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.

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.

Pipeline Health Integrity Monitoring (PHIM) Based on Acoustic Emission Technique

2012 ◽  
Author(s):  
Giuseppe Giunta ◽  
Sergio Budano ◽  
Antonio Lucci ◽  
Luca Prandi
Keyword(s):  
Acoustic Emission ◽  
Oil And Gas ◽  
Fracture Mechanisms ◽  
Assessment Procedure ◽  
Essential Information ◽  
Integrity Assessment ◽  
Environment Exposure ◽  
Artificial Surface ◽  
Steel Grades ◽  
Variable Stresses

The Acoustic Emission (AE) technique allows taking under control the damage as superficial flaws (S-Flaws) occurred during service operation of remarkable zones of steel components, monitoring the initiation and the propagation of critical defects, submitted to static or variable stresses and aggressive environment exposure. In the framework of the eni gas&power research project oriented to the development of a “AE methodology” for monitoring critical sections of gas transmission pipelines, a study has been carried out jointly with Centro Sviluppo Materiali (CSM), aimed to investigate reliability and applicability of the AE technique to steels used in the Oil&Gas industry. Steel grades API 5L X65, X80 and X100, representative of traditional and new gas pipelines, have been selected. The project was scheduled investigating the potential of these steels to release elastic waves generated by sources of damage related to ductile or brittle fracture mechanisms. Hydraulic tests until failure were carried out on single pipes using steel grade API 5L X65 for monitoring the growing of the damage on the tip of artificial surface notches (S-flaw), machined on the wall thickness [1]. Water was used as internal fluid and temperature effect was considered as well. The capability of the AE technique to discriminate ductile and brittle fractures, the essential information to approach an integrity assessment procedure, was achieved. This paper, respect to the previous ones [1], extends the AE methodology for monitoring pipelines supplying both oil and gas. In fact a third burst test was carried out filling the pipe by air and the results on this item are presented.

Attributes of Modern Linepipes and Their Implications on Girth Weld Strain Capacity

2018 ◽  
Author(s):  
Yong-Yi Wang ◽  
Steve Rapp ◽  
David Horsley ◽  
David Warman ◽  
Jim Gianetto
Keyword(s):  
Tensile Properties ◽  
Weld Strength ◽  
Potential Contribution ◽  
Contributing Factors ◽  
Strain Capacity ◽  
Strain Tolerance ◽  
Industry Standards ◽  
Girth Welding ◽  
Girth Welds ◽  
Welding Procedure

There has been a number of unexpected girth weld failures in newly constructed pipelines. Girth weld failures have also been observed in pre-service hydrostatic testing. Post-incident investigations indicated that the pipes met the requirements of industry standards, such as API 5L. The welds were qualified per accepted industry standards, such as API 1104. The field girth welding was performed, inspected, and accepted per industry standards, such as API 1104. Some of the traditional causes of girth weld failures, such as hydrogen cracks and high-low misalignment, were not a factor in these incidents. This paper starts with a review of the recent girth weld incidents. A few key features of a failed weld and their implications are examined. The characteristics of the recent failures is summarized, and the major contributing factors known to date are given. Some of the options to prevent future failures include (1) changes to the tensile properties of the pipes and enhanced hardenability, (2) welding options aimed at increasing the weld strength and minimizing heat-affected zone (HAZ) softening, and (3) reduction of stresses on girth welds. This paper focuses on the first two options. The trends of chemical composition and tensile properties of linepipe are reviewed. The potential contribution of these trends to the girth weld incidents is examined. Possible changes to the linepipe properties and necessary updates in the testing and qualification requirements of the linepipes are provided. Welding options beneficial to enhanced girth weld strain capacity are discussed. Possible revisions to welding procedure qualification requirements, aimed at achieving a minimum level of strain tolerance/capacity, are proposed. The application of previously developed tools in estimating the propensity of HAZ softening is reviewed.

Expert System for Integrity Assessment of Piping Containing Defects

2006 ◽  
Author(s):  
Y. C. Lin
Keyword(s):  
Expert System ◽  
Material Properties ◽  
Bending Moment ◽  
Computation Method ◽  
Assessment Procedure ◽  
Assessment Methodology ◽  
Integrity Assessment ◽  
Analysis Methodology ◽  
External Forces ◽  
The Relationship

The mechanical integrity of in-service pressure piping is a matter of great importance for both economical and safety reasons. Considering the uncertainties in various internal operating loadings and external forces, flaw sizes, material properties, this paper presents a probabilistic assessment methodology for in-service pressure piping containing defects, which is especially designed for programming. A general sampling computation method of the stress intensity factor (SIF), in the form of the relationship between SIF and axial force, bending moment and torsion, is adopted in the probabilistic analysis methodology. Based on the European flaw assessment procedure, SINTAP, Integrity Assessment Expert System of In-service Pressure Piping Containing Flaws (IAESPP-SINTAP) is developed using the presented probabilistic methodology. A numerical example is given to show the application of IAESPP-SINTAP software. The failure probabilities of every defect and the whole piping can be obtained by using this software.

Structure and Properties of X80 and X100 Pipeline Girth Welds

2004 ◽  
Author(s):  
J. A. Gianetto ◽  
J. T. Bowker ◽  
D. V. Dorling ◽  
D. Horsley
Keyword(s):  
Yield Strength ◽  
Weld Metal ◽  
Tensile Properties ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Narrow Gap ◽  
Line Pipe ◽  
Metal Arc Welding ◽  
Girth Welds ◽  
Strength And Toughness

This study aims to provide an understanding of the factors that control weld metal strength and toughness of mechanized field girth welds produced in X80 and X100 line pipe steels using a range of pipeline gas metal arc welding procedures. In the investigation of X80 welds, a series of experimental single and dual torch gas metal arc welds were prepared with three C-Mn-Si wires, which contained additions of Ti, Ni-Ti and Ni-Mo-Ti. The weld metal microstructures, tensile properties, notch toughness, and fracture resistance were evaluated. The results indicate that high weld metal yield strength and good toughness can be achieved. The X80 single torch welds exhibited higher yield strength but lower toughness compared to the corresponding dual torch welds. For the development and evaluation of welding procedures for mainline girth welding of X100 pipe, two narrow gap mechanized gas metal arc welding procedures were evaluated with emphasis placed on measurement of the tensile properties. The results show that dramatically different properties (strength and toughness) can be found as a result of differences in energy input, interpass temperature and weld width or offset distance. Additionally, the preliminary tensile testing, which utilized both standard round bar and modified strip tensile specimens, illustrates the potential variation that can occur when assessing all-weld-metal tensile properties of narrow gap pipeline girth welds.

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.

Probabilistic Integrity Assessment of Pressure Piping Containing Defects

2010 ◽  
Vol 146-147 ◽  
pp. 390-393
Author(s):  
Ming Li ◽  
Feng Hui Wang ◽  
Ping Wei Chen ◽  
Kang Lou
Keyword(s):  
Experimental Data ◽  
Fracture Toughness ◽  
Weld Metal ◽  
Reliability Assessment ◽  
Assessment Procedure ◽  
J Integral ◽  
Engineering Applications ◽  
Integrity Assessment ◽  
X52 Steel ◽  
Level Analysis

In the present paper, integrity assessment is made to the defects in weld metal zone of pressure piping of X52 steel using the two basic routes, FAD and CDF, which are provided in the European flaw assessment procedure SINTAP. Based on the experimental data various analysis levels of SINTAP are discussed, including the uncommonly used J-integral level in particular. Furthermore, to meet the need of the reliability assessment of pressure piping containing defects in engineering applications, probabilistic procedures are employed to obtain several probability curves with given survivability on the J-integral level with respect to the great scatter of the tested fracture toughness which is required in the J-integral level analysis.

NIMROD 617KS

Alloy Digest ◽  
2002 ◽  
Vol 51 (5) ◽  
Keyword(s):  
Fracture Toughness ◽  
High Temperature ◽  
Weld Metal ◽  
Tensile Properties ◽  
Base Metal ◽  
Heat Treating ◽  
Nominal Composition

Abstract Nimrod 617KS is an Inconel-type consumable with a nominal composition of nickel, 24% Cr,12% Co, and 9% Mo and is used to join UNS N06617 and Nicrofer 6023 to themselves. The alloy is designed for high-temperature service and is often used as the weld metal in dissimilar cases to ensure the weld is as strong as the base metal. This datasheet provides information on composition, hardness, and tensile properties as well as fracture toughness. It also includes information on heat treating and joining. Filing Code: Ni-583. Producer or source: Metrode Products Ltd.

BS 7910: History and Future Developments

2009 ◽  
Author(s):  
Isabel Hadley
Keyword(s):  
Assessment Methods ◽  
Weld Strength ◽  
Assessment Procedure ◽  
Metallic Structures ◽  
History Of ◽  
Fracture Assessment ◽  
Offshore Industry ◽  
Crack Tip Constraint ◽  
The Uk ◽  
Assessment Procedures

BS 7910, the UK procedure for the assessment of flaws in metallic structures, was first published almost 30 years ago in the form of a fracture/fatigue assessment procedure, PD6493. It provided the basis for analysing fabrication flaws and the need for repair in a rational fashion, rather than relying on long-established (and essentially arbitrary) workmanship rules. The UK offshore industry in particular embraced this new approach to flaw assessment, which is now widely recognised by safety authorities and specifically referred to in certain design codes, including codes for pressure equipment. Since its first publication in 1980, PD6493/BS 7910 has been regularly maintained and expanded, taking in elements of other publications such as the UK power industry’s fracture assessment procedure R6 (in particular the Failure Assessment Diagram approach), the creep assessment procedure PD6539 and the gas transmission industry’s approach to assessment of locally thinned areas in pipelines. The FITNET European thematic network, run between 2002 and 2006, has further advanced the state of the art, bringing in assessment methods from SINTAP (an earlier European research project), R6, R5 and elsewhere. In particular, the FITNET fracture assessment methods represent considerable advances over the current BS 7910 methods; for example, weld strength mismatch can be explicitly analysed by using FITNET Option 2, and crack tip constraint through Option 5. Corrosion assessment methods in FITNET are also more versatile than those of BS 7910, and now include methods for vessels and elbows as well as for pipelines. In view of these recent advances, the BS 7910 committee has decided to incorporate many elements of the FITNET procedure into the next edition of BS 7910, to be published c2012. This paper summarises the history of the development of BS 7910, its relationship with other flaw assessment procedures (in particular FITNET and R6) and its future.

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