Challenges in Engineering Critical Assessment

of CRA Pipelines
2nd Welding Technology Asia 2012 Conference
17 April 2012
 Challenges

ƒ Tensile properties of the weld metal and base/parent metal

- As per DNV-OS-F101, the weld metal tensile properties shall over-match
or at least even-match the base metal properties at all conditions and
strain level under consideration.

- May not be the case for CRA pipelines.

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 800 Engineering Stress-Strain curves at room temperature

700
- Yield strength of weld
600 metal is under-matching
500 the base metal.
Stress (MPa)

BM1, full WT including Clad

400
BM2, full WT including Clad
- Severe under-matching
BM3, full WT including Clad
300
PW1, all weld at design temperature
PW2, all weld
200 PW3, all weld
RW1, all weld (>120°C) !
100 RW2, all weld
RW3, all weld

0
0 5 10 15 20 25 30 35 40 45 50
Strain (%)
700 Engineering Stress-Strain curves at design temperature

Upper bound BM curve used for ECA

- Material strength de-rating for 600

the weld metal is greater than 500

lower bound RW curve used for ECA

the parent metal ! 400

Lower bound PW curve used for ECA BM1, full WT including Clad
BM2, full WT including Clad
300
BM3, full WT including Clad
PW1, all weld

200 PW2, all weld

PW3, all weld
RW1, all weld
100 RW2, all weld
RW3, all weld

0
0 5 10 15 20 25 30 35 40 45
© Det Norske Veritas AS. All rights reserved. 3 Strain (%)
 700 True stress strain curves of 622 AUTO Weld Metal used for ECA

600
- Different weld consumable,

500
different strength de-rating at
high temperature.
Stress (MPa)

400

300

622 AUTO at 140°C, S3

200
622 AUTO at 120°C, S2
100 622 AUTO at 100°C, S1

0
0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0
Strain (%)

700 True stress strain curves of 625 AUTO Weld Metal used for ECA

- Selection of weld consumable is

600

very important. 500

Stress (MPa)

400

300

625 AUTO at 140°C, S3

200
625 AUTO at 120°C, S2
100 625 AUTO at 100°C, S1

0
0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0

© Det Norske Veritas AS. All rights reserved. 4 Strain (%)

 800 True Stress-Strain curves for Crackwise (23°C)
- Testing of 309Mo shop weld.
700

600
- At RT, ultimate tensile strength
500
of weld metal is higher than the
Stress (MPa)

400 parent metal >> join transverse

300
tensile specimen shows
specimen broke at parent
200

BM, upper bound true stress strain curve

metal.
100
WM, lower bound true stress strain curve

0
0 5 10 15 20 25 30 35
Strain (%)

800 True Stress-Strain curves for Crackwise (110°C)

„ At DT, the UTS of weld metal is

700
lower than that of the parent
metal due to the de-rating of the 600

weld metal strength and for this 500

situation we have serious 400

under-matching and almost no

300
defect can be tolerated for the
large strain condition. 200

BM, upper bound true stress strain curve

100
WM, lower bound true stress strain curve

0
0 5 10 15 20 25 30
Strain (%)

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 Wide Plate Test of 309LMo Weld
- Wide plate test was performed by DNV to obtain information about under-
matching weld metal and conservatism inherent in the ECA.
- The EDM notch was prepared either at the weld centre line (WCL) or
fusion line/ HAZ location from cap side. The EDM notch size was 7 mm in
length and 1 mm in height, estimated on the basis of acceptance criteria of
the manual UT.
200 200
EDM notch
R=25

140
100

250

350 350 Strain gauges (two each side)

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 Wide Plate Test of 309Mo Welds
EDM Notch

Damaged specimen with notch at weld centre, Damaged specimen with notch at weld centre,
broken at the notch location. (test temperature: 110°C) broken at the notch location. (test temperature: 110°C)

EDM Notch

Damaged specimen WP-3 with notch at weld centre, Damaged specimen WP-6 with notch at weld fusion line,
broken in the notch location (test temperature: 70°C) broken in parent (test temperature: 50°C)

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 Wide Plate Test (continued)
¾Due to the good fracture resistance of the weld, the failure mode of the wide
plate specimen is plastic collapse of weld metal or parent metal, and the
crack ductile tearing is more than 1.0 mm in all specimens.
1400 J R- curves, JSM G7 (Design Temp)

1300

1200 0.75
J=980∆a
1100 0.75
J=710∆a
1000
Fracture toughness, J [N/mm]

900

800

700

600

500

400

300

G7 JSW WM G7 JSW WM Curve

200

100
G7 JSW FL G7 JSW FL Curve
0
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
Stable crack extension, ∆a [mm]

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 Wide Plate Test (continued)
¾All the four segment specimens at 110°C broke at the centre
of the weld metal independent of the flaw location. Whether at
the WCL or at the FL / HAZ, the failure mode of the four
specimens was plastic collapse of the weld metal.
¾The specimens tested at 70°C broke in the weld metal, and
the failure mode was the same as for the specimens tested at
110°C. However, the strain increased to 8.1%, which is much
higher than for the specimens tested at 110°C i.e. 2.4%.
¾The specimen tested at 50°C was broken in parent metal and
the strain level is up to 10.3% that is close to the parent metal
strain corresponding to ultimate strength of parent metal.

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 Wide Plate Test (continued)
ƒ SS 309LMo tensile properties and fracture resistance
properties is very sensitive to the test temperature.
ƒ Because of the difference between the de-rating of the weld
metal and parent metal strengths at higher temperatures, PQR
test must be performed at the design temperature to obtain the
actual stress-strain behavior of the weld metal compared to
that of the parent metal.

© Det Norske Veritas AS. All rights reserved. 10

 Challenges (continued)

ƒ High Strain, HP/HT (High Pressure High Temperature)

- Effect of temperature on the tensile properties of the materials.

- High strain above yield (from 0.5% up to 2%) especially at buckle trigger
portion.

- According to DNV-OS-F101, combination of internal pressure and

longitudinal load (e.g. bi-axial loading condition) will lead to reduction of
strain capacity.

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 Challenges (continued)
- 3D finite element analysis to study the influence of bi-axial loading
condition on the integrity of the pipeline girth welds.

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 Challenges (continued)
800
BS7910 WMCL BS7910 FL

700 WMCL without pressure WMCL with pressure

FL without pressure FL with pressure

600
J-integral (N/mm)

500

400

300

200

100

0
0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00%
Applied strain

© Det Norske Veritas AS. All rights reserved. 13

 Challenges (continued)

ƒ ECA results: critical flaw size curve

3 Critical Flaw Size Curves for 10" x 20.9 mm WT Pipeline Field Production Girth Welds (i.e. Zone-2)

Weld metal:
Design Temperature (DT)
2.5 E = 209000 MPa, Weld Metal, YS = 357 MPa, UT = 589 MPa
otal peak strain = 2.2 % + welding strain = 0.5% => Pm = 556 MPa from parent metal
1.6 mm Misalignment => SCF = 1.3 =>Pb = 4 MPa
Lr cut-off = UT/YS = 1.75
Cyclic Stress Range, ∆Pm = 346 MPa for month no. 1, SCF = 1.3 =>Pb = 77.7 MPa
2 Stress ranges for other months as per Report No.: 4211136-PL-ET-014, Rev. A
Critical Flaw Height [mm]

Fatigue Crack Growth Rate : CP -850 mV Ag/ AgCl

Fatigue life factor (FLF) = 2

1.5

PW, Surface Flaw in Field Production Weld Metal

0.5

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Critical Flaw Length [mm]

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 Challenges (continued)

ƒ ECA results: critical flaw size curve

- Critical flaw size curve which is smaller than workmanship criteria.

- If adopted, high repair rate is anticipated.

- Slow installation is expected.

- High cost!

© Det Norske Veritas AS. All rights reserved. 15

 Summary
ƒ Workmanship weld flaw acceptance criteria may not be always
conservative and may not be applicable for all situation as
perceived generally.
ƒ Tensile testing at design temperatures to check the actual
stress strain behaviour.
ƒ Proper consideration of parameters used in the ECA in getting
workable flaw acceptance criteria.
ƒ Validation of ECA results by testing of segment/wide plate
specimens.

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