Pneumatic Testing of Piping Assemblies: Criteria for Stored Energy and Pinhole Leak Detectability

Author(s):  
Kamal Botros ◽  
Vivian Liu ◽  
Jason Lu

Abstract Pneumatic testing is beneficial as an alternative to hydrotesting particularly in remote areas where access to hydrotest fluids becomes logistically difficult or impossible. The present work is aimed at addressing two salient questions often face pneumatic testing. First is related to the appropriate piping volume to consider for calculating the stored energy in use with ASME PCC-2 calculation for determining the safe exclusion distance for a given piping geometry and test conditions. It was found that the 8D criteria specified in ASME PCC-2 cannot be generalized for all pipe sizes, different material toughness, grades, wall thicknesses and test conditions. A criterion is developed based on the ductile fracture arrest length that considers all these factors combined. The second criterion is related to the ability to detect pinhole leak from the pneumatic test data, again for a given geometry and test conditions, and what constitutes the minimum pinhole effective area in relation to the system total volume, measured uncertainties in the test pressure and temperature over the duration of the test. A semi-normalized physics-based parameter is suggested that can be applied to determine the effective pinhole leak size in relation to the volume of the piping assembly and conditions for detectability limit. A methodology is developed and applied to a pneumatic filed test on DN200, 12.2 km pipeline lateral.


2021 ◽  
Vol 3 (2) ◽  
Author(s):  
Fin O’Flaherty ◽  
Fathi Al-Shawi

AbstractThis study presents a detailed analysis of the lateral forces generated as a result of vertically applied loads to recycled plastic drainage kerbs. These kerbs are a relatively new addition to road infrastructure projects. When concrete is used to form road drainage kerbs, its deformation is minimum when stressed under heavy axle loads. Although recycled plastic kerbs are more environmentally friendly as a construction product, they are less stiff than concrete and tend to deform more under loading leading to a bursting type, lateral force being applied to the haunch materials, the magnitude of which is unknown. A method is proposed for establishing the distribution of these lateral forces resulting from deformation under laboratory test conditions. A load of 400 kN is applied onto a total of six typical kerbs in the laboratory in accordance with the test standard. The drainage kerbs are surrounded with 150 mm of concrete to the front and rear haunch and underneath as is normal during installation. The lateral forces exerted on the concrete surround as a result of deformation of the plastic kerbs are determined via a strain measuring device. Analysis of the test data allows the magnitude of the lateral forces to the surrounding media to be determined and, thereby, ensuring the haunch materials are not over-stressed as a result. The proposed test methodology and subsequent analysis allows for an important laboratory-based assessment of any typical recycled plastic drainage kerbs to be conducted to ensure they are fit-for-purpose in the field.



2021 ◽  
Vol 87 ◽  
pp. 104211
Author(s):  
Jong-Min Lee ◽  
Jin-Ha Hwang ◽  
Yun-Jae Kim ◽  
Jin-Weon Kim




Author(s):  
Jin-Ha Hwang ◽  
Gyo-Geun Youn ◽  
Naoki Miura ◽  
Yun-Jae Kim

To evaluate the structural integrity of nuclear power plant piping, it is important to predict ductile tearing of circumferential cracked pipe from the view point of Leak-Before-Break concept under seismic conditions. CRIEPI (Central Research Institute of Electric Power Industry) conducted fracture test on Japanese carbon steel (STS410) circumferential through-wall cracked pipes under monotonic or cyclic bending load in room temperature. Cyclic loading test conducted variable experimental conditions considering effect of stress ratio and amplitude. In the previous study, monotonic fracture pipe test was simulated by modified stress-strain ductile damage model determined by C(T) specimen fracture toughness test. And, ductile fracture of pipe under cyclic loading simulated using damage criteria based on fracture strain energy from C(T) specimen test data. In this study, monotonic pipe test result is applied to determination of damage model based on fracture strain energy, using finite element analysis, without C(T) specimen fracture toughness test. Ductile fracture of pipe under variable cyclic loading conditions simulates using determined fracture energy damage model from monotonic pipe test.



Author(s):  
Da-Ming Duan ◽  
Yong-Yi Wang ◽  
Yaoshan Chen ◽  
Joe Zhou

Curved wide plate (CWP) tests are frequently used to measure the tensile stress and strain capacity of pipeline girth welds. The parameters affecting the CWP measurement include specimen geometry and cooling setups. High-quality data is obtained when valid test conditions are confirmed. Crack mouth opening displacement (CMOD) is often measured in CWP tests. CMOD is a direct indicator of the amount of deformation at the cracked plane. It is an indirect indicator of the crack driving force (CDF) imparted on the crack. For a given test geometry and material, certain relationships can be derived between the measured CMOD and the more conventional representation of crack driving force, such as CTOD (crack tip opening displacement) and J-integral. Such relationships are a key element in fracture toughness testing standards. This kind of relationship is also particularly useful in strain-based design where CWP specimens are used for strain capacity and flaw growth prediction. In this paper finite element (FE) analysis is first used in modeling CWP testing conditions for X100 specimens with girth weld flaws to validate the test conditions. A novel approach called CMOD mapping is then developed to characterize the flaw behavior which, by making a direct use of CMOD test data from the CWP tests, is used to estimate the crack growth in the CWP. Finally analysis of strain limits using crack driving force (CDF) for the CWP specimens is also given by comparing experimental test data and FE estimation.



Author(s):  
D. Rudland ◽  
D.-J. Shim ◽  
G. M. Wilkowski ◽  
S. Kawaguchi ◽  
N. Hagiwara ◽  
...  

The ductile fracture resistance of newer line pipe steels is of concern for high grade/strength steels and higher-pressure pipeline designs. Although there have been several attempts to make improved ductile fracture arrest models, the model that is still used most frequently is the Battelle Two-Curve Method (TCM). This analysis incorporates the gas-decompression behavior with the fracture toughness of the pipe material to predict the minimum Charpy energy required for crack arrest. For this analysis, the influence of the backfill is lumped into one empirically developed “soil” coefficient which is not specific to soil type, density or strength. No attempt has been made to quantify the effects of soil depth, type, total density or strength on the fracture speeds of propagating cracks in line pipe steels. In this paper, results from small-scale and large-scale burst tests with well-controlled backfill conditions are presented and analyzed to determine the effects of soil depth and cohesiveness on the fracture speeds. Combining this data with the past full-scale burst data used in generating the original backfill coefficient provides additional insight into the effects of the soil properties on the fracture speeds and the arrest of running ductile fractures in line pipe materials.



2005 ◽  
Vol 8 (02) ◽  
pp. 113-121 ◽  
Author(s):  
Michael M. Levitan

Summary Pressure/rate deconvolution is a long-standing problem of well-test analysis that has been the subject of research by a number of authors. A variety of different deconvolution algorithms have been proposed in the literature. However, none of them is robust enough to be implemented in the commercial well-test-analysis software used most widely in the industry. Recently, vonSchroeter et al.1,2 published a deconvolution algorithm that has been shown to work even when a reasonable level of noise is present in the test pressure and rate data. In our independent evaluation of the algorithm, we have found that it works well on consistent sets of pressure and rate data. It fails, however, when used with inconsistent data. Some degree of inconsistency is normally present in real test data. In this paper, we describe the enhancements of the deconvolution algorithm that allow it to be used reliably with real test data. We demonstrate the application of pressure/rate deconvolution analysis to several real test examples. Introduction The well bottomhole-pressure behavior in response to a constant-rate flow test is a characteristic response function of the reservoir/well system. The constant-rate pressure-transient response depends on such reservoir and well properties as permeability, large-scale reservoir heterogeneities, and well damage (skin factor). It also depends on the reservoir flow geometry defined by the geometry of well completion and by reservoir boundaries. Hence, these reservoir and well characteristics are reflected in the system's constant-rate drawdown pressure-transient response, and some of these reservoir and well characteristics may potentially be recovered from the response function by conventional methods of well-test analysis. Direct measurement of constant-rate transient-pressure response does not normally yield good-quality data because of our inability to accurately control rates and because the well pressure is very sensitive to rate variations. For this reason, typical well tests are not single-rate, but variable-rate, tests. A well-test sequence normally includes several flow periods. During one or more of these flow periods, the well is shut in. Often, only the pressure data acquired during shut-in periods have the quality required for pressure-transient analysis. The pressure behavior during the individual flow period of a multirate test sequence depends on the flow history before this flow period. Hence, it is not the same as a constant-rate system-response function. The well-test-analysis theory that evolved over the past 50 years has been built around the idea of applying a special time transform to the test pressure data so that the pressure behavior during individual flow periods would be similar in some way to constant-rate drawdown-pressure behavior. The superposition-time transform commonly used for this purpose does not completely remove all effects of previous rate variation. There are sometimes residual superposition effects left, and this often complicates test analysis. An alternative approach is to convert the pressure data acquired during a variable-rate test to equivalent pressure data that would have been obtained if the well flowed at constant rate for the duration of the whole test. This is the pressure/rate deconvolution problem. Pressure/rate deconvolution has been a subject of research by a number of authors over the past 40 years. Pressure/rate deconvolution reduces to the solution of an integral equation. The kernel and the right side of the equation are given by the rate and the pressure data acquired during a test. This problem is ill conditioned, meaning that small changes in input (test pressure and rates) lead to large changes in output result—a deconvolved constant-rate pressure response. The ill-conditioned nature of the pressure/rate deconvolution problem, combined with errors always present in the test rate and pressure data, makes the problem highly unstable. A variety of different deconvolution algorithms have been proposed in the literature.3–8 However, none of them is robust enough to be implemented in the commercial well-test-analysis software used most widely in the industry. Recently, von Schroeter et al.1,2 published a deconvolution algorithm that has been shown to work when a reasonable level of noise is present in test pressure and rate data. In our independent implementation and evaluation of the algorithm, we have found that it works well on consistent sets of pressure and rate data. It fails, however, when used with inconsistent data. Examples of such inconsistencies include wellbore storage or skin factor changing during a well-test sequence. Some degree of inconsistency is almost always present in real test data. Therefore, the deconvolution algorithm in the form described in the references cited cannot work reliably with real test data. In this paper, we describe the enhancements of the deconvolution algorithm that allow it to be used reliably with real test data. We demonstrate application of the pressure/rate deconvolution analysis to several real test examples.



Author(s):  
Igor Pyshmintsev ◽  
Alexey Gervasyev ◽  
Victor Carretero Olalla ◽  
Roumen Petrov ◽  
Andrey Arabey

The microstructure and fracture behavior of the base metal of different X80 steel line pipe lots from several pipeline projects were analyzed. The resistance of the pipes to ductile fracture propagation was determined by the full-scale burst tests. The high intensity of fracture surface separation (secondary brittle cracks parallel to the rolling plane of the plate) appeared to be the main factor reducing the specific fracture energy of ductile crack propagation. A method for quantitative analysis of microstructure allowing estimation of the steel’s tendency to form separations is proposed. The procedure is based on the EBSD data processing and results in Cleavage Morphology Clustering (CMC) parameter evaluation which correlates with full-scale and laboratory mechanical test results. Two special laboratory mechanical test types utilizing SENT and Charpy test concepts for prediction of ductile fracture arrest/propagation in a pipe were developed and included into Gazprom specifications.



Author(s):  
Anita Bausman ◽  
Jerry Waterland ◽  
Dan Reid

Abstract The ASME B16.20 Metallic Gaskets for Pipe Flanges standard was extensively revised in 2017 [1]. One of the significant changes is the introduction of maximum permissible leakage rate. This marks a landmark introduction of an actual leakage performance criterion into ASME B16.20, a most welcome advance. A common maximum permissible leakage rate of 0.0137 mg/s-m (7.67E−10 lb/s-in) is specified for all sizes and pressure classes of finished spiral wound gaskets, that is, including the windings and any or no gauge rings for that particular gasket. Test conditions are defined — ambient temperature and calibration gas with a known methane concentration and flow rate of 1 L/min. The test pressure is defined by the pressure class: 20 bar (290 psi) for Class 150 and 40 bar (580 psi) for Class 300 and above. The qualification parameters listed in B16.20-2017 include prescribed gasket seating stress targets which also vary by pressure class. These gasket seating stress requirements are defined as 35 MPa (5,000 psi) for Class 150, 56 MPa (8,000 psi) for Class 300 and Class 400, and 70 MPa (10,000 psi) for Class 600 and above. Three questions will be explored in this paper. First, to what tightness does the new B16.20 spiral wound gasket leakage rate criterion correspond? Second, do current generation spiral wound gaskets meet this criterion? Several commercially available spiral wound gaskets will be analyzed and compared to the new B16.20 requirements. Leak rates and tightness at the new B16.20 performance qualification test conditions can be determined using publicly available, published Room Temperature Tightness (ROTT) test constants for these gaskets. Finally, an exploration of Assembly Tightness compared to Operating Tightness for a selection of spiral wound gaskets will be presented and compared to the new B16.20 Performance Testing requirements. This exploration of the new maximum leakage performance criterion in ASME B16.20-2017 will help to familiarize the end user with a valuable new aspect of this gasket standard as well as how the current generation of spiral wound gaskets meets that criterion using publicly available ROTT performance data.



Author(s):  
K. K. Botros ◽  
E. J. Clavelle ◽  
M. Uddin ◽  
G. Wilkowski ◽  
C. Guan

Axial ductile fracture propagation and arrest in high energy pipelines has been studied since the early 1970’s with the development of the empirical Battelle Two-Curve (BTC) model. Numerous empirical corrections on the backfill, gas decompression models, and fracture toughness have been proposed over the past decades. While this approach has worked in most cases, the dynamic interaction between the decompression of the fluid in the vicinity of the crack tip and the behaviour of the pipe material as it opens to form flaps behind the crack has been very difficult to solve from a more fundamental approach. The effects of the pressure distribution on the flap inner surface making up the crack-driving force which drives the crack propagation speed has been suggested in the past, but due to intensive computational effort required, it was never realized. The present paper attempts to tackle this problem by employing an iterative solution procedure where the gas pressure field in the vicinity of the crack tip is accurately solved for by computational fluid dynamics (CFD) for a given flap geometry determined from a dynamic FEA model to render a new flap geometry. In this model a cohesive-zone element at the crack tip is employed as a representation of the material toughness parameter. The final outcome is the determination of the cohesive energy in the FEA (as a representation of the material toughness parameter) to match the measured fracture propagation speed for the specific case. A case study was taken from full-scale rupture test data from one of the pipe joints from the Japanese Gas Association (JGA) unbackfilled pipe burst test data conducted in 2004 on the 762 mm O.D., 17.5 mm wall thickness, Gr. 555 MPa (API 5L X80) pipe.



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