In-Field Production of a New Metallic Composite Pipeline

The composite pipe system, known as XPipe™, is a steel strip laminate technology which uses high-performance adhesives to manufacture a metallic composite pipe. It offers a new method of low cost pipeline construction suitable for onshore gas and oil pipelines in a variety of configurations. The pipe is based on a thin wall liner that provides the fluid containment, the material of which will vary according to service requirements. Fusion bonded epoxy (FBE) coated martensitic ultra-high strength steel strips are then pre-formed and helically wound around the liner to form a laminated high strength reinforcing layer providing the pipe’s hoop strength. These are bonded using an adhesive. Unlike conventional linepipe that is manufactured in a pipe mill away from the construction site, this lightweight composite pipe can be produced at the construction facility using a portable manufacturing line. All components of the manufacturing process fit within standard ISO containers, each weighing between 5 and 15 tonnes. This allows for easy transportation via truck, and handling or shipping. This paper describes the Factory Acceptance Test (FAT) and subsequent Site Integration Test (SIT) of the containerised pipe manufacturing facility. The FAT was performed in factory conditions in Rome, NY (December 2008) and demonstrated acceptable operation of the complete pipe production line. For the SIT, a site in Houston, TX was chosen which would be broadly representative of in-field conditions. The SIT was performed between April and June 2009 and demonstrated acceptable in-field operation of the pipe production system. The paper also describes the results of full-scale testing performed on pipe produced during the SIT and FAT, including burst, tension and cyclic pressure testing pipe sections.