Analysis of Data From a Full-Scale Burst Test on 1219 mm OD Grade 550 Pipe: Implications for the Prediction of Fracture Velocity

2016 ◽  
Author(s):  
Brian Rothwell ◽  
Cindy Guan ◽  
Satoshi Igi
Keyword(s):  
Traditional Approach ◽  
Large Diameter ◽  
Crack Tip ◽  
Management Program ◽  
Full Scale ◽  
Correction Factors ◽  
Long Distance ◽  
Line Pipe ◽  
Fracture Arrest ◽  
Fracture Velocity

In recent years, considerable doubt has arisen over the prediction of the level of toughness required to arrest a propagating fracture in higher-strength line pipe. It has been clear for many years that the most widely used traditional approach, the Two-Curve Method (TCM) developed at Battelle in the early 1970s, could not be applied directly when the required toughness, expressed as full-size Charpy energy, exceeded about 80–90 J. Initially, this issue was addressed by the adoption of empirical correction factors, but more recently, there have been indications that this approach is no longer effective for modern, high-strength materials. Additional information, which in general can only be derived from well-characterized burst tests, is essential to furthering understanding of the fracture arrest problem under conditions that are typical of modern, long-distance, large-diameter pipeline design. In the context of the Coastal GasLink (CGL) project, TransCanada has carried out a program of full-scale burst testing at the Spadeadam test site of DNV GL. The tests were supported by LNG Canada and the TransCanada Technology Management Program. These tests are described in another paper at this conference [1]. Though most of the testing was directed towards the assessment of different crack arrestor designs, one half of one test contained a run of four pipes of progressively increasing Charpy energy, up to a very high level (over 450 J). The fracture was observed to run through all four pipes, before being arrested by a crack arrestor fitted to a fifth pipe having lower toughness. Nearly all approaches to determining requirements for fracture arrest depend, directly or indirectly, on relationships between fracture velocity (for given levels of fracture resistance) and the driving force, generally considered to be directly related to the pressure in the plane of the crack tip. By comparing measured fracture velocity with the crack tip pressure determined either directly at pressure transducer locations or by comparison with propagation velocities within the expansion wave, conclusions can be drawn regarding the accuracy of existing relationships. Most previous work regarding correction factors has been based simply on discrepancies between predicted and observed propagation and arrest behaviour. Direct comparisons of observed and predicted fracture speed potentially provide much more data and focus more clearly on where model deficiencies may lie. The current analysis focuses on comparisons with the predictions of the traditional TCM and those of a transient model developed by JFE. While data from the present work are clearly limited, this approach appears to present a way of recalibrating fracture velocity formulations that may extend the range over which traditional, Charpy-based approaches can be applied. For the future, the incorporation of additional results from other recent, well-characterized burst tests would be extremely valuable in this respect.

Development of X80M Line Pipe Steel for Spiral Welded Pipes With Low Temperature Toughness and Excellent Weldability

2014 ◽  
Author(s):  
Nuria Sanchez ◽  
Özlem E. Güngör ◽  
Martin Liebeherr ◽  
Nenad Ilić
Keyword(s):  
Low Temperature ◽  
Life Cycle Cost ◽  
Volume Fraction ◽  
Large Diameter ◽  
Pipe Production ◽  
Strain Accumulation ◽  
Long Distance ◽  
Line Pipe ◽  
Low Temperature Toughness ◽  
Welded Pipe

The unique combination of high strength and low temperature toughness on heavy wall thickness coils allows higher operating pressures in large diameter spiral welded pipes and could represent a 10% reduction in life cycle cost on long distance gas pipe lines. One of the current processing routes for these high thickness grades is the thermo-mechanical controlled processing (TMCP) route, which critically depends on the austenite conditioning during hot forming at specific temperature in relation to the aimed metallurgical mechanisms (recrystallization, strain accumulation, phase transformation). Detailed mechanical and microstructural characterization on selected coils and pipes corresponding to the X80M grade in 24 mm thickness reveals that effective grain size and distribution together with the through thickness gradient are key parameters to control in order to ensure the adequate toughness of the material. Studies on the softening behavior revealed that the grain coarsening in the mid-thickness is related to a decrease of strain accumulation during hot rolling. It was also observed a toughness detrimental effect with the increment of the volume fraction of M/A (martensite/retained austenite) in the middle thickness of the coils, related to the cooling practice. Finally, submerged arc weldability for spiral welded pipe manufacturing was evaluated on coil skelp in 24 mm thickness. The investigations revealed the suitability of the material for spiral welded pipe production, preserving the tensile properties and maintaining acceptable toughness values in the heat-affected zone. The present study revealed that the adequate chemical alloying selection and processing control provide enhanced low temperature toughness on pipes with excellent weldability formed from hot rolled coils X80 grade in 24 mm thickness produced at ArcelorMittal Bremen.

Mechanical and Metallurgical Aspects of the Resistance to Ductile Fracture Propagation in the New Generation of Gas Pipelines

2014 ◽  
Author(s):  
Igor Pyshmintsev ◽  
Alexey Gervasyev ◽  
Victor Carretero Olalla ◽  
Roumen Petrov ◽  
Andrey Arabey
Keyword(s):  
Ductile Fracture ◽  
Mechanical Test ◽  
Fracture Propagation ◽  
Rolling Plane ◽  
Full Scale ◽  
Charpy Test ◽  
Line Pipe ◽  
Surface Separation ◽  
Fracture Arrest ◽  
New Generation

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.

Assessment of the Remaining Strength of Corroded Small Diameter (Below 6”) Pipelines and Pipework

2012 ◽  
Author(s):  
Troy Swankie ◽  
Vinod Chauhan ◽  
Robert Owen ◽  
Robert Bood ◽  
Geoffrey Gilbert
Keyword(s):  
Large Diameter ◽  
Small Diameter ◽  
Ductile Failure ◽  
Corrosion Damage ◽  
Full Scale ◽  
Alternative Methods ◽  
Low Grade ◽  
Numerical Work ◽  
Line Pipe ◽  
Failure Pressure

Internal and external corrosion damage is a major cause of pipeline failures worldwide. When corrosion features in pipelines are detected by in-line inspection (ILI), a decision whether to replace, repair or accept and monitor must be made. Extensive experimental and numerical work has been undertaken to develop methods for assessing the remaining strength of corroded transmission pipelines. Common methods used by the pipeline industry include ASME B31G, modified ASME B31G and LPC. These methods are semi-empirical and have been developed using a modified version of a toughness independent ductile failure criterion for pressurized pipes containing axially orientated surface breaking defects. The validity range of these models is dominated by large diameter (10 to 48″), thin walled, low grade (API 5L grade A to X65) and low yield to tensile ratio line pipe. Smaller diameter (not greater than 6″), thick walled pipelines and pipework located, for example, at above ground installations, compressor and pressure reduction stations are very common. The use of ASME B31G, modified ASME B31G or LPC may not be appropriate when assessing the remaining strength of small diameter pipelines and pipework. No alternative methods are available in the public domain and hence a program of work was undertaken to derive appropriate defect acceptance limits by conducting a series of full-scale burst tests on small diameter pipe with simulated corrosion defects. It was concluded that the LPC method gave the most accurate prediction of failure pressure when compared with the results of the full-scale tests, and the most conservative predictions of failure pressure were obtained using the ASME B31G method.

Development of Heavy Gauge X70 Helical Line Pipe

2018 ◽  
Author(s):  
L. E. Collins ◽  
K. Dunnett ◽  
T. Hylton ◽  
A. Ray
Keyword(s):  
Low Temperature ◽  
Large Diameter ◽  
High Strength ◽  
Helical Line ◽  
Slab Thickness ◽  
Long Distance ◽  
Austenite Grain Size ◽  
Line Pipe ◽  
Nitrogen Levels ◽  
Low Temperature Toughness

A decade ago, the pipeline industry was actively exploring the use of high strength steels (X80 and greater) for long distance, large diameter pipelines operating at high pressures. However in recent years the industry has adopted a more conservative approach preferring to utilize well established X70 grade pipe in heavier wall thicknesses to accommodate the demand for increased operating pressures. In order to meet this demand, EVRAZ has undertaken a substantial upgrade of both its steelmaking and helical pipemaking facilities. The EVRAZ process is relatively unique employing electric arc furnace (EAF) steelmaking to melt scrap, coupled with Steckel mill rolling for the production of coil which is fed into helical DSAW pipe mills for the production of large diameter line pipe in lengths up to 80 feet. Prior to the upgrade production had been limited to a maximum finished wall thickness of ∼17 mm. The upgrades have included installation of vacuum de-gassing to reduce hydrogen and nitrogen levels, upgrading the caster to improve cast steel quality and allow production of thicker (250 mm) slabs, upgrades to the power trains on the mill stands to achieve greater rolling reductions, replacement of the laminar flow cooling system after rolling and installation of a downcoiler capable of coiling 25.4 mm X70 material. As well a new helical DSAW mill has been installed which is capable of producing large diameter pipe in thicknesses up to 25.4 mm. The installation of the equipment has provided both opportunities and challenges. Specific initiatives have sought to produce X70 line pipe in thicknesses up to 25.4 mm, improve low temperature toughness and expand the range of sour service grades available. This paper will focus on alloy design and rolling strategies to achieve high strength coupled with low temperature toughness. The role of improved centerline segregation control will be examined. The use of scrap as a feedstock to the EAF process results in relatively high nitrogen contents compared to blast furnace (BOF) operations. While nitrogen can be reduced to some extent by vacuum de-gassing, rolling practices must be designed to accommodate nitrogen levels of 60 ppm. Greater slab thickness allows greater total reduction, but heat removal considerations must be addressed in optimization of rolling schedules to achieve suitable microstructures to achieve both strength and toughness. This optimization requires definition of the reductions to be accomplished during roughing (recrystallization rolling to achieve a fine uniform austenite grain size) and finishing (pancaking to produce heavily deformed austenite) and specification of cooling rates and coiling temperatures subsequent to rolling to obtain suitable transformation microstructures. The successful process development will be discussed.

How New Vintage Line-Pipe Steel Fracture Properties Differ From Old Vintage Line-Pipe Steels

2012 ◽  
Author(s):  
G. Wilkowski ◽  
D.-J. Shim ◽  
Y. Hioe ◽  
S. Kalyanam ◽  
F. Brust
Keyword(s):  
Brittle Fracture ◽  
Fracture Behavior ◽  
Pipe Steel ◽  
Full Scale ◽  
Actual Behavior ◽  
Correction Factors ◽  
Pipe Steels ◽  
Line Pipe ◽  
Line Pipe Steel ◽  
Fracture Control

Newer vintage line-pipe steels, even for lower grades (i.e., X60 to X70) have much different fracture behavior than older line-pipe steels. These differences significantly affect the fracture control aspects for both brittle fracture and ductile fracture of new pipelines. Perhaps one of the most significant effects is with brittle fracture control for new line-pipe steels. From past work brittle fracture control was achieved through the specification of the drop-weight-tear test (DWTT) in API 5L3. With the very high Charpy energy materials that are being made today, brittle fracture will not easily initiate from the pressed notch of the standard DWTT specimen, whereas for older line-pipe steels that was the normal behavior. This behavior is now referred to as “Abnormal Fracture Appearance” (AFA). More recent work shows a more disturbing trend that one can get 100-percent shear area in the standard pressed-notch DWTT specimen, but the material is really susceptible to brittle fracture. This is a related phenomenon due to the high fracture initiation energy in the standard DWTT specimen that we call “Abnormal Fracture Behavior” (AFB). This paper discusses modified DWTT procedures and some full-scale results. The differences in the actual behavior versus the standard DWTT can be significant. Modifications to the API 5L3 test procedure are needed. The second aspect deals with empirical fracture control for unstable ductile fractures based on older line-pipe steel tests initially from tests 30-years ago. As higher-grade line-pipe steels have been developed, a few additional full-scale burst tests have shown that correction factors on the Charpy energy values are needed as the grade increases. Those correction factors from the newer burst tests were subsequently found to be related to relationship of the Charpy energy values to the DWTT energy values, where the DWTT has better similitude than the Charpy test for fracture behavior (other than the transition temperature issue noted above). Once on the upper-shelf, recent data suggest that what was once thought to be a grade correction factor may really be due to steel manufacturing process changes with time that affect even new low-grade steels. Correction factors comparable to that for X100 steels have been indicated to be needed for even X65 grade steels. Hence the past empirical equations in Codes and Standards like B31.8 will significantly under-predict the actual values needed for most new line-pipe steels.

Ruptures in Gas Pipelines, Liquid Pipelines and Dense Phase Carbon Dioxide Pipelines

2012 ◽  
Author(s):  
Andrew Cosham ◽  
David G. Jones ◽  
Keith Armstrong ◽  
Daniel Allason ◽  
Julian Barnett
Keyword(s):  
Large Diameter ◽  
Saturation Pressure ◽  
Fracture Propagation ◽  
Full Scale ◽  
Gas Pipeline ◽  
Thick Wall ◽  
Dense Phase ◽  
Line Pipe ◽  
Rich Mixture ◽  
High Toughness

Ruptures in gas and liquid pipelines are different. A rupture in a gas pipeline is typically long and wide. A rupture in a liquid pipeline is typically short and narrow, i.e. a slit or ‘fish-mouth’ opening. The decompression of liquid (or dense) phase carbon dioxide (CO2) immediately after a rupture is characterised by a rapid decompression through the liquid phase, and then a long plateau. At the same initial conditions (pressure and temperature), the initial speed of sound in dense phase CO2 is greater than that of natural gas and less than half that of water. Consequently, the initial decompression is more rapid than that of natural gas, but less rapid than that of water. A question then arises … Does a rupture in a liquid (or dense) phase CO2 pipeline behave like a rupture in a liquid pipeline or a gas pipeline? It may exhibit behaviour somewhere in-between the two. A ‘short’ defect that would rupture at the initial pressure might result in a short, narrow rupture (as in a liquid pipeline). A ‘long’ defect that would rupture at the (lower) saturation pressure might result in a long, wide rupture (as in a gas pipeline). This is important, because a rupture must be long and wide if it is to have the potential to transform into a running fracture. Three full-scale fracture propagation tests (albeit shorter tests than a typical full-scale test) published in the 1980s demonstrate that it is possible to initiate a running ductile fracture in a CO2 pipeline. However, these tests were on relatively small diameter, thin-wall line pipe with a (relatively) low toughness. The results are not applicable to large diameter, thick-wall line pipe with a high toughness. Therefore, in advance of its full-scale fracture propagation test using a dense phase CO2-rich mixture and 914×25.4 mm, Grade L450 line pipe, National Grid has conducted three ‘West Jefferson Tests’. The tests were designed to investigate if it was indeed possible to create a long, wide rupture in modern, high toughness line pipe steels using a dense phase CO2-rich mixture. Two tests were conducted with 100 mol.% CO2, and one with a CO2-rich binary mixture. Two of the ‘West Jefferson Tests’ resulted in short ruptures, similar to ruptures in liquid pipelines. One test resulted in a long, wide rupture, similar to a rupture in a gas pipeline. The three tests and the results are described. The reasons for the different behaviour observed in each test are explained. It is concluded that a long, wide rupture can be created in large diameter, thick-wall line pipe with a high toughness if the saturation pressure is high enough and the initial defect is long.

Recent Progress in Development of Ductile Fracture Arrest Methodology Based on CTOA: Test Standard, Transferability and Methodology

2020 ◽  
Author(s):  
S. Xu ◽  
C. Bassindale ◽  
J. Xue ◽  
B. W. Williams ◽  
X. Wang
Keyword(s):  
Crack Velocity ◽  
Damage Mechanics ◽  
Loading Rate ◽  
Test Procedure ◽  
Full Scale ◽  
Correction Factors ◽  
Type Specimens ◽  
Model Calculations ◽  
Resistance Curves ◽  
Fracture Arrest

Abstract Significant progress has been made in development of a new fracture arrest methodology based on a toughness parameter designed to characterize propagation — the crack-tip opening angle (CTOA). A CTOA test procedure using lab-scale DWTT-type specimens has been standardized by ASTM, and recently published experimental work has demonstrated transferability of CTOA from DWTT to full-scale pipe. This paper will present the basic methodology for determination of CTOA using DWTT-type specimens (i.e., ASTM E3039) and other specimens such as modified double-cantilever-beam (MDCB). Recent numerical studies using cohesive zone models (CZM) and others based on damage mechanics will be discussed, including models of full-scale pipe fracture. The effects on CTOA of loading rate, specimen flattening and constraint (bending vs. tension) will be reviewed. The effect on CTOA of loading rate between quasi-static and impact (covering five orders of magnitude) is small or negligible, being within experimental scatter. Observed differences between surface and mid-thickness CTOA values will be discussed. Models of DWTT specimens using damage mechanics have shown that the CTOA for tensile loading is the same at the surface and mid-thickness and equal to the mid-thickness value for bend loading, but that the surface CTOA is significantly larger than the mid-thickness CTOA in bending. Model calculations have revealed the dependence of crack velocity on stress for a given CTOA, enabling construction of fracture resistance curves (pressure required to propagate fracture as a function of crack velocity). These first-principles curves based on CTOA can then be used in the Battelle two-curve model (BTCM) to replace empirical resistance curves based on Charpy absorbed energy (Cv). It has been known for some time that Cv over-represents the propagation resistance for high-strength high-toughness steels, requiring empirical “correction factors” to Cv in the BTCM. Experiments have shown that there is a non-linear correlation between Cv and CTOA, explaining the need for correction factors to Cv and supporting the use of CTOA as a more appropriate propagation toughness.

Study on the Weldability of X100 Pipeline Steel on Scene

2013 ◽  
Vol 753-755 ◽  
pp. 343-352
Author(s):  
Pin Yi Wang ◽  
Zong Yuan Mou
Keyword(s):  
Oil And Gas ◽  
Pipeline Steel ◽  
Large Diameter ◽  
Welding Process ◽  
Field Application ◽  
Organization Performance ◽  
Long Distance ◽  
Line Pipe ◽  
Pipe Welding ◽  
X100 Pipeline Steel

With the long-distance oil and gas pipelines are to development of the direction of large-diameter, high-pressure, high grade pipeline steel applications gradually become the trend of the development of the oil and gas pipeline construction. The welding process of the X100 line pipe which is about to industrial application is not yet to be determined. It is not clear that the affect to the weldability from the metallurgical composition, organization, performance, and other factors which would affect the site construction welding process and welding measures. In addition, it is not yet the discussion and analysis of the key technologies X100 line pipe-site welding process and defect types. In this paper, the X100 pipeline on-site application of welding technology research commenced work and studied the weldability and welding process of X100 which solve the field application of X100 pipeline steel pipe welding issues.

Fracture Resistance in Line Pipe

1965 ◽  
Vol 87 (3) ◽  
pp. 265-278 ◽  
Author(s):  
G. M. McClure ◽  
A. R. Duffy ◽  
R. J. Eiber
Keyword(s):  
Fracture Behavior ◽  
Large Diameter ◽  
Full Scale ◽  
Laboratory Studies ◽  
Research Committee ◽  
Line Pipe ◽  
Diameter Pipe ◽  
On Line ◽  
Fracture Tests ◽  
Scale Behavior

The program of research on line pipe under the sponsorship of the A.G.A. Pipeline Research Committee is a comprehensive effort to investigate the important properties of pipe used in gas transmission. Several different phases are involved in this project, ranging from fundamental laboratory studies to fracture-behavior experiments on large-diameter pipe. This paper discusses the full-scale experimental parts of the program in which the fracture toughness of line pipe is being studied. Some of the factors that influence full-scale fracture behavior are discussed—material properties, fracture speed, temperature, wall thickness, nominal stress level, and type of backfill. Laboratory fracture tests that are being run and correlated with full-scale behavior are also described.

Fracture Propagation in Underwater Gas Pipelines

1986 ◽  
Vol 108 (1) ◽  
pp. 29-34 ◽  
Author(s):  
W. A. Maxey
Keyword(s):  
Ductile Fracture ◽  
Pipe Wall ◽  
Fracture Propagation ◽  
Full Scale ◽  
Gas Pipelines ◽  
Buried Pipelines ◽  
Nitrogen Gas ◽  
Line Pipe ◽  
Fracture Velocity

Two full-scale ductile fracture propagation experiments on segments of line pipe pressurized with nitrogen gas have been conducted underwater at a depth of 40 ft (12 m) to evaluate the ductile fracture phenomenon in underwater pipelines. The pipes were 22-in. (559-mm) diameter and 42-in. (1067-mm) diameter. Fracture velocities were measured and arrest conditions were observed. The overpressure in the water surrounding the pipe resulting from the release of the compressed nitrogen gas contained in the pipe was measured in both experiments. The overpressure in the water reduces the stress in the pipe wall and thus slows down the fracture. In addition, the water surrounding the pipe appears to be more effective than soil backfill in producing a slower fracture velocity. Both of these effects suggest a greater tendency toward arrest for a pipeline underwater than would be the case for the same pipeline buried in soil onshore. Further verification of this effect is planned and a modified version of the existing model for predicting ductile fracture in buried pipelines will be developed for underwater pipelines.

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