Mario L. Macia

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

Continued Advancements Regarding Capacity Prediction of Strain-Based Pipelines

In areas of large ground movements, pipelines may be subjected to large longitudinal strains. It is imperative that strain-based design methods are developed for such pipelines. As reported previously, a comprehensive experimental and numerical program to characterize the tensile strain capacity of welded pipelines was undertaken. Models were developed that are capable of predicting strain capacity based on input parameters such as pipe geometry and properties, internal pressure, weld flaw geometry, weld properties, and high-low misalignment. These models (equations) have been validated against a data base of about 50 full-scale pipe strain tests that included a broad range of geometries and pipe grades (8–42″, 13–25mm, X60–X80). In the current paper, further developments are described. A pressure factor has been incorporated into the models. Whereas the previous models assumed that the circumferential stress from internal pressure was 80% of the specified minimum yield strength (SMYS) of the pipe, the pressure factor allows the calculation of strain capacity as a function of pressure that results in hoop stresses from zero to 80% of SMYS. Additionally, ranges for pipe yield-to-tensile ratio and weld tearing resistance curves (R-curves) have been expanded. New equations and associated flaw assessment diagrams for example cases are provided.Copyright

Research Progress on Friction Stir Welding of Pipeline Steels

Friction Stir Welding (FSW) has been widely commercialized to join aluminum alloys, but is yet to be broadly applied to structural steels. The primary difficulty in welding steels relates to severe loads and temperatures experienced at the interface between the FSW tool and the base material. These conditions are challenging even for the most advanced and expensive tool materials. However, within the last five years, tool advancements have begun to enable FSW of steels. Polycrystalline boron nitride (PCBN), tungsten-rhenium alloys, and mixtures thereof appear to be capable of producing sound welds in steel. This paper describes the results of a continuing study on the FSW of pipeline steels. Pipe grades from API X65 to X120 were subjected to FSW. Strength and toughness measurements using the crack tip opening displacement test were performed. The weld microstructure was evaluated using optical, scanning electron, and transmission electron microscopy. A computational fluid dynamics model was developed to better understand the effect of process parameters on thermal cycles, strain rates and strain experienced by material in the weld stir zone. The results indicate that the microstructure and properties of the welds have little dependence on the tool material, while significant variations in properties were observed between steels produced by different manufacturers. In general, obtaining high levels of toughness on par with gas metal arc mechanized girth welds appears difficult when using the FSW process. The results emphasize the need for a better understanding on the role of process parameters on microstructural evolution and weld quality during FSW of pipeline steels. As a full-scale demonstration of FSW on pipeline steels, several circumferential girth welds were produced in 762 mm (30 inch) diameter X80 pipe. The results of these efforts are discussed.Copyright

Evaluation of Hydrogen Cracking Susceptibility in X120 Girth Welds

To reduce the cost of long distance gas transmission, high strength pipeline steels are being developed. Implementation of high strength pipeline materials requires the avoidance of hydrogen cracking during field girth welding. A study of hydrogen cracking in X120 girth welds has been conducted. Cracking resistance of both the weld metal and heat affected zone (HAZ) were investigated. The laboratory tests included the controlled thermal severity (CTS) test, the WIC test and the Y-groove test. In addition, multi-pass plate welds and full pipe welds were completed and examined for the presence of hydrogen cracks. The suitability of each test method for predicting cracking in X120 girth welds is determined. The morphology of hydrogen cracks in X120 girth welds is described, and the conditions necessary to prevent hydrogen cracking are identified. Following the laboratory studies, construction of X120 pipelines without cracking was demonstrated through a 1.6 km field trial.Copyright

A Case Study in High Strain Capacity Pipeline Qualification: PNG LNG Project

The onshore pipeline portion of the Papua New Guinea Liquefied Natural Gas (PNG LNG) project traverses terrain with seismically active faults with potential ground displacements up to four meters. The resulting longitudinal strain demand exceeds 0.5% strain, thereby requiring use of strain-based pipeline design (SBD) technology. This paper discusses the application of previously developed strain-based design methodologies to successfully qualify the PNG LNG pipeline system for a design tensile strain demand up to 3%, and flexibility to increase the design strain demand with additional restrictions on key variables impacting strain capacity at select locations. Key SBD pipeline qualification activities are discussed along with the required project timeline. The first activity is specifying, evaluating and procuring line pipe suitable for strain-based design. SBD line pipe must be strain-age resistant, have excellent longitudinal uniform elongation, and have tightly controlled ultimate tensile strength (UTS) limits to ensure robust girth weld overmatch. The girth welds must exhibit upper shelf fracture toughness, excellent tearing resistance, and have sufficient tensile strength to ensure adequate girth weld strength overmatch. The pipeline qualification effort culminates in full scale pipe strain testing as proof of performance. The specimens for these tests are fabricated with project-specific pipe, girth welds, and pipe fit-up (hi-lo misalignment). The girth welds contain machined flaws in both weld metals and heat affected zones, these flaws being sized consistent with acceptable flaw sizes predicted from analytical models and prior experience. The results of these tests and their significance are described. Efforts to reduce capacity through lowering strain demand are outlined, along with examples of construction challenges the project has successfully faced. Key engineering and project decisions, and lessons learned from this qualification effort are also detailed.Copyright

Advanced Strain-Based Design Pipeline Welding Technologies

To meet the increasing worldwide demand for natural gas, there is a need to safely and economically develop remotely located resources. Pipeline construction is a major activity required to connect these remote resources to markets. Such pipeline routes may cross areas containing geohazards such as discontinuous permafrost, active seismicity and offshore ice gouging. These pipelines may be subjected to longitudinal strains above 0.5%. To safely design pipelines for such conditions, a strain-based design (SBD) approach can be used in addition to conventional allowable stress designs (ASD).Significant pipeline construction cost savings can be achieved with the use of higher strength steels (X70+) due to reduced pipe wall thicknesses (less steel) and faster girth welding. However, a robust welding technology for higher strength SBD pipelines is often a technology gap depending on the target level of longitudinal strain that needs to be accommodated, since such applications often demand excellent weld toughness at low temperatures (−15°C) and high tensile strength (>120ksi). This paper discusses the development of an enabling welding technology that offers a superior combination of strength and toughness compared to commercially available technologies.Acicular ferrite interspersed in martensite (AFIM) has been previously identified as a useful high strength weld metal microstructure that can be applied in field pipeline construction. This paper describes how this microstructure has been used to create welds with excellent strength overmatch and good ductile tearing resistance for X80 SBD pipelines. This approach has been implemented for mainline, double-joining and repair welding applications. This paper describes the welding procedures, mechanical properties achieved, estimated strain capacities, and the results of a full-scale pipe strain capacity test.Copyright

Approaches to Qualify Strain-Based Design Pipelines

The importance of using strain-based design pipelines is growing due to the increasing number of projects in challenging environments such as permafrost, offshore ice hazards, active seismic areas, and in high temperature/high pressure operations. To ensure pipeline integrity in environmentally sensitive areas and overall cost effectiveness, a strain-based design approach needs to consider all key interrelated design aspects including strain demand, design methods, material selection, strain capacity validation, and impact on construction and operation. To that end, significant research and development efforts have been made by the industry to facilitate the qualification of strain-based designed pipelines. This paper describes methods developed for the qualification of strain-based design pipelines, and demonstrates how recently developed strain capacity prediction tools, calibrated by full scale testing, can facilitate concept selection, material qualification and integrity verification of such pipelines.Copyright

Reliability of Fracture Mechanics Approach to Fatigue

Current fatigue design of fracture-critical components, such as tendons and risers, requires dual fatigue life criteria to be satisfied. The S-N approach includes a safety factor (SF) of 10 on the life of the component, while the fracture mechanics (FM) approach includes a safety factor of 5 on the life through-thickness of an acceptable initial flaw. FM provides critical initial flaw sizes such that suitability of the selected NDE methods and weld acceptance criteria can be established. This paper pertains to a comparative fatigue life reliability study between those two approaches. The objective is to develop a rationale for the selection of a safety factor on fatigue life to use in FM calculations. A reliability-based methodology is proposed and implemented. The SFs for FM are obtained by targeting the reliability obtained in fatigue designs based on historically proven S-N damage approach. Random variables entering both approaches were characterized and a number of weld design cases devised to obtain reliabilities. One important variable is the distribution of initial flaw sizes. For this study, flaw distributions were developed from actual inspection records, accounting for the effects of probability of detection and sizing accuracy of the inspection system, as well as the flaw acceptance criteria during fabrication. Comparisons of reliabilities obtained for designs by both approaches for various quality S-N curves, stress spectra, pipe sizes, and initial flaw sizes indicate that there is ample scope to modify downward the current FM safety factor. However, given the limited scope of this study, it is recommended to asses the FM SF using reliability analysis on a project-specific basis.Copyright

Godin Lake Trial: X120 Field Welding

In February 2004, ExxonMobil and TransCanada PipeLines, Limited (TCPL) cooperated to construct a 1.6 km long segment of X120 pipeline near Wabasca, Alberta. The line included numerous mainline and tie-in welds, and an extra section of pipe was constructed in the field for later destructive testing to assess the characteristics of field welds. This line represented the first field application of welding procedures and consumables developed specifically for X120. The technologies used performed well; productivity and weld repair rates were better than expected, and the properties of these welds made in challenging conditions compare well with development welds made under controlled “shop” conditions.Copyright