Corrosion Fatigue Mechanisms and Fracture Mechanics Based Modelling for Subsea Pipeline Steels

Subsea structures such as pipelines are vulnerable to environment-assisted crackings (EACs). As a type of EAC, corrosion fatigue (CF) is almost inevitable. For such a process, stress corrosion (SC) and hydrogen-assisted cracking (HAC) are the two mainly driving mechanisms. And it was further pointed out that slip dissolution (SD) and hydrogen embrittlement (HE) should be responsible for SC and HAC respectively. Based on such a fact, a two-component physical model for estimating the CF crack propagation rate was proposed. The proposed model was built in a frame of fracture mechanics integrated with a dissolution model for C-Mn steel and a newly established model by the authors accounting for the influence from HE upon crack propagation. The overall CF crack propagation rate is the aggregate of the two rates predicted by the two sub-individual models, and then the crack propagation time is calculated accordingly. The model has been proven to be capable of capturing the features of HE influenced fatigue cracking behaviour as well as taking mechanical factors such as the loading frequency and stress ratio into account by comparison with the experimental data of X42 and X65 pipeline steels.

Modeling the Fatigue Damage Evolution in Welded Joints

The present paper presents a two-phase model for the fatigue damage evolution in welded steel joints. The argument for choosing a two-phase model is that crack initiation and subsequent crack propagation involve different damage mechanisms and should be treated separately. The crack initiation phase is defined as the number of cycles to reach a crack depth of 0.1 mm. This phase is modelled based on the Dang Van multiaxial stress approach. Both a multiaxial stress situation introduced by the acting loads and the presence of the multiaxial welding residual stresses are accounted for. The local notch effect at the weld toe becomes very important and the irregular weld toe geometry is characterized by extreme value statistics for the weld toe angle and radius. The subsequent crack growth is based in classical fracture based on the Paris law including the effect of the Stress Intensity Factor Range (SIFR) threshold value. The unique fatigue crack growth rate curve suggested by Huang, Moan and Cui is adopted. This approach keeps the growth rate parameters C and m constant whereas an effective SIFR is calculated for the actual stress range and loading ratio. The model is developed and verified based on fatigue crack growth data from fillet welded joints where cracks are emanating from the weld toe. For this test series measured crack depths below 0.1 mm are available. The two-phase model was in addition calibrated to fit the life prediction in the rule based S-N curve designated category 71 (or class F). A supplementary S-N curve is obtained by the Random Fatigue Limit Method (RFLM). The test results and the fitted model demonstrated that the crack initiation phase in welded joins is significant and cannot be ignored. The results obtained by the Dang Van approach for the initiation phase are promising but the modelling is not yet completed. The fracture mechanics model for the propagation phase gives good agreement with measured crack growth. However, it seems that the prediction of crack retardation based on a threshold value for the SIFR gives a fatigue limit that is overly optimistic for small cracks at the weld toe. The threshold value has been determined based on tests with rather large central cracks in plates. The validity for applying this threshold value for small cracks at the weld toe is questioned. As the present two-phase model is based on applied mechanics for both phases the parameters that have an influence on the fatigue damage evolution are directly entering into the model. Any change in these parameters can then be explicitly taken into account in logical and rational manner for fatigue life predictions. This not the case with the rule based S-N curves that are based on pure statistical treatment of the bulk fatigue life.

Experimental Study on the Interaction Effect of Sulfate Ions and Chloride Ions on Reinforcement Corrosion in Marine Environment

Reinforced concrete is one of the most widely used construction materials for marine structures. Due to the abundance of the aggressive ions such as chloride ions and sulfate ions in the seawater, the reinforcement exposed to the marine and costal environment are exposed to a high corrosion risk. Localized corrosion will occur once the passive film on the rebar is damaged. In this work, the corrosion behavior of the steel in the simulated pore solution containing with both sulfate ions and chloride ions are studied by using cyclic potentialdynamic polarization methods and the corrosion morphologies observed using scanning electron microscope (SEM). The test results show that the initial rebar corrosion is caused by the absorption of the chloride ions in the passive film. The sulfate ions nearly had no effect on the corrosion of the rebar in pore solution and it can further mitigate the pitting corrosion in chloride containing pore solution.

Recent Experiences With Cracking of Load Bearing Dissimilar Metal Welds on Subsea Production Systems

The process piping on subsea production systems (SPS) is normally made of solid corrosion resistant alloys (CRAs). However, some process components are made of low alloyed steels (LASs) which are internally cladded with a CRA. These components require post weld heat treatment (PWHT) to improve the properties in the LAS heat affected zone (HAZ). In order to avoid PWHT during on-site welding to adjoining piping systems, it has been common to weld a buttering layer (e.g. 15 – 20mm long) on to the connecting end of the LAS. The buttering layer consumable has traditionally been an austenitic nickel alloy, Alloy 625/725. The LAS HAZ and the buttering layer are thereafter PWHT’d and machined prior to on-site welding to the adjoining piping system. By this, it is not necessary to perform PWHT on the on-site (e.g. tie-in or closure) dissimilar welds. In the beginning of the century, some operators experienced cracking along the fusion line interface between the nickel alloy buttering and the LAS. These problems were typically experienced during start-up or prior to first production. An extensive research programme was established in order to determine the causes and remedial actions. A group sponsored project led by TWI was performed to understand the failure mechanisms and essential parameters leading to hydrogen assisted cracking, (HAC) of dissimilar metal welds (DMWs). Recommendations were made related to LASs chemistry, welding parameters, bevel geometry and especially PWHT time and temperature. Based on these recommendations there have been only a few incidents with cracking of such welded combinations before 2013 and onwards. Since then Statoil has experienced four off incidents with cracking of dissimilar welds on subsea LAS components. Common for these incidents are that they have been in operation for about 15 years and the cracking happened during cold shut-down periods. This paper presents key observations made and lessons learnt from the incidents summarized above. The main focus has been on environmental fracture mechanics-based testing of samples charged with hydrogen by cathodic protection (CP). Variables have been pre-charging temperature and time, as well as testing temperature. The testing has revealed strong dependency between the operating temperature (i.e. shutdown versus operation) and the sensitivity to HAC. Further, the investigations have shown that the integrity of the coating, as an effective barrier to hydrogen ingress, is the main feature to prevent HAC on this kind of DMWs. The investigation of the four off cracked welds showed clearly that the insulating polyurethane (PU) coating was heavily degraded by hydrolysis at higher temperatures. This exposed the dissimilar weldments to CP which contributed to the hydrogen charging of the weldments. The paper gives also result that show that it is not only PWHT’d LAS (e.g. type 8630M, 4130 and F22M) with dissimilar welds that may suffer from this failure mechanism. Testing has shown that as-welded F65 steel /Alloy 59 combinations may also suffer when charged with hydrogen and tested at low temperatures (e.g. shut down temperature).

Evaluation of the Effect of Different Mean Stress Levels on the Fatigue Resistance of OCTG Premium Threaded Connections

Identification of the effect of mean stress for fatigue performance of the premium threaded connection for the OCTG pipes, was conducted via full-scale test. API standard material [grade L80-1] was used for the test. The nominal pipe outside diameter and wall thickness were 244.48 mm (9-5/8 inch) and 11.99 mm (0.472 inch), respectively. The fatigue life of the specimens tested with no mean stress was longer than that of the specimens tested with a tensile mean stress. Through-wall cracks were found at the imperfect thread area of the male embodiment, but the crack initiation site depended on the mean stress. However, the primary root cause of the failure on both mean stress levels can be regarded as the fretting fatigue. Fatigue life was also able to be estimated using modified Goodman relation.

Experimental Analysis of Ratcheting Failure Based on the Piezomagnetic Response of X80 Pipeline Steel

The objective of this research is to explore the correlation between the piezomagnetic response and ratcheting failure behavior under asymmetrical cyclic stressing in X80 pipeline steel. The magnetic field variations from cycle to cycle were recorded simultaneously during the whole-life ratcheting test. Analysis made in the present work shows that the piezomagnetic hysteresis loop evolves systematically with the number of cycles in terms of its shape and position. Corresponding to the three-stage process in the mechanical response, piezomagnetic response can also be divided into three principal stages, but the evolution of magnetic parameter is more complex. Furthermore, the loading branch and unloading branch of the magnetic field-stress hysteresis loop separate gradually from each other during ratcheting failure process, leading to the shape of hysteresis loop changes completely. Therefore, the progressive degradation of the steel under ratcheting can be tracked by following the evolution of the piezomagnetic field. And the shape transition of the hysteresis loop can be regarded as an early warning of the ratcheting failure.

Improvement on Mechanical Properties of Cu-Containing Low Alloy Steel of Long Part Forging for Offshore Applications by Manufacturing Process

Effects by intercritical quenching, which is quenching from dual-phase of ferrite (α) and austenite (γ) region from 953 to 1068 K, on mechanical properties and microstructures of Cu-containing low alloy steel based on ASTM A707 5L grade (hereafter called A707 modified steel) were investigated using 50 kg test ingots. The mechanical properties of the A707 modified steel, i.e. strength at room temperature and fracture toughness at low temperature, were significantly improved by intercritical quenching. This is probably because its effective grain size decreased by intercritical quenching. Then, the optimum temperature of intercritical quenching for A707 modified steel was 1068 K near the AC3 point. Based on the experimental results of the test ingot, we applied intercritical quenching to a trial full-size forging production of about 20,000 mm in length, and researched the tensile, Charpy impact, crack tip opening displacement (CTOD) and drop weight test (DWT) properties across whole length of the trial production. It was found that the trial production has good mechanical properties across whole length. From the present work, an appropriate intercritical quenching is considered to apply for improvement method of the mechanical properties in A707 modified steel forgings.

Fatigue Assessment of Drill Pipes

Fatigue failures during offshore drilling operations is still a very costly problem. The fatigue behavior of drill pipes is reviewed, and typical failure modes are identified. The effects of drill string curvature during directional drilling on pipe body stress and on the fatigue life is examined. Effects on applied mean stress from drill string weight are discussed. Interaction effects of degradation mechanisms such as fatigue, wear and corrosion are evaluated. Experimental background data and statistical evaluation that form the basis for the current design practice issued by American Petroleum Institute (API) and other guidance in codes and standards is reviewed. Results from several recent testing programs performed under rotating bending of pipes with threaded connections, and tests involving the pipe body under resonance conditions are presented. The tests were made with pipe sizes from 2 7/8 in. to 5 7/8 in. in Grade S-135 pipes. The results are compared with published test data and design guidance such as API Recommended Practice G7 [1]. Recommendations are given for research and testing to improve reliability and the safe operation of drill strings.

Wear Performance of the Mooring Chain Used in Floating Wind Turbines

To produce offshore wind power generation plants, deep-sea floating wind turbine facilities are required. Commercial installation of floating wind turbine facilities requires a reduction of the mooring cost. Mooring chain breaks due to progressive wear will lead to enormous damages. Therefore, a quantitative wear evaluation method for mooring chains needs to be established. In this study, an experimental setup was constructed to reproduce the wearing phenomenon in mooring chains due to the motion of the floating body induced by waves, and its usefulness was confirmed. The result of the wear test conducted in this study suggests that the tensile force between links affects the degree of wear. Additionally, numerical simulations were performed using a finite element model with measured wear characteristics of the link material to reproduce the phenomenon of wear between links and confirmed that the wear phenomenon could be represented by numerical simulation.

A Tribute to the Extraordinary Research Work Within the Domain of Fatigue and Fracture of Offshore and Ship Structures Carried Out by Prof. Stig Berge and Per Jahn Haagensen at the Norwegian University of Science and Technology

The motivation of this paper is to highlight the importance of the work carried out during the last decade by Prof. Haagensen and Prof. Berge at the Norwegian University of Science and Technology NTNU, with the aim to inspire and motivate young engineers to continue their important and valuable research within fatigue and fracture. This paper will focus on their historical contribution to the research within fatigue and fracture of offshore and ship structures. Stig Berge is a professor of Marine Technology at the Norwegian University of Science and Technology NTNU. He has spent his academic carrier focusing on fatigue of offshore and ship structures; he has published more than 70 papers and articles in well-known journals and conferences since 80’s. Per Jahn Haagensen is currently an Emeritus professor at Department of Mechanical Engineering and Logistic Faculty of Technology. He has spent his whole research carrier within fatigue and fracture related topics mainly for the offshore industry. He is especially known for the different fatigue improvement methods which have been developed since the 90’s. He has until recently been an active member of the International Institute of Welding (IIW). This article aims to present their main findings and conclusions from their long academic carrier. While the authors have strived to convey in a single paper an overview of the careers and important contributions, the Professors themselves may well have chosen to place a different emphasis on their work.