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IPC2012
September 24-28, 2012, Calgary, Alberta, Canada
IPC2012-90404
Rp0.2 Rm uEL
300
N/mm² N/mm² Y/T %
Weld cap (round bar specimen)
min (max) 758 (853) 856 (891) 0.89 (0.96) 7.8 (9.8)
avg 819 873 0.94 9.0
STDV 29 13 0.02 0.7
200
0 2 4 6 8 10 12 Weld root (round bar specimen)
Indent min (max) 815 (876) 876 (919) 0.93 (0.96) 5.2 (7.7)
Weld cap Mid thickness Weld root avg 855 899 0.95 6.6
STDV 19 12 0.01 0.7
Figure 2: Example of a Vickers hardness survey (weld A06, Full-thickness (rectangular specimen)
12:00 position). min (max) 811 (886) 873 (914) 0.93 (0.97) 6.3 (7.6)
avg 845 890 0.95 7.0
A summary of the results of the hardness surveys is given STDV 24 14 0.01 0.4
below (values are HV10): Notes: min, max and avg are the minimum, maximum and average value from
• Average pipe metal hardness ranged from 295-297 (Pipe the set of specimens, and STDV is the standard deviation.
A), 272-300 (Pipe B) and 271-291 (Pipe C). Table 2: Weld B10: Summary tensile test results.
• Average HAZ hardness of the mainline welds ranged from
279-282 (Pipe A), 263-292 (Pipe B) and 252-272 (Pipe C). Similar results and observations have been
Tie-in weld A17 was lower, ranging from 248-251. reported[14][15][16], but the location of minimum and maximum
• The average pipe metal hardness was consistently higher strength is seen to vary around the pipe circumference. Hence
than the average HAZ hardness, inferring HAZ softening for these tests it was considered important to characterize the
in all welds. Pipe C was found to have a higher sensitivity circumferential variation in tensile properties specific to the
to HAZ softening. welds being tested.
• Average WM hardness of the mainline welds ranged from The test results showing the variation in yield strength
290-296, which was similar, if not greater than the around the weld circumference are shown in Figure 3. As can
corresponding pipes. be seen, there is a difference in strength of approximately
• The average WM hardness of the tie-in weld (A17) was 100N/mm² around the weld circumference; the lowest values
much lower than the mainline welds. were measured at approximately the weld 12:00 and 06:00
In addition, a through-thickness hardness survey was positions, the highest at approximately the weld 03:00 and
undertaken at the WM centre-line of weld B10; measurements 09:00 positions. Comparing the RB specimen results, the yield
were made at 1.5mm increments, starting 1mm up from the strength of the weld cap region was consistently lower than that
weld root. The hardness ranged from 266-331, the lowest measured in the weld root region. The yield strength measured
values being measured in the weld cap region, and the highest from the rectangular specimen was similar to that measured in
individual peaks occurred at the weld root and near weld mid- the weld root (the results are consistent with the results of the
thickness. It is likely that the reduction in hardness in the near hardness survey; highest hardness/strength in the weld
weld cap region is attributed to the lower cooling rate (or the root/near weld mid-thickness region, lowest in the near weld
increase in welding cooling time) associated with the welding cap region).
process. The variation in tensile strength showed a similar trend;
Tensile tests the weld 12:00 and 06:00 positions giving the lowest values,
The test procedure in BS EN 10002-1[13] was used but the variation in strength was less; approximately 60N/mm².
throughout for each different type and size of specimen tested. As a consequence of this, there was also a sizeable variation in
In total, 217 tests have been undertaken to fully characterize Y/T ratio (0.92 to 0.97) around the weld circumference, as
the stress-strain behavior of the weldments. shown in Figure 4.
The detailed testing of weld B10 showed that there is a
significant variation in strength around the weld circumference.
The test results are summarized in Table 2 in terms of
maximum and minimum measured values, average value and
standard deviation for each specimen type and through wall
position sampled by the specimen. The individual quantities of
yield and tensile strength are presented in Figure 3 and Figure 4
1000 P1 (12:00) - L
750 P1 (03:00) - L
0 3 6 9 12 P1 (06:00) - L
P1 (08:00) - L
Weld circumferential position (o'clock)
P1 (08:30) - L
P2 (06:00) - L
strength measured using RB specimens (cap and P2 (08:00) - L
root region) and rectangular full thickness P2 (08:30) - L
800
not one consistently achieved the highest average values of
yield or tensile strength, Y/T ratio or elongation.
• The variation in strength observed between the different
pipe manufacturers and plate sources resulted in a wide
range of weld metal strength mismatch, ranging from 11%
600 WM root (07:45)
under-matching to 26% over-matching. API 1104, CSA
WM root (09:30)
WM cap (00:30)
WM cap (02:45)
WM cap (06:15)
WM cap (08:00)
P1 (12:00) - L
P1 (03:00) - L
P1 (06:00) - L
P1 (08:00) - L
P1 (08:30) - L
P2 (12:00) - L
P2 (03:00) - L
P2 (06:00) - L
P2 (08:00) - L
P2 (08:30) - L
Z662 and EPRG require that the weld metal yield strength
is not less than the yield strength of the line pipe.
Charpy impact energy tests
Notes: P1, P2 - pipe 1, pipe 2 Each specimen was prepared and tested according to BS
L - pipe longitudinal specimen orientation
EN 10045-1[18]. The Charpy impact energy and percentage
All parent pipe (P1, P2) specimens were full-thickness strap
All WM specimens were round bar shear area was measured from each tested specimen. A total of
Figure 6: Weld A06: Circumferential variation of yield 108 tests have been undertaken.
(Rp0.2) and tensile strength (specimen location The results from the specimens notched at the WM centre-
referenced to the weld 12:00 position). line are presented in Figure 8, in relation to the weld ID and the
position around the weld circumference that the specimens
20 were extracted. The data are presented as the minimum,
WM strength over-match maximum and average values from a set of 3 full-sized Charpy
specimens. The results from the specimens notched at the HAZ
(50/50) are presented in an identical manner in Figure 9.
Yield strength mismatch (%)
10
300
min
Full size Charpy energy (J)
0 max
avg
200
WM strength under-match
-10 100
P1(max) : WM(min)
P1(avg) : WM(min)
P2(max) : WM(min)
P2(avg) : WM(min)
P1(min) : WM(min)
P2(min) : WM(min)
P1(avg) : WM(max)
P1(min) : WM(max)
P1(max) : WM(max)
P2(min) : WM(max)
P2(max) : WM(max)
P2(avg) : WM(max)
P1(max) : WM(avg)
P1(avg) : WM(avg)
P2(max) : WM(avg)
P2(avg) : WM(avg)
P1(min) : WM(avg)
P2(min) : WM(avg)
0
B 06 (04:00)
A 06 (06:00)
A 33 (06:00)
A 44 (06:00)
A 46 (06:00)
A 50 (06:00)
B 03 (06:00)
B 08 (06:00)
A 06 (12:00)
A 33 (12:00)
A 44 (12:00)
A 46 (12:00)
A 50 (12:00)
B 03 (12:00)
B 06 (12:00)
B 08 (12:00)
A 17 (06:00)
A 17 (12:00)
Figure 7: Weld A06: Variation in yield strength (Rp0.2)
mismatch.
Figure 8: Charpy impact tests: all WM test results (tested at
A summary of the results and observed trends from the -20°C).
tensile tests undertaken on all 9 girth welds is given below:
300
• All line pipe achieved the specified minimum yield and min
Full size Charpy energy (J)
max
tensile strength requirements of the line pipe specification, avg
ANSI/API 5L[17]. 200
A 06 (06:00)
A 33 (06:00)
A 44 (06:00)
A 46 (06:00)
A 50 (06:00)
B 03 (06:00)
B 08 (06:00)
A 06 (12:00)
A 33 (12:00)
A 44 (12:00)
A 46 (12:00)
A 50 (12:00)
B 03 (12:00)
B 06 (12:00)
B 08 (12:00)
A 17 (06:00)
A 17 (12:00)
CTOD (mm)
Fracture mechanics tests
0.20
Each specimen was prepared and tested in three-point-
bend loading according to BS 7448:Part 2[19]. To ensure
accuracy of notch placement, the sides of each specimen were 0.10
ground to a fine finish and etched (5% nital) to reveal the weld
profile/microstructure. After notching, each specimen was
locally compressed and fatigue pre-cracked at ambient 0.00
laboratory temperature to produce a sharp crack of depth Figure 11: Fracture tests: all HAZ (50/50) test results (tested
approximately equal to half of the specimen thickness. at -20°C)
On completion of each test the fracture faces were
measured to confirm the initial crack depth (i.e., depth of the As can be seen in Figure 11 the fracture toughness of the
fatigue pre-crack) and final crack depth. HAZ exhibited a high degree of scatter, CTOD ranging from
Single point values of fracture toughness (CTOD, J and K 0.03 to 0.38mm. Of the 27 specimens tested, 11 resulted in a
at the fracture point) were calculated for each specimen tested. type ‘c’ failure, 11 type ‘u’ and 5 type ‘m’. The fracture
The results, in terms of CTOD, are presented in Figure 10 toughness of the HAZ region was low; 9 tests failed to achieve
(WM tests) and Figure 11 (HAZ, 50/50). Type ‘c’, ‘u’ and ‘m’ the minimum CTOD requirement of API 1104 (CSA Z662 does
are used to describe the failure behavior of each specimen: not specify a minimum requirement, the minimum measured
Type ‘c’ - the critical value of fracture toughness at the value is used in the assessment, and EPRG does not require
onset of brittle crack extension (or ‘pop-in’) fracture mechanics testing to be undertaken).
when the average stable crack extension is less The high degree of scatter in the HAZ results is likely to be
than 0.2mm. due to the abutting pipes being from 3 different sources and/or
Type ‘u’ - the critical value of fracture toughness at the different production heats. Those data from different welds, but
onset of brittle crack extension (or ‘pop-in’) from pipe from the same source and production heat are
when the average stable crack extension is described in more detail below:
equal to or greater than 0.2mm. • Three of the welds tested were from Source B (A06, A33
Type ‘m’ - the value of fracture toughness at the first and A50), and from the same production heat. CTOD
attainment of a maximum force plateau for varied from 0.04 to 0.19mm, the average being 0.10mm
fully ductile behavior. with a standard deviation of 0.05mm. One specimen failed
to achieve the minimum CTOD requirement of API 1104.
0.30 The data set consisted of 5 type ‘c’ failures (2 ‘pop-in’
Type 'c' events) and 4 type ‘u’.
Type 'u'
Type 'm'
• Four of the welds tested were from Source C (A17, A44,
A46 and B03), and from the same production heat. CTOD
0.20
CTOD (mm)
Brittle Fracture, Kr
until the corresponding assessment point (Kr, Lr) was
coincident with the FAC (the results of this analysis are 0.8
presented in Table 4). 0.6
0.4
10
0.2
8 0.0
0.0 0.2 0.4 0.6 0.8 1.0 1.2
Defect height (mm)
6
Plastic Collapse, Lr
4 FAC HAZ (1) HAZ (2) HAZ (3) WM
0.8 defects, 2 tests with 6mm deep defects) and was tested at either
0.6 +20°C or -20°C. Although the analysis resulted in conservative
0.4 predictions, a reduction in conservatism was highlighted when
comparing the predictions for a lower strength material (20
0.2 CWP tests undertaken on grade X70 material).
0.0 CSA Z662
0.0 0.2 0.4 0.6 0.8 1.0 1.2 To verify the applicability of the CSA Z662 assessment
Plastic Collapse, Lr procedures the following analyses were undertaken:
FAC HAZ (1) 1. Construct loci of critical defect height as a function of
Figure 14: API 1104 (Option 2) analysis: Critical stress defect length for the prevention of brittle fracture and
predictions based on the FAD (example shown: plastic collapse respectively, and compare these loci with
weld A06). the CWP specimen defects. Each locus was constructed
based on the minimum measured mechanical properties of
The method used to predict the critical (failure) stress for the weldment, and the applied longitudinal tensile bending
each CWP specimen and the corresponding failure stress ratio stress used in the analysis was limited to SMYS.
(results presented in Table 4) is shown in Figure 15. 2. For each CWP specimen tested, determine the theoretical
maximum longitudinal bending stress for failure. The
yield strength is not less than the line pipe and the pipe’s Y/T
100
ratio in the axial direction is not greater than 0.9. The results of
the tensile tests showed that the tensile properties varied
significantly; resulting in WM yield strength mismatch ranging
from -11% (under-match) up to +26% (over-match), and Y/T
ratios ranging from 0.86 to 0.99.
0
0.0 0.2 0.4 0.6 0.8 1.0 An example of the analysis undertaken of each weld and
Defect depth ratio, d/t individual CWP specimen to verify the applicability of EPRG
Plastic collapse Brittle fracture HAZ (1) HAZ (2) HAZ (3) WM to grade X100 pipelines is summarized below.
Figure 16: CSA Z662 analysis: Critical defect size loci of As can be seen from Figure 17, each CWP specimen from
weld A06 compared with the CWP defect sizes weld A06 exceeded the EPRG performance criterion of 0.5%
tested. remote strain
1000
Defect height
h≤3mm 3<h≤4mm 4<h≤5mm
Defect length 5.3t 3.9t 3.2t
Notes: h - Defect height
t - Pipe wall thickness
800 Table 5: Theoretical limits (grade X80 line pipe).
4.0 1.0
Brittle fracture, Kr
3.0 0.8
2.0 0.6
1.0 0.4
0.0 0.2
0 50 100 150 200
Defect length (mm) 0.0
0.0 0.2 0.4 0.6 0.8 1.0 1.2
FAC HAZ (1) HAZ (2) HAZ (3) WM Plastic collapse, Lr
Figure 20: BS 7910 Level 2A analysis: Critical ‘surface FAC CWP test, HAZ (1) Critical stress, HAZ (1)
breaking’ defect size locus of weld A06, compared Figure 21: BS 7910 Level 2A analysis: assessment of CWP
with the CWP defect sizes tested. test HAZ (1) from weld A06 and the corresponding
assessment of a critical failure stress.
Figure 20 is an example of a critical ‘surface breaking’
defect size locus, which was calculated for weld A06. As can An additional series of assessments were undertaken to
be seen, each CWP specimen would be predicted to fail at an investigate the effect of material toughness. For each
applied longitudinal stress less than SMYS, as the CWP defect assessment, if the input value of fracture toughness was
sizes are above the critical defect size locus. However, each sufficiently large to ensure that failure was controlled by the
CWP specimen failed at a stress greater than SMYS; the tensile properties of the weldment (i.e., collapse dominated),
minimum recorded failure stress was from specimen HAZ (3), the corresponding predicted failure stresses were found to be in
787 N/mm². much better agreement with the actual CWP test results which
The method used to undertake an individual assessment of failed by plastic collapse; failure stress ratios ranging from 1.07
each CWP specimen is presented in Figure 21. The FAD was to 1.22.
constructed using Rp0.2 and Rm measured closest to where the The fracture mechanics assessment procedures in BS 7910
CWP specimen was extracted. This analysis shows that the are very versatile, enabling a number of different types of
actual failure stress of the CWP specimen was greater than assessment to be undertaken to fully describe the behavior of
SMYS as the assessment point lays outside the FAC. Also the weldment. The method is dependent on three factors;
shown on Figure 21 is the result of the assessment to determine applied loading, material properties and defect geometry.
the critical stress for failure which was predicted to be Although measured tensile properties have been obtained
206.3 N/mm², giving a failure stress ratio of 4.19 (see Table 4). for each weldment, the fracture toughness properties were
As can be seen from the position of the critical stress result on measured using highly constrained fracture mechanics
the FAC, failure at such a low stress is due to the relatively low specimens which do not necessarily reflect the true material
fracture toughness measured for the weldment. This is contrary toughness of the pipe geometry. Essentially, the lower the value
to the test result where failure was controlled by the tensile of toughness used in the assessment, the greater the likelihood
properties across the weldment. of failure in a brittle manner. This effect was illustrated in the
As can be seen from the results presented in Table 4 a additional analyses undertaken where the input value of
conservative prediction of failure stress was determined for fracture toughness was increased to ensure failure was collapse
each specimen, as the margin between actual and predicted dominated.
stress was greater than 1.0; ranging from 1.18 up to 23.0. This API 579-1/ASME FFS-1
large variation between actual and predicted failure stress was To verify the applicability of the API 579-1/ASME FFS-1
found to be due to the input value of fracture toughness for fracture mechanics assessment procedures, the same type of
each assessment. assessments were undertaken as those described for the
BS 7910 assessments.
As with the BS 7910 assessment, the methodology and
results are presented below for weld A06 in Figure 22
(comparison of the CWP specimen defect sizes with the critical
surface breaking defect locus) and CWP specimen HAZ (1) in
Figure 23 (CWP test assessment and prediction of the critical
failure stress).
4.0 1220x19.8mm.
2. API 1104 (Option 2): The procedure gave conservative
3.0
predictions of failure stress for all, except one CWP
2.0 specimen (predicted failure stress was 3% lower than
actual). In many cases the ratio of predicted to actual
1.0 failure stress was close to 1.0.
3. CSA Z662: The procedure gave conservative predictions
0.0
0 50 100 150 200 of failure stress, greater than 2%, when compared with the
Defect length (mm) actual CWP test data.
FAC HAZ (1) HAZ (2) HAZ (3) WM 4. EPRG: The defect size limits recommended for inclusion
Figure 22: API 579-1/ASME FFS-1 analysis: Critical ‘surface in the EPRG guidance document for X80 pipelines appear
breaking’ defect size locus of weld A06, compared suitable for grade X100 pipelines; however the length of
with the CWP defect sizes tested. the defects tested did not extend to the 7t limit proposed.
The defect size limits are applicable to surface breaking
1.4 defects and embedded defects of an equivalent size.
5. BS 7910: The failure stress of each CWP specimen was
1.2
conservatively predicted; ratio of actual to predicted failure
1.0 stress ranging from 1.15 to 6.5, except for three CWP
Brittle fracture, Kr
0.8
specimens which had a very low predicted failure stress
(corresponding ratios of actual to predicted failure stress
0.6 ranging from 11.5 to 23.0).
0.4 6. API 579-1/ASME FFS-1: The failure stress of each CWP
specimen was conservatively predicted; ratio of actual to
0.2
predicted failure stress ranging from 1.48 to 5.6, except for
0.0 four CWP specimens which had a very low predicted
0.0 0.2 0.4 0.6 0.8 1.0 1.2
Plastic collapse, Lr
failure stress (corresponding ratios of actual to predicted
failure stress ranging from 11.3 to 19.9).
FAC CWP test, HAZ (1) Critical stress, HAZ (1)