Dave has worked in the steel industry for 28 years, joining BlueScope Steel (then BHP) straight out of high school. He has had a number of roles ranging from production, supervisory, technical, research and development and now sales and marketing, with 17 years dedicated to the development of linepipes.
His first exposure to oil and gas pipelines was as a first year metallurgy cadet based at Tubemakers (now OneSteel Oil and Gas Mill) collecting samples for evaluation for BHP’s newly introduced slab cast feed for transmission pipe.
Eleven years later, in 1992, he joined BlueScope Steel’s metallurgical technology group as a Development Metallurgist. BlueScope Steel had just commenced developing the first X70 grade that was to be used on the Ballera to Moomba Pipeline, and over the next few years, Dave worked in the team responsible for refining that steel design and the hot rolling practices required for linepipe steels.
“I had the opportunity to work closely with the steelmaking and rolling mill teams, gaining an appreciation of all of the technical aspects involved in manufacturing linepipe steels,” he says.
Following this, he took a lead role in the development of the first ever centre-slit X65 PIPESTEELâ„¢ grade that was to be used on the Moomba to Sydney Ethane Pipeline. Dave says that he found his involvement in this project particularly exciting because of the unique technical challenges presented and the number of key technical people within the pipeline industry that he met as a result of this.
“As part of my role within metallurgical technology I was responsible for reviewing all pipeline project enquiries to determine that the appropriate steel was to be used in order to meet the final pipe properties… I certainly learnt a lot very quickly.”
Dave says that his current role is one that he has found challenging, given that he doesn’t have a commercial background, but says that his technical background has proven advantageous to the position.
“It’s essential that you listen to people and relate to them,” he says, “You need a sound technical understanding of the product and the needs of a project.
“Changing from a technical function within BlueScope Steel to take on the role of Industry Manager – Water, Oil & Gas has certainly presented some new challenges for me but it can be very rewarding. I really enjoy being able to mix with people across the whole industry.”
Pipe evolution
Dave says that the most significant technical change, from a steel maker’s perspective, has been the development of increased strengths of steel in order to accommodate higher pipeline operating pressures and the drive for increased steel toughness.
He points to the early 1980s when ERW pipelines were typically produced in grades X42 and X56, until the construction of the Darwin to Alice Springs Pipeline in 1986 saw a move to higher strength grades of ERW pipe.
In the 20 years leading up to 1993, the maximum operating pressures of pipelines had risen from 6.8 MPa to 15.3 MPa. Dave says that as a result, the strength of pipe steel has developed to the point where X70 grade steel has become the industry “˜standard’.
“There is a clear trend in Australia to have heavier wall sections and higher toughness.
“I suspect that X70 will continue to be the grade of choice for high pressure transportation pipelines,” he says.
He also points to the increased requirements in steel toughness that are associated with the revision of AS2885 Part 1 as shaping the industry.
He says that, from a steel maker’s point of view, the major challenges in linepipe design need to be holistically reviewed and responded to. These include the need to achieve the demanding pipe mechanical properties, in particular high strength and toughness, while providing steels that can be welded using the existing procedures of pre-heat free welding with cellulosic electrodes. Other considerations include higher Charpy energy levels, due to the higher operating stresses, as well as to permit rich gas transportation; and the desire to have a narrow range of pipe yield strengths.
Dave says that he suspects a level of stability and consolidation will occur regarding the development of weldable, property-consistent steel over the next few years. He states that the current generation of PIPESTEEL grades have all been designed to optimise weldability using current manual metal arc cellulosic welding techniques. BlueScope continually monitors the chemistry and mechanical properties of all PIPESTEEL projects to ensure that a level of consistency is maintained.
“Ultimately the pipe that you get is only as good as the steel used to make it, as someone once quoted to me – “˜you can only make good pipe if you start with good steel’.”
“There is, however, a need for the industry to consider a move toward automatic welding, especially as we consider some of the technical and operational advantages as well as the ageing of our experienced pipeline welders.”
He says that this may require some minor revisions of steel grades used to ensure they are suitable for automatic welding.
“From a pipeline perspective, I think that we will see project timeframes being compressed even more, which will mean that pipeline design may change right up to the last minute and even potentially during the construction phase.”
Although this will prove a challenge, Dave believes that BlueScope is well placed to be able to respond.
“Ultimately the pipe that you get is only as good as the steel used to make it, as someone once quoted to me – “˜you can only make good pipe if you start with good steel’.”
Climate change
Research into the development of carbon capture and storage (CCS) has come to the fore following the Australian Government’s focus on tackling climate change.
Dave says that transporting pressurised carbon emissions by pipelines is likely to be one of the most feasible approaches for moving waste gas to storage facilities.
“In the United States, API 5LX-65 steel has been used for this purpose.”
CCS will require the pipeline to remain in service for a long period of time, as such, challenges will be posed in relation to the sort of materials needed to be developed to stand the test of time needed for CCS projects.
Dave sees the materials related performance issues for carbon emission transportation pipelines as corrosion and fracture propagation. He also says that safety and environmental considerations will differ from those pipelines transporting natural gas.
“Due to the decompression rate of carbon emissions and the lower operating temperature for CCS pipelines, higher toughness steel may be required and potentially heavier thickness pipe,” he says.
“These material related issues will certainly present challenges for the pipeline industry as a whole as well as steelmakers to address. However, at BlueScope we have had a long history of working co-operatively with the pipeline industry to assist in meeting the needs of the pipeline community, so I am sure we will all face this challenge together.”
Doing business in a tight-knit community
The Australian pipeline industry is known for being a close-knit business community. Because of this, it is important that satisfactory business outcomes are achieved with every client.
He says that BlueScope achieve this by providing the level of support that its customer and channel partners need. The company works closely with pipeline manufacturers and has a dedicated service team headed by internationally recognised experts who can draw on decades of experience to provide assistance throughout the life of a project.
“Above all, we’re prepared to listen in order to understand the particular needs of the project and help find solutions.”
Dave says pipeline end-users can benefit from interacting directly with steel manufacturers, such as BlueScope, to advise them of the total project requirements including any specific material requirements through to project timing.
“If engineers and pipeline designers consult with the steel manufacturer in the early stages of the project, production and supply can be optimised to help project managers meet their deadlines.”
Dave says that it is also possible to tailor the steel grade to suit any special end-use requirements.
BlueScope has also involved itself in the industry by supporting the Australian Pipeline Industry Association Research and Standards Committee and a number of other industry initiatives including the Young Pipeliners Forum.
Steel for the future
Dave’s career is interesting in that he has spent his entire working life at BHP/BlueScope Steel. He says that he hasn’t seen a need to change employer because of the varied roles he has been employed in.
BlueScope Steel are continuing their commitment to train the next generation of metallurgists to develop the pipe steel of the future. The company employs between 10 – 15 materials engineering cadets each year.
“I’m a product of BlueScope Steel’s investment and commitment to training and development, as are so many of our key engineers and technical staff.
“Our metallurgical technology group, which undertakes steel grade development, welding research and other research and development tasks, has a cross section of people at various stages of their careers – and with a number of internationally recognised experts like Jim Williams, Frank Barbero and Chris Kilmore – we have some very good mentors for people coming through.”
He points to industry initiatives, such as the Young Pipeliners Forum, as identifying and dealing with the shortage of human resources that the pipeline industry is faced with.
Reflecting on his 28-year career in the steel industry, Dave says that his roles have allowed him to understand the steel grades and technical requirements for the pipe maker and the end user.
“I’ve had the good fortune to work with some very knowledgeable and internationally recognised experts in the steel and pipeline industries,” he says.
When asked what he sees as the most important lesson learnt over his years in the industry, he says that no two projects are the same, each have their own unique challenges.
“Personally I don’t think I operate any differently now to what I ever have. I suppose the only difference is that I am older and hopefully a bit wiser. I recognise that the important thing is to be yourself. I believe that honesty and integrity are the most important things.”
Dave on safety
“Unlike some of the more “˜secret’ aspects of what we do, everybody is prepared to share their safety lessons. From a material perspective, the risk assessment process involves identifying all possible threats to the pipeline along its entire length. The result is that steel is tending to be designed to the higher levels of its specification.
“BlueScope Steel is particularly proud of its recent safety performance but it is not something that occurs over night,” Dave says. “It really requires everybody to be involved and prepared to challenge the way they have always done things. Though the steel industry is very different to a pipeline right of way there are still a lot of things we can learn from one another right across the industry.”
Dave on price
The shift in strength and toughness requirements of linepipe steel grades has meant that the cost of the steel has increased. Dave says that stronger steel requires more alloys and tougher steel means that you need to remove more impurities, the process of which adds to the cost of the steel. However, he goes on to say that the benefits of increased strength and toughness become apparent when looking at the project as a whole.
“The benefit comes when you look at the total cost of the project. For the same operating pressure, a higher strength pipe can have thinner wall section. Thinner pipe means lower transport costs, ease of handling and improved welding rates.
“The benefits however, will vary for each project and so the grade chosen and the cost benefit needs to be assessed on a project by project basis,” he cautions.
Dave on CSG
When asked if the growth in Queensland’s coal seam gas (CSG) market would affect the types of pipe being produced, he says that he doesn’t really see the need for different pipe specifically for the CSG market. “The steel grades we have now have been proven over a range of conditions. What we will see is continuing high demand for pipelines to service this market.”