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.

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.

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.

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.

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.

Numerical Simulation of Tube-Bending Process with Internal Pressure for Titanium Alloy Tube

2005 ◽  
Vol 475-479 ◽  
pp. 3279-3282
Author(s):  
Xia Huang ◽  
Yuan Song Zeng ◽  
Zhi Qiang Li ◽  
Xin Hua Zhang
Keyword(s):  
Titanium Alloy ◽  
Internal Pressure ◽  
Forming Process ◽  
Cold Bending ◽  
Bending Process ◽  
Thickness Prediction ◽  
Bending Radius ◽  
Experimental Values ◽  
Titanium Alloy Tube ◽  
Good Agreement

In this paper, a new cold bending process is presented to form the titanium alloy tubular part with small relative bend radius, that is, its centerline bending radius is less than 2 times the outside diameter of the tube. FEM is applied to simulate the forming process, and at the same time the results, such as the distribution of the stress and the wall thickness, prediction of defects area, the effects of the internal pressure and friction condition on the tube deformation, are also analyzed. Finally, experimental research was preformed. It is found that the numerical results are in good agreement with the experimental values.

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.

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.

The Influence of the UOE Forming Process on Material Properties and Collapse of Deepwater Linepipe

2009 ◽  
Author(s):  
Chris Timms ◽  
Luciano Mantovano ◽  
Hugo A. Ernst ◽  
Rita Toscano ◽  
Duane DeGeer ◽  
...  
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Manufacturing Process ◽  
Thermal Ageing ◽  
Full Scale ◽  
Sensitivity Analyses ◽  
Thickness Variation ◽  
Forming Process ◽  
Cold Forming ◽  
Pipe Manufacturing

It has been demonstrated in previous work that, for deepwater applications, the cold forming process involved in UOE pipe manufacturing significantly reduces pipe collapse strength. To improve the understanding of these effects, Tenaris has embarked on a program to model the stages of the UOE manufacturing process using finite element methods. Previous phases of this work formulated the basis for model development and described the 2D approach taken to model the various stages of manufacture. More recent developments included some modeling enhancements, sensitivity analyses, and comparison of predictions to the results of full-scale collapse testing performed at C-FER. This work has shown correlations between manufacturing parameters and collapse pressure predictions. The results of the latest phase of the research program are presented in this paper. This work consists of full-scale collapse testing and extensive coupon testing on samples collected from various stages of the UOE pipe manufacturing process including plate, UO, UOE, and thermally-aged UOE. Four UOE pipe samples manufactured with varying forming parameters were provided by Tenaris for this test program along with associated plate and UO samples. Full-scale collapse and buckle propagation tests were conducted on a sample from each of the four UOE pipes including one that was thermally aged. Additional coupon-scale work included measurement of the through-thickness variation of material properties and a thermal ageing study aimed at better understanding UOE pipe strength recovery. The results of these tests will provide the basis for further refinement of the finite element model as the program proceeds into the next phase.

Risers Stability Under External Pressure, Axial Compression and Bending Moment Considering the Welded as Geometrical Imperfection

2006 ◽  
Author(s):  
He´ctor A. Sa´nchez Sa´nchez ◽  
Carlos Corte´s Salas
Keyword(s):  
Structural Integrity ◽  
Numerical Models ◽  
Local Buckling ◽  
Offshore Structures ◽  
External Pressure ◽  
Critical Conditions ◽  
Offshore Platforms ◽  
Theoretical Methods ◽  
Geometrical Imperfection ◽  
Bending Capacity

In Mexico, PEMEX manage more than 60,000 Km of oil and gas land and marine pipelines. Therefore, their structural integrity must be carefully assessed. The current development of offshore structures requires the design of better risers capable of assuring an optimal level of security. For that, some factors must be taken into account, which in critical conditions might become risky. It is common to find situations, in the performance of fixed offshore platforms, in which risers might be found empty due to maintenance or repairing. This condition could represent an unfavorable situation that in many cases might become highly critical given the conditions they are found in. Several studies had been completed with the aim to define a design methodology for the local buckling of pipes. In this paper, the bending capacity of the empty steel marine pipelines (risers) with girth-welded, placed to the legs of the offshore platforms very near to the deep sea, is studied by numerical models. The objective is to study the behavior and local buckling of these pipes submitted to combine loads, bending, external pressure and axial force, considering the girth-welded as the geometrical imperfection and to estimate the bending capacity of the pipes. Critical pressure of buckling, and modal configurations are evaluated by theoretical methods and numerical approaches such as finite element method (FEM). The numerical results are compared with theoretical methods.

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