Luigi Di Vito

Techniques for Fracture Toughness Testing of Offshore Pipelines

The need to evaluate the significance of flaws in welded pipelines for gas transportation requires the knowledge of the material resistance to ductile tearing. In particular, the fracture resistance of pipe girth welds should be evaluated since they may potentially be critical for structural integrity. Standard toughness Three Point Bending tests (SENB) are too conservative since they are more constrained than actual pipeline. In this case, the adoption of a reduced notch depth, which is considered to reproduce well actual stress-strain conditions at the crack tip of a weld flaw, increases critical toughness values when compared to standard specimen configuration. Alternative solutions may be applied, even if not yet included in toughness standards. In particular, the Single Edge Notch Tensile (SENT) test is a possible solution reducing conservatism. A matter of concern for toughness characterization of weld joint is also represented by the notch orientation, since the weld microstructure is inhomogeneous in nature. The L–R oriented specimen (notch at the pipe inner surface) typically shows CTOD values strongly lower than the ones of L–T oriented specimens (through thickness notch) for both weld metal and heat affected zone. All these issues are discussed within this paper, while an advanced approach is presented to determine the resistance curve by using a single SENT specimen with the compliance method for crack growth evaluation. A relationship between the specimen elastic compliance and actual crack growth was determined through Finite Element Analysis and a Fracture Mechanics model. Such a relationship is presented and compared to other solutions available in scientific literature.Copyright

Ultra Heavy Wall Linepipe X65: Ratcheting in Severe Cyclic Straining

Tenaris and Centro Sviluppo Materiali (CSM) launched a Joint Industrial Project aimed at developing heavy wall line pipes. The suitability for very severe applications, involving high service pressures and temperatures, the latter causing large strain fluctuations, in presence of an aggressive sour environment, is analyzed both theoretically and experimentally, including small and full pipe models. The full project program aims at developing a new generation heavy wall product, supported by: a comprehensive laboratory analysis of the material response under severe mechanical loading in aggressive environment; and full scale testing program, including both pipe and girth weld. Both investigations are mainly addressed to basic understanding of impact on design criteria from interaction between severe loading and aggressive environment. Two papers have been already presented on this project, [2] and [3]. The present paper deals with the study, carried out in cooperation with Saipem Energy Services, aimed at setting up a tool for the prediction of ratcheting extent for the pipeline in pressure subjected to axial cyclic, even plastic, straining. In such conditions, ratcheting may develop in the circumferential direction, as a consequence of both material cyclic performance and bi-axial plastic flow. So, detailed characterization of material is required, as well as calibration of plastic performance parameters, particularly in relation to relevant modeling. The final objective of the study is to establish a threshold for the plastic strain development at peak load, beyond which circumferential ratcheting may develop. A numerical model was set up, on-purpose developed and implemented on commercial software, where reverse yielding is modeled by kinematic hardening referring to Von-Mises yield criterion. Use of relevant parameters describing/approximating the actual material response has been made, based on laboratory Multi Plastic Straining Cycling (MPSC) of pipe full thickness samples. Full scale testing of pressurized X65, 10 3/4″ OD × 46 mm WT linepipe has been performed including plastic axial and cyclic straining. A huge measurement campaign allowed to establish the relevant parameters that characterize the response from numerical modeling, facilitating the validation of the set up by comparing the actual ratcheting exhibited by the heavy wall pipe with predictions obtained by the model. Limits of current tools for numerical modeling are also shown, with some degree of dependence on applied straining sequence. Possible paths of numerical modeling improvement are then envisaged.Copyright

Ultra Heavy Wall Linepipe X65: Material Performances for Severe Applications

Tenaris together with Centro Sviluppo Materiali launched a Joint Industrial Project aimed at developing heavy wall linepipes and evaluating their suitability for very severe applications possibly involving high service pressures and temperatures, large strains applied to the line, aggressive sour environment. The full project programme includes development of a the new generation of heavy wall products, laboratory scale evaluation of the material response when subjected to severe mechanical and environmental loading, evaluation of full component, pipe and girth weld, behaviour by means of full scale testing. Another technical publication in this conference (OMAE2009-79153) reports the activities of development of the new generation of heavy wall seamless pipes. In the present paper indeed, main outcomes of laboratory testing activities of the above programme on pipe material (grade X65, outer diameter 10 3/4″ , wall thickness 46 mm) are reported as far as pipe body material properties are concerned. A fitted for purpose special testing programme, including mechanical and SSC laboratory scale testing, has been executed. Full thickness longitudinal specimens were extracted from the pipe body to apply severe strain cycling (1% and 2% maximum strain for various numbers of cycles, up to 200 cycles). Material showed a very encouraging behaviour, exhibiting an important reserve of strength even after application of severe strain cycling. Both mechanical, tensile compressive and toughness, properties and stress corrosion properties resulted to be suitable for the envisaged applications. Furthermore the pipe material showed suitable mechanical and stress-corrosion properties even after the severe cycling as well as after severe cycling and subsequent ageing. The influence of different straining conditions was also investigated, showing no significant difference in material properties after strain–ageing, due to different straining histories.© 2009 ASME

Free-Span Flowlines Resistance to In-Service Fatigue Loading

Offshore petroleum fields frequently pass over areas with uneven seafloor. In such cases the pipeline may have free spans due to depressions crossing and are subjected to complex loading spectra. A major source for dynamic stresses in free span pipelines is vortex induced vibrations (VIV) caused by steady current since wave induced velocities and accelerations will decay with increasing water depth.The complex loading spectrum differs sensibly from the constant amplitude loading commonly adopted for qualification of the product (line pipe and its girth welds). Centro Sviluppo Materiali and Tenaris for some years are involved in the study of in-service variable amplitude fatigue loading of risers trough numerical calculations and comparison of the actual fatigue loading experienced by free span system with constant amplitude qualification typical loading. Two papers [1, 2] have been already presented in previous OMAE conferences. The present work reports a study dedicated to the free-span flow lines.The flow line analyzed is composed by OD 273.05 mm × WT 25.4 mm pipe lying on the uneven seabed. In particular the attention is focused on the analysis of VIV and its effect on fatigue life of the line. The Ormen Lange field, located at 120 km northwest of the Mid-Norway, was selected as reference scenario for the study.One of the most important factors influencing the pipeline response to the VIV is the free-span length. A sensitivity analysis about the influence of different parameters (free span length and fluid velocity) on system response and consequent fatigue damage has been performed.A case study has been selected among the cases considered in the sensitivity analysis, to produce the loading spectra to be considered in a laboratory fatigue testing campaign on strip specimens.The fatigue performance of these samples has been compared to analogous samples subjected to constant and variable amplitude loading available from previous works [1, 2] on riser systems (Steel catenary riser and Hybrid riser).Copyright

Hybrid Riser Resistance to In-Service Fatigue Loading

Riser systems are subjected to complex loading spectra. A wide range of amplitude loading are induced by naturally complex sea states. The complex loading spectrum differs sensibly from the constant amplitude loading commonly adopted for qualification of the product (riser pipe and its girth welds or threaded connections).The present paper reports numerical calculations and a comparison of the actual fatigue loading experienced by different riser systems, Steel Catenary Risers (SCR), Lazy Wave Riser (LWR), Hybrid Risers (HR). For the Hybrid riser system, a good fatigue resistance, due to the vessel and wave first motion decoupling, is obtained. On the other hand, the phenomenon of cross flow vibration induced by Vortex Induced Vibrations (VIV), could significantly affect the hybrid riser fatigue performance. In this case, a sensitivity analysis has been performed to evaluate the influence of different parameters, on the applied fatigue loading, like: riser tension, hydro diameter (i.e. external pipe diameter including coating), riser wall thickness, current velocity.The HR variable amplitude loading spectrum, derived from in-service conditions, referred to Gulf of Mexico scenario, has been calculated and applied in laboratory tests on girth welds of X65, 10.75″ OD, 25.4 mm WT riser. Furthermore, the fatigue performance of these tests has been compared to analogous tests on samples subjected to constant and variable amplitude loading available from previous work on SCR system[1].© 2014 ASME

Riser Resistance to In-Service Fatigue Loading

Riser systems are subjected to complex loading spectra induced by sea states. The complex loading spectrum differs sensibly from the constant amplitude loading commonly adopted for qualification of the product (riser pipe and its girth welds).The present work deals with numerical calculations of the actual loading spectrum experienced by a Steel Catenary Riser when adopted in different scenarios, Gulf of Mexico (GoM) and West of Africa (WoA). Sensitivity analyses have been performed to evaluate the influence on applied fatigue loading of different parameters, like: water depth, seabed stiffness, hang-off angle.The variable amplitude loading, derived from in-service conditions, has been applied to laboratory scale, full thickness specimens from X65 SCR girth welds. The fatigue performance of these samples has been compared to analogous samples subjected to constant amplitude loading. The samples subjected to in-service loading conditions exhibited a lower fatigue performance than in constant amplitude.To allow a comparison with common qualification procedure under constant amplitude, full scale testing of SCR girth welds have been performed on resonance machine by in-service loading spectra rearranged in constant amplitude blocks. Laboratory full thickness specimens have been adopted to compare the girth weld fatigue performance when subjected to the original cycle-by-cycle sequence and the in-blocks rearranged sequence.Copyright

Ultra Heavy Wall Linepipe X65: Double Joint Girth Weld Performances for Severe Applications

Tenaris and Centro Sviluppo Materiali (CSM) launched a Joint Industrial Project aimed at developing heavy wall line pipes. The suitability for very severe applications, involving high service pressures and temperatures, the latter causing large strain fluctuations, in presence of an aggressive sour environment, is analyzed both theoretically and experimentally, including small and full scale pipe models. The full project program aims at developing a new generation heavy wall product, supported by: comprehensive laboratory analysis of the material response under severe mechanical loading in aggressive environment; and full scale testing program, including both pipe and girth weld. Both investigations are mainly addressed to the basic understanding of impact on design criteria from interaction between severe loading and aggressive environment. Three papers have been already presented, in previous OMAE conferences, on this project. In the present paper, main outcomes of laboratory testing activities of the above program on girth welds for double jointing (fill passes by Submerged Arc Welding) are reported. A fitted for purpose special testing program, including mechanical and SSC laboratory scale testing, has been executed. Full thickness longitudinal specimens were extracted crossing girth weld to apply severe strain cycling. The strain cycling has been defined as extreme in terms of resistance against ratcheting for the pressurized pipeline, as deduced in a work reported in one of the previously mentioned papers. The girth welds exhibited very satisfactory performance during severe cyclic straining. Furthermore, mechanical and stress-corrosion properties of the As-Weld girth joint have been compared with the corresponding properties after severe straining and ageing. This comparison highlighted high level of mechanical and SSC resistance, even after the application of severe straining and ageing.© 2011 ASME

FATIGUE PERFORMANCE OF SMLS SCR GIRTH WELDS - COMPARISON OF PREFABRICATION-TYPE WPS

The objective of the present research work is focused on evaluating the fatigue performance of different prefabrication welding procedures and determining the best compromise between manufacturing specifications, productivity and fatigue strength. Therefore, a large full scale fatigue campaign was launched at Tenaris to comply with this objective. SMLS SCR pipe (grade X65, outer diameter 10 ¾’ ’, wall thickness 25.4 mm) was selected and manufactured according with the current most challenging offshore specifications and girth joints representative of prefabrication welding were manufactured in 1G position. Two different bevel geometries, two different welding techniques for the root pass and two different welding techniques for fill and cap passes were studied and compared. Finally, a post weld finishing technique has been implemented, aiming to improve the fatigue strength by removal of the weld root and cap reinforcements. Misalignment measurements, with stress concentration factor calculations, and post-tests fractographic investigations have been systematically performed on all the samples after testing. This activity was of paramount importance in determining the causes for fatigue initiation.

Ultra Heavy Wall Linepipe X65 for the Most Stringent Applications: Metallurgical Design and Industrial Development

Offshore industry has evolved to meet numerous challenges, e.g. deep water, high currents, high pressure and high temperature (HPHT), and sour reservoirs, facing deepwater exploration. The trend in flowline specifications for deepwater offshore fields is a consequence of complex oil-gas field conditions, such as HPHT and developments in design criteria (i.e. limit state design), welding and laying technologies. The technological evolution exhibits a trend towards an increasing wall thickness (WT) to provide sufficient resistance for the very high operating pressures. Furthermore, the pipelay operations, especially when linepipes are installed by means of the reel laying method, cause repeated plastic bending and straightening deformation cycles. These cyclic loads affect final material stress-strain properties. Reeling is currently applied to an increasing range of pipe geometries, being the present limit given by pipes with 16″ outer diameter (OD) and 30 mm wall thickness (WT). Other pipeline installation techniques, for example, J-lay, S-lay and steep S-lay also introduce plastic strain. All previous factors mentioned before and adding one more variable when exploring and producing in regions alike to the Artic where low temperatures implied several material challenges calls for high performance seamless pipes tailored to the specific application required by the oil and gas industry. In this paper, a description is given of the results of latest fundamental studies on high-strength heavy-wall steel materials manufactured by Q&T processing. This work is part of an on-going development program on high performance heavy wall seamless pipes for special applications such as HPHT, low temperature design criteria, sour requirements and studying the material under the strain based design criteria involving metallurgical modeling, laboratory tests, industrial trials and advanced metallographic examinations. The most recent findings and overall conclusions are reported hereafter, these results have been exploited by Tenaris to manufacture a limited production seamless pipes in a wall thickness range from 40 mm to 48 mm in steel grade X65 Sour Service.© 2009 ASME