Umbilicals are important tubes assembly essentially used for subsea equipment controlling functions and fluid injection. Super duplex stainless steel 2507 (UNS 32750 / EN 1.4410) has been the historical grade used for its corrosion resistance and mechanical properties. The Oil and Gas industry is gradually working on the exploration and exploitation of offshore and deep offshore resources. These operating conditions lead to new philosophy in the design of subsea umbilicals, which are evolving to answer the needs of new functionalities. Recent years development supported by O&G operators, have seen innovative super duplex stainless seam welded tube solution being used for their high mechanical characteristics (YS0.2≥ 750 MPa; UTS≥ 900 MPa), tight dimension tolerances, and their ability to generate cost saving during installation. The specific metallurgical manufacturing route for the 2507 strip together with an efficient roll forming process and NDT control allows to obtained tubes for umbilicals which push the usual boundaries of utilization of this super duplex grades. In this paper, Hydrogen Induced Stress Cracking (HISC) behavior, possible failure mode of the super duplex stainless steel tubes exposed to cathodic protection in the termination unit, was extensively studied. A stress load of 110% YS0.2 was applied using a dead weight bench and the tubes performance was characterized after 500h of exposure in synthetic sea water under cathodic protection. Crevice corrosion is also a reported failure mode for umbilical tubes. Corrosion resistance of the 2507 seam welded tubes was also assessed in natural sea water in crevice conditions at open circuit potential (OCP). No failure was observed during the HISC testing in synthetic sea water after 500hours of exposure and no micro-crack was detected on the tubes after characterization. The metallurgical microstructure of the laser weld is not preferential initiation zone for crevice corrosion.

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Subsea umbilical systems developed for deep offshore applications become more and more demanding regarding injection capacity, number of functionalities and water depth. Some applications, such as subsea boosting, subsea separation or gas lift are even more severe, leading to tube temperature, which can exceed, in some cases 70°C. These operating conditions and requirements are significantly impacting the performance of the main umbilical. The most common solution, to avoid such issues, is to design thicker tubes to improve the strength of the umbilical cross section. The positive effect of the wall thickness increase has to be opposed to major drawbacks, such as weight increase and fatigue performance degradation generating more issues than providing solutions. To face these challenges, Vallourec Umbilicals, with the technical support of TOTAL SA headquarter Technology Division, has developed a new manufacturing process for seam welded stainless steel tubes (SAF 2507), with higher mechanical properties and tighter wall thickness tolerances. The benefit of this innovation is to provide for a given application (i. e. pressure, water depth and temperature) thinner tubes able to meet severe operating conditions without impacting performances of the umbilical structure. This paper, after a description of the manufacturing process and product qualification protocol (that led to a Type Approval Certificate from Bureau Veritas in October 2012), presents the technical advantages brought by seam welded solution, compared to seamless super duplex tubes.

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