On the Effect of the U-O-E Manufacturing Process on the Collapse Pressure of Long Tubes

1994 ◽  
Vol 116 (1) ◽  
pp. 93-100 ◽  
Author(s):  
S. Kyriakides ◽  
E. Corona ◽  
F. J. Fischer
Keyword(s):  
Manufacturing Process ◽  
Large Diameter ◽  
External Pressure ◽  
Cold Forming ◽  
Collapse Pressure ◽  
Circular Shape ◽  
Strain Behavior ◽  
Offshore Pipeline ◽  
Numerical Process ◽  
Two Stages

A commonly used process for manufacturing large-diameter tubes for offshore pipeline, riser and tension-leg platform tether applications involves the cold forming of long plates. The plates are bent into a circular shape and then welded. The circumference of the pipe is then plastically expanded to develop a high tolerance circular shape. Collectively, these steps comprise the U-O-E manufacturing process. These mechanical steps cause changes in the material properties and introduce residual stresses in the finished pipe. This paper presents the results of a combined experimental and analytical study of the effect on the U-O-E process on the capacity of the tube to resist collapse under external pressure loading. The U-O-E manufacturing process for a 26 in. (660 mm) diameter, 1.333 in. (33.86 mm) wall thickness pipe was simulated numerically. The numerical process was validated by comparing the predicted stress-strain behavior of the material at two stages in the process with properties measured from actual pipe specimens obtained from the mill. Following the simulation of the U-O-E process the collapse pressure was calculated numerically. The manufacturing process was found to significantly reduce the collapse pressure. A similar pipe for which the final sizing was conducted (simulated) with circumferential contraction (instead of expansion) was found not to have this degradation in collapse pressure.

Methods for Collapse Pressure Prediction of UOE Linepipe

2006 ◽  
Author(s):  
Andreas Liessem ◽  
Ulrich Marewski ◽  
Johannes Groß-Weege ◽  
Gerhard Knauf
Keyword(s):  
Boundary Conditions ◽  
Large Diameter ◽  
External Pressure ◽  
Test Method ◽  
Future Research ◽  
Line Pipe ◽  
Cold Forming ◽  
Research Issues ◽  
Collapse Pressure ◽  
Strain Behavior

Line pipe intended for deep water applications has to be designed predominantly with regard to external pressure in order to avoid plastic collapse. As a consequence of cold forming during UOE pipe manufacture and the subsequent application of anticorrosion coating, the characteristic stress strain behavior has to be taken into account for a reliable prediction of the collapse pressure. Verification of collapse resistance of large diameter pipes against external pressure requires adequate and reliable component testing using a sufficient number of pipe samples. These samples have to be subjected to test conditions, which closely simulate the situation in service. As the test results may depend significantly on its boundary conditions, the results needs to be thoroughly analysed and compared with existing prediction methods. It is for these reasons that such full-scale testing is time-consuming and costly. The work presented in this paper aims at clarifying and quantifying the effect of existing test boundary conditions on the results of collapse tests (collapse pressures). Correlations will be established between material properties found in laboratory tests and associated component behavior. In this context it had been necessary to develop an accurate and reproducible compression test method. The actual collapse pressures and those predicted using current available equations are compared and verified by Finite Element calculations. The paper concludes with a discussion of the major findings and with a brief outlook to future research issues.

scholarly journals The Effect of Spiral Cold-Bending Manufacturing Process on Pipeline Mechanical Behavior

2016 ◽  
Author(s):  
Giannoula Chatzopoulou ◽  
Gregory C. Sarvanis ◽  
Chrysanthi I. Papadaki ◽  
Spyros A. Karamanos
Keyword(s):  
Internal Pressure ◽  
Manufacturing Process ◽  
Numerical Models ◽  
Large Diameter ◽  
External Pressure ◽  
Forming Process ◽  
Cold Forming ◽  
Cold Bending ◽  
Offshore Pipeline ◽  
Bending Capacity

Large-diameter spiral-welded pipes are employed in demanding hydrocarbon pipeline applications, which require an efficient strain-based design framework. In the course of a large European project, numerical simulations on spiral-welded pipes are conducted to examine their bending deformation capacity in the presence of internal pressure referring to geohazard actions, as well as their capacity under external pressure for offshore applications in moderate deep water. Numerical models that simulate the manufacturing process (decoiling and spiral cold bending) are employed. Subsequently, the residual stresses due to cold bending are used to examine the capacity of pipe under external pressure and internally-pressurized bending. A parametric analysis is conducted to examine the effect of spiral cold forming process on the structural behavior of spiral welded pipes and the effect of internal pressure on bending capacity. The results from the present study support the argument that spiral-welded pipes can be used in demanding onshore and offshore pipeline applications.

Optimization of UOE Pipe Manufacturing Process for Improved Collapse Performance Under External Pressure

2006 ◽  
Author(s):  
Stelios Kyriakides ◽  
Mark D. Herynk ◽  
Heedo Yun
Keyword(s):  
Mechanical Properties ◽  
Parametric Study ◽  
Large Diameter ◽  
External Pressure ◽  
Material Degradation ◽  
Forming Process ◽  
Cold Forming ◽  
Collapse Pressure ◽  
Large Diameter Pipes ◽  
Pipe Manufacturing

Large-diameter pipes used in offshore applications are commonly manufactured by cold-forming plates through the UOE process. Collapse experiments have demonstrated that these steps, especially the final expansion, degrade the mechanical properties of the pipe and result in a reduction in its collapse pressure, upwards of 30%. In this study, the UOE forming process has been modeled numerically so that the effects of press parameters of each forming step on the final geometry and mechanical properties of the pipe can be established. The final step involves simulation of pipe collapse under external pressure. An extensive parametric study of the problem has been conducted, through which ways of optimizing the process for improved collapse performance have been established. For example, it was found that optimum collapse pressure requires a tradeoff between pipe shape (ovality) and material degradation. Generally, increase in the O-strain and decrease in the expansion strain improve the collapse pressure. Substituting the expansion by compression can not only alleviate the UOE collapse pressure degradation but can result in a significant increase in collapse performance.

Numerical Simulation of UOE Pipe Process and its Effect on Pipe Mechanical Behavior in Deep-Water Applications

2015 ◽  
Author(s):  
Giannoula Chatzopoulou ◽  
Spyros A. Karamanos ◽  
George E. Varelis
Keyword(s):  
Deep Water ◽  
Manufacturing Process ◽  
Large Diameter ◽  
Structural Response ◽  
Structural Instability ◽  
External Pressure ◽  
Line Pipe ◽  
Simulation Tools ◽  
Large Diameter Pipes ◽  
Pipe Manufacturing

Large-diameter thick-walled steel pipes during their installation in deep-water are subjected to a combination of loading in terms of external pressure, bending and axial tension, which may trigger structural instability due to excessive pipe ovalization with catastrophic effects. In the present study, the UOE pipe manufacturing process, commonly adopted for producing large-diameter pipes of significant thickness, is considered. The study examines the effect of UOE line pipe manufacturing process on the structural response and resistance of offshore pipes during the installation process using nonlinear finite element simulation tools.

Qualification of UOE SAWL Linepipes With Enhanced Collapse Resistance for Ultra Deepwater Applications

2013 ◽  
Author(s):  
Fábio Arroyo ◽  
Rafael F. Solano ◽  
Luciano Mantovano ◽  
Fábio B. de Azevedo ◽  
Hélio Alves ◽  
...  
Keyword(s):  
New Technology ◽  
Large Diameter ◽  
Final Analysis ◽  
Load Testing ◽  
Offshore Pipelines ◽  
Cold Forming ◽  
Collapse Resistance ◽  
Offshore Pipeline ◽  
Key Factor ◽  
Combine Load

Large diameter UOE pipes are being increasingly used for the construction of offshore pipelines. Since oil discoveries are moving towards ultra-deepwater areas, such as Pre-Salt in Brazil, collapse resistance is a key factor in the design of the pipelines. It is known that the cold forming, and the final expansion in the UOE linepipe manufacturing process, reduces the elastic limit of the steel in subsequent compression. Due to this, the DNV collapse formula includes a fabrication factor that derates by a 15% the yield strength of UOE Pipes. However, DNV also recognizes the effect of thermal treatments and the code allows for improvement of the fabrication factor when heat treatment or external cold sizing (compression) is applied, if documented. This paper presents the qualification of UOE pipes with enhanced collapse capacity focusing the use of a fabrication factor (αfab) equal to 1. TenarisConfab has performed a technology qualification process according to DNV-RP-A203 standard “Qualification Procedures for New Technology”. The main aspects of the qualification process are presented in this paper which included significant material and full scale testing, including combine load testing, and final analysis. The qualification process achieved successful results and this will allow use of a fabrication factor equal to 1 directly in deepwater and ultra-deepwater offshore pipeline projects with a possible reduction in material and offshore installation costs and also potentially enhancing the feasibility of many challenging offshore projects.

Numerical Simulation of JCO Pipe Forming Process and its Effect on the External Pressure Capacity of the Pipe

2017 ◽  
Author(s):  
Giannoula Chatzopoulou ◽  
Konstantinos Antoniou ◽  
Spyros A. Karamanos
Keyword(s):  
Manufacturing Process ◽  
Large Diameter ◽  
Structural Response ◽  
Structural Instability ◽  
External Pressure ◽  
Forming Process ◽  
Line Pipe ◽  
Structural Capacity ◽  
Large Diameter Pipes ◽  
Pipe Manufacturing

Large-diameter thick-walled steel pipes during their installation in deep-water are subjected to external pressure, which may trigger structural instability due to excessive pipe ovalization with catastrophic effects. The resistance of offshore pipes against this instability mode strongly depends on imperfections and residual stresses introduced by the line pipe manufacturing process. In the present paper, the JCO pipe manufacturing process, a commonly adopted process for producing large-diameter pipes of significant thickness, is examined. The study examines the effect of JCO line pipe manufacturing process on the structural response and resistance of offshore pipes during the installation process using nonlinear finite element simulation tools. At first, the cold bending induced by the JCO process is simulated rigorously, and subsequently, the application of external pressure is modeled until structural instability is detected. For the simulation of the JCO manufacturing process and the structured response of the pipe a two dimensional generalized plane strain model is used. Furthermore, a numerical analysis is also conducted on the effects of line pipe expansion on the structural capacity of the JCO pipe.

Enhanced Collapse Resistance for Different D/t Ratios of UOE Pipes for Ultra Deepwater Application

2015 ◽  
Author(s):  
Rodrigo De Lucca ◽  
Rafael F. Solano ◽  
Doug Swanek ◽  
Fabio B. de Azevedo ◽  
Fábio Arroyo ◽  
...  
Keyword(s):  
Oil And Gas ◽  
Cold Work ◽  
Large Diameter ◽  
Forming Process ◽  
Collapse Pressure ◽  
Processing Strategies ◽  
Collapse Resistance ◽  
Offshore Pipeline ◽  
Key Factor ◽  
Water Depths

Energy consumption outlook shows that the demand for Oil and Gas is increasing worldwide and since most of the undemanding reserves are already being explored, new reserves means longer distances from the shore and increasing water depths, of up to 3,000 meters. Collapse resistance has become a key factor in the design of pipelines for ultra-deepwater applications. UOE process is commonly used for manufacturing pipelines of large diameter and the cold work involved in this forming process modifies the mechanical properties of the pipes. This paper presents the effect of thermal treatment on final material properties, proving the validity of enhancing collapse for different D/t, as allowed by DNV-OS-F101 αFab, and extending what has been shown as valid on previous studies. In this work, the inputs for the processing strategies are presented, along with coupon compression testing and full scale testing, in order to qualify the selected route as compliant with producing pipes with αFab equal to 1, for usual D/t combinations. An analysis of the predicted collapse pressure compared to the real collapse pressure of the pipes is also presented. The extension of the qualification process achieved successful results and allows the use of a fabrication factor equal to 1 in ultra-deepwater offshore pipeline projects. This enables the reduction of wall thickness, generating reductions in material and offshore installation costs and also potentially enhancing the feasibility of many challenging offshore projects.

scholarly journals Numerical Simulation of JCO-E Pipe Manufacturing Process and Its Effect on the External Pressure Capacity of the Pipe1

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Konstantinos Antoniou ◽  
Giannoula Chatzopoulou ◽  
Spyros A. Karamanos ◽  
Athanasios Tazedakis ◽  
Christos Palagas ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Large Diameter ◽  
Welding Process ◽  
Structural Instability ◽  
External Pressure ◽  
Forming Process ◽  
Line Pipe ◽  
Geometric Deviations ◽  
Large Diameter Pipes ◽  
Pipe Manufacturing

Large-diameter thick-walled steel pipes during their installation in deep-water are subjected to external pressure, which may trigger structural instability due to pipe ovalization, with detrimental effects. The resistance of offshore pipes against this instability is affected by local geometric deviations and residual stresses, introduced by the line pipe manufacturing process. In the present paper, the JCO-E pipe manufacturing process, a commonly adopted process for producing large-diameter pipes of significant thickness, is examined. The study examines the effect of JCO-E line pipe manufacturing process on the external pressure resistance of offshore pipes, candidates for deepwater applications using nonlinear finite element simulation tools. The cold bending induced by the JCO forming process as well as the subsequent welding and expansion (E) operations are simulated rigorously. Subsequently, the application of external pressure is modeled until structural instability (collapse) is detected. Both the JCO-E manufacturing process and the external pressure response of the pipe, are modeled using a two-dimensional (2D) generalized plane strain model, together with a coupled thermo-mechanical model for simulating the welding process.

Blue Stream Collapse Test Program

2005 ◽  
Author(s):  
D. DeGeer ◽  
C. Timms ◽  
V. Lobanov
Keyword(s):  
Black Sea ◽  
Wall Thickness ◽  
Large Diameter ◽  
External Pressure ◽  
Combined Loading ◽  
The Black Sea ◽  
Pipe Material ◽  
Test Program ◽  
Bend Testing ◽  
Strain Behavior

The Blue Stream pipeline is a gas transmission line delivering natural gas from the Russian grid. across the Black Sea, to Turkey. The submarine portion of this pipeline consists of a pair of 24-inch diameter, 31.8 mm wall thickness, API grade X65 pipelines running almost 400 km along the floor of the Black Sea. Over one half of the submarine pipeline lies at a water depth of more than 2000 metres, with the deepest portion of the line reaching a depth of 2150 metres. First gas was supplied through the lines in February of 2003. There were numerous engineering obstacles facing this technically challenging pipeline undertaking. including a lack of heavy-wall, large diameter pipe experimental data to support the pipeline design. Recognizing this need, PeterGaz commissioned a collapse test program during the preliminary engineering phase of the project to generate these data and to gain a better understanding of pipe behavior under combined loading conditions. Numerous full-scale tests were performed on prototype pipe samples, including external pressure testing, combined external pressure and bend testing, and bend testing. Hundreds of material coupon tests were also performed to characterize material stress strain behavior around the circumference of the pipe, through the wall thickness of the pipe, and before and after UOE manufacturing. Tests were also performed to quantify the strength recovery of thermally treated pipe material resulting from the pipe coating process. This paper presents the results of this experimental work and provides some comparisons to collapse predictions.

Collapse Pressure Enhancement of Offshore Pipeline Considering ERW Pipe Manufacturing Process

2020 ◽  
Author(s):  
Seong-Wook Han ◽  
Yeun Chul Park ◽  
Soo-Chang Kang ◽  
Ho-Kyung Kim ◽  
Jiwoon Yi
Keyword(s):  
Manufacturing Process ◽  
Limit State ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Collapse Pressure ◽  
Offshore Pipeline ◽  
Collapse Analysis ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Pipe Manufacturing

Abstract As the application of electric resistance welded (ERW) pipes in deep-water increases, accurate structural performance assessment satisfying the limit state, which is collapse performance, is necessary. Advantages of ERW pipes are effective productivity coming from continuous manufacturing process, but it is hard to track change in mechanical properties during manufacturing. In this study, the ERW pipe manufacturing process was simulated as a three-dimensional finite element method, and the collapse analysis was performed by reflecting the results of the ERW pipe manufacturing process. The results showed that adjustment of ERW pipe manufacturing process had a significant effect on enhancement of collapse performance.

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