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1 Präsentation / presentationUNTERNEHMEN/ COMPANY
REEL-LAYING SIMULATION BY MEANS OF A FOUR-POINT-BENDING TEST
16th Biennial Joint Technical Meeting on Pipeline Research, 16. - 20. April 2007, Canberra
Presented
by
U. Zeislmair (V&M)Authors: M. Erdelen-Peppler, A. Meißner
T. Schmidt (V&M)
2 Reel-laying Simulation16. - 20. April 2007, Canberra
•• IntroductionIntroduction•• Pipeline installation methods & requirementsPipeline installation methods & requirements
•• Physical phenomenaPhysical phenomena
•• Finite element analysisFinite element analysis•• Real reelingReal reeling
•• Full scale reeling simulation testsFull scale reeling simulation tests
•• Experimental detailsExperimental details•• Full scale reeling simulation tests Full scale reeling simulation tests –– 4 point bending4 point bending
•• Small scale reeling simulation testsSmall scale reeling simulation tests
•• Mechanical testing after reeling simulationMechanical testing after reeling simulation
•• Results & discussionResults & discussion
3 Reel-laying Simulation16. - 20. April 2007, Canberra
Introduction
influence on mechanical propertiesand subsequent service of line pipe
material
pipe
laying e.g.
J-layingS-layingreel-laying
plastic deformation and ageing
importance for ...importance for ...production of V&M seamless line pipe
image: Salzgitter AG, annual
report
2005
PIPELINE INSTALLATIONPIPELINE INSTALLATION
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Introduction
control of mechanical properties of the linepipe material
tests, e.g. with reference to DNV-OS-F101
•
small scale reeling simulation tests
•
where required: full scale reeling simulation tests (cost-, time-intensive!)
•
uniaxial
tension and compression in
steps corresponding to those of the installation process
•
artificial ageing at 250
°C for one hour
•
mechanical testing (tensile tests, Charpy
V-notch impact toughness testing etc.)
REQUIREMENTSREQUIREMENTS
5 Reel-laying Simulation16. - 20. April 2007, Canberra
Introduction
REEL LAYING: STRAIN CONTROLLED BENDING PROCESSREEL LAYING: STRAIN CONTROLLED BENDING PROCESS
Curvature
Ben
ding
Mom
ent
step Istep IIstep IIIstep IV
I
II
III
IV
I.
reeling onto drum (onshore)II.
unreeling
III.
aligningIV.
straightening
6 Reel-laying Simulation16. - 20. April 2007, Canberra
Introduction
PHYSICAL PHENOMENAPHYSICAL PHENOMENA
I.I. strain hardening: strain hardening: increase of dislocation densityII.II. residual stresses:residual stresses: Bauschinger
effect
III.III. strain ageing:strain ageing: interaction interstitial atoms ↔ dislocations
……occurring during real reeling, full andoccurring during real reeling, full and small scale reeling simulation testssmall scale reeling simulation tests
7 Reel-laying Simulation16. - 20. April 2007, Canberra
Approach
finite element analysis
full and small scale reeling simulation tests
mechanical testingaccording DNV-OS-F101
8 Reel-laying Simulation16. - 20. April 2007, Canberra
Approach FEA
finite element analysis
real reeling
simulation of I. load step
bending rig test 4 point bending
9 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
REAL REELING PROCESSREAL REELING PROCESS
loadingloadingbending momentaxial force
information from pipe layers:axial force ≈
1.5 Mp
/ RDrum
10 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
BENDING RIG TESTBENDING RIG TEST
loadingloadingbending momentlateral force
bendbend formerformer
FL
straightstraight pipepipe
pipepipe afterafter I. I. bendingbending stepstep
11 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
4 POINT BENDING TEST4 POINT BENDING TEST
loadingloadingpure bending moment
pipea
bending moment diagramMB = F × a
F F
F F
inner supportouter support
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FEA Reeling
equivalent plastic strain distribution
evaluation of stress and strain distribution over the pipe cross section
FEA REAL REELING PROCESSFEA REAL REELING PROCESS
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FEA Reeling
axial force = 110 kNaxial force = 110 kN axial force = 500 kN axial force = 500 kN
axial stress
σmax
= 558 MPa
σmin
= -573 MPa
σmax
= 569 MPa
σmin
= -586 MPa
σmax
= 115 MPa
σmin
= -126 MPa
σmax
= 153 MPa
σmin
= -176 MPa
STRESS DISTRIBUTION OVER PIPE CROSS SECTIONSTRESS DISTRIBUTION OVER PIPE CROSS SECTION
circum- ferential stress12:00
12:00
12:0012:00
6:006:00
6:006:00
14 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
0,0%
0,5%
1,0%
1,5%
2,0%
2,5%
3,0%
0 100 200 300 400 500
Axial Load in kN
ε pl i
n A
xial
Dir
ectio
n
axial load duringreal reeling
INFLUENCE OF AXIAL FORCE ON PLASTIC STRAININFLUENCE OF AXIAL FORCE ON PLASTIC STRAIN
minor influence of axial load on axial plastic strain
15 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
-2,5%
-2,0%
-1,5%
-1,0%
-0,5%
0,0%
0,5%
1,0%
1,5%
2,0%
2,5%
Real Reeling Bending Rig 4 Point Bending
Plas
tic S
trai
n ε p
l in
%
max axial tension max circumferential tensionmax axial compression max circumferential compression
REAL REELING PROCESS VS. REELING SIMULATION TESTSREAL REELING PROCESS VS. REELING SIMULATION TESTS
16 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
RESULTS FROM FE SIMULATIONSRESULTS FROM FE SIMULATIONS
•
longitudinal force during real reeling (I. step) of minor importance
•
similar results concerning stress and strain evolution by
real reeling
four point bending
bending rig test
17 Reel-laying Simulation16. - 20. April 2007, Canberra
Mechanical Testing
full scale reeling simulation tests
artificial ageing
mechanical testing(tensile, Charpy…)
small scale reeling simulation tests
evaluation of results
18 Reel-laying Simulation16. - 20. April 2007, Canberra
Experimental Details
TESTING MATERIAL & TEST PARAMETERSTESTING MATERIAL & TEST PARAMETERS
two seamless pipes, API 5L grade X65, produced in plug millspipe I: OD 219.1 mm × WT 20 mmpipe II: OD 273.1 mm × WT 18.3 mm
small scale reeling simulation acc. DNV OS-F101εpl of coupons 2 × (+/- 2 %) and 2 × (-/+ 2 %), respectively
ageing 1 h / 250 °C
full scale reeling simulation by four point bending testsεpl > 2 % in each step in 12 o’clock and 6 o’clock positionageing 1 h / 250 °C after reeling simulation
19 Reel-laying Simulation16. - 20. April 2007, Canberra
Full Scale Reeling Simulation Tests
4 POINT BENDING TEST RIG4 POINT BENDING TEST RIG
+
one test rig for different bending moments and bending radii
+
constant load in-between inner supports
+
monitoring of deformation easily achievable
INSTRUMENTATIONINSTRUMENTATION12:00 position
6:00 position
strain gauge
inner supports
2 000 mm
500 mm 500 mm 500 mm 500 mm
pos. 3pos. 2pos. 1
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Full Scale Reeling Simulation Tests
STEP I / IIISTEP I / III12 o12 o’’clock position clock position compressioncompression6 o6 o’’clock position clock position tensiontensiondeflection from straightdeflection from straight--lined geometrylined geometry
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Full Scale Reeling Simulation Tests
STEP II / IVSTEP II / IV180180°° rotation about longitudinal axisrotation about longitudinal axisrere--straighteningstraightening
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Results Full Scale Reeling
DIMENSIONAL PROPERTIESDIMENSIONAL PROPERTIES wall thicknesswall thickness
18,5
19,0
19,5
20,0
20,5
12:00 1:30 3:00 4:30 6:00 7:30 9:00 10:30
Circumferential Position
Wal
l Thi
ckne
ss in
mm
Pos. 1 prePos. 1 post
500 mm 500 mm 500 mm 500 mm
pos. 3pos. 2pos. 1
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Results Full Scale Reeling
DIMENSIONAL PROPERTIES DIMENSIONAL PROPERTIES ovalizationovalization
calculated acc. DNV OS-F101
excellent ovality before reeling of 0.1 to 0.35 %
ovality after full scale reeling between 0.3 and 0.6 %noticeable increase
acc. DNV OS-F101: ovality f0 ≤ 3 % after reeling
nomDDDf minmax
0−
=
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Results Full Scale Reeling
RESIDUAL STRESSES RESIDUAL STRESSES after reelingafter reeling
-200
-150
-100
-50
0
50
100
150
200
1 2 3
Position
Stre
ss in
MPa
12:00 Longitudinal Stress 12:00 Circumferential Stress
6:00 Longitudinal Stress 6:00 Circumferential Stress
BAUSCHINGER EFFECT,BAUSCHINGER EFFECT, influence on YIELD STRENGTHYIELD STRENGTH
25 Reel-laying Simulation16. - 20. April 2007, Canberra
Results Mechanical Testing
SSR
2
x (+
/-2 %
)
SSR
2
x (-/
+2 %
)
Bas
e M
ater
ial
SSR
2
x(+
/-2 %
)
SSR
2
x (-/
+2 %
)
Bas
e M
ater
ial
FSR
6:
00
FSR
12
:00
FSR
6:
00
FSR
12
:00
0
100
200
300
400
500
600
700
Rt0,5
σ in
MPa
Rt0,5
SMYS
YSmax
Pipe I Pipe II
TENSILE TESTS TENSILE TESTS yield strength (YS)yield strength (YS)
step IV: compression step IV: compression
step IV: tension step IV: tension
after full scale reeling simulation and artificial ageing
26 Reel-laying Simulation16. - 20. April 2007, Canberra
SS
R
2 x
(+/-2
%)
SS
R
2 x
(-/+
2 %
)
Bas
e M
ater
ial
SS
R
2 x
(+/-2
%)
SS
R
2 x
(-/+
2 %
)
Bas
e M
ater
ial
FSR
6:
00
FSR
12
:00
FSR
6:
00
FSR
12
:00
0
100
200
300
400
500
600
700
Rm
σ in
MPa
Rm
SMTS
Pipe I Pipe II
TENSILE TESTS TENSILE TESTS tensile strength (UTS)tensile strength (UTS)
Results Mechanical Testing
after full scale reeling simulation and artificial ageing
27 Reel-laying Simulation16. - 20. April 2007, Canberra
Results Mechanical Testing
FSR
6:
00
SS
R
2 x
(+/-2
%)
FSR
12
:00
SS
R
2 x
(-/+
2 %
)
Bas
e M
ater
ial
FSR
6:
00
SS
R
2 x
(+/-2
%)
FSR
12
:00
SS
R
2 x
(-/+
2 %
)
Bas
e M
ater
ial
0
10
20
30
40
50
60
70
80
90
100
Rt0
,5 /
Rm
in %
Pipe I Pipe II
TENSILE TESTS TENSILE TESTS Y/T ratioY/T ratioafter full scale reeling simulation and artificial ageing
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Results Mechanical Testing
HARDNESS TESTHARDNESS TEST
FSR
6:
00
FSR
6:
00
FSR
6:
00
SS
R
2 x
(+/-2
%)
SS
R
2 x
(+/-2
%)
SS
R
2 x
(+/-2
%)
FSR
12
:00
FSR
12
:00
FSR
12
:00
SS
R
(-/+2
%)
SS
R
(-/+2
%)
SS
R
(-/+2
%)
0
50
100
150
200
250
300
Inner Radius Mean Radius Outer Radius
Har
dnes
s in
HV1
0after full scale reeling simulation and artificial ageinghardness values higher at outer surfaceSSR slightly higher hardness
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Results Mechanical Testing
CVN IMPACT TESTSCVN IMPACT TESTS
0
50
100
150
200
250
300
350
-140 -120 -100 -80 -60 -40 -20 0
Temperature in °C
Impa
ct E
nerg
y in
J
SSR 2 x (-/+2 %)
SSR 2 x (+/-2 %)
FSR 12 o'clock
FSR 6 o'clock
after full scale reeling simulation and artificial ageingno clear trend regarding test method full scale ↔ small scale
30 Reel-laying Simulation16. - 20. April 2007, Canberra
Results Mechanical Testing
CTODCTOD at at --40 40 °°CC
0,0
0,3
0,5
0,8
1,0
1,3
1,5
FSR 6:00
SSR
2x(+/-2 %)
FSR 12:00
SSR
2x(-/+2 %)
Basic
Material
δ in
mm
after reeling simulationand artificial ageing!
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Summary
CONCLUSIONSCONCLUSIONS
suitability of full scale reeling simulation by 4 point bending verified by FEAnegligible influence of axial forces on stress/strain statefull scale reeling simulation by 4 point bending led to
increase in ovalizationno distinct change in wall thicknessincreased residual stresses (mainly axial) primarily influencing yield strength
mechanical properties: SSR ↔ FSR no distinct difference,similar results
32 Reel-laying Simulation16. - 20. April 2007, Canberra
Thank you for your attention.
A whole world of seamless hot-rolled tubes.
33 Reel-laying Simulation16. - 20. April 2007, Canberra
Introduction
PHYSICAL PHENOMENAPHYSICAL PHENOMENASMALL AND FULL SCALE REELINGSMALL AND FULL SCALE REELING**
I. strain hardeningI. strain hardeningincrease of dislocation density with increase of accumulated strainYS , Y/T-ratio , elongation , UTS , CVN transition temp. , CTOD
*
q.v.: Gehrmann
R, et al.: Influence of Plastic Deformation on Line Pipe Material. 15th Biennial Joint Technical Meeting on Pipeline Research, Orlando, Florida, USA (2005)
I.I.
σ
ε
34 Reel-laying Simulation16. - 20. April 2007, Canberra
Introduction
PHYSICAL PHENOMENAPHYSICAL PHENOMENASMALL AND FULL SCALE REELINGSMALL AND FULL SCALE REELING**
II. residual stressesBauschinger
effect:
-
tensile residual stresses (YS )
-
compressive residual stresses (YS )
*
q.v.: Gehrmann
R, et al.: Influence of Plastic Deformation on Line Pipe Material. 15th Biennial Joint Technical Meeting on Pipeline Research, Orlando, Florida, USA (2005)
35 Reel-laying Simulation16. - 20. April 2007, Canberra
Introduction
PHYSICAL PHENOMENAPHYSICAL PHENOMENASMALL AND FULL SCALE REELINGSMALL AND FULL SCALE REELING**
III. bake hardeninghardening effect due to interaction of solute interstitial atoms (e.g. carbon, nitrogen) and dislocations, Cottrell atmospheresYS , Y/T-ratio , elongation , UTS , CVN transition temp. , CTOD
image: Macherauch E: Praktikum in Werkstoffkunde. 10. Auflage, Vieweg, Braunschweig/Wiesbaden, 1992
agei
ng*
q.v.: Gehrmann
R, et al.: Influence of Plastic Deformation on Line Pipe Material. 15th Biennial Joint Technical Meeting on Pipeline Research, Orlando, Florida, USA (2005)
36 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
AIM AIM • Numerical simulation of the material loading during reeling (real reeling process)•
Analysis of the differences between the real reeling process and
the
corresponding experimental tests• Verification of significance of experimental test conditions
PROCEDUREPROCEDURE• Determination of stress/strain state in tubes during real reeling• Determination of stress/strain state in tubes during experimental reeling tests
Reel drum bending test (bending with lateral and axial forces)4 - point bending test (pure bending loading)Fully 3-dimensional modeling (MSC.MARC)
INPUT PARAMETERSINPUT PARAMETERS• Pipe outer diameter
273.1 mm
• Wall thickness:
15.9 mm• Diameter of reeling drum:
11 m
• Material grade:
SML 450• Stress strain curve acc. to tensile test
37 Reel-laying Simulation16. - 20. April 2007, Canberra
FEA Reeling
equivalent plastic strain distribution
equivalent plastic strain distribution
REEL DRUM BENDING TESTREEL DRUM BENDING TEST FOUR POINT BENDING TESTFOUR POINT BENDING TEST