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.

Improved Linepipe Specifications and Welding Practice for Resilient Pipelines

2020 ◽  
Author(s):  
Yong-Yi Wang ◽  
Dan Jia ◽  
Dave Warman ◽  
David L. Johnson ◽  
Steve Rapp
Keyword(s):  
Construction Projects ◽  
Tensile Tests ◽  
Weld Strength ◽  
Contributing Factors ◽  
The North ◽  
Pipe Replacement ◽  
Girth Welds ◽  
Welding Procedure ◽  
Internal Procedures ◽  
Welding Processes

Abstract At least 10 girth weld incidents in newly constructed pipelines are known to have occurred in North America. More than 30 girth weld incidents in newly constructed pipes have been identified worldwide. A review of the North American incidents identified a few main contributing factors: (1) weld strength undermatching, (2) heat-affected zone (HAZ) softening, and (3) elevated stresses/strains from normal settlement and other loads. Weld bevel geometries of manual welding processes that favor plastic straining along the softened HAZ and low strength root passes were also compounding contributing factors. Prior publications focused on the industry practices that led to the formation of those contributing factors. This paper covers the enhanced linepipe specifications and improved welding practice that aim to reduce the risk of similar girth weld incidents, thus leading to more resilient pipelines. The enhanced linepipe specifications include interim recommendations that aim to limit the upper-bound longitudinal strength for a given pipe grade and reduce the linepipe steels’ susceptibility to HAZ softening. The implementation of the interim recommendations is assisted by allowing alternative hoop tensile tests. The improved welding practice includes (1) the selection of welding procedures, including consumables, that minimizes the likelihood of weld strength undermatching and reduces the propensity for HAZ softening and (2) welding procedure qualification tests and requirements for the production of strain-resistant girth welds. The recommendations covered in this paper principally target new pipeline construction projects but are also applicable to pipe replacement projects. It is expected that pipeline operators would incorporate the recommendations in their internal procedures and work with welding contractors to execute the recommendations. The improved linepipe specifications and welding practice are expected to increase the resilience of pipelines subjected to realistic construction and in-service loads. The implementation of the recommendations requires changes to some long-standing industry practices and can only occur with collaborative efforts from all stakeholders.

Effects of Biaxial Loading on the Tensile Strain Capacity of Girth Welds With Weld Strength Undermatching and HAZ Softening

2020 ◽  
Author(s):  
Banglin Liu ◽  
Yong-Yi Wang ◽  
Xiaotong Chen ◽  
David Warman
Keyword(s):  
Internal Pressure ◽  
Tensile Strain ◽  
Biaxial Loading ◽  
Reduction Factor ◽  
Pressure Level ◽  
Weld Strength ◽  
Strain Capacity ◽  
Weld Region ◽  
Girth Welds ◽  
Tensile Strain Capacity

Abstract The ability to accurately estimate the tensile strain capacity (TSC) of a girth weld is critical to performing strain-based assessment (SBA). A wide range of geometry, material, and loading factors can affect the TSC of a girth weld. Among the influencing factors, an increase in the internal pressure level has been shown to have a detrimental effect on the TSC. The overall influence of internal pressure is usually quantified by a TSC reduction factor, defined as the ratio of the TSC at zero pressure to the lowest TSC typically attained at pressure factors around 0.5–0.6. Here the pressure factor is defined as the ratio of the nominal hoop stress induced by pressure to the yield strength (YS) of the pipe material. A number of numeric and experiment studies have reported a TSC reduction factor of 1.5–2.5. These studies generally focused on strain-based designed pipelines with evenmatching or overmatching welds, minimum heat affected zone (HAZ) softening, and a surface breaking flaw at the weld centerline or the fusion boundary. This paper examines the effects of pipe internal pressure on the TSC of girth welds under the premise of weld strength undermatching and HAZ softening. The interaction of biaxial loading and the local stress concentration at the girth weld region was quantified using full-pipe finite element analysis (FEA). The relationship between TSC and the internal pressure level was obtained under several combinations of weld strength mismatch and HAZ softening. Results from the FEA show that the effects of the internal pressure on the TSC are highly sensitive to the material attributes in the girth weld region. Under less favorable weld strength undermatching and HAZ softening conditions, the traditionally assumed reduction factor or 1.5–2.5 may not be applicable. Further, the location of tensile failure is found to depend on both the weld material attributes and the internal pressure. It is possible for the failure location to shift from pipe body at zero internal pressure to the girth weld at elevated internal pressure levels. The implications of the results for both girth weld qualification and integrity assessment are discussed.

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.

Framework for Key Influences on Tensile Strain Capacity of Flawed Girth Welds

2015 ◽  
Vol 137 (4) ◽  
Author(s):  
Stijn Hertelé ◽  
Rudi Denys ◽  
Anthony Horn ◽  
Koen Van Minnebruggen ◽  
Wim De Waele
Keyword(s):  
Tensile Strain ◽  
Influence Factor ◽  
Weld Strength ◽  
Strain Capacity ◽  
Strain Behavior ◽  
Weld Geometry ◽  
Girth Welds ◽  
Tearing Resistance ◽  
Tensile Strain Capacity ◽  
Element Study

A key influence factor in the strain-based assessment of pipeline girth weld flaws is weld strength mismatch. Recent research has led to a framework for tensile strain capacity as a function of weld flow stress (FS) overmatch. This framework is built around three parameters: the strain capacity of an evenmatching weldment, the sensitivity of strain capacity to weld FS overmatch, and the strain capacity at gross section collapse (GSC). A parametric finite element study of curved wide plate (CWP) tests has been performed to identify the influence of various characteristics on each of these three parameters. This paper focuses on flaw depth, tearing resistance of the weld, stress–strain behavior of the base metal, and weld geometry. Influences of these characteristics are mostly found to be limited to one or two of the three framework parameters. A preliminary structure is proposed for equations that further develop the strain capacity framework.

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.

Weld Strength Mismatch in Strain Based Flaw Assessment: Which Definition to Use?

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Stijn Hertelé ◽  
Wim De Waele ◽  
Rudi Denys ◽  
Matthias Verstraete ◽  
Koen Van Minnebruggen ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Driving Force ◽  
Experimental Validation ◽  
Weld Strength ◽  
Crack Driving Force ◽  
Strain Capacity ◽  
Strength Based ◽  
Key Factor ◽  
Girth Welds

Weld strength mismatch is a key factor in the strain based assessment of flawed girth welds under tension. A strength overmatching weld shields potential flaws within the weld itself from remotely applied deformations and consequently reduces crack driving force. Although this effect has been recognized for decades, different weld strength overmatch definitions exist, and it is not yet fully established which of those is most relevant to a strain based flaw assessment. In an effort to clarify this unsolved question, the authors have performed a large series of parametric finite element analyses of curved wide plate tests. This paper provides an experimental validation of the model and subsequently discusses representative results. It is found that crack driving force is influenced by the shape of the pipe metals' stress–strain curves, which influences the representativeness of two common mismatch definitions (based on yield strength and on ultimate tensile strength). Effects of strength mismatch on strain capacity of a flawed girth weld are best described on the basis of a flow stress, defined as the average of yield and ultimate tensile strength. Based on the observations, a framework for a new strain capacity equation is proposed.

Effect of Girth Welding on Strain Capacity of X80 SAW Pipes

2014 ◽  
Author(s):  
Hidenori Shitamoto ◽  
Eiji Tsuru ◽  
Hiroyuki Nagayama ◽  
Nobuaki Takahashi ◽  
Yuki Nishi
Keyword(s):  
Matching Condition ◽  
Construction Cost ◽  
Bending Test ◽  
Long Distance ◽  
Strain Capacity ◽  
Girth Welding ◽  
Girth Welds ◽  
Welded Pipe ◽  
Submerged Arc ◽  
Pipe Bending

Application of API X80 grade line pipes has been promoted to reduce a construction cost of the pipeline. Assessment of the strain capacity of X80 submerged arc welded (SAW) pipe is required for strain-based design (SBD). Long distance gas pipelines are usually constructed using girth welded line pipes. In the assessment of the strain capacity, it is important to keep over-matching at girth welds. However, since strength variation exists in base metal and girth weld metal, the value of the matching ratio also changes. In this study, X80 SAW pipes produced by the UOE process were welded under slightly over-matching condition and full-scale pipe bending test of the girth welded pipe was performed to evaluate the effect of the matching ratio on the strain capacity.

Weld Strength Mismatch in Strain Based Flaw Assessment: Which Definition to Use?

2012 ◽  
Author(s):  
Stijn Hertelé ◽  
Wim De Waele ◽  
Rudi Denys ◽  
Matthias Verstraete ◽  
Koen Van Minnebruggen ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Driving Force ◽  
Experimental Validation ◽  
Weld Strength ◽  
Crack Driving Force ◽  
Strain Capacity ◽  
Strength Based ◽  
Key Factor ◽  
Girth Welds

Weld strength mismatch is a key factor in the strain based assessment of flawed girth welds under tension. A strength overmatching weld shields potential flaws within the weld itself from remotely applied deformations and consequently reduces crack driving force. Although this effect has been recognized for decades, different weld strength overmatch definitions exist and it is not yet fully established which of those is most relevant to a strain based flaw assessment. In an effort to clarify this unsolved question, the authors have performed a large series of parametric finite element analyses of curved wide plate tests. This paper provides an experimental validation of the model and subsequently discusses representative results. It is found that crack driving force is influenced by the shape of the pipe metals’ stress-strain curves, which influences the representativeness of two common mismatch definitions (based on yield strength and on ultimate tensile strength). It can be concluded from further observations that effects of strength mismatch on strain capacity of a flawed girth weld are best described on the basis of a flow stress, defined as the average of yield and ultimate tensile strength. Based on the observations, a framework for a new strain capacity equation is proposed.

A Preliminary Strain-Based Design Criterion for Pipeline Girth Welds

2002 ◽  
Author(s):  
Yong-Yi Wang ◽  
David Rudland ◽  
Rudi Denys ◽  
David Horsley
Keyword(s):  
Strain Hardening ◽  
Design Criterion ◽  
Defect Size ◽  
Applied Strain ◽  
Full Scale ◽  
Weld Strength ◽  
Factors Affecting ◽  
Strain Capacity ◽  
Girth Welds ◽  
Strain Hardening Rate

The strain capacity of girth welds containing surface-breaking welding defects is examined through numerical analysis and experimental verification under a PRCI (Pipeline Research Council International) funded project. Some important insights on the various factors affecting the girth weld strain capacity are generated. The defect size is identified as one of the most important factors in determining strain capacity of a girth weld. Other factors, such as the strain hardening rate of the pipe and weld metals, weld strength mismatch, fracture toughness, and weld cap height, can play a significant role if the defect size is within certain limits. It is discovered that the girth weld response to the remotely applied strain may be characterized by a three-region diagram. For a given set of defect size and weld strength mismatch conditions, the crack driving force may be bounded, unbounded, or gradually changing, with respect to the remotely applied strain. A set of parametric equations is developed that allow the computation of allowable strains with the input of defect depth, defect length, CTOD toughness, and weld strength mismatch. The comparison of the developed strain criteria with full-scale bend tests and tensile-loaded CWPs (curved wide plates) shows the criteria are almost always conservative if lower bound CTOD toughness for a given set of welds is used. However, the criteria can significantly underpredict strain capacity of girth welds with short defects. Although defect length correction factors were added to the strain criteria based on the comparison of axisymmetric finite element (FE) results and full-scale bend test results, a more thorough investigation of the effects of defect length on strain capacity is needed. Future investigation that incorporates the finite length defects is expected to greatly reduce the underprediction. The influence of other factors, such as strain hardening rate, should be further quantified.

Microstructure and Mechanical Properties of Girth Weld HAZ in X80 Line Pipe With High Deformability for Strain Based Design Applications

2016 ◽  
Author(s):  
Yu Liu ◽  
Yezheng Li ◽  
Shuo Li ◽  
Zongbin You ◽  
Zhanghua Yin
Keyword(s):  
Mechanical Properties ◽  
Tensile Properties ◽  
Heat Input ◽  
Thermal Simulation ◽  
Impact Testing ◽  
Pipe Material ◽  
Line Pipe ◽  
Microstructure And Mechanical Properties ◽  
Girth Welding ◽  
Girth Welds

X80 line pipe with high longitudinal deformability (X80HD) has been developed and applied in the Strain Based Design (SBD) of pipelines in harsh environment such as seismic areas, permafrost areas, fault zones, etc. For SBD pipelines it is critical that the pipeline girth welds overmatch the tensile properties of the pipe material to avoid local strain accumulation in the girth weld during a strain event. Also, it is important that pipeline girth welds that may experience high strains in operation have sufficient toughness to ensure adequate resistance to failure by fracture. The objective of this research was to gain a better understanding of the influence of chemical composition and essential welding variables on microstructure and properties of the HAZ regions formed in X80HD pipeline girth welds. In this study, by using the weld thermal simulation approach, the peak temperatures (Tp, representative of the distance to the fusion boundary) and the cooling times, particularly between 800 °C and 500 °C (t8/5, representative of the weld heat input), identical to those occurring in the girth weld HAZ of three different X80HD pipe steels, were artificially reproduced. It should be noted that t8/5 is influenced by both heat input and preheat temperature. The weld peak temperatures, Tp, from 500 °C to 1300 °C, in 100 °C increment, whereas the cooling times t8/5 from 5 to 30 seconds were in 5, 15, and 30 seconds, associated with the heat input range of self-shielded flux cored arc welding (FCAW-S). The thermal simulation specimens on tensile properties, Charpy impact toughness, and Vickers hardness were tested and analyzed. Microstructures of these simulated HAZ were characterized by optical microscopy (OM) and scanning electron microscopy (SEM). Finally, the actual FCAW-S girth welding experiments were carried out. These girth welds were subjected to different testing for evaluation of microstructure and mechanical properties of X80HD girth welded joints. These included transverse weld tensile testing, microhardness map of the weld joint, Charpy V-notch impact testing of weld metal and HAZ, and microstructure analysis. The results demonstrated that softening occurs in the fine grained HAZ (FGHAZ) and the inter-critical HAZ (ICHAZ) of X80HD line pipe girth welds. The severity of HAZ softening depends on the steel chemistry and the heat input applied during girth welding. The metallurgical design of the X80HD pipeline steel and the optimization of the girth welding procedures were proposed.

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