Comparison of Methods for Evaluation of Crack Growth at Welds in Offshore Risers

2015 ◽  
Author(s):  
Fengjie Yin ◽  
Mark Cerkovnik ◽  
Wasy Akhtar ◽  
Tracy Yang
Keyword(s):  
Stress Intensity ◽  
Crack Growth ◽  
Stress Profile ◽  
Butt Weld ◽  
Weld Joints ◽  
Weld Geometry ◽  
Welded Structure ◽  
Offshore Risers ◽  
Offshore Industry ◽  
Cyclic Changes

In checking the fitness of fatigue critical welded structure, the stress concentration at the weld due to the weld geometry needs to be considered. Where fatigue is assessed using crack growth methodology, two approaches are commonly used. In the offshore industry in regions where BS 7910 [1] is followed, the effect of weld geometry is assessed using the Mk factor approach. The Mk factor directly magnifies the stress intensity. Mk factor solutions are available for T-butt weld joints from the British Standard BS7910. Alternatively, API579 [2] offers stress intensity solutions that can account for the stress profile through the wall thickness of the pipe. In using this method, the engineer will use an FEA program to find the stress profile for use as an input for the stress intensity factor computation. Since the goal is the assessment of crack growth, the stress profile must represent the cyclic changes in stress. Further, a histogram of such profiles is required. While the Mk factor approach of BS7910 offers the easier path by supplying factors for pre-solved geometries, the API approach offers an opportunity to refine the solution by conducting relatively simple linear FEA of the un-cracked component. This study compares the two approaches using an example taken from offshore riser fatigue analysis.

Crack propagation in a welded polyolefin pipe

2012 ◽  
Vol 3 (2) ◽  
pp. 148-157 ◽  
Author(s):  
Martin Sevcik ◽  
Pavel Hutar ◽  
Lubos Nahlik ◽  
Ralf Lach ◽  
Zdenek Knesl ◽  
...  
Keyword(s):  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Crack Front ◽  
Fracture Behavior ◽  
Continuous Change ◽  
Butt Weld ◽  
Critical Crack Length ◽  
Content Type ◽  
Welded Structure

PurposeThe purpose of this paper is to study the effect of the material inhomogeneity on crack behavior initiated both axially and circumferentially in or near the butt weld and to discuss consequences on residual lifetime of the welded structure.Design/methodology/approachA three‐dimensional numerical model of pipe weld with smooth and continuous change of material properties has been used to study the fracture behavior of the cracked pipe structure. The stress intensity factor was considered as a parameter controlling the fracture behavior. The semi‐elliptical shape of the crack front was estimated under assumption of constant stress intensity factor along the crack front.FindingsAccording to the results obtained in the paper the following conclusions were deduced. First, the most critical location of the crack is in the middle of the inhomogeneous region (weld center) regardless of the crack orientation. The stress intensity factor is substantially higher than in the case of a crack located in the homogenous pipe. Second, with regard to crack shapes, the circumferentially oriented cracks are practically identical regardless to the crack location if compared with the axial cracks. Third, the stress intensity factors of axially‐oriented cracks are approximately twice higher than in the case of circumferential cracks. This implies that the cracks are more likely to grow in an axial direction.Originality/valueThe results described in the paper can be used for estimation of critical crack length or for estimation of the critical applied inner pressure of medium transported in the pipe and are of paramount importance for service life estimations of polymer welded pipes in actual use.

Finite Element Modeling and Analysis of Orthotropic Butt Welds

2010 ◽  
Author(s):  
Masoud Mojtahed ◽  
Qingtian Cai
Keyword(s):  
Finite Element ◽  
Stress Intensity ◽  
Static Loads ◽  
Butt Weld ◽  
Butt Welds ◽  
Modeling And Analysis ◽  
Weld Geometry ◽  
Design Engineers ◽  
The Relationship ◽  
Orthotropic Behavior

Butt welds with orthotropic behavior are widely applied in mechanical and structural designs. Since welds cannot always be perfect in practice, it is important to understand the weld’s stress behavior under different imperfect geometries. In this paper research has been performed to investigate the relationship between stress intensity factors and change of geometry of orthotropic butt welds. Finite element methods were applied to simulate weld geometries. The simulation was performed using ANSYS software assuming two beams are welded together with a discontinuity at the bottom of the weld. The combined beams and the butt weld are then considered to be one piece of glued structure. The discontinuity in the structure is used to model a crack and lack of weld penetration. By changing three important factors of the weld geometry under uniform axial static loads, the trend of stress intensity factor behavior versus change of geometry has been investigated. Both single and double sided butt welds were considered in this paper. The results of this investigation will be a helpful tool for design engineers in deciding the best weld geometry in applications.

Residual Stress Evaluation In Austenitic Stainless Steel Butt Weld Joints By Ultrasonic Technique

1992 ◽  
Vol 25 (3) ◽  
pp. 130 ◽  
Author(s):  
P. Palanichamy ◽  
A. Joseph ◽  
K. V. Kasiviswanathan ◽  
D. K. Bhattacharya ◽  
Baldev Raj
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Ultrasonic Technique ◽  
Butt Weld ◽  
Stress Evaluation ◽  
Weld Joints

Fatigue Crack Growth of Alloy 7050-T7451 Plate in L-S Orientation

2012 ◽  
Vol 525-526 ◽  
pp. 221-224
Author(s):  
Rui Bao ◽  
Xiao Chen Zhao ◽  
Ting Zhang ◽  
Jian Yu Zhang
Keyword(s):  
Growth Rate ◽  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Crack Growth Rate ◽  
Crack Growth ◽  
Growth Characteristics ◽  
Stress Intensity Factor Range ◽  
Constant Amplitude ◽  
Stress Ratios

Experiments have been conducted to investigate the crack growth characteristics of 7050-T7451 aluminium plate in L-S orientation. Two loading conditions are selected, i.e. constant amplitude and constant stress intensity factor range (ΔK). The effects of ΔK-levels and stress ratios (R) on crack splitting are studied. Test data shows that crack splitting could result in the reverse of crack growth rate trend with the increasing R ratio at high ΔK-level. The appearance of crack splitting depends on both ΔK and R.

Effective Modeling of Fatigue Crack Growth in Pipelines

2012 ◽  
Author(s):  
Steven J. Polasik ◽  
Carl E. Jaske
Keyword(s):  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Growth Models ◽  
Critical Parameters ◽  
Operating Pressure ◽  
Mechanics Model ◽  
Key Variables

Pipeline operators must rely on fatigue crack growth models to evaluate the effects of operating pressure acting on flaws within the longitudinal seam to set re-assessment intervals. In most cases, many of the critical parameters in these models are unknown and must be assumed. As such, estimated remaining lives can be overly conservative, potentially leading to unrealistic and short reassessment intervals. This paper describes the fatigue crack growth methodology utilized by Det Norske Veritas (USA), Inc. (DNV), which is based on established fracture mechanics principles. DNV uses the fracture mechanics model in CorLAS™ to calculate stress intensity factors using the elastic portion of the J-integral for either an elliptically or rectangularly shaped surface crack profile. Various correction factors are used to account for key variables, such as strain hardening rate and bulging. The validity of the stress intensity factor calculations utilized and the effect of modifying some key parameters are discussed and demonstrated against available data from the published literature.

Crack Growth in Stainless Steel 304 under Creep-Fatigue Loading

2007 ◽  
Vol 353-358 ◽  
pp. 485-490 ◽  
Author(s):  
Y.M. Baik ◽  
K.S. Kim
Keyword(s):  
Stress Intensity Factor ◽  
Stainless Steel ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Crack Growth ◽  
Growth Rates ◽  
Static Loading ◽  
Fatigue Loading ◽  
Creep Fatigue ◽  
Crack Growth Rates

Crack growth in compact specimens of type 304 stainless steel is studied at 538oC. Loading conditions include pure fatigue loading, static loading and fatigue loading with hold time. Crack growth rates are correlated with the stress intensity factor. A finite element analysis is performed to understand the crack tip field under creep-fatigue loading. It is found that fatigue loading interrupts stress relaxation around the crack tip and cause stress reinstatement, thereby accelerating crack growth compared with pure static loading. An effort is made to model crack growth rates under combined influence of creep and fatigue loading. The correlation with the stress intensity factor is found better when da/dt is used instead of da/dN. Both the linear summation rule and the dominant damage rule overestimate crack growth rates under creep-fatigue loading. A model is proposed to better correlate crack growth rates under creep-fatigue loading: 1 c f da da da dt dt dt Ψ −Ψ     =         , where Ψ is an exponent determined from damage under pure fatigue loading and pure creep loading. This model correlates crack growth rates for relatively small loads and low stress intensity factors. However, correlation becomes poor as the crack growth rate becomes large under a high level of load.

Slow Crack Growth in Glasses and Ceramics Under Residual and Applied Stresses

1989 ◽  
Vol 111 (1) ◽  
pp. 61-67 ◽  
Author(s):  
F. Erdogan
Keyword(s):  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Residual Stresses ◽  
Crack Growth ◽  
Slow Crack Growth ◽  
Threshold Value ◽  
Crack Arrest ◽  
Growing Crack ◽  
Applied Stresses

The problem of slow crack growth under residual stresses and externally applied loads in plates is considered. Even though the technique developed to treat the problem is quite general, in the solution given it is assumed that the plate contains a surface crack and the residual stresses are compressive near and at the surfaces and tensile in the interior. The crack would start growing subcritically when the stress intensity factor exceeds a threshold value. Initially the crack faces near the plate surface would remain closed. A crack-contact problem would, therefore, have to be solved to calculate the stress intensity factor. Depending on the relative magnitudes of the residual and applied stresses and the threshold and critical stress intensity factors, the subcritically growing crack would either be arrested or become unstable. The problem is solved and examples showing the time to crack arrest or failure are discussed.

Handling Uncertainty in the Remnant Fatigue Life Assessment of Offshore Process Pipework

2016 ◽  
Author(s):  
Arvind Keprate ◽  
R. M. Chandima Ratnayake
Keyword(s):  
Fatigue Life ◽  
Crack Growth ◽  
Life Assessment ◽  
Assessment Process ◽  
Linear Elastic ◽  
Fatigue Life Assessment ◽  
Process Piping ◽  
Growth Laws ◽  
Elastic Fracture ◽  
Offshore Industry

A typical procedure for a remnant fatigue life (RFL) assessment is stated in the BS-7910 standard. The aforementioned standard provides two different methodologies for estimating RFL; these are: the S-N curve approach and the crack growth laws (i.e. using Linear Elastic Fracture Mechanics (LEFM) principles) approach. Due to its higher accuracy, the latter approach is more commonly used for RFL assessment in the offshore industry. Nevertheless, accurate prediction of RFL using the deterministic LEFM approach (stated in BS-7910) is a challenging task, as RFL prediction is afflicted with a high number of uncertainties. Furthermore, BS-7910 does not provide any recommendation in regard to handling the uncertainty in the deterministic RFL assessment process. The most common way of dealing with the aforementioned uncertainty is to employ Probabilistic Crack Growth (PCG) models for estimating the RFL. This manuscript explains the procedure for addressing the uncertainty in the RFL assessment of process piping with the help of a numerical example. The numerically obtained RFL estimate is used to demonstrate a calculation of inspection interval.

scholarly journals Forensic Engineering Investigation Of Failure Of An Oil Pipeline

2012 ◽  
Vol 29 (1) ◽  
Author(s):  
William R. Broz
Keyword(s):  
Contaminated Soil ◽  
Fuel Oil ◽  
Weld Repair ◽  
Butt Weld ◽  
Oil Pipeline ◽  
Weld Joints ◽  
General Contractor ◽  
Forensic Engineering ◽  
Engineering Investigation ◽  
Surrounding Soil

A Below-Grade, Nps 12 Pipeline Serving A Major Commercial Marine Terminal Failed At A Flanged Joint, Causing A Major Leak And Contamination Of The Surrounding Soil. The Gasket At The Failed Joint Showed Evidence Of Localized, Radial Through-Leakage. At The Terminal, The Initial Excavation Of Contaminated Soil Caused Minor Damage To Several Non-Leaking Segments Of Pipe And The Author Was First Tasked To Oversee The Related Inspection, Weld Repair And Corrosion Protection Work. The Author Subsequently Performed A Forensic Pipe Stress Analysis Of The Affected Portion Of The Fuel Oil System Per The Governing Pressure Piping Code. The Results Indicated That The Leaking Joint Failed With Respect To The Code Criterion Of Equivalent Pressure. Further Investigation Revealed That The System As Originally Designed Was Entirely Of Butt Weld Construction With No Flanged Joints, And Would Have Complied With All Code Requirements. The Investigation Determined That The General Contractor Had Made An Unauthorized Substitution Of Flanged Joints For Butt Weld Joints, Without Informing The Owner Or Design Engineer Of Record.

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