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.

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.

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.

Fracture Toughness of X70 Pipe Girth Welds Using Clamped SE(T) and SE(B) Single-Specimens

Shallow-notched single edge-notched tension (SE(T) or SENT) and deep- and shallow-notched single edge-notched bend (SE(B) or SENB) specimens with notches positioned in the weld and the heat-affected zone were tested. Crack-tip opening displacement (CTOD) versus resistance curves were obtained using both a single and double clip gauge consolidated in a SE(T) single-specimen. Up until the peak load the resistance curves from both gauging methods yield approximately the same results; thereafter the curves deviate. Interrupted testing showed that the crack had initiated below 50% of the peak load, and in some cases had propagated significantly prior to reaching the peak load.

Pipeline Response to Slope Movement and Evaluation of Pipeline Strain Demand

Pipelines installed on active slopes can be exposed to slope failure mechanisms. The soil movement can introduce substantial axial and bending strains on buried pipeline, and possibly damage. The techniques to predict pipeline displacements, loads, stress or strains are not well described in design standards or codes of practice. The practice of using finite element analysis of soil-pipe interaction has developed in recent years and is proving to be a useful tool in evaluating the pipeline behavior in response to slope movement. A description of advanced pipe soil interaction modeling tools and their validation against full scale trails has been previously presented. This paper describes the ongoing work involved in a study investigating the mechanical behavior of buried pipelines interacting with active slope movement and evaluation of pipeline strain demand. Detailed pipe-soil interaction analyses were completed with a 3D continuum SPH (Smooth Particle Hydrodynamic) model to examine the pipeline behavior and evaluate the pipeline strain demand in relation to key parameters. This includes the effect of soil movement mechanism, pipeline geometry (D/t), material grade, pipeline burial depth and soil conditions and properties. Sample results of the application of the validated 3D continuum modeling process will be presented. The strain demand determined from the analyses were compared with calculated CSA-Z662 strain limit design, local FEA analyses and BS 7910. These results are being used to develop generalized trends in pipeline response to slope movements.

Curved-Wide Plate Testing of X100 Girth Welds

Curved-wide plate (CWP) tests are frequently used for assessing the quality of pipeline girth welds. Despite a large number of CWP tests having been conducted at great expense over many decades, an industry consensus standard remains unavailable. Considerable effort at several research institutions is focused on the standardization of test protocols. It is widely recognized that comparing results from CWP tests from different institutions is difficult without accounting for all the possible parametric differences. This paper presents the procedural details recently used in testing X100 girth welds. The protocols cover (1) specimen design and dimensions, (2) instrumentation plan and data acquisition, (3) specimen fabrication and preparation, (4) preparing and executing the tests, (5) processing of raw test data and (6) post-test metallurgical examination. The evaluation of specimen deformation, flaw growth, and comparison of test data with model predictions will be presented in a future paper. Selected CWP test data from this program were evaluated and compared to tensile strain models of the girth welded pipe in a recent paper [1].

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.