MECHOCEAN

Eng. Solutions

Material,
fabrication
welding and ECA

6-Sep-18
6-Sep-18 Page 1 www.mechocean.com Dasharatha Achani
 MECHOCEAN
Eng. Solutions

When it goes wrong with wrong material

selection

 Local buckling
 Ovalising
 Ductile crack growth

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Eng. Solutions

Plastic deformation
R = 7.5m

Elastic deformation

6-Sep-18 www.mechocean.com FormDasharatha

Rev: Achani
 MECHOCEAN
Table of contents Eng. Solutions

1. Engineering Critical Assessment summary

2. Material properties

3. ECA inputs

4. Crackwise

5. Crackwise output

6. Optimising the results

7. Comments and suggestions on conservatism

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
ECA Summary Eng. Solutions

 Why
 Determine an acceptance criteria for pipeline welds
 When
 Once the pipe geometry and loads are defined
 Who
 SINTEF, EXOVA, DNV, TWI etc.
 What
 Data supplied by Installation Contractor, material properties from testing
 Crackwise
 LINKpipe

5 Footer can be customized

6-Sep-18 www.mechocean.com Dasharatha Achani
 MECHOCEAN
Pipeline loads Eng. Solutions

Pipeline lifecycle

 Reeling
 Drum diameter
 Coating thickness
 Aligner radius
 Pipe geometry
 Installation
 Sea state
 Hold time
 Distance between weld and clamp
 Operation
 Vortex Induced Vibration
 Shut downs
 Trawl impacts
Convert this to stresses
 End of life

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
ECA Summary Eng. Solutions

 BS7910
 Basis for ECAs using Crackwise
 Used as a reference by DNV-OS-F101
 Available material properties
 Depend on how extensive the testing was
 Assessment levels
 Level 1: simplified assessment method applicable when the information on
materials properties is limited
 Level 2: normal assessment route
 Installation, operational stresses
 Level 3: appropriate for ductile materials and enables a tearing resistance
analysis to be performed
 Reeling

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
ECA Summary Eng. Solutions

Assessment levels, Failure Assessment Diagrams

LEVEL 1 LEVEL 2
LEVEL 3

 Sublevels
 A, general assumption
 B, tensile material specific
 C, Finite Element based
Industry ECAs are usually Level 2B and Level 3B

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Material properties (1/5) Eng. Solutions

Testing
 Tensile properties
 Tensile testing of parent metal
 All Weld Tests
 Notched Cross Weld Tests
 Elastic modulus, Ultimate tensile strength, Yield strength
 Toughness
 SENT (Closer to pipe loading, demonstrated by FE)
 SENB
 Impact (Charpy)
 Stress intensity factor (K), CTOD, J-R curve
 Specimen condition
 As received => reeling on
 Strained => reeling off & installation
 Strained and Aged => operational loads

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Material properties (2/5) Eng. Solutions

A classification of material tests

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Material properties (3/5) Eng. Solutions

Testing, SENT

 SENT testing set up

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Material properties (4/5) Eng. Solutions

Testing, SENT
 Crack observation

Pre Crack a0
Tearing Δa

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Material properties (5/5) Eng. Solutions

Testing, SENT

 SENT Results

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Theoretical elements (1/6) Eng. Solutions

Factors

 Stress concentration factors

 Applies to elastic strains
 Takes into account geometric irregularities
 Primary bending stress

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Theoretical elements (2/6) Eng. Solutions

Factors

 Neuber’s rule

 2   2   1   1  SCF 2
 Applies to plastic strain
 Primary bending stress

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Theoretical elements (3/6) Eng. Solutions

Material characteristics

 Bauschinger effect
 Steel’s “Memory”
 Tensile properties are affected by the plastic deformation
 Lüder’s plateau in carbon steels

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Theoretical elements (4/6) Eng. Solutions

Material characteristics
 Toughness
 SENT testing
 J-R curve
 CTOD-R curve
 Offset power law type 2

y  0,796x 0,585

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Theoretical elements (5/6) Eng. Solutions

Failure Assessment Diagram

 UTS   Y
 Defined in BS7910 (1)  Lr max 
2 Y
 Fundamental tool used in ECAs

 Determines the acceptable flaws. (2)  Lr max  UTS
Y

KI
Kr 
K mat
 ref
Lr 
y

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Crackwise inputs Eng. Solutions

Adapting the inputs to Crackwise

 Reeling
 Convert the strains to stresses
 Neuber’s Rule
 Installation
 Adapt the stress spectra to the Crackwise format:
 Bending stress (SCF)
 Membrane stress
 Number of cycles
 Operation
 Bending stress (SCF)
 Membrane stress
 Number of cycles

Input into Crackwise

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Crackwise (18/22) Eng. Solutions

Results, Failure Assessment Diagram

Unsafe

Unacceptable Flaw, crack

propagates

Safe

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Crackwise (19/22) Eng. Solutions

Results, Failure Assessment Diagram

Unsafe
Acceptable Flaw, crack
will arrest

Safe

”Safe” zone

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Crackwise (21/22) Eng. Solutions

Tolerable defect sizes

Tolerable defect size for reeling 16" X52

900

750
Flaw length (mm)

600

450 Mainline
Tie-in
300
Full Pen repair

150

0
1 1.5 2 2.5 3 3.5 4 4.5 5
Flaw Height (mm)

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Crackwise (22/22) Eng. Solutions

Tolerable defect sizes

Evolution of the flaw size

through the different pipe
lifecycle steps.

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Eng. Solutions
Project Phase Verification
Material Properties Geometry Fracture Properties

 Stress vs Strain curve  Pipe Dimension CTOD vs Tearing from testing

 Reel / Aligner actual material. ie:
From manufacturer derived for  Load Cycles
actual pipe material  SENB
Normally no changes from initial  SENT
evaluation

LINKPipe Limiting Criteria

 Perform Simulations  Max 0.3 mm ductile crack

 Iterative Process growth for one cycle
 Max 1.0mm ductile crack growth
for complete reeling cycle

Results
Acceptance criteria
 Plot Critical Crack Size
As evaluated during ininitial analysis
 Length vs Depth
and / or agreed with client..

(Ie. 2mm x 50mm, Statoil)

Evaluate
Is acceptance
No  Challenge Acceptance Criteria
criteria within
 Evaluate Safety Margin
critical crack
size?
Discuss possible route with client

Yes

Acceptance Criteria Verified

6-Sep-18 www.mechocean.com Dasharatha Achani

 MECHOCEAN
Eng. Solutions

Thank you

6-Sep-18 www.mechocean.com Dasharatha Achani