Modeling Stress-Activated Creep at Axial Cracks in Pipelines

2020 ◽  
Author(s):  
Brian N. Leis ◽  
Xian-Kui Zhu ◽  
Andrew Cosham
Keyword(s):  
Service Failure ◽  
Operating Pressure ◽  
Element Analysis ◽  
Line Pipe ◽  
Pressure Reversal ◽  
First Case ◽  
Axial Part ◽  
Critical Anomaly ◽  
Stable Growth ◽  
Stable Tearing

Abstract The failure of a pipeline that had just passed a proof-pressure test as it was being re-pressurized for its return to service (a so-called pressure reversal) reflects the stable growth due to stress-activated creep of a near-critical anomaly that had remained stable as the proof test ended. In the same way that stable growth of a near-critical anomaly can lead to a pressure reversal, stable tearing (cracking) can occur and remain stable at the pressure first imposed upon the pipeline’s return to service, and so pose concern for in-service failure. Ductile failures that are absent evidence of time-dependent degradation mechanisms, like corrosion, and show the traits of stable tearing have been termed time-delayed failures. As time passed, the reasons for time-delayed failures became clear, and criteria to prevent such failures through a pressure reduction were established. The advent of much tougher steels opened to the potential for crack initiation and stable tearing at service pressures under circumstances that differed from that for the early line pipe steels. The 2004 incident at Ghislenghien involving a modern high-toughness X70 pipeline raised the need to better understand how to manage time-delayed failures in such steels. This paper develops a model to quantify stable tearing and possible instability at axial part-through-wall defects as a function of the steel, the length and depth of the defect, and the operating pressure. The theoretical basis for this nonlinear fracture mechanics (NLFM) model is outlined first. Case-specific finite-element analysis were used to benchmark NLFM Handbook results, which extended the use of predictive technology developed previously for lower toughness steels. As before, this solution is recast for time-marching analysis that is coupled with isochronous stress-strain response and NLFM resistance curves. Finally, the model is used to make blind predictions of cracking and instability in step-load and hold testing, and found to be viable in that context. Companion papers at this conference present the details of related work.

scholarly journals Analysis for Wrinkling Behavior of Girth-Welded Line Pipe

1996 ◽  
Author(s):  
Luiz T. Souza ◽  
David W. Murray
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Model ◽  
Internal Pressure ◽  
Experimental Test ◽  
Element Model ◽  
Element Analysis ◽  
Line Pipe ◽  
New Era ◽  
Analytical Tools

The paper presents results for finite element analysis of full-sized girth-welded specimens of line pipe and compares these results with the behavior exhibited by test specimens subjected to constant axial force, internal pressure and monotonically increasing curvatures. Recommendations for the ‘best’ type of analytical finite element model are given. Comparisons between the behavior predicted analytically and the observed behavior of the experimental test specimens are made. The mechanism of wrinkling is explained and the evolution of the deformed configurations for different wrinkling modes is examined. It is concluded that the analytical tools now available are sufficiently reliable to predict the behavior of pipe in a manner that was not previously possible and that this should create a new era for the design and assessment of pipelines if the technology is properly exploited by industry.

Do We Need a Safe Excavation Pressure for Dented Pipelines: How Should it Be Defined?

2018 ◽  
Author(s):  
Muntaseer Kainat ◽  
Doug Langer ◽  
Sherif Hassanien
Keyword(s):  
Fracture Mechanics ◽  
Boundary Conditions ◽  
Structural Reliability ◽  
Limit State ◽  
Stress And Strain ◽  
Operating Pressure ◽  
Fitness For Purpose ◽  
Element Analysis ◽  
Overburden Pressure ◽  
Conflicting Objectives

Pipeline operators’ utmost priority is to achieve high safety measures during the lifecycle of pipelines including effective management of integrity threats during excavation and repair processes. A single incident pertaining to a mechanical damage in a gas pipeline has been reported previously which resulted in one fatality and one injury during investigation. Some operators have reported leaking cracks while investigating rock induced dents. Excavation under full operating pressure can lead to changes in boundary conditions and unexpected loads, resulting in failure, injuries, or fatalities. In the meantime, lowering operating pressure during excavation can have a significant impact on production and operational availability. The situation poses two conflicting objectives; namely, maximizing safety and maximizing operational availability. Current pipeline regulations require that operators have to ensure safe working conditions by depressurizing the line to a level that will not cause a failure during the repair process. However, there are no detailed guidelines on how an operator should determine a safe excavation pressure (SEP) level, which could lead to engineering judgment and subjectivity in determining such safety level. While the pipeline industry relies on well-defined fitness for purpose analyses for threats such as crack and corrosion, there is a gap in defining a fitness for purpose for dents and dents associated with stress riser features in order to set an SEP. Stress and strain based assessment of dents can be used in this matter; however, it requires advanced techniques to account for geometric and material nonlinearity. Additionally, loading and unloading scenarios during excavation (e.g. removal of indenter, overburden pressure, etc.) drive a change in the boundary conditions of the pipe that could lead to leakage. Nevertheless, crack initiation or presence within a dent should be considered, which requires the incorporation of crack geometry and application of fracture mechanics in assessing a safe excavation pressure. Recently, there have been advancements in stress and strain based finite element analysis (FEA) of dents coupled with structural reliability analysis that can be utilized to assess SEP. This paper presents a reliability-based approach to determine a safe excavation pressure for dented liquid pipelines. The approach employs nonlinear FEA to model dents interacting with crack features coupled with uncertainties associated with pipe properties and in-line-inspection information. A fracture mechanics-based limit state is formulated to estimate the probability of failure of dents associated with cracks at different levels of operating pressure during excavation. The application of the developed approach is demonstrated through examples within limited scope. Recommended enhancements and future developments of the proposed approach are also discussed.

Standardization of Flattening Procedure of Transverse to Pipe Axis Strap Tensile Samples

2018 ◽  
Author(s):  
M. Rashid ◽  
S. Chen ◽  
L. E. Collins
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Tensile Testing ◽  
Standard Procedure ◽  
Large Diameter ◽  
Spring Back ◽  
Pipe Axis ◽  
Element Analysis ◽  
Line Pipe ◽  
Experimental Approaches

Tensile testing on large diameter line pipe is generally done using strap samples obtained in the transverse to pipe axis (TPA) orientation of a pipe. The strap samples are then flattened and machined prior to testing. Although the standardized tensile testing is well documented, the variability in the reported TPA tensile properties of the same material tested within a lab or at different labs has always been an issue. Recent work conducted at EVRAZ NA research lab has identified flattening as the main source of the variability in reported yield strength (YS) values for line pipe. The lack of a standard procedure for flattening TPA strap samples is a major obstacle to obtaining consistent results. Therefore, the main objective of this current study was to establish a standardized flattening procedure for TPA strap samples. Both finite element analysis (FEA) and experimental approaches were adopted. Various flattening methods and fixtures were studied. Extensive flattening experiments were conducted on TPA samples from different line pipe products. Results showed that the spring back after flattening in a TPA sample is different for pipes with different gauge and grades. It was established that consistent flattening can be achieved using appropriate fixtures for differerent ranges of tubular products defined by grade, diameter and gauges. Evaluation of the flattening fixture designs and experimental results are discussed in this paper.

Development and Implementation of a Risk Based Prioritization Methodology for MAOP Reconfirmation of Gas Transmission Facilities

2016 ◽  
Author(s):  
Wytze Sloterdijk ◽  
Martin Hommes ◽  
Roelof Coster ◽  
Troy Rovella ◽  
Sarah Herbison
Keyword(s):  
Oil And Gas ◽  
Environmental Data ◽  
Operating Pressure ◽  
Line Pipe ◽  
Relative Significance ◽  
Coherent Risk ◽  
Relative Risks ◽  
Short And Long Term ◽  
Selection Of

As part of Pacific Gas and Electric Company’s (PG&E) on-going commitment to public safety, the company has begun a comprehensive engineering validation of its gas transmission facilities that will ultimately support the reconfirmation of maximum allowable operating pressure (MAOP) for these assets. In addition to 6,750 miles of line pipe, PG&E’s gas transmission system contains over 500 station facilities. Since this set of facilities is not only large but diverse, and the validation effort for these facilities is expected to be an extensive, multi-year process, a methodology for the prioritization of the facilities needed to be developed to facilitate planning of the process for the efficient mitigation of risk. As a result, DNV GL was retained to develop and implement a risk-based prioritization methodology to prioritize PG&E’s gas transmission facilities for the engineering validation and MAOP reconfirmation effort. Ultimately, a weighted multiple criteria decision analysis (MCDA) approach was selected and implemented to generate the prioritization. This MCDA approach consisted of the selection of relevant criteria (threats) and the weighting of these criteria according to their relative significance to PG&E’s facilities. Relevant criteria selected for inclusion in the analysis include factors that are important in order to assess both the short- and long-term integrity of the facility as a whole as well as the integrity of features for which design records cannot be located. The criteria selected encompass stable threats, time-dependent threats, as well as environmental impact. Enormous amounts of data related to design, operations, maintenance history and meteorological and seismic activity in addition to other environmental data were evaluated with this newly developed methodology to assess the relative risks of the facilities. Pilot field visits were performed to validate the selection of the various criteria and to confirm the outcome of the analysis. The novelty of this approach lies in the prioritization of facilities in a coherent risk-based manner. The described approach can be used by operators of oil and gas facilities, either upstream, midstream or downstream.

Accelerating the Product Development of a Commercial Vehicle Radiator using Finite Element Analysis

2017 ◽  
Vol 9 (1) ◽  
Author(s):  
P.R. Roy ◽  
V. Hariram ◽  
M. Subramanian
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Product Development ◽  
Commercial Vehicle ◽  
Cooling System ◽  
Experimental Testing ◽  
Engine Oil ◽  
Operating Pressure ◽  
Element Analysis ◽  
Engine Cooling

Emissions such as Nox and CO resulting from the combustion of the diesel engines in the commercial vehicles leads to environmental degradation and ozone layer depletion. Alarming environment trend forces the government institutions to develop and enforce strict emission laws for the next generation transportation vehicles. Stricter emission laws mean higher operating pressure, temperature, reduced weight, tight packaging space, engine downsizing etc. Engine cooling systems are the critical components in the managing the engine cooling requirement of the commercial vehicle. Generally engine cooling system includes radiator, charge air cooler, engine oil cooler etc. Product development of thermal management system using the traditional design process takes more time, resource and money. To solve the complex design problem, numerical technique such as finite element analysis is performed upfront in the product development of the radiator to evaluate the structure behaviour under mechanical loading. In this paper, internal static pressure analysis of a radiator is presented to showcase the benefits of using the finite element technique earlier in the product design phase. Pressure cycle life at a critical joint of the radiator is calculated using strain-life approach. Finite element analysis aids in visualization of the hot spots in the design, comparing different design options with less turnaround time. Experimental testing and prototypes can be reduced. Risk of a product being failed is greatly minimized by performing the numerical simulation.

Simulation of Low Pressure MEMS Sensor for Biomedical Application

2011 ◽  
Vol 2 (3) ◽  
Author(s):  
S. Sathyanarayanan ◽  
A. Vimala Juliet
Keyword(s):  
Pressure Sensor ◽  
Microelectromechanical Systems ◽  
Biomedical Application ◽  
Applied Pressure ◽  
Analysis Data ◽  
Operating Pressure ◽  
Capacitive Pressure Sensor ◽  
Element Analysis ◽  
Mems Sensor ◽  
Relationship Of

Micromachining technology has greatly benefited from the success of developments in implantable biomedical microdevices. In this paper, microelectromechanical systems (MEMS) capacitive pressure sensor operating for biomedical applications in the range of 20–400 mm Hg was designed. Employing the microelectromechanical systems technology, high sensor sensitivities and resolutions have been achieved. Capacitive sensing uses the diaphragm deformation-induced capacitance change. The sensor composed of a rectangular polysilicon diaphragm that deflects due to pressure applied over it. Applied pressure deflects the 2 µm diaphragm changing the capacitance between the polysilicon diaphragm and gold flat electrode deposited on a glass Pyrex substrate. The MEMS capacitive pressure sensor achieves good linearity and large operating pressure range. The static and thermo electromechanical analysis were performed. The finite element analysis data results were generated. The capacitive response of the sensor performed as expected according to the relationship of the spacing of the plates.

Structural Integrity of Hydrogen Storage Tanks at Pre-Stressing and Operating Pressures

2005 ◽  
Author(s):  
J. L. Parham ◽  
Y. B. Guo ◽  
W. H. Sutton
Keyword(s):  
Hydrogen Storage ◽  
Stress Level ◽  
Structural Integrity ◽  
Real Life ◽  
Peak Stress ◽  
Operating Pressure ◽  
Middle Section ◽  
Element Analysis ◽  
Residual Strains ◽  
Simulation Results

With the fuel prices reaching record highs and ever-increasing tighter environmental policies, hydrogen-powered vehicles have great potential to substantially increase overall fuel economy, reduce vehicle emissions, and decrease dependence on foreign oil imports. While hydrogen fuel is exciting for automotive industries due to its potentials of significant technical and economic advantages, design and manufacture safe and reliable hydrogen tanks is recognized as the number one priority in hydrogen technology development and deployment. Real life testing of tank performance is extremely useful, but very time consuming, expensive, and lacks a rigorous scientific basis, which prohibits the development of a more reliable hydrogen tank. However, very few testing and simulation results can be found in public literature. This paper focused on the development of an efficient finite element analysis (FEA) tool to provide a more economical alternative for hydrogen tank analysis, though it may not be an all-out replacement for physical testing. A FEA model has been developed for the hydrogen tank with 6061-T6 aluminum liner and carbon-fiber/epoxy shell to investigate the tank integrity at pre-stresses of 45.5 MPa, 70 MPa, and 105 MPa and operating pressures of 35 MPa, 70 MPa, and 105 MPa. The residual stresses induced by different pre-stresses are at the equivalent level in the middle section but vary significantly in other tank sections. Residual stress magnitudes may saturate at a certain pre-stress level. In contrast, the residual strains in the middle section increases with pre-stress. The simulation results indicate that the optimal pre-stress level depends on the specific operating pressure to enhance tank integrity. A certain area of the neck and the top and bottom domes also experiences peak stress and strain at pre-stressing and regular operating pressures. The research findings may help manufacturing industries to build safety into manufacturing practices of hydrogen storage infrastructures.

Analysis for Wrinkling Behavior of Girth-Welded Line Pipe

1999 ◽  
Vol 121 (1) ◽  
pp. 53-61
Author(s):  
L. T. Souza ◽  
D. W. Murray
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Model ◽  
Internal Pressure ◽  
Experimental Test ◽  
Element Model ◽  
Element Analysis ◽  
Line Pipe ◽  
New Era ◽  
Analytical Tools

The paper presents results for finite-element analysis of full-sized girth-welded specimens of line pipe and compares these results with the behavior exhibited by test specimens subjected to constant axial force, internal pressure, and monotonically increasing curvatures. Recommendations for the “best” type of analytical finite element model are given. Comparisons between the behavior predicted analytically and the observed behavior of the experimental test specimens are made. The mechanism of wrinkling is explained and the evolution of the deformed configurations for different wrinkling modes is examined. It is concluded that the analytical tools now available are sufficiently reliable to predict the behavior of pipe in a manner that was not previously possible and that this should create a new era for the design and assessment of pipelines if the technology is properly exploited by industry.

Analysis of Contact Pressure Distribution on 3-Bolt Self-Energized Connector Seals

2009 ◽  
Author(s):  
Rajeev Madazhy ◽  
Sheril Mathews ◽  
Erik Howard
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Pressure Distribution ◽  
Contact Pressure ◽  
Maximum Pressure ◽  
Operating Pressure ◽  
Seal Ring ◽  
Contact Pressure Distribution ◽  
Element Analysis ◽  
Novel Design

A novel design using 3 bolts for a self-energized seal connector is proposed for quick assembly applications. Contact pressure distribution on the surface of the seal ring during initial bolt-up and subsequent operating pressure is analyzed for 3″ and 10″ connectors using Finite Element Analysis. FEA is performed on a 3″ and 10″ ANSI RF flange assembly and contact pressure distribution on the RF gasket is compared with the tapered seal ring assemblies. Hydrostatic tests are carried out for the tapered seal and ANSI bolted connectors to evaluate maximum pressure at which leak occurs for both size assemblies.

Rational Stress Limits and Load Factors for Finite Element Analyses in Pipeline Applications: Part III — Elastic-Plastic Load Factor Development

2016 ◽  
Author(s):  
Rhett Dotson ◽  
Chris Alexander ◽  
Ashwin Iyer ◽  
Al Gourlie ◽  
Richard Kania
Keyword(s):  
Finite Element ◽  
Case Studies ◽  
Large Diameter ◽  
Load Factor ◽  
Pipe Material ◽  
Line Pipe ◽  
Elastic Plastic ◽  
First Case ◽  
Load Factors

In this paper, a methodology is presented to develop load factors for use in elastic-plastic assessments of pipelines and their components. The load factors are based on the pipe material properties and the ASME pipeline code’s design margin for the service and location of the pipeline installation [1, 2]. These codes are recognized by 49 CFR 192 and 195 [3, 4]. Minimum required load factors for internal pressure loads can be derived analytically based on design equations from the ASME B31 piping codes and minimum material requirements for API 5L line pipe [6]. Once the load factor is established for a particular case, the elastic-plastic methodology may be used in the Finite Element Analysis (FEA) of pipelines and related components. This methodology is particularly useful in the assessment of existing systems when linear elastic numerical analysis shows that local stresses may exceed the elastic design limits. Two case studies are presented showing analyses performed with Abaqus [5], a commercial, general purpose FEA software package. The first case study provides an assessment of a large diameter elbow where the stress on the outer fibers of the intrados exceeded the longitudinal stress limits from B31.8. The second case study examines an assessment of a tee connection where the stresses on the ID exceeded the yield strength of the component. In addition to the case studies, the paper also presents the results of a full-scale test that demonstrated what margin was present when the numerical calculations were based on specified minimum properties. This paper is not intended to revise or replace any provision of B31.4 and/or B31.8 [1, 2]. Instead, it provides the means for calculating load factors that can be used with an elastic-plastic analysis approach in a manner that provides the same design margins as the ASME B31 codes. The approach described in this paper is intended for use in the detailed FEA of pipelines and their associated components.

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