Study on test procedure development to evaluate pipe...
Transcript of Study on test procedure development to evaluate pipe...
© 2013 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.
API 1104 Committee Meeting, Jan. 2013
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Study on test procedure development to evaluate pipe properties
at HAZ in girth welded portion
Masahiko Hamada, Hiroyuki Nagayama Jun Nakamura, Hidenori Shitamoto
Tetsuya Fukuba
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API 1104 Committee Meeting, Jan. 2013
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Outlines /Field girth welding simulation project in NSSMC Main part: Test procedure development to evaluate pipe properties in HAZ /Introduction /Outlines of developing test procedure /Review of trial test results Macrographic examination, CTOD, CVN, Hardness /Summary
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API 1104 Committee Meeting, Jan. 2013
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Field girth welding simulation project in Nippon Steel & Sumitomo Metal Corporation
<Objective> •Better understanding on field girth welding •Better understanding on properties of HAZ in girth welds •Feedback on material design •Better communication with customers
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API 1104 Committee Meeting, Jan. 2013
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Field girth welding simulation project in Nippon Steel & Sumitomo Metal Corporation
Pipe mills S’less: Wakayama UOE: Kashima & Kimitsu HFW: Hikari & Nagoya
Welding joint marketing & development dep. (2007~)
Pipe & Tube business unit
R&D Center Material, Corrosion Welding, Mechanics
NIPPON STEEL & SUMIKIN Pipeline & Engineering (Domestic pipeline contractor)
Project organization
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Narrow gap PGMAW in 1G position
Pipe size: 323.9mm OD x 53mm WT, Bevel angle: 5 deg. Pass numbers: 19 pass, Root pass: STT without Cu-backing
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Narrow gap PGMAW in 5G position
Pipe size: 273mm OD x 14mm WT, Bevel angle: 5 deg. Root pass: STT without Cu-backing
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SAW in 1G position
Installation in 2011
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Introduction
•Nippon Steel & Sumitomo Metal Co. (NSSMC) is conducting test procedure development to evaluate pipe properties (especially CTOD properties) at HAZ in girth welded portion. •API-1104 does not cover the test procedure to evaluate base metal properties at HAZ. •API-RP-2Z covers this area but the recommended welding conditions is deferent from the field girth welding of pipe line constructions.
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API 1104 Committee Meeting, Jan. 2013
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Outline of the test procedure (for welding)
<Bevel design> Single-bevel (half-K bevel) (Figure shows an example. ) <Welding process> Mechanized GMAW/PGMAW Mechanized SAW <Welding position> ASME 1G (Pipe rotating)
2.0-10.0
40
+/ - 10 o
1.0 +/ - 1.0
20 +/ - 5
5.0-15.0
(mm)
Backing ring
o
Items in this page is same as API-RP-2Z
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Outline of the test procedure (for welding)
API-RP-2Z NSSMC procedure
Weld heat input (kJ/mm)
0.8 3.0 4.5 0.5 1.6
Preheat/ Inter pass temp.
(deg. C) Max.100 100~250 min. 250 Max.50 125~150
Welding conditions
•NSSMC considered that the main line welding could be covered our proposal for welding conditions. •An extra larger heat input condition should be considered for the double joint process.
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Outline of the test procedure (for CTOD test)
API-RP-2Z NSSMC procedure
HAZ straightness
Precrack intersect the etched HAZ for 75% of central 2/3 of the specimen thickness.
Measured the fusion line straightness in 60% of wall thickness. Target value is less than 1.0 mm
Precrack position for coarse grain
specimen
More than 15% of precrack in CGHAZ within *0.3 or 0.5 mm of fusion line. The 15% must be within central 2/3 of the specimen. *0.3 mm for 0.8kJ/mm 0.5 mm for 3.0 &4.5kJ/mm
1. Average distance from precrack to fusion line should be 0.5 mm or less.
2. HAZ ratio on precrack should be 80 % or more.
3. Unaltered CGHAZ ratio at fusion line should be 25 % or more
Metallographic examination
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API 1104 Committee Meeting, Jan. 2013
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Outline of the test procedure (for CTOD test)
60% of wall
thickness
1.0mm or less1.0mm or less
HAZ straightness
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API 1104 Committee Meeting, Jan. 2013
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Outline of the test procedure (for CTOD test)
Unaltered CGHAZ ratio
Etched HAZ
CGHAZ next to un-
refined columnar weld
metal
(Unaltered CGHAZ)
Criterion
Total length of Unaltered
CGHAZ >= 25% in 60% of
wall thickness
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<Test pipe> Grade: API 5L X65QO PSL2 OD x WT: 8.625” x 1.317” (219.1mm x 33.45mm) <Welding conditions> 1. Low heat input Process: PGMAW, Position: 1G Aimed heat input: 0.5kJ/mm Preheat/ Interpass temp.: max. 50 deg.C 2. High heat input Process: SAW, Position: 1G Aimed heat input: 1.6 kJ/mm Preheat/ Interpass temp.: 125~150 deg.C
Trial test results
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Macrographic examination for 0.5kJ/mm GMAW joint
In 60 % of wall thickness HAZ straightness: 0.76 mm, Unaltered CGHAZ: 64.9 %
Trial test results
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Macrographic examination for 1.6 kJ/mm SAW joint
In 60 % of wall thickness HAZ straightness: 0.98 mm, Unaltered CGHAZ: 52.5 %
Trial test results
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HAZ straightness & unaltered CGHAZ ratio
WPS Joint ID
Specimen ID
HAZ straightness (mm)
Unaltered CGHAZ (%)
PGMAW 0.5 kJ/mm
M-2 MW-1 0.76 64.9%
MW-2 0.88 66.9%
M-3 MW-3 0.68 58.9%
MW-4 0.73 62.8%
SAW 1.6 kJ/mm
S-2 SW-1 0.98 52.5%
SW-2 0.85 57.3%
S-3 SW-3 0.95 67.1%
SW-4 0.56 63.8%
In 60 % of wall thickness; HAZ straightness was controlled less than 1.0 mm Unaltered CGHAZ ratio was more than 50 %
Trial test results
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Average distance from the fusion line to the precrack and HAZ ratio on the precrack
-0.4 -0.2 0 0.2 0.4 0.60
20
40
60
80
100
HA
Z r
ati
o o
n t
he
pre
cra
ck
(%
)
Average distance from the fusion line to the precrack (mm)
●: GMAW 0.5kJ/mm△: SAW 1.6kJ/mm
In both case of 0.5kJ/mm GMAW and 1.6kJ/mm SAW; Average distance from the fusion line to the precrack should be keep 0.2 mm or more to keep the HAZ ratio on the precrack more than 80 %.
Trial test results
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CTOD test results
-20 -10 00.05
0.1
0.5
1
5
Temperature (deg.C)
CT
OD
va
lue
(m
m)
CGHAZ
●:δm△:δu
-20 -10 0
Etched HAZ
GMAW 0.5kJ/mm
-20 -10 00.05
0.1
0.5
1
5
Temperature (deg.C)C
TO
D v
alu
e (
mm
)
CGHAZ
-20 -10 0
Etched HAZ
SAW 1.6kJ/mm
●:δm△:δu
Measured CTOD values were more than 0.25 mm.
Trial test results
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Charpy impact test results
The transition temperature of CGHAZ in 1.6kJ/mm SAW joint was higher than 0.5kJ/mm PGMAW joint.
-60 -40 -20 00
100
200
300
400
Ab
so
rbe
d e
ne
rgy
(J
)
Temperature (oC)
PGMAW,0.5kJ/mm
CGHAZ EtchedHAZ
0
50
100
Sh
ear
are
a (
%)
CGHAZ vTs: <-60 oC
Etched HAZ vTs: <-60 oC
-60 -40 -20 00
100
200
300
400
Ab
so
rbe
d e
ne
rgy
(J
)
Temperature (oC)
SAW, 1.6kJ/mm
CGHAZ Etched HAZ
0
50
100
Sh
ear
are
a (
%)
CGHAZ vTs: -35 oC
Etched HAZ vTs: -53 oC
Trial test results
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Hardness distribution in 0.5 kJ/mm GMAW joint
1.5mm -0 / +0.5mm
1.5mm -0 / +0.5mm 1mm 0.5-1.0mm
-15 -10 -5 0 5 10 15150
175
200
225
250
275
300
Vic
ke
rs h
ard
ne
ss
(H
v 1
0k
gf)
OD Straight OD Bevel ID Straight ID Bevel
Distance from fusion line (mm)
Fusion line
PGMAW 0.5kJ/mm
Significant hardening occurred at CGHAZ near the outer surface. Near the inner surface, hardening was not significant.
Trial test results
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0 5 10 15150
175
200
225
250
275
300
Th
rou
gh
th
ick
ne
ss
h
ard
ne
ss
dis
trib
uti
on
o
f F
L+
0.4
mm
(H
v 1
0k
gf)
Bebel side (Last pass side)
Distance from outside surface (mm)
PGMAW, 0.5kJ/mm
HAZ of Cap pass
Max. 307
It was confirmed that significant HAZ hardening occurred only in the cap pass region
Hardness distribution in 0.5 kJ/mm GMAW joint
Trial test results
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Hardness distribution in 1.6 kJ/mm SAW joint
1.5mm -0 / +0.5mm
1.5mm -0 / +0.5mm 1mm 0.5-1.0mm
No significant hardening occurred at CGHAZ.
-15 -10 -5 0 5 10 15150
175
200
225
250
275
300
Vic
ke
rs h
ard
ne
ss
(H
v 1
0k
gf) OD Straight
OD Bevel ID Straight ID Bevel
Distance from fusion line (mm)
Fusion line
SAW, 1.6kJ/mm
Trial test results
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API 1104 Committee Meeting, Jan. 2013
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4. Summary
• NSSMC is conducting test procedure development to evaluate pipe properties (especially CTOD properties) at HAZ in girth welded portion based on API-RP-2Z • Outlines of developing procedure and trial test results were introduced. NSSMC will continue to develop the test procedure to obtain broad consensus with our customers.