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. Meiner T. Schmidt (V&M)

UNTERNEHMEN/ COMPANY 1 Prsentation / presentation

 Introduction Finite element analysis Experimental details

Pipeline installation methods & requirements Physical phenomena Real reeling Full scale reeling simulation tests Full scale reeling simulation tests 4 point bending Small scale reeling simulation tests Mechanical testing after reeling simulation
2 Reel-laying Simulation

Results & discussion

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Introduction PIPELINE INSTALLATION

pipe laying e.g. J-laying S-laying reel-laying plastic deformation and ageing

influence on mechanical properties and subsequent service of line pipe material

importance for ... production of V&M seamless line pipe

image: Salzgitter AG, annual report 2005
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Introduction REQUIREMENTS
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.)

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Reel-laying Simulation

Introduction REEL LAYING: STRAIN CONTROLLED BENDING PROCESS

I. II. III. IV. reeling onto drum (onshore) unreeling aligning straightening

I III

Bending Moment

IV II

step step step step

I II III IV

Curvature

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Reel-laying Simulation

Introduction PHYSICAL PHENOMENA

occurring during real reeling, full and small scale reeling simulation tests

I.

strain hardening: increase of dislocation density

II. residual stresses: Bauschinger effect III. strain ageing: interaction interstitial atoms dislocations

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Reel-laying Simulation

Approach

finite element analysis

full and small scale reeling simulation tests

mechanical testing according DNV-OS-F101

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Approach FEA

finite element analysis

simulation of I. load step

real reeling

bending rig test

4 point bending

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Reel-laying Simulation

FEA Reeling REAL REELING PROCESS

loading bending moment axial force

information from pipe layers: axial force 1.5 Mp / RDrum

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Reel-laying Simulation

FEA Reeling BENDING RIG TEST

loading bending moment lateral force pipe after I. bending step

bend former FL

straight pipe

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FEA Reeling 4 POINT BENDING TEST

inner support F F outer support

pipe

bending moment diagram MB = F a loading pure bending moment

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FEA Reeling FEA REAL REELING PROCESS

evaluation of stress and strain distribution over the pipe cross section

equivalent plastic strain distribution

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FEA Reeling STRESS DISTRIBUTION OVER PIPE CROSS SECTION

axial force = 110 kN axial stress 12:00 12:00
max = 558 MPa min = -573 MPa max = 569 MPa min = -586 MPa

axial force = 500 kN

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6:00 6:00

6:00 circumferential stress

12:00

12:00

max = 115 MPa min = -126 MPa

max = 153 MPa min = -176 MPa

6:00

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Reel-laying Simulation

FEA Reeling INFLUENCE OF AXIAL FORCE ON PLASTIC STRAIN

3,0%

pl in Axial Direction

2,5% 2,0% 1,5% 1,0% 0,5% 0,0% 0 100 200 300 400 500 Axial Load in kN
axial load during real reeling

minor influence of axial load on axial plastic strain

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Reel-laying Simulation

FEA Reeling REAL REELING PROCESS VS. REELING SIMULATION TESTS

2,5% 2,0%

pl in %
Plastic Strain

1,5% 1,0% 0,5% 0,0% -0,5% -1,0% -1,5% -2,0% -2,5% Real Reeling max axial tension max axial compression Bending Rig 4 Point Bending

max circumferential tension max circumferential compression

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FEA Reeling

RESULTS 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

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Reel-laying Simulation

Mechanical Testing

full scale reeling simulation tests

small scale reeling simulation tests

artificial ageing

mechanical testing (tensile, Charpy)

evaluation of results
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Experimental Details TESTING MATERIAL & TEST PARAMETERS

two seamless pipes, API 5L grade X65, produced in plug mills pipe I: OD 219.1 mm WT 20 mm pipe II: OD 273.1 mm WT 18.3 mm small scale reeling simulation acc. DNV OS-F101 pl of coupons 2 (+/- 2 %) and 2 (-/+ 2 %), respectively ageing 1 h / 250 C full scale reeling simulation by four point bending tests pl > 2 % in each step in 12 oclock and 6 oclock position ageing 1 h / 250 C after reeling simulation

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Reel-laying Simulation

Full Scale Reeling Simulation Tests 4 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
2 000 mm 500 mm pos. 1 500 mm pos. 2 500 mm pos. 3 6:00 position 500 mm 12:00 position

INSTRUMENTATION

inner supports strain gauge

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Reel-laying Simulation

Full Scale Reeling Simulation Tests STEP I / III

12 oclock position compression 6 oclock position tension deflection from straight-lined geometry

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Full Scale Reeling Simulation Tests STEP II / IV

180 rotation about longitudinal axis re-straightening

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Results Full Scale Reeling DIMENSIONAL PROPERTIES wall thickness

20,5
500 mm 500 mm 500 mm 500 mm pos. 1 pos. 2 pos. 3

20,0 Wall Thickness in mm

19,5

19,0 Pos. 1 pre Pos. 1 post 18,5 12:00 1:30 3:00 4:30 6:00 7:30 9:00 10:30

Circumferential Position
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Results Full Scale Reeling

DIMENSIONAL PROPERTIES ovalization

Dmax Dmin Dnom

calculated acc. DNV OS-F101

f0 =

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

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Results Full Scale Reeling RESIDUAL STRESSES after reeling

200 150 100 Stress in MPa 50 0 -50 -100 -150 -200 1 2 Position 3
12:00 Longitudinal Stress 6:00 Longitudinal Stress 12:00 Circumferential Stress 6:00 Circumferential Stress

BAUSCHINGER EFFECT, influence on YIELD STRENGTH

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Results Mechanical Testing TENSILE TESTS yield strength (YS)

after full scale reeling simulation and artificial ageing step IV: tension
700 600
YSmax

step IV: tension

Pipe II

Pipe I

500 in MPa
SMYS

400 SSR 2 x (+/-2 %) SSR 2 x (-/+2 %) 300 FSR 6:00 200 100 0 SSR 2 x (-/+2 %) SSR 2 x(+/-2 %)

Base Material

FSR 12:00

Rt0,5 Rt0,5

step IV: compression

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step IV: compression

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FSR 12:00

FSR 6:00

Base Material

Results Mechanical Testing TENSILE TESTS tensile strength (UTS)

after full scale reeling simulation and artificial ageing
700 600
SMTS

Pipe I

Pipe II

500 in MPa 400 SSR 2 x (+/-2 %) SSR 2 x (+/-2 %) SSR 2 x (-/+2 %) SSR 2 x (-/+2 %) 300 FSR 6:00 200 100 0

Base Material

Rm Rm

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FSR 12:00

Base Material

FSR 12:00

FSR 6:00

Reel-laying Simulation

Results Mechanical Testing TENSILE TESTS Y/T ratio

after full scale reeling simulation and artificial ageing
100 90 80 Rt0,5 / Rm in % 70 60 50 SSR 2 x (-/+2 %) 40 30 20 10 0 FSR 6:00 SSR 2 x (+/-2 %) SSR 2 x (-/+2 %) SSR 2 x (+/-2 %) Pipe I Pipe II

Base Material

FSR 12:00

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FSR 6:00

Base Material

FSR 12:00

Reel-laying Simulation

Results Mechanical Testing HARDNESS TEST

after full scale reeling simulation and artificial ageing hardness values higher at outer surface SSR slightly higher hardness
300 250 Hardness in HV10 200 150 SSR 2 x (+/-2 %) SSR 2 x (+/-2 %) SSR (-/+2 %) SSR (-/+2 %) SSR (-/+2 %) 100 FSR 6:00 50 0 SSR 2 x (+/-2 %)

FSR 12:00

FSR 12:00

Inner Radius
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Mean Radius
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Outer Radius
Reel-laying Simulation

FSR 12:00

FSR 6:00

FSR 6:00

Results Mechanical Testing CVN IMPACT TESTS

after full scale reeling simulation and artificial ageing no clear trend regarding test method full scale small scale
350 300 Impact Energy in J 250 200 150 100 50 0 -140 -120 -100 -80 -60 -40 -20 0 Temperature in C
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SSR 2 x (-/+2 %) SSR 2 x (+/-2 %) FSR 12 o'clock FSR 6 o'clock

Results Mechanical Testing CTOD at -40 C

1,5 1,3 1,0 in mm 0,8 0,5 0,3 0,0 Basic Material FSR 6:00 SSR 2x(+/-2 %)
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after reeling simulation and artificial ageing!

FSR 12:00

SSR 2x(-/+2 %)

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Reel-laying Simulation

Summary

CONCLUSIONS
suitability of full scale reeling simulation by 4 point bending verified by FEA negligible influence of axial forces on stress/strain state full scale reeling simulation by 4 point bending led to increase in ovalization no distinct change in wall thickness increased residual stresses (mainly axial) primarily influencing yield strength mechanical properties: SSR FSR no distinct difference, similar results
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Reel-laying Simulation

A whole world of seamless hot-rolled tubes.

Thank you for your attention.

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Reel-laying Simulation

Introduction PHYSICAL PHENOMENA SMALL AND FULL SCALE REELING*

I. strain hardening increase of dislocation density with increase of accumulated strain YS , Y/T-ratio , elongation , UTS CVN transition temp. , CTOD

, I.

* 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)
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Introduction PHYSICAL PHENOMENA SMALL AND FULL SCALE REELING*

II. residual stresses Bauschinger 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)
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Introduction PHYSICAL PHENOMENA SMALL AND FULL SCALE REELING*

* 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)
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image: Macherauch E: Praktikum in Werkstoffkunde. 10. Auflage, Vieweg, Braunschweig/Wiesbaden, 1992

Reel-laying Simulation

age

ing

III. bake hardening hardening effect due to interaction of solute interstitial atoms (e.g. carbon, nitrogen) and dislocations, Cottrell atmospheres YS , Y/T-ratio , elongation , UTS CVN transition temp. , CTOD

FEA Reeling
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 PROCEDURE 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 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
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FEA Reeling REEL DRUM BENDING TEST FOUR POINT BENDING TEST

equivalent plastic strain distribution

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equivalent plastic strain distribution

Reel-laying Simulation