Getting to Know Your Bends to Support SCC Management

2020 ◽  
Author(s):  
Chris Wood ◽  
Fernando Merotto ◽  
Brian Kerrigan ◽  
Ramon Loback ◽  
Pedro Gea
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Crack Detection ◽  
Axial Stress ◽  
Corrosion Cracking ◽  
Inspection System ◽  
Pipe Material ◽  
Baseline Assessment ◽  
Limited Information ◽  
Metallographic Examination

Abstract Nova Transportadora do Sudeste (NTS) own and operate a gas transmission system in Brazil constructed in 1996. One of the confirmed primary integrity threats to this system is axial stress corrosion cracking. The pipelines vary in diameter, weld type, manufacturer and age. One of the pipelines failed in 2015 due to an axial stress corrosion crack. Since the failure, NTS have executed an intense inspection campaign to detect and size axial cracking within their network. The 2015 failure occurred on a field bend. The inspection campaign and following dig campaign has confirmed that cracking (both axial and circumferential) within field bends is the primary integrity threat. Brazil has a challenging terrain and approximately 40% of joints within the network were subject to cold field bending. The influences of the pipeline geometry within these areas have resulted in localised elevated stresses where the axial stress corrosion cracking colonies are initiating and growing. To date, no cracking (axial or circumferential) has been verified within their straight pipe joints. NTS initially took a conservative baseline assessment approach using API 579 Part 9, due to the limited information regarding the pipe material and complex stress state. In addition to the hoop stress from internal pressure, the baseline assessment also considered weld residual stress and bending stress due to ovalization to determine immediate and future integrity. An intensive dig campaign is underway following a crack detection in-line inspection campaign using electromagnetic acoustic transducer technology. A large number of deep cracks were reported by the in-line inspection system, these were verified to be deep and repaired with a type B sleeve. However, at one site an entire joint was removed for further analysis, to investigate the crack morphology, confirm material properties and refine the predictive failure pressure modelling. This paper outlines how NTS have combined a burst test, mechanical testing, FEA modelling, fractography and metallographic examination to further understand the feature morphology and stresses within these areas and how they have been able to reduce conservatism from their baseline assessment with confidence and adopt a plastic collapse approach to accurately predict failure.

Methodology to Develop Fitness-for-Service Assessments for Crack Detection In-Line Inspection Data

2006 ◽  
Author(s):  
David Shanks ◽  
Rob Leeson ◽  
Corina Blaga ◽  
Rafael G. Mora
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Crack Detection ◽  
Corrosion Cracking ◽  
Life Extension ◽  
Remaining Life ◽  
Service Monitoring ◽  
Criticality Assessment ◽  
Inspection Data

Implementation of Integrity Management Programs (IMP) for pipelines has motivated the design of Fitness-For-Service methodologies to assess Stress Corrosion Cracking (SCC) and fatigue-dependent features reported by Ultrasonic Crack Detection (UTCD) In-Line Inspections. The philosophical approach defined by the API 579 [1] “Fitness-For-Service” from the petrochemical industry in conjunction with Risk-based standards and regulations (i.e. CSA-Z662-2003 [2] and US DOT 49 Parts 192 [3] and 195 [4]) and in-line inspection validation (i.e. API 1163 [5]) approaches from the pipeline industry have provided the engineering basis for ensuring the safety, reliability and continued service of the in-line inspected pipelines. This paper provides a methodology to develop short and long-term excavation and re-inspection programs through a four (4) phase-process: Pre-Assessment, Integrity Criticality Assessment, Remediation and Repair, Remaining Life Extension and In-Service Monitoring. In the first phase, Pre-assessment, areas susceptible to Stress Corrosion Cracking (SCC) and fatigue-dependent features are correlated to in-line inspection data, soil modeling, pipeline and operating conditions, and associated consequences in order to provide a risk-based prioritization of pipeline segments and technical understanding for performing the assessment. The second phase, Integrity Criticality Assessment, will develop a short-term maintenance program based on the remaining strength of the in-line inspection reported features previously correlated, overlaid and risk-ranked. In addition, sites may be identified in Phase 1 for further investigation. In the third phase, a Remediation and Repair program will undertake the field investigation in order to repair and mitigate the potential threats as well as validating the in-line inspection results and characterization made during the Pre-assessment and Integrity Criticality Assessment (Phases 1 & 2). With the acquired knowledge from the previous three (3) phases, a Remaining Life Extension and In-Service Monitoring program will be developed to outline the long-term excavation and re-inspection program through the use of SCC and Fatigue crack growth probabilistic modeling and cost benefit analysis. The support of multiple Canadian and US pipeline operating companies in the development, validation and implementation of this methodology made this contribution possible.

Developing Response Functions for Crack Opening Displacement to Calculate Leak-Rates Through Complex Cracks in Pipes With Weld Overlays

2010 ◽  
Author(s):  
Arindam Chakraborty ◽  
Wasimreza Momin ◽  
Angah Miessi ◽  
Peihua Jing ◽  
Haiyang Qian
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Crack Opening ◽  
Corrosion Cracking ◽  
Flaw Size ◽  
Pipe Material ◽  
Response Functions ◽  
Plant Design ◽  
Alloy 690 ◽  
Complex Crack

Leak-Before-Break (LBB) is employed in design of nuclear power reactor piping to eliminate consideration of the dynamic effects of pipe rupture from the plant design basis for the affected piping system. LBB cannot be applied if environmental conditions that could lead to degradation by stress corrosion cracking exists. For Alloy 600/82/182 dissimilar metal welds (DMW) in pressurized water reactor plants, primary water stress corrosion cracking (PWSCC) is found to be active. Application of weld overlay (WOL) of non-susceptible Alloy 690/52/152 material has been shown to mitigate PWSCC growth in DMW. Therefore, LBB can be considered for a DMW with Alloy 690/52/152 overlay. However, WOL sizing design postulates a complex crack which is through wall in the overlay material and part through or full circumferential in the DMW base material. This significantly reduces the critical flaw size and in turn the maximum allowable flaw size for leak rate. The current industry practice conservatively ignores the full circumferential crack in the original pipe material and assumes a through wall crack along the entire pipe thickness. This assumptions leads to significantly reduced leakage due to smaller crack opening. The problem becomes more critical with small diameter pipes. The current work calculates the crack opening displacements (CODs) for a pipe with complex crack. Since it is a function of several geometry and materials parameters, response functions are generated to calculate CODs.

scholarly journals DEVELOPMENT OF AN EMAT IN-LINE INSPECTION SYSTEM FOR DETECTION, DISCRIMINATION, AND GRADING OF STRESS CORROSION CRACKING IN PIPELINES

2003 ◽  
Author(s):  
Jeff Aron ◽  
Roger Dalton Jon Gore ◽  
Stuart Eaton ◽  
Adrian Bowles ◽  
Owen Thomas ◽  
...  
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Corrosion Cracking ◽  
Inspection System

Development and Experiences of a Circumferential Stress Corrosion Crack Management Program

2018 ◽  
Author(s):  
Neil Bates ◽  
Mark Brimacombe ◽  
Steven Polasik
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Crack Detection ◽  
Circumferential Stress ◽  
Management Program ◽  
Corrosion Cracking ◽  
Pipeline System ◽  
Average Growth ◽  
Proactive Management ◽  
Inspection Data

A pipeline operator set out to assess the risk of circumferential stress corrosion cracking and to develop a proactive management program, which included an in-line inspection and repair program. The first step was to screen the total pipeline inventory based on pipe properties and environmental factors to develop a susceptibility assessment. When a pipeline was found to be susceptible, an inspection plan was developed which often included ultrasonic circumferential crack detection in-line inspection and geotechnical analysis of slopes. Next, a methodology was developed to prioritize the anomalies for investigation based on the likelihood of failure using the provided in-line inspection sizing data, crack severity analysis, and correlation to potential causes of axial or bending stress, combined with a consequence assessment. Excavation programs were then developed to target the anomalies that posed the greatest threat to the pipeline system or environment. This paper summarizes the experiences to date from the operator’s circumferential stress corrosion cracking program and describes how the pipeline properties, geotechnical program, and/or in-line inspection programs were combined to determine the susceptibility of each pipeline and develop excavation programs. In-line inspection reported crack types and sizes compared to field inspection data will be summarized, as well as how the population and severity of circumferential stress corrosion cracking found compares to the susceptible slopes found in the geotechnical program completed. Finally, how the circumferential SCC time-average growth rate distributions were calculated and were used to set future geohazard inspections, in-line inspections, or repair dates will be discussed.

Characteristics, Causes, and Management of Circumferential Stress-Corrosion Cracking

2014 ◽  
Author(s):  
Raymond R. Fessler ◽  
Millan Sen
Keyword(s):  
Residual Stresses ◽  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Axial Stress ◽  
Circumferential Stress ◽  
The United States ◽  
Maximum Tensile Stress ◽  
Corrosion Cracking ◽  
Poisson Effect ◽  
Bent Pipe

While much more rare than axial stress-corrosion cracking (SCC), circumferential SCC (CSCC) has been observed in pipelines in Canada, the United States, and two European countries. In some cases, the CSCC has been of sufficient size to cause in-service leaks. Because the orientation of stress-corrosion cracks invariably is perpendicular to the maximum tensile stress, the axial stresses at the locations of the cracks must have been greater than the hoop stress. The Poisson effect and thermal effects can account for about half of the axial stresses. Evidence from the field suggests that there are three probable sources of additional axial stresses that can promote CSCC: residual stresses in bent pipe, axial stresses caused by movement of unstable soil on slopes, and residual stresses opposite rock dents. CSCC can be managed by one or a combination of the following procedures: direct assessment (DA), in-line inspection (ILI), or hydrostatic testing. Guidance for selection of sites for DA is derived from industry experience, which was determined from responses to a questionnaire and published reports. The capabilities of ILI to detect circumferential stress-corrosion cracks or the conditions that promote them are summarized. The benefits and limitations of hydrostatic testing also are described. A method for calculating the size of circumferential flaws that can cause ruptures is presented and compared with service experience. That information can provide useful guidance for ILI requirements and decisions about which flaws need to be removed immediately.

scholarly journals Remote detection of stress corrosion cracking: Surface composition and crack detection

2018 ◽  
Author(s):  
Cliff J. Lissenden ◽  
Igor Jovanovic ◽  
Arthur T. Motta ◽  
Xuan Xiao ◽  
Samuel Le Berre ◽  
...  
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Crack Detection ◽  
Surface Composition ◽  
Corrosion Cracking ◽  
Remote Detection ◽  
Detection Of Stress

scholarly journals Detection and Verification of SCC in a Gas Transmission Pipeline

2000 ◽  
Author(s):  
B. Ashworth ◽  
Neb Uzelac ◽  
H. Willems ◽  
O. A. Barbian
Keyword(s):  
Stress Corrosion ◽  
Wall Thickness ◽  
Stress Corrosion Cracking ◽  
Confidence Level ◽  
Crack Detection ◽  
Corrosion Cracking ◽  
Inspection Method ◽  
Transmission Pipeline ◽  
History Of ◽  
Location Type

Two sections of a 914mm OD (36 in.) TransCanada (TCPL) gas transmission pipeline (predominantly with 9.14 mm wall thickness) were inspected using an ultrasonic liquid coupled crack detection In-Line Inspection (ILI) tool. One of the objectives of the inspection was to establish the condition of the pipeline sections with a known history of stress-corrosion cracking (SCC). Under test was the practicability of inspecting a gas line using a liquid coupled ILI tool, specifically its ability to detect and size defects deeper than 1 mm and distinguish cracks and crack-like defects from other types of anomalies, such as inclusions and laminations. In order to assess the confidence level of the tool, both sections were inspected in two independent runs and the repeatability of inspection was assessed. Cracks and crack-like defects with depths greater than 12.5% of the wall thickness from both runs were compared and correlation was established to assess repeatability. The accuracy of tool predictions was verified in excavations in both sections. 40 reported features, varying in depths up to over 40% were examined with respect to location, type, and size. Examples of defect patterns are shown to demonstrate the accuracy of the inspection method.

Crack Detection Using Acoustic Emission Methods – Fundamentals and Applications

2005 ◽  
Vol 293-294 ◽  
pp. 33-48 ◽  
Author(s):  
Leonard M. Rogers
Keyword(s):  
Acoustic Emission ◽  
Stress Corrosion ◽  
Crack Growth ◽  
Stress Wave ◽  
Stress Corrosion Cracking ◽  
Crack Detection ◽  
Signal Amplitude ◽  
Offshore Structures ◽  
Corrosion Cracking ◽  
Measured Signal

This paper addresses the fundamentals of the acoustic emission effect associated with fatigue and stress corrosion cracking in metals. It considers the microstructure of cracks and the magnitude of the different types of physical event that can occur at the crack tip during plastic deformation and stable crack growth. Expressions are given for the threshold plastic zone size ‘Dl’ at which local fracture instability occurs and the stress-wave displacement amplitude as a function of distance ‘ui(r)’ for the different wave types ‘i’ produced during crack extension. Dispersion of the stress-wave and its convolution into an electrical burst signal at the sensor is considered together with the choice of appropriate sensing frequency. A methodology is described for correcting the measured signal amplitude for attenuation in the structure and for determining the maximum sensor spacing for the detection and location of events of a specified magnitude ‘Mae’ similar to the Richter scale. Case studies are presented to illustrate the extensive database now available on acoustic emission from crack growth in metallic structures and the technical and commercial benefits to be gained from an acoustic emission based inspection strategy. The applications considered are: • Fatigue crack growth in the node joints of offshore structures, • Stress corrosion cracking in platform flow lines.

An Automated ACFM Peak Detection Algorithm With Potential for Locating SCC Clusters on Transmission Pipelines

1998 ◽  
Author(s):  
L. Blair Carroll ◽  
Craig C. Monahan ◽  
Raymond G. Gosine
Keyword(s):  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Liquid Fuel ◽  
Crack Detection ◽  
Alternating Current ◽  
Detection Algorithm ◽  
Peak Detection ◽  
Corrosion Cracking ◽  
Peak Detection Algorithm ◽  
Memorial University Of Newfoundland

The Alternating Current Reid Measurement (ACFM) crack detection and sizing technique has demonstrated its potential as a stress corrosion cracking (SCC) characterization tool in studies conducted at Memorial University of Newfoundland (MUN). It’s ability to detect and size cracks through non-conductive coating thicknesses of 5 mm or more can have a significant impact on the costs associated with the current SCC investigation practices of many gas and liquid fuel transmission companies. This paper outlines work conducted at MUN in automating the detection of SCC within ACFM signals. The technique may be refined and incorporated into SCC characterization procedures.

A Robust Risk Assessment Model for Stress Corrosion Cracking

2018 ◽  
Author(s):  
Mohammad Al-Amin ◽  
Shahani Kariyawasam ◽  
Elvis SanJuan Riverol
Keyword(s):  
Risk Assessment ◽  
Stress Corrosion ◽  
Stress Level ◽  
Stress Corrosion Cracking ◽  
Risk Model ◽  
Corrosion Cracking ◽  
Assessment Model ◽  
Pipe Material ◽  
Risk Assessment Model ◽  
Integrity Assessment

Stress Corrosion Cracking (SCC) is a time dependent mechanism. Three conditions are required at the same location for the formation of SCC namely, susceptible material, susceptible environment and sufficient stress. Pipe age, operating stress level and coating type are significant parameters in determining the susceptibility to near-neutral pH SCC; whereas, additional parameters such as operating temperature and distance from compressor station are considered for high pH SCC. Environmental conditions such as soil type, topography and drainage have also shown correlation to SCC susceptibility. Several integrity assessment methods can be used to identify SCC on pipeline including hydrostatic testing, in-line inspection (ILI), and direct assessment (DA). Because the occurrence of SCC is a complex phenomenon and it depends on many parameters, it is important to develop a risk assessment model that can systematically incorporate all relevant evidences of SCC in a sensible way. This paper presents a robust risk assessment model for SCC, which uses evidence from failure histories, observation from assessments (i.e., digs, pressure tests, and ILIs), and mechanistic understanding of SCC (i.e. susceptible coating, pipe material, stress level, soil properties, etc.). This risk model is transparent and updateable, which allows incorporation of new scientific learnings and findings of SCC.

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