Abstract
The demand for electric resistance welded (ERW) pipe for deep-water installation has increased, which necessitates a higher degree of accuracy in evaluating the strength of pipe in order to satisfy the design limit state, otherwise referred to as the collapse performance. Since ovality and residual stress governs the collapse performance, an accurate evaluation of these factors is needed. An analytical approach using a three-dimensional finite element method was proposed to simulate the roll-forming and sizing processes in manufacturing ERW pipe. To simulate significant plastic deformation during manufacturing, a nonlinear material model that included the Bauschinger effect was incorporated. The manufacturing of ERW pipe made of API 5L X70 steel was simulated and analyzed for collapse performance. Controlling the ovality of the pipe significantly decreased the amount of pressure that would cause a collapse, whereas the effect of residual stress was minor. These two factors could be improved via the use of a proper sizing ratio.
Highlights
As the energy industry continues to grow, engineers have applied electric resistance welded (ERW) pipe to oil and gas transport pipeline due to low cost and high performance
Roll-forming is a process whereby a steel plate is rolled into a circular pipe shape, welding joins the two opposing edges to form a pipe, and sizing is the process of applying compression to the pipe following the welding to optimize the circular shape
These five steps are performed along one linear continuous process from the plate to when the pipe is cut into desired lengths, and these steps lead to ERW pipe with smaller deviations in diameter and thickness in the circumferential direction compared with other types of pipe such as UOE and spiral pipes
Summary
As the energy industry continues to grow, engineers have applied electric resistance welded (ERW) pipe to oil and gas transport pipeline due to low cost and high performance. Roll-forming is a process whereby a steel plate is rolled into a circular pipe shape, welding joins the two opposing edges to form a pipe, and sizing is the process of applying compression to the pipe following the welding to optimize the circular shape These five steps are performed along one linear continuous process from the plate to when the pipe is cut into desired lengths, and these steps lead to ERW pipe with smaller deviations in diameter and thickness in the circumferential direction compared with other types of pipe such as UOE and spiral pipes. Bastola et al [5] conducted finite element analysis and confirmed that residual stress could reduce the resistance to collapse pressure by as much as 20%, and that the residual stress along the circumferential direction of the pipe were more significant on collapse performance than those along the longitudinal direction Factors such as out-of-roundness and residual stress could be determined during manufacturing, during the roll-forming and sizing steps. Residual stress and out-of-roundness are the outcomes of the manufacturing process, and these were evaluated for the effect on collapse performance
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