An Approach to Establishing Manufacturing Process and Vintage of Line Pipe Using In-Situ Nondestructive Examination and Historical Manufacturing Data

2020 ◽  
Author(s):  
Nathan Switzner ◽  
Peter Veloo ◽  
Michael Rosenfeld ◽  
Troy Rovella ◽  
Jonathan Gibbs
Keyword(s):  
Manufacturing Process ◽  
Operating Pressure ◽  
Pipe Material ◽  
Line Pipe ◽  
Nondestructive Examination ◽  
Natural Gas Pipelines ◽  
Rule Changes ◽  
Integrity Management ◽  
Pipe Manufacturing

Abstract The October 2019 revisions to US federal rules governing natural gas pipelines require Operators to establish vintage and manufacturing process for line-pipe assets with incomplete records. Vintage and manufacturing process are considerations when establishing populations of pipe for maximum allowable operating pressure (MAOP) reconfirmation, materials verification, and integrity management programs. Additionally, the rule changes establish an allowance to utilize in-situ nondestructive examination (NDE) technologies to verify line-pipe material properties including strength, composition, microstructure, and hardness. Economic and market demands have driven changes in steelmaking technologies and pipe-forming approaches. Knowledge of the relationships between processing, microstructure and mechanical properties have been fundamental to the evolution of steel line pipe manufacturing. Product specifications and standards for the manufacture and testing of pipe and tube have crystallized this evolution as performance expectations increased. The resulting manufacturing process changes have left a variety of “fingerprints” observable from in-situ materials verification NDE data, when analyzed holistically. The purpose of this work is to enable operators to begin leveraging these fingerprints to illuminate the vintage and manufacturing process of their line pipe assets using the NDE data. A method is proposed to re-establish line-pipe asset manufacturing and vintage records using historical line pipe manufacturing practices and NDE materials verification data.

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.

The Practical Application of Fracture Control to Natural Gas Pipelines

2008 ◽  
Author(s):  
K. A. Widenmaier ◽  
A. B. Rothwell
Keyword(s):  
Natural Gas ◽  
Large Scale ◽  
High Strength ◽  
Fracture Initiation ◽  
Opening Angle ◽  
Pipe Material ◽  
Design Factor ◽  
Line Pipe ◽  
Natural Gas Pipelines ◽  
Crack Tip Opening

The use of high strength, high design-factor pipe to transport natural gas requires the careful design and selection of pipeline materials. A primary material concern is the characterization and control of ductile fracture initiation and arrest. Impact toughness in the form of Charpy V-notch energies or drop-weight tear tests is usually specified in the design and purchase of line pipe in order to prevent large-scale fracture. While minimum values are prescribed in various codes, they may not offer sufficient protection in pipelines with high pressure, cold temperature, rich gas designs. The implications of the crack driving force arising from the gas decompression versus the resisting force of the pipe material and backfill are examined. The use and limitations of the Battelle two-curve method as the standard model are compared with new developments utilizing crack-tip opening angle and other techniques. The methodology and reasoning used to specify the material properties for line pipe are described and the inherent limits and risks are discussed. The applicability of Charpy energy to predict ductile arrest in high strength pipes (X80 and above) is examined.

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.

Material Characterization of Pipeline Steels: Inspection Techniques Review and Potential Property Relationships

2016 ◽  
Author(s):  
Lucinda J. Smart ◽  
Brady J. Engle ◽  
Leonard J. Bond ◽  
John MacKenzie ◽  
Greg Morris
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Grain Size ◽  
Magnetic Measurements ◽  
Probability Of Detection ◽  
Steel Pipe ◽  
Operating Pressure ◽  
Pipe Material ◽  
Ultrasound Measurements

The oil and gas industry in North America operates an aging infrastructure of pipelines, 70% of which were installed prior to 1980 and almost half of which were installed during the 1950s and 1960s. There is growing interest in having knowledge of pipe properties so that a safe operating pressure can be determined, yet there are a significant number of cases where records are incomplete. Current in-line inspection (ILI) technologies focus on defect detection and characterization, such as corrosion, cracking, and the achieved probability of detection (POD). As a part of the process in assessing defect significance it is necessary to know the pipe properties, so as to determine potential failure limits. The mechanical properties (yield strength, tensile strength and fracture toughness) of steel pipe must be known or conservatively estimated in order to safely respond to the presence of detected defects in an appropriate manner and to set the operating pressure. Material property measurements such as hardness, chemical content, grain size, and microstructure can likely be used to estimate the mechanical properties of steel pipe without requiring cut-outs to be taken from pipes for destructive tests. There are in-ditch methods of inspection available or being developed that can potentially be used to determine many of the material characteristics and at least some mechanical properties. Furthermore, there is also potential ILI data to be used for obtaining some information. Advances in ILI technologies for this purpose are currently being explored by several interested parties. ILI companies are specifically focusing on relating magnetic measurements from eddy current and magnetic flux leakage measurements to mechanical properties. ILI also regularly uses ultrasound measurements for wall thickness determination. Potential application of advances in ultrasound measurements for grain size and other properties are being explored. However, nondestructive methods of inspection in common use today usually do not enable determination of either the material or mechanical properties, leaving the only alternative to be destructive testing. This is costly, time-consuming, and often not practical for pipe that is in-service. ILI and in-situ techniques are reviewed in this paper and provide an analysis of a sample set of data is presented. The paper explores the possibility of obtaining mechanical property data from data potentially measurable by ILI and in-situ measurements. Ideally, results would allow mechanical property measurements desired to assess pipelines so as to ensure that at a specific operating pressure there is the proper response to anomalies that might pose a significant threat. The use of a multivariate regression analysis showed better results than the traditional two-variable regression plots, and may be key to determining which properties are necessary to provide the best results for reliably estimating the mechanical properties of pipe. However, there is still much work to done in understand and account for the many sources of variability within the pipe material, and how that relates to the resultant relationships between the mechanical and material properties.

Validation of EMAT ILI for Management of Stress Corrosion Cracking in Natural Gas Pipelines

2014 ◽  
Author(s):  
Toby Fore ◽  
Stefan Klein ◽  
Chris Yoxall ◽  
Stan Cone
Keyword(s):  
High Resolution ◽  
Natural Gas ◽  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Corrosion Cracking ◽  
Probability Of Detection ◽  
Gas Pipelines ◽  
Line Pipe ◽  
Natural Gas Pipelines ◽  
Electro Magnetic

Managing the threat of Stress Corrosion Cracking (SCC) in natural gas pipelines continues to be an area of focus for many operating companies with potentially susceptible pipelines. This paper describes the validation process of the high-resolution Electro-Magnetic Acoustical Transducer (EMAT) In-Line Inspection (ILI) technology for detection of SCC prior to scheduled pressure tests of inspected line pipe valve sections. The validation of the EMAT technology covered the application of high-resolution EMAT ILI and determining the Probability Of Detection (POD) and Identification (POI). The ILI verification process is in accordance to a API 1163 Level 3 validation. It is described in detail for 30″ and 36″ pipeline segments. Both segments are known to have an SCC history. Correlation of EMAT ILI calls to manual non-destructive measurements and destructively tested SCC samples lead to a comprehensive understanding of the capabilities of the EMAT technology and the associated process for managing the SCC threat. Based on the data gathered, the dimensional tool tolerances in terms of length and depth are derived.

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