Cost Effective Fabrication of Large Diameter High Strength Titanium Catenary Riser

2002 ◽  
Author(s):  
Agnes Marie Horn ◽  
Mons Hauge ◽  
Per-Arne Ro̸stadsand ◽  
Bjarne Bjo̸rnbakk ◽  
Peer Dahlberg ◽  
...  
Keyword(s):  
Fatigue Testing ◽  
Fatigue Cracks ◽  
Large Diameter ◽  
High Strength ◽  
Cost Effective ◽  
Full Scale ◽  
Scale Production ◽  
Wear Properties ◽  
Field Development ◽  
Main Challenge

A large diameter high strength titanium free-hanging catenary riser was evaluated by the Demo 2000 Ti-Rise project, from initiative of the Kristin Field development license. In order to reduce the uncertainties related to the schedule, cost, and special technical issues identified in the work related to a similar riser for future installation on the A˚sgard B semi-submersible platform, a fabrication qualification of a full scale riser in titanium was run. Several full-scale production girth welds were made in an in-situ fabrication environment. The welding was performed on extruded titanium grade 23 (ASTM) pipes with an ID of 25.5″) and wall thickness of 30 mm. The main challenge was to develop a highly productive TIG orbital welding procedure, which produced welds with as low pore content as possible. It is well known that sub-surface pores often are initiation sits for fatigue cracks in high strength titanium welds. This paper describes how a greatly improved productivity was obtained in combination with a high weld quality. NDT procedures were developed whit the main on the reliability to detect and locate possible sub-surface weld defects, volumetric defects such as pores and tungsten particles and planar defects such as lack of fusion. The results from the actual Non Destructive Testing (NDT), the mechanical testing, and the fatigue testing of the subjected welds are presented. The response of the catenary is optimised by varied distribution of weight coating along the riser’s length. A satisfactory weight coating with sufficient strength, bond strength, and wear properties was developed and qualified. The riser is planned to be fabricated from extruded titanium pipes, welded together onshore to one continuous piece. The field coating is added and the riser is loaded into the sea and towed offshore and installed.

Use of DNVGL-RP-C203 for Determining the Fatigue Capacity of Connectors

2021 ◽  
Author(s):  
Anthony Muff ◽  
Anders Wormsen ◽  
Torfinn Hørte ◽  
Arne Fjeldstad ◽  
Per Osen ◽  
...  
Keyword(s):  
Finite Element ◽  
Fatigue Testing ◽  
Experimental Testing ◽  
High Strength ◽  
Element Model ◽  
Fatigue Analysis ◽  
Full Scale ◽  
The Finite Element Model

Abstract Guidance for determining a S-N based fatigue capacity (safe life design) for preloaded connectors is included in Section 5.4 of the 2019 edition of DNVGL-RP-C203 (C203-2019). This section includes guidance on the finite element model representation, finite element based fatigue analysis and determination of the connector design fatigue capacity by use of one of the following methods: Method 1 by FEA based fatigue analysis, Method 2 by FEA based fatigue analysis and experimental testing and Method 3 by full-scale connector fatigue testing. The FEA based fatigue analysis makes use of Appendix D.2 in C203-2019 (“S-N curves for high strength steel applications for subsea”). Practical use of Section 5.4 is illustrated with a case study of a fatigue tested wellhead profile connector segment test. Further developments of Section 5.4 of C203-2019 are proposed. This included acceptance criteria for use of a segment test to validate the FEA based fatigue analysis of a full-scale preloaded connector.

Deformation Measurements on Full-Scale Fracture Tests of Pre-Cracked Tubular Joints

2003 ◽  
Author(s):  
Bijan Talei-Faz ◽  
Feargal P. Brennan ◽  
Stuart Robson
Keyword(s):  
Large Scale ◽  
Fatigue Testing ◽  
Three Dimensional ◽  
Steel Structures ◽  
High Strength ◽  
Static Strength ◽  
Full Scale ◽  
Structural Testing ◽  
Tubular Joints ◽  
Large Steel

A series of six static strength destructive tests were performed on full-scale pre-cracked tubular welded T-joints manufactured from a high strength weldable steel used in the construction of offshore Jack-Up platforms. All specimens had at least one through-thickness fatigue crack at the weld toe, from a previous fatigue-testing programme. The tests were aimed at analysing the residual static strength of the cracked members. As destructive tests are costly to perform, every effort was made to maximise the data collected. This included the use of a novel photogrammetric technique to provide three-dimensional measurement in real time of the deformation in the vicinity of the brace-chord intersection. The technique has been used for large-scale structural testing in a number of civil and aerospace applications, but to the author’s knowledge this is the first time that it has been employed for the full-scale mechanical testing of large steel structures. This paper describes the details of the photogrammetric technique applied to the large steel specimens which were loaded to failure, resulting in the total separation of the intersecting members. It is hoped that the technique can be used to generate information which can be used in conjunction with finite element or other numerical analyses to increase the accuracy and reliability of modelling cracked tubular joints.

Crack Propagation Versus Crack Initiation Lives of FPSO Weld Details

2010 ◽  
Author(s):  
Inge Lotsberg ◽  
Mamdouh M. Salama
Keyword(s):  
Crack Initiation ◽  
Crack Propagation ◽  
Fatigue Testing ◽  
Fatigue Cracks ◽  
Full Scale ◽  
Test Results ◽  
Inspection Strategy ◽  
Scale Test ◽  
Crack Initiation Life

Documentation of a long crack propagation phase is important for planning a sound inspection program for fatigue cracks in FPSOs. Test results of full scale FPSO weld details have shown that fatigue lives of FPSO details are governed by crack propagation and that crack propagation lives are several times that of the crack initiation life. However, some analysis packages predict a short crack propagation life until failure compared to the crack initiation life. These predictions are not consistent with full scale test results and thus cannot be relied on in developing inspection strategy. The reason for this inconsistency in analysis as compared with test results may be due to limitations in the analysis program packages. The paper presents analysis of fatigue testing data on several full scale FPSO weld details. The paper also discusses the effect of “shake-down’ that is not simulated in the full scale constant amplitude testing and would even lead to longer crack propagation lives under the actual long term loading on FPSOs.

Numerical Simulation Analysis of High Strength UOE Steel Pipes

2008 ◽  
Author(s):  
Juliana E. Roza ◽  
Giuliano Malatesta ◽  
Marcelo C. Fritz ◽  
Gianluca Mannucci ◽  
Luis Chad ◽  
...  
Keyword(s):  
Natural Gas ◽  
Simulation Analysis ◽  
Large Diameter ◽  
High Strength ◽  
Cost Effective ◽  
Element Model ◽  
Outer Diameter ◽  
High Grade ◽  
Technical Requirements ◽  
Forming Tools

Large diameter longitudinally welded linepipes have to fulfil increasing technical requirements in order to guarantee best performance during construction and service. The increase in natural gas demand in European, North American, South American and Asian countries, foreseen for the immediate future, necessitates the development of cost effective transportation solutions to economically exploit gas fields located in remote area. A competitive option of gas to market is represented by the use of high-pressure natural gas transmission pipelines. In particular, for natural gas transportation over long distances, the use of high grade steel (X80, X100 or even higher) large diameter (36″ to 56″ of outer diameter), gas pipelines is found to be very attractive and economical. With respect to SAW pipes attention is focused on seam weld consumables and forming tools. In particular, forming tools must be designed in order to manage the large spring back effect that high grade plates, such as those for X100 pipes, exhibits when the pipes go from the U-press to the O-press. The objective of this paper is to present the evaluation of X100 pipes inside the UOE process from TenarisConfab mill with a mathematic modeling to get the best parameters. The X100 production process has been analyzed via Finite Element Model to evaluate goodness of tools geometry and pipe mill capability to produce higher grades pipes.

scholarly journals Performance of a UASB Effluent Treatment Plant Treating Malt Ingredient Manufacturing Wastewater

2017 ◽  
Vol 6 (2) ◽  
pp. 198 ◽  
Author(s):  
Ryland Cairns ◽  
Paul Mead
Keyword(s):  
Treatment Plant ◽  
High Strength ◽  
Cost Effective ◽  
Full Scale ◽  
Effluent Treatment ◽  
Operational Performance ◽  
Organic Loading Rate ◽  
Anaerobic Sludge ◽  
Effluent Treatment Plant ◽  
Wide Range

Anaerobic Digestion has gained popularity in recent years due to its significant contribution towards achieving waste management and renewable energy targets. One particular technology that has been widely used in the treatment of high strength organic wastewaters across a wide range of industries is upflow anaerobic sludge blankets (UASBs). A malt ingredients manufacturing factory has successfully applied this technology as a cost effective way to treat their high strength effluent, however unlike other industries there is a lack of research regarding the wastewater characterisation or UASB performance at either lab or full scale. This paper aims to address this gap in knowledge and provide information on both the wastewater composition and on the ability of a full-scale mesophilic UASB to treat it over a period of 638 days. Analysis of the wastewater revealed that the manufacture of malt ingredients produces a high strength effluent, which fits within the realms of previously documented wastewaters despite not sharing a similar characterisation profile. Mesophilic UASB has been show to be an effective and robust technology option for the treatment of this type of wastewater displaying steady operational performance even when conditions were in excess of the design limit. Due to the robust operational performance of the plant the main factor limiting total methane production was shown to be the organic loading rate. 

Development of Fatigue Resistant Heavy Wall Riser Connectors for Deepwater HPHT Dry Tree Riser Systems

2009 ◽  
Author(s):  
Ce´line Sches ◽  
Roy Shilling ◽  
Steve Shademan ◽  
Jacky Massaglia ◽  
Mike Payne ◽  
...  
Keyword(s):  
Fatigue Testing ◽  
Base Material ◽  
High Strength Steels ◽  
High Strength ◽  
Cost Effective ◽  
Development Projects ◽  
Element Analysis ◽  
Comprehensive Development ◽  
Parametric Studies ◽  
Technical Solutions

BP is currently looking at the next generation of dry tree development projects in the US Gulf of Mexico (GOM) deepwater operating region. Some HPHT wells call for the design of 15 ksi or greater riser systems with sour service requirements. Over the last 10 years, NACE compliant high strength steels (HSS) together with fatigue resistant threaded and coupled connectors have proved to be reliable technical solutions top tensioned riser (TTR). Today their light weight and increased performance capabilities enable cost effective dry tree systems for water depths up to 10,000 feet. In the frame of BP xHPHT development projects, the design and qualification of Heavy Wall Threaded and Coupled (T&C) riser connectors for TTR applications was launched. Comprehensive development programs were built, involving numerous design variations, Finite Element Analysis evaluation and optimization — including parametric studies —, followed by intensive full scale static and fatigue testing campaigns. Those developments benefited from the design and field running experience accumulated with previous TTR projects, where innovative fatigue enhancement techniques and premium fatigue compliant sealing devices were engineered. In addition, combined static, dynamic and corrosion testing of base material is being conducted to assess and qualify the fatigue resistance of HSS up to 140 ksi under those conditions. This paper will present results and conclusions from these developments and will report the performance levels reached by Heavy Wall High Pressure T&C riser connectors and the associated high strength base material. Forward work plans on riser connectors for xHPHT, SCR and flowlines will also be discussed.

Modified Two-Curve Model for Predicting Fracture Arrest Toughness and Arrest Distance of Full-Size Burst Tests

2016 ◽  
Author(s):  
Xian-Kui Zhu
Keyword(s):  
Test Data ◽  
Pipeline Steel ◽  
Large Diameter ◽  
High Strength ◽  
Full Scale ◽  
Burst Test ◽  
Pipe Segment ◽  
Single Pipe ◽  
Fracture Arrest ◽  
Arrest Toughness

Running fracture control is a very important technology for gas transmission pipelines with large diameter and high pressure. The Battelle two-curve (BTC) model developed in the early 1970s has been widely used in pipeline industry to determine arrest toughness in terms of the Charpy energy. Because of its semi-empirical nature and calibration with test data only for grades up to X65, the BTC does not work for higher grades. Simple corrections were thus proposed to extend the BTC model to higher grades, but limited to those grades considered. Moreover, the BTC model only predicts the minimum arrest toughness, but not arrest distance. To fill the technical gaps, this paper proposes a modified two-curve (MTC) model and a fracture arrest distance model in reference to the Charpy energy. The MTC model coupling with an arrest distance algorithm can predict fracture arrest toughness and arrest distance in one simulation of numerical integration for a single pipe or a set of multiple pipes with given toughness. Two sets of full-scale burst test data for X70 and X80 are used to validate the proposed model, and the results show good agreements between the predictions and full-scale test data of arrest toughness and arrest distance as well. The MTC model is then applied to optimize a design of pipe segment arrangements for a mockup full-scale burst test on a high-strength pipeline steel. The MTC simulation results confirm the experimental observation that different pipe arrangements determine different arrest toughness and arrest distance for the same grade pipes.

FERRIUM M54

Alloy Digest ◽  
2018 ◽  
Vol 67 (9) ◽  
Keyword(s):  
Fracture Toughness ◽  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
High Resistance ◽  
High Strength ◽  
Cost Effective ◽  
High Fracture Toughness ◽  
High Fracture ◽  
Structural Applications ◽  
Resistance To Stress

Abstract Ferrium M54 was designed to create a cost-effective, ultra high-strength, high-fracture toughness material with a high resistance to stress-corrosion cracking for use in structural applications. This datasheet provides information on composition, hardness, and tensile properties as well asfatigue. Filing Code: SA-822. Producer or source: QuesTek Innovations, LLC.

The 1st International Project Competition for Structural Health Monitoring (IPC-SHM, 2020): A summary and benchmark problem

2021 ◽  
pp. 147592172110064
Author(s):  
Yuequan Bao ◽  
Jian Li ◽  
Tomonori Nagayama ◽  
Yang Xu ◽  
Billie F Spencer ◽  
...  
Keyword(s):  
Structural Health Monitoring ◽  
Undergraduate Students ◽  
Health Monitoring ◽  
Fatigue Cracks ◽  
Full Scale ◽  
Asia Pacific ◽  
International Project ◽  
Full Time ◽  
Structural Health ◽  
Institute Of Technology

To promote the development of structural health monitoring around the world, the 1st International Project Competition for Structural Health Monitoring (IPC-SHM, 2020) was initiated and organized in 2020 by the Asia-Pacific Network of Centers for Research in Smart Structures Technology, Harbin Institute of Technology, the University of Illinois at Urbana-Champaign, and four leading companies in the application of structural health monitoring technology. The goal of this competition was to attract more young scholars to engage in the study of structural health monitoring, encouraging them to provide creative and effective solutions for full-scale applications. Recognizing the recent advent and importance of artificial intelligence in structural health monitoring, three competition projects were set up with the data from full-scale bridges: (1) image-based identification of fatigue cracks in bridge girders, (2) data anomaly detection for structural health monitoring, and (3) condition assessment of stay cables using cable tension data. Three corresponding data sets were released at http://www.schm.org.cn and http://sstl.cee.illinois.edu/ipc-shm2020 . Participants were required to be full-time undergraduate students, M.S. students, Ph.D. students, or young scholars within 3 years after obtaining their Ph.D. Both individual and teams (each team had no more than five individuals) could compete. Submissions for the competition included a 10- to 15-page technical paper, a 10-min presentation video with PowerPoint slides, and commented code. The organizing committee then conducted the validation, review, and evaluation. A total of 330 participants in 112 teams from 70 universities and institutions in 12 countries registered for the competition, resulting in 75 papers from 56 teams from 57 different affiliations finally being submitted. Of those submitted, 31, 30, and 14 papers were for Projects 1, 2, and 3, respectively. After completion of the review by the organization committee and awards committee, the top 10, 10, and 5 teams were selected as the prize winners for the three competition projects.

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