Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
org
San Francisco, CA, USA, June 25-30, 2017
Copyright 2017 by the International Society of Offshore and Polar Engineers (ISOPE)
ISBN 978-1-880653-97-5; ISSN 1098-6189
ABSTRACT al. 2015). By modelling the corrosion surface for geometrical structural
change consisting of a general thickness reduction combined with an
A fracture mechanics based approach is proposed to quantify the equivalent crack due to localised stress concentration of pitting, the
influence of corrosion damage on structural integrity. This approach influence of corrosion damage on structural integrity can be quantified
investigates the corrosion surface for geometrical structural change using fracture mechanics parameters such as the Stress Intensity Factor,
consisting of a general thickness reduction combined with localised K, and the J-integral. Hence, this paper presents a numerical model of
stress concentration where cracks are predicted to initiate or have corrosion damage which is then checked against experimental results.
already initiated from pitting. It comprises a numerical model of With this model validated, a test program combined with inspection
corroded SENT specimens of high strength offshore steel which is then capabilities is proposed.
validated against Thermoelastic Stress Analysis (TSA) and Digital
Image Correlation (DIC) experimental results. With this validation, this PROPOSED MODEL OF CORROSION DAMAGE
concept can provide a basis for a complete test program using
numerical method combined with in-situ inspection capabilities to To maximise asset management of ageing system, measurement and
estimate the remaining strength the corroded material. prediction of damage development during life through numerical
methods to predict performance and remnant strength is vital (Cosham,
KEY WORDS: Fracture Mechanics, Corrosion, Thermoelastic Stress Hopkins et al. 2007). An initial damage assumption is required to apply
Analysis, Digital Image Correlation, Offshore Structures fracture mechanics to evaluate corrosion. To approximate this, it can be
modelled as a combination of the following two geometric changes:
INTRODUCTION
1) Uniform damage: a general thickness reduction of area that
Offshore structures, pipelines and ships are exposed to the seawater increases stress in the remaining structure (represented by c and d)
environment which leads to corrosion damage. Furthermore, pitting
causes high stress intensity regions that possibly develops into cracks 2) Local pitting-crack: High stress concentration and cracks can be
(Turnbull, Wright et al. 2010). Since corrosion can lead to structural found at the corrosion locations with localised pitting. The
strength degradation and fatigue cracks, the integrity of such structures deepest/largest crack will then be considered. However, if no such
can be considerably affected (Wang, Wharton et al. 2014). As such, cracks are found, the highest stress concentration location can be
corrosion defects are commonly evaluated using the defect geometry considered as an equivalent crack (represented by 2a).
and a plastic collapse-based criterion applying methods such as DNV-
RP-F101 (Veritas 2010), while several codes exist to evaluate cracks This can be seen in Fig. 1 where the corroded area can be taken as
including BS 7910 (Institution 2013). Recently, a hybrid defect known uniform damage (as represented by the dashed lines) and the local
as Crack-in-Corrosion (CIC) (Bedairi, Cronin et al. 2012) has been pitting-crack is represented by a through crack with crack length, 2a. In
identified and investigated to determine the integrity evaluation of other words, this models a CIC situation. With such a proposed model,
corroded pipelines. If safety of these corroded marine platforms is to be it must be proven that numerical methods can predict results of these
ensured, taking into consideration such CIC defects and pitting with actual corroded specimens. A simple corroded plate specimen with
high stress concentration that may develops into cracks, a fracture through-crack is considered for an initial study of the application of
mechanics based approach may have to be applied to evaluate the fracture mechanics to quantify corrosion damage.
effects of corrosion on the strength of these structures (Zhang, Tan et
376
addition, through-cracks are considered as the equivalent cracks as a
basis for this study, instead of semi-elliptical or penny-shaped cracks
due to manufacturing constraints.
NUMERICAL ANALYSIS
Numerical Model
377
Fig. 4 Boundary and load conditions of model (U1 is in the x-direction,
U3 is in the z-direction and P is the pressure)
Material Properties
The isotropic power-law hardening model was adopted to characterize Fig. 6 Specimen after corrosion
the uniaxial true stress-strain relationship of EN10225 offshore steel,
written as The specimens were then washed and prepared using ASTM G1-03
(Standard 2004). Here, TSA is utilised under cyclic load to predict the
(1) extent of corrosion damage in terms of cracks Stress Intensity Factor,
K. TSA is a non-contacting technique that provides full field stress
where is the yield stress, is the corresponding yield maps from the surface of cyclically loaded components (Stanley and
strain, E is the Youngs modulus and n is the hardening exponent. In DulieuSmith 1996). It measures small temperature changes induced
the analyses, the Youngs modulus, E, was taken as 211 GPa while the because of cyclic load. For cracking problem, it computes cyclic stress
Poissons ratio v was assumed to be 0.3. The true stress-strain response field ahead of the crack-tip; makes it possible to evaluate the actual
for the pipeline material is shown in Fig. 5. This is done using strain crack driving force. Hence, coupons are cyclically loaded with an
gauges and guidelines of ASTM E8/E8M (Standard). amplitude of 5kN at about a mean load of 10kN with loading
frequency of 10 Hz using an Instron 8032 servo-hydraulic test machine
with a load capacity of 100kN. The coupons were first sprayed with a 3
700
passes of matt black paint coating with an estimate thickness of 16 20
microns. A Cedip Silver infrared detector system was used. This is to
600
obtain the mean temperature, T, and the change in temperature,
which is then used to calculate the thermoelastic constant, k using the
500
following relation
(2)
Stress (MPa)
400
Specimen and setup are prepared as shown in Fig. 7 respectively.
300
200
0
0.00 0.005 0.01 0.015 0.02 0.025 0.03 0.035
Strain (mm/mm)
Fig. 5 Stress vs. Strain graph of EN10225 offshore steel
In this Fig. 5, the symbols represent the experimental data, and the solid
line denotes the Least Square Fitting of the data. In addition, yield
stress ( of 585MPa and hardening exponent n of 0.0315 were
obtained for isotropic hardening behavior based on the uniaxial tension
tests. It should be noted that in the present work, the ratio of the
ultimate tensile strength to yield stress was estimated at
0.935 based on the experimental data.
2 fatigue pre-cracked coupon specimens with varying crack sizes, a Fig. 7 a) Specimen sprayed with black matt paint for TSA b) TSA
(between 4 to 6mm), are immersed in solution of 3.5wt% NaCl in experimental setup
distilled water for a period of 4 weeks. This provided an artificial
corrosion of 0.1mm depth. Such a corrosion specimen sample is shown Before the samples were tested, the technique was initially used to
in Fig. 6. obtain the thermoelastic constant, k. Thus, the thermoelastic constant
for this material is 3.40 x 10-12 0.03 Pa-1. An example of the full-field
stress from this technique can be seen in Fig. 8. Higher stresses are
observed around the crack-tip with lower stresses along the crack itself.
The crack-tip is estimated at the point of highest stress which enables
the calculation of the crack length.
378
1.7e+7
Numerical Solutions
TSA
0.5
1.5e+7
1.4e+7
1.3e+7
1.2e+7
3.5 4.0 4.5 5.0 5.5 6.0 6.5
90
1.8e+7
Numerical Solutions
TSA Numerical Solutions
89
TSA
1.7e+7
Stress Intensity Factor (Pa.m )
0.5
88
1.6e+7
Stress (MPa)
87
1.5e+7
86
1.4e+7
85
1.3e+7
84 1.2e+7
0.05 0.10 0.15 0.20 0.25 0.30 3.5 4.0 4.5 5.0 5.5 6.0 6.5
Depth of Corrosion (mm) Crack Length (mm)
Fig. 9 Numerical and TSA obtained Stress vs depth of corrosion Fig. 11 Stress Intensity Factor vs Crack length for corroded specimen
(0.1mm depth)
To check the validity of the stress intensity obtained through TSA, TSA With cracks of 4.2 and 6.1mm, the specimens are corroded to 0.1mm
were conducted on pre-cracked specimens without corrosion. Various depth. Referring to Fig. 11, TSA provides good estimation for crack
crack lengths ranging from 4.2 to 6.1mm were investigated. The stress length of 4.2mm, like the ones observed without corrosion. As
intensity factor, , can be calculated from TSA stress field using the expected, longer crack length of 6.1mm shows lower by 14.3%.
following relationship Consequently, TSA technique provided a full-field stress analysis
technique that allows to calculate experimentally the stress intensity
(3)
factor which validates the numerical solutions for crack lengths of 4mm
but has a limitation to provide any validation for crack lengths of 6mm.
where is the change in temperature, is the mean temperature, is
the thermoelastic constant and r is the distance away from the crack-tip.
379
Digital Image Correlation (DIC)
To overcome the short comings of TSA for crack lengths of 6mm, 2-D
Digital Image Correlation (DIC) was employed to observe the J-
integral of the cracks as measures of the fracture toughness of these (5b)
coupons. DIC allows visualization and quantification of deformation
(strain) of an object (Crammond, Boyd et al. 2014). The commercial where is the xx-direction strain, is the yy-direction strain, is
software LaVisiaon DaVis correlation software was used in all the xy-direction strain, is the y-direction displacement, is
analyses. A 5 Mp 12 bit monochromatic LaVision E-lite camera with a
Poissons ratio, with Equation 5a taking a summation of the various
Sigma 105 mm lens attached together with a LED ring flash light was
contours around the crack tip.
set up to obtain the experimental images and consistent illumination of
specimen for data collection. The specimens were sprayed white with
The DIC data provided various vector and strain data such as , ,
black speckles and DIC setup can be seen in Fig, 12.
and ; Fig. 13 provides an example of from DIC captured
strain data. With these field data, this excel spreadsheet creates the
visual calculation for each pixel with the summation of the pixel values
to obtain the contour and area integrals.
Like TSA, DIC was first utilised on non-corroded specimens with crack
length of 4.55 and 5.8mm. Using Equation 5, the J-integral was
calculated for these 2 crack lengths.
Fig. 12 a) Specimen sprayed with white and black speckles for DIC b)
DIC experimental setup 1400
Numerical Solutions
As DIC processing is sensitive to its subset and step sizes, an initial 1300 TSA
check on the various step and subset size is conducted with the subset
1200
size of 41x41 and step size of 15 chosen for this study. Following that,
J-integral can be calculated from the DIC data. There has been research
J-Integral (m.Pa)
1100
done using J-integral and DIC such as JMAN (Barhli, Hollis et al.
2015) and others (Becker, Mostafavi et al. 2012). Hence, an in-house 1000
excel spreadsheet was created and used to calculate the J-integral using
the following Equation 4; 900
800
(4)
where is the strain energy, is the dot product traction, is along 700
the contour path. Equation 4 is then discretised to
600
3.5 4.0 4.5 5.0 5.5 6.0 6.5
(5a)
Crack Length (mm)
Fig. 14 J-Integral vs Crack length for uncorroded specimen
380
From the plot of J-Integral against crack length for uncorroded
specimen in Fig. 14, the J-integral calculated using strain field data
from DIC are 6% and 10% lower (respectively) than the numerical
calculated values. This provided sufficient confidence to continue the
experiment for corroding the specimen to 0.1mm depth. The J-integral
against crack length for corroded specimen was plotted in Fig. 15.
1500
Numerical Solutions
1400 DIC
1300
J-Integral (m.Pa)
1200
1100
1000
900 Fig. 16 Von Mises Stress for uncorroded numerical model a = 6mm
800
The stress intensity factors, K, and J-integral were analysed for various
700
depth of corrosion between 0 2mm and crack length of 4 and 6mm.
3.5 4.0 4.5 5.0 5.5 6.0 6.5 The K and J-integral were plotted against the depth of corrosion and
Crack Length (mm)
compared with the handbook solution values in Fig. 17 to 20.
Fig. 15 J-Integral vs Crack length for corroded specimen (0.1mm
depth) 3.5e+7
5e+7
(6)
(7) 4e+7
381
Fig. 18 K vs Depth of Corrosion for a = 6mm specimen
4500 10000
3500
J-Integral (m.Pa)
J-Integral (m.Pa)
3000 6000
2500
4000
2000
1500 2000
1000
0
500 0.0 0.5 1.0 1.5 2.0
0.0 0.5 1.0 1.5 2.0
Depth of Corrosion (mm)
Depth of Corrosion (mm) Fig. 21 J-Integral vs Depth of Corrosion for a = 4, 5 & 6mm specimen
Fig. 19 J-Integral vs Depth of Corrosion for a = 4mm specimen
Proposed Test Program
10000
With non-destructive and intrusive techniques, such as TSA and DIC, it
is possible for in-situ inspection of corroded structures. This paper
Handbook Solutions for 6mm crack
Numerical Solutions for 6mm crack
provides a basis of procedure that could be further be used in industry
8000
where numerical modelling with full-field techniques can be used
together to have a comprehensive structural analysis of corroded
structures.
J-Integral (m.Pa)
6000
4000
2000
0
0.0 0.5 1.0 1.5 2.0
It can be seen from Fig. 17 to 20 that for corrosion depth of 0.5mm and
below, the numerical calculated fracture parameter values differ from Fig. 22 Schematics of proposed test program on offshore pipelines
handbook solutions within the range of 2 10% for both crack lengths.
With increasing corrosion depth, these differences increase with a Referring to Fig. 22, an example that can be applied in the offshore
significant difference occurring more for the 6mm crack length (at industry would be for the offshore pipelines where pigging systems can
2.0mm depth, difference of 97% for K and 82% for J-integral). This employ TSA and DIC techniques to detect corroded damaged structures
difference could be because of the corroded area dimensions as the and analyse the stress and strain fields around it. With the obtained
boundary of the corroded area was having more effect on the stress stress and strain data, numerical modelling can then be utilised to
field around the crack tip. Thus, it is not a simple case of implying that provide various iterations of the conditions (load, etc.) which then
SENT handbook solutions can represent corroded damage specimen validate back by the inspection data provided by TSA and DIC
without taking in consideration the length and width of corroded area, techniques. This will therefore provide a complete analysis and
especially for depth of more than 0.5mm. quantifying the corrosion damage on the offshore pipeline based on
fracture mechanics.
Furthermore, plotting crack length 4, 5 and 6mm J-integral against
depth of corrosion in Fig. 21, the increase in J-integral trend are similar CONCLUSIONS
with increasing depth of corrosion. This is expected as the longer crack
length will have a consistently higher J-integral. As such, to have a The proposed fracture mechanics based approach was shown to
more comprehensive analysis of the fracture parameters of such quantify the influence of corrosion damage on structural integrity. This
corroded structures, numerical modelling is a good recommendation to approach investigates the corrosion surface for geometrical structural
be utilised. change consisting of a general thickness reduction combined with
382
localised pitting-crack where cracks are predicted to initiate or initiated 97: 90-99.
from pitting. These two parameters enable quantification of the damage Cosham, A., P. Hopkins and K. Macdonald (2007). "Best practice for
and the application of fracture mechanics principles to corrosion the assessment of defects in pipelinesCorrosion." Engineering
damage. Failure Analysis 14(7): 1245-1265.
Crammond, G., S. Boyd and J. Dulieu-Barton (2014). "Evaluating the
A numerical model concept was validated against TSA and DIC localised through-thickness load transfer and damage initiation in a
experimental results of coupon specimens for corrosion depth of 0.1mm composite joint using digital image correlation." Composites Part A:
with varying cracks (length between 4 to 6.1mm). Comparison of Stress Applied Science and Manufacturing 61: 224-234.
Intensity Factor, K, & J-integral with experimental shows good validity Institution, B. S. (2013). BS7910:2013. Guide to methods for assessing
of numerical model proposed to quantify corrosion damage of offshore the acceptability of flaws in metallic structures. London.
steel. As such, 30 numerical models of varying corrosion depth (0 to Standard, A. E8/E8M, 2013a," Standard Test Methods for Tension
2mm) and crack length (4, 5 and 6mm) were carried out and the results Testing of Metallic Materials," ASTM International, West
showed a consistent trend with the handbook solutions. However, for Conshohocken, PA, 2013, DOI: 10.1520/E0008_E0008M.
corrosion deeper than 0.5mm, numerical solutions calculated a higher K Standard, A. (2004). "Standard practice for preparing, cleaning, and
and J-integral as compared with handbook solutions which leads to the evaluating corrosion test specimens." American Society for Testing
importance of employing numerical solutions for accurate and Materials G1-03.
representation of the corroded damage material/structure. Stanley, P. and J. DulieuSmith (1996). "The determination of crack-tip
parameters from thermoelastic data." Experimental Techniques 20(2):
With this validation, this concept will be able to provide a numerical 21-23.
method to estimate the remaining strength the material can withstand Tada, H., P. C. Paris and G. R. Irwin (1973). "The stress analysis of
due to expected loads without failure. For engineers, the investigation cracks." Del Research Corp, Hellertown PA.
results demonstrate good confidence in applying these testing TL., A. (2005). Fracture mechanics: fundamentals and applications 3rd
techniques in ensuring a more robust damage-tolerant design for edition, CRC Press.
offshore structures. Turnbull, A., Wright, L., & Crocker, L. (2010). New insight into the
pit-to-crack transition from finite element analysis of the stress and
REFERENCES strain distribution around a corrosion pit. Corrosion Science, 52(4),
1492-1498.
Barhli, S., D. Hollis, B. Wieneke, M. Mostafavi and T. Marrow (2015). Veritas, D. N. (2010). "Recommended Practice DNV-RP-F101
Advanced 2D and 3D Digital Image Correlation of the Full-Field Corroded Pipelines." Hovik, Norway 11.
Displacements of Cracks and Defects. Evaluation of Existing and Wang, Y., J. A. Wharton and R. A. Shenoi (2014). "Ultimate strength
New Sensor Technologies for Fatigue, Fracture and Mechanical analysis of aged steel-plated structures exposed to marine corrosion
Testing, ASTM International. damage: A review." Corrosion Science 86: 42-60.
Becker, T., M. Mostafavi, R. Tait and T. Marrow (2012). "An approach Zhang, Y., M. Ariffin, Z. Xiao, W. Zhang and Z. Huang (2014).
to calculate the Jintegral by digital image correlation displacement "Nonlinear elasticplastic stress investigation for two interacting 3D
field measurement." Fatigue & Fracture of Engineering Materials & cracks in offshore pipelines." Fatigue & Fracture of Engineering
Structures 35(10): 971-984. Materials & Structures.
Bedairi, B., D. Cronin, A. Hosseini and A. Plumtree (2012). "Failure Zhang, Y., T. Tan, Z. Xiao, W. Zhang and M. Ariffin (2015). "Failure
prediction for Crack-in-Corrosion defects in natural gas transmission assessment on offshore girth welded pipelines due to corrosion
pipelines." International Journal of Pressure Vessels and Piping 96 defects." Fatigue & Fracture of Engineering Materials & Structures.
383