Chris Alexander

Repair of Dents Subjected to Cyclic Pressure Service Using Composite Materials

For the better part of the past 15 years composite materials have been used to repair corrosion in high pressure gas and liquid transmission pipelines. This method of repair is widely accepted throughout the pipeline industry because of the extensive evaluation efforts performed by composite repair manufacturers, operators, and research organizations. Pipeline damage comes in different forms, one of which involves dents that include plain dents, dents in girth welds and dents in seam welds. An extensive study has been performed over the past several years involving multiple composite manufacturers who installed their repair systems on the above mentioned dent types. The primary focus of the current study was to evaluate the level of reinforcement provided by composite materials in repairing dented pipelines. The test samples were pressure cycled to failure to determine the level of life extension provided by the composite materials relative to a set of unrepaired test samples. Several of the repaired dents in the study did not fail even after 250,000 pressure cycles were applied at a range of 72% SMYS. The results of this study clearly demonstrate the significant potential that composite repair systems have, when properly designed and installed, to restore the integrity of damaged pipelines to ensure long-term service.Copyright

Finite Element Analysis of Composite Repairs With Full-Scale Validation Testing

Composite repair systems for pipelines are continuing to be used for increasingly difficult and complex applications which can have a high consequence of failure. In these instances, full-scale testing is typically pursued at a high-cost to the manufacturer or operator. Finite element analysis (FEA) modeling is a valuable tool that becomes especially attractive as a method to reduce the number of full-scale tests required. This is particularly true when considering the costs associated with recreating complex load and temperature conditions. In order for FEA to fill this role, it is necessary to validate the results through full-scale testing at the same loads and temperatures. By using these techniques, FEA and full-scale testing can be used in unison to efficiently produce accurate results and allow for the adjustment of critical parameters at a much lower cost than creating additional full-scale tests. For this program, a series of finite element analysis (FEA) models were developed to evaluate the performance of composite materials used to reinforce corroded steel pipe in critical applications at elevated temperatures up to 120 °C. Two composite repair manufacturers participated in the study which was conducted on 12-inch x 0.375-inch Gr. X60 pipes with machined simulated corrosion defects that represented 50% wall loss. Load conditions consisted of axial compressive loads or bending moments to generate compressive stresses in the machined defect. In the described evaluation program, FEA simulations were able to produce results which supported those found in fullscale validation testing. From the FEA models stresses and strains were extracted from the reinforced steel and composite materials. Good correlation was observed in comparing the results. Although limitations of the modeling included accurately capturing differential thermal strains introduced by the elevated test temperature, the results indicated that FEA models could be used as a cost-effective means for assessing composite repair systems in high-temperature applications. INTRODUCTION Over the last two decades, the composite repairs in the pipeline industry have seen significant increases in the technical complexity of desired applications. As a result, pipeline operators have been forced to demonstrate rigorous technical due diligence during design of the repair system prior to receiving the approval of industry regulators. For repairs associated with transmission pipelines, this is most often accomplished through full-scale testing that replicates the loads, temperatures, and pressures to be experienced by the repair system. In high-temperature applications, this can be an extremely costly endeavor. The use of FEA allows for critical parameters to be adjusted without the significant costs associated with multiple full-scale tests; however, this approach can only be used following the validation of initial modeling with the results of full-scale testing. For this particular assessment, a comprehensive program was developed in which experimental and analytical approaches were used to evaluate the use of composite materials as a means for reinforcing corroded pipelines operating at elevated temperatures up to 120 °C. Experimental efforts focused on full-scale bending and compression testing of two prospective 1 Copyright

Repair of High Pressure Pipe Fittings Using Composite Materials

Pipelines and piping frequently suffer from metal loss that threatens their integrity and serviceability. Multiple repair options exist for straight sections of pipe; however, repair options for pipe fittings such as elbows and tees are typically limited to composite repair systems, or section replacement. The latter method can be costly as it often requires at least a partial shut down of the pipeline while the section is replaced. A composite repair system however, can be performed in place during operations at a greatly reduced cost. The main challenge with the composite repair system is the required demonstrated ability to restore integrity and serviceability to the same level as the original metal system. Over the past 10 years, Stress Engineering Services, Inc. has been greatly involved in evaluating the ability of many composite repair systems to restore the original pipeline structural integrity by testing methods and analysis methods. The current paper investigated the ability of the Armor Plate Pipe Wrap (APPW) system to restore the burst pressure of tee and elbow pipe fittings with 60% metal loss to that of a nominal thickness system. In this program four full scale burst tests were conducted: on 12-inch nominal pipe size (NPS) Y52 tee and elbow pipe fittings. All four fittings had 60% metal loss; two were repaired with APPW, and the other two were not repaired. Prior to burst testing, elastic plastic finite element analyses (FEA) were performed to adequately size the repair thickness. The results of the FEA calculations predicted the restoration of the burst pressures of the repaired fittings up to a 1.6% agreement with the actual burst pressure results. Furthermore, the burst pressure of the 60% metal loss tee was increased from 3,059 psi (unrepaired) to 4,617 psi, or a 51% improvement. The burst pressure of the 60% metal loss elbow was increased from 2,610 psi to 4,625 psi, or a 77% improvement. Both the analysis and testing results demonstrated that composite materials can restore the pressure integrity of corroded tee and elbow pipe fittings.Copyright

Rational Stress Limits and Load Factors for Finite Element Analyses in Pipeline Applications: Part III — Elastic-Plastic Load Factor Development

In this paper, a methodology is presented to develop load factors for use in elastic-plastic assessments of pipelines and their components. The load factors are based on the pipe material properties and the ASME pipeline code’s design margin for the service and location of the pipeline installation [1, 2]. These codes are recognized by 49 CFR 192 and 195 [3, 4]. Minimum required load factors for internal pressure loads can be derived analytically based on design equations from the ASME B31 piping codes and minimum material requirements for API 5L line pipe [6]. Once the load factor is established for a particular case, the elastic-plastic methodology may be used in the Finite Element Analysis (FEA) of pipelines and related components. This methodology is particularly useful in the assessment of existing systems when linear elastic numerical analysis shows that local stresses may exceed the elastic design limits. Two case studies are presented showing analyses performed with Abaqus [5], a commercial, general purpose FEA software package. The first case study provides an assessment of a large diameter elbow where the stress on the outer fibers of the intrados exceeded the longitudinal stress limits from B31.8. The second case study examines an assessment of a tee connection where the stresses on the ID exceeded the yield strength of the component. In addition to the case studies, the paper also presents the results of a full-scale test that demonstrated what margin was present when the numerical calculations were based on specified minimum properties. This paper is not intended to revise or replace any provision of B31.4 and/or B31.8 [1, 2]. Instead, it provides the means for calculating load factors that can be used with an elastic-plastic analysis approach in a manner that provides the same design margins as the ASME B31 codes. The approach described in this paper is intended for use in the detailed FEA of pipelines and their associated components. INTRODUCTION ASME B31.4 and B31.8 provide simplified design equations for pressure piping [1, 2]. These equations give the design pressure such that the hoop stress is nominally limited to a certain portion of the specified minimum yield strength of the pipe material (Sy). Additional equations from the ASME codes permit the calculated longitudinal and combined stresses to be some fraction of Sy. These equations can be applied to straight segments of pipe with relative ease. However, many piping components have complex shapes or non-linear stressdisplacement relationships that require the use of FEA to precisely calculate their state of stress. Typical examples may include tees, elbows, or wyes. The current pipeline codes do not specify a method or outline an approach for conducting FEA. Instead they refer to the ASME B&PV code, Section VIII, Division 2 (Division 2). When an analysis approach according to Division 2 [7] is used to assess a pipeline component, several methodologies are available including linear, limit-load, and elastic-plastic. This paper focuses on the elastic-plastic assessment methodology. When performing an elastic-plastic assessment, the following question must be answered. What is the appropriate load factor Proceedings of the 2016 11th International Pipeline Conference IPC2016 September 26-30, 2016, Calgary, Alberta, Canada

Developing an Engineering Based Integrity Management Program for Piping, Pipelines, and Plant Equipment

Establishing integrity for piping and pipelines requires an understanding of the specific threats, their relationship to the overall condition of the system, and the mitigating measures required to assure safe operation. In the past, industry has relied on years of research and experience to develop a set of tools to analyze these threats and apply conservative solutions to ensure integrity and fitness for service. An effective integrity management program as discussed in this paper, known as the Engineering Based Integrity Management Program (EB-IMP), provides operators with a resource for integrating inspection results, analysis, and testing to qualify the components within a pressurized system.This paper presents a detailed discussion on how experience, advances in analytical techniques, experimental methods, and engineering rigor are combined to develop a tool to characterize and ensure system integrity. Several case studies are included to demonstrate how the EB-IMP method was used to evaluate the integrity of a piping system, as well as rail gondola cars used to transport coal. The intent with the approach presented in this paper is to foster further developments for advanced integrity management efforts.© 2014 ASME