Electromagnetic Induction Post Heating to Reduce NDE Delay Times of Welding In-Service Repairs

2020 ◽  
Author(s):  
Liam Hagel ◽  
Jonathan Prescott ◽  
Alireza Kohandehghan ◽  
Stuart Guest ◽  
Sean Lepine
Keyword(s):  
Stress Concentration ◽  
Hydrogen Concentration ◽  
Induction Heating ◽  
Thermal Convection ◽  
Heat Affected Zone ◽  
Hydrogen Diffusion ◽  
Heat Removal ◽  
High Energy ◽  
Fillet Weld ◽  
Delay Times

Abstract When a pipeline requires a repair, a pressure-containing steel sleeve or an emergency repair fitting is often fillet welded to the in-service pipe to return the pipeline to normal service conditions. During welding, the flowing product rapidly quenches the fillet weld, promoting the formation of high hardness and low ductility microstructures in the heat-affected zone. The rapid cooling rates also limit the mobility of diffusible hydrogen introduced from the welding electrodes. The hydrogen can be trapped in the weld metal and heat-affected zone and concentrated in specific locations throughout the weld based on the welding deposition sequence. Fillet welds also contain inherent locations of geometric stress concentration at the weld toes and root locations. The elevated hydrogen concentration in the in-service weld, combined with the geometrical stress concentrations at the location of crack-susceptible microstructures, can increase the likelihood of forming a hydrogen-induced crack. Delayed non-destructive examination (NDE) is often employed to wait a sufficient time for any cracks to form so they can be detected. To reduce hydrogen concentration at the locations of stress concentration and NDE delay times, post-heating can be applied to the in-service weld. Elevating the temperature within the weld can enable hydrogen diffusion and reducing the cracking propensity. The rapid heat removal due to flowing product requires post-heating techniques with high energy outputs that will not overheat the steel surfaces. Electromagnetic induced current (induction heating) methods can produce sufficient thermal energy in the electrically conductive steel pipe and sleeve. Coupled numerical finite element analysis (FEA) models were utilized to simulate various induction cable arrangements and thermal convection coefficients, representative of various pipeline products. The analysis of the induction heating arrangements for the studied thermal convection coefficient was conducted to achieve a minimum temperature of 120 °C in the fillet weld root and toes to enable sufficient thermal driving force for hydrogen diffusion while ensuring the pipe and sleeve surface temperature does not exceed 200 °C. An optimal induction heating procedure was found to which could achieve the target temperatures within a reasonable heating time such that NDE delay times of in-service welds can be reduced by 5–6 times.

Investigation of Hydrogen Diffusion Characteristics of the Heat Affected Zone of 2.25Cr-1Mo-0.25V Steel by an Electrochemical Permeation Method

2019 ◽  
Author(s):  
Xin Song ◽  
Zelin Han ◽  
Bin Liu ◽  
Mu Qin ◽  
Yuancai Duo ◽  
...  
Keyword(s):  
Grain Boundaries ◽  
Hydrogen Concentration ◽  
Heat Affected Zone ◽  
Hydrogen Diffusion ◽  
Trap Density ◽  
Hydrogen Diffusivity ◽  
Hydrogen Flux ◽  
Hydrogen Trap ◽  
Diffusion Characteristics ◽  
Effective Hydrogen

Abstract The heat affected zone (HAZ) of 2.25Cr-1Mo-0.25V welded joint is a critical part for the safety of hydrogenation reactors. Hydrogen has a significant effect on the HAZ, studying hydrogen diffusion characteristics, such as: hydrogen flux and the effective hydrogen diffusivity has a remarkable value in investigating the hydrogen-induced material degradation mechanisms. In this work, an electrochemical permeation method was applied to study the hydrogen diffusion characteristics of HAZ. Then, the metallographic microscope and a software “Image J” were used to analyze the density of grain boundaries of HAZ. The effect of the post–weld heat treatment (PWHT, i.e. annealing) on the hydrogen diffusion characteristics of HAZ was also been investigated. The results show that after PWHT, the effective hydrogen diffusivity of HAZ increases from 1.63 × 10−7cm2·s−1 to 3.68 × 10−7cm2·s−1, the hydrogen concentration decreases from 1.92 × 10−4mol·cm−3 to 1.09 × 10−4mol·cm−3, and the hydrogen trap density decreases from 3.00 × 1026m−3 to 0.76 × 1026m−3. Thus, PWHT can significantly reduce density of grain boundaries, thereby reducing the hydrogen trap density, enhancing the hydrogen diffusivity and reducing the hydrogen concentration.

Minimization of Heat-Affected Zone Size in Welded Ultra-Fine Grained Steel under Cooling by Liquid Nitrogen during Laser Welding

2007 ◽  
Vol 539-543 ◽  
pp. 4063-4068 ◽  
Author(s):  
Hideki Hamatani ◽  
Yasunobu Miyazaki ◽  
Tadayuki Otani ◽  
Shigeru Ohkita
Keyword(s):  
Laser Welding ◽  
Liquid Nitrogen ◽  
Heat Affected Zone ◽  
Laser System ◽  
Heat Removal ◽  
Plate Temperature ◽  
Fine Grained ◽  
Laser Beam Irradiation ◽  
Average Grain Size ◽  
Plume Temperature

Ultra-fine grained steel (UFGS) with an average grain size of less than 1μm has been developed and is expected to demonstrate superior properties. However, its welded heat-affected zone, HAZ, substantially affecting the strength of a welded joint, will be easily softened after welding. Therefore, minimization of UFGS’s HAZ size during laser welding was carried out using the cooling conductor liquid nitrogen. It was found that a shielding gas with adequate flow rate for the liquid nitrogen depth was used to displace nitrogen on the area of laser beam irradiation to stabilize the weld bead. Also, because YAG laser system was mainly used because it has a lower laser induced plasma or plume temperature, which results in a decreased occurrence of pit and blowhole. HAZ size minimization strongly depends on the initial plate temperature. Reduced initial plate temperature shrinks the specific heated temperature range in which softening occurs. However, due possibly to decreasing thermal conductivity under room temperature, which prevents heat removal, the benefit of reducing the initial plate temperature is limited. The optimal initial temperature to minimize the HAZ size, in the present work, was found to be 123K.

Justification for Reducing In-Service Weld Inspection Delay Times for Liquid Pipelines

2018 ◽  
Author(s):  
Matt Boring ◽  
Mike Bongiovi ◽  
David Warman ◽  
Harold Kleeman
Keyword(s):  
Hydrogen Concentration ◽  
Delay Time ◽  
Time Dependent ◽  
Accelerated Cooling ◽  
Hydrogen Cracking ◽  
Inspection Method ◽  
Time To Peak ◽  
Preventative Measures ◽  
Increased Risk ◽  
Delay Times

Welds that are made onto an operating pipeline cool at an accelerated rate as a result of the flowing pipeline contents cooling the weld region. The accelerated cooling rates increase the probability of forming a crack-susceptible microstructure in the heat-affected zone (HAZ) of in-service welds. The increased risk of forming such microstructures makes in-service welds more susceptible to hydrogen cracking compared to welds that do not experience accelerated cooling. It is understood within the pipeline industry that hydrogen cracking is a time-dependent failure mechanism. Due to the time-dependent nature and susceptibility of in-service welds to hydrogen cracking, it is common to delay the final inspection of in-service welds. The intent of the delayed inspection is to allow hydrogen cracks, if they were going to occur, to form so that the inspection method could detect them and the cracks could repaired. Many industry codes provide a single inspection delay time. By providing a single inspection delay time it is implied that the inspection delay time should be applied for all situations independent of the welding conditions or any other preventative measures the company may employee. There are many aspects that should be addressed when determining what should be considered an appropriate inspection delay time and these aspects can vary the inspection delay time considerably. Such factors include the cooling characteristics of the operating pipeline, the welding procedure that is being followed, the chemical composition of the material being welded and if any preventative measures such as post-weld heating are applied. The objective of this work was to provide an engineering justification for realistic minimum inspection delay times for different in-service welding scenarios. The minimum inspection delay time that was determined was based on modelling results from a previously developed two-dimensional hydrogen diffusion model that predicts the time to peak hydrogen concentration at any location within a weld HAZ. The time to peak hydrogen concentration was considered equal to the minimum inspection delay time since the model uses the assumption that if a weld was to crack the cracking would occur prior to or at the time of peak hydrogen concentration. Several factors were varied during the computer model runs to determine the effect they had on the time to peak hydrogen concentration. These factors included different welding procedures, different material thicknesses and different post-weld heating temperatures. The post-weld heating temperatures were varied between 40 F (4 C) and 300 F (149 C). The results of the analysis did provide justification for reducing the inspection delay time to 30 minutes or less depending on the post-weld heating temperature and pipeline wall thickness. This reduction in inspection delay time has the potential to significantly increase productivity and reduce associated costs without increasing the associated risk to pipeline integrity or public safety.

scholarly journals Experimental Research and Numerical Simulation of Weld Repair with High Energy Spark Deposition Method

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 980 ◽  
Author(s):  
Yingjie Zhang ◽  
Kai Yang ◽  
Jianping Zhao
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Residual Stress ◽  
Heat Affected Zone ◽  
Welded Joints ◽  
High Energy ◽  
Repair Welding ◽  
Repair Processes ◽  
Repair Technology ◽  
Surface Repair

For long-serviced pressure equipment that is under severe working conditions such as a high temperature, high pressure, and corrosion, the material properties and structure will be unavoidably damaged or degraded, especially cracks and other damages at key positions such as welded joints, which seriously threaten the safe operation of the equipment. In order to promote the sustainable development of industries such as the chemical and petrochemical industries, remanufacturing technology has emerged worldwide, and various surface repair processes have also rapidly developed. As an important branch of surface repair technology, the high energy spark deposition (HESD) process is a new pulse cold welding repair technology developed from electro-spark deposition, which combines the advantages of multiple surface repair processes. The HESD process has the characteristics of a smaller heat affected zone and lower welding residual stress. It is a new type of repair method that is worthy of popularization and application. The process has been initially applied in the fields of surface modification and die steel repair. In this paper, the application of the HESD process to the repair of welded joints was introduced, the mechanical properties of the joints and the residual stress distribution after welding were analyzed, and the feasibility of HESD as a repair welding method for pressure structures was discussed. First, a numerical simulation of the temperature and stress field of HESD was proposed by using ABAQUS and the related subprograms, and the validity of the simulation results was verified by the residual stress test with the indentation strain method. Due to the precise control of the heat and pulse discharge working mode, the heat-affected zone and deformation caused by the HESD were extremely small, and the residual stress that was generated was low and only concentrated on the repair welding seam. Second, according to the numerical simulation and the test results of the mechanical properties of the welded joint, the optimal repair welding process parameters were obtained through the orthogonal experiment: peak current 45 A, pulse width 90 ms, and output voltage 10 V.

Experimental investigation on new low cycle fatigue precision cropping process

2014 ◽  
Vol 229 (8) ◽  
pp. 1470-1476 ◽  
Author(s):  
Renfeng Zhao ◽  
Shengdun Zhao ◽  
Bin Zhong ◽  
Yong Tang
Keyword(s):  
Stress Concentration ◽  
Cross Sections ◽  
Low Cycle Fatigue ◽  
Fatigue Loading ◽  
High Energy ◽  
Concentration Effect ◽  
Cycle Fatigue ◽  
Stable Crack Propagation ◽  
New Type ◽  
Stress Concentration Effect

The traditional cropping processes have some disadvantages, such as poor surface quality, low yield, the waste of materials, and high energy consumption. The low cycle fatigue precision cropping process with circumferential loading, which is a new type of precision cropping process, is studied. According to the stress concentration effect of the V-shape notch, the fatigue crack on the tip of the V-shape notch is prompted to initiate and extend. The working principle of the precision cropping machine is described. The criterion that whether the crack on the root of the V-shape notch is initiated or not is provided under the effect of low cycle fatigue loading. The materials which are 0.2%C steel, H59 copper, 0.45%C steel, 20Cr steel, and LY12 aluminum are tested under two control curves. The initiation and propagation of crack are accelerated and the good cross sections of the metal bar are obtained. The results show that the mean stress of the metal bar in the cropping process can be effectively reduced due to the stress concentration effect of the V-shape notch. The metal bar’s stable crack propagation and fracture can be obtained when constantly increasing striking displacement and reducing the striking frequency in the cropping process at the same time in the process.

A Parametric Optimization Approach of an Induction Heating System for Energy Consumption Reduction

2017 ◽  
Author(s):  
Paolo Cicconi ◽  
Anna Costanza Russo ◽  
Mariorosario Prist ◽  
Francesco Ferracuti ◽  
Michele Germani ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Induction Heating ◽  
Heating System ◽  
High Energy ◽  
Design Parameters ◽  
Optimization Approach ◽  
Multi Objective Optimization ◽  
Molding Process ◽  
Multi Objective ◽  
Induction Heating System

Nowadays, electromagnetic high-frequency induction is very used for different non-contact heating applications such as the molding process. Every molding process requires the preheating and the thermal maintenance of the molds, to enhance the filling phase and the quality of the final products. In this context, an induction heating system, mostly, is a customized equipment. The design and definition of an induction equipment depends on the target application. This technology is highly efficient and performant, however it provides a high-energy consumption. Therefore, optimization strategies are very suitable to reduce energy cost and consumption. The proposed paper aims to define a method to optimize the induction heating of a mold in terms of time, consumption, and achieved temperature. The proposed optimization method involves genetic algorithms to define the design parameters related to geometry and controller. A test case describes the design of an induction heating system for a polyurethane molding process, which is the soles foaming. This case study deals with the multi-objective optimization of parameters such as the geometrical dimensions, the inductor sizing, and the controller setting. The multi-objective optimization aims to reduce the energy consumption and to increase the wall temperature of the mold.

scholarly journals Investigation of Strong Strata Behaviors in the Close-Distance Multiseam Coal Pillar Mining

2021 ◽  
Vol 2021 ◽  
pp. 1-14
Author(s):  
Hongwei Mu ◽  
Yongsheng Bao ◽  
Dazhao Song ◽  
Dongfang Su
Keyword(s):  
Computed Tomography ◽  
Theoretical Model ◽  
Stress Concentration ◽  
Stress Distribution ◽  
Coal Pillar ◽  
High Energy ◽  
Support Pressure ◽  
Pillar Mining ◽  
Coal Pillars ◽  
Close Distance

According to the new stress distribution pattern and the strong strata behaviors as the characteristics of the coal pillars in the close-distance multiseam coal pillar mining, the common characteristics of different types of overlying coal pillars were summarized and analyzed. Moreover, a theoretical model for the mechanism of strong strata behaviors in the close-distance multiseam coal pillar mining was established, which was validated by the monitoring data of seismic computed tomography CT, microseism, and electromagnetic radiation (EMR). Furthermore, the results of the study indicated that the main factors affecting the strong strata behaviors were the static stress concentration caused by the overlying coal pillars and the dynamic disturbance caused by the fracturing and slipping of the overlying coal pillars and roof under the influence of mining. In the case of Xinzhouyao coal mine, the transmitted stress and lateral support pressure of the overlying coal pillars accounted for 78.3% and 16% of the vertical concentrated stress, respectively, and the areas closer to the overlying coal pillars were more susceptible to dynamic load disturbances. The monitoring results of seismic computed tomography CT and EMR demonstrated the static load stress concentration area was distributed near the overlying coal pillar, and the stress concentration degree was greater in the area of superimposed lateral support pressure and advanced support pressure. Moreover, microseismic spatial positioning revealed that the high-energy microseismic events were mainly concentrated near the overlying large coal pillars and roof. The on-site multiparameter detection results were highly consistent with the characteristics of actual strata behaviors and the conclusions of the theoretical model. This method could provide a reference for the quantitative calculation of stress distribution under similar conditions and the identification of the danger zone of strata behaviors.

scholarly journals Study on the impact of lack of fusion in the fillet weld on its fatigue strength under various load combinations

2020 ◽  
Vol 92 (1) ◽  
pp. 17-24
Author(s):  
Kwiryn Wojsyk ◽  
Jerzy Nawrocki
Keyword(s):  
Fatigue Strength ◽  
Stress Concentration ◽  
Tensile Test ◽  
T Joints ◽  
Fillet Weld ◽  
Fatigue Score ◽  
Experimental Part ◽  
Lack Of Fusion ◽  
Static Tensile ◽  
The Impact

The article refers to the issue of incomplete penetration in T-joints allowed by the obligatory Eurocode EN 1993-1-8. Based on it, the joint’s model was made, and then they were FEM simulated in various load combinations. As a result of this simulation, a Whöller's welded joints diagram was obtained. In the experimental part a T-joint was made. A static tensile test was carried out on it, which showed the areas of stress concentration and plasticization anticipated earlier during the simulation. The study concluded that the lack of mutual penetration of fillet welds generates a significant fatigue score.

scholarly journals Design of an electromagnetic induction steam generator device based on air source heat pump

2022 ◽  
Vol 355 ◽  
pp. 02059
Author(s):  
Zhimo Li ◽  
Jiachun Li ◽  
Xiangli Dong ◽  
Bo Chen ◽  
Qing Li
Keyword(s):  
Heat Pump ◽  
Steam Generator ◽  
Induction Heating ◽  
Electromagnetic Induction ◽  
High Energy ◽  
Heat Pumps ◽  
Outlet Temperature ◽  
Air Source Heat Pump ◽  
Electromagnetic Induction Heating ◽  
Heating Technology

Aiming at the current problems of coal-fired boilers and electromagnetic induction steam generators for environmental pollution and high energy consumption, this article combines air source heat pumps and electromagnetic induction heating technology, and at the same time carries out the structure of the condensate tank and electromagnetic induction steam generator. Redesign. Through trial production and experimentation of the prototype, the results show that compared with traditional coal-fired boilers and separate electromagnetic induction heating technology to generate steam, this device not only achieves energy saving and environmental protection, but also the stability of the steam outlet temperature and the amount of steam generated. Compared with the use of electromagnetic induction heating alone, it has increased by 20%. It can be seen that the use of air source heat pump’ electromagnetic induction heating technology to generate steam saves energy and increases the amount of steam generated.

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