Effect of multiple repairs welding on the properties of welded API 5L X-52 steel pipeline.

Eng. Ahmed Hosni Ahmed Ghonemi, Prof.Dr. Mahmoud Abass Ibrahim, Prof.Dr. Mohammed Abdel KhalekShahen
(M.Sc. of Materials science & Engineering, Faculty of petroleum and mining engineering, Suez Canal UniversityPetrojet Company (The Petroleum Projects & Technical Consultations Co.) One of the Egyptian Petroleum Corporation Companies, EGYPT.Tel. +201009001175 E-mail:

eng_ahmed_h@yahoo.com
Prof.Dr.Lecturer at Faculty of Petroleum and mining engineering, Suez

Canal University, EGYPT. Tel. +201005850756 E mail: prof_abbas@hotmail.com

Prof.Dr.Lecturer at Faculty of Petroleum and mining engineering, Suez

Canal University, EGYPT. Tel. +201222380876 E mail: smart_ahmed83@hotmail.com

Abstract :This work presents the results of multiple repairs in the same area
in API 5LGrade X-52 steel pipe .Four conditions of (SMAW) repairs and one as-welded specimen of the weld were characterized to determine changes in the microstructure, grain size and to evaluate their effects on the mechanical and electrochemical properties of the weld joints. The results of metallography (optical and scanning electron microscopy) indicated that changes are observed in the microstructural constituents besides grain growth in the heat affected zone at the specimen as the number of repairs increased. Tensile strength of the weld joints meets the requirements of the API 1104 standard even after the fourth weld repair where values of ultimate tensile strength (UTS) greater than 455 MPa(min.UTS). Significant reduction

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in charpy-V impact resistance with the number of weld repairs was found when the notch location was in weld centerline and the intersection of the fusion line with the specimen , all obtained tests satisfy the requirements of NRF-001PEMEX-2000 standard [27] which indicate that the values of absorbed energy for standard size specimens (10x10) tested at -10 C, should be of 29.8J of min absorbed energy for individual specimens and 35.2 J of average min absorbed energy for three specimens. . A significant increase in the Vickers hardness of the heat affected zone occurred as the number of repairs increases. The bend test was acceptable according to API 1104 where no crack or other imperfection exceeding 1/8 in. (3 mm). The present work is good for industries applications where the obtained mechanical properties results that repairing until four times doesn't make appreciable change which could be accepted according to API 1104.

Keywords:API

52

steel,

HAZ,SMAW,Weld

repair.

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1. INTRODUCTION
When a defect is detected in a weld by means of some non-destructive tests, the weld should be repaired; generally, the weld metal is removed by grinding and inspected to verify the effective removal of the defect in order to re-weld under a qualified welding procedure. Repair by welding involving removal of defective areas and replacement by sound material can cost up to 10 times as much as depositing similar quantities of weld metal correctly in the first place, however, repair welding of apart is the most economical way in comparison with replacement of that part especially in a complex structure. Also can save time where cut out the weld make anew weld take more time and effort. API-1104 [1] and ASME IX [2] show the main requirements to make weld repairs in areas previously repaired of line pipes and indicate that the weld repair should be carried out with a qualified welding procedure, inspection personnel and welders should be qualified; however, these standards do not limit the number of times that can be repaired. The only reference found in which the number of weld repairs in line pipe is limited is the offshore standard (DNV-OS-F101) [3] Appendix C, Subsection G 300 Repair Welding, which states: '' Weld seams may only be repaired twice in the same area". Also some local pipeline companies such as EgyptianNatural Gas Company (GASCO) [4] and Engineeringforthe Petroleumand Process Industries (ENPPI) [5] specifications reported that ''The re-welded joint should be tested again and if there is any defect, this joint should be cut out and a new weld carried out (two repairs on any weld are not accepted)''. Most of the investigations in weld repairs are focused on studying the effect or distribution of residual stresses, and the great majority of these studies are based on simulation by finite element [6-14]. Restricted publications have been found relating to weld multi repairs that evaluate changes or effects on the mechanical properties of the welds [15-17] in girth pipe line.

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Lai et al. [15]studied the fracture resistance of welds, after welds were repaired up to three times. Their study mentions that "the apparent lowering in fracture resistance of weld repair is attributed not due to the micro-structural change in the heat affected zone, but is more likely caused by the introduction of defects in the repair". McGaughy [16, 17]they evaluated the effects of shielded metal arc welding (SMAW) repairs on the residual stress distribution, fracture toughness and hardness of girth welds steel Pipe line and they found that the single repair increased the residual stress distribution when compared to the as-welded condition and dramatic reductions in toughness were found in the multiple repairs due to coarse-grained regions produced during the repair operations and concluded that weld repair produces larger grains in the HAZ compared with the as-welded condition; this could be the reason for the reduction in toughness found in the HAZ. AlberSadek andM.Goda [18] investigated the effect of temper bead (half bead) technique repair welding on mechanical properties of thick wall structure steel (40 mm).It should be mentioned that their repair technique was far different from the multi pass technique (which used in the present work) and needs more time and effort.

2. EXPERMINTAL WORK
2.1. Material

A welded API 5L Grade X-52 steel pipe was used. The dimensions of the test pipe were 508 mm (20 inch) inner diameter and 12.7 mm (0.5 inch) of nominal wall thickness and length of each test pipe is 305 mm (12 inch).Welding techniques and welding consumables Girth welds were carried out under a qualified welding procedure (WPS) according to API 1104 [1]. Before welding, two test pipes were assembled by external clamping [1]. The (SMAW) and the consumable electrodes used were E-6010 electrode of 3.25 mm[24] for the root and 4 mm E-7010G electrode [24] for hot pass and

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the subsequent weld beads and 5 mm E-7010G electrode for the cap weld and the heat input was estimated in the interval of l.2 to1.5 kj/mm. 2.2. Repair Welding Procedure

A hard disc 9 inches(23mm) was used to remove the weld (cap and the filling passes) not the root pass then visual inspection has performed. 2.3. Radiographic inspection

Radiographic inspection was used to verify the quality of weld and each repair (the source was used is Iridium-192 (Ir-192), its strength was 50 Curies and the time of exposure was 46 Sec. 2.4. Mechanical Properties of the Weld Repairs The specimens were cut and machined traverse to the direction of application of the girth weld for tensile, impact, hardness, bending, and metallography and corrosion tests.

2.4.1.Tension Tests
Three tension tests for the as welded and weld repair conditions were made in accordance with ASTM E-8 standard [25] and carried out at room temperature.

2.4.2.Impact Tests
According to ASTM E-23[26], three specimens of 10x10 mm with notches in weld centerline and fusion line and in HAZ were tested at -10 C according to NRF-001-PEMEX-2000 [27] standards.

2.4.3.Hardness Tests
Hardness measurements were done using hardness tester machine according to ASTM E-384 standard [28].

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Fig. positions of hardness points carried out on specimens

2.4.4.Bending tests
Tests were carried out at room temperature at 180 degree. The cap and root-bead reinforcements were removed flush with the surfaces of the specimen. The specimens dimensions was 12.7x25x300 mm andits surfaces were smooth 2.5. Metallography Perpendicular sections of the weld containing three different zones were obtained as shown in Fig. 2: the weld metal (WM), heat affected zone (HAZ) and base metal (BM) which were used for metallographic characterizations. Before metallographic investigation the specimens (0R ,1R ,2R ,3R and 4R) were mounted, coarse grinding, fine grinding, and final polishing using 1 m diamond paste then etching using Nital solution (2 ml HNO3 + 98 ml ethanol) The microstructural characterization by optical and scanning microscopy and an energy dispersive X-Ray analysis (EDAX) unit of the welds and heat affected zones were employed. Scanning electron microscopy (SEM) conducted using JEOL scanning electron microscope at an accelerating voltage of 20 kv.

3. Results and Discussions The effects of multi repairs welding on the microstructure and mechanical properties of API 5L Grade X-52 pipelines were investigated as follow.
3.1. Material and electrodes characterizations

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I. Chemical compositions
Chemical composition of material specimen API 5L Grade X-52 is shown in table 1.
Table 1: The average chemical composition of API 5L X-52

C 0.22 Co 0.006

Si 0.25 Cu 0.034

Mn 1.25 Nb 0.016

P 0.001 Ti 0.003

S 0.0006 V 0.065

Cr 0.053 W 0.015

Mo 0.0009 Pb 0.002

Ni 0.049 Fe 98.1

Al 0.052

II. Mechanical properties

Mechanical properties of material specimen API 5L Grade X-52 is shown in Table 2.
Table 2: The average Mechanical properties of material specimen API 5L Grade X-52.

0.2 (MPa) 390

U.T.S(MPa) 530

% El 27.4

3.2. Macro graphic investigation The average areaof all weld metal and average HAZ width at three points upper, center and bottom of weld of each condition 0R-1R-2R-3R-4R was determined using planimeter Model It could be observed in Fig.1that the area of repair welds indicated insignificant changes; this could be that for each repair the V-groove of repair nearly constant and width of HAZ increased as the number of repair increased; this may be related to the accumulation of heat input.

a)

200 195 190

rea (mm)

185 Corresponding author: Tel. +201009001175 180 E-mail: eng_ahmed_h@yahoo.com

175 170

b)

2.50 2.00

HAZ size (mm)

1.50

1.00
0.50 0.00 0 rep 1st Rep 2nd Rep 3rd Rep 4th Rep

Figure 1: a) Weld area b) HAZ size for as weld and multi repair welding.

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Figure 2: Macrographic pictures for a) As-welded, b) First, c) Second, d) Third and e) Fourth repairs.

3.3. Microstructural Characterization The microstructural characterization through optical and scanning microscopy of the weld joint is shown in Fig.3. Optical characterization was made in the three different regions of the specimens. The microstructure of the weld is (ferritic-bainitic), The HAZ microstructure shows a structure of grains of polygonal ferrite with pearlite in the grain boundary and the base metal microstructure consists of ferrite and pearlite. [29] Repair welding lead to the formation of acicular ferrite in both weld and HAZ as shown in the Fig. 4, 6 as well as

increase in the grain size of

HAZ with the number of repairs (Acicular ferrite is a non-equiaxed ferrite with an irregular configuration). These microstructure observations are in agreement with [29, 30] Optical micrographs of the fined grained heat affected zone (FGHAZ) taken at the specimen mid-thickness for each one of the weld repair conditions are shown in Fig.6. It can be observed in a qualitative way that increasing the number of weld repairs promotes grain growth in the FGHAZ.

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Fig. 5, 7 and Tables 3,4 show the scanning micrograph and analysis of weld and HAZ , it could be observed that the chemical composition of both weld and HAZ changed as the number of repairs increased attributed to the diffusion of Mn, Si andC this it could be the accumulative heat input for each repair.

Figure 3: Zero repair condition microstructures. a) Base metal, b) Weld metal and c) Heat Affected Zone.

a) R

b) R

Figure 4: Multi repair conditions weld microstructures. a) First repair, b) Second repair c) Third repair, d) Fourth repair

a) R

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b) R

c) R

d) R

e) R

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Figure 5: Scanning microstructures and chemical analysis for welds. a) As weld b) First repair, c) Second repair d) Tthird repair, e) Fourth repair

a) R

b) R

c) R

d) R

Figure 6: Fined grained heat affected zone microstructure at specimen mid-thickness a) First, b) Second, c) Third and d) Fourth repairs. Table 3: EDAX chemical analysis results of weld at different conditions

Conditions 0R 1R 2R 3R 4R

C% 0.16 0.175 0.19 0.21 0.25

Mn% 0.64 0.80 0.99 1.17 1.27

Si% 0.12 0.15 0.2 0.22 0.22

Fe% Balance Balance Balance Balance Balance

a) R

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b) R

c) R

d) R

e) R

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Figure 7: Scanning microstructures and chemical analysis for HAZ a) As weld b) First repair, c) Second repair d) Third repair, e) Fourth repair Table 4 : EDAX chemical analysis results of HAZ at different conditions

Conditions 0R 1R 2R 3R 4R

C% 0.15 0.16 0.164 0.169 0.2

Mn% 0.8 1.1 1.41 1.52 2.10

Si% 0.15 0.18 0.22 0.25 0.3

Fe% Balance Balance Balance Balance Balance

3.4. Mechanical Tests assessment

3.4.1.Tension Results
Results of the tension tests for the different weld repair conditions are shown in Fig.8. The values ultimate tensile strength (UTS) satisfy the specified min values of the material according to API 5L standard, whose values are 359 and 455 MPa for YS and UTS respectively these values also satisfy the API 1104 standard that states to qualify a welding procedure the tensile strength of the weld of each specimen, shall be greater than or equal to the specified minimum tensile strength of the pipe material. If the specimen breaks outside the weld and fusion zone (that is, in the parent pipe material) and meets the minimum tensile-strength requirements of the specification [1], the weld shall be accepted as meeting the requirements. If the specimen breaks in the weld or fusion zone and the observed strength is greater than or equal to the specified minimum tensile strength of the pipe material and meets the soundness requirements, the weld shall be accepted as meeting the requirements. The behavior indicates a gradual decrease in ultimate tensile strength (UTS) at a first repair then an increase in a second, third and fourth repairs.

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The increase in U.T.S of the fourth repair compared with the third repair due to accumulation of Mn and formation of acicular ferrite. It was observed that breaking occurred at base metal in all cases except at some cases for 2nd, 3rd, 4th repair but the values of ultimate tensile strength of each condition satisfy the specified minimum value of the material API 5L X-52 according to API 1104 [1], whose accepted minimum value is 455 MPa for ultimate tensile strength according to API 5L standard. [20]

530 525

Tensile Sterength (MPa)

520 515 510 505 500 495 490 485 0 rep 1st Rep 2nd Rep 3rd Rep 4th Rep

Figure 8: Ultimate Tensile Strength (UTS) MPa as a function of the numbers of repairs.

3.4.2.Hardness Results
Fig.9 shows the obtained results in the hardness measurements of the HAZ as a function of the number of weld repairs. The behavior indicated a gradual increase in the first, second, third and fourth repairs. This behavior is related to the fact that during the first weld repair an apparent grain refinement is generated in the HAZ as indicated in the tendency observed in Fig. 6. Similar results were reported by McGaughy [16, 17] made for three regions of the weld (cap, mid-wall and root). The increase in hardness

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of HAZ from the second to the fourth repair could be related to diffusion of Mn from base metal to HAZ which lead to formation of acicular ferrite in adjacent from HAZ Fig.4, 6. 200.00 190.00 180.00 170.00 160.00 150.00 140.00 130.00 120.00 110.00 100.00 0 rep 1st Rep 2nd Rep 3rd Rep 4th Rep

Vickers Hardness (HV)

Figure 9: Average Vickers hardness in the HAZ as a function of the numbers of repairs for a) Upper area b) Central area c) Bottom area.

3.4.3.Toughness Assessment
Charpy V tests with four different notch locations to measure the impact resistance were used. The average values of absorbed energy obtained for each one of the weld repair conditions are shown in Fig.10 (which shows absorbed energy in weld metal center line, intersection of fusion line (FL), (FL+1) and (FL+2) with specimen mid-thickness) and the small value belongs to the weld than fusion line of HAZ, because the content of alloying elements coming from the electrode enhances the formation of hard phases that possess low toughness. When notch was placed on fusion line, a slight increase in absorbed energy was observed for first repair, followed by a significant fall in the energy values as the number of weld repairs increases, to reach the lowest value in absorbed energy in the fourth repair.

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This behavior can be associated to the grain refinement in the HAZ for the first repair and later grain growth with the number of repairs as indicated in the tendency observed in Fig.6. All obtained values in Charpy-V impact tests satisfy the requirements of NRF-001-PEMEX-2000 standard [27] which indicate that the values of absorbed energy for standard size specimens (10x10) tested at -10 C, should be of 29.8J of minimum absorbed energy for individual specimens and 35.2 J of average minimum absorbed energy for three specimens. McGaughy et al. [9, 10] evaluated charpy-V sub-size specimens of 5x10 mm in cross section by triplicate at -15 C at each one of the following notch locations: (1) weld centerline,(2) intersection of the fusion line(FL) with the specimen mid-thickness ,(3) FL+2 mm at the specimen mid-thickness and (4) parent pipe. No agreement was found with the tendency reported for the case where the notch location was in the weld centerline indicated an increase in the first repair and decrease in the second repair.

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450 400 350

absorbed energy (J)

300
250 200 150 100 50 0 W.M HAZ (F.L) HAZ (F.L+1) HAZ (F.L+2)

0 rep 1st Rep 2nd Rep 3rd Rep 4th Rep

Figure 10:Absorbed energy in weld metal center line and intersection of fusion line with specimen mid-thickness.

O.E. Vega and J.M. Hallen [30] indicated that the weld repairs promote grain growth of the HAZ in the specimen mid-thickness and this grain growth contributed to decrease the toughness as the number of weld repairs increases. Even after the fourth repair the toughness meets the requirements of the NRF001-PEMEX-2000 standard [27]. In contrarily the present study proved that a slight increase in the toughness and strength which could be attributed to the formation of acicular ferrite (to some extent) however there is an increase in grain size.

3.4.4.Bending Results
No cracks or imperfections were observed in repair, this could be related to the formation of acicular ferrite and increase of Mn in welds and the heat affected zones. It should be mentioned that API 1104[1] reported that, the bend test was considered acceptable if no crack or other imperfection exceeding 1/8 in. (3 mm)

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4. Conclusions
Mechanical , microstructural and electrochemical evaluation in girth welds of welded API 5L X-52 steel pipe with one, two, three and four SMAW repairs in the same area were studied. According to the results obtained, it can be concluded that: 1. An increase in tensile, hardness and toughness was observed. This could be attributed to formation of acicular ferrite .The values of ultimate tensile strength of the weld joints satisfied the specified minimum of the material according to API 5L standard, even after a fourth weld repair made in the same area. 2. Energy dispersive X-ray analysis (EDAX) showed that Manganese and silicon (Mn, Si) diffused from base metal to HAZ and weld. Their concentrations increase in weld and HAZ as the number of repairs increased. It could be attributed to the accumulation of heat input for each repair. 3. Significant grain growth observed at HAZ as the number of repairs increased Also, it can be stated that repair welding till four times could be used in applicant industries as some local Egyptian line pipes companies like GASCO and ENPPI stated in their specifications that The re-welded joint should be tested again and if there is any defect, this joint shall be cut out and a new weld carried out (two repairs on any weld are not accepted and it can be save time and effort and also it is economical.

5. Acknowledgment
I wish to express my sincere thanks and deep graduate to supervisor Professor Mahmoud Ibrahim Abbas, PETROJET Company, ENERGYA Steel Company, and all my around friends.

The authors have no competing interests or funding

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Reference
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Reference
[25] ASTM E-8,Standard tests methods for tension testing of metallic materials, (2004), p.1-24. [26] ASTM E-23, Standard methods for notched bar impact testing of metallic materials, (2006), p.1-27. [27] NRF-001-PEMEX-2000, Tubria de acero Para recollection y transporte de hidrocarburosamargos, (2000), p.1 -31. [28] ASTM E-384,Standard test method for micro indentation hardness, (2006), p.1-33. [29] WELDING METALLURGY OF STEELS, Module 21 of the modular learning system devised by the welding institute of Canada of materials, Published by Abington Publishing ,Cambridge, England, (1994), p.1-65. [30] O.E. Vega and J.M. Hallen, Effect of multiple repairs girth welds of pipelines on the mechanical properties, REVISTA MEXICANA DE FISICA, (2008), p.1499-1507.

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