Fatigue Life Extension Procedure for Subsea Wells Based on Pressure Testing

2021 ◽  
Author(s):  
Arne Fjeldstad ◽  
Torfinn Hørte ◽  
Gudfinnur Sigurdsson ◽  
Anders Wormsen ◽  
Espen Berg ◽  
...  
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Fatigue Damage ◽  
Hot Spots ◽  
Fatigue Cracks ◽  
Load Test ◽  
Life Extension ◽  
Case Examples ◽  
Pressure Test ◽  
Number Of Cycles

Abstract This article presents a fatigue life extension procedure for subsea wells based on fracture mechanics. It makes use of the outcome of an internal pressure test to determine a safe period for drilling and completion. The pressure test is used as a load test and can only reveal deep fatigue cracks. The safe operational period is estimated as the number of cycles required to grow a fatigue crack from the largest fatigue crack that remains stable after the pressure test until it becomes unstable due to an accidental load. The procedure takes into account the probability of the presence of the fatigue crack that can be revealed by the pressure test. This is used to determine design fatigue factors for the procedure. The design fatigue factor is formulated in terms of the (S-N based) accumulated fatigue damage for historical operations. The procedure is illustrated with two case examples (fatigue hot spots) for illustrating the procedure in more detail: wellhead extension girth weld and wellhead profile. Conditions for use are given at the end of the article.

Plastic Slip and Early Stage of Fatigue Damage in Polycrystals: Comparison between Experiments and Crystal Plasticity Finite Elements Simulations

2014 ◽  
Vol 891-892 ◽  
pp. 1711-1716 ◽  
Author(s):  
Loic Signor ◽  
Emmanuel Lacoste ◽  
Patrick Villechaise ◽  
Thomas Ghidossi ◽  
Stephan Courtin
Keyword(s):  
Fatigue Crack ◽  
Finite Elements ◽  
Crack Initiation ◽  
Fatigue Damage ◽  
Crystal Plasticity ◽  
Early Stage ◽  
Low Cycle Fatigue ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
Plastic Slip

For conventional materials with solid solution, fatigue damage is often related to microplasticity and is largely sensitive to microstructure at different scales concerning dislocations, grains and textures. The present study focuses on slip bands activity and fatigue crack initiation with special attention on the influence of the size, the morphology and the crystal orientation of grains and their neighbours. The local configurations which favour - or prevent - crack initiation are not completely identified. In this work, the identification and the analysis of several crack initiation sites are performed using Scanning Electron Microscopy and Electron Back-Scattered Diffraction. Crystal plasticity finite elements simulation is employed to evaluate local microplasticity at the scale of the grains. One of the originality of this work is the creation of 3D meshes of polycrystalline aggregates corresponding to zones where fatigue cracks have been observed. 3D data obtained by serial-sectioning are used to reconstruct actual microstructure. The role of the plastic slip activity as a driving force for fatigue crack initiation is discussed according to the comparison between experimental observations and simulations. The approach is applied to 316L type austenitic stainless steels under low-cycle fatigue loading.

scholarly journals Structural and mechanical defects of materials of offshore and onshore main gas pipelines after long-term operation

2015 ◽  
Vol 5 (1) ◽  
Author(s):  
Pavlo Maruschak ◽  
Sergey Panin ◽  
Iryna Danyliuk ◽  
Lyubomyr Poberezhnyi ◽  
Taras Pyrig ◽  
...  
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Quantitative Analysis ◽  
Stress Concentration ◽  
Cyclic Loading ◽  
Fatigue Cracks ◽  
Preliminary Deformation ◽  
Term Operation ◽  
Steel Pipes

AbstractThe study has established the main regularities of a fatigue failure of offshore gas steel pipes installed using S-lay and J-lay methods.We have numerically analyzed the influence of preliminary deformation on the fatigue life of 09Mn2Si steel at different amplitudes of cyclic loading. The results have revealed the regularities of formation and development of a fatigue crack in 17Mn1Si steel after 40 years of underground operation. The quantitative analysis describes the regularities of occurrence and growth of fatigue cracks in the presence of a stress concentration.

Fatigue Damage Analysis on Crack Growth and Fatigue Life of Welded Bridge Members with Initial Crack

2006 ◽  
Vol 324-325 ◽  
pp. 251-254 ◽  
Author(s):  
Tai Quan Zhou ◽  
Tommy Hung Tin Chan ◽  
Yuan Hua
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
Fatigue Damage ◽  
Initial Crack ◽  
Traffic Loading

The behavior of crack growth with a view to fatigue damage accumulation on the tip of cracks is discussed. Fatigue life of welded components with initial crack in bridges under traffic loading is investigated. The study is presented in two parts. Firstly, a new model of fatigue crack growth for welded bridge member under traffic loading is presented. And the calculate method of the stress intensity factor necessary for evaluation of the fatigue life of welded bridge members with cracks is discussed. Based on the concept of continuum damage accumulated on the tip of fatigue cracks, the fatigue damage law suitable for steel bridge member under traffic loading is modified to consider the crack growth. The proposed fatigue crack growth can describe the relationship between the cracking count rate and the effective stress intensity factor. The proposed fatigue crack growth model is then applied to calculate the crack growth and the fatigue life of two types of welded components with fatigue experimental results. The stress intensity factors are modified by the factor of geometric shape for the welded components in order to reflect the influence of the welding type and geometry on the stress intensity factor. The calculated and measured fatigue lives are generally in good agreement, at some of the initial conditions of cracking, for a welded component widely used in steel bridges.

Fatigue Life Prediction for Variable Strain at a Mixing Tee by Use of Effective Strain Amplitude

2020 ◽  
Author(s):  
Koji Miyoshi ◽  
Masayuki Kamaya
Keyword(s):  
Growth Rate ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Crack Growth Rate ◽  
Crack Growth ◽  
Fatigue Damage ◽  
Hot Spot ◽  
Effective Strain ◽  
Single Overload ◽  
Loading Sequence

Abstract Mixing flow causes fluid temperature fluctuations near the pipe walls and may result in fatigue crack initiation. The authors have previously reported the loading sequence effect on thermal fatigue in a mixing tee. The fatigue damage around the hot spot, which was heated by the hot jet flow from the branch pipe, obtained by Miner’s rule was less than 1.0. Since the strain around the hot spot had waveforms with periodic overload, the loading sequence with periodic overload caused reduction of the fatigue life around the hot spot. In this study, the effect of a single overload on the fatigue crack growth rate was investigated in order to clarify the reduction of the fatigue life at the mixing tee due to strain with periodic overload. In addition, the prediction method of the fatigue life for the variable thermal strain at the mixing tee was discussed. It was shown the crack growth rate increased after an overload for both cases of tensile and compressive overloads. The effective strain amplitude increased after the application of a single overload. The fatigue life curve was modified by considering the increment of the effective strain range. The fatigue damage recalculated using the modified fatigue life curve was larger than 1.0 except in a few cases. The fatigue life could be assessed conservatively for variable strain at the mixing tee using the developed fatigue curve and Miner’s rule.

Development of a Quantifiable Approach in Monitoring the Fatigue Cracks Using Digital Image Correlation

2016 ◽  
Vol 701 ◽  
pp. 211-215
Author(s):  
Sze Wei Khoo ◽  
Saravanan Karuppanan ◽  
Ching Seong Tan
Keyword(s):  
Digital Image Correlation ◽  
Fatigue Damage ◽  
Digital Image ◽  
Fatigue Cracks ◽  
Image Correlation ◽  
Correlation Technique ◽  
Digital Image Correlation Technique ◽  
Deformation Parameters ◽  
Industrial Grade ◽  
Number Of Cycles

From the viewpoint of engineering, fatigue is an important issue as most of the mechanical failures are associated with fatigue damage. In fact, these disastrous events had occurred unexpectedly during the regular working conditions and most of the time the applied stresses are well below the yield strength of the material. Thus, it makes the prediction of fatigue damage a challenging task in the field of engineering, especially when the manmade structures and machines are getting more complex than before. Even though fatigue has been studied extensively in the past 170 years, many limitations are still being found within the current fatigue analysis, testing and the non-destructive inspection. Hence, there is a great need to develop a precise and yet efficient inspection technique in quantifying the fatigue cracks. Therefore, the objective of this study is to develop a quantifiable approach in monitoring the fatigue cracks using digital image correlation technique. This can be achieved by using a developed two-dimensional sub-pixel accuracy deformation measurement algorithm which determines the deformation parameters of the first-order shape function of a material subjected to cyclic loading. Next, fatigue tests for samples made of mild steel (Grade: JIS G 3101 SS400) were conducted in accordance to the ASTM E466. Simultaneously, an industrial grade camera was used to capture the fatigue crack’s region at a specific interval until the sample broke into two pieces. The captured images were then analysed and the deformation parameters such as translations, normal and shear strains values were determined by using the developed digital image correlation algorithm. Based on the determined deformation patterns, a specific trend was observed throughout the graphs of respective deformation parameters against the number of cycles. Besides, drastic changes were observed when the average number of cycles was approaching 95.5% (min. loading) and 93.8% (max. loading) of the total fatigue life. In conclusion, the digital image correlation technique was proven to be capable in monitoring the severity of a fatigue crack and the proposed monitoring system would serve as an inspection technique in examining the fatigue damage of a structural component throughout its operational period.

The Creep-Fatigue Interaction in Solders and Solder Joints

1990 ◽  
Vol 112 (2) ◽  
pp. 100-103 ◽  
Author(s):  
D. S. Stone
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Solder Joints ◽  
Fatigue Cracks ◽  
Solution Concentration ◽  
Grain Boundary Sliding ◽  
Cycle Frequency ◽  
Low Frequencies ◽  
Creep Fatigue ◽  
Failure Life

Two models are proposed for relating the metallurgy of the solder to the growth of fatigue cracks through solder joints. These models illustrate how different aspects of the creep behavior can contribute to the so-called “creep-fatigue interaction”. The first model treats fatigue crack growth through the solder, far from the interface between solder and substrate. Either an intragranular or intergranular path may be taken depending upon conditions of loading. Intragranular fatigue dominates when the cycle frequency is high, in which case failure life is governed by the Coffin-Manson law. Intergranular failure occurs at low frequencies because grain boundary sliding at low frequencies allows the grain boundaries to become exposed to the atmosphere, which in turn causes oxidation. This model predicts the effects of frequency, strain amplitude, and grain size on fatigue life. In the second model, the fatigue crack travels within the interface region between solder and substrate. Here, the strain introduced in the solder joint during fatigue is not relevant; instead, the stress transferred to the interface is more important. The second model considers the effect of solid solution concentration on fatigue life. The predictions of both models agree reasonably well with published fatigue data from solders and solder joints.

Fatigue Damage Repair and Life Extension of a Floating Production Unit: The VFB Platform Revisited

2011 ◽  
Author(s):  
P. J. Haagensen ◽  
J. E. Larsen ◽  
O. T. Va˚rdal
Keyword(s):  
Fatigue Damage ◽  
Fatigue Cracks ◽  
Fatigue Cracking ◽  
Life Extension ◽  
Conference Paper ◽  
Safe Operation ◽  
Damage Repair ◽  
Production Platform ◽  
Low Levels ◽  
Extension Program

The Veslefrikk B platform was built in 1985 as a drilling exploration unit but was converted to a production platform in 1989. After only two years in service fatigue cracks were discovered and several repairs were made. However, extensive fatigue cracking continued and a retrofitting program was planned. In addition, increased payload was necessitated by more topside equipment required for a tie-in to the Huldra field which was scheduled to start production in 2001. In 1999 the platform was temporarily decommissioned and dry-docked for a comprehensive repair and upgrading program, this was completed in approximately two months. The life extension program was described in the OMAE 2000 conference paper 2954. However, after only one more year of service new cracks were found and subsequent fatigue damage necessitated new repairs. It is noteworthy that cracking this time occurred only in areas of the structure that were left untreated in the 1999 retrofitting program due to assumed low levels of stress in those areas. The paper describes the original repair and strengthening program, and the types of subsequent fatigue damage that required new repairs. Most of the cracks occurred in the hull skin plates and caused water leakage. The objective of the recent life extension program is to ensure safe operation of the platform for a period of another 20 years.

Fatigue crack growth behavior of rib-to-deck double-sided welded joints of orthotropic steel decks

2020 ◽  
pp. 136943322096175
Author(s):  
Yang Liu ◽  
Fanghuai Chen ◽  
Da Wang ◽  
Naiwei Lu
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Crack Growth ◽  
Welded Joints ◽  
Mixed Mode ◽  
Fatigue Cracks ◽  
Growth Behavior ◽  
Crack Growth Behavior ◽  
Fatigue Crack Growth Behavior ◽  
Orthotropic Steel Decks

Innovative double-sided welding is expected to improve the fatigue resistance of rib-to-deck welded joints of orthotropic steel decks (OSDs). Welding crack-like defects are the crucial issue affecting the fatigue performance of rib-to-deck double-sided welded joints. This study presents a numerical simulation of three-dimensional (3D) mixed mode fatigue crack growth behavior of rib-to-deck double-sided welded joints of OSDs. Maximum tensile stress theory and equivalent stress intensity factor (SIF) were used to simulate mixed mode fatigue cracks growth. The Paris law model was employed to predict the fatigue life. Fatigue cracks of rib-to-deck double-sided welded joints were characterized by the presence of mixed mode cracks of modes I (open), mode II (shear), and mode III (tear), which was dominated by mode I. The equivalent SIF was found to be complex at the growth stage with the maximum value at the two ends of the crack front and the minimum value at the midpoint of the crack front. The crack shape became flatter in the later phase of the crack growth. The fatigue crack surface underwent deflections during crack growth, making the final crack shape exhibiting the characteristic of a spatial curved surface. The initial crack geometry showed a significant impact on the fatigue life.

scholarly journals Experimental and Numerical Investigations of Fretting Fatigue Behavior for Steel Q235 Single-Lap Bolted Joints

2016 ◽  
Vol 2016 ◽  
pp. 1-10 ◽  
Author(s):  
Yazhou Xu ◽  
Zhen Sun ◽  
Yuqing Zhang
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Crack Initiation ◽  
Failure Mode ◽  
Contact Stress ◽  
Fatigue Cracks ◽  
Fretting Fatigue ◽  
Bolted Joints ◽  
Normal Contact Stress ◽  
Normal Contact

This work aims to investigate the fretting fatigue life and failure mode of steel Q235B plates in single-lap bolted joints. Ten specimens were prepared and tested to fit theS-Ncurve. SEM (scanning electron microscope) was then employed to observe fatigue crack surfaces and identify crack initiation, crack propagation, and transient fracture zones. Moreover, a FEM model was established to simulate the stress and displacement fields. The normal contact stress, tangential contact stress, and relative slipping displacement at the critical fretting zone were used to calculate FFD values and assess fretting fatigue crack initiation sites, which were in good agreement with SEM observations. Experimental results confirmed the fretting fatigue failure mode for these specimens. It was found that the crack initiation resulted from wear regions at the contact surfaces between plates, and fretting fatigue cracks occurred at a certain distance away from hole edges. The proposed FFD-Nrelationship is an alternative approach to evaluate fretting fatigue life of steel plates in bolted joints.

Thermographic Determination of Fatigue Damage

1978 ◽  
Vol 100 (2) ◽  
pp. 200-203 ◽  
Author(s):  
J. A. Charles ◽  
F. J. Appl ◽  
J. E. Francis
Keyword(s):  
Fatigue Life ◽  
Mild Steel ◽  
Surface Temperature ◽  
Fatigue Damage ◽  
Fatigue Cracks ◽  
Temperature Distributions ◽  
Fatigue Failures

The energy released due to hysteresis effects in cyclically loaded materials can be used to predict where fatigue cracks are likely to initiate and to determine the stage of fatigue life. In the present study, thermography is used to monitor the surface temperature distributions on a series of double-notched, mild steel fatigue specimens cyclically loaded in bending. The results indicate that the fatigue life of the material encompasses three thermal stages, each of which is indicative of the fatigue damage the material has sustained. This information can be used to avoid in-service fatigue failures.

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