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Improving Data Collection With In-Line Inspection in Low-Pressure Gas Distribution Networks 改进低压配气网络在线检测数据采集
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9481
Johannes Becker, C. Richards, Guenter Sundag, Ronald Wittig
A large majority of urban gas distribution pipelines are designed to accommodate future integrity management surveys with in-line inspection (ILI) tools. However, even with typical inspection design parameters considered, many pipelines end up on a “difficult-to-inspect” list and/or fall into a “gray” zone. Often this is due to operational parameters, which may have adverse effects on how in-line inspection technologies perform during a survey. One of these effects may be stop-start behaviors of the tool itself. Although most segments meet minimum technical specifications to conduct ILI surveys, vintage pipeline design practices, such as numerous 1.5D bends, multiple heavy wall transitions, and narrow ID fittings, consistently present ongoing issues when running ILI tools in gas distribution lines. The first assessment characteristically indicates that standard inspection tools are viable solutions for these types of pipelines, but results from previous inspections typically indicate, after the first inspection of the pipeline, that standard technologies should not be applied, or rather, do not deliver satisfactory results. New methodologies and technologies are required to reduce, if not eliminate, the incidents of stationary tools and the resultant areas of degraded data while improving overall data quality. In the end, operators consider these lines a critically important component of their entire system and are keen to gain a clear picture of the assets’ integrity. Suitable in-line inspection solutions are therefore in demand to instill confidence in the assets safe and efficient operation. This paper outlines several elements, including technologies, procedures, or mechanical adaptations, that are often overlooked when selecting and applying inspection and/or cleaning technologies to these gray-zone pipelines. Applying these elements may allow for inspection tools to traverse various obstacles and debris fields encountered while still providing high-resolution data sets. A detailed case study of a NPS 08” pipeline will be used to support the content. This pipeline did not provide the required operational parameters to gather acceptable data when utilizing standard ILI technologies. This NPS 08” line contained various challenges, such as: • Unknown or unreliable pipeline information, specifically for bend radii and wall thicknesses • No previous cleaning and inspection records • Low operational pressures of 1000 to 2100 kPa • Pipeline length over 100 km • MOP restrictions did not allow for higher pressures • Flow rate was only available within limited windows • Cleanliness was unknown and assumed to be a concern • Pipe grade documentation required verification Many technical challenges were encountered in the initial stages of the project. The lessons learned will be discussed and outlined to better support the approach chosen. In the end, tailored geometry and low-friction MFL technologies, capable of safely traversing the pip
绝大多数城市燃气分配管道的设计都是为了适应未来使用在线检查(ILI)工具进行完整性管理调查。然而,即使考虑到典型的检查设计参数,许多管道最终也会被列入“难以检查”的名单和/或落入“灰色”地带。这通常是由于操作参数,这可能会对在线检测技术在测量过程中的表现产生不利影响。这些影响之一可能是工具本身的启停行为。尽管大多数管段满足进行ILI调查的最低技术规范,但传统的管道设计实践,如大量1.5D弯道、多个厚壁过渡和窄内径接头,在天然气分配管道中使用ILI工具时,始终存在持续存在的问题。第一次评估的特点是表明标准检查工具是这些类型管道的可行解决方案,但是先前检查的结果通常表明,在管道的第一次检查之后,不应该应用标准技术,或者更确切地说,不能提供令人满意的结果。需要新的方法和技术来减少(如果不能消除的话)固定工具事件和由此产生的数据退化区域,同时提高总体数据质量。最后,作业者认为这些管线是整个系统中至关重要的组成部分,并渴望获得资产完整性的清晰图像。因此,需要合适的在线检测解决方案,以增强对资产安全高效运行的信心。本文概述了在选择和应用检测和/或清洁技术时经常被忽视的几个要素,包括技术、程序或机械适应性。应用这些元素可以允许检查工具穿越遇到的各种障碍物和碎片场,同时仍然提供高分辨率的数据集。将使用NPS 08管道的详细案例研究来支持内容。当使用标准ILI技术时,该管道不能提供所需的操作参数来收集可接受的数据。这条NPS 08“线包含各种挑战,例如:•未知或不可靠的管道信息;•没有之前的清洁和检查记录•1000至2100千帕的低工作压力•管道长度超过100公里•MOP限制不允许更高的压力•流量仅在有限的窗口内可用•清洁度未知并被认为是一个问题•管道等级文件需要验证在项目的初始阶段遇到了许多技术挑战。将讨论和概述吸取的经验教训,以便更好地支持所选择的方法。最后,利用定制的几何形状和低摩擦的MFL技术,能够安全地穿过管道并收集高质量的数据,进行了检查。该案例研究将为其他作业者提供有价值的见解,帮助他们了解如何检查类似的资产,同时概述适合于支持检查的专业技术。
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引用次数: 0
Statistical Analysis of Dig Operations Leading to Productive Repairs 挖掘作业导致生产性维修的统计分析
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9493
Ye. A. Petrov, J. Dubuc, Michael H. Murray, T. Edward
Inline inspection data from several runs spanning many years is available for individual pipeline segments, but compilation of this data into a comprehensive picture of pipeline integrity necessarily relies on computational tools. A critical advantage of modern data storage, analysis, and visualization techniques is the relative ease of performing statistical assessments of integrity operations. Data from a single user of OneBridge Solution’s software may comprise over 1,000 in-line inspections (ILI) runs, hundreds of pipe segments, several million aligned anomalies, and thousands of repair records. Automated alignment of ILI data allows a single physical anomaly to be reliably tracked through many years of growth and repeated measurement and then correlated to repair records. We present a study of cases where ILI anomaly measurements warranted a dig operation in which repair actions were either performed or found to be unnecessary. The fraction of dig operations leading to a productive repair varies with the condition triggering the dig and discretionary choices about dig condition parameters. The analysis is done through the exploration of different methods of corrosion growth forecasting in use by operators and how they compare. The measures that have been taken into consideration for the purpose of this study include half-life vs. pit-to-pit where the effectiveness of identifying and mitigating fast-growing anomalies is compared across models. Further exploration of how forecasting and building a dig program based on pit-to-pit alignments and a comprehensive growth model through the advances in data science and machine learning can bring efficiency improvements and an overall reduction in risk. We analyze the relationship between these parameters, ILI measurements, repair-to-dig ratios and the impact on operational spend. We examine whether a reduction in overall inspection frequency and expenses is possible through advanced growth modeling. Ultimately this would provide a more accurate view of long-term operating costs and allow for operators to consider scenarios relating to repair and replacement of assets.
从多年的几次运行中获得的内联检测数据可以用于单个管道段,但是将这些数据汇编成管道完整性的综合图像必须依赖于计算工具。现代数据存储、分析和可视化技术的一个关键优势是相对容易地执行完整性操作的统计评估。OneBridge solutions软件的单个用户的数据可能包括1000多次在线检查(ILI),数百个管段,数百万个对齐异常以及数千个维修记录。ILI数据的自动校准可以通过多年的增长和重复测量来可靠地跟踪单个物理异常,然后将其与修复记录相关联。我们提出了一项研究,在这些病例中,ILI异常测量证明了挖掘作业的必要性,其中要么进行了修复,要么发现没有必要进行修复。导致生产性修复的挖掘作业的比例随触发挖掘的条件和对挖掘条件参数的任意选择而变化。分析是通过对运营商使用的不同腐蚀增长预测方法的探索以及它们之间的比较来完成的。为了本研究的目的,考虑到的措施包括半衰期与坑对坑的比较,其中识别和减轻快速增长异常的有效性在不同模型之间进行了比较。通过数据科学和机器学习的进步,进一步探索如何预测和建立基于坑到坑对齐和综合增长模型的挖掘计划,从而提高效率并降低整体风险。我们分析了这些参数、ILI测量值、修复-挖掘比率以及对运营支出的影响之间的关系。我们检查是否可以通过先进的增长模型减少总体检查频率和费用。最终,这将提供更准确的长期运营成本视图,并允许运营商考虑与资产维修和更换相关的方案。
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引用次数: 0
Generation and Monitoring of Synthetic Crack-Like Features in Pipeline Materials Using Cyclic Pressure Loading 循环压力加载下管道材料合成裂纹特征的产生与监测
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9781
C. Alexander, J. Rickert, R. Dotson, F. Freitas, S. Slater, Christopher De Leon
Crack management has become a major focus for many gas and liquid transmission pipeline operators. Failures associated with crack-like features have been a concern for both pipe operators and regulatory agencies. As a result, pipeline operators are excavating large numbers of features for not only in-line inspection (ILI) validation purposes, but also to make repairs. Additionally, ILI technologies have advanced significantly in recent years and are identifying an increasing number of features with greater levels of accuracy. With increased data generation, operators are faced with an unprecedented amount of information that requires response prioritization. Because of high levels of conservatism associated with today’s assessment methods, pipeline operators are spending a significant amount of capital excavating crack-like features. There is a need for improved assessment methods that integrates testing simulated / synthetic crack-like features. This paper will provide details on a study funded to systematically generate crack-like features in pipeline materials with the application of cyclic internal pressure loading. Synthetic crack-like features were generated in 12.75-inch × 0.250-inch, Grade X42 pipe material using electronic discharge machining (EDM) to form notches. Notch depths were 10% of the nominal wall thickness and ranged from 1-inch to 3-inches in length. The pipe samples were then pressure cycled to achieve microcracking at the base of each notch. Initial stages of the program involved sectioning features to quantify crack growth levels. Once a systematic process for growing cracks from EDM starter notches had been validated, testing involved cyclic pressure fatigue to failure and burst testing. The advantage with the crack generation methodology used in this study was the ability to generate sharp, crack-like features without altering the microstructure of the pipe material in the vicinity of the feature. Programs such as the one presented in this paper are useful for both generating features in pipeline materials and quantifying behavior of pipeline materials subjected to cyclic pressure and burst loading.
裂缝管理已成为许多天然气和液体输送管道运营商的主要关注点。与裂缝相关的故障一直是管道运营商和监管机构关注的问题。因此,管道运营商正在挖掘大量特征,不仅用于在线检查(ILI)验证目的,还用于进行维修。此外,近年来ILI技术取得了显著进步,正在以更高的精度识别越来越多的特征。随着数据量的增加,运营商面临着前所未有的海量信息,需要优先响应。由于目前的评估方法高度保守,管道运营商花费大量资金挖掘裂缝状特征。有必要改进评估方法,集成测试模拟/合成裂纹样特征。本文将详细介绍一项研究,该研究旨在系统地利用循环内压加载在管道材料中产生裂纹状特征。在12.75英寸× 0.250英寸的X42级管材上使用电火花加工(EDM)形成切口,产生合成裂纹状特征。缺口深度为公称壁厚的10%,长度从1英寸到3英寸不等。然后对管道样品进行压力循环,以在每个缺口的底部实现微裂纹。该程序的初始阶段包括切片特征,以量化裂纹增长水平。一旦系统地验证了从电火花切割切口开始的裂纹扩展过程,测试包括循环压力疲劳到失效和爆裂测试。本研究中使用的裂纹生成方法的优点是能够生成尖锐的裂纹状特征,而不会改变特征附近管道材料的微观结构。本文所提供的程序既可用于生成管道材料的特征,又可用于量化管道材料在循环压力和爆裂载荷作用下的行为。
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引用次数: 0
Integrity Management of Flange Connections Using Reliability Model 基于可靠性模型的法兰连接完整性管理
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9512
S. Haider, M. Sen, Doug Lawrence, Angela Rodayan
There is demonstrated potential for failures to occur on station piping assets in facilities, therefore it is critical to take measures to manage preventable releases. In 2018, Enbridge developed a reliability model that uses available asset information to quantify the likelihood of failure of station piping assets. Enbridge based this model on the CFER PIRIMID software, with some modifications to minimize the use of default values and to meet the company’s integrity management program requirements. With successful implementation of station piping model, Enbridge realized opportunity to develop a much-needed flange model leveraging the station piping model. Historical leak data indicates that flanged connections often experience a higher leak frequency than other assets in a facility. While there are industry guidelines that provide guidance for the assembly of process flange connections in a facility, there are few that discuss integrity management of flange connections once they are operational. Most published condition assessment flange models require inputs which are not readily available, e.g. condition of flange faces and gaskets. These inputs often require the flange to be disassembled just to obtain the data. For pipeline operators, data gathering is even more challenging as there are stations (with numerous flanges) that are spread out along the entire pipeline. Given the high number of flange connections and their wide variation in parameters within transmission pipeline facilities, there is benefit in developing a reliability-based model to guide the integrity management of flange connections. A reliability model that works in two stages was developed for this purpose. The pre-inspection assessment stage was designed to utilize available inputs to prioritize groups of flanges for inspection, and the post-inspection assessment (second) stage is then applied to select the specific flanges that require maintenance action. Enbridge utilized industry guidelines, relevant standards, historical failure data, and subject matter experts’ inputs to develop the station piping and flange models. This paper will discuss the design concepts, model architectures, the contributing factors, and their sensitivities to the likelihood of failure results. These concepts may be utilized by any operator managing such assets, and the model designs may be tailored to suit a wide range of facility environments.
有证据表明,设施中的站管资产可能发生故障,因此,采取措施管理可预防的排放是至关重要的。2018年,Enbridge开发了一种可靠性模型,该模型使用可用的资产信息来量化站内管道资产故障的可能性。Enbridge基于CFER PIRIMID软件建立了该模型,并进行了一些修改,以尽量减少默认值的使用,并满足公司的完整性管理程序要求。随着泵站管道模型的成功实施,Enbridge实现了利用泵站管道模型开发急需的法兰模型的机会。历史泄漏数据表明,法兰连接的泄漏频率通常高于设施中的其他设备。虽然有一些行业指南为设施中的工艺法兰连接的组装提供了指导,但很少有人讨论法兰连接在运行后的完整性管理。大多数已发表的状态评估法兰模型需要不易获得的输入,例如法兰面和垫圈的状态。这些输入通常需要拆卸法兰才能获得数据。对于管道运营商来说,数据收集更具挑战性,因为整个管道上分布着许多站点(有许多法兰)。考虑到输送管道设施中法兰连接的数量众多,其参数变化很大,开发基于可靠性的模型来指导法兰连接的完整性管理是有益的。为此,开发了一个分两个阶段工作的可靠性模型。预检验评估阶段旨在利用可用的输入来优先考虑需要检查的法兰组,然后应用检验后评估(第二阶段)来选择需要维修措施的特定法兰。Enbridge利用行业指南、相关标准、历史故障数据和主题专家的意见,开发了泵站管道和法兰模型。本文将讨论设计概念、模型架构、影响因素及其对失败结果可能性的敏感性。这些概念可以被任何管理此类资产的运营商使用,并且模型设计可以定制以适应各种设施环境。
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引用次数: 0
Incorporating Inline Inspection Internal Measurement Unit Data Analysis Into Integrity Management Programs 将内联检验内部测量单元数据分析纳入完整性管理程序
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9495
Douglas Dewar
Inline Inspection Internal Measurement Unit (ILI IMU) data analysis is a well understood but often under-utilized technology for detecting, defining, assessing and monitoring soil to pipeline interactions. The technology has been successfully used to detect landslide interactions since 1996 [1]. Operators can be provided with a vendor analysis (initial bending strain or run to run movements) and/or processed raw data for either internal or third-party raw data Analysis [2]. Vendor Analysis typically identifies major soil/pipeline interactions but primarily reports dig related settlements [3] and static construction related features. Raw data analysis is typically used to define interactions and provide detailed pipe shapes and deformations within targeted pipeline segments. An approach for determining ILI IMU analysis/data requirements for individual ILI run segments for any size of pipeline system is presented. Guidelines for analysis are provided for Operators to optimize efforts based on the hazards encountered in individual pipelines or pipeline systems. The process includes feature screening, integrity/geotechnical specialist review and risk control/mitigation measures, if required. To facilitate the feature screening process, a classification system for ILI IMU features is presented based on their type, activity and source modified from the system presented in [3].
在线检测内部测量单元(ILI IMU)数据分析是一种很好理解但经常未充分利用的技术,用于检测、定义、评估和监测土壤与管道的相互作用。自1996年以来,该技术已成功用于检测滑坡相互作用[1]。作业者可以提供供应商分析(初始弯曲应变或井间移动)和/或经过处理的原始数据,用于内部或第三方原始数据分析[2]。供应商分析通常识别主要的土壤/管道相互作用,但主要报告与挖掘相关的沉降[3]和与静态施工相关的特征。原始数据分析通常用于定义相互作用,并在目标管段内提供详细的管道形状和变形。提出了一种确定任何规模的管道系统的各个ILI运行段的ILI IMU分析/数据需求的方法。为作业者提供了分析指南,以便根据个别管道或管道系统中遇到的危险进行优化。这一过程包括特征筛选、完整性/岩土工程专家审查和风险控制/缓解措施(如有必要)。为了方便特征筛选过程,本文在[3]的基础上,根据特征的类型、活动和来源,提出了一个ILI IMU特征的分类系统。
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引用次数: 0
Reliability-Based Assessment of Safe Excavation Pressure for Dented Pipelines 基于可靠性的凹陷管道安全开挖压力评估
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9399
Chike Okoloekwe, M. Fowler, A. Virk, N. Yoosef-Ghodsi, Muntaseer Kainat
Dents in a pipe result in alteration of its structural response when subjected to internal pressure. Excavation activities further lead to change in load and boundary conditions of the pipe segment which may exacerbate the stress state within the dented region. Depending on the severity of a dent, excavation under full operating pressure may lead to failure, injuries or fatalities. Although uncommon, an incident has been reported on a gas pipeline where a mechanical damage failed during investigation leading to one death and one injury [10]. While current pipeline regulations require that operators must depressurize a line to ensure safe working conditions during repair activities, there are no detailed provisions available in the codes or standards on how an operator should determine such a safe excavation pressure (SEP). As a result, the safe excavation process of dents has received attention in the industry in recent years. A detailed review of the recent research on dent SEP showed that the current recommendations are primarily dependent on one of two aspects: careful assessment of inline inspection (ILI) data, or a fitness for service (FFS) assessment of the dent feature leveraging numerical models. Enbridge Liquid Pipelines had previously demonstrated a feature specific assessment approach which incorporated both ILI data and finite element analysis (FEA) to determine the SEP. This assessment also accounted for uncertainties associated with material properties and ILI tool measurement. In the previous publication, the authors demonstrated a methodology for assessing the SEP of dents at a conceptual level from both deterministic and reliability-based standpoints. In this paper, a validation study has been performed to compare the results of fracture mechanics based FEA models against ten full scale burst tests available in literature. The study showed good agreement of the burst pressure of dent-crack defects predicted by FEA models with those observed in the full-scale tests. The assessment method is further streamlined by incorporating the API 579 [14] Failure Assessment Diagram (FAD) method on an uncracked FEA model as opposed to explicitly incorporating the crack geometry in the FEA model. The results of FEA in conjunction with FAD are compared with the full-scale tests to ensure accuracy and conservatism of burst pressure prediction. A reliability-based approach is then designed which accounts for the uncertainties associated with the analysis. A case study is presented where the reliability-based SEP assessment method has been implemented and feature specific SEP has been recommended to ensure target reliability during excavation.
管道中的凹痕在受到内部压力时导致其结构响应的改变。开挖活动进一步导致管段载荷和边界条件的变化,可能加剧凹陷区域内的应力状态。根据凹痕的严重程度,在全操作压力下的挖掘可能导致失败、受伤或死亡。尽管不常见,但据报道,在调查过程中发生了一起天然气管道机械损坏事故,导致一人死亡,一人受伤。虽然目前的管道法规要求作业人员必须对管道进行减压,以确保在维修活动期间的安全工作条件,但对于作业人员如何确定安全开挖压力(SEP),规范或标准中没有详细的规定。因此,凹痕的安全开挖过程近年来受到了业界的重视。对最近凹痕SEP研究的详细回顾表明,目前的建议主要依赖于两个方面中的一个:对在线检查(ILI)数据的仔细评估,或利用数值模型对凹痕特征的适用性(FFS)评估。Enbridge Liquid Pipelines之前展示了一种特征特定评估方法,该方法结合ILI数据和有限元分析(FEA)来确定SEP,该评估还考虑了与材料特性和ILI工具测量相关的不确定性。在之前的出版物中,作者展示了一种从确定性和基于可靠性的角度在概念层面评估凹痕SEP的方法。在本文中,进行了一项验证研究,将基于断裂力学的有限元模型的结果与文献中可用的10个全尺寸爆炸试验的结果进行了比较。研究结果表明,有限元模型预测的凹痕裂纹的破裂压力与实际试验结果吻合较好。通过将API 579[14]失效评估图(FAD)方法纳入无裂纹有限元模型,而不是明确地将裂纹几何形状纳入有限元模型,进一步简化了评估方法。为了保证爆破压力预测的准确性和稳健性,将有限元分析与FAD相结合的结果与全尺寸试验结果进行了比较。然后设计了一种基于可靠性的方法,该方法考虑了与分析相关的不确定性。结合工程实例,提出了基于可靠性的SEP评价方法,并提出了基于特征的SEP评价方法,以保证开挖过程中的目标可靠性。
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引用次数: 1
The Impact of Pressure Fluctuations on the Early Onset of Stage II Growth of High pH Stress Corrosion Crack 压力波动对高pH应力腐蚀裂纹II期早期扩展的影响
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9511
H. Niazi, Hao Zhang, Lyndon Lamborn, Weixing Chen
Steel pipelines undergo the following sequential stages prior to high pH stress corrosion cracking (HpHSCC) failure, viz., formation of environmental condition, initiation of the intergranular cracks followed by cracks coalescence to form critical crack size (Stage I), mechanically dictated crack growth with higher rate (Stage II) compared to Stage I, rapid crack propagation to failure (Stage III). From fracture mechanics perspective, the crack size reaches the critical value at the onset of stage II; consequently, stress intensity factor (K) ahead of the crack tip exceed the critical value (KISCC). Although many researches have been devoted to understanding HpHSCC behavior, the mechanical conditions that accelerate the onset of stage II remains unknown. This study investigates the mechanical loading conditions that yield to early onset of stage II with respect to the most severe loading condition in operating pipeline, underload-minor-cycle type of pressure fluctuation. In this study, several loading scenarios were applied to pre-cracked CT specimens exposed to 1 N NaHCO3-1N Na2CO3 at 40° C and −590 mVSCE. The first series of tests were conducted through applying variable amplitude loading waveforms to determine the K value below the KISCC. It was observed the crack growth rate decreases from 1.5 × 10−7 mm/s to 2.5 × 10−8 mm/s when Kmax decreases from 36 to 15 MPa·m0.5. Then, both constant amplitude and variable amplitude loading scenarios with the Kmax = 15 MPa·m0.5 were applied to pre-cracked CT specimens. It was observed that low R-ratio constant amplitude cycles yield to highest crack growth rate (3.6 × 10−7 mm/s), which was one order of magnitude higher than other waveforms. However, comparing the intergranular crack advancement per block resulted in similar crack growth rates for those waveforms containing low R-ratio cycles. These results imply that stage I of crack growth is assisted by fatigue due to low R-ratio cycles. It was observed that loading/unloading frequency of low R-ratio cycles has a direct relation with crack growth rate at stage I, i.e., high frequency cycles accelerate onset of stage II. The implication of these results for pipeline operator is that pressure fluctuation, particularly large and rapid pressure fluctuation at the sites susceptible to HpHSCC, threatens the pipeline integrity. Avoiding such pressure fluctuations, if possible, increase pipeline lifespan and prevents catastrophic damages by intergranular stress corrosion crack growth through delaying the onset of stage II of HpHSCC crack growth.
钢管道在高pH应力腐蚀开裂(HpHSCC)失效之前经历了以下顺序阶段,即环境条件的形成,晶间裂纹的萌生,裂纹合并形成临界裂纹尺寸(阶段1),力学上决定了裂纹的扩展速度(阶段2)比阶段1更快,裂纹的快速扩展到失效(阶段3)。裂纹尺寸在第二阶段开始时达到临界值;因此,裂纹尖端前的应力强度因子K超过了临界值KISCC。尽管许多研究都致力于了解HpHSCC的行为,但加速II期发病的力学条件仍然未知。本研究针对运行管道中最严重的负荷工况,即欠载小循环型压力波动,探讨了产生II期早发的机械负荷条件。在这项研究中,对暴露于40°C和- 590 mVSCE下的1N NaHCO3-1N Na2CO3的预裂CT样品进行了几种加载场景。通过应用可变振幅加载波形进行了第一系列试验,以确定低于KISCC的K值。当Kmax从36 MPa·m0.5减小到15 MPa·m0.5时,裂纹扩展速率从1.5 × 10−7 mm/s减小到2.5 × 10−8 mm/s。然后对预裂CT试件分别施加Kmax = 15 MPa·m0.5的恒幅加载和变幅加载两种加载方式。结果表明,低r比等幅循环产生的裂纹扩展速率最高(3.6 × 10−7 mm/s),比其他波形高一个数量级。然而,比较每个块的晶间裂纹扩展,发现含有低r比循环的波形的裂纹扩展速率相似。这些结果表明,由于低r比循环,裂纹扩展的第一阶段是由疲劳辅助的。结果表明:低r比循环的加载/卸载频率与第一阶段的裂纹扩展速率有直接关系,即高频循环加速了第二阶段的开始;这些结果对管道运营商的影响是,压力波动,特别是在易受高温高温scc影响的位置,压力波动大和快速,威胁到管道的完整性。如果可能的话,避免这种压力波动可以延长管道寿命,并通过延迟HpHSCC II阶段裂纹扩展来防止晶间应力腐蚀裂纹扩展造成的灾难性破坏。
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引用次数: 1
A Data Driven Validation of a Defect Assessment Model and its Safe Implementation 缺陷评估模型的数据驱动验证及其安全实现
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9690
S. Kariyawasam, Shenwei Zhang, Jason Yan
This paper presents data analytics that demonstrates the safe implementation of defect assessment models which use uncertain measurements of defect and material properties as inputs. Even though this validation is done for a corrosion assessment model implementation, it can be generalized for any defect assessment validation where the inputs have uncertainty (as they do in implementation). The questions arising from the validation of the Plausible Profiles (Psqr) model and related review led to a large amount of data analytics to demonstrate various aspects of safety in implementation. The data analytics demonstrates how the safety of model implementation can be verified using a well-designed set of data. The validation of Psqr model was conducted on a unique set of data consisting of metal-loss corrosion clusters with Inline Inspection (ILI) reported size, laser scan-measured dimension, and well monitored burst testing pressure. Therefore, this validation provided an unprecedented set of validation data that could represent many perspectives, such as model performance (with all uncertainties associated with other parameters removed), in-the-ditch decision scenario, and ILI-based decision scenario. Moreover, the morphologies of the 30 corrosion clusters tested is a good representation of large corrosion clusters that have failed historically in the pipeline industry. One of learnings from post-ILI failures due to corrosion in the industry is that corrosion morphology played a significant role. Previous model validations were mostly performed on simple single anomalies or simple clusters with few individual corrosion anomalies. It is important that a corrosion model is validated using real corrosion morphologies that are representative of in-service conditions. The analysis of this unprecedented and comprehensive set of data led to great learning and revealed how safety can be achieved optimally with good understanding of how uncertainties associated with ILI sizing error, material property, model error, and safety factors interact and play into integrity. It also revealed the role of common misunderstandings that are barriers to effective pipeline integrity assessment. Overcoming these misunderstandings have helped in developing a more effective ILI based corrosion management program that will avoid more failures and reduce unnecessary integrity actions.
本文提出了数据分析,证明了缺陷评估模型的安全实现,该模型使用不确定的缺陷和材料特性测量作为输入。即使这种验证是为腐蚀评估模型实现完成的,它也可以推广到输入具有不确定性的任何缺陷评估验证中(正如它们在实现中所做的那样)。可信配置文件(Psqr)模型的验证和相关审查所产生的问题导致了大量数据分析,以展示实施过程中安全性的各个方面。数据分析演示了如何使用一组设计良好的数据来验证模型实现的安全性。Psqr模型的验证是在一组独特的数据上进行的,这些数据包括金属损失腐蚀簇、在线检测(ILI)报告的尺寸、激光扫描测量的尺寸和良好监测的爆炸测试压力。因此,此验证提供了一组前所未有的验证数据,可以表示许多透视图,例如模型性能(删除与其他参数相关的所有不确定性)、在沟里的决策场景和基于ili的决策场景。此外,测试的30个腐蚀簇的形态很好地代表了管道行业历史上失败的大型腐蚀簇。从工业中由于腐蚀而导致的ili后故障中吸取的教训之一是腐蚀形态起了重要作用。以前的模型验证大多是在简单的单一异常或简单的簇上进行的,很少有单独的腐蚀异常。使用实际腐蚀形态来验证腐蚀模型是很重要的,这些腐蚀形态代表了使用条件。通过对这组前所未有的综合数据的分析,我们获得了大量的知识,并揭示了如何通过充分理解与ILI尺寸误差、材料特性、模型误差和安全因素相关的不确定性如何相互作用并影响完整性来实现最佳安全性。它还揭示了阻碍有效管道完整性评估的常见误解的作用。克服这些误解有助于开发更有效的基于ILI的腐蚀管理程序,从而避免更多的故障并减少不必要的完整性操作。
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引用次数: 0
Pipeline Plain Dent Fatigue Assessment: Shedding Light on the API 579 Level 2 Fatigue Assessment Methodology 管道平原凹痕疲劳评估:阐明API 579 2级疲劳评估方法
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9655
Z. Shirband, Adrian Gosselin, S. Guest, Lee Falcon
For continued safe operation of pipelines, thousands of integrity digs are conducted every year to repair ILI detected defects. Integrity-driven pipeline excavations can be quite costly, present significant scheduling challenges with landowner consultation and seasonal access limitations, and an unmitigated defect may have required a pressure reduction or service outage, resulting in a loss of revenue from the asset. Dents are known to be one of the drivers for many integrity excavations, especially for liquid pipelines. A pipeline with a minimal mechanical deformation is not expected to fail immediately, however, severe pressure cycles combined with the geometric distortion can cause fatigue crack initiation and growth that can lead to failure. To account for the possibility of fatigue failure, recent changes to pipeline codes, such as CSA Z662, are requiring pipeline operators to repair any dent susceptible to fatigue failure unless an engineering assessment proves it is fit for service. A commonly used dent fatigue assessment methodology is outlined in API RP 579, also known as the EPRG-2000 model. The assessment methodology uses an S-N curve from DIN 2413 part 1 with a safety factor of 10, which has been derived from undamaged pressurized pipe sections experiencing pressure cycles with stress ratios of zero, and separate stress enhancement factors for dents and gouges which take into account the shape of dents and gouges. To account for the effect of mean stress, Gerber mean stress correction, which has been developed for pressure cycles with stress ratios of −1 (i.e., for fatigue bar specimens), is also applied on pressure cycles. According to the literature, API 579 Level 2 fatigue assessment methodology results in very conservative estimates of fatigue lives compared to experimental data. This paper will discuss the potential factors resulting in conservative assessments and propose refinements in the methodology. This will include the safety factor used for pipes with known operating pressure fluctuations and the mean stress correction model suitable for a pipeline with pressure cycles that have R ratios greater than zero. The acceptable number of cycles obtained using the proposed refinements were compared to experimental data and EPRG-1995 model’s predictions — the comparison revealed that the proposed methodology results in a more realistic safety margin for dented pipelines. The proposed methodology can be used as a part of engineering assessments in mechanical damage integrity management programs to improve the pipeline operator’s understanding of a dent’s remaining life and enable a more appropriate repair timeline.
为了管道的持续安全运行,每年进行数千次完整性挖掘,以修复ILI发现的缺陷。以完整性为导向的管道挖掘成本相当高,在土地所有者咨询和季节性访问限制方面存在重大的调度挑战,并且未缓解的缺陷可能需要降低压力或中断服务,从而导致资产收入损失。众所周知,凹痕是许多完整性挖掘的驱动因素之一,特别是对于液体管道。机械变形最小的管道不会立即失效,然而,剧烈的压力循环加上几何变形会导致疲劳裂纹的萌生和扩展,从而导致失效。为了考虑疲劳失效的可能性,最近对管道规范(如CSA Z662)进行了修改,要求管道运营商修复任何容易产生疲劳失效的凹痕,除非工程评估证明该凹痕适合使用。API RP 579概述了常用的凹痕疲劳评估方法,也称为EPRG-2000模型。评估方法使用DIN 2413第1部分的S-N曲线,其安全系数为10,该曲线是从经历应力比为零的压力循环的未损坏的加压管段中得出的,并且考虑到凹痕和沟槽的形状,对凹痕和沟槽进行单独的应力增强因子。为了考虑平均应力的影响,已经为应力比为- 1的压力循环(即疲劳杆试样)开发的Gerber平均应力校正也应用于压力循环。根据文献,与实验数据相比,API 579 2级疲劳评估方法对疲劳寿命的估计非常保守。本文将讨论导致保守评估的潜在因素,并提出改进方法。这将包括用于已知工作压力波动的管道的安全系数,以及适用于压力循环R比大于零的管道的平均应力修正模型。使用所提出的改进方法获得的可接受循环次数与实验数据和EPRG-1995模型的预测进行了比较,对比表明,所提出的方法对凹陷管道的安全裕度更为现实。所提出的方法可以作为机械损伤完整性管理项目工程评估的一部分,以提高管道运营商对凹痕剩余寿命的理解,并制定更合适的修复时间表。
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引用次数: 1
Full Encirclement Engineered Laminated Steel Sleeve System for Repairs and Augmentation of Pipelines: The Engineering Development, Validation Test Results, and Implications for Mitigation of Both Stress and Strain Dependent Integrity Threats 用于管道维修和扩建的全包围工程层压钢套系统:工程开发,验证测试结果,以及减轻应力和应变相关完整性威胁的含义
Pub Date : 2020-09-28 DOI: 10.1115/IPC2020-9303
S. Laughlin, K. Leewis, C. Alexander
A full encirclement thin layer steel laminated sleeve system has been designed, developed, and optimized for pipeline integrity management applications. Development goals included the elimination of thixotropic concerns as well as the exclusion of the degradation of material properties of composite repairs. Elimination of cyclical fatigue of welded repairs and safety concerns associated with hot work were also considerations. The use of thin layer steel with a modulus matched to base pipe and steel’s homogenous isotropic properties enable axial calculations and evaluation of strain-based concerns. The thin layer steel laminated design results in extremely high fracture toughness and promotes intrinsic mitigation of potential future third party damage. The resulting system has demonstrated the reliable engineering data and analysis required for pipeline repairs and demonstrates applicability for the augmentation of existing pipes without defects. An Engineering Critical Assessment (ECA) has been completed. This ECA follows the industry’s precedents of ASME B31G and ASME PCC-2 Article 4 type assessments and provides operators with greater functionality. This ECA has been named the Leewis Augmentation Analysis (LAA) and is presented, reviewed, and discussed. Third party full scale ASME PCC-2 style burst testing has been completed. The results are presented. Highly instrumented tests were also conducted to determine an effective modulus of elasticity of the installed system as well as a determination of any delay in system acceptance of load. As installed, an effective modulus of 14 million psig (96526.60 MP)a with loading in layer 3 of the laminate at only 50 micro strain is reviewed. Long term creep and cyclical fatigue testing of the steel/adhesive laminate is presented and reviewed. 10 million cycles at 50% of ultimate lap shear has been achieved, which exceeds current industry practice by several orders of magnitude. The classic metal loss defect mitigation principle is reviewed and updated in light of these available technical advances. Finally, the implications for mitigation of both stress and strain dependent integrity concerns is discussed.
针对管道完整性管理应用,设计、开发并优化了一种全包围薄层钢夹套系统。发展目标包括消除触变问题,以及排除复合材料修复材料性能的退化。消除焊接修复的周期性疲劳以及与热工相关的安全问题也被考虑在内。使用模量与基管相匹配的薄层钢,以及钢的均匀各向同性,可以进行轴向计算和基于应变的评估。薄层钢层压设计具有极高的断裂韧性,并促进了潜在的未来第三方损伤的内在缓解。由此产生的系统证明了管道维修所需的可靠工程数据和分析,并证明了对现有管道进行无缺陷扩建的适用性。工程关键评估(ECA)已经完成。该ECA遵循ASME B31G和ASME pc -2第4条类型评估的行业先例,并为操作员提供更大的功能。该ECA被命名为lelewis增强分析(LAA),并被提出、审查和讨论。第三方全尺寸ASME PCC-2型爆炸测试已完成。并给出了实验结果。还进行了高度仪器化的测试,以确定安装系统的有效弹性模量,以及确定系统接受负载的任何延迟。安装后,在仅50微应变的层压板第3层中加载时,有效模量为1400万psig (96526.60 MP)a。介绍并评述了钢/胶粘剂层合板的长期蠕变和循环疲劳试验。在50%的极限剪切速率下实现了1000万次循环,超过了目前的工业实践几个数量级。根据这些现有的技术进步,对经典的金属损耗缺陷缓解原理进行了回顾和更新。最后,对应力和应变相关的完整性问题的影响进行了讨论。
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引用次数: 0
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Volume 1: Pipeline and Facilities Integrity
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