Review of Phase II for the Comprehensive Study to Understand Longitudinal ERW Seam Failures

2016 ◽  
Author(s):  
Bruce A. Young ◽  
Jennifer M. O’Brian ◽  
Steve Nanney
Keyword(s):  
Phase Ii ◽  
Structural Integrity ◽  
Prediction Models ◽  
Transportation Safety ◽  
Develop Software ◽  
Integrity Management ◽  
Resistance Weld ◽  
Weld Corrosion ◽  
Pipeline Safety ◽  
Comprehensive Study

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to significantly reduce longitudinal seam failures in electric resistance weld (ERW) pipe. The purpose of this paper is to provide a review of Phase II of the project with focus on the study objectives and results. Phase II of the project consisted of five tasks with the following objectives relevant to the ERW and flash weld (FW) process: 1) develop and optimize viable hydrotest protocols for ERW/FW seam defects 2) improve the sensors, interpretive algorithms, and tool platforms in regard to In-Line-Inspection (ILI) and In-the-Ditch-Methods (ITDM) to better ensure structural integrity by developing and optimizing concepts to address problems in detecting and sizing, 3) bridge gaps in defect characterization in regard to types, sizes, geometries, and idealizations, to increase pipeline safety through improvements needed to implement both ILI and hydrotesting, 4) validate existing failure prediction models and, where gaps preclude validation, refine or develop these models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary ERW/FW seam threats) for failure subject to loadings that develop both during hydrotests and in service, and 5) develop software to support integrity management of seam welds with enough flexibility to benefit from the experience gained during this project. The reports generated during the course of the project are publically available and are located on following PHMSA website: http://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390.

Overview of a Comprehensive Study to Understand Longitudinal ERW Seam Failures

2014 ◽  
Author(s):  
Bruce A. Young ◽  
Steve Nanney ◽  
Brian Leis ◽  
Jennifer M. Smith
Keyword(s):  
Phase I ◽  
Management Practices ◽  
Structural Integrity ◽  
Experimental Studies ◽  
Current Approach ◽  
Transportation Safety ◽  
Seam Weld ◽  
Integrity Management ◽  
Weld Corrosion ◽  
Comprehensive Study

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to eliminate longitudinal seam failures in electric resistance weld (ERW) pipe. This study was contracted with Battelle, working with Kiefner and Associates (KAI) and Det Norske Veritas (DNV) as subcontractors. The purpose of this paper is to provide an overview of the project with focus on the study objectives, results, and on-going work. Phase I of the project consisted of four major tasks aimed at understanding the current state of the issues. Task 1 analyzed the databases gathered and qualified in five interim reports that dealt with 1) the failure history of vintage ERW seams, including flash-weld (FW) pipe and selective seam-weld corrosion (SSWC); documented in two subtask 1.4 reports, 2) the effectiveness of in-line inspection (ILI) and hydrotesting, and experience with predictive modeling, documented in subtask reports 1.2 and 1.3 and 3) literature concerning SSWC documented in subtask 1.5 report. Task 2 addressed experimental studies designed to better characterize the failure of ERW/FW seams and quantify the resistance of such seams (Subtask 2.1–2.3 and 2.6 reports) and their response to pressure (Subtask 2.4 and 2.5 reports). Task 3 considered aspects related to SSWC with four separate reports from subtask 3.1–3.4. Task 4 focused on integration of the other tasks, trending, and analysis. Phase II has been initiated and consists of five tasks with the following objectives relevant to the ERW and FW process: 1) develop and optimize viable hydrotest protocols for ERW/FW seam defects 2) improve the sensors, interpretive algorithms, and tool platforms in regard to ILI and In-the-Ditch-Methods (ITDM) to better ensure structural integrity with optimized detection and sizing, 3) bridge gaps in defect characterization in regard to types, sizes, shapes, and idealizations. The goal of this subtask is to increase pipeline safety through improvements in the tools needed to implement both ILI and hydrotesting, 4) validate existing models and, where gaps preclude validation, refine or develop models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary threats) for failure subject to loadings that develop both during hydrotests and in service, and 5) develop a digitally based framework to support integrity management of seam welds with enough flexibility to benefit from the experience embedded in the stopgap protocol. To date, this study has led to seventeen (17) reports. These publically available reports are located on the PHMSA website: http://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390. Based on the work completed during Phase I, gaps identified in the context of the NTSB Recommendation P-09-1 were supported by the historic records. Additionally, recent improvements in related technologies and integrity management practices point to the practical utility and viability of PHMSA’s current approach to manage the integrity of the U.S. pipeline.

Development of Selective Seam Weld Corrosion Test Method

2014 ◽  
Author(s):  
J. A. Beavers ◽  
C. S. Brossia ◽  
R. A. Denzine
Keyword(s):  
Base Metal ◽  
Field Testing ◽  
Test Method ◽  
Transportation Safety ◽  
Seam Weld ◽  
Corrosion Kinetics ◽  
Pipeline Failures ◽  
Weld Corrosion ◽  
Pipeline Safety ◽  
Non Destructive

Selective seam weld corrosion (SSWC) of electric resistance welded (ERW) pipelines has been identified as a potential risk to pipeline safety. Due to recent pipeline failures, where seam weld defects may have played a significant role, the National Transportation Safety Board called upon the Pipeline and Hazardous Materials Safety Administration (PHMSA) to conduct a comprehensive study to identify actions that can be used by operators to eliminate catastrophic longitudinal seam failures in pipelines. Battelle contracted Kiefner and Associates, Inc. and Det Norse Veritas (U.S.A.) Inc. (DNV GL) with the objective to assist PHMSA in addressing this issue. The objective of one of the tasks performed by DNV GL was to develop a reliable, rapid, non-destructive, field-deployable test method that can quantify SSWC susceptibility on operating pipelines containing ERW seams. For this effort, two different, field deployable, non-destructive methods were evaluated in laboratory testing. The methods were validated using a standard destructive test for assessing SSWC susceptibility. One method was based on measurement of the local potential difference between the seam weld and the adjacent base metal while the second was based on differences in the corrosion kinetics between the seam weld and the base metal. The method that is based on corrosion kinetics was found to be most effective in identifying SSWC susceptible pipe steels. It utilizes a barnacle cell to conduct linear polarization resistance measurements on small, selected areas of the pipe (e.g., the weldment or base metal). Additional laboratory as well as field-testing is planned to further validate the test method.

An Overview of Time Dependent Crack Growth Models Used for ERW Seam Weld Analyses

2017 ◽  
Author(s):  
Richard Olson ◽  
Bruce Young ◽  
Jennifer O’Brian
Keyword(s):  
Crack Growth ◽  
Prediction Models ◽  
Growth Models ◽  
Time Dependent ◽  
Creep Model ◽  
Transportation Safety ◽  
Seam Weld ◽  
Integrity Management ◽  
Crack Growth Model ◽  
Time Dependent Crack Growth

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to significantly reduce longitudinal seam failures in electric resistance weld (ERW) pipe. As part of the project, Task 4 in Phase II was designed to validate existing failure prediction models and, where gaps exist, refine or develop the models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary ERW/Flash Weld seam threats) for failure subject to loadings that develop both during hydrotests and in service. These models would then be used to develop new software to support integrity management of seam welds with enough flexibility to benefit from the experience gained during this project. The purpose of this paper is to review the time-dependent crack growth model used in the development of the PipeAssess PI™ pipeline integrity management software. The model will be discussed in the context of its underlying theory, validation, and application to a set of test cases. Both the stress-activated creep model and consequential tie to fatigue crack growth models are presented, which describe crack growth under hydrostatic holds and subsequent pressure cycles. Full-scale experiments are used to validate the models. The reports generated during the course of the project are publically available and are located at the PHMSA website: HTTP://PRIMIS.PHMSA.DOT.GOV/MATRIX/PRJHOME.RDM?PRJ=390.

Stress Intensity Factor Solutions for Crack-Like Anomalies in ERW Seam Welded Pipe

2017 ◽  
Author(s):  
Jennifer O’Brian ◽  
Richard Olson ◽  
Bruce Young
Keyword(s):  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Transportation Safety ◽  
Department Of Transportation ◽  
Axial Crack ◽  
Resistance Weld ◽  
Welded Pipe ◽  
Weld Corrosion ◽  
Longitudinal Seam

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to significantly reduce longitudinal seam failures in electric resistance weld (ERW) pipe. As part of the project, Task 3 in Phase II was designed to determine more appropriate stress intensity factor solutions for non-standard, axial, crack-like anomalies in ERW seam-welded pipe. The purpose of this paper is to provide an overview of the normalized stress intensity factor solutions for cold weld (CW), selected seam-weld corrosion (SSWC), and hook crack type anomalies. ERW seams with and without weld caps are also included. The limitations on design space are discussed in the context of presenting results and interpolation and extrapolation schemes beyond that space with infinitely long solutions used as a boundary value. Results are presented in the form of surface plots for various combinations of parameters. The reports generated during the project are publicly available and are located on the following PHMSA website: http://primis.phmsa.dot.gov/matrix/PrjHome. rdm?prj=390.

Validation of Fatigue Models for ERW Seam Weld Cracking

2017 ◽  
Author(s):  
Bruce A. Young ◽  
Richard J. Olson ◽  
Jennifer M. O’Brian
Keyword(s):  
Growth Rate ◽  
Fatigue Crack ◽  
Crack Growth Rate ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Fatigue Crack Growth Rate ◽  
Prediction Models ◽  
Transportation Safety ◽  
Seam Weld ◽  
Develop Software

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to significantly reduce longitudinal seam failures in electric resistance weld (ERW) pipe. As part of the project, Task 4 in Phase II was designed to validate existing failure prediction models and, where gaps exist, refine or develop these models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary ERW/Flash Weld seam threats) for failure subject to loadings that develop both during hydrotests and in service. These models would then be used to develop software to support integrity management of seam welds with enough flexibility to benefit from the experience gained during this project. The purpose of this paper is to review the models used for fatigue crack growth rate (FCGR) calculations. Both the Willenborg Model, which is used to incorporate the retardation of crack growth after an overload occurs (such as a hydrostatic test in a pipeline), and the Walker Model, which is used to account for variation in stress ratio during the operation of a structure (i.e. pressure cycles in a liquid pipeline), will be discussed. Laboratory fatigue crack growth rate test results on several grades of pipe will be used to generate the constants employed in these models. The reports generated during the course of the project are publicly available and are located on the following PHMSA website: http://primis.phmsa.dot.gov/matrix/PriHome.rdm?pri=390.

Testing of Acoustic Emission Technology to Detect Cracks and Corrosion in the Marine Environment

2010 ◽  
Vol 26 (02) ◽  
pp. 106-110
Author(s):  
Ge Wang ◽  
Michael Lee ◽  
Chris Serratella ◽  
Stanley Botten ◽  
Sam Ternowchek ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Structural Integrity ◽  
Pilot Project ◽  
Development Project ◽  
Management Program ◽  
Pipeline System ◽  
Inspection Planning ◽  
Structural Degradation ◽  
Integrity Management ◽  
Acoustic Emission Technology

Real-time monitoring and detection of structural degradation helps in capturing the structural conditions of ships. The latest nondestructive testing (NDT) and sensor technologies will potentially be integrated into future generations of the structural integrity management program. This paper reports on a joint development project between Alaska Tanker Company, American Bureau of Shipping (ABS), and MISTRAS. The pilot project examined the viability of acoustic emission technology as a screening tool for surveys and inspection planning. Specifically, testing took place on a 32-year-old double-hull Trans Alaska Pipeline System (TAPS) trade tanker. The test demonstrated the possibility of adapting this technology in the identification of critical spots on a tanker in order to target inspections. This targeting will focus surveys and inspections on suspected areas, thus increasing efficiency of detecting structural degradation. The test has the potential to introduce new inspection procedures as the project undertakes the first commercial testing of the latest acoustic emission technology during a tanker's voyage.

A Hybrid Topside Structural Approach to the Management of Aging Fleet

2021 ◽  
Author(s):  
Biramarta Isnadi ◽  
Luong Ann Lee ◽  
Sok Mooi Ng ◽  
Ave Suhendra Suhaili ◽  
Quailid Rezza M Nasir ◽  
...  
Keyword(s):  
Structural Integrity ◽  
Metal Loss ◽  
Web Based ◽  
Strong Basis ◽  
Asset Risk ◽  
Risk Ranking ◽  
Design Life ◽  
Industry Standards ◽  
Integrity Management ◽  
Inspection Data

Abstract The objective of this paper is to demonstrate the best practices of Topside Structural Integrity Management for an aging fleet of more than 200 platforms with about 60% of which has exceeded the design life. PETRONAS as the operator, has established a Topside Structural Integrity Management (SIM) strategy to demonstrate fitness of the offshore topside structures through a hybrid philosophy of time-based inspection with risk-based maintenance, which is in compliance to API RP2SIM (2014) inspection requirements. This paper shares the data management, methodology, challenges and value creation of this strategy. The SIM process adopted in this work is in compliance with industry standards API RP2SIM, focusing on Data-Evaluation-Strategy-Program processes. The operator HSE Risk Matrix is adopted in risk ranking of the topside structures. The main elements considered in developing the risk ranking of the topside structures are the design and assessment compliance, inspection compliance and maintenance compliance. Effective methodology to register asset and inspection data capture was developed to expedite the readiness of Topside SIM for a large aging fleet. The Topside SIM is being codified in the operator web-based tool, Structural Integrity Compliance System (SICS). Identifying major hazards for topside structures were primarily achieved via data trending post implementation of Topside SIM. It was then concluded that metal loss as the major threat. Further study on effect of metal loss provides a strong basis to move from time-based maintenance towards risk-based maintenance. Risk ranking of the assets allow the operator to prioritize resources while managing the risk within ALARP level. Current technologies such as drone and mobile inspection tools are deployed to expedite inspection findings and reporting processes. The data from the mobile inspection tool is directly fed into the web based SICS to allow reclassification of asset risk and anomalies management.

scholarly journals Integrity Management of Marine Structures; With Emphasis on Design for Structural Robustness

2018 ◽  
Author(s):  
Torgeir Moan
Keyword(s):  
Structural Damage ◽  
Structural Integrity ◽  
Oil And Gas ◽  
Offshore Structures ◽  
Design Standards ◽  
Limit States ◽  
Fabrication Errors ◽  
Integrity Management ◽  
Operational Errors ◽  
And Control

Based on relevant accident experiences with oil and gas platforms, a brief overview of structural integrity management of offshore structures is given; including an account of adequate design criteria, inspection, repair and maintenance as well as quality assurance and control of the engineering processes. The focus is on developing research based design standards for Accidental Collapse Limit States to ensure robustness or damage tolerance in view damage caused by accidental loads due to operational errors and to some extent abnormal structural damage due to fabrication errors. Moreover, it is suggested to provide robustness in cases where the structural performance is sensitive to uncertain parameters. The use of risk assessment to aid decisions in lieu of uncertainties affecting the performance of novel and existing offshore structures, is briefly addressed.

Sign in / Sign up

Export Citation Format

Share Document