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EFFECT OF WELDING SCHEME ON RESIDUAL STRESSES DURING IN-

SERVICE SLEEVE REPAIR WELDING OF GAS PIPELINES

Conference Paper · November 2015

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Ahmed R. Alian Mostafa Shazly

Next Structural Integrity Inc. & Tetra Tech Inc. The British University in Egypt
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 EFFECT OF WELDING SCHEME ON
RESIDUAL STRESSES DURING IN-SERVICE
SLEEVE REPAIR WELDING OF GAS
PIPELINES
Ahmed R. Alian, Mohammad M. Megahed
Teaching Assistant, Cairo University Professor, Cairo University

Mostafa Shazly
Associate Prof., The British University in Egypt

3rd International Conference in Africa and Asia: Welding and

Failure Analysis of Engineering Materials, Luxor, 2-5 Nov., 2015
2
Outline
1. In-Service Sleeve Repair Method
2. Objectives
3. In-Service Sleeve Repair Model
4. Verification Problems
5. Results and Discussions
6. Conclusions
 IN-SERVICE SLEEVE REPAIR METHOD
3

 The use of full-encirclement

steel sleeves for pipeline
repair was developed in 1970.
 Reinforce the area containing
the damage to prevent the
pipeline from bulging, leaking
or bursting.
 IN-SERVICE SLEEVE REPAIR METHOD
4

MAJOR DIFFICULTIES OF WELDING ONTO IN-SERVICE PIPELINE

 Pipe-wall melt-through: Localized heating cause the

pipe material to lose its strength, which may lead to
bursting under internal pressure

 High cooling rates by flowing gas at high velocity

during welding may promote formation of
martensite in the HAZ

 Residual stresses cause crack opening and growth

as well enhancement of hydrogen cracking
 IN-SERVICE SLEEVE REPAIR METHOD
5

LITERATURE SURVEY
 Bang, et al. (2002) developed an axisymmetric FE model
for in-service multi-pass sleeve repair welding of gas
pipelines and predicted transient temperature distributions,
weld HAZ size and hardness, and residual stresses
distribution.

 Liu et al. (2012) developed a 3D FE model for X70

pipelines to analyze the effects of gas flow rate on the
susceptibility of burn-through during the in-service welding.
 OBJECTIVES
6

 Predicting Residual Stresses of

Pipe
full encirclement repair sleeve
for different welding conditions
1. Influence of welding sequence Right Fillet
Weld

Repair Sleeve
2. Influence of welding schemes Left Fillet
Weld

Scheme # 1 Scheme # 2 Scheme # 3 Scheme # 4

(1 welder in one (two welders in (two welders in the (Backstep)
direction) opposite direction) same direction)
 IN-SERVICE SLEEVE REPAIR MODEL
7

GEOMETRICAL MODELING AND WELDING PARAMETERS

Pipe material: API 5L X65

Pipe size=8’’,
sch20

Geometry and dimensions of the welded joint

Welding Parameters
Filler Metals
Voltage Current Welding Speed Heat Input
Size
Type (V) (Amp) (mm/min) (KJ/mm)
(mm)
E8010 5.0 29 195 170 1.5
 IN-SERVICE SLEEVE REPAIR MODEL
8

 Finite Element Modeling

 Coupled thermo-mechanical procedure
 Liquid to solid phase transformation was accounted for.
 Element birth technique was
 IN-SERVICE SLEEVE REPAIR MODEL
9

Loads and boundary conditions

Natural
Convection Forced
Convection

3D FE model simulate
sequential welding sequence
loaded by thermal and
structural loads
 IN-SERVICE SLEEVE REPAIR MODEL
10

Loads and boundary conditions

Moving heat source acting on the deposited molten metal at different welding
steps
(element birth technique)
 MODEL VERIFICATION
11

 Verification problem # 1
Simulation of girth
welding of two pipes
 Test results published by Um
and Yoo (1997) are utilized.
 Test results provide
distributions of residual hoop
and axial stresses as
measured by the hole drilling
technique, for a girth weld of
carbon steel
 MODEL VERIFICATION
12

 Verification problem # 1
Simulation of girth welding of two pipes
ame 001  30 May 2012  | |
 Comparison between FE results and published test Frame 001  30 May 2012  | |

(a) 3D FE model
(b)400 3D FE model
400
Axisym FE model Axisym FE model
Expermental Expermental
300
300
Axial residual stress (MPa)

Hoop stress (MPa)

200
200

100

100
0

0
-100

-100 -200

0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80
Axial distance (mm) Axial distance (mm)

Axial Residual stresses Hoop residual stresses

 MODEL VERIFICATION
13

 Verificationproblem # 2
Simulation of fillet welding of two plates
 3D FE model is conducted to compare the predicted vertical
deflection with the experimental results published by Deng et al
(2007).
 MODEL VERIFICATION
14

 Verificationproblem # 2
Simulation of fillet welding of two plates
 3D finite element model was conducted

FE mesh and boundary conditions

 MODEL VERIFICATION
15

 Verificationproblem # 2
Simulation of fillet welding of two plates
 Comparison between FE results and published test
 The comparison of vertical deflections of the flange at the mid-
length section demonstrates very good agreement
Frame 001  30 May 2012  | |

3D FE model
-1
Expermental

-2

Deflection (mm)
-3

-4

-5

-6

-7
0 60 120 180 240 300 360 420 480
Axial distance (mm)

Deflected Welded Plate Vertical deflection

 IN-SERVICE SLEEVE REPAIR MODEL
16

Analysis
 RESULTS AND DISCUSSIONS
17

 Base Line Results (Gas Velocity= 10 m/sec, Working Pressure=

12.4 MPa, simultaneous welding sequence)
 Temperature contours at four different times during the
Frame 001  21 May 2012 

welding process 1000

Peak Temperature= 960 oC

800

Temperature (oC)
600

400

200

0 15 30 45 60 75

At time 6 sec Time (sec)

(1st step) Temperature history of

point-A (Peak temperature
along pipe inner surface)
At time 244 sec
(40st step)
 RESULTS AND DISCUSSIONS
18
 Base Line Results
 Welding distortion during welding process (X--70)

at welding step # 1 (start of welding, t=6 sec) at welding step # 14 (t=85 sec)

at welding step # 34 (t=207sec) final deformation after cooling to RT

 RESULTS AND DISCUSSIONS
19

Effect of welding sequence on residual stresses

ame 001  21 May 2012 
 Residual distribution along pipe outer surface Frame 001  21 May 2012 

(a) (b) 0.4

0

Normalized hoop residual stress (S/Syield)

0.3
Normalized axial residual stress (Sz/Syield)

Simultaneous
Sequential
0.2
-0.1

0.1

-0.2
0

-0.3 -0.1

Simultaneous
Sequential -0.2
-0.4
-0.3

0 10 20 30 40 50
-0.5 Axial distance (mm)
0 10 20 30 40 50
Axial distance (mm)

Axial residual Stresses Hoop residual Stresses

 RESULTS AND DISCUSSIONS
20

Effect of welding sequence on residual stresses

 Axial residual distribution along circumferential path on the pipe inner
Frame 001  26 Jun 2012 

surface
(a) 1
Normalized axial residual stress (Sz/Syield)

0.8

0.6

0.4

0.2

-0.2 Simultaneous
Sequential
-0.4

-0.6
0 45 90 135 180 225 270 315 360
Angle from weld start (o)
 RESULTS AND DISCUSSIONS
21

 Effect of welding sequence on residual stresses

Frame 001  26 Jun 2012 

 Hoop residual distribution along circumferential path on the pipe inner surface
(b) 0.8
Normalized hoop residual stress (S/Syield)

0.7

0.6

0.5

0.4

0.3

0.2 Simultaneous
Sequential
0.1

0
0 45 90 135 180 225 270 315 360
Angle from weld start (o)
 RESULTS AND DISCUSSIONS
22

Effect of welding scheme on pipe distortion (Radial)

Scheme #1

Scheme #2
Scheme #3

Scheme #4
 RESULTS AND DISCUSSIONS
23

 Effectof welding scheme on hoop residual stresses (along

Frame 001  27 Jun 2012 

pipe outer surface)

1
Normalized hoop residual stress (S/Syield)

0.8

0.6

0.4

0.2

-0.2

-0.4
Sequence #1
-0.6 Sequence #2
Sequence #3
-0.8
Sequence #4
-1
0 45 90 135 180 225 270 315 360
Angle from weld start (o)
 RESULTS AND DISCUSSIONS
24

 Effect
of welding scheme on axial residual stresses
Frame 001  27 Jun 2012 

(along pipe outer surface)

(a)0.6 Sequence #1
Sequence #2
Normalized axial residual stress (Sz/Syield)

0.4 Sequence #3
Sequence #4

0.2

-0.2

-0.4

-0.6

-0.8
0 45 90 135 180 225 270 315 360
Angle from weld start (o)
 RESULTS AND DISCUSSIONS
25

 Effect
of welding scheme on hoop residual stresses
Frame 001  21 May 2012 

(along pipe inner surface)

0.8
(b)
Normalized hoop residual stress (S/Syield)

0.6

0.4

0.2

0
Sequence #1
Sequence #2
Sequence #3
-0.2
Sequence #4

0 45 90 135 180 225 270 315 360

Angle from weld start (o)
 CONCLUSIONS
26

1) Axial and hoop residual stresses varies along pipe circumference,

specially at the pipe start point where the residual stresses dropped
dramatically then raised to peak value
2) Sequential welding sequence generates lower distortion and
residual stresses than simultaneous welding sequence
3) Backstep welding scheme generates the least pipe distortion, while
Scheme number 2 generates the highest pipe distortion
4) Backstep welding scheme generates the least residual stresses
Thank You For Your Attention
 6-8 3D FEM of In-Service Sleeve Repair Method

28
Discussion of Results (cont.)
comparison between axisymmetric model and 3D
Frame 001  21 May 2012  |
models Frame 001  21 May 2012  |

 Residual stress distribution along pipe0.5 inner surface

1
(a) (b)
0.4

Normalized hoop residual stress (S/Syield)

Normalized axial residual stress (Sz/Syield)

0.8
0.3
0.6
0.2

0.4 0.1

0
0.2
-0.1
0
-0.2

-0.2 3D model -0.3

Axisymmetric model 3D model
-0.4 Axisymmetric model
-0.4
-0.5
70 80 90 100 110 120 130 70 80 90 100 110 120 130
Axial distance (mm) Axial distance (mm)

Axial residual Stresses Hoop residual Stresses

 6-8 3D FEM of In-Service Sleeve Repair Method

29
Discussion of Results (cont.)
comparison between axisymmetric model and 3D
models
Frame 001  21 May 2012  | Frame 001  21 May 2012  |

 Residual stress distribution along pipe outer surface

(a) 0
(b)0.4
3D model

Normalized hoop residual stress (S/Syield)

Normalized axial residual stress (Sz/Syield)

0.3 Axisymmetric model

-0.1
0.2
-0.2
0.1
-0.3
0

-0.4 -0.1

-0.5 -0.2

-0.3
-0.6
3D model
Axisymmetric model -0.4
-0.7
-0.5
0 10 20 30 40 50 0 10 20 30 40 50
Axial distance (mm) Axial distance (mm)

Axial residual Stresses Hoop residual Stresses

 6-8 3D FEM of In-Service Sleeve Repair Method

30
Discussion of Results (cont.)

Effect of welding sequence on joint deflection

 Welding deflection contours

Simultaneous welding sequence sequential welding sequence

 RESULTS AND DISCUSSIONS
31

Effect of welding scheme on residual stresses

Scheme#1&3 Scheme#2 Scheme#4

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