Ductile Crack Extension Analysis for X80 Bending Deformation Using Damage-Based Model

This paper presents experimental and analytical results focusing on the strain limit of X80 linepipe. Ductile crack growth behavior from a girth weld notch is simulated by FE analysis based on a proposed damage model and is compared with the experimental results. The simulation model for ductile crack growth accompanied by penetration through the wall thickness consists of two criteria. One is a criterion for ductile crack initiation from the notch-tip, which is described by the plastic strain at the notch tip, because the onset of ductile cracking can be expressed by constant plastic strain independent of the shape and size of the components and the loading mode. The other is a damage-based criterion for simulating ductile crack extension associated with damage evolution influenced by plastic strain in accordance with the stress triaxiality ahead of the extending crack tip. The proposed simulation model is applicable to prediction of ductile crack growth behaviors from a circumferentially-notched girth welded pipe with high internal pressure, which is subjected to tensile loading or bending (post-buckling) deformation.

Different Failure Modes of Non-Metallic Pipelines at Connections

The article provides an overview of different modes of failures in composite pipeline connections. Non-metallic spoolable (SCP) and reinforced thermoplastic pipelines (RTP) of different makes will be addressed. The article is based on actual case histories of pipeline failures (root cause analysis). Numerous factors contributing to failures and recommendations are discussed.

Evaluation of Design Premises and Uncertainties on the Thermo-Mechanical Behavior of a Subsea Pipeline

Buckle formation process is a key subject for the design of subsea pipelines laid on the seabed and operating under high pressure and high temperature (HP/HT) conditions. When the controlled lateral buckling methodology is adopted triggers are placed along pipeline route in order to increase the buckle formation probability in specific locations, sharing pipeline expansion between these sites and reducing the level of stress and strain in each buckle. Despite of its importance, buckle formation process is influenced by several parameters such as the seabed bathymetry, engineered triggers, lateral out-of-straightness (OOS) and pipe-soil interaction. While the first two items above can be defined with reasonable accuracy at previous stages of design, lateral OOS will only be known with tolerable confidence after pipeline installation. The level of uncertainty related to pipe-soil interaction is also considerable since pipeline embedment and friction factors are estimated using equations that include empirical correlations and field collected data. In addition these parameters are influenced by the installation process. Due to these uncertainties, conservative premises are usually assumed in order to obtain a robust pipeline thermo-mechanical design. After pipeline installation and/or start of operation an investigation can be performed in order to confirm the assumptions considered in the design. This paper presents a comparison of premises adopted during design stage of a pipeline based on the controlled lateral buckling methodology and the feedback obtained with the post-lay survey performed. After a brief introduction, pipeline embedment, global buckling at crossings, lateral OOS and sleepers’ height are some of the subjects addressed. Finally, conclusions and recommendations are presented in order to support future similar projects.

Effects of Weld Strength Heterogeneity on Crack Driving Force in Stress and Strain Based Design Scenarios

Weld strength mismatch is a key factor with respect to the assessment of a flawed girth weld. However, it is challenging to assign a single strength mismatch value to girth welds, which are generally heterogeneous in terms of constitutive behavior. The authors have recently developed a method (‘homogenization’) to account for weld strength property variations in the estimation of crack driving force response and the corresponding tensile limit state. This paper separately validates the approach for stress based and strain based assessments. Whereas homogenization is reliably applicable for stress based assessments, the strain based crack driving force response is highly sensitive to effects of actual heterogeneous weld properties. The sensitivity increases with increased weld width and decreased strain hardening behavior. For strain based design, a more accurate methodology is desirable, and large scale testing and/or advanced numerical modeling remain essential.

Identifying Optimal Pigging Frequency for Oil Pipelines Subject to Non-Uniform Wax Deposition Distribution

Wax deposition in oil pipelines causes reduced throughput and other associated problems. Periodical pigging program can effectively minimize the cost of wax deposition. This paper shows a typical pigging case study for a field pipeline subject to non-uniform wax deposition distribution by using a developed wax deposition model. The model prediction results prove that the wax is distributed in a short, localized accumulation along the first half pipeline. The resultant pressure drop along the pipeline was examined to reveal the effects of non-uniform wax deposition distribution on the pipeline production. In extreme case, the pressure drop of severe localized section increases by 50%, while this value between pump stations is merely 3%. A maximum wax thickness of 2–4 mm is used as a criterion to determine an optimal pigging frequency. The case study pipeline is recommended to be pigged at a frequency of 10 to 15 days, using by-pass pigs.

Full-Scale Reeling Tests of HFI Welded Line Pipe for Offshore Reel-Laying Installation

During reel-laying repeated plastic strains are introduced into a pipeline which may affect strength properties and deformation capacity of the line pipe material. Conventionally the effect on the material is simulated by small-scale reeling simulation tests. For these, coupons are extracted from pipes that are loaded in tension and compression and thermally aged, if required. Afterwards, specimens for mechanical testing are machined from these coupons and tested according to the corresponding standards. Today customers often demand additional full-scale reeling simulation tests to assure that the structural pipe behavior meets the strain demands as well. Realistic deformations have to be introduced into a full-size pipe, followed by aging, sampling and mechanical testing comparable to small-scale reeling. In this report the fitness for use of a four-point-bending test rig for full-scale reeling simulation tests is demonstrated. Two high-frequency-induction (HFI) welded pipes of grade X65M (OD = 323.9 mm, WT = 15.9 mm) from Salzgitter Mannesmann Line Pipe GmbH (MLP) are bent with alternate loading. To investigate the influences of thermal aging from polymer-coating process one test pipe had been heat treated beforehand, in the same manner as if being PE-coated. After the tests mechanical test samples were machined out of the plastically strained pipes. A comparison of results from mechanical testing of material exposed to small- and full-scale reeling simulation is given. The results allow an evaluation of the pipe behavior as regards reeling ability and plastic deformation capacity.

Under Pressure Operations on Dense Phase CO2 Pipelines: Issues for the Operator

National Grid, in the United Kingdom (UK), has extensive experience in the management and execution of under pressure operations on its natural gas pipelines. These under pressure operations include welding, ‘hot tap’ and ‘stopple’ operations, and the installation of sleeve repairs. National Grid Carbon is pursuing plans to develop a pipeline network in the Humber and North Yorkshire areas of the UK to transport dense phase Carbon Dioxide (CO2) from major industrial emitters in the area to saline aquifers off the Yorkshire coast. One of the issues that needed to be resolved is the requirement to modify and/or repair dense phase CO2 pipeline system. Existing under pressure experience and procedures for natural gas systems have been proven to be applicable for gaseous phase CO2 pipelines; however, dense phase CO2 pipeline systems require further consideration due to their higher pressures and different phase behaviour. Consequently, there is a need to develop procedures and define requirements for dense phase CO2 pipelines. This development required an experimental programme of under pressure welding trials using a flow loop to simulate real dense phase CO2 pipeline operating conditions. This paper describes the experiments which involved: • Heat decay trials which demonstrated that the practical limitation for under pressure welding on dense phase CO2 systems will be maintaining a sufficient level of heat to achieve the cooling time from 250 °C to 150 °C (T250–150) above the generally accepted 40 second limit. • A successful welding qualification trial with a welded full encirclement split sleeve arrangement. The work found that for the same pipe wall thickness, flow velocity and pressure, dense phase CO2 has the fastest cooling time when compared with gaseous phase CO2 and natural gas. The major practical conclusion of the study is that for dense phase CO2 pipelines with a wall thickness of 19.0 mm or above, safe and practical under pressure welding is possible in accordance with the existing National Grid specification (i.e. T/SP/P/9) up to a flow velocity of around 0.9 m/s. The paper also outlines the work conducted into the use of the Manual Phased Array (MPA) inspection technique on under pressure welding applications. Finally, the paper identifies and considers the additional development work needed to ensure that a comprehensive suite of under pressure operations and procedures are available for the pipeline operator.

Design of the Full Scale Experiments for the Testing of the Tensile Strain Capacity of X52 Pipes With Girth Weld Flaws Under Internal Pressure and Tensile Displacement

Pipelines can be subjected to significant amounts of tensile forces due to geotechnical movements like slope instabilities and seismic activities as well as due to frost heave and thaw cycles in arctic regions. The tensile strain capacity εtcrit of pipelines is crucial in the prediction of rupture and loss of containment capability in these load cases. Currently the Oil and Gas Pipeline Systems code CSA Z662-11 0 contains equations for the prediction of εtcrit as a function of geometry and material properties of the pipeline. These equations resulted from extensive experimental and numerical studies carried out by Wang et al [2]–[6] using curved wide plate tests on pipes having grades X65 and higher. Verstraete et al 0 conducted curved wide plate tests at the University of Ghent which also resulted in tensile strain capacity prediction methods and girth weld flaw acceptability criteria. These criteria are included in the European Pipeline Research Group (EPRG) Tier 2 guidelines. Furthermore Verstrate et al 0 introduced a pressure correction factor of 0.5 in order to include the effect of internal pressure in the tensile strain capacity predictions in a conservative way. Further research by Wang et al with full scale pipes having an internal pressure factor of 0.72 also showed that εtcrit decreases in the presence of internal pressure [10]–[15]. In their work, Wang et al presented a clear methodology for the design of full scale experiments and numerical simulations to study the effect of internal pressure on the tensile strain capacity of pipes with girth weld flaws [10]–[15]. However, there has been limited testing to enable a precise understanding of the tensile strain capacity of pipes with grades less than X65 as a function of girth weld flaw sizes and the internal pressure. In this paper the experimental setup for the testing of grade X52 full scale specimens with 12″ diameter and ¼″ wall thickness is demonstrated. In the scope of this research 8 full scale specimens will be tested and the results will be used to formulate the tensile strain capacity of X52 pipes under internal pressure. The specimens are designed for the simultaneous application of displacement controlled tensile loading and the internal pressure. Finite element analysis is applied in the optimization process for the sizes of end plates and connection elements. Also the lengths of the full scale specimens are determined based on the results from finite element analysis. The appropriate lengths are chosen in such a way that between the location of the girth weld flaw and the end plates uniform strain zones could be obtained. The internal pressure in these experiments is ranging between pressure values causing 80% SMYS and 30% SMYS hoop stress. The end plates and connection elements of the specimens are designed in such a way that the tensile displacement load is applied with an eccentricity of 10% of the pipe diameter with the purpose of increasing the magnitude of tensile strains at the girth weld flaw location. The results of two full scale experiments of this research program are presented. The structural response from the experiments is compared to the finite element simulation. The remote strain values of the experiment are found to be higher than the εtcrit values predicted by the equations in 0.

Combining Speed Control Function and Wye Passage in a Long Subsea Gas Line: A Case Study

Challenging conditions for pipeline inspection can be caused by several different parameters and conditions (length, diameter changes, installations and operating conditions). Very often the real challenge is resulting from a combination of these influencing parameters. For example, a very long pipeline becomes particularly critical for battery lifetime if the flow rate is low. Each single individual parameter does not necessarily constitute such challenge. Some basic examples and a particular combination of pipeline parameters and operational conditions are presented in this article. The crucial parameters of the regarded pipeline are: 36″, about 700 km length, high wall thickness, high pressure and flow rates and a subsea wye piece. Some of these requirements are already demanding for former inspection tools. But the complex interaction of the features increases the challenge for the tool design significantly. Particularly the combination of high flow, high wall thickness and the wye piece passage required special attention. The article describes the pipeline properties and run conditions and the consequences for the entire cleaning and inspection program. Notably the interactions of the parameters regarding the MFL inspection are highlighted and the resulting tool concept is presented as well as the run results.

Enhancing Pipeline Research Project Management With Post-Assessment

Post-assessment of pipeline research project assesses the project implementation process and the subsequent effect of the project application. The former assesses the realization of the research goals, the quality of the project implementation, the conformity to the research plan, and the ability of the project manager, while the latter attaches more importance on the long-term application and achievement of the technology developed by the research project after it has been accepted by the administrative department for one year or more. Post-assessment of pipeline research project provides a reference for scientific and technological administrative department in decision-making to improve project quality and investment efficiency of research activities, upgrade the management level. PetroChina Pipeline Company (PPC) used two years to set up the index system, choose the weight factors and build the assessment modeling of the post-assessment method. After that, a large number of research projects had been assessed by project managers and management staff to test the post-assessment method in order to modify the assessment software. This paper will: • Demonstrate the characteristics of the post-assessment of pipeline research project • Describe the scope and content of the post-assessment • Illustrate the process of the post-assessment • Identify required index system and calculation modeling • Discuss advantages of post-assessment in enhancing pipeline research project management