620 - 860 960 - 1 140 0.65 - 0.75 -80 - -90 250 - 300
tempered lamellar
960 - 1 030 1 000 - 1 070 0.94 - 0.99 -90 - -105 100 - 240
martensite
Table 2. Mechanical technological properties of the three tested micro-structures of X120
(DBTT … Ductile-to-Brittle Transition Temperature, CVN … absorbed impact energy tested
with Charpy-V specimens) [29]

The production of the pipes made of X120 is reduced presently to a wall thickness of 12 mm
to 20 mm. This range can be enlarged by improved processing procedures [29]. For further
information see [27], [28], and [30] to [38].

Pipeline-Steel X100
This high strength material has a specified yield strength of 690 N/mm2 minimum and a tensi-
le strength of 865 N/mm² minimum, which allows high operation pressure with small wall
thickness. The chemical composition and the mechanical properties are shown in Table 3.

C Si Mn P Cr Al Ti S B
0.070 0.030 1.900 - - - 0.020 - -
Ni Mo V Nb Cu N Ca YS TS
0.300 - - 0.050 0.200 0.005 - 690 N/mm2 865 N/mm2
absorbed impact energy 180 J at 0 °C
-… details not available
Table 3. Chemical composition (values in mass-%) and strength values of the tested steel
X100 [6] and [39] to [41]

For X100 no technological breakthroughs in TM rolling and accelerated cooling were neces-
sary, just an optimization of the existing technology. Since 1995 six small mill production
trials have been completed in a wall thickness range from 12.7 mm up to 25.4 mm and
diameters between 30” (768 mm) and 56” (1 434 mm) [42]. As a result, the production win-
dow becomes narrower but a heat treatment of the plates or pipes is obviously not neces-
sary. Some investigations performed with this steel are described in [43]. For further infor-
mation see [3], [35], [41], [42], and [44] to [58].

Pipeline-Steel X120
This steel has a specified yield strength of 830 N/mm² minimum and a tensile strength of 931
N/mm² minimum.
The chemical composition of the test material used can be seen in Table 4, where also the
specified mechanical properties are shown.

C Si Mn P S Al Cr + Ni + Mo
0.05 0.3 1.9 0.01 0.0006 0.04 < 0.5
Nb + V + Ti B N PS TS
< 0.06 0.001 0.004 890 N/mm² 1 035 N/mm²
YS / TS ≈ 86 %, absorbed impact enery 280 J at -40 °C
-1... details not available
Table 4. Chemical composition (values in mass-%) and mechanical properties of the tested
steel X120 [59]

5
 XI-929-09

The required properties of a steel in grade X120 are only attainable with a mainly bainitic
micro-structure that predominantly consists of lower bainite. Due to the combination of a high
dislocation density and a very fine scale substructure, so-called domains, this lower bainitic
micro-structure is a reasonable option for an ultra-high-strength level along with sufficient
toughness properties. The basic alloying system contains Cu, Ni, Cr, Mo, and the micro-
alloying elements V, Nb, Ti, and B. There is a very narrow production window in terms of
chemistry and rolling and cooling conditions. One of the special challenges is the pipe for-
ming, especially the U-forming step is affected by spring back. It can lead to shells that can-
not be inserted into the O-press [42]. For further information see [42] to [44], [58], and [60] to
[63].

3 WELDING OF PIPES

For pipelines the welding processes Manual Metal Arc Welding (MMAW), Gas Metal Arc
Welding (GMAW), Tungsten Inert Gas (TIG) Welding, and Submerged Arc Welding are in ge-
neral used. In regard to more details on the welding processes see [64] and [65].

MMAW:
Supplement 4 shows a welding procedure specification for X100 and Supplement 5 one for
X120.

GMAW:
In regards to the gas metal arc processes just the CAPS-process should be explained more in
detail, because it was tested for welding in the field for X100.
The CAPS-Process:
The CAPS-process, the "Cranfield Automated Pipewelding System”-process, is a special gas
metal arc welding process on the basis of the tandem-technology, which was developed by
Cranfield University for pipeline engineering. The CAPS process makes pipeline welding fas-
ter and more economic, even under hard environmental conditions, as extreme cold climate
[66]. Although the potential of multi-wire GMAW was first explored as early as the 1950s, it
has not become commercially viable as the power source technology in the process was un-
stable. Tandem GMAW differs from conventional GMAW as two welding wires are passed
through the same welding torch. A single torch with two contacts is used to feed both wires
into a single weld pool. This tandem GMAW torch is specifically developed for the use of nar-
row gap weld preparations utilized in pipeline welding. Further development led to the use of
two tandem torches on a single carriage, called therefore “dual tandem welding”. The high
speed of tandem GMAW is retained and two passes are deposited simultaneously [67] to
[70].
The weld metal micro-structure and metallurgical properties are also similar to conventional
mechanized pipeline welds. CAPS is therefore suitable for the use on all line pipe materials
including X100 steels. The system can be fitted to any welding head using dual oscillation
capabilities. It is important that each torch has a separate oscillator to allow the last fill and
cap passes to be completed simultaneously. Because of the high travel speed, an oscillation
rate of more than 400 beats per minute is required to avoid a “saw-tooth” effect. Travel
speeds of 1 m/min can be used for all filler layers and speeds of 1.5 m/min can be used in
the position 2G. This compares with speeds of approximately 50 cm/min for the mechanized
GMAW process currently used for pipelines. Surprisingly, it was found that the cap pass
could also be welded at 1 m/min. The cap pass is normally the slowest pass with travel
speeds of approximately 30 cm/min. The girth welds were satisfying X80 mechanical tests
requirements [67]. The chemical compositions of these welding rods are given in Supple-
ment 6. For detailed information on the root pass and the filler layer technique see [71].
The mentioned Alaska gas pipeline made of X100 will be built with a diameter of 1 321 mm
and a wall thickness of 22.9 mm. The yield strength of the weld metal will be 810 N/mm2.
These requirements were simulated in field tests with the pipeline-steel X80 with a pipe
diameter of 1 016 mm and a wall thickness of 19.1 mm from March 3 to 13, 2003 with the

6
 XI-929-09

CAPS-process in Edmonton, Alberta, Canada. The preparation of the joint was similar to the
one for the CRC-Evans-process, see Figure 4 [66] and [72].

°
- 52
45° 5°
2.3
1

1.5
4.0 - 5.0

37. 5
°

Figure 4. Preparation of the joint for the CAPS-process and macroscopic picture of a
circumferential joint with a wall thickness of 14.9 mm made of the pipeline-steel X100 [73]

The pipes were preheated to 100 °C before the internal layer was welded. The welding wire
was GSNi1Mo (1 % Ni, 0.3 % Mo). All layers were protected with a mixed Ar gas with 5 %
He, 12.5 % CO2. The internal welding device had 4 welding heads using the wire ER480S-6.
After the root pass, the welding tents were built up and the external layers were welded with
the CAPS dual-tandem-process with the wire ER690S-G. The welding velocity was double
the one of the root pass for the filler layers and twice as large as common in pipeline engi-
neering. For the top layer single-tandem-gas metal arc welding was used [66]. In regard to
further information and the mechanical technological properties see [66], [68], [69], [71], and
[74] to [88].
At the beginning of January 2002 the work started in Canada with single-tandem-devices on
a pipe with a diameter of 610 mm made of X80 and with dual-tandem-devices on a pipe with
a diameter of 914 mm made of X100, and in September 2002 the first pipeline was laid made
of X100 by TransCanada Pipelines [73]. The pipes can only be laid in winter, when the
ground is frozen enough to hold the weight of the construction equipment and the snow and
ice protects the tundra form permanent damage by vehicles. The 24 m long pipes must be
welded inside a special shelter. This protective enclosure is transported from weld-seam to
weld-seam suspended from a side-boom tractor. Each welding shelter needs to be self-
sufficient, carrying all equipment and consumables for the welding operation and powering
the welding power sources from a diesel generator. To obtain the largest welding speeds,
welding has to be performed vertical down with one machine on each side of the pipe. The
welding passes shall be made by using the RMS Internal Welding Machine. This equipment
acts as an internal alignment clamp for the pipe to align the pipe bevels and incorporates 4
GMAW welding heads that travel around the inside of the pipe at a speed of 762 mm/min.
Once the root is completed, the welding shelter shall be set over the weld and the external
passes shall be completed using the CAPS dual-tandem process. Each welding machine
carries two tandem welding torches spaced 70 mm apart, so two weld passes can be depo-
sited simultaneously. Three weld runs shall be performed with dual-tandem GMAW, before
the final cap pass is made with single tandem GMAW. All filler layers shall be welded at a
travel speed of 1 300 mm/min, which is more than twice the speed of the current welding
technology used for pipeline construction. The Alaska Gas Pipeline is being designed using a
X100 line pipe. However, X100 has never been used in a long-distance pipeline before and
the 690 N/mm² of the pipe must be overmatched by the strength of the weld metal. BP requi-
res a minimum weld metal yield strength of 810 N/mm² for X100 [72]. The completed weld
has a very similar profile to conventional mechanized pipeline welds so conventional radio-
graphy and automated ultrasonic testing can be used for welding inspection. The weld metal

7
 XI-929-09

micro-structure and metallurgical properties are also similar to conventional mechanized pi-
peline welds [67]. Supplement 7 shows the welding parameters for the CAPS-process.
Recommendations of consumables for different pipeline-steel grades according to Boehler
can be found in Supplement 8.
Figure 5 shows the sensitiveness of different welding processes to hydrogen induced
cracking.

40
ml of diffusible hydrogen

111-C unacceptable
100 g steel

acceptable

5
111-B and 136
2
135 and 136

X65 X60 X100 X120

sensitivity for hydrogen induced cracks

Figure 5. Sensitiveness of different welding processes to hydrogen induced cracking

(111 ... manual metal arc welding, C ... cellulosic electrodes, B ... basic electrodes,
135 ... MAG-welding with solid wire, 136 ... MAG-welding with filler wire) [89] and [90]

4 HEAT TREATMENT OF PIPES

According to [91] with the Taper test the maximum hardness is identified depending on the
cooling time t8/5 and two different wall thicknesses, see Figure 6. It shows clearly that the
influence of the cooling time and hardening is very small for this steel. With the Tekken-test it
was found, see Figure 7, that the preheating temperature should be at least 125 °C. It should be
mentioned that for X100 cracks in the weld metal are more likely than interpass cracks [91].
ignition spot
30 mm

70 mm 200 mm
thickness
kJ/cm
mm
64 133 thickness of the wedge [mm]
17 22 18 16 14 12 10
9.5 18 16 14 12 10
450
maximum hardness HV 10

400

350

300
0.5 2 5 10 20
cooling time t8/5 [s]

Figure 6. Taper test at X100 [91]

8
 XI-929-09

200 60°
A

150

t
60 80 A' 60
A - A'
100
thickness 64 mm 133 mm
surface

number of cracks [%]

80 tr. microgr.
root pass
60

40

20

0
0 50 100 150 200
preheating temperature [°C]

Figure 7. Tekken test on X100 (tr. microgr. … transverse micrograph) [91]

In Supplement 9 the preheating and interpass temperatures, as specified by the manufactu-

rers or used in welding, are collected.

5 WELDING TECHNOLOGICAL EXAMINATIONS AND MECHANICAL TECHNOLOGICAL

PROPERTIES

Pipeline-Steel X100
The impact energy values of the test plate of the pipeline-steel X100 are shown in Figure 8.
In regard to combined welding of this steel with cellulosic and basic electrodes of this steel
see the welding procedure specification Supplement 4, in regard to GMAW with a single or
dual torch see [92], in regard to MMAW and SAW see [90], in regard to mechanized rolled
welds see [85], and in regard to results of different laser and laser hybrid welds on X100 see
[93].

300
X100-longitudinal specimen
X100-transverse specimen
250 X120-longitudinal specimen
X120-transverse specimen

200
impact energy [J]

150

100

50

0
-200 -160 -120 -80 -40
temperature [°C]

Figure 8. Impact energy values over the temperature for the pipeline-steels X100 and X120

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 XI-929-09

Pipeline-Steel X120
The impact energy values of the test plate of the pipeline-steel X120 are shown in Figure 8.
In regard to manual metal arc welding of this steel see the welding procedure specification
Supplement 5. In regard to further results see [42].

6 METALLOGRAPHIC EXAMINATIONS

After taking of the specimens, marking, and the first grinding or flattening of the surfaces of
the specimens, the surfaces have been fine-ground in steps up to a granulation of 4 000 μm.
After grinding, the surface of the specimens has been polished in steps down to 1 μm. Unfor-
tunately, not all the materials react in the same way to the etching, which led to strong con-
trasts and coloring on the light microscopic pictures.
The alcoholic nitric acid (HNO3 (nital etching fluid)) used for the etching process is a grain
boundary etching fluid. The etching with nitric acid is especially useful for unalloyed and low
alloyed structural steels, so also for the ferritic-pearlitic and bainitic steels. It results into a
sufficient etching already after a few seconds, depending on the material and the concen-
tration of the etching fluid [94] and [95].
etching fluid: 1 to 5 cm³ nitric acid (HNO3),
100 cm³ ethyl alcohol (methanol, ethanol) [96].
The grain boundary etching has been performed with nital. The pearlite and the grain
boundaries stand out dark against the ferrite. In case of the tested ferritic-pearlitic pipeline-
steels X70 etching times of approximately 10 to 15 seconds were appropriate. In case of the
tested bainitic pipeline-steels X80 and X120 the etching times have been slightly longer to
achieve a good contrast of the grain boundaries.
For the light microscopic examinations, see also [97] and [98], a longitudinal, a transverse,
and a surface micrograph, see Figure 9, have been performed.

microscopic pictures of the pipeline-steels (etched with nital 2 %)

X70 (L) X70 (S) X80 (B) X80 (N) X120

Figure 9. Structure of the pipeline-steels X70, X80, and X120 (magnification )

In case of the pipeline-steel X120, the arithmetic averages of the determined microhardness
values have been HV 330 / 0.1 for the longitudinal cross-section, HV 338 / 0.1 for the
transverse cross-section, and HV 323 / 0.1 for the flat cross-section. In comparison to that
the normal Vickers hardness tests resulted in average hardness values of 320 HV10 for the
longitudinal cross-section, of 320 HV10 for the transverse cross-section, and 325 HV10 of
the flat cross-section.

7 DESIGN, SAFETY, ECOLOGICAL, AND ECONOMICAL ASPECTS FOR PIPELINES

For information about design factors, design codes, and safety factors see [99] to [107], in re-
gard to fatigue design and fatigue assessment see [99], [100], [103], and [108] to [112]. More
information on “Good-Workmanship” or “Fitness-for Purpose” can be found in [99] and [113]

10
 XI-929-09

to [120], on construction in [121]. Since 1964 also safety requirements against earthquakes
have been taken into consideration in most of the countries [113], [122], and [123].
Often over- or undermatching is discussed in case of welding procedure qualifications.
Overmatching means that the ultimate strength of the weld metal is larger than the strength
of the base material:

YS weld metal > YS base material (1)

If this requirement is accepted for the area construction of the pipeline, the following effects
have to be considered:
- the steel manufacturers have to meet the specifications and
- the consumable manufacturers have to produce suitable consumables [2].
For further information, especially in regard to pipeline-steels with higher strength than X70,
see [102] and [124] to [127].
Undermatching means that the yield strength of the base material is higher than the one of
the weld metal.

YS weld metal < YS base material (2)

For more details see [102] and [128] to [131]. For information on mismatching see [132].
In Figure 10 the entire project costs for the building of a pipeline are spread in percentage of
the main cost causes. It can be clearly seen that the main costs are building and material
costs. A big saving potential is therefore just in case of these costs [133] and [134], but in
general the following considerations lead to cost savings:
• high strength pipe
o reduced material costs
o higher operating pressures
• higher design factors
o higher operating pressures
• high productivity welding / inspection
• improved construction methods & equipment
Also according to [135] half of the entire pipeline costs are building costs, and so the welded
joints per day. This amount is mainly influenced by the welding velocity and especially by the
welding velocity for performing the root pass.
engineering and operator
design 3%
7%
communication
2%

material
34 %

construction
54 %

Figure 10. Typical distribution of costs for the building of an onshore natural gas pipeline
[133] and [134]

A major cost factor are “fitness for purpose“-considerations, which are especially influenced
by the repair rates. For European pipelines the repair rates are 5 of 100 welded joints and
the “cut out“-rates (e.g. because of cracks) 0.3 of 100 welded joints. A repair rate of 3 to 5 %
percent is often seen as the best compromise solution between maximum welding velocity
and optimum quality, see also [136]. The mainly occurring defects in case of welding of on-
shore pipelines are slag inclusions, followed in general by defects in the root pass. The repair
costs could be reduced substantially, if the acceptance criteria for slag inclusions and other

11
 XI-929-09

voluminous defects were less strict, and the welding of the root pass were inspected and
checked more accurately. Mechanized welding processes cannot be found very often in
Europe, with the exception of Russia. The repair rates for these processes are certainly al-
ready below the ones of 17 to 23 %, known from older publications from Russia [137]. [138]
reports on the 50 km field trial at the RUHRGAS project, performed with the CRC process,
that only 4 % of the welds had to be repaired. Also the CAPS process as field trial in Canada,
performed by Cranfield University and Fronius, showed repair rates of 3.9 %. In this field trial,
a grade X80 pipeline with a length of 3 km including 182 welds has been performed under
arctic conditions of -50 °C. This field trial is one of the primary parts to the big project of the
Alaska Gas Pipeline planned with the pipeline-steel X100, with a total length of approxima-
tely 5 700 km. Further projects using the CAPS process in Indonesia, Korea, and Canada
are planned [139]. In case of the TIG hot wire welding process used on a pressure pipe ma-
de of X100, the defect rate of 0.3 % at the beginning could be reduced to below 0.1 % [140].
Project cost reduction may result from various benefits that can be derived from using high-
strength steels, even when the price per ton of the pipe increases as the material grade in-
creases.
The benefits include:
- reduced quantity of steel required,
- lower pipe transportation costs, and
- lower pipe laying costs.
The use of grade X80 line pipes in the construction of the first RUHRGAS X80 pipeline led to
a material saving of approximately 20 000 t to the total amount of approximately 145 000 t,
compared with grade X70 pipes through a reduction of the wall thickness from 20.8 mm for
X70 to 18.3 mm for X80. This resulted also in a reduction of the pipe laying costs, because of
reduced pipe transportation costs and reduced welding costs due to reduced welding times
needed for the thinner walls [40]. According to [113] a total cost reduction of approximately 5
% is expected by upgrading from X65 to X80 and approximately 8 % by upgrading to X100,
and, according to [141], the use of X80 pipe should provide an overall cost saving, compared
to X70 pipe, equivalent to 8 - 12 % of the total pipe supply cost or 3 - 5 % of total project
cost. The use of materials with still higher strength, such as grade X100 or grade X120 could
lead to further material cost savings, as illustrated in Figure 11.
3 500

3 000

2 500
costs [USD/m]

2 000

common costs
1 500
welding
1 000
laying

500 materials

not identified
0
API 5L X70 API 5L X80 API 5L X100

Figure 11. Estimated costs per meter pipelines [56]

A preliminary economic evaluation as feasibility study on X100 has been performed in 1997.
Costs have been evaluated for several hypotheses:
- Steel costs have been estimated according extrapolations from lower grades.
- Costs of fittings and valves have been considered as a constant portion of the total steel
costs.
- Transportation costs have been evaluated as dependent on the steel weight.

12
 XI-929-09

- Laying costs have been analyzed completely: trenching and field bending have been consi-
dered constant for both solutions, and welding costs have been divided in two parts,
one constant and the other proportional to the thickness. Moreover, the possibly higher
costs of consumables and the possibly greater difficulties for welders has been taken
into consideration.
- The other costs, like costs for coating and cathodic protection, have been considered to be
equal for both solutions.
On the other hand the reduction in the manufacturing cost per ton of the pipe at a given
transport capacity of a pipeline is amplified not only by an increase in the material grade of
the steel but also by a reduction in the wall thickness of the pipe. A reduction of the diameter
of the pipe with the same wall thickness and a simultaneous increase in the pipeline opera-
ting pressure would represent a more favorable solution to the problem [27]. Not only the
pipe costs but also the pipe laying costs have an important influence. The use of pipes with a
length of 18 m results in a reduction of the number of girth welds required in the construction
by approximately 33 % compared with the use of pipes with a length of 12 m. Larger pipes
also result in faster and safer pipe lying with reduced costs for welding, testing, and site
coating. Of course, also the use of intermediate lengths between 18 m and 12 m leads to
reduced pipe laying costs, should the pipe lengths be restricted for transport reasons [47]. Of
great importance are the same internal pipe diameters and out of roundness tolerances. To
make the pipe more stable and, thereby, simplifying handling, it is necessary that the dia-
meter to wall thickness ratio should be less than 100. Since thin-wall pipes are aligned by
means of an internal alignment clamp in the field, out-of roundness of the pipe ends is not as
important as the same internal diameter. The same diameter can be achieved particularly
with expanded pipes. Large pipe diameters require more care in handling above the ditch. If
the pipe laying requires a large number of field-bent pipes, contractors prefer submerged-arc
welded pipes with lengths of 16 to 18 m [47].

8 DISCUSSION OF THE RESULTS

For X100 no technological breakthroughs in TM rolling and accelerated cooling were neces-
sary, just an optimization of the existing technology. The production window becomes nar-
rower but a heat treatment of the plates or pipes is obviously not necessary. The required
properties of a steel in grade X120 are only attainable with a mainly bainitic micro-structure
that predominantly consists of lower bainite. Due to the combination of a high dislocation
density and a very fine scale substructure, so-called domains, this lower bainitic micro-struc-
ture is a reasonable option for an ultra-high-strength level along with sufficient toughness
properties.
Unfortunately there were no values for fracture toughness investigations of the pipeline-
steels X100 and X120.
Further investigations for evaluation of these pipeline-steels should be done. Perhaps it is a
benefit to make some experiences on investigations in the laboratory, the subjects are:
• examinations on the pipeline-steel X100 and X120,
o CTOD,
o hardness,
• repair rates, and repair procedures,
• high productivity inspection, and
• improved construction methods & equipment.

9 ACKNOWLEDGMENTS

The authors thank the staff of the Institute for Testing and Research in Materials Technology
(TVFA GmbH) of the Vienna University of Technology, of OMV-EEB-TS, of Boehler Welding,
and of VOEST Alpine Steel Linz for their help.

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[106] Hopkins, P.: High Design Factor Pipelines: Integrity Issues. WTIA International Pipeline Integrity Conference,
Wollongong, Australia, March 7 - 9, 2005, paper 1.
[107] Blackman, S.A.: An economic assessment of mechanized welding of high-strength linepipe for the Australian
pipeline industry. Pipes and Pipelines International, vol. 48 (2003) no. 2, March / April, pp. 27-37.
[108] Zhang, Y.H., Maddox, S.J., Razmjoo, G.R.: Experimental study and prediction of fatigue crack growth in girth
welded pipes. OMAE:2002 Offshore Mechanics and Arctic Engineering Conference, Oslo, Norway, June 23 -
28, 2002.
[109] Erdelen-Peppler, M., Knauf, G., Marewski, U., Reepmeyer, O.: Longitudinal welded pipes with enhanced
th
fatigue strength (Hifa ® pipe). 4 International Conference on Pipeline Technology, Ostend, Belgium, May 9 -
12, 2004, Europipe GmbH, Ratingen, 2004.
[110] Macdonald, K.A., Maddox, S.J.: New guidance for fatigue design of pipeline girth welds. Engineering Failure
Analysis, vol. 10 (2003) no. 2, April, pp. 177-197.
[111] Chapetti, M.D., Otegui, J.L., Motylicki, J.: Fatigue assessment of an electrical resistance welded oil pipeline.
International Journal of Fatigue, vol. 24 (2002) no. 1, January, pp. 21-28.
[112] Bai, Y., Knauf, G., Hillenbrand, H.-G.: Materials and design of high strength pipelines. Europipe GmbH, Ratin-
gen, 2000.
[113] Nagahama, Y., Yamamoto, S.: High Performance Steel Pipes and Tubes. NKK Technical Review (2003) no.
88, pp. 81-87.
[114] Barbaro, F.J.: Requirements for Welding X80 Grade Linepipe. WTIA International Pipeline Integrity Confe-
rence, Wollongong, Australia, March 7 - 9, 2005, paper 17.
[115] Bilston, K., Dietsch, A., Fletcher, L.: Performance requirements for onshore pipeline girth welds in Australia a
discussion paper. WTIA/APIA Panel 7 Research Seminar, Wollongong, Australia, October 26, 1995, paper 8.
[116] Shuanlu, L., Yong, H., Changyi, Q., Pengbin, Y., Xinwei, Z., Jinheng, L.: Crack and fitness-for-service assess-
ment of ERW crude oil pipeline. Engineering Failure Analysis, vol. 13 (2006) no. 4, June 2006, pp. 565-571.
[117] Denys, R.M.: Weld-defect acceptance models need more validated inputs, Part 2: Using good mechanical,
toughness and defect-size data could reduce unneeded repairs. Pipe Line & Gas Industry (1999) October, pp.
59-64.
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[118] Hopkins, P.: Limitation of fitness-for-purpose assessments of pipeline girth welds. 7 NG-18/EPRG, Joint
Biennial Technical Meeting on Line Pipe Research, Calgary, Alberta, Canada, August 29 - September 1, 1988,
paper 22.
[119] Roodbergen, A.H., Denys, R.M.: Limitations of fitness for purpose assessments of pipeline girthwelds. Pipe
Technology, International Conference, Rome, Italy, November 17 - 19, 1987.
[120] Fazzini, P.G.,Cisilino, A.P., Otegui, J.L.: Experimental validation of the influence of lamination defects in
electrical resistance seam welded pipelines. International Journal of Pressure Vessels and Piping, vol. 82
(2005) no. 12, December, pp. 896-904.
[121] Nayyar, M.L.: Piping Handbook. Sixth Edition, McGraw-Hill Inc., New York, St. Louis, San Francisco, Auckland,
Bogotá, Caracas, Lisbon, London, Madrid, Mexico, Milan, Montreal, New Delhi, Paris, San Juan, São Paulo,
Singapore, Sydney, Tokyo, Toronto, 1992.
[122] Akiyoshi,T., Fuchida, K., Shirinashihama, S., Tsutsumi, T.: Effectiveness of Anit-Liquefaction Techniques for
Buried Pipelines. Transactions of ASME, Journal of Pressure Vessel Technology 116 (1994) August, pp. 261-
266.
[123] Ozaki, H.: Gas Industry and Technical Activities of the Japan Gas Association. Norway-Japan Seminar "Mile-
stones in onshore/offshore pipeline research", Tokyo, Japan, May 27, 2003.
[124] Denys, R.M.: Methods for the assessment of girth weld strength. WTIA/APIA Panel 7 Research Seminar,
Wollongong, Australia, October 26, 1995, paper 7.
[125] Graef, M.K., Niederhoff, K.A.: Overmatching Criterion and Manual Welding of Linepipes in Grades ≥ X 70.
Pipeline Technology Conference, Ostend, Belgium, September 11 - 14, 1995, vol. 1, pp. 487-504.
[126] Schwalbe, K.-H.: Welded joints with non-matching weld metal-crack driving force considerations on the basis of
the Engineering Treatment Model (ETM). International Journal of Fracture, 62 (1993) pp. 1-24.
[127] Chuanjing, Z.: Study for West-East gas pipeline shows safety benefits of overmatched girth welds. Oil and Gas
Journal, vol. 101 (2003) March 10, pp. 62-65.
[128] Boothby, P.J.: Pipeline-Schweissen in der Gasindustrie in Grossbritannien. Schweiss- und Prueftechnik, 53
(1999) H. 12, S. 178-181.
[129] Koenigshofer, H., Bischof, R. Perteneder, E.: Schweisszusaetze fuer das Schweissen von Rohrrundnaehten im
Pipelinebau. Schweiss- & Prueftechnik (2000) 3, S. 34-40.
[130] Denys, R.: Provisional definitive statement on the significance of over and undermatching weld metal strength.
IIW X-1222/91.
[131] Denys, R.M.: Is the Transverse Weld Tensile Test a Reliable Test? Pipeline Technology Conference, Ostend,

17
 XI-929-09

Belgium, September 11 - 14, 1995, vol. 2, pp. 581-590.

[132] Pisarski, H.G., Tkach, Y., Quintana, M.: Evaluation of weld metal strength mismatch in X100 pipeline girth
welds. IPC 2004, International Pipeline Conference, Calgary, Alberta, Canada, October 4 - 8, 2004.
[133] Graef, M.K., Hillenbrand, H.G.: High quality line pipe a prerequisite for project cost reduction. Europipe GmbH,
Ratingen, 1999.
[134] Venton, P.: Pipeline construction costs in Australia. WTIA/APIA Panel 7 Research Seminar, Wollongong,
Australia, October 26, 1995, paper 21.
[135] Kwiatkowski, J.: Barriers and aids to cost efficient cellulosic MMA welding of pipelines. WTIA/APIA Panel 7
Research Seminar, Wollongong, Australia, October 26, 1995, paper 18.
[136] Norrish, J.: Mechanised and automatic girth welding methods current options and future trends in Australia.
First International Conference on Weld Metal Hydrogen Cracking in Pipeline Girth Welds, Wollongong, Austra-
lia, March 1 - 2, 1999.
[137] Prosser, K.: Fitness-For-Purpose Assessments of Pipeline Girth Welds - Economic Considerations. IIW XI-E-
4/89.
[138] Jansen, J.P., Mullie, J.P., Amoris, E., Jalty, P.: Present status, development and qualification of "TSE 550"-
th
grade steel for large-diameter pipelines. 113 Gas Congress, Paris, France, September 10 - 13, 1996, Euro-
pipe GmbH, Ratingen, 1997.
[139] Woodward, N.: Offshore Hyperbaric Welding. Intermediate Meeting der IIW SC. XI-A und XI-E, Cranfield, UK,
November 29 - 30, 2007.
[140] Auberger, G., Friedl, H., Klug, P., Rauch, R., Zimmerl, E.: Einfuehrung leistungsfaehiger Schweisstechnologien
bei der Montage von Druckrohrleitungen aus hochfesten Feinkornbaustaehlen. Schweiss- & Prueftechnik
(2001) 3, S. 38-41.
[141] Robinson, R.: Value improvement through the use of X-80 pipe. Version for Pipeliner 161202.
[142] OENORM EN 10 208 - 2: Stahlrohre fuer Rohrleitungen fuer brennbare Medien, Technische Lieferbedingun-
gen, Rohre der Anforderungsklasse B (enthaelt auch Berichtigung AC:1996). Ausg. 1. April 1997.
[143] DIN 17 172: Stahlrohre fuer Fernleitungen fuer brennbare Fluessigkeiten und Gase, Technische Lieferbedin-
gungen. Ausg. Mai 1978.
[144] API Spec 5L: Specification for Line Pipe. Ed. April 1995.
[145] Sommer, B., et al.: Stahlrohr Handbuch. 12. Auflage, Vulkan-Verlag, Essen, 1995.
[146] Drehsen, H.: Werkstoffschluessel der Schweisstechnik, Grundwerkstoffe - Schweisszusaetze, Erzeugnisfor-
men. DVS-Berichte, Band 3, 1992.
[147] Wegst, C.W.: Stahlschluessel. 17. Auflage, Verlag Stahlschluessel, Wegst GMBH, Marbach, 1995.
[148] N.N.: Linepipe Plates. http://www.voestalpine.com/grobblech/en/products/heavy_plates/linepipe_plates.html.
[149] N.N.: Line Pipe Tables. Pipeline & Gas Journal (2003) September, pipelineandgasjournalonline.com.
[150] Widgery, D.: Pipeline welding - back to the future. IIW XI-E-1011/07.
[151] N.N.: Pipeline catalogue. Esab.
[152] N.N.: Pipelines Welding Handbook. Esab.
[153] N.N.: Boehler Welding: Welding Consumables for Pipeline Construction. Boehler Welding.
[154] Ornig, H., Starnberger, R.: Schweissen von Druckrohrleitungen aus StE 690. Stahl (1993) H. 3, S. 69-71.
[155] N.N.: Pipeline welding consumables. Boehler Schweisstechnik GmbH, Maerz 2000.
[156] Mlekusch, J.: Fallnahtschweissen mit basischen Stabelektroden im Rohrleitungsbau. Boehler Schweisstechnik
Austria GmbH, Kapfenberg, 1997.
[157] Knoche, E.: Selbstschuetzende Fuelldrahtelektroden fuer das Schweissen von Grossrohrleitungen. Der Prakti-
ker (1995) Nr. 2, S. 52-57.
[158] Muesch, H., Chaudhari, V., Hess, H., Wellnitz, G.: Feldschweissungen von Pipelines im Sauergaseinsatz. 3R
international 29 (1990) H. 6, S. 332-338.

18
 XI-929-09

steel grades according to material chemical composition maximum values [mass-%]

API EN 10 208 DIN 17 172 number C1) Si Mn1) P S V Nb Ti Al2) N Cu Ni Cr Mo
steels for seamless and welded pipes
B L 245NB StE 240.7 1.0457 0.16 0.40 1.1 0.025 0.02 -1 -1 -1 0.06 0.012 0.25 0.30 0.30 0.10
X42 L 290NB StE 290.7 1.0484 0.17 0.40 1.2 0.025 0.02 0.05 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10
X52 L 360NB StE 360.7 1.0582 0.20 0.45 1.6 0.025 0.02 0.10 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10
X60 L 415NB StE 415.7 1.8972 0.21 0.45 1.6 0.025 0.02 0.15 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.35
steels for seamless pipes
1
X52 L 360QB - 1.8948 0.16 0.45 1.4 0.025 0.02 0.05 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10
X60 L 415QB -1 1.8947 0.16 0.45 1.6 0.025 0.02 0.08 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.35
X65 L 450QB -1 1.8952 0.16 0.45 1.6 0.025 0.02 0.09 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35
X70 L 485QB -1 1.8955 0.16 0.45 1.7 0.025 0.02 0.10 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35
X80 L 555QB -1 1.8957 0.16 0.45 1.8 0.025 0.02 0.10 0.06 0.06 0.06 0.012 0.25 0.60 0.50 0.35
steels for welded pipes
B L 245MB -1 1.0418 0.16 0.45 1.5 0.025 0.02 0.04 0.04 -1 0.06 0.012 0.25 0.30 0.30 0.10
X42 L 290MB StE 290.73) 1.0429 0.16 0.45 1.5 0.025 0.02 0.04 0.04 -1 0.06 0.012 0.25 0.30 0.30 0.10
X52 L 360MB StE 360.73) 1.0578 0.16 0.45 1.6 0.025 0.02 0.05 0.05 0.04 0.06 0.012 0.25 0.30 0.30 0.10
X60 L 415MB StE 415.73) 1.8973 0.16 0.45 1.6 0.025 0.02 0.08 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35
X65 L 450MB StE 445.73) 1.8975 0.16 0.45 1.6 0.025 0.02 0.10 0.05 0.06 0.06 0.012 0.25 0.30 0.30 0.35
X70 L 485MB StE 480.73) 1.8977 0.16 0.45 1.7 0.025 0.02 0.10 0.06 0.06 0.06 0.012 0.25 0.30 0.30 0.35
X80 L 555MB -1 1.8978 0.16 0.45 1.8 0.025 0.02 0.10 0.06 0.06 0.06 0.012 0.25 0.30 0.30 0.35
X100 L 690MB -1 -1 0.07 0.30 1.9 -1 -1 -1 0.05 0.02 -1 0.005 0.20 0.30 -1 -1
1 1 1 1 1 1 1 1 1
X120 L 830MB - - 0.06 0.23 1.9 - - - 0.04 0.02 - 0.004 - - - 0.20
1
) ... for every decrease of 0.01 % under the maximum carbon content an increase of the manganese content
0.05 % over the adjusted highest level is allowed, whereas the increase is limited by 0.2 %
2
) ... 0.015 < Al < 0.060
3
) ... thermomechanical treatment
steel grades according to material YS TS A4) YS / TS CVNmin5)
API EN 10 208 DIN 17 172 number [N/mm²] [N/mm²] [%] [-] [J]
L 245NB StE 240.7 1.0457 max 0.80
B 1 245 to 440 min 415 min 22 40
L 245MB - 1.0418 max 0.85
L 290NB StE 290.7 1.0484
X42 290 to 440 min 415 min 21 max 0.85 40 to 42
L 290MB StE 290.73) 1.0429
L 360NB StE 360.7 1.0582 max 0.85
1
X52 L 360QB - 1.8948 360 to 510 min 460 min 20 max 0.88 40 to 42
L 360MB StE 360.73) 1.0578 max 0.85
L 415NB StE 415.7 1.8972 max 0.85
1
X60 L 415QB - 1.8947 415 to 565 min 520 min 18 max 0.88 40 to 51
L 415MB StE 415.73) 1.8973 max 0.85
1
L 450QB - 1.8952 max 0.90
X65 3) 450 to 570 min 535 min 18 40 to 57
L 450MB StE 445.7 1.8975 max 0.87
1
L 485QB - 1.8955
X70 485 to 605 min 570 min 18 max 0.90 40 to 77
L 485MB StE 480.73) 1.8977
1
L 555QB - 1.8957
X80 1 555 to 675 625 to 827 min 18 max 0.90 48 to 120
L 555MB - 1.8978
1 1 1
X100 L 690MB - - 690 to 825 760 to 970 - 0.95 180 to 240
X120 L 830MB -1 -1 min 827 min 931 min 14 0.88 min 231
3
) ... thermomechanical treatment
) ... for transverse specimens taken out of the pipe body, L0 = 5.65 . S0
4
5
) ... for transverse specimens at 0 °C dependent on the external diameter of the pipe and a safety factor
-1 ... details not available
Supplement 1. Chemical composition and mechanical properties of pipeline-steels according
to OENORM EN 10 208 - 2 [142], DIN 17 172 [143], and API-standard [144] and the pipeline-
steels X100 and X120 [6], [39], [40], [41], [43], [48], and [61]

19
 XI-929-09

designations according to material numbers ac-

API 5L OENORM EN DIN 17 172 ASME / UNS cording to OENORM
10 208 - 2 EN 10 027 - 2
B L 245NB StE 240.7 -1 1.0457
L 245MB StE 240.7 TM K 03005 / K 03006 1.0418
X42 L 290NB StE 290.7 -1 1.0484
L 290MB StE 290.7 TM -1 1.0429
X52 L 360NB StE 360.7 -1 1.0582
L 360QB -1 -1 1.8948
L 360MB StE 360.7 TM -1 1.0578
X60 L 415NB StE 415.7 -1 1.8972
L 415QB -1 -1 1.8947
L 415MB StE 415.7 TM -1 1.8973
X65 L 450QB -1 -1 1.8952
L 450MB StE 445.7 TM -1 1.8975
X70 L 485QB -1 -1 1.8955
L 485MB StE 480.7 TM -1 1.8977
X80 L 555QB -1 -1 1.8957
L 555MB -1 K 12700 / K 12709 1.8978
X100 L 690MB -1 -1 -1
X120 L 830MB -1 -1 -1
-1 ... details not available
Supplement 2. Comparison of designations of pipeline-steels according to different standards
[142] to [147]

outside wall max

country, town highest
process diameter thickness length
company name grade
[mm] [mm] [m]
AUSTRIA plates, b =
VOEST Grobblech -1 X100
2 600 - 3 950
5.0 - 50.0 18.7

FRANCE, Boulogne
SMLS X100 25 - 711 3.2 - 101.6 16.2
VALLOUREC & MANNESMANN
GERMANY, Siegen
BERGROHR GmbH
DSAW X100 -1 -1 12.0

GERMANY, Hilchenbach
DSAW X100 406 - 1 524 6.3 - 203.0 13.4
EISENBAU KREMER
GERMANY, Salzgitter
DSAW X100 508 - 1 676 6.3 - 20.6 18.3
SALZGITTER
JAPAN, Chiyoda-Ku Tokyo
DSAW X100 406 - 1 422 6.0 - 44.0 18.4
NIPON KOKAN
JAPAN, Tokyo
SAW X100 609 - 1 625 6.4 - 38.0 18.4
SUMITOMO METAL INDUSTRIES INC.
1
- … details not available
Supplement 3. Suppliers for the pipeline-steel X100 [148] and [149] (DSAW … double
submerged arc welding, SMLS … seamless, SAW … submerged arc welding)

20
 XI-929-09

X100SP1 electrode amperage voltage

layers AWS Ø [mm] [A] [V]
E 6010
electrodes
cellulosic

R 4.0 120-160 24
E 7010-A1
E 9010-G
H 5.0 180-200 24
E 7010-A1
E 10018-G 4.0 190-210 20
electrodes

F
E 11018-G 4.5 230-250 20
basic

E 10018-G
T 4.0 190-210 20
E 11018-G

Supplement 4. Welding procedure specification for X100 (X100SP1) combined welding with
cellulosic and basic electrodes (R … root pass, H … hot-pass, F … filler layer,
T … top layer, SP … welding specimen) [48] and [55]

α
material grade X120
wall thickness 20 mm
welding consumable EXX 26 and EXX 27 A B
welding process manual metal arc welding
preheating temperature min 150 °C 1

interpass temperature max 200 °C

size current voltage travel speed heat-input
run process consumable [mm] [A] [V] [m/min] [kJ/mm]
1 111 ↓ EXX 26 3.0 120 19 0.20 0.68
2 111 ↓ EXX 27 4.0 215 22 0.36 0.79
3-8 111 ↓ EXX 27 4.0 215 22 0.57 - 0.39 0.50-0.73
9 111 ↓ EXX 27 4.0 210 21 1.50 0.18
10 111 ↓ EXX 27 4.0 210 21 0.88 0.30
11-29 111 ↓ EXX 27 4.0 210 21 0.39 - 0.58 0.46-0.68
PS [N/mm²] TS [N/mm²] A [%] R of A [%] CVN at -40 °C [J]
941, 953 950, 962 21.2, 21.2 63, 63 61, 65, 63, 72, 70, 68

Supplement 5. Welding procedure specification for X120 (X120SP1) manual metal arc welding
in vertical down position with basic electrodes (SP … welding specimen) [150]

21
 XI-929-09

AWS rod chemical composition CVN

YS TS A
specification designation of the weld metal at T
C Si Mn Mo Ni [N/mm²] [N/mm²] [%] [J]
according to -1 -40 °C
ER 100S-G -2 -1 -1 -1 -1 0.3 1.0 804 -1 19.5 182
ER 120S-G -1 -1 -1 -1 0.6 2.5 964 990 16,5 133
GSNi1Mo -1 -1 -1 -1 -1 -1 -1 -1 -1 -1
ER480S-6 -1 -1 -1 -1 -1 -1 - 1
- 1
- 1
-1
ER690S-G -1 -1 -1 -1 -1 -1 -1 -1 -1 -1
-20 °C
-1 G3Ni1Mo -1 -1 -1 0.3 1.0 753 810 23 206
according to PHILIPS -40 °C
ER 100S-G -3 -1 -1 -1 0.3 1.0 841 888 20.5 188
according to THYSSEN WIRE -40 °C
ER 100S-G -4 -1 -1 -1 -1 0.3 1.0 753 810 23 -1
1 2 3
- ... details not available, - …tandem GMAW, - …single torch GMAW,
-4…CAPS dual tandem
Supplement 6. Chemical composition (in mass-%) and mechanical properties of welding rods
used for the CAPS-process [67], [71], and [72]

root pass filler layers top layers

electrode type ER480S-6 ER690S-G ER690S-G ER690S-G ER690S-G ER690S-G ER690S-G
diameter [mm] 0.9 1.0 1.0 1.0 1.0 1.0 1.0
amperage [A] 185 - 210 200 - 220 140 - 170 190 - 210 140 - 160 110 - 140 110 - 140
voltage [V] 20 - 22 20 - 23 19 - 22 19 - 22 18 - 21 18 - 20 18 - 20
wire feed 12 200/ 12 9 200/ 11 500/ 11 8 500/ 7 000/ 7 000/
9 652
[mm/min] 200 9 200 500 8 500 7 000 7 000
welding velocity 1 270 1 270 1 270 1 270
760 1 270 1 270
[mm/min] +/- 10 % +/- 10 % +/- 20 % +/- 20 %
heat-input [kJ/mm] 0.32 - 0.38 0.30 - 0.40 0.30 - 0.40 0.30 - 0.40 0.30 - 0.40 0.20 -0.30 0.20 -0.30
head velocity [mm] N/A 2.0 - 3.0 2.5 - 3.5 3.0 - 4.0 3.5 - 4.5 1.5 - 2.5 1.5 - 2.5
frequence [cpm] N/A 350 350 350 350 300 300
welding head
5° - 7° -2° to +2° -2° to +2° -2° to +2° -2° to +2° -2° to +2° -2° to +2°
angle [°]

Supplement 7. Welding parameters for the CAPS-process [66]

22
 XI-929-09

steel 111
135 136 12
grade 111-C-PG 111-C-PF 111-B-PG 111-B-PF
PIPEWELD
ESAB 6010(1) PIPEWELD OK 48.00 OK Autrod 1
X56 FILARC 27P - -1
PIPEWELD 6010(1) OK 53.70 12.66-
7010
FOX CEL(1)
FOX BVD(1)
FOX CEL S(1)
Boehler

FOX EV Pipe
FOX BVD SG-3-P
FOX CEL MO FOX CEL S(1) (1) FOX EV 60 -1 -1
RP K-Nova Ni
FOX CEL 75- (2) Pipe
FOX BVD 85
X60 85
PIPEWELD
(1) PIPEWELD OK 48.00
ESAB

6010 (1) OK Autrod

6010 FILARC 27P OK 53.70(1) -1 -1
PIPEWELD 12.66-
OK 74.70
8010
FOX EV
FOX CEL(1)
(1) FOX BVD(1) Pipe
(1)
Boehler

FOX CEL S
FOX BVD FOX EV 60 SG-3-P
FOX CEL 75(1) FOX CEL S(1) 1
(1) - -1
RP Pipe K-Nova Ni
FOX CEL 85- (2)
FOX BVD 85 FOX EV 70
X65 90
Pipe
PIPEWELD
(1) OK
6010(1)
ESAB

PIPEWELD OK 53.70 OK Autrod OK Tubrod

FILARC 27P Tubrod
PIPEWELD 6010(1) OK 74.70 12.66- 15.17
15.00 S
8010
FOX CEL(1)
FOX BVD(1) FOX EV
FOX CEL S(1)
Boehler

FOX BVD Pipe(1) K-Nova Ni

FOX CEL 75(1) FOX CEL S(1) -1 -1
RP(1) FOX EV 70 NiMo1-IG
FOX CEL 85-
FOX BVD 90(2) Pipe
X70 90
PIPEWELD
(1)
OK 53.70(1)
ESAB

6010 PIPEWELD OK Autrod OK Tubrod

(1) FILARC 27P -1
PIPEWELD 6010 OK 74.70 12.66- 15.17
9010
(1)
FOX BVD
FOX BVD FOX EV
FOX CEL(1)
Boehler

(1)
(1) (1) RP(1) Pipe
FOX CEL S FOX CEL S (2) NiMo1-IG -1 -1
FOX BVD 90 FOX EV 70
FOX CEL 90
FOX BVD Pipe
X80 100
(2)

OK Autrod OK Tubrod
FILARC 37P
ESAB

PIPEWELD 1 (1) 12.66 15.07

- FILARC OK 53.70 -1
9010 OK Autrod OK Tubrod
108MP
13.13- 15.09
FOX BVD(1)
Boehler

FOX BVD
-1 -1 (1) 1
RP - -1 -1 -1
FOX BVD
X100 110(2)
OK Tubrod
ESAB

1 1 1 1 OK Autrod 15.09
- - - - -1
13.13- Coreshield
8Ni1
-1 ... details not available, (1)… only for root pass, (2)… only for filler and top layers
Supplement 8. Recommendations of consumables for different pipeline-steel grades
according to Boehler (2) (111 … manual metal arc welding, C … cellulosic electrodes,
B … basic electrodes, PG ... vertical down position, PF ... vertical up position,
135 ... MAG-welding with solid wire, 136 ... MAG-welding with filler wire,
12 ... submerged arc welding) [151] to [153]

23
 XI-929-09

process cover, designation wall thickness PT IT comment

wire [mm] [°C] [°C]
Boehler 50-100 -1
FOX CEL < 20 for steels with a
FOX CEL Mo 150 100 ± 30 higher C content
FOX CEL 75
C FOX CEL 85 ≥ 20 ~ 200 -1
FOX CEL S
Boehler < 20 50 - 150 150 ± 30 -1
FOX CEL 90 ≥ 20 ~ 200 -1
Boehler not
FOX BVD RP < 20 required
111 FOX EV Pipe outside temp. > 5 °C,
FOX BVD 85 100 ± 30 at steels tending to
FOX BVD 90 ≥ 20 50 - 100 hardening:
FOX BVD 100 PT ~ 100 °C
B FOX EV 50-W
Boehler X100, fixing and root
FOX EV 50 pass
X100, assembly
Boehler 31, 230 150 250 welding, post weld
FOX EV 85 heat treatment: 250-
300 °C, 2 - 4 h
welding in the field at
135 solid wire -1 50 120 a pipe made of X65,
25 outer diameter:
136 filler wire -1 -1 70 - 180 914 mm
wire: S3 NiMoCr X100, prefabrication
powder: (longitudinal-,
single wire UV 421 TT-LH 130 180 circumferential- and
12 31, 230 fillet welding),
post weld heat
double wire 120 170 treatment:
250 - 300 °C, 2 - 4 h
designation acc. to
114 filler wire EN 758: T563 < 25 120 150 X80
1NiYn1H5
-1 ... details not available
Supplement 9. Heat guidance for welding pipeline-steels
(111 ... manual metal arc welding, 135 ... MAG-welding with solid wire,
136 ... MAG-welding with filler wire, 12 ... submerged arc welding,
114 ... metal arc welding with filler wire, C ... cellulosic covered, B ... basic covered,
PT ... preheating temperature, IT ...interpass temperature) [154] to [158]

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