Development and Qualification of Pipeline Welding Procedures for Strain Based Design

2007 ◽  
Author(s):  
Martin W. Hukle ◽  
Dan B. Lillig ◽  
Brian D. Newbury ◽  
John Dwyer ◽  
Agnes Marie Horn
Keyword(s):  
Large Scale ◽  
Scale Validation ◽  
Gas Metal Arc Welding ◽  
Full Scale ◽  
Pipe Material ◽  
Metal Arc Welding ◽  
Offshore Pipeline ◽  
Pipeline Welding ◽  
Girth Welds ◽  
Procedure Development

This paper reviews the specific testing methodologies implemented for the qualification of mechanized pulsed gas metal arc welding (PGMAW) procedures for strain based design applications. The qualified welding procedures were used during recent construction of an offshore pipeline subject to potential ice scour with an initial design target of 4% tensile strain capacity. This paper addresses the integrated development of linepipe specifications, large scale validation testing, weld procedure development, and finally, the verification of robustness through full scale pressurized testing of actual girth welds on project pipe material. The qualification sequence, from linepipe specification development through final full scale girth weld proof test is described.

The First L555 (X80) Pipeline in Japan

2012 ◽  
Author(s):  
Yoshiyuki Matsuhiro ◽  
Noritake Oguchi ◽  
Toshio Kurumura ◽  
Masahiko Hamada ◽  
Nobuaki Takahashi ◽  
...  
Keyword(s):  
Gas Metal Arc Welding ◽  
Control Process ◽  
High Strength ◽  
Longitudinal Direction ◽  
Full Scale ◽  
Ground Movement ◽  
Bending Test ◽  
Metal Arc Welding ◽  
S Curve ◽  
Girth Welds

The construction of the first L555(X80) pipeline in Japan was completed in autumn, 2011.In this paper, the overview of the design consideration of the line, technical points for linepipe material and for girth welds are presented. In recent years the use of high strength linepipe has substantially reduced the cost of pipeline installation for the transportation of natural gas. The grades up to L555(X80) have been used worldwide and higher ones, L690(X100) and L830(X120), e.g., are being studied intensively. In the areas with possible ground movement, the active seismic regions, e.g., pipeline is designed to tolerate the anticipated deformation in longitudinal direction. In Japan, where seismic events including liquefaction are not infrequent, the codes for pipeline are generally for the grades up to L450(X65). Tokyo Gas Co. had extensively investigated technical issues for L555(X80) in the region described above and performed many experiments including full-scale burst test, full-scale bending test, FE analysis on the girth weld, etc., when the company concluded the said grade as applicable and decided project-specific requirements for linepipe material and for girth weld. Sumitomo Metals, in charge of pipe manufacturing, to fulfill these requirements, especially the requirement of round-house type stress-strain (S-S) curve to be maintained after being heated by coating operation, which is critical to avoid the concentration of longitudinal deformation, developed and applied specially designed chemical composition and optimized TMCP (Thermo-Machanical Control Process) and supplied linepipe (24″OD,14.5∼18.9mmWT) with sufficient quality. It had also developed and supplied induction bends needed with the same grade. Girth welds were conducted by Sumitomo Metal Pipeline and Piping, Ltd and mechanized GMAW (Gas Metal Arc Welding) was selected to achieve the special requirements, i.e., the strength of weld metal to completely overmatch the pipe avoiding the concentration of longitudinal strain to the girth weld, and the hardness to be max.300HV10 avoiding HSC (Hydrogen Stress Cracking) on this portion. Both of RT (Radiographic Test) and UT (Ultrasonic Test) were carried out to all the girth welds. These were by JIS (Japan Industrial Standards) and the project-specific requirements.

Girth Welding of X100 Pipeline Steels

2002 ◽  
Author(s):  
Mark G. Hudson ◽  
Stephen A. Blackman ◽  
John Hammond ◽  
David V. Dorling
Keyword(s):  
Mechanical Property ◽  
Gas Metal Arc Welding ◽  
Data Generation ◽  
Pipeline Steels ◽  
Metal Arc Welding ◽  
Property Data ◽  
Girth Welding ◽  
Pipeline Welding ◽  
Welding Consumable ◽  
Girth Welds

Girth welding trials involving pipes of minimum proof strength 690 MPa (X100) from several linepipe manufacturers have been conducted. Welding consumable selections for the trials were based on background data generated at Cranfield University coupled with potential weld metal mechanical property requirements thought necessary for the implementation of X100 pipeline steels. Mechanised pulsed gas metal arc welding (PGMAW) and semi-automatic/ manual welding procedures were used to generate mechanical property data of mainline girth welds, tie-ins and repairs using equipment and procedures as close to current field practice as possible. The trials showed no detrimental weldability issues for the X100 steels examined. Testing comprised tensile, toughness (CVN and CTOD), hardness, side bend and nick break data generation, using pipeline welding specifications where possible.

scholarly journals Wire Arc Additive Manufacturing (WAAM) of Aluminum Alloy AlMg5Mn with Energy-Reduced Gas Metal Arc Welding (GMAW)

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2671 ◽  
Author(s):  
Maximilian Gierth ◽  
Philipp Henckell ◽  
Yarop Ali ◽  
Jonas Scholl ◽  
Jean Pierre Bergmann
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Energy Input ◽  
Large Scale ◽  
Unit Length ◽  
Gas Metal Arc Welding ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Wire Arc Additive Manufacturing

Large-scale aluminum parts are used in aerospace and automotive industries, due to excellent strength, light weight, and the good corrosion resistance of the material. Additive manufacturing processes enable both cost and time savings in the context of component manufacturing. Thereby, wire arc additive manufacturing (WAAM) is particularly suitable for the production of large volume parts due to deposition rates in the range of kilograms per hour. Challenges during the manufacturing process of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with adaptable energy input. In this study, WAAM of AlMg5Mn alloy was systematically investigated by using the gas metal arc welding (GMAW) process. Herein, correlations between the energy input and the resulting temperature–time-regimes show the effect on resulting microstructure, weld seam irregularities and the mechanical properties of additively manufactured aluminum parts. Therefore, multilayer walls were built layer wise using the cold metal transfer (CMT) process including conventional CMT, CMT advanced and CMT pulse advanced arc modes. These processing strategies were analyzed by means of energy input, whereby the geometrical features of the layers could be controlled as well as the porosity to area portion to below 1% in the WAAM parts. Furthermore, the investigations show the that mechanical properties like tensile strength and material hardness can be adapted throughout the energy input per unit length significantly.

scholarly journals A New Method for Seismically Safe Managing of Seismotectonic Deformations in Fault Zones

2020 ◽  
pp. 45-66
Author(s):  
Valery V. Ruzhich ◽  
Evgeny V. Shilko
Keyword(s):  
Large Scale ◽  
Scale Validation ◽  
Fault Zones ◽  
Full Scale ◽  
Coseismic Slip ◽  
Stick Slip ◽  
Slip Regime ◽  
Deep Wells ◽  
Seismic Vibrations ◽  
Large Scale Tests

AbstractThe authors outline the results of long-term interdisciplinary research aimed at identifying the possibility and the methods of controlling tangential displacements in seismically dangerous faults to reduce the seismic risk of potential earthquakes. The studies include full-scale physical and numerical modeling of P-T conditions in the earth’s crust contributing to the initiation of displacement in the stick-slip regime and associated seismic radiation. A cooperation of specialists in physical mesomechanics, seismogeology, geomechanics, and tribology made it possible to combine and generalize data on the mechanisms for the formation of the sources of dangerous earthquakes in the highly stressed segments of faults. We consider the prospect of man-caused actions on the deep horizons of fault zones using powerful shocks or vibrations in combination with injecting aqueous solutions through deep wells to manage the slip mode. We show that such actions contribute to a decrease in the coseismic slip velocity in the fault zone, and, therefore, cause a decrease in the amplitude and energy of seismic vibrations. In conclusion, we substantiate the efficiency of the use of combined impacts on potentially seismically hazardous segments of fault zones identified in the medium-term seismic prognosis. Finally, we discuss the importance of the full-scale validation of the proposed approach to managing the displacement regime in highly-stressed segments of fault zones. Validation should be based on large-scale tests involving advanced technologies for drilling deep multidirectional wells, injection of complex fluids, and localized vibrational or pulse impacts on deep horizons.

scholarly journals Mitigating Scatter in Mechanical Properties in AISI 410 Fabricated via Arc-Based Additive Manufacturing Process

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4855 ◽  
Author(s):  
Sougata Roy ◽  
Benjamin Shassere ◽  
Jake Yoder ◽  
Andrzej Nycz ◽  
Mark Noakes ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Gas Metal Arc Welding ◽  
Martensitic Steels ◽  
Stamping Dies ◽  
Metal Arc Welding ◽  
Δ Ferrite ◽  
Tensile Data ◽  
Metal Additive

Wire-based metal additive manufacturing utilizes the ability of additive manufacturing to fabricate complex geometries with high deposition rates (above 7 kg/h), thus finding applications in the fabrication of large-scale components, such as stamping dies. Traditionally, the workhorse materials for stamping dies have been martensitic steels. However, the complex thermal gyrations induced during additive manufacturing can cause the evolution of an inhomogeneous microstructure, which leads to a significant scatter in the mechanical properties, especially the toughness. Therefore, to understand these phenomena, arc-based additive AISI 410 samples were fabricated using robotic gas metal arc welding (GMAW) and were subjected to a detailed characterization campaign. The results show significant scatter in the tensile properties as well as Charpy V-notch impact toughness data, which was then correlated to the microstructural heterogeneity and delta (δ) ferrite formation. Post-processing (austenitizing and tempering) treatments were developed and an ~70% reduction in the scatter of tensile data and a four-times improvement in the toughness were obtained. The changes in mechanical properties were rationalized based on the microstructure evolution during additive manufacturing. Based on these, an outline to tailor the composition of “printable” steels for tooling with isotropic and uniform mechanical properties is presented and discussed.

Full Scale Fatigue Performance of Pre-Strained SCR Girth Welds: Comparison of Different Reeling Frames

2010 ◽  
Author(s):  
Philippe P. Darcis ◽  
Israel Marines-Garcia ◽  
Eduardo A. Ruiz ◽  
Elsa C. Marques ◽  
Mariano Armengol ◽  
...  
Keyword(s):  
Arc Welding ◽  
Oil And Gas ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Full Scale ◽  
Strain History ◽  
Oil And Gas Development ◽  
Arc Welding Process ◽  
Girth Welds ◽  
Welding Procedure

The current work aims to point out the influence of plastic strain history, due to reel-lay installation, on the fatigue resistance of welded SMLS (seamless) steel pipes used for fabrication of Steel Catenary Risers (SCRs) for oil and gas development. A C-Mn steel X65 pipe 10.75″ (273.1 mm) outside diameter (OD) and 25.4 mm wall thickness (WT) was chosen for this program. The Welding Procedure designed for girth welds manufacturing involved the use of Lincoln STT-GMAW™ (Surface Tension Transfer–Gas Metal Arc Welding) process for the root pass and SAW (Submerged Arc Welding) process with twin wire configuration for the fill and cap passes. This welding procedure presents a special post-weld finishing treatment, which consists in flapping the inner and outer weld overfills to produce a flush profile between weld metal and outer/inner pipe surfaces. The experimental approach was focused on quantifying the effect of accumulated plastic deformation using two different reeling frames simulating the same laying vessel: the Technip’s Apache. In this program, two reeling trials were performed at Heriot Watt University, Edinburgh, U.K., and two other trials at Stress Engineering Services, Houston, U.S.A. Then, the strained specimens were full scale fatigue tested at TenarisTamsa R&D facilities. Those results have been compared with fatigue results obtained on unstrained specimens. Post-tests fractographic investigations were systematically performed on all samples to identify the causes for fatigue initiation. The results were statistically analyzed to determine which standard fatigue design curves best represent the measured S-N fatigue endurance. Finally, the results were also compared with the available literature.

Structures and Properties of X80 Pipeline Girth Welds for Different Welding Procedures

2012 ◽  
Author(s):  
Xiaodong He ◽  
Yangqin Liu ◽  
Lixia Zhu ◽  
Ke Tong ◽  
Xiaodong Shao
Keyword(s):  
Tensile Properties ◽  
Welded Joints ◽  
Arc Welding ◽  
Mass Fraction ◽  
Gas Metal Arc Welding ◽  
High Strength ◽  
Single Wire ◽  
Metal Arc Welding ◽  
The Difference ◽  
Girth Welds

The X80 girth welds were produced by solid-wire gas metal arc welding (GMAW) and shield metal arc welding (SMAW) using two welding consumables respectively, which contained different mass fraction of C, Mo and Ni. The tensile properties, notch toughness, hardness, and microstructures of welded joints were evaluated. The results indicate that high strength and good toughness of welded joints can be achieved. But the tensile properties of all weld metal of GMAW and SMAW process were evidently different because of the difference of mass fraction of C, Mo, Ni. The strength reduced slightly in softening zone of HAZ. Using welding consumable which contain higher Mo additions, the microstructure in weld seam and fusion zones were IAF+GB and GB+M respectively. Furthermore, the mechanical properties of X80 pipeline welded by single wire welding and double wire welding respectively have been compared. The double wire welds exhibited lower yield strength but higher toughness compared to the corresponding single wire welds.

Girth Weldability Evaluation of SAWH Pipes Produced From 23.7mm Thick, High-Nb Containing X70 Linepipe Steel

2014 ◽  
Author(s):  
Özlem E. Güngör ◽  
Martin Liebeherr ◽  
Hervé Luccioni
Keyword(s):  
Gas Metal Arc Welding ◽  
Construction Companies ◽  
Controlled Processing ◽  
Metal Arc Welding ◽  
Increasing Demand ◽  
Girth Welds ◽  
Welding Procedure ◽  
Linepipe Steels ◽  
Linepipe Steel

In the energy market, there is an increasing demand for oil & gas transmission pipelines with larger wall thicknesses and from higher strength linepipe steels. Addition of niobium (Nb) to the steel chemistry in combination with thermo-mechanical controlled processing allow increasing the thickness of the linepipe steels on coil while maintaining good strength and toughness. However, pipeline construction companies often indicate their concerns about the weldability of high Nb containing linepipe steels and in addition, Nb levels are restricted in some of the steel specifications for linepipe applications. In this study, field weldability of industrially produced helical pipes made from 23.7 mm thick, high Nb containing X70 linepipe steel was evaluated. Welding procedure development was realized for narrow-groove mechanized gas metal arc welding (GMAW). Characterization of the girth welds produced revealed the suitability of the material for typical field welding procedures for onshore pipe laying. The details and the results of the investigations are presented and discussed in the paper.

Integration of Welding, NDT, Mechanical Testing and Field Control When Using an ECA Flaw Acceptance Criteria in Pipeline Construction

2018 ◽  
Author(s):  
Junfang Lu ◽  
Bob Huntley ◽  
Luke Ludwig ◽  
Axel Aulin ◽  
Andy Duncan
Keyword(s):  
Mechanical Testing ◽  
Gas Metal Arc Welding ◽  
Probability Of Detection ◽  
Destructive Testing ◽  
Acceptance Criteria ◽  
Pipeline Construction ◽  
High Productivity ◽  
Metal Arc Welding ◽  
Field Control ◽  
Girth Welds

The fracture mechanics based engineering critical assessment (ECA) method has been accepted as a fitness for service (FFS) approach to defining weld flaw acceptance criteria for pipeline girth welds. Mechanized gas metal arc welding (GMAW) processes are commonly used in cross country pipeline girth weld welding because of the advantages in good quality and high productivity. With the technical advancements of non-destructive testing (NDT) techniques, automated ultrasonic testing (AUT) has greatly improved flaw characterization, sizing and probability of detection during weld inspection. Alternative weld flaw acceptance criteria are permitted in pipeline construction code to assess the acceptability of mechanized girth welds using an ECA. The use of an ECA based weld flaw acceptance criteria can significantly reduce the construction cost. Mechanized girth weld acceptance criteria have been progressively transitioned from workmanship standards into using fitness for service based ECAs. To successfully deliver an ECA on a pipeline project, a multidisciplinary approach must be taken during the welding design and construction stages. Welding, NDT, mechanical testing and field control are all integral elements of pipeline construction. All these four elements have to be fully integrated in order to implement the ECA and achieve the overall integrity of a pipeline. The purpose of this paper is to discuss the importance of the integration of these four elements necessary for proper implementation of the ECA weld flaw acceptance criteria.

A Systematic Material Evaluation Program for High Grade Line Pipe Materials

2008 ◽  
Author(s):  
Da-Ming Duan ◽  
Joe Zhou ◽  
Brian Rothwell ◽  
David Taylor ◽  
Kevin Widenmaier
Keyword(s):  
Quality Management System ◽  
Pipe Material ◽  
High Grade ◽  
Line Pipe ◽  
Evaluation Program ◽  
Material Evaluation ◽  
Management Procedures ◽  
Pipeline Welding ◽  
Girth Welds ◽  
Pipe Materials

TransCanada Pipelines has decades of experience in both research and application of high grade materials in its pipeline systems. This evolution process has led to a unique way for the company to understand and evaluate high grade materials including X80, X100 and X120. As part of its pipeline construction quality management system, TransCanada has launched a systematic material evaluation program that, in addition to its pipe material specifications which were built on top of relevant CSA standards, specifies procedures for qualification and evaluation of line pipe materials. Consequently, a multi-tiered pipe material quality control system is established. The material evaluation program consists of both management procedures and technical procedures. This paper is to present the framework and the major components of the technical procedure. Due to the specific mechanical properties of high grade line pipe materials and their specific features of applications, material testing matrix is defined to evaluate not only the pipe body material but also girth welds made with modern pipeline welding technologies. For X80 pipes, while the program is concentrated for material qualification based on stress-based design requirements, a “further look” into the material properties is taken to evaluate the suitability of the pipe products to be applied under strain-based design conditions. For X100 and higher grade pipes, a full research test matrix is defined to explore the applicability of the material in strain-based design conditions, particularly the northern development design conditions.

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