Overview of a Comprehensive Study to Understand Longitudinal ERW Seam Failures

2014 ◽  
Author(s):  
Bruce A. Young ◽  
Steve Nanney ◽  
Brian Leis ◽  
Jennifer M. Smith
Keyword(s):  
Phase I ◽  
Management Practices ◽  
Structural Integrity ◽  
Experimental Studies ◽  
Current Approach ◽  
Transportation Safety ◽  
Seam Weld ◽  
Integrity Management ◽  
Weld Corrosion ◽  
Comprehensive Study

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to eliminate longitudinal seam failures in electric resistance weld (ERW) pipe. This study was contracted with Battelle, working with Kiefner and Associates (KAI) and Det Norske Veritas (DNV) as subcontractors. The purpose of this paper is to provide an overview of the project with focus on the study objectives, results, and on-going work. Phase I of the project consisted of four major tasks aimed at understanding the current state of the issues. Task 1 analyzed the databases gathered and qualified in five interim reports that dealt with 1) the failure history of vintage ERW seams, including flash-weld (FW) pipe and selective seam-weld corrosion (SSWC); documented in two subtask 1.4 reports, 2) the effectiveness of in-line inspection (ILI) and hydrotesting, and experience with predictive modeling, documented in subtask reports 1.2 and 1.3 and 3) literature concerning SSWC documented in subtask 1.5 report. Task 2 addressed experimental studies designed to better characterize the failure of ERW/FW seams and quantify the resistance of such seams (Subtask 2.1–2.3 and 2.6 reports) and their response to pressure (Subtask 2.4 and 2.5 reports). Task 3 considered aspects related to SSWC with four separate reports from subtask 3.1–3.4. Task 4 focused on integration of the other tasks, trending, and analysis. Phase II has been initiated and consists of five tasks with the following objectives relevant to the ERW and FW process: 1) develop and optimize viable hydrotest protocols for ERW/FW seam defects 2) improve the sensors, interpretive algorithms, and tool platforms in regard to ILI and In-the-Ditch-Methods (ITDM) to better ensure structural integrity with optimized detection and sizing, 3) bridge gaps in defect characterization in regard to types, sizes, shapes, and idealizations. The goal of this subtask is to increase pipeline safety through improvements in the tools needed to implement both ILI and hydrotesting, 4) validate existing models and, where gaps preclude validation, refine or develop models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary threats) for failure subject to loadings that develop both during hydrotests and in service, and 5) develop a digitally based framework to support integrity management of seam welds with enough flexibility to benefit from the experience embedded in the stopgap protocol. To date, this study has led to seventeen (17) reports. These publically available reports are located on the PHMSA website: http://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390. Based on the work completed during Phase I, gaps identified in the context of the NTSB Recommendation P-09-1 were supported by the historic records. Additionally, recent improvements in related technologies and integrity management practices point to the practical utility and viability of PHMSA’s current approach to manage the integrity of the U.S. pipeline.

Review of Phase II for the Comprehensive Study to Understand Longitudinal ERW Seam Failures

2016 ◽  
Author(s):  
Bruce A. Young ◽  
Jennifer M. O’Brian ◽  
Steve Nanney
Keyword(s):  
Phase Ii ◽  
Structural Integrity ◽  
Prediction Models ◽  
Transportation Safety ◽  
Develop Software ◽  
Integrity Management ◽  
Resistance Weld ◽  
Weld Corrosion ◽  
Pipeline Safety ◽  
Comprehensive Study

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to significantly reduce longitudinal seam failures in electric resistance weld (ERW) pipe. The purpose of this paper is to provide a review of Phase II of the project with focus on the study objectives and results. Phase II of the project consisted of five tasks with the following objectives relevant to the ERW and flash weld (FW) process: 1) develop and optimize viable hydrotest protocols for ERW/FW seam defects 2) improve the sensors, interpretive algorithms, and tool platforms in regard to In-Line-Inspection (ILI) and In-the-Ditch-Methods (ITDM) to better ensure structural integrity by developing and optimizing concepts to address problems in detecting and sizing, 3) bridge gaps in defect characterization in regard to types, sizes, geometries, and idealizations, to increase pipeline safety through improvements needed to implement both ILI and hydrotesting, 4) validate existing failure prediction models and, where gaps preclude validation, refine or develop these models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary ERW/FW seam threats) for failure subject to loadings that develop both during hydrotests and in service, and 5) develop software to support integrity management of seam welds with enough flexibility to benefit from the experience gained during this project. The reports generated during the course of the project are publically available and are located on following PHMSA website: http://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390.

Development of Selective Seam Weld Corrosion Test Method

2014 ◽  
Author(s):  
J. A. Beavers ◽  
C. S. Brossia ◽  
R. A. Denzine
Keyword(s):  
Base Metal ◽  
Field Testing ◽  
Test Method ◽  
Transportation Safety ◽  
Seam Weld ◽  
Corrosion Kinetics ◽  
Pipeline Failures ◽  
Weld Corrosion ◽  
Pipeline Safety ◽  
Non Destructive

Selective seam weld corrosion (SSWC) of electric resistance welded (ERW) pipelines has been identified as a potential risk to pipeline safety. Due to recent pipeline failures, where seam weld defects may have played a significant role, the National Transportation Safety Board called upon the Pipeline and Hazardous Materials Safety Administration (PHMSA) to conduct a comprehensive study to identify actions that can be used by operators to eliminate catastrophic longitudinal seam failures in pipelines. Battelle contracted Kiefner and Associates, Inc. and Det Norse Veritas (U.S.A.) Inc. (DNV GL) with the objective to assist PHMSA in addressing this issue. The objective of one of the tasks performed by DNV GL was to develop a reliable, rapid, non-destructive, field-deployable test method that can quantify SSWC susceptibility on operating pipelines containing ERW seams. For this effort, two different, field deployable, non-destructive methods were evaluated in laboratory testing. The methods were validated using a standard destructive test for assessing SSWC susceptibility. One method was based on measurement of the local potential difference between the seam weld and the adjacent base metal while the second was based on differences in the corrosion kinetics between the seam weld and the base metal. The method that is based on corrosion kinetics was found to be most effective in identifying SSWC susceptible pipe steels. It utilizes a barnacle cell to conduct linear polarization resistance measurements on small, selected areas of the pipe (e.g., the weldment or base metal). Additional laboratory as well as field-testing is planned to further validate the test method.

An Overview of Time Dependent Crack Growth Models Used for ERW Seam Weld Analyses

2017 ◽  
Author(s):  
Richard Olson ◽  
Bruce Young ◽  
Jennifer O’Brian
Keyword(s):  
Crack Growth ◽  
Prediction Models ◽  
Growth Models ◽  
Time Dependent ◽  
Creep Model ◽  
Transportation Safety ◽  
Seam Weld ◽  
Integrity Management ◽  
Crack Growth Model ◽  
Time Dependent Crack Growth

In response to the National Transportation Safety Board (NTSB) Recommendation P-09-1, the Department of Transportation (DOT) Pipeline and Hazardous Material Safety Administration (PHMSA) initiated a comprehensive study to identify actions that could be implemented by pipeline operators to significantly reduce longitudinal seam failures in electric resistance weld (ERW) pipe. As part of the project, Task 4 in Phase II was designed to validate existing failure prediction models and, where gaps exist, refine or develop the models needed to assess and quantify defect severity for cold welds, hook cracks, and selective seam weld corrosion (SSWC) (the primary ERW/Flash Weld seam threats) for failure subject to loadings that develop both during hydrotests and in service. These models would then be used to develop new software to support integrity management of seam welds with enough flexibility to benefit from the experience gained during this project. The purpose of this paper is to review the time-dependent crack growth model used in the development of the PipeAssess PI™ pipeline integrity management software. The model will be discussed in the context of its underlying theory, validation, and application to a set of test cases. Both the stress-activated creep model and consequential tie to fatigue crack growth models are presented, which describe crack growth under hydrostatic holds and subsequent pressure cycles. Full-scale experiments are used to validate the models. The reports generated during the course of the project are publically available and are located at the PHMSA website: HTTP://PRIMIS.PHMSA.DOT.GOV/MATRIX/PRJHOME.RDM?PRJ=390.

What Do Pipelines and Airplanes Have in Common?

2016 ◽  
Author(s):  
Sergio Limon ◽  
David W. Hoeppner ◽  
Paul N. Clark ◽  
Jerzy Komorowski
Keyword(s):  
Management Practices ◽  
Failure Modes ◽  
Structural Integrity ◽  
Safety Concern ◽  
The United States ◽  
Risk Assessments ◽  
Great Success ◽  
Degradation Mechanisms ◽  
Safety And Reliability ◽  
Integrity Management

In 1958, General Curtis E. LeMay established the structural integrity program for the United States Air Force (USAF). Since then, the USAF has been honing the requirements for extending the service life, durability, and safety of aircraft. These requirements have evolved to include Damage Tolerance principles that encompass the design and the management of aircraft with the objective of reducing maintenance burdens and ensure structural integrity for airworthiness, safety, and mission capability. Recently, requirements of some agencies and companies include Holistic Life Structural Integrity Process (HOLSIP) and concepts aimed at improving the early prediction and detection of structural discontinuities that can pose a safety concern. HOLSIP is intended to reduce the inspection & maintenance cycle while identifying prevention and mitigative measures to be employed. This holistic methodology addresses the total life of components and related issues. It is a physics based approach that incorporates the interaction of known possible degradation mechanisms and their potential failure modes. It provides the basis for analytical, experimental and procedural methods to make structural integrity predictions of components from the design, manufacturing, commissioning, maintenance and inspection intervals that would meet the desired level of safety and reliability. Non-destructive evaluation methods are incorporated in this approach as well. As part of continuing to ensure the safety and reliability of pipelines systems, the energy pipeline industry performs periodic risk assessments and maintenance activities and can enhance current integrity management programs by adopting HOLSIP principles and framework. In the early 2000s, pipeline industry associations and government regulators published a risk assessment based process for prioritizing pipeline segments for inspection and remediation. These processes have been formally integrated into an Integrity Management Program (IMP). By incorporating risk assessments and periodic inspections as part of the IMP, energy pipeline operators have achieved great success in removing damage that can pose an immediate or short-term safety concern to the public, environment and piping facilities. However, in-service pipeline failures continue to occur suggesting that the treatment of integrity threats, degradation mechanisms and failure modes is still fragmented. There needs to be a strong sense of wholeness in the approach to managing pipeline integrity. The absence of this can lead to unnecessary inspections and assessments, early pipeline retirements, over conservative assumptions or worse, further in-service accidents. As energy pipelines around the world continue to age and their safe performance is expected to increase, the need for HOLSIP becomes more apparent. This paper provides an overview of the fundamental principles and concepts of a holistic approach developed for maintaining aircraft fleets and how they apply to structural integrity engineering assessments for pipelines. A comparison with the current pipeline integrity management practices and regulations is highlighted.

Managing the Threat of Selective Seam Weld Corrosion Using a State of the Art ILI System

2020 ◽  
Author(s):  
Christopher Davies ◽  
Simon Slater ◽  
Christoper De Leon
Keyword(s):  
Material Properties ◽  
Weld Zone ◽  
Evaluation Process ◽  
Management Plan ◽  
Management Approach ◽  
Metal Loss ◽  
Integrity Assessment ◽  
Seam Weld ◽  
Integrity Management ◽  
Weld Corrosion

Abstract For many years, pipeline safety regulations in the US have defined prescriptive minimum requirements for integrity management combined with a clear expectation that operators should do more than the minimum where appropriate. The regulations have also provided operators with the flexibility to take a performance based integrity management approach leveraging as much information available to manage threats effectively. One the threats that must be managed is Selective Seam Weld Corrosion (SSWC). SSWC is an environmentally assisted mechanism in which there is increased degree of metal loss in the longitudinal weld in comparison to the surrounding pipe body. An appropriate definition is linear corrosion that is deeper in the longitudinal weld zone than the surrounding pipe body. In some cases, the surrounding pipe body may have limited or no corrosion present, and in other cases the pipe body corrosion may have occurred but at a slower rate than the local corrosion in the longitudinal weld zone. Conventional responses to potential or identified threats focus on in-situ investigations, often resulting in expensive and un-planned repairs for features reported by In-line Inspection (ILI) that when assessed properly demonstrate a remnant life well into the next inspection interval. When ILI identifies metal loss indications co-located with the longitudinal seam weld, the current prescribed response is often a blanket call for remediation. Such a response may not be appropriate if an ILI system is deployed to discriminate feature types and integrity assessment is exercised leveraging a sound understanding of the pipe’s material properties. This paper describes an approach that can be taken to manage the threat of SSWC. The foundation of the approach is deployment of an appropriate ILI system incorporating an effective ILI technology, an optimized evaluation process considering the specific threat morphology, material testing and a structured dig program. The evaluation process uses the ILI data and data from the field in combination material properties data and a susceptibility analysis to classify anomalies as “Likely”, “Possible” and “Unlikely” SSWC. This is aligned with the guidance in API RP 1176 “Assessment and Management of Cracking in Pipelines” for defining an appropriate response to ILI calls. Approaching the management of SSWC in this way allows operators to define a structured response for excavation activities to verify the process and remediate features as required. By using likelihood classification the risk to pipeline integrity can be reduced by acting on the most likely SSWC features as a priority, whilst collecting the data needed to make informed decisions on where to focus resources and efforts on what is a very complicated and difficult to manage threat. The output form this work, including a future plan for managing the remaining metal loss features, can be documented in a procedure and incorporated into an existing Integrity Management Plan.

scholarly journals Computational and experimental mechanical performance of a new everolimus-eluting stent purpose-built for left main interventions

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Saurabhi Samant ◽  
Wei Wu ◽  
Shijia Zhao ◽  
Behram Khan ◽  
Mohammadali Sharzehee ◽  
...  
Keyword(s):  
Structural Integrity ◽  
Mechanical Performance ◽  
Experimental Studies ◽  
Patient Specific ◽  
Wall Structure ◽  
Left Main ◽  
Element Analysis ◽  
Stent Expansion ◽  
Radial Strength ◽  
Different Diameters

AbstractLeft main (LM) coronary artery bifurcation stenting is a challenging topic due to the distinct anatomy and wall structure of LM. In this work, we investigated computationally and experimentally the mechanical performance of a novel everolimus-eluting stent (SYNERGY MEGATRON) purpose-built for interventions to large proximal coronary segments, including LM. MEGATRON stent has been purposefully designed to sustain its structural integrity at higher expansion diameters and to provide optimal lumen coverage. Four patient-specific LM geometries were 3D reconstructed and stented computationally with finite element analysis in a well-validated computational stent simulation platform under different homogeneous and heterogeneous plaque conditions. Four different everolimus-eluting stent designs (9-peak prototype MEGATRON, 10-peak prototype MEGATRON, 12-peak MEGATRON, and SYNERGY) were deployed computationally in all bifurcation geometries at three different diameters (i.e., 3.5, 4.5, and 5.0 mm). The stent designs were also expanded experimentally from 3.5 to 5.0 mm (blind analysis). Stent morphometric and biomechanical indices were calculated in the computational and experimental studies. In the computational studies the 12-peak MEGATRON exhibited significantly greater expansion, better scaffolding, smaller vessel prolapse, and greater radial strength (expressed as normalized hoop force) than the 9-peak MEGATRON, 10-peak MEGATRON, or SYNERGY (p < 0.05). Larger stent expansion diameters had significantly better radial strength and worse scaffolding than smaller stent diameters (p < 0.001). Computational stenting showed comparable scaffolding and radial strength with experimental stenting. 12-peak MEGATRON exhibited better mechanical performance than the 9-peak MEGATRON, 10-peak MEGATRON, or SYNERGY. Patient-specific computational LM stenting simulations can accurately reproduce experimental stent testing, providing an attractive framework for cost- and time-effective stent research and development.

Testing of Acoustic Emission Technology to Detect Cracks and Corrosion in the Marine Environment

2010 ◽  
Vol 26 (02) ◽  
pp. 106-110
Author(s):  
Ge Wang ◽  
Michael Lee ◽  
Chris Serratella ◽  
Stanley Botten ◽  
Sam Ternowchek ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Structural Integrity ◽  
Pilot Project ◽  
Development Project ◽  
Management Program ◽  
Pipeline System ◽  
Inspection Planning ◽  
Structural Degradation ◽  
Integrity Management ◽  
Acoustic Emission Technology

Real-time monitoring and detection of structural degradation helps in capturing the structural conditions of ships. The latest nondestructive testing (NDT) and sensor technologies will potentially be integrated into future generations of the structural integrity management program. This paper reports on a joint development project between Alaska Tanker Company, American Bureau of Shipping (ABS), and MISTRAS. The pilot project examined the viability of acoustic emission technology as a screening tool for surveys and inspection planning. Specifically, testing took place on a 32-year-old double-hull Trans Alaska Pipeline System (TAPS) trade tanker. The test demonstrated the possibility of adapting this technology in the identification of critical spots on a tanker in order to target inspections. This targeting will focus surveys and inspections on suspected areas, thus increasing efficiency of detecting structural degradation. The test has the potential to introduce new inspection procedures as the project undertakes the first commercial testing of the latest acoustic emission technology during a tanker's voyage.

A Hybrid Topside Structural Approach to the Management of Aging Fleet

2021 ◽  
Author(s):  
Biramarta Isnadi ◽  
Luong Ann Lee ◽  
Sok Mooi Ng ◽  
Ave Suhendra Suhaili ◽  
Quailid Rezza M Nasir ◽  
...  
Keyword(s):  
Structural Integrity ◽  
Metal Loss ◽  
Web Based ◽  
Strong Basis ◽  
Asset Risk ◽  
Risk Ranking ◽  
Design Life ◽  
Industry Standards ◽  
Integrity Management ◽  
Inspection Data

Abstract The objective of this paper is to demonstrate the best practices of Topside Structural Integrity Management for an aging fleet of more than 200 platforms with about 60% of which has exceeded the design life. PETRONAS as the operator, has established a Topside Structural Integrity Management (SIM) strategy to demonstrate fitness of the offshore topside structures through a hybrid philosophy of time-based inspection with risk-based maintenance, which is in compliance to API RP2SIM (2014) inspection requirements. This paper shares the data management, methodology, challenges and value creation of this strategy. The SIM process adopted in this work is in compliance with industry standards API RP2SIM, focusing on Data-Evaluation-Strategy-Program processes. The operator HSE Risk Matrix is adopted in risk ranking of the topside structures. The main elements considered in developing the risk ranking of the topside structures are the design and assessment compliance, inspection compliance and maintenance compliance. Effective methodology to register asset and inspection data capture was developed to expedite the readiness of Topside SIM for a large aging fleet. The Topside SIM is being codified in the operator web-based tool, Structural Integrity Compliance System (SICS). Identifying major hazards for topside structures were primarily achieved via data trending post implementation of Topside SIM. It was then concluded that metal loss as the major threat. Further study on effect of metal loss provides a strong basis to move from time-based maintenance towards risk-based maintenance. Risk ranking of the assets allow the operator to prioritize resources while managing the risk within ALARP level. Current technologies such as drone and mobile inspection tools are deployed to expedite inspection findings and reporting processes. The data from the mobile inspection tool is directly fed into the web based SICS to allow reclassification of asset risk and anomalies management.

scholarly journals Integrity Management of Marine Structures; With Emphasis on Design for Structural Robustness

2018 ◽  
Author(s):  
Torgeir Moan
Keyword(s):  
Structural Damage ◽  
Structural Integrity ◽  
Oil And Gas ◽  
Offshore Structures ◽  
Design Standards ◽  
Limit States ◽  
Fabrication Errors ◽  
Integrity Management ◽  
Operational Errors ◽  
And Control

Based on relevant accident experiences with oil and gas platforms, a brief overview of structural integrity management of offshore structures is given; including an account of adequate design criteria, inspection, repair and maintenance as well as quality assurance and control of the engineering processes. The focus is on developing research based design standards for Accidental Collapse Limit States to ensure robustness or damage tolerance in view damage caused by accidental loads due to operational errors and to some extent abnormal structural damage due to fabrication errors. Moreover, it is suggested to provide robustness in cases where the structural performance is sensitive to uncertain parameters. The use of risk assessment to aid decisions in lieu of uncertainties affecting the performance of novel and existing offshore structures, is briefly addressed.

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