FEM-Based Comparison of Mandrel Wear Resulting from Elongation of Pipes Manufactured from Various Materials on a Two-Roll Screw Rolling Mill

The present article discusses the cylindrical mandrel wear change during rolling using MISIS - 130 D mill depending on the type of rolled billets materials used. The research on the mandrel wear of the screw rolling mill during pipes elongation was carried out using the finite element method (FEM). The results of the wear modeling showed that the depth of the metal removed on the mandrel surface during stainless steel pipes elongation was higher as compared to alloyed and carbon steel pipes. The significant wear of the mandrel during stainless steel pipe rolling can be explained by the rise in the applied metal force resulting from the introduction of alloying components such as chromium and nickel into rolled billets materials. Consequently, the obtained modeling results can allow predicting the service life of working tools.

Ultra-Compact Eddy Current Transducer for Corrosion Defect Search in Steel Pipes

This research is devoted to the application of non-destructive testing methods for detecting defects of the internal structure of the material in steel pipelines. Despite the use of modern approaches to the design and manufacture of pipelines, which make it possible to lay a significant margin of safety in the created system, the task of developing new approaches to measuring the technical and operational characteristics and parameters of steel parts using software and hardware complexes for non-destructive testing does not lose its relevance. The paper presents the results of the development of defect detection system aimed at detecting damage of the structure of the material with a diameter of 0.2 mm and located at a depth of up to 2 mm. The proposed system is based on the physical principles of the influence of the existing defect on the value of the transformer voltage, which is induced in the measurement circuit of the sensor built on eddy current effects. The focus of the research is the relationship between the linear dimensions of the defect, its location and the generated voltage indications of the developed sensor. Also, within the framework of the study, the results of processing and analysis of the data collected by the defect detection system are presented, the result of which was the determination of the parameters of the detected defects.

Investigation of the gas losses in transmission networks

As air pollution has become a major issue in nowadays world, reducing methane emissions from the natural gas transmission systems is an issue that definitely has to be addressed. In order to do that, there are a few solutions available, such as the replacement of steel pipes with high-density polyethylene (HDPE) pipes. The main causes of these leaks are the corrosion defects and third-party interventions. The paper presents a new methodology for technological gas loss calculation from the natural gas transmission system. In order to obtain the most accurate calculation formulas, the flow coefficients for different cases were determined by experimental measurements. The paper presents the details regarding the construction and equipment of the experimental stand, as well as a new method for calculating the volumes of gas lost due to defects of this type. Thus, the aerial and buried defects were studied and the results obtained on statistical data were verified. Using the results of the study, the average emission of CH4 per year in Romania was calculated, and it was proven to be about 30% bigger than the European average. The findings of this study can help for a better understanding of the level of the losses and the effect on the final costs for the population, as well as the negative impact on the environment, in case the transporter does not take any measures.

Non-Metallic Technology Deployment for the Next Generation of ADNOC Production Facilities

Industry-wide, the degradation and corrosion of steel infrastructure and the associated maintenance to prevent or mitigate this, poses a heavy environmental and operational burden across many industry segments. To address these challenges, ADNOC Group Technology, led by our Non-Metallic Steering Committee and ADNOC Upstream, in partnership with several selected specialist product companies, is deploying a range of innovative solutions as pilot trials within a holistic R&D program – which is aiming to transform our production and processing facilities, with a close focus on integrity management – and specifically we are assessing the deployment of non-metallic pipelines, storage and process vessels as well as downhole tubing and casing. Focusing specifically on flowlines and pipelines - traditional steel pipes used in the oil patch are burdensome to store, transport and install, as well as susceptible to degradation, corrosion-driven wall loss in challenging operational environments, such as those found Onshore and Offshore Abu Dhabi. This vulnerability results in increased operating risks as facilities mature, adding cost and time for inspection, maintenance and eventually - replacements that will lead to production deferrals or interruptions. A range of non-metallic pipeline technologies are being assessed and piloted in this program, including stand-alone extruded polymeric pipe and liners, Reinforced Thermoplastic Pipe (RTP) used Onshore and Offshore, specialized non-metallic flexible pipelines for Offshore including Thermoplastic Composite Pipe (TCP) and downhole tubulars. The methodology involves placing segments of RTP into live pipeline systems for a finite duration of operation – usually one year – and then removing sections to assess any degradation in performance, or capability of the RTP during that time. These test results will be the subject of a further publication at the end of this trial period. In this paper, we will focus on RTP piloting Onshore and specifically mention a unique trial in an ultra-sour gas field, where the technology has already delivered the required performance: safely transporting gas with levels of H2S up to 10% by volume. This trial also proves that specifically engineered non-metallic products may be successfully operated at the high temperature and high pressure (HPHT) levels that are characteristic of our reservoirs.

Giant magneto resistance (GMR) sensors for non destructive testing

<p>The thesis investigates the use of giant magneto resistance sensors for eddy current testing in order to identify defects in steel pipes. An automated test rig which included the device under test, sensor array, excitation unit, electronic measurement equipment, mechanical setup and LabVIEW automation was designed and built. This was used to investigate the effect of excitation parameters such as current, frequency and distance to the pipe. Some preliminary algorithms to improve the signal were developed and tested. The effect of the shape and size of the defect and aluminum shield on the magnetic field was investigated. A qualitative model to describe the magnetic field, including measured defect signals, was developed. Minimum defect parameters and maximum distance values were evaluated in the context of signal to noise.</p>

Giant magneto resistance (GMR) sensors for non destructive testing

<p>The thesis investigates the use of giant magneto resistance sensors for eddy current testing in order to identify defects in steel pipes. An automated test rig which included the device under test, sensor array, excitation unit, electronic measurement equipment, mechanical setup and LabVIEW automation was designed and built. This was used to investigate the effect of excitation parameters such as current, frequency and distance to the pipe. Some preliminary algorithms to improve the signal were developed and tested. The effect of the shape and size of the defect and aluminum shield on the magnetic field was investigated. A qualitative model to describe the magnetic field, including measured defect signals, was developed. Minimum defect parameters and maximum distance values were evaluated in the context of signal to noise.</p>

Analysis of Ultimate Bearing Capacity and Parameters of Steel Support Cutting Pipe Roofing Structure

A new pipe-roof construction method, the steel support cutting pipe method (SSCP), was proposed to improve the construction security and accuracy of pipe jacking as well as underground space usage. The pipe-roof method is one of the underground excavation methods which push multiple steel pipes into the soil, then connect the steel pipes horizontally to form a whole. The proposed structure’s failure mode and force characteristics were determined through theoretical analysis, and then its ultimate bearing capacity and influencing parameters were analyzed through laboratory experiments and numerical simulation. The research results show that the structure’s bearing capacity depends on the steel pipe’s buckling load; the structure’s failure mode is a result of the steel pipe’s buckling. The ultimate bearing capacity of the pipe-roof structure first increases and then decreases with the increase of the steel pipe chord height ratio. The ultimate bearing capacity reaches the maximum when the ratio is 0.33. In addition, the structure’s ultimate bearing capacity is positively related to the steel pipe wall thickness and the pipe section’s length. This can be obtained from the relationship curve showing that the steel pipe wall thickness should be selected according to the engineering requirements and that the pipe section’s length is preferably 2.3 times the diameter of the steel pipe in the construction design.

Study on Combined Energy Absorption Support for Rockburst Disaster Control in Tunnelling

In order to better realize the rockburst disaster control mechanism and approach, the rockburst response of concrete blocks with different energy absorption levels under different energy storage conditions was observed and analyzed by loading tests. The occurrence and control mechanism of rockburst were explored from the perspective of energy aggregation and energy dissipation. On this basis, a combined energy absorption support system of concrete-filled steel tube frames and hollow steel pipes for rockburst disaster control was designed, and the effectiveness of the system was verified by numerical simulation and field tests. The results of loading tests show that the failure mode of the specimens changes from static failure to dynamic burst under energy storage loading. The occurrence of rockburst is inevitable when the energy supply is sufficient, but the disaster can be reduced or eliminated by strengthening constraints and improving energy-absorbing capacity to transform rockburst into large deformation. The combined structure consists of the hollow steel pipes being energy-absorbing part and the concrete-filled steel tube frames being strong confinement part was proposed to control rockburst disaster in tunnel support. The numerical analysis on the dynamic response of the support under strong rockburst impact shows that the hollow steel pipes effectively reduced the impact force on the concrete-filled tube frames, and accordingly, the deformation of the entire support system decreased. Given the condition that the hollow steel pipes be able to absorb all the impact energy during deformation, the smaller the strength of the hollow steel pipe is, the smaller the impact force and the displacement is. The combined energy absorption support provides an effective solution for rockburst disaster management in tunnels with strict clearance requirements.