idt expo – pipeline crack assessment & repair workshop

INTEGRATED PIPELINE analytics

Assessing the Performance of Non-WeldableRepair Sleeves for Repairing Planar Defects: A

Joint Industry Project

Sergio Limón


Presenter:

January 29, 2021

IDT EXPO – Pipeline Crack Assessment & Repair Workshop


Outline

• Program objectives and scope

• Participating companies

• Test matrix

• Project schedule

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Program Objectives

Increase understanding of the conditions that control fracture of pipelines with cracks and long seam weld anomalies (both referred to as planar defects)

1

Develop an assessment calculator for determining planar defects sizes candidate for the installation of a non-weldable sleeve repair

2

Test the performance of non-weldable composite repair systems on pipe samples with target planar defects3

Increase the recognition of composite-reinforcement of crack-like features among regulators4


Can a Composite Sleeve be Used to Repair a Crack?

• What does it mean to ‘repair a crack’?– Stop it from leading to failure…stop it from becoming critical– What is the definition of a critical crack? How is it determined?– What are the options for repairing subcritical cracks?– Do all subcritical cracks need to be repaired? – Do all imperfections in humans need repair? Do all people need a COVID vaccine?

• It has been demonstrated before– For natural SCC in a 34-inch gas pipeline using composite sleeves-ClockSpring (2007)

• V. Linton, E. Gamboa, M. Law, “Strategies for the repair of stress-corrosion cracked gas transmission pipelines: assessment of the potential for fatigue failure of dormant stress-corrosion cracks due to cyclic pressure service? Journal of Pipeline Engineering, 2007, 4(1), pp. 207-217

– For artificial seam weld defects in ERW pre-1970 ethylene pipeline using Altas carbon fiber composite sleeve and ComposiSleeve, a metal + e-glass hybrid sleeve system (2015)• Alexander, C.R., Rizk, T., Wang, H., Clayton, R., Scrivner, R., “Reinforcement of Planar Defects in Low-Frequency ERW Long

Seams using Composite Reinforcing Materials”, 11th International Pipeline Conference, Paper No. PC2016-64082,September 26-30, 2016, Calgary, AB

– For artificial seam weld defects in HF-ERW and LF-ERW pipe samples using carbon fiber composite sleeves (2018)• C. Sheets, C. Denowh, “Evaluating the performance of composite systems for reinforcing non-leaking crack-like defects in

transmission pipelines”, 31st PPIM conference, Paper 23, February 22, 2019, Houston, TX

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What Type of Defects are We Targeting to Repair?

5

D. Katz, et al.

J. Beavers, et al.

D. Katz, et al.

Battelle-PHMSA ERW Report

Pipe body cracks

Seam weld

defects


What Do the Industry Standards Say?

• Any of the defect repair methods listed in ASME B31.4 & 31.8 and CSA Z662 repair tables are default answers

• These standardized codes allow for the use of other repair methods not listed in their tables, as long as the repair has been demonstrated through engineering analysis and testing

• PHMSA stipulates a similar clause in 49CFR192.713

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Ref: ASME B31.4 sections 451.6.1 & 2.9, ASME B31.8 section 851.4.2, CSA Z662 section 10.11.4


How is our Repair Testing Program Different?

• Focus on the variables that control fracture of pipelines in the presence of a crack– What can make an existing

crack grow to failure?

• We will look at how crack stability and growth are affected by the repair systems and cyclic loading– Knowing the cycles to failure is

important…but that is not science

– We will perform metallurgical analysis to examine the crack growth behavior

• We are keeping regulators appraised of the testing progress

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Stress Analysis

Material Properties

Flaw Characteristic

s

Fracture Mechanics Approach

D. Katz, et al.

stable crack growth

existing crackscrack coalescence


Not All Planar Defects Sizes Would be Candidate for Repair with Composite Sleeves

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Crac

k De

pth

Crack Length

MAOP

SF X MAOP

100% WT

Candidate for Repair with a Non-Weldable Composite Repair

“Critical or Near Critical Defects”… to be Repaired with a Type B or Cut Out

“Significant”…Possibly to be Repaired with Type B, Compression Metallic Sleeves or Cut Out


Determining Candidate Defect Sizes for Repair

9

0

200

400

600

800

1,000

1,200

1,400

1,600

0 20 40 60 80 100 120 140 160 180 200 220 240 260

Pred

icte

d Fa

ilure

Pre

ssur

e [p

si]

Fracture Toughness, KJMAT [ksi-sqrt(in)]

4" X 32% WT"

4" X 42% WT"

4" X 52% WT"


What are We Testing?• Reinforced and unreinforced axial cracks starting from manufactured

notch• Pipe materials

– 12.75-inch x 0.250-inch, Grade X46, LF-ERW (1950s era)– 30-inch x 0.375-inch, Grade X52, A.O. Smith (1950s era)– Mechanical material testing to be performed

• All three repair manufacturer companies will be using carbon-epoxy based technologies– Each will be responsible for bringing a previously tested repair material and matrix

design– They will also be responsible for the installation of their repair systems

• Repaired samples will be pressure cycled (ΔP ~ 72% SMYS) and if no failure occurs, then a burst test will follow

• Integrate the effects of installation pressure (limited testing)• One set of three tests at 150°F (65°C)


What are We Not Testing?

• Multiple external defects• Internal axial defects• Internal and external circumferential defects• The composition or strength of various layers or

configurations of repair system itself• Bending or torsional cyclic loads• Corrosive effects on defect growth or repair

systems• Pipe microstructural or chemical composition

effects on defect growth


JIP Participants(9 pipeline companies | 3 repair companies)

Repair Companies

Pipeline Companies


Sergio [email protected]

(801) 258-1125

Chris [email protected]

(281) 450-6642

The Imperfect Troublemakers


Test Matrix10 Unreinforced Samples | 27 reinforced samples

Sample Description Number of Samples

10 Unreinforced Samples (1)

12-inch NPS pipe with defect in pipe body (ΔP = 72% SMYS) 1 (burst) and 3 (fatigue); 3 pipe samples

30-inch NPS pipe with defect in pipe body (ΔP = 72% SMYS) 1 (burst) and 3 (fatigue); 4 pipe samples

12-inch NPS pipe with defect in LF-ERW seam (ΔP = 72% SMYS) 1 (burst) and 3 (fatigue); 3 pipe samples

27 (24 + 3(6)) Reinforced Samples (each manufacturer will complete the following test matrix) (2) (3)

12-inch NPS pipe with defect in pipe body (ΔP = 72% SMYS) 1-in-3 (fatigue followed by burst) (4)

12-inch NPS pipe with defect in pipe body with Pinstall (ΔP = 72% SMYS) 1-in-3 (fatigue followed by burst) (5)

30-inch NPS pipe with defect in pipe body (ΔP = 72% SMYS) 3 (fatigue followed by burst)

12-inch NPS pipe with defect in LF-ERW seam (ΔP = 72% SMYS)3 (fatigue followed by burst) + Elev. Temp.

3 (fatigue followed by burst) + Elev. Temp. (6)

NOTES:(1) The unreinforced samples will be used as a reference data set against which all results will be compared.(2) The number of Reinforced Samples listed is “per manufacturer”.(3) The “fatigue” portion of these tests will involve a targeted 25,000 fatigue cycles. If no failures have occurred after reaching this target number

of cycles, burst testing will be conducted.(4) The “1-in-3” sample will be a single 12-inch NPS sample that will have three EDM notches located at the same axial position and separated

circumferentially 120°.(5) Internal pressure present during installation, SAFE pressure value to be determined after burst testing unreinforced samples.(6) CS-NRI will also include one set of three tests at 150°F (65°C).


Starting Notch Characteristics

• Pre-cycling will be used to generate cracks at base of EDM notches

• For 12.75-inch – 3 inches long– 30% deep

• For 30-inch– 3 inches long– 35% deep

Starting Notch

Fatigue Growth


Pipe Sample Configurations

Standard Sample (notch in base pipe)

Standard Sample (notch in seam weld)


Project Schedule

Task Description Date

Project kick-off meeting October 28

Complete contracting October - December

Start & complete sample fabrication November – December

Start unrepaired sample testing and pre-cycle samples January & February

Composite repair installations March & April

Conduct pressure cycle and burst testing January through June

Project completion End of Q2 2021 (goal)


Preguntas?

Sergio [email protected]

(801) 258-1125

Chris [email protected]

(281) 450-6642

idt expo – pipeline crack assessment & repair workshop

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