FENET Barcelona Feb2003 DLE Wright PDF

Industry Sector
RTD Thematic Area
Date
Power & Pressure Systems
Durability and Life Extension
Feb-03
Comparison of Predicted and Measured Residual Stresses in a Pipeline Girth Weld

Keith Wright - Structural Integrity Assessments Ltd, Melbourne, Derbyshire, United Kingdom
&
Vinod Chauhan Advantica Technologies Ltd, Loughborough, Leicestershire, United Kingdom
Summary
The use of FEA in the prediction of pipeline girth weld residual stresses and a comparison with
experimental measurements is described. The effects of hydrotesting on the weld residual
stresses are also considered. A summary of some possible future workshop activities for the
Durability and Life Extension technology areas of FENet are presented.
FENET THEMATIC NETWORK

COMPETITIVE AND SUSTAINABLE GROWTH
(GROWTH) PROGRAMME
Acknowledgement and Reference of Published Work:
Pipeline Girth Weld Residual Stresses and the Effects of Hydrotesting.

Vinod Chauhan, Advantica Technologies Ltd, UK.
Zhilli Feng, Engineering Mechanics Corporation of Columbus, USA.
ASME 4th International Pipeline Conference, October 2002, Calgary, Canada.
Reference: Proceedings of IPC02 - 27140

(GROWTH) PROGRAMME
Advantica
A premier provider of advanced technology and systems solutions that help high
performance energy and water delivery companies world-wide improve their
operating performance.
Origins in British Gas in the UK and in Stoner Associates in the US.
Proven track record of over 30 years experience servicing more than 550 clients in
over 50 countries.

(GROWTH) PROGRAMME
Weld Residual Stresses
Pipeline girth welds are not Post Weld Heat Treated.
Hence weld residual stress is an important factor in Fitness-For-Purpose

Assessments.
Many Codes (BS7910, R6 Revision 4, API RP579) recommend residual stress

profiles in weld region that could be overly conservative.
Evidence that welding residual stresses are reduced following hydrotesting.

(GROWTH) PROGRAMME
Axial Stress Profiles in Pipeline Girth Weld as Recommended by BS7910 and R6

Residual stress is
normalized to yield or
0.2% proof strength of
weld metal.
Derived from upper
bound data not
necessarily self
equilibrating.
For girth weld made
with manual SMAW
process, codes
suggest using the high
heat input profile.
Normalized Axial Residual Stress
1.2
E/B < 50 J/mm2
1
0.8
0.6
50 < E/B < 120 J/mm2
0.4
0.2
0
-0.2
-0.4
-0.6
SMAW = shielded metal arc welding

(GROWTH) PROGRAMME
0.2
0.4
0.6
0.8
Low Heat Input

Medium Heat Input
E/B > 120 J/mm2
High Heat Input
(z/B)
Case 1 Assumed As Welded Residual Stresses (Hoop Direction)
Weld elements at
tensile yield (475MPa) in
hoop direction.

(GROWTH) PROGRAMME
Case 1 - Assumed As Welded Residual Stresses (Axial Direction)
Axial Stress Distribution

at Equilibrium with Weld
elements at tensile yield
(475MPa) in hoop
direction.
Tensile axial stress at
inner surface of pipe
close to weld of approx
49MPa.

(GROWTH) PROGRAMME
Case 1 Post Hydrotest Residual Stresses (Axial)
Modified Axial Stress

Distribution after
application and then
removal of hydrotest
loading..
close to weld has
reduced to approx
31MPa.

(GROWTH) PROGRAMME
Case 2 Assumed As Welded Residual Stresses (Hoop Direction)
Weld elements have a

through thickness
variation of hoop stress
from tensile yield
(475MPa) at outer
surface to 100MPa
tensile at inner surface.

(GROWTH) PROGRAMME
Case 2 - Assumed As Welded Residual Stresses (Axial Direction)
Axial Stress Distribution

at Equilibrium with Case
2 through thickness
variation of hoop stress.
close to weld of approx
38MPa.

(GROWTH) PROGRAMME
Case 2 Post Hydrotest Residual Stresses (Axial)
Modified Axial Stress

Distribution after
application and then
removal of hydrotest
loading..
close to weld has
marginally increased to
approx 40MPa.

(GROWTH) PROGRAMME
Confidence in the Simplified Approach?
NONE !!
Experimental data required.
Fortunately an experimental programme had been initiated.
Objectives of Work Programme:
Conduct detailed experimental and finite element analysis to determine the residual
stress fields in the vicinity of gas transmission pipeline girth welds.
Determine the effects of hydrotesting on pipeline girth weld residual stress fields.
Compare the results to those recommended in BS7910.

(GROWTH) PROGRAMME
Experimental Programme (Advantica)
Materials and pipe geometry selected are representative of most

common pipeline within UK gas transmission systems.
API 5L grades X60 and X65 pipes: 0.13-0.2%C, 1.3-1.6%Mn, 0.31-0.33%Si

3m long
Pipe A - API X65
36-in OD (914.4mm)
Wall thickness: 5/8 and in
(15.9mm and 12.7mm)
600
Stress-strain curves were

measured for both base metal and
weld metal
True Stress, N/mm2
500
400
300
200
100
Parent M01-04
Parent M01-05
Parent M01-06
0
0
0.005
0.01
0.015
True Strain

(GROWTH) PROGRAMME
0.02
0.025
Welding Details
Manual SMAW girth weld. Six passes, 60 deg V-groove
AWS E6061 electrode for root and second pass, and E8010 for other 4 passes.
Two welders simultaneous vertical down progression.
Pass
No.
1
2
3
4
5
6 (cap)
Travel
Speed
(cm/min)
26
35
24
12
13
13
Interpass
Temp.
(C)
50
60
80
50
70
90

(GROWTH) PROGRAMME
Electrode
Size
(mm)
4
4
5
5
5
5
Electrode
Type
AWS
E6010
E6010
E8010
E8010
E8010
E8010
Heat
Input
(kJ/mm)
0.84
0.76
1.26
2.16
1.86
1.59
o+5
30 0
+1
1.5 0
Typical Welds

(GROWTH) PROGRAMME
Full Scale Hydrotesting
6m long girth welded pipes with two end-caps

Hydro-test pressures
High pressure case: 120 bar on two -in thick X60 pipes
correspond to the 105% SMYS requirement (UK pipeline design code
IGE/TD/1) (SMYS = Specified Minimum Yield Stress)
Low pressure case: 105 bar on one 5/8-in thick X65 pipe
simulate above-ground installation (AGI) pipework (IGE/TD/13)
Girth Weld
6 meters

(GROWTH) PROGRAMME
Surface Residual Stress Measurements
Air abrasive centre hole drilling method

Hole was about 2-mm diameter and depth
Estimated measurement accuracy:
About 8% if stress is below 65% of SMYS
About 16% otherwise, due to plastic deformation in hole drilling
Measurements both before and after hydro-test
Measurements on both inside and outside surfaces

Initially, at one circumferential position at weld centreline and HAZ
Subsequent measurements on weld centreline at every 45 deg position
around the circumference, covering weld start and stop locations

(GROWTH) PROGRAMME
Surface Residual Stress Measurements
Air abrasive
centre hole
drilling
method.

(GROWTH) PROGRAMME
Finite Element Analysis (Engineering Mechanics Corporation of Columbus)

Welding Process &
Parameters
Sequentially coupled approach
Weld heat flow

Microstructure, mechanical
property
Stress
ABAQUS, enhanced with set of
proprietary user subroutines developed
specifically for microstructure and welding
computations
Weld Heat
Flow Model
Thermal
History
Mechanical
Model
Residual Stress Distribution
Steel & Weld Metal

Compositions
Microstructure &
Property Model
Weldment Microstructure
& Mechanical Properties
Experiment
Validation
An Integrated Thermal-Mechanical-Metallurgical Weld Stress Model

(GROWTH) PROGRAMME
Finite Element Analysis Axisymmetric Mesh
Applicable for girth weld with the exception of the weld start/stop positions
Half model for perfectly aligned pipes, Full model for misaligned pipes
Four noded linear isoparametric quadrilateral element
Very fine mesh (element length about 0.1mm) in the weld and HAZ region for
microstructure analysis

(GROWTH) PROGRAMME
Temperature Dependent Material Properties Used

Yield and flow stress functions of both temperature and microstructure.
Other temperature
dependent
properties included:
700
Elastic Modulus
500
Specific Heat
Conductivity
Stress (MPa)
Poissons Ratio
600
HAZ
400
Base
Metal
300
200
100
0
200
400
600
800
1000
Temp (K)
(GROWTH) PROGRAMME
1200
1400
1600
FE Model Results Predicted Microstructures consistent with those in Actual Weld.
Ferrite Fraction
Pearlite Fraction
Bainite & Acicular Ferrite Fraction

(GROWTH) PROGRAMME
FE Model Results Predicted Hardness consistent with those in Actual Weld.

250
Weld Metal
Base Metal
Hardness (VHZ)
200
150
X
100
50
O
0
0
(GROWTH) PROGRAMME
10
X (mm)
15
20
FE Model Results As Welded Residual Stresses
Axial Stresses
Max value 392MPa
Hoop Stresses

(GROWTH) PROGRAMME
FE Model Results Residual Stresses After Hydrotest
Axial Stresses
Max value 196MPa
Hoop Stresses

(GROWTH) PROGRAMME
Comparison of Predicted Through Wall & Experimental Surface Residual Stresses

1
As Welded Results
0.8
Max Axial
Stress Point
Outer Surface
Location 2
Location 1
Weld Centerline
ace
Normalised Axial Stress
0.6
0.4
0.2
0
-0.2
-0.4
FE simulation - Weld Centreline

FE simulation - Location 1
FE simulation - Location 2
BS7910 High Heat Input Distribution
Inner Surface Measurements
Outer Surface Measurements
-0.6
-0.8
-1
0
0.1
0.2
0.3
0.4
0.5
z/B
(GROWTH) PROGRAMME
0.6
0.7
0.8
0.9
Comparison of Predicted Through Wall & Experimental Surface Residual Stresses

Results Following Hydrotest
1
0.8
Normalised axial stress
0.6
0.4
0.2
0
-0.2
-0.4
FE simulation - Weld Centreline
-0.6
FE simulation - 13.5mm from Weld Centreline
FE simulation - 7.2mm from Weld Centreline

BS7910 High Heat Input Distribution
Inner Surface Measurements
-0.8
Outer Surface Measurements
-1
0
0.1
0.2
0.3
0.4
0.5
z/B
(GROWTH) PROGRAMME
0.6
0.7
0.8
0.9
Some Observations
The objectives of the experimental programme of work were achieved in that it did
demonstrate that hydrotesting does significantly reduce girth weld residual stresses.
The through wall axial residual stress distribution recommended by BS7910 was
shown to be conservative at and near to the inner surface of the weld. At the outer
surface of the weld this is not the case, for both as welded and after hydrotesting.
The supporting analytical work using a sequentially coupled Thermal-MechanicalMetallurgical Weld Stress Model was able to predict reasonably well the as-welded
microstructure and the mechanical properties (Hardness) observed in actual welds.
Hence the predicted residual streses from this Model would appear to have greater
credibility than the simplified modelling approach described at the outset.
But the experimentally measured residual stresses exhibit significant variability at

both inner and outer surfaces. Is it real or measurement error?

(GROWTH) PROGRAMME
Observations Continued
The scatter in the as welded measured axial stresses at the inner surface ranged
from high tensile (244MPa) to compressive (-136MPa). The high tensile value was
measured at the weld start/stop positions. The axisymmetric FE simulation is unable
to predict stresses at the weld start/stop positions. If the weld start/stop locations
are not considered then the comparison of the measured and FE stresses is much
better.

(GROWTH) PROGRAMME
So What About the Residual Stresses in the Practical Case?
Confidence in the simplified approach simulation model was LOW as subsequently

borne out by the experimental measurements.
In light of the more advanced Thermal-Mechanical-Metallurgical simulation model

would reliance be placed on predicted residual stresses now ?
UNLIKELY unless it was used with some form of safety factor.
Therefore, an upper bound to the experimentally measured axial residual stress was
used instead in the Fitness-For-Purpose assessments,

(GROWTH) PROGRAMME
What Next ?
It would be nice to have: Simulation model extended to 3D and attempt to reproduce weld start/stops.
Confidence limits associated with the through wall residual stress profiles.
Hence a stress distribution to an appropriate confidence level could be used in
defect assessments. Possibly by using Monte Carlo Simulation techniques with
the Thermal-Mechanical-Metallurgical Weld Stress model.

(GROWTH) PROGRAMME
Suggestions For Future FENet Activities
Benchmarks for verification and validation
Provide guidance on accuracy of simulations, identify potential pitfalls eg the

simplified approach described.
Reference of Published Work:
Pipeline Girth Weld Residual Stresses and the Effects of Hydrotesting,

Vinod Chauhan & Zhili Feng.
ASME 4th International Pipeline Conference, October 2002, Calgary, Canada,

Proceedings of IPC02 27140.

(GROWTH) PROGRAMME

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Industry Sector

RTD Thematic Area

Power & Pressure Systems

Durability and Life Extension

Comparison of Predicted and Measured Residual Stresses in a Pipeline Girth Weld

FENET THEMATIC NETWORK

Acknowledgement and Reference of Published Work:

Pipeline Girth Weld Residual Stresses and the Effects of Hydrotesting.

ASME 4th International Pipeline Conference, October 2002, Calgary, Canada.

Reference: Proceedings of IPC02 - 27140

FENET THEMATIC NETWORK

Origins in British Gas in the UK and in Stoner Associates in the US.

FENET THEMATIC NETWORK

Weld Residual Stresses

Pipeline girth welds are not Post Weld Heat Treated.

Hence weld residual stress is an important factor in Fitness-For-Purpose

Many Codes (BS7910, R6 Revision 4, API RP579) recommend residual stress

Evidence that welding residual stresses are reduced following hydrotesting.

FENET THEMATIC NETWORK

Axial Stress Profiles in Pipeline Girth Weld as Recommended by BS7910 and R6

Normalized Axial Residual Stress

50 < E/B < 120 J/mm2

SMAW = shielded metal arc welding

Low Heat Input

E/B > 120 J/mm2

High Heat Input

Case 1 Assumed As Welded Residual Stresses (Hoop Direction)

FENET THEMATIC NETWORK

Case 1 - Assumed As Welded Residual Stresses (Axial Direction)

Axial Stress Distribution

FENET THEMATIC NETWORK

Case 1 Post Hydrotest Residual Stresses (Axial)

Modified Axial Stress

FENET THEMATIC NETWORK

Case 2 Assumed As Welded Residual Stresses (Hoop Direction)

Weld elements have a

FENET THEMATIC NETWORK

Case 2 - Assumed As Welded Residual Stresses (Axial Direction)

Axial Stress Distribution

FENET THEMATIC NETWORK

Case 2 Post Hydrotest Residual Stresses (Axial)

Modified Axial Stress

FENET THEMATIC NETWORK

Confidence in the Simplified Approach?

Experimental data required.

Fortunately an experimental programme had been initiated.

Objectives of Work Programme:

Compare the results to those recommended in BS7910.

FENET THEMATIC NETWORK

Experimental Programme (Advantica)

Materials and pipe geometry selected are representative of most

API 5L grades X60 and X65 pipes: 0.13-0.2%C, 1.3-1.6%Mn, 0.31-0.33%Si

Stress-strain curves were

True Stress, N/mm2

FENET THEMATIC NETWORK

Manual SMAW girth weld. Six passes, 60 deg V-groove

Two welders simultaneous vertical down progression.

FENET THEMATIC NETWORK

FENET THEMATIC NETWORK

Full Scale Hydrotesting

6m long girth welded pipes with two end-caps

FENET THEMATIC NETWORK

Surface Residual Stress Measurements