Best Practice Guidance for Evaluating Knock-Down Factors in Corrosive Environments

2012 ◽  
Author(s):  
Colum M. Holtam ◽  
Charles R. A. Schneider ◽  
Graham Slater
Keyword(s):  
Corrosion Fatigue ◽  
Best Practice ◽  
Fatigue Tests ◽  
Reduction Factor ◽  
Fatigue Performance ◽  
Corrosive Environment ◽  
Design Curve ◽  
Knock Down ◽  
Girth Welding ◽  
Girth Welds

The term knock-down factor is commonly used to describe the reduction in fatigue life in a corrosive environment (e.g. sour service) compared to performance in air. However, the mere concept of such a reduction factor is potentially misleading, particularly when comparing different welding procedures that demonstrate different in-air performance. This paper examines the concept and calculation of so-called knockdown factors. To demonstrate the performance of girth welds in a corrosive environment, strip fatigue tests are conducted in air and in a simulated service environment, to determine an appropriate knock-down factor, which is then applied to the base design curve. However, there are a number of ways that such knock-down factors can be calculated, with different degrees of conservatism. For example, two different welding procedures may exhibit a different fatigue performance in air, but a similar performance when tested in a sour environment. The better performing weld (in air) is therefore assigned a greater knock-down factor, and possibly a more stringent sour design curve. In other instances, fatigue performance in air may significantly exceed that required. The determined knock-down factor, between strip tests in air and in a sour environment, can then be very large. Applying this reduction factor to the design curve results in a very stringent sour design curve, and may penalize the use of a girth welding procedure that results in good in-air fatigue performance. There are no explicit, published guidelines for calculating corrosion fatigue knock-down factors. This paper describes an approach, based on experience and considering best practice guidance for the statistical analysis of fatigue data obtained from welded joints. The method is demonstrated using published sour corrosion fatigue endurance data, evaluating both mean and design curves.

An Investigation of the Fatigue Performance of Riser Girth Welds

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
Stephen J. Maddox ◽  
Julian B. Speck ◽  
G. Reza Razmjoo
Keyword(s):  
Oil And Gas ◽  
Welding Process ◽  
Fatigue Loading ◽  
Fatigue Tests ◽  
Fatigue Performance ◽  
Steel Catenary Riser ◽  
Gas Recovery ◽  
Fatigue Design ◽  
Pipeline Welding ◽  
Girth Welds

Increasing deep-water oil and gas recovery has highlighted the need for high integrity, high fatigue performance girth welds in steel catenary riser systems. Such systems include girth welds made from one side. However, the widely used fatigue design classification, UK Class F2, for such welds is not well founded, but probably overconservative for pipeline welds. In an attempt to justify upgrading current fatigue design classifications and providing a better basis for design, fatigue tests were performed on a range of girth-welded pipes produced by pipeline welding contractors. This paper presents the results of those tests and their evaluation in terms of the factors that influence the fatigue performance of girth welds, including welding process, welding position, backing system, joint alignment, weld quality, specimen type, and fatigue loading conditions. Conclusions are drawn regarding the scope for adopting higher design classifications and the conditions that must be met to justify them.

Consistent Endurance Fatigue Knockdown Factors for Sour Service From Industry-Wide Database

2011 ◽  
Author(s):  
Weiwei Yu ◽  
Pedro M. Vargas ◽  
Jonathan Bowman
Keyword(s):  
Ph Value ◽  
Fatigue Performance ◽  
Small Scale ◽  
Loading Frequency ◽  
Solution Ph ◽  
Knock Down ◽  
Service Testing ◽  
Highly Correlated ◽  
Girth Welds ◽  
Sour Service

The embrittlement of steel in the presence of water and hydrogen sulfide is a well known phenomenon. For the resulting degradation in fatigue performance, the industry today applies a knock-down factor onto in-air S-N endurance curve that relates the sour-service life to the in-air performance. Several published results are available, and most of these, although rigorous in test approach, report knock-down factors that include unspecified levels of conservatism, consistent with that particular author’s engineering intuition. (For example, typically a lower bound S-N curve in sour-service testing is related to a mean S-N curve in-air). This paper summarizes all of the published small scale sour service testing results, and applies a consistent knock-down factor calculation. Analyses of the data show that sour degradation is highly correlated to H2S concentration and solution pH value. In practice frequency scanning test is highly recommended since sour fatigue test results are highly dependent on loading frequency. Although the database is small, some trends are discernable. In particular, observations indicate that sour service exposure may act as an equalizer, removing the initiation life associated with the time for initial micro-defects at the weld toes to become macro-cracks and leaving only aggravated propagation due to sour service. In this paper, we use initiation life (for welds) to describe the life for the micro-defects (∼0.1mm height) to become macro-cracks (∼1.0 mm height), and a postulation is made that associates the fatigue performance of girth welds (F2, E, D, etc.) with the size and magnitude presence of these micro-defects. The metal surface attack of the sour environment is postulated to provide pitting-like initiation sites for the macro-crack for fatigue propagation. As a base we can use the F2 level performance as the performance due to presence of macro-cracks, and any margin for the D and E level fatigue performances then is associated with more benign initial micro-defects. Once we remove the differences in initiation life; all of the sour performance converges on a single lower performance curve. In this scenario, the knockdown factor is more consistently computed from a standard performance S-N curve rather than the same girth weld’s in-air performance since the in-air data may include significant initiation life. Furthermore, if project sour condition is less severe than NACE TM0177, Solution B with pH = 3.5 and H2S partial pressure = 70mbar, a knock down factor of 45 indexed to BS7608 E design curve is supported from the current database. This provides a design recommendation which can be used for preliminary design in sour environments.

Statistical Analysis of Fatigue Test Data

2017 ◽  
Author(s):  
Carol Johnston
Keyword(s):  
Statistical Analysis ◽  
Fatigue Strength ◽  
Cyclic Loading ◽  
Fatigue Test ◽  
Test Data ◽  
Fatigue Tests ◽  
Fatigue Performance ◽  
Test Results ◽  
Girth Welds ◽  
New Procedures

The offshore environment contains many sources of cyclic loading. Standard design S-N curves, such as those in DNVGL-RP-C203, are usually assigned to ensure a particular design life can be achieved for a particular set of anticipated loading conditions. Girth welds are often the ‘weak link’ in terms of fatigue strength and so it is important to show that girth welds made using new procedures for new projects that are intended to be used in fatigue sensitive risers or flowlines do indeed have the required fatigue performance. Alternatively, designers of new subsea connectors, used for example in tendons for tension leg platforms, mooring applications or well-heads which will experience cyclic loading in service, also wish to verify the fatigue performance of their new designs. Often operators require contractors to carry out resonance fatigue tests on representative girth welds in order to show that girth welds made using new procedures qualify to the required design S-N curve. Operators and contractors must then interpret the results, which is not necessarily straightforward if the fatigue lives are lower than expected. Many factors influence a component’s fatigue strength so there is usually scatter in results obtained when a number of fatigue tests are carried out on real, production standard components. This scatter means that it is important first to carry out the right number of tests in order to obtain a reasonable understanding of the component’s fatigue strength, and then to interpret the fatigue test results properly. A working knowledge of statistics is necessary for both specifying the test programme and interpreting the test results and there is often confusion over various aspects of test specification and interpretation. This paper describes relevant statistical concepts in a way that is accessible to non-experts and that can be used, practically, by designers. The paper illustrates the statistical analysis of test data with examples of the ‘target life’ approach (that is now included in BS7608:2014 + A1) and the equivalent approach in DNVGL-RP-C203, which uses the stress modification factor. It gives practical examples to designers of a pragmatic method that can be used when specifying test programmes and interpreting the results obtained from tests carried out during qualification programmes, which for example, aim to determine whether girth welds made using a new procedure qualify to a particular design curve. It will help designers who are tasked with specifying test programmes to choose a reasonable number of test specimens and stress ranges, and to understand the outcome when results have been obtained.

An Investigation of the Fatigue Performance of Riser Girth Welds

2006 ◽  
Author(s):  
Stephen J. Maddox ◽  
Julian B. Speck ◽  
G. Reza Razmjoo
Keyword(s):  
Oil And Gas ◽  
Welding Process ◽  
Fatigue Loading ◽  
Fatigue Tests ◽  
Fatigue Performance ◽  
Steel Catenary Riser ◽  
Gas Recovery ◽  
Fatigue Design ◽  
Pipeline Welding ◽  
Girth Welds

Increasing deep-water oil and gas recovery has highlighted the need for high integrity, high fatigue performance girth welds in steel catenary riser systems. Such systems include girth welds made from one side. However, the widely used fatigue design classification, UK Class F2, for such welds is not well founded, but probably over-conservative for pipeline welds. In an attempt to justify upgrading current fatigue design classifications and providing a better basis for design, fatigue tests were performed on a range of girth-welded pipes produced by pipeline welding contractors. This paper presents the results of those tests and their evaluation in terms of the factors that influence the fatigue performance of girth welds, including welding process, welding position, backing system, joint alignment, weld quality, specimen type and fatigue loading conditions. Conclusions are drawn regarding the scope for adopting higher design classifications and the conditions that must be met to justify them.

Fatigue Performance of Thick Section Titanium Grade 29 Girth Welds

2020 ◽  
Author(s):  
Gabriel Rombado ◽  
David A. Baker ◽  
Lars M. Haldorsen ◽  
Kenneth Macdonald ◽  
Heath Walker ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Fatigue Testing ◽  
Fatigue Performance ◽  
Fluid Temperature ◽  
Design Curve ◽  
Fatigue Design ◽  
Dog Bone ◽  
Titanium Grade ◽  
Girth Welds ◽  
Welding Procedure

Abstract Design of Steel Catenary Risers (SCRs) requires the use of specialized connection hardware to mitigate the high dynamic bending moments at the hang-off location induced by host floater motion. Reliability of this connection hardware is imperative, especially in those applications involving high tension loads, high pressure and elevated fluid temperature. One option for connection hardware is a monolithic, metallic tapered stress joint. Because of its inherent density, strength, and stiffness properties, steel is not well suited for these applications due to excessive stress joint length and weight requirements. Titanium Grade 29 has been identified as an attractive material candidate for demanding service applications due to its unique mechanical properties including increased flexibility, excellent fatigue performance and corrosion resistance to sour fluids. This technology is well established in the offshore industry and utilized in over 60 SCR installations with operating lives exceeding 20 years of continuous subsea operation. Large titanium stress joints (TSJs) for deep-water applications are typically not fabricated as a single piece due to titanium ingot volume limitations thus making one or more intermediate girth weld(s) necessary to satisfy the overall length requirements. Fatigue testing of 38 mm (1.5-in) wall thickness girth welds, utilizing an optimized GTAW welding procedure to limit defect sizes to sub-millimeter, has previously been performed in seawater (OD exposure) under cathodic protection potentials and sour service (ID exposure) under galvanic potentials. Fatigue testing results fully verified the vendor S-N fatigue design curve, in addition, no appreciable differences in fatigue performance in environments were observed allowing project-specific testing to be limited to in-air testing. This paper presents in-air fatigue testing results of 51 mm (2.0-in) wall thickness Grade 29 girth welds, using the same optimized welding procedure, to assess thickness size effect on the vendor S-N fatigue design curve. Verification of the vendor fatigue design curve was demonstrated by testing curved dog-bone specimens, extracted longitudinally across the girth weld, with production level surface finishes on inner and outer surfaces in-air up to a predefined S-N fatigue target curve with 95% confidence level.

Corrosion Fatigue of Steel Armours in Flexible Risers

2002 ◽  
Author(s):  
Tore Roberg Andersen
Keyword(s):  
Carbon Dioxide ◽  
Fatigue Life ◽  
Corrosion Fatigue ◽  
Hydrogen Sulphide ◽  
Fatigue Performance ◽  
Corrosive Environment ◽  
Test Program ◽  
Flexible Risers

Fatigue life calculation of flexible risers is normally based on the assumption that the annulus is dry. Experience has, however, shown that the annulus may become water flooded. Carbon dioxide and hydrogen sulphide permeate from the bore and into the annulus, making the annulus environment corrosive. In such conditions the influence of corrosion fatigue on fatigue life has to be taken into account. A test program was performed to investigate the corrosion fatigue performance of steel armour in water containing carbon dioxide. The results showed that the corrosive environment reduced the fatigue life to about 1/10 to 1/50 of that derived in air. The lifetime was significantly shorter in the environment with 0.1 bar compared to 0.01 bar, indicating that corrosion fatigue becomes more pronounced as the corrosivity increases. The work shown that corrosion fatigue has to be considered for flexible risers with annulus that is or may be water flooded.

Effect of Reeling on Welded Umbilical Tubing Fatigue

2006 ◽  
Author(s):  
Jaime Buitrago ◽  
Krasimir Doynov ◽  
Allen Fox
Keyword(s):  
Plastic Strain ◽  
Fatigue Testing ◽  
Fatigue Tests ◽  
Fatigue Performance ◽  
Experimental Program ◽  
Design Curve ◽  
Duplex Steel ◽  
Steel Tubing ◽  
Pressurized Fluids ◽  
Welding Procedure

One key component of umbilicals is the steel tubing carrying the pressurized fluids. During manufacturing and deployment of the umbilical, the tubing is subjected to a series of reeling and unreeling operations, resulting in a cumulative amount of plastic strain. For conventional design, this plastic strain is thought to limit the fatigue performance of the tubing, thereby limiting the number of such operations. This paper discusses an experimental program aimed at assessing the effect of the cumulative reeling strain on the fatigue life of girth-welded, super duplex steel tubing. In particular, the reeling simulation and fatigue testing equipment used are described and the experimental procedures are presented. Interpretation of fatigue tests indicate that (1) reeling degrades the fatigue performance of the welded tubing, (2) 75% of the B design curve may represent the 97.5% survival bound for tubing reeled up to 12% cumulative reeling strain, and (3) the fraction of the B design curve reduces to 40% for the same bound when the data from the 20% reeling strain tests are included. However, given the uncertainties involved, project-specific applications will require a fatigue qualification program for the specific tubing size, reeling history, and welding procedure at hand.

Corrosion - Fatigue Performance of Magnesium Alloys

2003 ◽  
Vol 17 (08n09) ◽  
pp. 1601-1607
Author(s):  
W. G. Ferguson ◽  
Wu Liu ◽  
John MacCulloch
Keyword(s):  
High Pressure ◽  
Fatigue Resistance ◽  
Corrosion Fatigue ◽  
Tap Water ◽  
Fatigue Tests ◽  
Fatigue Performance ◽  
Natural Seawater ◽  
Die Cast ◽  
Point Bend ◽  
Protection From Corrosion

To determine the effect of a coating on fatigue strength, three point bend fatigue tests of coated and un-coated AM50 and AZ91D magnesium high pressure die cast specimens were made and S-N curves determined. Environments used were air, tap water and natural seawater. A difference in corrosion fatigue performance has been found, between AZ91D and AM50 and for both alloys performance in air was superior to both water environments. AZ91D has better corrosion fatigue resistance in tap water than in seawater; conversely, AM50 has better corrosion fatigue resistance in seawater than tap water. The results showed that the fatigue life was not reduced in these water environments for coated specimens, as the coating usually provided protection from corrosion.

Investigation of the processes of fatigue and corrosion-fatigue destruction of pseudo-α titanium alloy

2021 ◽  
Vol 7 ◽  
pp. 37-48
Author(s):  
A. A. Murashov ◽  
◽  
N. N. Berendeyev ◽  
A. V. Nokhrin ◽  
E. A. Galaeva ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Corrosion Fatigue ◽  
Nuclear Power ◽  
Power Plants ◽  
Fatigue Cracks ◽  
Cyclic Fatigue ◽  
Fatigue Tests ◽  
Corrosive Environment ◽  
Β Phase ◽  
Loading Scheme

The paper describes the results of fatigue and corrosion-fatigue tests of the pseudo α titanium alloy PT-3V, which is actively used in nuclear engineering for the manufacture of heat exchange equipment for modern nuclear power plants. Alloy PT-3V has an inhomogeneous coarse-crystalline structure with precipitates of β-phase particles along the grain boundaries of the lamellar shape. It is shown that smooth specimens tested according to the bending-with-rotation loading scheme do not show a noticeable decrease in the cyclic fatigue life when exposed to a neutral corrosive environment (3 % aqueous NaCl solution). However, specimens with a notch (stress concentrator) tested according to the cantilever bending loading scheme demonstrate sensitivity to the action of a corrosive environment at the stages of initiation and growth of fatigue cracks, as evidenced by a significant decrease in the number of cycles before crack initiation, as well as before specimen failure, in comparison with tests in air. Fractographic analysis of fractures of smooth specimens and specimens with a concentrator after fatigue and corrosion-fatigue tests has been carried out. The main stages of the initiation and growth of fatigue cracks are revealed. It has been established that a decrease in the resistance to the initiation and propagation of corrosion-fatigue cracks during testing of notched specimens may be due to the effect of hydrogen embrittlement, accelerated by stress concentration.

scholarly journals Experimental study on fatigue performance of Q420qD high-performance steel cross joint in complex environment

2021 ◽  
Author(s):  
Haigen Cheng ◽  
Cong Hu ◽  
Yong Jiang
Keyword(s):  
Fatigue Life ◽  
High Performance ◽  
Steel Structure ◽  
Steel Structures ◽  
Fatigue Tests ◽  
Fatigue Performance ◽  
Corrosive Media ◽  
Joint Connection ◽  
High Performance Steel ◽  
The Cross

AbstractThe steel structure under the action of alternating load for a long time is prone to fatigue failure and affects the safety of the engineering structure. For steel structures in complex environments such as corrosive media and fires, the remaining fatigue life is more difficult to predict theoretically. To this end, the article carried out fatigue tests on Q420qD high-performance steel cross joints under three different working conditions, established a 95% survival rate $$S{ - }N$$ S - N curves, and analyzed the effects of corrosive media and high fire temperatures on its fatigue performance. And refer to the current specifications to evaluate its fatigue performance. The results show that the fatigue performance of the cross joint connection is reduced under the influence of corrosive medium, and the fatigue performance of the cross joint connection is improved under the high temperature of fire. When the number of cycles is more than 200,000 times, the design curves of EN code, GBJ code, and GB code can better predict the fatigue life of cross joints without treatment, only corrosion treatment, and corrosion and fire treatment, and all have sufficient safety reserve.

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