07/06/2015

Group Project
Engineering Failure Analysis

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

Objectives

Investigate the possible root causes of failure in river

crossing gas pipe

Provide recommendations so that similar failure can
be prevented in the future

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

07/06/2015

Field Survey and Inspection

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Field Survey and Inspection

Service loading condition

Field Data

Quantity

Pipe outer diameter

6 in

Initial pipe thickness

0.28 in

Temperature

30 C

Internal pressure

16-40 kg/cm2

Flow rate

5-18 MMSCFD

Fluid density

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

0.675 kg/m3

Dr. A. Andriyana

07/06/2015

Field Survey and Inspection

Pipe materials
Type or Quantity

Field Data
Type of material

Steel

Yield strength (y)

290 MPa

Tensile strength (u)

420 MPa

Fracture toughness (KIC)

70 MPam1/2

Fatigue limit

85 MPa

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Methodology

Stress analysis
using FEA
(with and without
crack)

Microstructural
analysis

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Fabrication
method

Dr. A. Andriyana

07/06/2015

Field Survey and Inspection

Failure location

Fracture

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

Field Survey and Inspection

Failure location

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

07/06/2015

Finite Element Analysis

Remark

Data
Software used

NASTRAN and AUTOPIPE

Pipe initial thickness

0.28 in

% of corroded thickness

29%

Effective thickness

0.2 in

Type of load

Internal pressure and

centrifugal thrust

Note:
Computation is performed without considering defects (crack)

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Finite Element Analysis

Finite element model around pipe bend
V1
L1
C1

23456
23456
23456
23456
23456

23456
23456
23456
23456
23456

Y
Z

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

07/06/2015

Finite Element Analysis

Modeling of centrifugal thrust due to fluid flow
V1
L2
C1

144.03

144.03
144.03

144.03
144.03

144.03

Y
Z

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

Finite Element Analysis: Static Loading

Stress field due to internal pressure and centrifugal thrust
V1
L2
C1

61641400.

Thickness
(in)
0.28
0.20

max
(MPa)
53.31
62.73

V1
L2
C1

61641400.

58496945.

58496945.

55352490.

55352490.

52208035.

52208035.

49063580.

49063580.

45919125.

45919125.

42774670.

42774670.

39630215.

39630215.

36485761.

36485761.

33341306.

33341306.

30196851.

30196851.

27052396.

27052396.
23907941.

23907941.

20763486.

20763486.
Y
X NASTRAN Case 1
Output ZSet: MSC/
Deformed(0.00138): Total Translation
Contour: Plate Bot VonMises Stress

V1
L2
C1

17619031.
14474576.
11330121.

61641400.
58496945.

17619031.

X NASTRAN Case 1
Output ZSet: MSC/
Deformed(0.00138): Total Translation
Contour: Plate Bot VonMises Stress
V1
L2
C1

58496945.

55352490.

55352490.

52208035.

52208035.

49063580.

49063580.

45919125.

45919125.

42774670.

42774670.

39630215.

39630215.

36485761.

36485761.

33341306.

33341306.

30196851.

30196851.
27052396.
23907941.

23907941.

20763486.

20763486.

Z
X
Output Set: MSC/ NASTRAN Case 1
Contour: Plate Bot VonMises Stress

11330121.

61641400.

27052396.

14474576.

17619031.
14474576.
11330121.

Y
Z

17619031.
X

Output Set: MSC/ NASTRAN Case 1

Contour: Plate Bot VonMises Stress

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

14474576.
11330121.

Dr. A. Andriyana

07/06/2015

Finite Element Analysis: Static Loading

Stress due to internal pressure and centrifugal thrust

Location of highest
stress

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Mechanical and Microstructure Analysis

Fracture

1
B (pipe bend)

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Weld

2
A (straight pipe)

Dr. A. Andriyana

07/06/2015

Microstructure Analysis
Location of the samples

(200x)

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Microstructure Analysis
Location of the samples

(200x)

(200x)

After annealing

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

07/06/2015

Microstructure Analysis
Location of the samples

(240x)
(200x)

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Mechanical Testing and Analysis

Yield strength

Fracture toughness

750 MPa

40 MPam1/2

290 MPa

70 MPam1/2

Sample location

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

07/06/2015

Stress analysis of crack

Initial crack length

(a)

Critical crack length

(ac)

Stress intensity
factor (KI)

2.95 m

4.00 mm

55 MPam1/2

2.95 m

6.00 mm

45 MPam1/2

Location

Note:
Computation is performed by considering internal pressure only

Dr. A. Andriyana

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Manufacturing of Pipe Bend: Ram Pipe Bending

Bending die

Pipe
Ram

Pressure die

The pipe is restrained at two points using pressure die and then heated
The ram advances by a mechanical force in the central axis and deforms the pipe
to the contours of the die
After bending occurs, the heated area is cooled by immersing it in water

KXGB 6301 / KXGM 6310 - Fatigue, Failure and Failure Analysis

Dr. A. Andriyana

10