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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 2, Issue 12, December 2012)
Investigation of Weld Integrity of X70 Grade Line Pipe by Full Scale Burst Test
A. A. Shaikh1, J. C. Purohit2
1
Associate Professor, Mech. Engg. Dept. S.V. National Institute of Technology, Surat-7 (India) 2 Head operation of HPML, Essar Steel India Ltd, Hazira, Surat (India) To ensure better quality material, its testing becomes mandatory. A large number of mechanical testing are conducted to analyze the properties of the pipe and to predict its bearing capacity. Researcher [3] shows that pipelines with higher strength levels are subjected to a variety of mechanical tests. For pipelines designed for high operating pressures, the assessment of fracture behavior has been studied by means of laboratory and full scale tests. Researchers have attempted to define safety criteria against a possible fracture by determining various fracture properties by means of studying the initiation and propagation of fracture upon failure. Also the influence of higher impact energy of pipe to resist such failures has contributed such pipes to sustain such hostile operating conditions. Burst test [4] forms a major part of the entire testing schedule in such pipes. During operating condition, the primary load on any pipeline is the internal pressure. Design pressures that result in hoop stresses in the pipe as high as 80% of the specified minimum yield strength are allowed by many pipeline codes. So to ensure sufficient pressure capacity, a series of burst tests are conducted. The objective of the burst tests is to ascertain the fracture behaviour of the pipes, integrity of the weld and thus understand the ductile fracture propagation control for the pipes so as to assure complete safety in their application. During the formation of a pipe [5], the steel loses its strength during the forming process due to mechanical work hardening, Bauschingers effect and development of corresponding residual stresses. The tendency of steel softening becomes more prominent in steels of higher grade, typically X70 and above. The consumable selection during the welding process must therefore be ensured to match this effect, and becomes very important aspect for weld integrity. The pre-service hydro test [6]or a full scale burst test with water has been widely used to combat the consequence of failure experienced as a result of pipeline testing using air or product. In more recent years the purpose of the test has moved from being a leak tightness test to one which benefits the pipeline as a structural system. 280
AbstractIn the oil and gas industry, high pressure long distance pipe lines are widely used for efficient and effective movement of natural gas, oil and other petroleum products. The gases are transported at extremely high operating pressures that can range from 200 to 1600 PSI depending on the size and length of the line pipe. For operating safety, Hydrostatic test is used for confirming mechanical integrity of pipe lines and is applied to check for leakages before putting the pipe lines in use. The test aims to evaluate the point of failure of the material and assess the structural integrity of a welded pipe. In present work, an experiment is carried out to confirm weld integrity of two X70 grade carbon steel pipes under the manufacturing process of hot rolling with left and right hand spiral plants. The tests are conducted at pressure in excess of the UTS of the steel/ pipes and aimed to sustain the pressure as per API convention. Both the pipes attained the expected results; however the results of theoretical predicted pressure minutely diverge as the thickness variation is not considered. Keywords - Burst, HSAW, Tolerance, UTS, Weld Integrity.
I. INTRODUCTION During the actual useful life of a Pipeline [1], it is exposed to internal and external corrosion. Internal corrosion is on account of hydrocarbon fluids which are susceptible to CO2 corrosion and external corrosion is on account of harsh environment of adjacent soil in case of offshore and hostile marine environment in case of offshore pipe lines. These corrosion leads to wall thinning process over periods of time. This leads to weakening of mechanical strength when the pipelines are subjected to high pressure conditions for longer periods of use. Over period of time, macro-economic considerations [2] have influenced the development of higher strength steel grades for pipeline use with lower wall thickness. As a result steel pipes of grades with strength levels X80, X100 and lately X120 are being proposed by pipeline designers. Accordingly attempts are made to improve the grade of the steel in order to have better mechanical properties. As manufacturing of higher strength pipes of smaller wall thickness becomes feasible, pipes would become lighter in weight reducing the cost significantly.
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1 2
HSAW 1 HSAW 2
914x14.3 mm 914x14.3 mm
Subsequent to the filling of the water, and continuously increasing water pressure, the first pipe made from the HSAW-1 unit burst at 194 bar pressure. Upon examination of the failure,as shown in Figure 1, it was observed that the crack was apparently a ductile fracture initiated from the body of the pipe and traversed in two opposite longitudinal directions parallel the pipe axis and perpendicular to the radial hoop stresses as the dimension detail is highlighted in Figure 2. The crack however did not propagate beyond the weld seam, which meant that not only was the weld seam strong enough, but it also acted as a crack arrestor. The second pipe made from the HSAW-2 unit also revealed a similar failure characteristic and crack propagation; however it burst at 180 bar pressure which was lower than expected. During the pressuring cycle of HSAW-2 pipe, it was observed that the pressure did not increase for a significant period of time, and the pipe burst after a long 130-minute wait as shown in Figure 3 and the dimension detail is shown in Figure 4. Before bursting, the pipe bulged from the centre like a balloon until it finally gave way.
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The criteria for judging the initiation point of the crack is from that portion of the pipe which has maximum bulge. On observing the pipes, it is found that pipes of HSAW-1 and HSAW-2 both had the crack initiated at the base metal which indicates that the weld joint of each pipe is defect free and stronger than the base metal. Fractured surfaces of all the pipes show ductile failure as the surfaces appear rough and show patches of cup and cone structure. V. CONCLUSIONS It is found that the thickness is the most sensitive parameter for the calculation of burst pressure calculation. In practice that localized wall thinning can cause bursting at lower pressures. Therefore in pipeline applications tolerance considerations play an important role in design. Practical demonstration of a full scale burst test represent results very close to those warranted by the theory, which reflect consistency in the pipe manufacturing process. In case of the pipe made from HSAW, one of the probable reasons for pressure not increasing beyond a certain value was due to the plastic deformation, which suggests localized lower yield strength. Due to increase in the volume of pipe on expansion could accommodate greater amount of the fluid. 283
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