Minimum Wall Thickness Requirements for Ultra Deep-Water Pipelines

2003 ◽  
Author(s):  
Enrico Torselletti ◽  
Luigino Vitali ◽  
Roberto Bruschi ◽  
Leif Collberg
Keyword(s):  
Wall Thickness ◽  
Deep Water ◽  
Failure Modes ◽  
Limit State ◽  
Strain Curve ◽  
External Pressure ◽  
Design Guidelines ◽  
Compressive Yield Strength ◽  
Pipe Material ◽  
Line Pipe

The offshore pipeline industry is planning new gas trunklines at water depth ever reached before (up to 3500 m). In such conditions, external hydrostatic pressure becomes the dominating loading condition for the pipeline design. In particular, pipe geometric imperfections as the cross section ovality, combined load effects as axial and bending loads superimposed to the external pressure, material properties as compressive yield strength in the circumferential direction and across the wall thickness etc., significantly interfere in the definition of the demanding, in such projects, minimum wall thickness requirements. This paper discusses the findings of a series of ultra deep-water studies carried out in the framework of Snamprogetti corporate R&D. In particular, the pipe sectional capacity, required to sustain design loads, is analysed in relation to: • The fabrication technology i.e. the effect of cold expansion/compression (UOE/UOC) of TMCP plates on the mechanical and geometrical pipe characteristics; • The line pipe material i.e. the effect of the shape of the actual stress-strain curve and the Y/T ratio on the sectional performance, under combined loads; • The load combination i.e. the effect of the axial force and bending moment on the limit capacity against collapse and ovalisation buckling failure modes, under the considerable external pressure. International design guidelines are analysed in this respect, and experimental findings are compared with the ones from the application of proposed limit state equations and from dedicated FE simulations.

Development of X90 and X100 Steel Grades for Seamless Linepipe Products

2014 ◽  
Author(s):  
Diana Toma ◽  
Silke Harksen ◽  
Dorothee Niklasch ◽  
Denise Mahn ◽  
Ashraf Koka
Keyword(s):  
Wall Thickness ◽  
Deep Water ◽  
High Strength ◽  
Oil And Gas Industry ◽  
Pipe Material ◽  
Line Pipe ◽  
Materials Development ◽  
Additional Tool ◽  
Technical Requirements ◽  
Steel Grades

The general trend in oil and gas industry gives a clear direction towards the need for high strength grades up to X100. The exploration in extreme regions and under severe conditions, e.g. in ultra deep water regions also considering High Temperature/High Pressure Fields or arctic areas, becomes more and more important with respect to the still growing demand of the world for natural resources. Further, the application of high strength materials enables the possibility of structure weight reduction which benefits to materials and cost reduction and increase of efficiency in the pipe line installation process. To address these topics, the development of such high strength steel grades with optimum combination of high tensile properties, excellent toughness properties and sour service resistivity for seamless quenched and tempered pipes are in the focus of the materials development and improvement of Vallourec. This paper will present the efforts put into the materials development for line pipe applications up to grade X100 for seamless pipes manufactured by Pilger Mill. The steel concept developed by Vallourec over the last years [1,2] was modified and adapted according to the technical requirements of the Pilger rolling process. Pipes with OD≥20″ and wall thickness up to 30 mm were rolled and subsequent quenched and tempered. The supportive application of thermodynamic and kinetic simulation techniques as additional tool for the material development was used. Results of mechanical characterization by tensile and toughness testing, as well as microstructure examination by light-optical microscopy will be shown. Advanced investigation techniques as scanning electron microcopy and electron backscatter diffraction are applied to characterize the pipe material up to the crystallographic level. The presented results will demonstrate not only the effect of a well-balanced alloying concept appointing micro-alloying, but also the high sophisticated and precise thermal treatment of these pipe products. The presented alloying concept enables the production grade X90 to X100 with wall thickness up to 30 mm and is further extending the product portfolio of Vallourec for riser systems for deepwater and ultra-deep water application [1, 3, 4].

Bending Capacity of Pipe Bends in Deepwater Conditions

2010 ◽  
Author(s):  
Shulong Liu ◽  
Alastair Walker ◽  
Philip Cooper
Keyword(s):  
Internal Pressure ◽  
Induction Heating ◽  
Wall Thickness ◽  
Failure Modes ◽  
Limit State ◽  
Bending Moment ◽  
External Pressure ◽  
Fe Method ◽  
Moment Capacity ◽  
Operation Conditions

Offshore pipeline systems commonly incorporate induction-heating formed bends along flowlines and in pipeline end termination assemblies and spools. In deepwater locations, the pipeline and bends are subjected to various combinations of external pressure, internal pressure, bending moment and temperature changes, during installation, and operation. Although there is a history of research into the limiting loads and failure modes of such bends and pipelines systems there is, as yet, no comprehensive guidance to enable the calculation of the maximum capacity under combined bending and external pressure loading. Conservative guidance is presented in DNV OS-F101 (2007) [1] that proposes increasing the pipe wall thickness to reduce the effect of external pressure collapse effects thus enabling bending formulations relevant to straight pipe to be used. This proposed approach leads to unfeasibly large wall thickness requirements in very deepwater applications. There is therefore a requirement for a method to design deepwater bends for installation and operation conditions with levels of safety comparable with those used in the design of straight sections of pipelines that does not depend on the requirement to increase the wall thickness to the extent proposed in the current DNV guidance. In this study, a nonlinear FE method using ABAQUS is proposed to evaluate the ultimate capacities of induction-heating formed bends. The method takes into account the combined effects of non-linear material properties, initial ovality, wall thinning/thickening, external or internal pressure, internal CRA cladding and temperature change on the ultimate moment capacity of the bend. The numerical model is validated by comparison with available published results. The method developed here is based on the limit state design formulations in the current DNV OS-F101 guidance.

scholarly journals Rational Modeling of Ultimate Pipe Strength Under Bending and External Pressure

2000 ◽  
Author(s):  
André C. Nogueira ◽  
Glenn A. Lanan
Keyword(s):  
Deep Water ◽  
Limit State ◽  
Local Buckling ◽  
External Pressure ◽  
Pressure Effects ◽  
Combined Loading ◽  
Empirical Prediction ◽  
Limit State Design ◽  
Controlled Conditions ◽  
Offshore Pipeline

The capacity of pipelines to resist collapse or local buckling under a combination of external pressure and bending moment is a major aspect of offshore pipeline design. The importance of this loading combination increases as oil and gas projects in ultra deep-water, beyond 2,000-m water depths, are becoming reality. The industry is now accepting, and codes are explicitly incorporating, limit state design concepts such as the distinction between load controlled and displacement controlled conditions. Thus, deep-water pipeline installation and limit state design procedures are increasing the need to understand fundamental principles of offshore pipeline performance. Design codes, such as API 1111 (1999) or DNV (1996, 2000), present equations that quantify pipeline capacities under combined loading in offshore pipelines. However, these equations are based on empirical data fitting, with or without reliability considerations. Palmer (1994) pointed out that “it is surprising to discover that theoretical prediction [of tubular members under combined loading] has lagged behind empirical prediction, and that many of the formula have no real theoretical backup beyond dimensional analysis.” This paper addresses the ultimate strength of pipelines under combined bending and external pressure, especially for diameter-to-thickness ratios, D/t, less than 40, which are typically used for deep water applications. The model is original and has a rational basis. It includes considerations of ovalization, anisotropy (such as those caused by the UOE pipe fabrication process), load controlled, and displaced controlled conditions. First, plastic analysis is reviewed, then pipe local buckling under pure bending is analyzed and used to develop the strength model. Load controlled and displacement controlled conditions are a natural consequence of the formulation, as well as cross section ovalization. Secondly, external pressure effects are addressed. Model predictions compare very favorably to experimental collapse test results.

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.

Prediction and Qualification of Radial Birdcage and Lateral Buckling of Flexible Pipes in Deepwater Applications

2015 ◽  
Author(s):  
Linfa Zhu ◽  
Zhimin Tan ◽  
Victor Pinheiro Pupo Nogueira ◽  
Jian Liu ◽  
Judimar Clevelario
Keyword(s):  
Failure Modes ◽  
Local Buckling ◽  
External Pressure ◽  
Design Guidelines ◽  
Prediction Theory ◽  
Flexible Pipe ◽  
Lateral Buckling ◽  
Operation Conditions ◽  
Flexible Pipes ◽  
Compressive Loads

Increasing oil exploitation in deepwater regions is driving the R&D of flexible pipes which are subjected to high external pressure loads from the hydrostatic head during their installation and operation. One of the challenges of flexible pipe design for such applications is to overcome the local buckling failure modes of tensile armor layers due to the combination of high external pressure, compressive loads and pipe curvature. This paper presents the latest progress in local buckling behavior prediction theory and the qualification process of flexible pipes. First, the mechanisms of two types of buckling behaviors, radial birdcage buckling and lateral buckling, are described. For each failure mode, the analytical buckling prediction theory is presented and the driving parameters are discussed. As part of the qualification process, the ability to resist radial birdcage and lateral buckling must be demonstrated. Suitable test protocols are required to represent the installation and operation conditions for the intended applications by deep immersion performance (DIP) tests. Several flexible pipes were designed based on radial birdcage and lateral buckling prediction theory, and pipe samples were manufactured using industrial production facilities for DIP tests. The results clearly show that flexible pipes following current design guidelines are suitable for deepwater applications. An alternative in-air rig was developed to simulate the DIP tests in a controlled laboratory environment to further validate the model prediction as a continuous development.

Improved Prediction of External Pressure Collapse of Seamless Pipe

2009 ◽  
Author(s):  
Josef Navarro ◽  
Philip Cooper
Keyword(s):  
Cross Section ◽  
Wall Thickness ◽  
Design Method ◽  
External Pressure ◽  
Thickness Variation ◽  
Seamless Pipe ◽  
Line Pipe ◽  
Collapse Pressure ◽  
Average Wall Thickness ◽  
Improved Design

Seamless pipe typically features well controlled average wall thickness around its cross-section, but is prone to significant local thickness variation arising from the manufacturing process. Pipeline design codes, such as DNV OS-F101, provide little guidance on how to treat thickness variation whilst designing for collapse resistance. Standard practice is to consider minimum wall thickness across the whole cross-section, an assumption that two dimensional finite element simulations have proven conservative. This justifies the need for an improved design method. A program of simulations has been carried out to investigate the effect of wall thickness variation on collapse pressure. A modification to the DNV OS-F101 collapse design equation using average wall thickness over the whole crossection together with a fabrication factor is presented based on the results of this study. The fabrication factor de-rates the collapse pressure according to the amount of thickness variation present. The correction has been calibrated for thickness variations up to the maximum permitted by typical line pipe specifications. A number of FE trials demonstrate that the proposed formula predicts simulated collapse pressures with 98% accuracy. Adopting this method could provide significant wall thickness savings for deep water flowlines which in turn could lead to a reduction in steel costs and transportation and lay vessel requirements.

Alloying Concept for High-Strength Seamless Heavy-Wall Line Pipe Suitable for Sour Service Applications

2004 ◽  
Author(s):  
K. Biermann ◽  
C. Kaucke ◽  
M. Probst-Hein ◽  
B. Koschlig
Keyword(s):  
Heat Treatment ◽  
Wall Thickness ◽  
Oil And Gas ◽  
High Strength ◽  
Gas Production ◽  
Pipe Material ◽  
Low Carbon ◽  
Line Pipe ◽  
Oil And Gas Production ◽  
Sour Service

Offshore oil and gas production worldwide is conducted in increasingly deep waters, leading to more and more stringent demands on line pipes. Higher grades and heavier wall thicknesses in combination with deep temperature toughness properties, good weldability and suitability for sour service applications are among the characteristics called for. It is necessary that pipe manufacturers develop materials to meet these at times conflicting requirements. An alloying concept based on steel with very low carbon content is presented. This type of material provides excellent toughness properties at deep temperatures in line pipe with a wall thickness of up to 70 mm, produced by hot rolling followed by QT heat treatment. Pipes from industrial production of identical chemical composition and heat treatment achieved grades X65 to X80, depending on wall thickness. The properties of the steel used in pipes are presented. The resistance of the pipe material to the influence of sour gas was assessed by standard tests. To demonstrate weldability, test welds were performed and examined.

Collapse Resistance Under Combined External Pressure and Bending Deformation of Coated Linepipe

2020 ◽  
Author(s):  
Takahiro Sakimoto ◽  
Hisakazu Tajika ◽  
Tsunehisa Handa ◽  
Yoshiaki Murakami ◽  
Satoshi Igi ◽  
...  
Keyword(s):  
Yield Strength ◽  
Deep Water ◽  
Thermal Cycle ◽  
Bauschinger Effect ◽  
Heating Temperature ◽  
External Pressure ◽  
Compressive Yield Strength ◽  
Heat Cycle ◽  
Bending Deformation ◽  
Collapse Resistance

Abstract As offshore pipeline projects have expanded to deeper water regions with depths of more than 2 000 m, higher resistance against collapse by external pressure is now required in linepipe. Collapse resistance is mainly controlled by the pipe geometry and compressive yield strength. In UOE pipe, the compressive yield strength along the circumferential direction changes dramatically due to tensile pre-strain that occurs in pipe forming processes such as the expansion process. In order to improve the compressive yield strength of pipes, it is important to consider the Bauschinger effect caused by pipe expansion. As the mechanism of this effect, it is understood that internal stress is generated by the accumulation of dislocations, and this reduces reverse flow stress. Compressive yield strength is also changed by the thermal cycle associated with application of fusion-bond epoxy in pipe anti-corrosion coating by induction heating. In the typical thermal heat cycle of this coating process, the maximum heating temperature is from 200 °C to 250 °C. In this case, compressive yield strength increases as an effect of the thermal cycle, resulting in increased collapse resistance. Thus, for deep water application of UEO linepipe, it is important to clarify the conflicting effects of the Bauschinger effect and the thermal heat cycle on compressive yield strength. During installation of deep water pipelines by a method such as J-lay, curvature is imposed on the pipe axis, but the circumferential bending that leads to ovalization is determined by the interaction of the curvature of bending deformation. This bending deformation decreases collapse resistance. The interaction of external pressure and bending is also important when evaluating collapse. Against this background, this study discusses the collapse criteria for coated linepipe and their bending interaction against collapse based on a full-scale collapse test under external pressure with and without bending loading. The effect of the thermal heat cycle on linepipe collapse criteria is also discussed based on the results of tensile pre-strain tests with simulation of the thermal cycle and a collapse calculation by FEA.

New Generation of Heavy Wall Thicknesses Line Pipes for HPHT and Ultra-Deep Water Applications

2018 ◽  
Author(s):  
Stefano Crippa ◽  
Lorenzo Motta ◽  
Alessandro Paggi ◽  
Emanuele Paravicini Bagliani ◽  
Alessandro Elitropi ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Deep Water ◽  
Oil And Gas ◽  
High Pressures ◽  
Oil And Gas Industry ◽  
Rolling Process ◽  
Corrosion Properties ◽  
Line Pipe ◽  
Gas Industry ◽  
New Generation

Oil and Gas industry in the last decades has increased the use and need of heavy wall thickness line pipes, in particular for onshore / offshore high pressures and high temperatures (HP/HT) and offshore deep water / ultra-deep water applications. The paper presents the results achieved by Tenaris on seamless line pipes in grades X65/X70, according to API 5L / ISO 3183, with wall thickness in a range from 40 to 60 mm and diameter between 6 5/8” and 16”, produced by hot rolling process followed by quenching and tempering. Such line pipes are able to withstand very demanding conditions, like sour environment, very high pressure and wide temperature range. In this publication, the main outcomes of laboratory testing activities on the mentioned materials will be presented as part of heavy wall line pipe qualification. For this purpose, a special testing program, including mechanical and corrosion tests, has been executed. Material demonstrated an excellent behaviour, exhibiting both mechanical, toughness and stress corrosion properties suitable for the envisaged harsh applications.

A Numerical Lab to Predict the Strength Capacity of Offshore Pipelines

2005 ◽  
Author(s):  
Roberto Bruschi ◽  
Lorenzo Bartolini ◽  
Maurizio Spinazze` ◽  
Enrico Torselletti ◽  
Luigino Vitali
Keyword(s):  
Failure Modes ◽  
Limit State ◽  
Design Procedure ◽  
Point Load ◽  
Fe Analysis ◽  
Quantitative Prediction ◽  
Load Force ◽  
Line Pipe ◽  
Offshore Pipelines ◽  
Strength Capacity

In the recent years, the offshore pipeline industry has been under pressure to provide solutions for demanding material and line pipe technology problems, installation technology to safely tackle the ultra-deep waters challenge, quantitative prediction of reliable operating lifetime for pipelines under high pressure/high temperature conditions and remedial measures to tackle considerable geo-morphic and human activity related hazards. Future pipelines are being planned in very difficult environments, i.e. crossing ultra-deep water and difficult geo-seismic-morphic conditions. In these circumstances, it is of crucial importance (1) to adopt advanced design procedure and criteria, possibly based on limit state principles recently implemented in the design codes, and (2) to use advanced engineering tools for predicting the strength capacity and the pipeline behaviour during the installation and operational phase, in order to design the pipeline safely and to assess properly the technic-economical feasibility of the project. This paper discusses the relevant failure modes for offshore pipelines, the FE analysis results relevant to the sectional capacity of thick-walled pipes, and the FE analysis results relevant to the global and local response effect of a pipeline, laid on the sea bottom, and subject to a point-load force.

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