Karel Minnaar

Development of the SENT Test for Strain-Based Design of Welded Pipelines

Strain-based design (SBD) pipelines are being considered to develop hydrocarbon resources in severe environments. As part of a research program to develop a SBD methodology, work was conducted to develop a suitable fracture mechanics test that can be used as part of a strain capacity prediction technique. The single edge notched tensile (SENT) specimen geometry has been chosen due to the similarity in crack-tip constraint conditions with that of defects in pipeline girth welds. This paper describes a single-specimen compliance method suitable for measuring ductile fracture resistance in terms of crack tip opening displacement resistance (CTOD-R) curves. The development work included investigation of the following items: specimen geometry, crack geometry and orientation (including crack depth effects), direct measurement of CTOD. The results demonstrate that toughness measurements obtained using a B = W configuration (B = specimen thickness, W = specimen width) with side grooves are similar to those using a B = 2W configuration without side grooves; however, specimens with side grooves and B = W geometry facilitates even crack growth. Studies of crack depth have shown that ductile fracture resistance decreases with increasing ratio of the initial crack depth to specimen width, a0 /W. Studies of notch location and orientation (outer diameter (OD) and inner diameter (ID) surface notches and through-thickness notches) have shown an effect of this variable on the CTOD-R curves. This has been partly attributed to crack progression (tearing direction) with respect to weld geometry and this effect is consistent with damage modeling predictions. However the experimentally observed difference of CTOD-R curves between ID and OD notches is believed to be primarily due to the material variability through the pipe thickness.Copyright

Tensile Strain Capacity Equations for Strain-Based Design of Welded Pipelines

Various industry efforts are underway to improve or develop new methods to address the design of pipelines in harsh arctic or seismically active regions. Reliable characterization of tensile strain capacity of welded pipelines is a key issue in development of strain-based design methodologies. Recently, improved FEA-based approaches for prediction of tensile strain capacity have been developed. However, these FEA-based approaches require complex, computationally intensive modeling and analyses. Parametric studies can provide an approach towards developing practical, efficient methods for strain capacity prediction. This paper presents closed-form, simplified strain capacity equations developed through a large-scale 3D FEA-based parametric study for welded pipelines. A non-dimensional parameter is presented to relate the influence of flaw and pipe geometry parameters to tensile strain capacity. The required input parameters, their limits of applicability and simplified equations for tensile strain capacity are presented. The equations are validated through a comprehensive full-scale test program to measure the strain capacity of pressurized pipelines spanning a range of pipe grades, thickness, weld overmatch and misalignment levels. It is shown that the current simplified equations can be used for appropriate specification of weld and pipe materials properties, design concept selection and the design of full-scale tests for strain-based design qualification. The equations can also provide the basis for codified strain-based design engineering critical assessment procedures for welded pipelines.Copyright

Strain Demand Estimation for Pipelines in Challenging Arctic and Seismically Active Regions

The need to use strain-based design is growing due to potential pipeline projects in environments that include permafrost, offshore ice hazards, active seismic areas and high temperature/high pressure operations. Proper design and construction of such pipelines poses numerous special challenges and requires consideration of some important processes that govern the behavior of soils. ExxonMobil has been conducting research to improve understanding of geotechnical mechanisms that result in large plastic strains in the pipelines, and to develop pipeline strain demand prediction methodologies in harsh arctic and seismically active regions. This paper discusses key challenges in strain demand estimates for Arctic onshore and offshore pipelines and is aimed at promoting industry discussion of strain demand prediction methodologies. The paper highlights ExxonMobil’s efforts in developing predictive technologies for strain demand estimation that forms the basis for the design, testing, and model development in strain-based pipeline applications.Copyright

Structural Design Capacity of X120 Linepipe

A new high strength steel linepipe with a specified minimum yield strength of 120 ksi (X120) has recently been introduced to industry. The newly developed linepipe meets all mechanical property targets of an X120 grade material as verified through an extensive small and large-scale experimental program. Design equations have been developed and verified with full scale testing that allow pipeline designs that take full economic advantage of the higher strength of X120. This paper focuses on the development and verification of capacity equations for bending loads, external pressure (collapse) loads, combined bending and external pressure loads, and internal pressure (burst) loads. The corresponding response of the pipe was investigated with finite element analysis (FEA). Analytical equations that predict the burst, bending, and collapse capacities were then established based on parametric studies performed using FEA models. To gain confidence in the models, full size pipe tests were conducted and the results compared to FEA. The testing demonstrated that the FEA models accurately predict the behavior of the X120 pipe. Modifications to the existing equations were made when necessary to ensure the capacity equations correctly capture the pipe response for higher D/t ratios and for the higher strength X120 material. Material sensitivity studies show that the new equations accurately predict the X120 behavior over the range of load conditions evaluated.Copyright