A FAD-Based Procedure for Defect Assessments of Welded Structures Including Effects of Weld Strength Mismatch: Micromechanics Approach and Application to Pipeline Girth Welds

2008 ◽  
Author(s):  
Gustavo H. B. Donato ◽  
Claudio Ruggieri
Keyword(s):  
Structural Integrity ◽  
Driving Forces ◽  
Pipeline Steel ◽  
Crack Tip ◽  
Weld Strength ◽  
Homogeneous Material ◽  
Fracture Parameter ◽  
Integrity Assessment ◽  
Girth Welds ◽  
Assessment Problems

ECA procedures of crack-like defects based upon the FAD philosophy have undergone extensive developments in the past decade to form the basis for industrial codes and guidelines for structural integrity assessments. However, the application of these procedures in welded structural components with mismatch in tensile properties between the weld and base metal remains a potential open issue. Weld strength mismatch may significantly alter the crack-tip driving forces, such as J and CTOD, thereby producing crack-tip stresses quite different than the fields that arise in corresponding homogeneous material. Weld strength mismatch also affects the plastic collapse load for the structural component which further complicates the interplay between fracture and plastic instability before gross yield section takes place. This work describes the development of a microme-chanics-based FAD methodology building upon a local fracture parameter, characterized by the Weibull stress (σw), to incorporate the effects of weld strength mismatch on crack-tip driving forces. As a further refinement, the study also addresses an exploratory application of a limit load analysis including effects of weld strength mismatch to correct the loading trajectory incorporated into the FAD procedure. Fracture testing of girth welds obtained from an API X80 pipeline steel provide the data needed to validate the proposed modified FAD procedure in failure predictions. Such an application serves as a prototype for a wide class of integrity assessment problems involving the effects of weld strength mismatch.

Evaluation of Ductile Tearing of X-80 Pipeline Girth Welds Using SE(T), SE(B) and C(T) Fracture Specimens

2013 ◽  
Author(s):  
Leonardo L. S. Mathias ◽  
Diego F. B. Sarzosa ◽  
Claudio Ruggieri
Keyword(s):  
Structural Component ◽  
Structural Integrity ◽  
Pipeline Steel ◽  
Crack Tip ◽  
Pipeline Steels ◽  
Ductile Tearing ◽  
Resistance Curves ◽  
Girth Welds ◽  
Crack Tip Constraint ◽  
Integrity Assessments

Structural integrity assessments of pipe girth welds play a key role in design and safe operation of piping systems, including deep water steel catenary risers. Current methodologies for structural integrity assessments advocate the use of geometry dependent resistance curves so that crack-tip constraint in the test specimen closely matches the crack-tip constraint for the structural component. Testing standards now under development to measure fracture resistance of pipeline steels (J and CTOD) most often employ single edge notched specimens under tension (SENT) to match a postulated defect in the structural component. This paper presents an investigation of the ductile tearing properties for a girth weld of an API 5L X80 pipeline steel using experimentally measured crack growth resistance curves (J-R curves). Testing of the girth weld pipeline steels employed clamped SE(T) specimen with center-crack weld and three-point bending SE(B) (or SENB) specimens to determine the J-R curves. Tests involving SE(B) specimens are usually considered conservative, however, the comparison between this two methods may point an accurate alternative for girth weld assessments, since adequate geometry is adopted to describe accurately the structure’s behavior.

Predictions of Cleavage Fracture in Welded Components Incorporating Strength Mismatch Effects: A Weibull Stress Based Approach

2010 ◽  
Author(s):  
Claudio Ruggieri
Keyword(s):  
Cleavage Fracture ◽  
Driving Forces ◽  
Failure Strain ◽  
Pipeline Steel ◽  
Strong Support ◽  
Weld Strength ◽  
J Integral ◽  
X80 Pipeline Steel ◽  
Loading Parameter ◽  
Weibull Stress

This work describes the development of a toughness scaling methodology incorporating the effects of weld strength mismatch on crack-tip driving forces. The approach adopts a nondimensional Weibull stress, σ¯w, as a the near-tip driving force to correlate cleavage fracture across cracked weld configurations with different mismatch conditions even though the loading parameter (measured by the J-integral) may vary widely due to mismatch and constraint variations. Application of the procedure to predict the failure strain for an overmatch girth weld made of an API X80 pipeline steel demonstrates the effectiveness of the micromechanics approach. Overall, the results lend strong support to use a Weibull stress based procedure in defect assessments of structural welds.

Dynamic Fracture Parameters and Calculations for 3-D Cracks

2003 ◽  
Author(s):  
Wing Cheng ◽  
Shigeru Itoh
Keyword(s):  
Dynamic Loading ◽  
Dynamic Fracture ◽  
Structural Integrity ◽  
Three Dimensional ◽  
Welding Process ◽  
Fracture Parameter ◽  
Integrity Assessment ◽  
Fracture Parameters ◽  
Cracked Structures ◽  
Geometrical Factors

Welded structures such as armor fighting vehicles, shipboard structures or munitions systems are required to sustain intense and rapidly applied dynamic loading due to gun firings, impact of enemy munitions and extreme loading from accident scenarios. Flaws are normally found in various extents in welds depending on quality control of the welding process. It is important to determine critical flaw sizes of three-dimensional cracks in a welded joint under dynamic loading introduced by the above scenarios. Calculation of dynamic fracture parameters of the three-dimensional cracks of various geometrical factors at different locations is important for use the crack growth evaluation, flacture and structural integrity assessment. This paper summarizes the methodologies and results of the dynamic fracture parameter calculations for stationary three-dimensional cracks in cracked structures subjected to both static and dynamic loads.

Engineering Critical Assessments of Ductile Pipes With Axial Flaws and High Strain Hardening Capacity

2008 ◽  
Author(s):  
Claudio Ruggieri
Keyword(s):  
Strain Hardening ◽  
Structural Integrity ◽  
Steel Pipes ◽  
Integrity Assessment ◽  
Ductile Materials ◽  
Axial Crack ◽  
Open Issue ◽  
Failure Predictions ◽  
Low Constraint ◽  
Assessment Problems

ECA procedures of crack-like defects based upon the FAD philosophy have undergone extensive developments in the past decade to form the basis for industrial codes and guidelines for structural integrity assessments. However, the application (and validation) of these procedures in defect assessments of structural components made of ductile materials under low constraint conditions remains a potential open issue. A central objective of this work is to assess the capability of the failure assessment diagram methodology to predict the failure pressure of ductile pipes with planar defects having different geometries. Specifically, the present work compares the burst pressure predictions for austenitic steel pipes with axial flaws derived from two widely used FAD procedures:BS7910 and API579. Such an application serves as a prototype for a wide class of integrity assessment problems involving the effects of strain hardening properties and ductility while, at the same time, assessing the robustness of FAD procedures in failure predictions. The direct application of BS7910 procedure indicate rather large margins between the predicted and the actual (measured) failure pressures. In contrast, the API 579 procedure appears to provide better agreement with experimental data. Overall, the results validate the use of FAD-based methodologies for defect assessments of ductile pipes with axial crack-like flaws.

The Effect of Strength Mis-Match and Residual Stress in ECA of Girth Welds With Internal Circumferential Cracks

2009 ◽  
Author(s):  
Ali Mirzaee Sisan ◽  
Afshin Motarjemi
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Driving Forces ◽  
Numerical Study ◽  
Welding Process ◽  
Detailed Comparison ◽  
Weld Strength ◽  
Residual Stress Field ◽  
Girth Welds ◽  
Welded Pipe

A numerical study was carried out to quantify the effect of a residual stress field on subsequent fracture behaviour of a girth welded pipe with an internal circumferential long crack when subjected to high applied strain loading. In order to introduce an initial residual stress field similar to a welding process in a pipe, a quenching process was numerically simulated and associated residual stress profiles were modified and mapped into the finite element (FE) models. A detailed comparison between the crack driving force for various cases with and without residual stress and weld strength mismatch was carried out for cases under a high plastic deformation regime. The BS7910 procedure was also used to predict crack driving forces using its current assumption of interaction of residual stress with primary loads. The results obtained from the FE analyses were compared with the BS7910 predictions.

A Transferability Model for Cleavage Fracture Toughness in Strength Mismatched Welds Using the Weibull Stress Approach

2010 ◽  
Author(s):  
Claudio Ruggieri
Keyword(s):  
Cleavage Fracture ◽  
Driving Forces ◽  
Failure Strain ◽  
Pipeline Steel ◽  
Strong Support ◽  
Weld Strength ◽  
J Integral ◽  
X80 Pipeline Steel ◽  
Loading Parameter ◽  
Weibull Stress

This work describes the development of a toughness scaling methodology incorporating the effects of weld strength mismatch on crack-tip driving forces. The approach adopts a nondimensional Weibull stress, σw, as a the near-tip driving force to correlate cleavage fracture across cracked weld configurations with different mismatch conditions even though the loading parameter (measured by the J-integral) may vary widely due to mismatch and constraint variations. Application of the procedure to predict the failure strain for an overmatch girth weld made of an API X80 pipeline steel demonstrates the effectiveness of the micromechanics approach. Overall, the results lend strong support to use a Weibull stress based procedure in defect assessments of structural welds.

Material Properties and Flaw Characteristics of Vintage Girth Welds

2020 ◽  
Author(s):  
Dan Jia ◽  
Yong-Yi Wang ◽  
Steve Rapp
Keyword(s):  
Tensile Properties ◽  
Material Property ◽  
Material Properties ◽  
Weld Strength ◽  
Basic Material ◽  
Essential Information ◽  
Integrity Assessment ◽  
Property Data ◽  
Girth Welds ◽  
Material Property Data

Abstract Vintage pipelines, which in the context of this paper refer to pipelines built before approximately 1970, account for a large portion of the energy pipeline systems in North America. Integrity assessment of these pipelines can sometimes present challenges due to incomplete records and lack of material property data. When material properties for the welds of interest are not available, conservative estimates based on past experience are typically used for the unknown material property values. Such estimates can be overly conservative, potentially leading to unnecessary remedial actions. This paper is a summary of PRCI-funded work aimed at characterizing material properties and flaw characteristics of vintage girth welds. The data obtained in this work can be utilized to understand and predict the behavior of vintage pipelines, which is covered in a companion paper [1]. The material property data generated in this work include (i) pipe base metal tensile properties in both the hoop (transverse) and the longitudinal (axial) directions, (ii) deposited weld metal tensile properties, (iii) macrohardness traverses, (iv) microhardness maps, and (v) Charpy impact transition curves of specimens with notches in the heat-affected zone (HAZ) and weld centerline (WCL). These data provide essential information for tensile strength, strength mismatch, and impact toughness. In addition to the basic material property data, instrumented cross-weld tensile (ICWT) tests were conducted on CWT specimens with no flaws, natural flaws, and artificially machined planar flaws. The ICWT tests provide an indication of the welds’ stress and strain capacity without and with flaws. For welds with even-matching or over-matching weld strengths, the CWT specimens usually failed outside of the weld region, even for specimens with natural flaws reported by non-destructive examination. Having over-matching weld strength can compensate for the negative impact of weld flaws. All tested girth welds were inspected using radiography and/or phased array ultrasonic testing. The inspection results are compared with the flaws exposed through destructive testing. The ability of these inspection methods to detect and size flaws in vintage girth welds is evaluated.

Structural Integrity Assessment Criteria and Service Life Prediction of Cold Wrinklebends

2012 ◽  
Author(s):  
Xian-Kui Zhu ◽  
Brian N. Leis
Keyword(s):  
Finite Element ◽  
Service Life ◽  
Structural Integrity ◽  
Pipeline Steel ◽  
Three Dimensional ◽  
Computation Time ◽  
Element Analysis ◽  
Integrity Assessment ◽  
Fea Model ◽  
Hardening Models

Three-dimensional elastic-plastic finite element analysis (FEA) is performed in this paper to simulate the complicated stresses and deformation of wrinklebends in a pipeline from its bending formation to operation under cyclic loading. Three plastic hardening models (isotropic, kinematic and combined isotropic/kinematic) are discussed and used in FEA of wrinklebend response that considers strain hardening and Bauschinger effects. The FEA simulation is carried out first for an elbow held at constant pressure while subject to cyclic bending, which serves as a benchmark case. The results show that the three hardening models lead to very different outcomes. Comparable FEA simulations are then developed for wrinklebends under cyclic pressure. Detailed parametric analysis is considered, including finite-element type, element sensitivity, computation time, and material input data. Based on those results viable nonlinear FEA model is developed as the basis to quantify wrinklebend response under service-like conditions. Based on the FEA results, fatigue damage is quantified using the Smith, Watson and Topper (SWT) parameter, and thereafter a damage criterion is proposed to predict the fatigue life of a wrinklebend under the pressure cycles of 72%–10% of SMYS for typical X42 pipeline steel. The results show that the wrinkle aspect ratio H/L is a key parameter to control the service life of a wrinklebend.

A Study of the Effects of Scaling on Structural Integrity Assessment and Feasibility of Physical Validation

2016 ◽  
Author(s):  
Paulo Orrock ◽  
Christopher E. Truman
Keyword(s):  
Scaling Laws ◽  
Structural Integrity ◽  
Driving Forces ◽  
Stress Fields ◽  
Complex Nature ◽  
Statistical Nature ◽  
Integrity Assessment ◽  
And Performance ◽  
Scaled Models ◽  
Random Nature

For nuclear welded components the complex nature of the stresses involved means it is often advantageous to produce mock-ups in order that the structural integrity and performance may be assessed. The weight and size of these components can make the production of mock-ups prohibitively expensive and impractical, and so the use of scaled models is considered here. The scaling laws encountered affecting the applied loads, residual stresses and crack driving forces that are of interest are investigated using numerical analyses and finite element simulations. Of particular interest is the physical validation of these laws and the statistical difficulties that may be encountered. The scaling of applied loads required to obtain the same residual stress fields and stress intensity factors are investigated using simulated four point bends. The statistical nature of fracture introduces uncertainty into fracture measurements which this paper takes into consideration in preparation for physical validation, ensuring that the random nature of fracture will not make the described laws impractical to validate.

Material Properties and Flaw Characteristics of Vintage Girth Welds

2016 ◽  
Author(s):  
Kunal Kotian ◽  
Yong-Yi Wang
Keyword(s):  
Weld Metal ◽  
Tensile Properties ◽  
Material Properties ◽  
Weld Strength ◽  
Basic Material ◽  
Additional Stress ◽  
Assessment Procedure ◽  
Essential Information ◽  
Integrity Assessment ◽  
Girth Welds

Integrity assessment of girth welds in in-service vintage pipelines is sometimes necessary, including regulatory requirements, changes in service or pipe support conditions which may cause additional stress on the girth welds, or “indications” being reported in in-line inspection (ILI). Material properties and flaw characteristics are essential in such assessment, but very little data are available in most cases. In a PRCI-funded effort, material properties and flaw characteristics of vintage girth welds are generated and analyzed to fill the critical gaps. The output of this effort is being used as the inputs to a vintage girth weld assessment procedure being developed in a separate and parallel effort. The outcome of these efforts collectively allows for the assessment of vintage girth welds, which is a part of an overall integrity management program. The basic material property data being generated include (i) pipe tensile properties in both hoop and longitudinal directions, (ii) weld metal tensile properties, (iii) macrohardness traverse, and (iv) Charpy impact transition curves with notches in the heat affected zone (HAZ) and deposited weld metal. These data provide essential information on tensile strength, weld strength mismatch, and toughness. In addition, tensile tests were conducted on cross-weld specimens with natural flaws and artificially machined planar flaws. These cross-weld tests provide an indication of the welds’ stress capacity in the presence of flaws. They also provide the apparent toughness which is essential in assessing welds’ tensile strain capacity. All tested girth welds were inspected using radiography and phased array UT. Thus, this work provides a coherent picture of the material properties, flaw characteristics, and stress and strain capacities of the tested vintage girth welds.

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