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The use of high temperature processing (HTP) steel for high strength oil and
gas transmission pipeline application

Article · January 2005

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The Use of High Temperature Processing(HTP) Steel for High
Strength Oil and Gas Transmission Pipeline Applications
Douglas G. Stalheim
(DGS Metallurgical Solutions, Inc., 16110 NE 4th Street, Vancouver, WA 98684 USA
Phone – (360) 713-2407, Fax – (360) 882-1775, E-mail: dgstalheim@comcast.net)

Abstract: The trend toward higher operating pressures in gas and oil transmission pipelines over the past 10 years has resulted in an
increased demand for higher strength steels such as API X70 and X80 with good low temperature toughness. The current alloy
design for API X70 transmission pipeline projects with higher toughness requirements over a variety of different temperature ranges
utilizes either a low C-Mn HSLA chemistry resulting in a ferrite/pearlite microstructure or a low C-Mn–Mo HSLA chemistry
resulting in a ferrite/acicular ferrite microstructure. The current alloy design for API X80 transmission pipeline projects with
improved toughness over a variety of temperature ranges utilizes a traditional ferrite/acicular ferrite microstructure generated with
low C-Mn-Mo based chemistry. This alloy design has been well documented as a viable approach for high strength oil and gas
pipelines with reasonable toughness over a variety of temperature ranges. Recently, an alternative low C-Mn HSLA chemistry
utilizing a high niobium level, that develops a ferrite/acicular ferrite microstructure, has been successfully utilized to produce an API
X80 transmission pipeline project. This chemistry is unique in that it has the ability to produce the strengths and pipe body impact
toughness required for an API X70 or X80 transmission pipeline projects utilizing higher than normal processing temperatures during
rolling than the traditional low C-Mn-Mo based design. In addition, the ability to produce the desired microstructure, strength and
toughness without the use of molybdenum has a positive effect in keeping the hardness in the pipe body, HAZ, and weld below 260
Hv10. This alloy design’s ability to utilize high temperature processing (HTP) improves productivity and alleviates issues in rolling
(mill loads, shape, etc.) associated with the lower temperatures required to process the traditional low C-Mn-Mo alloy design. This
paper describes the development and implementation of the first large scale commercial production of an API X80 gas transmission
pipeline project utilizing the high temperature processing (HTP) low C-Mn (Nb-only) steel alloy design.
Key words: HTP; acicular ferrite; X80; toughness; molybdenum; niobium; pipeline steel

1 Introduction alternative cost-effective alloy design that created a

The trend towards increased pipeline operating
pressures while keeping steel costs low has resulted in
higher strength steels such as API X70 (483 MPa) and
X80 (550 MPa) becoming commonplace. In North
America the move to commercial production of API
X80 (550 MPa) first occurred in 1994 and then again
in 1996 in Canada.[1,2] The decision to build the first
commercial X80 pipeline project in the US was made
in 2003. The Cheyenne Plains project comprised
611km (380 miles) of NPS 36 (914 mm) and NPS 30
(762 mm) in thickness from 9.8 – 16.9 mm with 11.8
mm representing the majority.
API X80 (550 MPa) has been traditionally produced
using a C-Mn-Mo based ferrite/acicular ferrite (F/AF)
steel microstructure design, and the previous North
American X80 projects used such a microstructure.[1,2]
In the 2003 US X80 project, steel cost, especially the
alloy cost of molybdenum (Mo), was of concern. An
F/AF microstructure was needed.
1.1 Cantarell trial slabs
An alloy design, named HTP (High Temperature
Processing), that produces a F/AF microstructure
using Nb contents up to 0.11% without the need for
Mo had been developed over 30 years ago. The high
Nb content of this alloy design had the unique
capability of allowing thermomechanical rolling at
higher than normal processing temperatures (>815 °C).
The ability to have enough solute Nb available to
retard recrystallization at the elevated temperatures
ensures that a fine, high strength F/AF microstructure
can be developed through thermomechanical rolling.
Nb is the only microalloy with this capability. This
can be seen in Figure 1.
Commercial implementation of this technology for oil
and gas transmission pipeline projects never
materialized until 1997/98 when a heavy gauge API
X70 (483 MPa) high pH HIC project in Mexico
(called Cantarell) emerged. This project presented the
first commercial opportunity for the HTP-generated
F/AF microstructure using the non-Mo-bearing alloy
design. At the conclusion of the project, Companhia
Brasileira de Metalurgia e Mineracao (CBMM)
requested that the remaining slabs be made available
to various steel mills around the world for additional
trial work[3].
Three such trial slabs were rolled into discrete plate in
a North American mill and then converted into pipe at
a UOE pipe mill. With technical support from CBMM,
an HTP rolling schedule was developed that produced
encouraging plate and pipe results for X80, Table 1.
Table 1 Cantarell chemistry and pipe strength
C Mn Cu+Ni+Cr Nb YS TS
MPa MPa
0.03% 1.50% 0.70% 0.10% 565 586
Fig. 1 Nb ability to retard recrystallization for HTP[3]
Based on these encouraging results, a decision was
made to use this HTP alloy design approach to supply
~ 36, 000 T (136 km) out of the ~165,000 T (611 km)
for the Cheyenne Plains project. A different supplier
supplied the balance of the tonnage from the
traditional C-Mn-Mo F/AF design.
Not only was this going to be the first API X80 (550
MPa) large diameter natural gas transmission line in
the US, but it would also be the first commercial use
of the HTP C-Mn (Nb-only) concept in North
America.
2 Material Design
2.1 Alloy design
The pipe specification [4] that drove the HTP alloy and
processing design considerations was as follows:
• Strength – API X80 with 138 MPa and 172 MPa
maximum range for yield and tensile strength,
respectively.
• Toughness – Transverse CVN pipe body
minimum average of 106 J @ -7 °C and DWTT
average shear of 80% at -7 °C with demonstrated low
temperature capability.
• Weldability – mechanized field welding was
specified for the project. A low Pcm < 0.20 and
Cu+Ni+Cr+Mo ≤ 0.60 were desirable.
• Hardness – 265 Hv10 maximum in the HAZ and
weld region and 248 Hv10 in the pipe body.
• F/AF microstructure generated upon appropriate
post rolling cooling for improved toughness.
The information from the Cantarell three-slab trial
along with information from the other mills around the
world that did trial work with the HTP slabs, was
shared at an HTP conference in Brazil[3] in 2003 and
was used to modify the alloy design to enhance pipe
properties towards API X80 (550 MPa), Table 2.
Table 2 API X80 HTP chemistry design
Cu+
C Mn Nb Ti N2 Pcm
Ni+Cr
≤ ≤ ≤
0.05% 1.55% 0.095% 0.16
0.60% 0.025% 0.008%
P and S maximums were 0.018% and 0.005% respectively
Fig. 2 CCT curve for API X80 HTP alloy design
This HTP alloy design yielded CCT curves that
showed that the desired F/AF microstructure for API
X80 (550 MPa) could be developed with cooling rates
of 15-20°C/sec - easily achievable with an accelerated
cooling system.[5] See Figure 2 with arrows showing
typical available accelerated cooling ranges.
2.2 Processing design
The material for the project was to be rolled as
discrete plate. Published Cantarell results, previous
trials and work done by others demonstrated that a key
point in the production of 550 MPa yield strength
material is to enter the accelerated cooling system at a
high enough temperature to promote the formation of
a F/AF microstructure. Previous experience
demonstrated that if the accelerated cooling entry
temperature was too low, acicular ferrite formation
would be replaced with pearlite formation, and thus
strength would be lowered. This key temperature is in
excess of 820 °C[5,6].
In combination with finish temperature and cooling
rate, an intermediate thickness of ≥3.5 times the final
thickness is desirable for austenite conditioning to
enhance strength and toughness.[5] Based on
niobium’s ability to retard recrystallization, the high
Nb content of this alloy design, coupled with the
desired high finish temperature, meant that the
thermomechanical rolling intermediate thickness
temperature range was between 950-1000 °C. The
final plate thickness and the desired finish rolling
temperature determined actual intermediate
thicknesses and temperatures.
The final process design step involved determining
accelerated cooling stop temperature. Previous work
with this HTP alloy design demonstrated that the
optimum temperature was between 500-550 °C;
however, a range of 450-600 °C could be used to
generate 550 MPa yield strength, Figure 3[5].
Fig. 3 Accelerated cooling stop temperature vs. strength
3 Production and Results
3.1 Timing of trials and pipe production
The elapsed time from the 2003 HTP Conference to
the start of pipe production was less than six months.
During that time, alloy and process design along with
production trials comprising 200T to 1200T of slabs,
plate and pipe were taking place. In many instances,
due to the short time to prime pipe production, not all
plate or pipe results were known before the next trial
was being set up. However, with technical support
from CBMM and critical production support from slab,
plate and pipe suppliers, a small three-slab trial turned
into a 36,000T pipe project within six months. Pipe
production started on schedule with only minor issues
to resolve.
3.2 Plate production
There were four different plate thicknesses produced
ranging from 9.8 to16.9 mm with the majority at 11.8
mm. The total number of rolling passes scheduled by
the mill automation system was typically 15-17 of
which 5 were finishing passes. The higher than typical
(70-100 °C) intermediate and finish temperatures (and
consequently short intermediate hold times) dictated
single slab rolling. However, these same higher
temperatures and shorter intermediate hold times
resulted in productivity equivalence to that of multiple
slab rolling schemes. In addition, the higher
temperatures had a positive effect on lowering mill
loads and minimizing shape issues compared to those
observed with the traditional API X80 F/AF Mo-based
alloy design. Minor issues with plate shape after
accelerated cooling where encountered, but were
corrected with a combination of slight modifications
to the cooling-stop temperature and operator
experience. The modifications to the cooling-stop
temperature were within the range that was shown to
have a negligible effect on strength.
3.3 Pipe production
Pipe was produced on a UOE pipe mill. Welding trials
were conducted during the initial trial period to
determine the optimum commercially available
welding consumable combination to meet the required
long seam weld metal properties of 55 J @ -7 °C. The
base weld wire chemistry chosen for the production
can be seen in Table 3.
The pipe mill operations personal found the HTP alloy
design easy to work with in pipe-making and so only
minor issues were experienced during pipe production. The very uniform increase in both yield and tensile
In fact the overall non-prime percentage on this strength during pipe production resulted in a
project was one of the lowest recorded. In addition, negligible shift in Y/T ratio. The average plate and
pipe productivity was 15-20% better than originally pipe Y/T ratio for the main wall thickness was 0.86.
forecast. Average plate and pipe elongations of 36% and 31%
in 50 mm, respectively, were typical for this strength
Table 3 Weld wire chemistry and microstructure.
C Mn Si Mo Ni Ti B Transverse CVN and DWTT impact toughness in the
0.11% 1.62% 0.63% 0.49% - - - pipe body were excellent with pipe impact toughness
specification requirements @ -7 °C being easily met,
3.4 Plate and pipe results Table 4. Pipe HAZ and weld centerline impacts were
The HTP alloy design when processed at the correct also satisfactory.
temperatures developed a continuous yielding stress-
strain curve characteristic of a F/AF microstructure, Table 4 Average pipe toughness vs. specification
Figure 4. Body – HAZ – Weld CL – DWTT – 80%
106 J 106 J 55 J Shear
292 290 80 J 100%

In addition, the HTP alloy and microstructure design

exhibited excellent low temperature toughness
Stress

characteristics with a 50% FATT of -60°C, Figure 6.

325
300
275
250
Joules and % Shear

Strain 225
200
Fig. 4 Example HTP plate stress-strain curves
175
150
125
Microstructural analyses throughout the production 100
75
confirmed the presence of a F/AF microstructure. 50
During pipe forming and expansion, this 25
0
microstructure characteristically work hardened -7 -20 -29 -46 -62 -73
TCVN
resulting in an average plate-to-pipe yield and tensile Temperature (C) DWTT

strength shift of a +57 MPa and +63 MPa, Fig. 6 API X80 TCVN and DWTT transition curves
respectively, Figure 5.
The low temperature toughness values generated with
720
700 the HTP API X80 F/AF alloy design in the course of
680
660
API X80 Minimum Ultimate
Strength Requirement
this project were higher than from a typical Mo-based
640
620
API X80 Minimum Yield
design. The low carbon equivalent (Pcm average of
Strength MPa

600 Strength Requirement

580
560
0.16), along with a mill that was capable of taking the
540
520
appropriate deformations at elevated temperatures for
500
480
the HTP alloy design, contributed to the good low
460
440 temperature toughness.
420
400 In high strength pipeline designs, pipe body, HAZ and
Plate Pipe Unexpanded Pipe Expanded 1.25%

Yield Ultimate
Strain weld hardness are always a concern. High hardnesses
in these regions have been associated with stress
Fig. 5 Average yield and ultimate shift from plate to pipe
corrosion cracking and thus are a point of focus in the
specification. The traditional API X80 F/AF Mo-
based alloy design, coupled with the traditional
welding consumables for impact toughness, makes it
challenging to keep hardness below 300 Hv10. With
Mo being a strong hardenability agent and typically
present in both plate and weld wire chemistries, areas
with hardness values in excess of 265 Hv10 are very
possible in the HAZ and weld regions.[7] Traditional
areas of focus are around the fusion line as these areas
typically will exhibit higher hardness.
This concern for this project resulted in a rigorous
hardness testing protocol with particular focus on the
fusion line region of the HAZ. In addition, the
customer had requested additional hardness checks
that would be used to modify the testing pattern to
help identify areas with the highest hardness potential.
During the initial trial and early production, these
additional hardness checks helped finalize the actual
testing pattern for the balance of the production. The
additional testing suggested that focus should be
placed on the ID weld and HAZ fusion line regions.
Even with the rigorous hardness testing, all pipe body
values were under the 248 Hv10 requirement, and all
HAZ and weld values were under the 265 Hv10
requirement. In fact, there were no values greater than
260 Hv10 in the HAZ or weld region. Typical ranges
can be seen in Table 5.
Table 5 Typical hardness values
Location Body HAZ Weld
Specification ≤248 Hv10 ≤265 Hv10 ≤265 Hv10
Typical Range 220-245 220-256 230-258
The success at balancing the weld region toughness
and hardness was enhanced by the base metal alloy
design’s lower average Pcm (0.16). A traditional C-
Mn-Mo-based design usually has a slightly higher
average Pcm of 0.18.
CTOD tests for information purposes were conducted
on initial trial pipe. Results were excellent with values
of 0.53 mm, 0.76 mm and 1.10 mm @ -5 C.
There were no reported field welding issues during
installation using this HTP alloy design.
4 Conclusions
This was the first API X80 pipeline project installed in
the US. In addition, it was the first commercial API
X80 project in North America to use the HTP alloy
design with approximately 34,500T of prime pipe
being produced. This project demonstrated that:
(1) The HTP alloy design can successfully produce
all aspects of high toughness API X80 transmission
pipeline requirements.
(2) The HTP alloy design coupled with the correct
slab and plate processing can produce a
ferrite/acicular ferrite microstructure.
(3) The resulting ferrite/acicular ferrite
microstructure work hardens during pipe manufacture
producing uniform yield and tensile strength increases.
(4) The high Nb level of this alloy design
successfully retards recrystallization in the
temperature range 815-1000 °C. This is evident by the
combination of high strength and high low-
temperature toughness characteristics which indicates
fine grain size formation.
(5) Cooling rates in excess of 15 °C/sec are required
to produce the desired ferrite/acicular ferrite
microstructure.
(6) The low Pcm of the HTP alloy design enhanced
weldability characteristics as witnessed by the
excellent weld toughness and hardness results.
(7) The HTP alloy design’s use of elevated
processing temperatures favorably reduces mill loads
and shape issues without negative effects on
productivity or mechanical properties.
(8) Cooperative efforts by suppliers and producers
can significantly reduce the time between initial
rolling developments to full production.
Acknowledgements
The author gratefully acknowledges CBMM and Dr. J.
Malcolm Gray (EWI-Microalloying) for their
technical support in making this API X80 project a
success. The author gratefully acknowledges Keith
Barnes (KB Technical Services) for his valuable input.
References:
[1] Afaganis AJ, et al., “Development and
Production of Large Diameter, High Toughness
Gr.550 (X80) Line Pipe at Stelco”, ISS 39th
Mechanical Working and Steel Processing Conference,
Indianapolis, IN. 1997.
 [2] Kostic MM, et al., “Development of Heavy
Gauge X80 Linepipe”, ASME International Pipeline
Conference, Calgary, Alberta, Canada 1998.
[3] Hulka K, et al., “Experience with Low Carbon
HSLA Steel Containing 0.06-0.10 Percent Niobium”,
International Seminar The HTP Steel Project, Araxá,
Brazil October 2003, Niobium Technical Report – No.
1/04 August 2004.
[4] Colorado Interstate Gas, “Double Submerged
Arc Welded (DSAW) Line Pipe Specification”, Rev.
00, April 2003.
[5] Hulka K, Gray JM, “High Temperature
Processing of Line-Pipe Steels”, Proceedings of the
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International Symposium Niobium 2001, Orlando,
Florida, USA 2001.
[6] Lin M, Bodnar RL, “Effects of Composition and
Processing Conditions in a 0.03%C-0.09%NB X70
Linepipe Steel”, ISS 40th Mechanical Working and
Steel Processing Conference, Warrendale,
Pennsylvania, USA 1998.
[7] Kostic MM, “Manufacture, Properties, and
Installations of X80 (550 MPa) Gas Transmission
Linepipe”, ASME International Pipeline Conference,
Calgary, Alberta, Canada 1996.