Measurement of Flaw Growth in Electric Resistance Welded Pipe Seams From Multiple Pressure Tests and Hold Time and Implications on Managing Pressure Reversals in Hydrostatic Tests

D. Warman, Dan Jia, Yong-Yi Wang, M. Bongiovi, Chad Destigter
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Abstract

The presence of low frequency (LF) ERW seam weld defects (e.g., lack of fusion, stitching, and hook cracks) can reduce the pressure-carrying capacity of a line pipe. In cases where these defects may have been subjected to a hydrostatic test, there is a possibility that the seam weld defects could fail at a lower pressure upon re-pressurization. This type of failure, which occurs at a pressure less than the previous pressure and where no time dependent degradation has contributed, is commonly referred to as a pressure reversal. LF ERW seam flaws can fail when held at a constant load below the straight-off to failure load. This is because ductile materials can exhibit time-dependent creep behavior. Evidence of time dependent behavior is provided by failures that occur during the maximum pressure hold period of a hydrostatic test. Time dependent growth and reverse yielding can be detrimental when performing multiple high pressure hydrostatic tests which can result in many blowouts during the hydrotests, and flaws that survive the hydrotest may experience some ductile tearing that could be detrimental to fatigue life. The objectives of the work described in this paper are to: 1) Develop a testing methodology to measure the time dependent growth of vintage LF ERW bondline flaws from actual test samples, at elevated stress levels as well as stress reversals (creep and pressure reversals). The testing would be analogous to pressure testing, 2) Perform a series of tests to measure the growth of flaws via CMOD from a 25% wt (wall thickness) EDM notch placed within the bondline or HAZ of vintage LF ERW seams, and 3) Produce a dataset of physical results that can be utilized to develop a model which can predict the growth of typical ERW flaws such as hook cracks and lack of fusion, as a function of hoop stress and stress reversals. This model could then be utilized to optimize pressure testing in the future to minimize any detrimental effects of flaw growth that could reduce fatigue life. A testing methodology consistent with the objectives was developed to measure creep associated with hold periods at elevated stresses (pressures) and pressure reversals. This testing methodology covers the following items: 1) The sample size, flaw size and overall configuration for loading and measurement with CMOD. 2) The straight-off to load failure stress and CMOD at a load rate consistent with pressure testing. 3) The loading steps and associated hold periods based on a fraction of the straight-off to load failure. 4) Cycles to zero and back to load to observe the effect of stress reversals. The methodology was successful in showing the time-dependent growth of the flaws at elevated loads, as well as establishing that after reducing the pressure down to zero and back to load, the time dependent growth could be re-activated. The results of the various tests performed are presented in this paper.
从多次压力试验和保持时间测量电阻焊管焊缝缺陷生长及其对静压试验中压力反转处理的影响
存在低频(LF) ERW焊缝缺陷(如缺乏熔合、拼接和钩裂纹)会降低管道的承压能力。在这些缺陷可能经受过静水试验的情况下,有可能在再加压时较低的压力下焊缝缺陷会失效。这种类型的故障发生在压力小于之前的压力下,并且没有时间依赖性的退化,通常被称为压力反转。当保持在低于直接失效载荷的恒定载荷下时,LF ERW接缝缺陷可能失效。这是因为延性材料可以表现出随时间变化的蠕变行为。在流体静力试验的最大保压期间发生的故障提供了时间依赖性行为的证据。当进行多次高压静水试验时,随时间变化的生长和反向屈服可能是有害的,在水压试验期间可能会导致多次井喷,并且在水压试验中幸存的缺陷可能会经历一些延性撕裂,这可能会损害疲劳寿命。本文所描述的工作目标是:1)开发一种测试方法,从实际测试样品中,在高应力水平和应力逆转(蠕变和压力逆转)下,测量复古LF ERW粘结线缺陷的随时间增长。测试将是类似于压力测试,2)执行一系列测试来测量缺陷的生长通过CMOD 25% wt(壁厚)电火花切口放置在古董低频一并接缝的不同或热影响区,和3)产生一个数据集的物理结果,可以用来开发一个模型,该模型可以预测的增长典型一并钩裂缝和未熔合等缺陷环向应力的函数和应力反向。该模型可用于优化未来的压力测试,以最大限度地减少可能降低疲劳寿命的缺陷生长的任何有害影响。开发了一种符合目标的测试方法,用于测量在高应力(压力)和压力反转下与保持时间相关的蠕变。该测试方法包括以下项目:1)CMOD加载和测量的样本量、缺陷大小和总体配置。2)在与压力测试一致的加载速率下,直接加载破坏应力和CMOD。3)加载步骤和相关的保持时间基于直接加载失败的一小部分。4)循环至零并返回载荷,观察应力逆转的效果。该方法成功地显示了高载荷下缺陷的随时间增长,并确定在将压力降至零并返回载荷后,随时间增长的缺陷可以重新激活。本文介绍了各种试验的结果。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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