BS7910海底管线3C级断裂评估
摘要
海底管线作为一种工程结构,在实际中有着广泛而重要的应用,担负着输送诸如石油、天然气等介质的重要任务。同时,作为一种焊接结构,管线的焊接接头也不可避免的会存在各种可能的焊接缺陷。
随着工程实际应用的发展,人们逐渐以“合于使用”的思想原则来对焊接缺陷可能给结构带来的影响进行合理的评价,而不再采用以往使用的“完美无缺”的经验方法来要求结构中不能存在任何的焊接缺陷。
本文以“合于使用”的思想为原则,依据在国际上广泛使用的标准BS7910,对中国石油总公司渤海石油公司(COOEC)所开发的旅顺至大连间海底石油传输管线X56海底管线进行3C级断裂评估。
我们首先对BS7910:1999标准进行了解和掌握。为了获得进行3C级评估所需的管道材料的性能数值,我们以对管道供应商提供的数据进行分析的方式获得母材金属的拉伸力学性能;通过对焊缝金属进行力学性能实验的方式获得其力学性能,并通过测定J阻力曲线确定热影响区和焊缝金属分别具有的断裂韧性。
在3C级断裂评估中,J积分是一个非常重要的参量,也是研究弹塑性断裂力学的重要内容之一。我们在广泛查阅大量国内外科技文献资料的基础上,收集并整理料国内外的J积分估算方法。提出了计算含环向穿透裂纹管道J积分估算方法:LBB.ENG2方法;提出了计算含表面裂纹管道J积分估算方法:SC.ENG1和SC.ENG2方法。我们通过对管道模型的等效简化,推导出其运算公式,避免了复杂的弹塑性断裂分析和有限元计算,适用于弹性到弹塑性整个范围。
在以上工作的基础上,我们对X56海底管线进行3C级断裂评估,得出了3C级评估的失效评定图与一系列评定点,并进行安全性能分析。
As a kind of engineering structure ,the submarineline has the abroad and important applications, which always is used to deliver the oil and the gas. In the same time , as a kind of welded structure ,the welded joint of the pipeline always has the inevitable welding defects.
With the development of the engineering practice , people gradually use the principle of the“fitness for use”to assess the influence of the welding defects on the structures, and don’t required that the structure should not contain any welding defects.
This paper uses the principle of the“fitness for use”and the regulation of the BS7910:1999 to make an 3C assessment for the submarineline which is developed by the COOEC and is located between Lvshun and Dalian..
To finish the assessment, at first ,we understand the regulations and the theories of the BS7910:1999. Then ,we obtain the tensile property of the X56 pipe by the analysis of the tensile and yield strength value which is obtained from the mill certificates, obtain the tensile property of the weld by performing the tensile testing of the weld metal and obtain the fracture toughness of the HAZ and the weld metal by determining the J-R cure of them.
In the fracture assessment of 3C,J-integer is a very important parameter,which is also an important contents in the elastic-plastic fracture mechanics.In this paper,the available domestic ana foreign J-integeral estimation methods were collected and digested on extensively reading science and technology bibilographic references.We brought forward LBB.ENG2 J-integral estimation methods for pipes
With circuferential through-wall crack ,and we brought forward SC.ENG1 and SC.ENG2 J-integral estimation methods for pipes with circuferential surface crack.We developed the equivalent reduced section analogies and derived the function equations,which avoid especially complex elastic-plastic fracture analyses and finite element numerical computations.These estimation methods can be applied in the complete range between elastic and fully plastic condition.
We assessed x56 seaside pipeline in 3C level based on the above work,obtaining 3C level invalidation assessment chart and a series of assessment points, catching through safety performance analysis。
随着工程实际应用的发展,人们逐渐以“合于使用”的思想原则来对焊接缺陷可能给结构带来的影响进行合理的评价,而不再采用以往使用的“完美无缺”的经验方法来要求结构中不能存在任何的焊接缺陷。
本文以“合于使用”的思想为原则,依据在国际上广泛使用的标准BS7910,对中国石油总公司渤海石油公司(COOEC)所开发的旅顺至大连间海底石油传输管线X56海底管线进行3C级断裂评估。
我们首先对BS7910:1999标准进行了解和掌握。为了获得进行3C级评估所需的管道材料的性能数值,我们以对管道供应商提供的数据进行分析的方式获得母材金属的拉伸力学性能;通过对焊缝金属进行力学性能实验的方式获得其力学性能,并通过测定J阻力曲线确定热影响区和焊缝金属分别具有的断裂韧性。
在3C级断裂评估中,J积分是一个非常重要的参量,也是研究弹塑性断裂力学的重要内容之一。我们在广泛查阅大量国内外科技文献资料的基础上,收集并整理料国内外的J积分估算方法。提出了计算含环向穿透裂纹管道J积分估算方法:LBB.ENG2方法;提出了计算含表面裂纹管道J积分估算方法:SC.ENG1和SC.ENG2方法。我们通过对管道模型的等效简化,推导出其运算公式,避免了复杂的弹塑性断裂分析和有限元计算,适用于弹性到弹塑性整个范围。
在以上工作的基础上,我们对X56海底管线进行3C级断裂评估,得出了3C级评估的失效评定图与一系列评定点,并进行安全性能分析。
As a kind of engineering structure ,the submarineline has the abroad and important applications, which always is used to deliver the oil and the gas. In the same time , as a kind of welded structure ,the welded joint of the pipeline always has the inevitable welding defects.
With the development of the engineering practice , people gradually use the principle of the“fitness for use”to assess the influence of the welding defects on the structures, and don’t required that the structure should not contain any welding defects.
This paper uses the principle of the“fitness for use”and the regulation of the BS7910:1999 to make an 3C assessment for the submarineline which is developed by the COOEC and is located between Lvshun and Dalian..
To finish the assessment, at first ,we understand the regulations and the theories of the BS7910:1999. Then ,we obtain the tensile property of the X56 pipe by the analysis of the tensile and yield strength value which is obtained from the mill certificates, obtain the tensile property of the weld by performing the tensile testing of the weld metal and obtain the fracture toughness of the HAZ and the weld metal by determining the J-R cure of them.
In the fracture assessment of 3C,J-integer is a very important parameter,which is also an important contents in the elastic-plastic fracture mechanics.In this paper,the available domestic ana foreign J-integeral estimation methods were collected and digested on extensively reading science and technology bibilographic references.We brought forward LBB.ENG2 J-integral estimation methods for pipes
With circuferential through-wall crack ,and we brought forward SC.ENG1 and SC.ENG2 J-integral estimation methods for pipes with circuferential surface crack.We developed the equivalent reduced section analogies and derived the function equations,which avoid especially complex elastic-plastic fracture analyses and finite element numerical computations.These estimation methods can be applied in the complete range between elastic and fully plastic condition.
We assessed x56 seaside pipeline in 3C level based on the above work,obtaining 3C level invalidation assessment chart and a series of assessment points, catching through safety performance analysis。
引文
[1] 曲文卿,油气管道缺陷评定方法的进展,油气储运,2002,21(7):3～8
[2] GB2038—91:金属材料延性断裂韧度 jlc 试验方法[S].
[3] 马良,海洋油气管道工程,北京:海洋出版社,1987,1～30
[4] V.F.162,86: Application of an engineering Critical Assessment in Design,Fabrication and Inspection to Assess the Fitness for Purpose of Welded Production. Foreword to IIW Documents, 1987
[5] IIW/IIS/-SST-1157-90, IIW Guidance on Assessment of the Fitness for Purpose of Welded Structures, Draft for Development. Printed by Force Institutes Copenhegen,1990
[6] 霍立兴,焊接结构的断裂行为及评定,北京:机械工业出版社,1995
[7] 李晓钢,石化设备在线安全评定技术进展,石油化工腐蚀与防护,1998,16(3):1～4
[8] 孟广喆、贾安东，焊接结构强度和断裂，北京：机械工业出版社，1986
[9] Ainsworth, R.A. Developments in the flaw assessment procedures of R6 revision 4 and BS7910, American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, v 463, 2003, p 19-25
[10] Burdekin, F.M. Developments in European defect assessment, American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, v 392, 1999, p 217-223
[11] BS7910:1999(incorporating Amendment No.1) Guide on methods for assessing the acceptability of flaws in metallic structures, British Standards Institution, London, 2000API.579,Recommended practice for fitness-for-service Washington, D.C. American Petroleum Institute,2000
[12] 曲文卿、鲍云杰,管道环焊接头断裂评定方法分析,油气储运-1999.18(7)
[13] Dong, Y.M.;Yang, W.; Hwang, K.C. New approach to structural integrity assessment for ductile fracture,Fatigue and Fracture ofEngineering Materials & Structures, v 13, n 4, 1990, p 399-410
[14] Takahashi, Yukio,Evaluation of leak-before-break assessment methodology for pipes with a circumferential through-wall crack. Part II: J-integral estimation ,The International Journal of Pressure Vessels and Piping,2002,79(6):393～402
[15] Ukadgaonker, Vijay G.; Babu, R. Shanmuga ,Review of work related to ‘leak-before-break’ assessment ,The International Journal of Pressure Vessels and Piping,1996,69(2):135～148
[16] Lenkey, Gyongyver B. On the determination of dynamic fracture toughness properties by instrumented impact testing,ASTM Special Technical Publication, n 1380, 2000
[17] Sharpe, W.N. Jr. ; Boehme, W. Dynamic fracture toughness measurements on small Charpy specimens: A preliminary study,: American Society of Mechanical Engineers, Applied Mechanics Division, AMD, v 176, Novel Experimental Techniques in Fracture Mechanics, 1993,
[18] Tierean, M.H., Determination of stress intensity factor using the J-integral method,Bulletin of the Transilvania University of Brasov, Series A, v 41, 1999, p 23-6
[19] SINTAP. Structure Integrity Assessment Procedure for European Industry Project BE 95 - 1426.Final Procedure, British Steel Report, Rotherham,1999
[20] Webster, Stephen; Bannister, Adam ,Structural integrity assessment procedure for Europe – of the SINTAP programme overview ,Engineering Fracture Mechanics,2000,67(6):481～514
[21] 李培宁,压力容器及管道断裂评定技术研究进展,中国机械工程学会压力容器分会,第四届全国压力容器学术会议大会专题报告集,《压力容器》杂志编辑部,无锡:1997 第 2 期增刊
[22] Tsiagbe, W.Y. ; Porter Golf, R.F.D.,Effect of PWHT on residual stress in tubular joints,Second Int Offshore Polar Eng Conf, 1992, p 342-346
[23] Smith, D.J. ;Garwood, S.J. Influence of postweld heat treatment on the variation of residual stresses in 50 mm thick welded ferriticsteel plates,International Journal of Pressure Vessels and Piping, v 51, n 2, 1992, p 241-256
[24] Green, D. ; Knowles, J. Treatment of residual stress in fracture assessment of pressure vessels,Journal of Pressure Vessel Technology, Transactions of the ASME, v 116, n 4, Nov, 1994, p 342-352
[25] 周剑秋,压力管道缺陷评定中焊接残余应力的处理分析,焊接,1998(1):15～18
[26] Takanashi, M.; Iida, K.,Relaxation of welding residual stresses by reversed and repeated loadings,Yosetsu Gakkai Ronbunshu/Quarterly Journal of the Japan Welding Society, v 19, n 1, February, 2001, p 129-139
[27] Guohua, Chen; Shuho Dai, Determination of partial safety factors of parameters for integrity assessments of welded structures containing defects, International Journal of Pressure Vessels and Piping, v 72, n 1, Jun, 1997, p 19-25
[28] Croce, Pietro; Cecconi, Andrea; Salvatore, Walter, Numerical procedure for the evaluation of partial safety factors for steel structural elements, Journal of Constructional Steel Research, v 46, n 1-3, Apr-Jun, 1998, 329, p 159-160
[29] Liu, Min; Huo, Lixing; Zhang, Yufeng, Partial factor reliability safety assessment method of welded structures, Shiyou Huagong Shebei/ Petro-Chemical Equipment, v 29, n 5, Sep 20, 2000, p 1-3
[30] Val, Dimitri V.; Stewart, Mark G., Safety factors for assessment of existing structures, Journal of Structural Engineering, v 128, n 2, February, 2002, p 258-265
[31] Cheaitani, M.J. ; Thurlbeck, S.D.; Burdekin, F.M. Fatigue, fracture, and plastic collapse of offshore tubular joints using BSI PD 6493:1991, : Proceedings of the International Conference on Offshore Mechanics and Arctic Engineering - OMAE, v 3, 1995, p 41-54
[32] Cheaitani, M.J.; Billington, C.J., Evaluation of fracture data on cracked offshore tubular joints using BSI PD 6493:1991, Proceedings of the International Conference on Offshore Mechanics and ArcticEngineering - OMAE, v 3, Materials Engineering, 1996, p 533-539
[33] 黎之奇、胡振威,含表面半椭圆裂纹板裂纹尖端应力强度因子的三维光弹分析,实验力学-1991.6(4).-347-354
[34] 高季明 、王晓春,焊接裂纹尖端应力强度因子数值计算,东北大学学报:自然科学版-1996.17(3).-296-300
[35] Chang, Peng-Hsiang;Teng, Tso-Liang, Numerical and experimental investigations on the residual stresses of the butt-welded ,Computational Materials Science, v 29, n 4, April, 2004, p 511-522
[36] Veiga, C.;Loureiro, A.; Pina, J.; Batista, A.C,Residual stress distribution in butt welded joints-effect of the weld groove shape,Materials Science Forum, v 404-407, 2002, p 387-92
[37] Batista, A. Castanhola;Veiga, C.; Loureiro, A.; Pina, J.,Residual stress distribution in butt welded joints - Effect of the weld groove shape,Materials Science Forum, v 404-407, 2002, p 387-392
[38] 姜伟之、赵时熙,工程材料的力学性能,北京:北京航空航天大学出版社, 1991
[39] 孙志雄,焊接断裂力学,西安:西北工业大学,1990
[40] 田锡唐,焊接结构,北京:机械工业出版社,1981
[41] 崔振源等,断裂韧性测试原理和方法,上海科学技术出版社,1981
[42] BS7448: part1: Method for determination of KIc, critical CTOD and critical J values of metallic materials[S],1997
[43] [46]BS7448: part2: Method for determination of KIc, critical CTOD and critical J values of welds in metallic materials[S],1997
[44] 张小鹏、刘增利、刘维波等,大尺寸金属焊接接头低温 CTOD 试验研究,大连理工大学学报,2001,41(2):144～148
[45] Det Norske Veritas:” Submarine Pipeline Systems”. DNV offshore Strandard OS-E101,2000
[46] 曲文卿,张鹏等,石油天然气输送管道底缺陷评定方法及应用,焊管,2002,25(2):1～6
[47] 贾大功,输水管道断裂力学性能研究及安全评定,[硕士学位论文],天津大学,2001
[48] 姜亮,焊接构件中缺陷安全性的评定方法研究,[硕士学位论文],天津大学,1996
[49] 刘月丽,在役含缺陷管道及其焊接接头的 J 积分理论和估算方法研究,[博士论文],天津大学,2001
[50] British Standards Institute:” Guide on methods for assessing the acceptability of flaws in fusion welded structures”.BS7910:1999 ISBN 0 580 33081 8
[51] Conelly,M.and Zettlemoyer,N.:” Stress concentrations at girth welds of tuulars with axial wall misalignment”.Proc. Conf. 5th International Symposium of Tubular Structures.Nottingham UK,August 1993.
[52] Kastner, W.E., Rohrich,W.,Schmitt and Steinbuch, R.:”Critical crack sizes in ductile piping.” Int.Journal of Pressure Vessels and Piping.9(3) 197-219 ISSN 308-0161.1981
[53]BS 7448:Part 2:1997,Fracture mecha/lics tougb/less tests. Method for determination of KIC,critical CTOD and critical J val—ues of welds in metallic materials『S].
[54]1981.81—126.BS7448:Part1.Fracture mechanics toughness tests, Part 1.Methods for determination of K IC,critical CTOD and critical J values of metallic materials.1991
[53] Zerbst, U.; Hamann, R.; Wohlschlegel, A., Application of the European flaw assessment procedure SINTAP to pipes, The International Journal of Pressure Vessels and Piping,2000,77(11): 697～702
[54] Ainsworth, R.A.; Gutierrez-Solana, F.; Ocejo, J. Ruiz, Analysis levels within the SINTAP defect assessment procedures, Engineering Fracture Mechanics Volume,2000,67(6): 515～527
[55] K. K. Yoon, and D.E.Killian J-estimation Method for a Semi-elliptical Surf-ace Flawin a Cylinder, Transactions of ASME, Journal of Pressure Vessel Technology, Febr-uary 1995, Vol.117, pp66~70
[2] GB2038—91:金属材料延性断裂韧度 jlc 试验方法[S].
[3] 马良,海洋油气管道工程,北京:海洋出版社,1987,1～30
[4] V.F.162,86: Application of an engineering Critical Assessment in Design,Fabrication and Inspection to Assess the Fitness for Purpose of Welded Production. Foreword to IIW Documents, 1987
[5] IIW/IIS/-SST-1157-90, IIW Guidance on Assessment of the Fitness for Purpose of Welded Structures, Draft for Development. Printed by Force Institutes Copenhegen,1990
[6] 霍立兴,焊接结构的断裂行为及评定,北京:机械工业出版社,1995
[7] 李晓钢,石化设备在线安全评定技术进展,石油化工腐蚀与防护,1998,16(3):1～4
[8] 孟广喆、贾安东，焊接结构强度和断裂，北京：机械工业出版社，1986
[9] Ainsworth, R.A. Developments in the flaw assessment procedures of R6 revision 4 and BS7910, American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, v 463, 2003, p 19-25
[10] Burdekin, F.M. Developments in European defect assessment, American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, v 392, 1999, p 217-223
[11] BS7910:1999(incorporating Amendment No.1) Guide on methods for assessing the acceptability of flaws in metallic structures, British Standards Institution, London, 2000API.579,Recommended practice for fitness-for-service Washington, D.C. American Petroleum Institute,2000
[12] 曲文卿、鲍云杰,管道环焊接头断裂评定方法分析,油气储运-1999.18(7)
[13] Dong, Y.M.;Yang, W.; Hwang, K.C. New approach to structural integrity assessment for ductile fracture,Fatigue and Fracture ofEngineering Materials & Structures, v 13, n 4, 1990, p 399-410
[14] Takahashi, Yukio,Evaluation of leak-before-break assessment methodology for pipes with a circumferential through-wall crack. Part II: J-integral estimation ,The International Journal of Pressure Vessels and Piping,2002,79(6):393～402
[15] Ukadgaonker, Vijay G.; Babu, R. Shanmuga ,Review of work related to ‘leak-before-break’ assessment ,The International Journal of Pressure Vessels and Piping,1996,69(2):135～148
[16] Lenkey, Gyongyver B. On the determination of dynamic fracture toughness properties by instrumented impact testing,ASTM Special Technical Publication, n 1380, 2000
[17] Sharpe, W.N. Jr. ; Boehme, W. Dynamic fracture toughness measurements on small Charpy specimens: A preliminary study,: American Society of Mechanical Engineers, Applied Mechanics Division, AMD, v 176, Novel Experimental Techniques in Fracture Mechanics, 1993,
[18] Tierean, M.H., Determination of stress intensity factor using the J-integral method,Bulletin of the Transilvania University of Brasov, Series A, v 41, 1999, p 23-6
[19] SINTAP. Structure Integrity Assessment Procedure for European Industry Project BE 95 - 1426.Final Procedure, British Steel Report, Rotherham,1999
[20] Webster, Stephen; Bannister, Adam ,Structural integrity assessment procedure for Europe – of the SINTAP programme overview ,Engineering Fracture Mechanics,2000,67(6):481～514
[21] 李培宁,压力容器及管道断裂评定技术研究进展,中国机械工程学会压力容器分会,第四届全国压力容器学术会议大会专题报告集,《压力容器》杂志编辑部,无锡:1997 第 2 期增刊
[22] Tsiagbe, W.Y. ; Porter Golf, R.F.D.,Effect of PWHT on residual stress in tubular joints,Second Int Offshore Polar Eng Conf, 1992, p 342-346
[23] Smith, D.J. ;Garwood, S.J. Influence of postweld heat treatment on the variation of residual stresses in 50 mm thick welded ferriticsteel plates,International Journal of Pressure Vessels and Piping, v 51, n 2, 1992, p 241-256
[24] Green, D. ; Knowles, J. Treatment of residual stress in fracture assessment of pressure vessels,Journal of Pressure Vessel Technology, Transactions of the ASME, v 116, n 4, Nov, 1994, p 342-352
[25] 周剑秋,压力管道缺陷评定中焊接残余应力的处理分析,焊接,1998(1):15～18
[26] Takanashi, M.; Iida, K.,Relaxation of welding residual stresses by reversed and repeated loadings,Yosetsu Gakkai Ronbunshu/Quarterly Journal of the Japan Welding Society, v 19, n 1, February, 2001, p 129-139
[27] Guohua, Chen; Shuho Dai, Determination of partial safety factors of parameters for integrity assessments of welded structures containing defects, International Journal of Pressure Vessels and Piping, v 72, n 1, Jun, 1997, p 19-25
[28] Croce, Pietro; Cecconi, Andrea; Salvatore, Walter, Numerical procedure for the evaluation of partial safety factors for steel structural elements, Journal of Constructional Steel Research, v 46, n 1-3, Apr-Jun, 1998, 329, p 159-160
[29] Liu, Min; Huo, Lixing; Zhang, Yufeng, Partial factor reliability safety assessment method of welded structures, Shiyou Huagong Shebei/ Petro-Chemical Equipment, v 29, n 5, Sep 20, 2000, p 1-3
[30] Val, Dimitri V.; Stewart, Mark G., Safety factors for assessment of existing structures, Journal of Structural Engineering, v 128, n 2, February, 2002, p 258-265
[31] Cheaitani, M.J. ; Thurlbeck, S.D.; Burdekin, F.M. Fatigue, fracture, and plastic collapse of offshore tubular joints using BSI PD 6493:1991, : Proceedings of the International Conference on Offshore Mechanics and Arctic Engineering - OMAE, v 3, 1995, p 41-54
[32] Cheaitani, M.J.; Billington, C.J., Evaluation of fracture data on cracked offshore tubular joints using BSI PD 6493:1991, Proceedings of the International Conference on Offshore Mechanics and ArcticEngineering - OMAE, v 3, Materials Engineering, 1996, p 533-539
[33] 黎之奇、胡振威,含表面半椭圆裂纹板裂纹尖端应力强度因子的三维光弹分析,实验力学-1991.6(4).-347-354
[34] 高季明 、王晓春,焊接裂纹尖端应力强度因子数值计算,东北大学学报:自然科学版-1996.17(3).-296-300
[35] Chang, Peng-Hsiang;Teng, Tso-Liang, Numerical and experimental investigations on the residual stresses of the butt-welded ,Computational Materials Science, v 29, n 4, April, 2004, p 511-522
[36] Veiga, C.;Loureiro, A.; Pina, J.; Batista, A.C,Residual stress distribution in butt welded joints-effect of the weld groove shape,Materials Science Forum, v 404-407, 2002, p 387-92
[37] Batista, A. Castanhola;Veiga, C.; Loureiro, A.; Pina, J.,Residual stress distribution in butt welded joints - Effect of the weld groove shape,Materials Science Forum, v 404-407, 2002, p 387-392
[38] 姜伟之、赵时熙,工程材料的力学性能,北京:北京航空航天大学出版社, 1991
[39] 孙志雄,焊接断裂力学,西安:西北工业大学,1990
[40] 田锡唐,焊接结构,北京:机械工业出版社,1981
[41] 崔振源等,断裂韧性测试原理和方法,上海科学技术出版社,1981
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