UpDate Pipeline Repair Manual

PART I – TECHNICAL PROPOSAL T 274-3553

UPDATED PIPELINE REPAIR MANUAL

PREPARED FOR

PRC INTERNATIONAL Pipeline Materials Committee

PREPARED BY

CC TECHNOLOGIES LABORATORIES, INC. CARL E. JASKE, PH.D., P.E. AUGUST 1, 2002

CC Technologies 6141 AVERY ROAD DUBLIN, OHIO 43016 614.761.1214 • 614.761.1633 fax www.cctechnologies.com

SUMMARY The objective of the proposed project is to develop and produce an update of PRCI Pipeline Repair Manual, PR-218-9307 (AGA L51716), which was published 1994. It will discuss response to anomaly or defect discovery, review repair methods, identify appropriate repairs for various types of defects, and provide generic guidelines for use of various repair methods taking into account current codes and regulations. CC Technologies will review existing and emerging pipeline repair technologies and evaluate them in comparison with those in the current repair manual. Then, the Manual will be revised to add and update the information on repair technologies. The review will be based on published literature, vendor literature, and industry experience. Methods for evaluating cost versus effectiveness of repair techniques will be included. The final product will be an updated printed and electronic Pipeline Repair Manual. The electronic version will be indexed and in Adobe Acrobat format and will include both written descriptions and illustrations of various repair methods. The Manual will include a generic repair procedure that can be used to upgrade or develop a company’s repair procedures. The generic procedure will be provided in an electronic, as well as printed, format so that an operator can easily tailor it for specific company use.

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CONTENTS INTRODUCTION............................................................................................................. 1 TECHNICAL DISCUSSION............................................................................................. 1 Objectives .................................................................................................................. 2 Work to Be Performed ............................................................................................... 2 Approach ................................................................................................................... 3 End Product ............................................................................................................... 3 Schedule.................................................................................................................... 4 Manpower Requirements........................................................................................... 4 SUPPORTING DATA ...................................................................................................... 4 Organization Information............................................................................................ 4 Corporate Qualifications ............................................................................................ 5 Related Project Descriptions...................................................................................... 5 Facilities..................................................................................................................... 9 CONTRACT REQUIREMENTS ...................................................................................... 9

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APPENDICES Appendix A – Résumés

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Updated Pipeline Repair Manual

INTRODUCTION The current PRCI Pipeline Repair Manual, PR-218-9307 (AGA L51716), was published in 1994. The Manual first discusses how an operator should respond to the discovery of an anomaly or defect. It then reviews various repair methods that are available and identifies appropriate repairs for the various types of defects. Finally, it provides a set of generic guidelines for use of the various repair methods. It is based on the state-of-the-art, accepted repair techniques, codes, and regulations in existence at the time of its development and has become an important benchmark for the development of pipeline damage assessment and repair strategies throughout the natural gas pipeline industry. Since its publication, there have been significant changes in codes and regulations as well as major advances in repair technology. U.S. DOT Regulations have been revised to accept new methods of permanent pipeline repair and to provide criteria for pipeline repair. GRI has completed extensive studies of reinforced composite repairs; the repair materials and procedures are now commercially available to pipeline operators. Others have developed similar composite repair methods. PRCI has developed new methods for in-service repair of pipelines by welding, and the in-service welding requirements of API and ASME Codes have been revised. Several pipeline operators have extensively evaluated the use of steel compression sleeves for repairing crack-like defects. Operators have also modified procedures for the application of standard steel sleeves and developed methods for improving and quantifying load transfer from the sleeve to the carrier pipe. Complete replacement of damaged pipeline segments with new sections of pipe is an obvious repair procedure. However, the replacement approach requires the pipeline segment to be taken out of service during the repair. Repairs that can be implemented without a service outage are preferred because they are less costly to implement than those that require pipeline shutdown and they do not significantly impact gas supply. The repair methods must satisfy the requirements of applicable codes, such as ASME B31.8, and regulations, such as CFR Title 49, Part 192. Because of these significant changes and developments in the gas pipeline industry, it is necessary to update the Pipeline Repair Manual to incorporate new information and include the best and most cost-effective practices that are available worldwide.

TECHNICAL DISCUSSION The project objectives, work to be performed, technical approach, end product, schedule, and manpower requirements are discussed in this section of the proposal.

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Updated Pipeline Repair Manual

Objectives The objective of the proposed work is to develop and produce an updated PRCI Pipeline Repair Manual. The Manual will be in both printed and electronic versions. Work to Be Performed CC Technologies proposes to achieve the project objective by thoroughly reviewing both existing and emerging pipeline repair technologies and then evaluating them in comparison with those described in the current Pipeline Repair Manual. Based on the comparative evaluations, areas of outdated or missing information will be identified. The Manual then will be revised and expanded as required to update and add its contents. There will be three steps in the review phase of the work. The first step will be a review and evaluation of the published literature on pipeline repair techniques. The literature review will concentrate on publications produced since 1994, when the current Pipeline Repair Manual was issued. The second step will be a review and evaluation of vendor publications and literature on repair techniques. We will contact vendors to make sure that we have the latest information on their products. The list of vendors contacted and incorporated into the manual will include linked Internet addresses for their web sites to facilitate use of the list. The third step will be a review and evaluation of industry experience with repair techniques for similar applications. Operators will be contacted and interviewed to obtain their experience and recommendations. We also will consider offshore repair techniques that have on-shore applications. Since we are doing similar reviews on our current PRCI project on Permanent Field Repair of SCC (GRI Contract Number 8511), we will expand that work to cover all types of anomalies and defects. CC Technologies’ extensive experience in pipeline integrity management uniquely qualifies us to undertake the proposed work. One particularly important topic is methods for evaluating the effectiveness versus cost of various repair techniques, especially for crack-like anomalies or defects where past repairs have often been replacement of pipe sections. Some repair techniques will either reduce the flaw severity or reduce the stress in the carrier pipe. Use of these techniques requires models for predicting the conditions for which no additional damage would be expected to occur. The models and their use will be included with the discussion of each repair applicable technique. Examples will be presented to illustrate their use in typical applications. As indicated above, CC Technologies will contact pipeline operators to obtain information on their experience with repairs. Much of this information is available in our files from past projects, and it will only be necessary to obtain permission to use it in the proposed research. This work has been for both U.S. and Canadian companies.

CC Technologies Laboratories, Inc.

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Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

The final product will be an updated printed and electronic Pipeline Repair Manual. The electronic version will be indexed in Adobe Acrobat format, so it can be easily and readily used in the field. The Manual will include both written descriptions and illustrations of various repair methods, organized in a modular fashion to facilitate their use. It also will include a generic repair procedure that can be used to upgrade or develop a company’s repair procedures. The generic procedure will be provided in an electronic, as well as printed, format so that an operator can easily tailor it for specific company use. The electronic version will include an interactive interface to facilitate input of the information that is typically operator dependent. Approach We will prepare a written review of the recently published literature (since 1994) on pipeline repair methods and incorporate the results into the updated Repair Manual. We already have much of the relevant literature in our files from recent and current projects, so we will just make sure that no recent information is excluded. For example, we will review the proceedings of the ASME International Pipeline Conference (IPC) that is to be held in Calgary, September 29 through October 3, 2002. We also will prepare a written synopsis of vendor information on various applicable repair techniques. Again, we have most of the relevant information in our files, so we will only need to contact the vendors to obtain any recent updates on their products and repair methods. CC Technologies will contact pipeline operators to obtain information on their experience with repairs. Much of this information is available in our files from past industrial projects. In these cases, it will only be necessary to obtain permission to use that information on the proposed research. This includes work for both United States and Canadian companies that have addressed repairs of various types of defects in operating pipelines. Once the information has been collected, we will evaluate and compare it with that in the current Manual. Areas of the Manual where revisions and additions are required will be identified. Based on these results, the Manual will be updated. End Product This project will produce an updated printed and electronic PRCI Pipeline Repair Manual. The electronic version will facilitate field use and development of company specific procedures. The discussion of response to discovery of an anomaly or defect will take into account current codes and regulations. A summary table and flowchart of various repair options will be produced. It will indicate the types of anomalies or defects that can be repaired by each technique and the advantages and disadvantages of each

CC Technologies Laboratories, Inc.

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Updated Pipeline Repair Manual

technique, including relative costs. The techniques to be included are pipe removal and replacement, grinding of metal, deposition of weld metal, steel sleeves, composite reinforcement, mechanical clamps, and hot taps. Methods of evaluating the effect of metal removal will be included in the discussion of grinding. Acceptable procedures for in-service welding will be presented. For reinforcement repairs, methods of determining load transfer will be presented. The generic repair procedure will incorporate the new and improved techniques. Schedule The proposed project will be completed within one year of the receipt of the contract. Manpower Requirements CC Technologies estimates that the following hours of manpower will be required to complete the proposed work: • • • •

Senior Group Leader Project Engineer Technologist Office Staff/Total

90 360 205 70

No subcontractors will be used. Based on the above requirements, the estimated project cost is $75,000. A detailed cost breakdown is given in Part II – Cost Proposal.

SUPPORTING DATA Supporting data on CC Technologies are included in this section of the proposal. They include organizational information, a discussion of corporate qualifications, descriptions of related past projects, and a description of available facilities. Organization Information CC Technologies is an engineering and research firm specializing in corrosion control, corrosion monitoring, and materials evaluation. We have laboratories in Columbus, Ohio and Calgary, Alberta, with a staff that includes Ph.D. scientists and engineers in a number of relevant fields including corrosion, metallurgical, mechanical, and welding engineering. Dr. Carl E. Jaske, P.E. will be the Principal Investigator on the proposed project. His resume is given in Appendix A. Dr. Jaske has conducted numerous investigations of pipeline and equipment mechanical integrity and fitness for service. His work includes studies of SCC, fatigue, fracture, and creep, as well as development of the CorLAS computer program for the assessment of crack-like flaws in pipelines. In addition, CC Technologies Laboratories, Inc.

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Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

Dr. Jaske has worked with pipeline operators in the development of pipeline repair manuals and procedures, including innovative procedures for application to crack-like flaws. Mr. Patrick H. Vieth of CC Technologies will serve as a technical advisor. Mr. Vieth is well known for his pipeline integrity work. Resumes are given in Appendix A. Corporate Qualifications CC Technologies is a contract research and engineering organization that specializes in corrosion control, metallurgy, and structural integrity. The combination of research and engineering experience permits CC Technologies to provide our clients with research results that are tempered by engineering applicability and engineering services that are of the highest quality from both practical and fundamental aspects. CC Technologies is highly qualified to perform the proposed research program. Since its inception in 1985, CC Technologies has grown to a staff of over ninety people that includes Ph.D. scientists, M.S. researchers, and B.S. engineers. Degrees earned by the staff cover a range of relevant disciplines, including, Metallurgical Engineering, Materials Science, Mechanical Engineering, Theoretical and Applied Mechanics, Chemical Engineering, Electrical Engineering, and Civil Engineering, and Geology. The highly qualified staff at CC Technologies has performed research for PRCI, GRI, and individual pipeline companies on underground corrosion, cathodic protection, and stress corrosion cracking since inception of the company in 1985. Related Project Descriptions Presented below is a list of projects that were performed by members of the CC Technologies’ staff and are specifically related to the proposed project. Highlighted for each project description are the accomplishments of the particular project, the client, and the principal investigator. Permanent Field Repair of SCC – Review. This research project is exploring the fieldcompatible techniques for permanently repairing SCC cracks and colonies without the need for service interruption. A review report is being prepared. C. E. Jaske – PRCI (GRI Contract No. 8511), One year, 2002 Evaluation And Use Of A Steel Compression Sleeve To Repair Longitudinal Seam-Weld Defects. An engineering evaluation of a steel compression sleeve as a means to repair longitudinal seam-weld defects in pipelines was performed. The technique was used in a subsequent field program in which more than 200 such repair sleeves were installed on an operating crude oil pipeline. The steel compression sleeve evaluated has been commercially available since 1994 and has been installed on NPS 6 to NPS 42 pipelines in Canada and Mexico; primarily as a means to repair stress CC Technologies Laboratories, Inc.

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corrosion cracking, corrosion, and dents. The field program undertaken in 2000 represents the first use of this repair sleeve in the United States. C. E. Jaske – Industrial Client, One year, 2000 Compression Sleeve Repair of Gas Pipeline. CC Technologies developed a simplified model for evaluating the effectiveness of compression steel sleeves. It included the effect of load transfer between the sleeve and carrier pipe as a function of internal pressure, filler material, and sleeve temperature. The model was validated by finite-element stress analysis and strain-gage measurements on test sleeve installations. TransCanada Pipelines Sleeve Repair of Crack-Like Defects in ERW Seams in an Oil Pipeline. CC Technologies performed an engineering critical assessment (ECA) to develop guidelines for repair of crack-like defects in ERW seams in an oil pipeline. The evaluation included the detection capabilities of in-line inspection, the possibility of fatigue crack propagation, and the potential of fracture. Industrial Client Pipeline Repair Manual. CC Technologies developed a pipeline repair manual for the operator of an oil pipeline. The manual included procedures for various repair options that can be implemented depending on the type of defect encountered. The manual was approved by the U.S. DOT. Industrial Client Compression Sleeve Repair of Oil Pipeline. CC Technologies helped implement the first US use of a steel compression sleeve for pipeline repair. The method can be used to permanently repair longitudinal defects on an operating pipeline, including crack-like defects in ERW seams. The method is non-intrusive and requires no welding to the carrier pipe. In comparison with a Type B sleeve, which relies on tapping through the pipe and the sleeve to reduce hoop stress, the steel sleeve applies compression to the carrier pipe to reduce the hoop stress and prevent crack growth. Evaluation of the sleeve included measuring mechanical properties of the three different steels, modeling of the stresses in the carrier pipe and in the sleeve, and full-scale burst and fatigue testing. AEC Pipelines Ltd.'s Platte Pipeline Environmentally Assisted Cracking Low-pH SCC: Mechanical Effects on Crack Propagation The objective of this PRCI program was to determine the effects of mechanical factors such as hydrotesting on low-pH stress corrosion crack growth. All testing was performed in a low-pH (nearneutral-pH) electrolyte (NS4 solution) under cyclic load conditions on pre-cracked specimens of one X-65 line pipe steel. The cyclic load conditions in the testing were related to field conditions using the J-integral parameter. Crack growth was initiated in specimens under cyclic load conditions. Once steady state crack growth had been

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Updated Pipeline Repair Manual

achieved, a typical hydrostatic test sequence was applied to the specimen. The initial cyclic load conditions were then reapplied to the specimen and crack growth was monitored to evaluate the effect of the hydrostatic testing on the rate of crack growth. It was found that some crack extension occurred during the simulated hydrostatic test sequence but the hydrostatic testing also promoted a decrease in the cracking velocity. The magnitude of the crack extension was slightly greater than that observed upon reloading, following unloading of the specimens. It was concluded that hydrostatic testing is no more harmful than simple depressurization of a pipeline. J. A. Beavers – CC Technologies, PRC International, 1994 – 1996 Investigations of Propagation of Low-pH SCC The objectives of this research for TransCanada Pipelines included: (1) to develop a laboratory technique to simulate the propagation of low-pH SCC, (2) to estimate rates of crack propagation, and (3) to evaluate the effects of environmental and metallurgical factors such as welding and pipe steel grade on crack growth rates. In this research, CC Technologies was one of the first laboratories to reproduce this form of cracking in the laboratory. An experimental technique that utilizes pre-crack compact type specimens was developed in the laboratory studies. The crack propagation rate information generated in the research has been utilized to assist TCPL in establishing safe hydrostatic testing intervals. The studies of metallurgical factors have demonstrated that some weld structures exhibit much higher crack propagation rates than the wrought steel. J. A. Beavers – TransCanada Pipelines Ltd., 1992 – 1997 Assessment Of Line Pipe Susceptibility To Stress Corrosion Cracking Under Tape, Enamel And Fusion Bonded Epoxy Coatings. The objectives of this PRC program were to evaluate the susceptibility of line pipe to stress corrosion cracking (SCC) when coated with polyethylene (PE) tape, coal tar enamel (CTE), and fusion bonded epoxy (FBE) and to establish whether SCC can occur on FBE coated pipelines. The program was divided into two tasks: Task 1 - Coating Characterization, and Task 2 - SCC Testing. The purposes of Task 1 were: (1) to establish a standard specimen geometry, incorporating a disbonded coating, for electrochemical and SCC tests, (2) to evaluate the effect of coating type on the potential gradients beneath a disbonded coating, and (3) to correlate the testing described above with standard industrial tests for coating evaluation. In Task 1, electrochemical impedance spectroscopy (EIS) and other electrochemical techniques were used for coating characterization. The purpose of Task 2 was to evaluate the individual and combined roles of surface preparation and cathodic protection shielding on SCC susceptibility. Two types of SCC tests were performed. Tapered Tensile SCC tests are being performed on uncoated specimens of line pipe steel to evaluate the role of surface preparation alone on SCC surface susceptibility. Cyclic load SCC tests were performed on coated straight-sided tensile specimens to evaluate the roles of cathodic protection shielding and surface preparation on SCC susceptibility. J. A. Beavers – CCT, American Gas Association (1989-1991). Investigation Of Line Pipe Steel That Is Highly Resistant To SCC. Principal Investigator on a Pipeline Research Committee of the American Gas Association

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(A.G.A.) program in which the relationship between metallurgical characteristics of line pipe steel and stress corrosion cracking susceptibility was investigated. The goal of this work was to understand the influence of processing parameters on those characteristics that control SCC susceptibility so that steels can be made consistently resistant to SCC. Experimental techniques used included potentiodynamic polarization, slow strain rate and constant load and fracture mechanics tests. J. A. Beavers - CCT, Client: American Gas Association (1983-1984). Test Method For Defining Susceptibility Of Line Pipe Steels To SCC. Principal Investigator on an A.G.A. program in which a standardized test method for defining the SCC susceptibility of line pipe steels was developed. Previous studies had identified the optimum environmental conditions and specimen geometry for performing such an evaluation and the aim of the work was to identify the optimum loading conditions and test time. J. A. Beavers - CCT, Client: American Gas Association (1984-1986). Modeling Of Stress-Corrosion Crack Initiation And Propagation. Program Manager of a program in which the initiation and propagation of stress-corrosion cracking in natural gas pipelines were being modeled. The goals of the research included the development of a methodology to estimate hydrostatic retest frequencies in operating pipelines and the development of SCC resistant steels. J. A. Beavers - CCT, Industrial Client (1986). Surface Related Factors Affecting Stress-Corrosion Cracking. Principal Investigator of an A.G.A. program to investigate the surface related factors affecting SCC initiation. The objective of the research was to identify those surface factors that affect and control SCC initiation to reduce the variation in the results of SCC tests and to optimize surface properties of operating pipelines. J. A. Beavers - CCT, Client: The American Gas Association (1985). Limitations Of The Slow Strain Rate Test For Stress Corrosion Cracking Testing. Materials Technology Institute of the Chemical Process Industries (MTI) Report Number 61. The overall objective of the program, which was performed for MTI, was to determine if SSR testing methods yield useful data in predicting SCC susceptibility of metals used in the Chemical Process Industry (CPI). The specific objectives of the Year 1 research were to identify the alloy-environment systems in which the SSR technique produces anomalous SCC results, identify which test variables must be controlled to make the SSR test results applicable to the CPI, identify the limitations of the SSR test technique, and identify what further program support is needed to resolve unanswered questions. The open literature was surveyed and contacts were made within the industry by means of a questionnaire and follow-up telephone calls. J. A. Beavers and G. H. Koch, Client: MTI. (1990) Stress Corrosion Cracking Of Low Strength Carbon Steels In Candidate High Level Waste Repository Environments. Nuclear Regulatory Commission Report NUREG/CR-3861, February 1987. Co-authors on a report of a literature survey

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performed to identify the potential stress corrosion cracking agents for low strength carbon and low alloy steels in repository environments. It was found that a number of potent cracking agents are present, but stress corrosion cracking is relatively unlikely in the bulk repository environments because of the low concentration of these species. J. A. Beavers, N. G. Thompson - CCT, Client: Nuclear Regulatory Comm. (1985-1986). Stress Corrosion Cracking Environments. A series of programs to establish the likely stress corrosion cracking environment containing CO2 for buried gas pipelines. The work includes examining changes to the environment at the pipe surface and beneath a coating during cathodic protection in the presence of CO2. J. A. Beavers - CCT, Industrial Client (1988). Estimating Intervals For Hydrostatic Retesting. Developed a Monte Carlo type model for estimating the safe time between hydrotests for a pipeline in which stress corrosion cracks are propagating. J. A. Beavers - CCT, Industrial Client (1987). Facilities CC Technologies is a fully equipped corrosion testing and research laboratory specializing in the evaluation of materials properties, materials selection, corrosion, corrosion control, and design and development of instrumentation and engineering software. CC Technologies has continued to grow since its inception in 1985 and has more than 25,000 square feet of space in its current office and laboratory facility.

CONTRACT REQUIREMENTS CC Technologies accepts the terms and conditions of its current standard contract agreements with PRC International. This same type of contract is proposed for this work.

CC Technologies Laboratories, Inc.

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APPENDIX A Résumés

6141 Avery Road, Dublin, OH 43016-8761 USA TEL 614-761-1214 FAX 614-761-1633

CARL E. JASKE, Ph.D., P.E. Dr. Jaske is Senior Group Leader of Materials Engineering and Research for CC Technologies. He is leading work in the areas of mechanical integrity, fitness-for-service, and remaining-life assessment of structures and equipment. He has developed the www.Fitness4Service.com web site and a short course on the API 579 Fitness-For-Service recommended practice. His work includes projects on fatigue, corrosion-fatigue, creep, creep-crack growth, hightemperature properties, in-service aging, and failure analysis of structural materials. These projects typically incorporate both analytical assessments and experimental evaluations of failure lives and material damage. Much of his work has been concerned with relating the physical metallurgy of carbon steels, low-alloy steels, stainless steels, and heat-resistant alloys to their mechanical properties and in-service aging. This research includes wrought products, castings, and weldments. Dr. Jaske has evaluated the effects of elevated temperatures and corrosive environments on mechanical properties of materials. He has developed and applied fracture-mechanics approaches for assessing creep, fatigue, and stress-corrosion cracking degradation and failure of engineering components, such as in-service pressure vessels and piping. He has served on industry and government advisory groups for life extension and remaining life assessment of key engineering equipment and facilities. Also, he has developed computer programs for life assessment of welded steam pipes, reformer furnace tubes, and pressure vessels. A major portion of Dr. Jaske’s work, since joining CC Technologies in 1990, has addressed the mechanical integrity of oil and gas pipelines. He developed a model for predicting the failure and remaining life of pipelines with local defects, including crack-like flaws, and commercialized the CorLAS computer program to make the model easily usable by engineers. His work on pipelines includes evaluations of stress-corrosion cracks, corrosion flaws, weld defects, dents, gouges, and dents with corrosion. He utilizes inspection and operational data to predict failures and remaining service life and advises companies on implementing and maintaining appropriate integrity programs. Education B.S., B.S., M.S., Ph.D.,

Liberal Arts and Sciences (Mathematics) with High Honors, University of Illinois General Engineering with Highest Honors, University of Illinois Theoretical and Applied Mechanics, University of Illinois Metallurgical Engineering, The Ohio State University

Experience Senior Group Leader Senior Research Scientist

CC Technologies Battelle Memorial Institute

1991 – Present 1967 – 1990

Resume: Carl E. Jaske, Ph.D., P.E. Page 2 Professional Organizations Fellow, American Society of Mechanical Engineers (ASME) Member, American Society for Testing and Materials (ASTM) Member, NACE International Professional Activities Program Chair, ASME Pipeline Systems Subdivision Associate Editor, Journal of Pressure Vessel Technology Past Chair, ASME Pressure Vessels and Piping (PVP) Division Past Chair of Central Ohio Section of ASME Technical Program Chairman (1992) and General Chairman (1993) of ASME PVP Conferences API Working Group on Pipeline Integrity Management Standard ASME Boiler and Pressure Vessel Code Committee, Subgroup on Fatigue Strength ASTM Committee E8 on Fatigue and Fracture Short Courses/Forums/Tutorials ASME Short Course on API-579 Fitness-For-Service Evaluation of Vessels, Tanks, and Piping ASME Short Course on Assessment of Material Aging and Prediction of Remaining Life Developer of NDE Demonstration Forum, 1996-2001 ASME PVP Conferences Tutorial on Remaining Life Prediction, 1987 PVP Conference Tutorial on Assessment of Material Degradation in Service, 1989 PVP Conference Tutorial on Life Extension and Remaining Life Assessment, 1995 PVP Conference Engineering Registration Dr. Jaske is a Registered Professional Engineer in the States of Ohio and Alaska. Relevant Experience Integrity of Oil and Gas Pipelines. Performed numerous projects on evaluating the integrity of oil and gas pipelines, including failure analyses. The CorLAS computer program was developed to predict the failure of pipelines with local defects, including crack-like flaws. An independent evaluation of available models for assessing SCC flaws showed that CorLAS gave the most accurate predictions of fourteen actual Canadian pipeline failures. Other projects include evaluation of stresses during hot tapping, assessment of dents and gouges, and predictions of remaining fatigue life. Fatigue Strength Reduction Factors for Welds. Completed an interpretative review of fatigue strength reduction and stress concentration factors for welds in pressure vessels and piping for the Welding Research Council (Bulletin 432, June 1998). Available procedures for evaluating the fatigue strength of welded structures were reviewed and evaluated. Guidelines for developing weld-joint fatigue strength reduction factors were developed. Aging of Nuclear Power Plant Components. Participated in the U.S. Nuclear Regulatory Commission's Nuclear Plant Aging Research (NPAR) program to help develop methodology for residual-life assessment of key safety-related nuclear-plant components, including evaluation of the thermal embrittlement of cast stainless steels.

Resume: Carl E. Jaske, Ph.D., P.E. Page 3 Relevant Experience (Continued) Remaining Life Assessment. Conducted numerous projects to assess the remaining life of operating equipment in industrial plants. This work included testing and examination of material samples and analytical calculations. Examples of equipment that have been evaluated include steam-turbine rotors, steam pipes, reformer furnace tubes, headers, superheater and reheater tubes, and pressure vessels. Creep-Fatigue Crack Growth. Developed a fracture-mechanics model and life-assessment approach for creep-fatigue crack growth interaction effects and performed creep, low-cycle fatigue, and creep-fatigue crack propagation experiments on Type 316 Stainless Steel. Creep Fracture and Creep-Fatigue Life of Welded Steam Lines. Developed personal computer codes to help assess the remaining creep and creep-fatigue life and the potential for unstable fracture of 2-1/4Cr-1Mo and 1-1/4Cr-1/2Mo welded steam pipes, including seamwelded hot reheat steam lines. Failure Analyses. Performed failure analyses of various components used in industrial equipment, including the failure of a large motor shaft, the failure of a generator rotor, the failure of a mold used for casting bronze alloys, steam pipe failures, and failures of fired furnace tubes. Long-Life Corrosion Fatigue Evaluation for the Development of Alloys Used in PaperMaking Equipment. Performed long-life (107 to 109 cycles to failure) corrosion-fatigue studies of cast alloys--bronze, martensitic stainless steel, austenitic stainless steel, and duplex stainless steel--in white water (low pH, chloride, sulfate, thiosulfate) environments; to realistically simulate expected service conditions, tests have been performed at low stresses for periods of several months to more than one year. Selected Publications 1.

C. E. Jaske and H. Mindlin, “Elevated-Temperature Low-Cycle Fatigue Behavior of 21/4Cr-1Mo and 1Cr-1Mo-1/4V Steels,” 2-1/4 Chrome 1 Molybdenum Steel in Pressure Vessels and Piping, ASME, New York (1971), pp. 137-210.

2.

C. E. Jaske, et al., “Combined Low-Cycle Fatigue and Stress-Relaxation Behavior of Alloy 800 and Type 304 Stainless Steel at Elevated Temperature,” Fatigue at Elevated Temperatures, STP 520, ASTM, Philadelphia (1973), pp. 365-376.

3.

C. E. Jaske, et al., “Development of Elevated-Temperature Fatigue Design Information for Type 316 Stainless Steel,” Paper C163/73, International conference on Creep and Fatigue in Elevated-Temperature Applications, Conference Publication 13, I. Mech. E., London (1973), pp. 163.1-163.7.

4.

C. E. Jaske, “Thermal-Mechanical, Low-Cycle Fatigue of AISI 1010 Steel,” Thermal Fatigue of Materials and Components, STP 612, ASTM, Philadelphia (1976), pp. 170198.

5.

C. E. Jaske, “Low-Cycle Fatigue of AISI 1010 Steel at Temperatures Up to 1200°F (649°C),” Journal of Pressure Vessel Technology, Vol. 99, No. 3 (1977), pp. 423-443.

6.

C. E. Jaske and W. J. O'Donnell, “Fatigue Design Criteria for Pressure Vessel Alloys,” Journal of Pressure Vessel Technology, Vol. 99, No. 4 (1977), pp. 584-592.

Resume: Carl E. Jaske, Ph.D., P.E. Page 4 Selected Publications (Continued) 7.

C. E. Jaske, “Corrosion Fatigue of Structural Steels in Seawater and for Offshore Applications,” Corrosion-Fatigue Technology, STP 642, ASTM, Philadelphia (1978), pp. 19-47.

8.

C. E. Jaske and J. A. Begley, “An Approach to Assessing Creep/Fatigue Crack Growth,” Ductility and Toughness Considerations in Elevated Temperature Service, MPC-8, ASME, New York (1978), pp. 391-409.

9.

C. E. Jaske and N. D. Frey, “Long-Life of Type 316 Stainless Steel at Temperatures up to 593°C,” Journal of Engineering Materials and Technology, Vol. 104, No. 2 (1982), pp. 137-144.

10.

C. E. Jaske, et al., “Predict Reformer Furnace Tube Life,” Hydrocarbon Processing, Vol. 62, No. 1 (1983), pp. 63-68.

11.

C. E. Jaske, “Creep-Fatigue-Crack Growth in Type 316 Stainless Steel,” Advances in Life Prediction Methods, ASME, New York (1983), pp. 93-103.

12.

With F. A. Simonen, “A Computational Model for Predicting the Life of Tubes Used in Petrochemical Heater Service,” Journal of Pressure Vessel Technology, Vol. 107, No. 3 (1985), pp. 239-246.

13.

C. E. Jaske, “Long-Term Creep-Crack Growth Behavior of Type 316 Stainless Steel,” Fracture Mechanics: Eighteenth Symposium, STP 945, ASTM, Philadelphia (1988), pp. 867-877.

14.

C. E. Jaske and A. P. Castillo, “Corrosion Fatigue of Cast Suction-Roll Alloys in Simulated Paper-Making Environments,” Materials Performance, Vol. 26, No. 4 (1987), pp. 37-43.

15.

C. E. Jaske, “Techniques for Examination and Metallurgical Damage Assessment of Pressure Vessels,” Performance and Evaluation of Light Water Reactor Pressure Vessels, ASME, New York (1987), pp. 103-114.

16.

C. E. Jaske and R. W. Swindeman, “Long-Term Creep and Creep-Crack-Growth Behavior of 9Cr-1Mo-V-Nb Steel,” Advances in Materials Technology for Fossil Power Plants, ASM International, Metals Park, Ohio (1987), pp. 251-258.

17.

C. E. Jaske, “Life Assessment of Hot Reheat Steam Pipe,” Paper 2.9.2, Proc, International Conference on Life Extension and Assessment, Volume II, The Hague, Netherlands (June 13-15, 1988), pp. 185-193 [also in the Journal of Pressure Vessel Technology, Vol. 112, No. 1 (1990), pp. 20-27.]

18.

C. E. Jaske, “Fatigue Curve Needs for Higher Strength 2-1/4Cr-1Mo Steel for Petroleum Process Vessels,” Fatigue Initiation, Propagation, and Analysis for Code Construction, MPC Vol. 29, ASME, New York (1988), pp. 181-195 [also in the Journal of Pressure Vessel Technology, Vol. 112, No. 4 (1990), pp. 323-332.]

Resume: Carl E. Jaske, Ph.D., P.E. Page 5 Selected Publications (Continued) 19.

C. E. Jaske and V. N. Shah, “Life Assessment Procedure for LWR Cast Stainless Steel Components,” Proceedings of the Fourth International Symposium on Environmental Degradation of Materials in Nuclear Power Systems-Water Reactors, National Association of Corrosion Engineers, Houston, Texas (1990), pp. 3-66 to 3-83.

20.

C. E. Jaske and V. N. Shah, “Life Assessment Procedures for Major LWR Components: Cast Stainless Steel Components,” NUREG/CR-5314, EGG-2562, Vol. 3 (October, 1990).

21.

With B. S. Majumdar and M. P. Manahan, “Creep Crack Growth Characterization of Type 316 Stainless Steel Using Miniature Specimens,” International Journal of Fracture, Vol. 47 (1991), pp. 127-144.

22.

C. E. Jaske and R. Viswanathan, “Predict Remaining Life of Equipment for High Temperature-Pressure Service,” Paper Number 213, Corrosion 90, Las Vegas, Nevada (April 23-27, 1990).

23.

C. E. Jaske and R. Viswanathan, “Remaining-Life Prediction for Equipment in HighTemperature/Pressure Service,” Materials Performance, Vol. 30, No. 4 (1991), pp. 6167.

24.

With A. P. Castillo and G. M. Michel, “Sandusky Alloy 86, A New Suction Roll Shell Material with Improved Corrosion-Fatigue Strength in Corrosive White Waters,” presented at the 24th EUCEPA Technical Conference, SPCI 90 International Exhibition, Stockholm, Sweden (May 7-10, 1990).

25.

With B. S. Majumdar, “Creep-Fatigue Crack Growth in 9Cr-1Mo-V-Nb Steel,” presented at the 1991 ASME Pressure Vessel and Piping Conference, San Diego, California (June 23 – 27, 1991).

26.

C. E. Jaske and F. A. Simonen, “Creep-Rupture Properties For Use In The Life Assessment Of Fired Heater Tubes,” Proceedings of the First International Conference On Heat-Resistant Materials, ASM International (1991), pp. 485-493.

27.

With G. H. Koch, “Prediction of Remaining Life of Equipment Operating in Corrosive Environments,” NACE Conference on Life Prediction of Corrodible Structures, Cambridge, UK (September 23-26, 1991) and Kauai, Hawaii (November 5-8, 1991).

28.

C. E. Jaske and G. H. Koch, “Failure and Damage Mechanisms – Embrittlement, Corrosion, Fatigue, and Creep,” Technology for the 90’s, ASME, New York (July, 1993), pp., 7-39.

29.

C. E. Jaske, “Review of Materials Property Relationships for Use in Computerized Life Assessment,” Fourth International Symposium of the Computerization and Use of Materials Property Data, ASTM, Gaithersburg, Maryland (October 6-8, 1993).

30.

C. E. Jaske, “Life Prediction in High-Temperature Structural Materials,” Fatigue and Fracture of Aerospace Structural Materials, AD-Vol. 36, ASME, New York (1993), pp. 59-71.

Resume: Carl E. Jaske, Ph.D., P.E. Page 6 Selected Publications (Continued) 31.

C. E. Jaske, “The Effects of High-Temperature Exposure on the Properties of HeatResistant Alloys,” Paper No. 397, Corrosion 94, Baltimore (February 28-March 4, 1994).

32.

C. E. Jaske, “Remaining Life Evaluation of Pressure Vessels and Piping – General Approach and Case Histories,” 3rd International Conference & Exhibition on Improving Reliability in Petroleum Refineries and Chemical Plants, Houston (November 15-18, 1994).

33.

C. E. Jaske, “Review of Materials Property Relationships for Use in Computerized Life Assessment,” Computerization and Networking of Materials Databases, STP 1257, ASTM, Philadelphia (1995), pp. 194-208.

34.

With B. A. Harle and J. A. Beavers, “Mechanical and Metallurgical Effects on Low-pH Stress Corrosion Cracking of Natural Gas Pipelines,” Paper No. 646, Corrosion 95, NACE International, Houston (1995).

35.

C. E. Jaske and R. Viswanathan, “Properties of Cr-Mo Steels after Long-Term HighTemperature Service,” Service Experience, Structural Integrity, Severe Accidents, and Erosion in Nuclear and Fossil Plants, PVP-Vol. 303, ASME, New York (1995), pp. 235-245.

36.

C. E. Jaske, “Remaining Life Assessment of High-Temperature Components,” HeatResistant Materials II, Proceedings of the 2nd International Conference on HeatResistant Materials, ASM International, Materials Park, Ohio (1995), pp. 405-412.

37.

C. E. Jaske, J. A. Beavers, and N. G. Thompson, “Improving Plant Reliability Through Corrosion Monitoring,” Fourth International Conference on Process Plant Reliability, Gulf Publishing Company, Houston (November 14-17, 1995).

38.

C. E. Jaske and J. A. Beavers “Effect of Corrosion and Stress-Corrosion Cracking on Pipe Integrity and Remaining Life,” Proceedings of the Second International Symposium on the Mechanical Integrity of Process Piping, MTI Publication No. 48, Materials Technology Institute of the Chemical Process Industries, Inc., St. Louis (1996), pp. 287-297.

39.

C. E. Jaske, J. A. Beavers, and B. A. Harle, “Effect of Stress Corrosion Cracking on Integrity and Remaining Life of Natural Gas Pipelines,” Corrosion 96, Denver, Colorado, March 1996, NACE Paper No. 255.

40.

C. E. Jaske and J. A. Beavers, “Fitness-for-Service Evaluation of Pipelines in GroundWater Environments,” PRCI / EPRG 11th Biennial Joint Technical Meeting on Line Pipe Research; Arlington, Virginia; April 8 – 10, 1997; Paper No. 12.

41.

J. A. Beavers and C. E. Jaske, “Near-Neutral pH SCC In Pipelines: Effects Of Pressure Fluctuations On Crack Propagation,” Corrosion NACExpo 98, NACE International, Paper No. 98257, San Diego, California (March 1998).

42.

C. E. Jaske and J. A. Beavers, “Review and Proposed Improvement of a Failure Model for SCC of Pipelines,” International Pipeline Conference — Volume 1, ASME International, New York, 1998, pp. 439-445.

Resume: Carl E. Jaske, Ph.D., P.E. Page 7 Selected Publications (Continued) 43.

C. E. Jaske, “Interpretive Review of Weld Fatigue-Strength-Reduction and StressConcentration Factors," Fatigue Strength Reduction and Stress Concentration Factors for Welds in Pressure Vessels and Piping, WRC Bulletin 432, Welding Research Council, Inc., New York, June, 1998.

44.

C. E. Jaske, “Integrity and Remaining Life of High-Temperature Equipment,” CIM Symposium on Materials for Resource Recovery and Transport, Calgary, Alberta, Canada, August 16 – 19, 1998.

45.

C. E. Jaske and J. A. Beavers, “Predicting the Failure and Remaining Life of Gas Pipelines Subject to Stress Corrosion Cracking,” International Gas Research Conference, San Diego, California; November 8 – 11, 1998; Paper TS0-13.

46.

J. A. Beavers and C. E. Jaske, “SCC of Underground Pipelines: A History of The Development of Test Techniques,” Corrosion NACExpo 99, NACE International, Paper No. 99142, San Antonio, Texas (April 1999).

47.

C. E. Jaske and J. A. Beavers, "Fitness-For-Service Evaluation of Pipelines with StressCorrosion Cracks or Local Corrosion," International Conference on Advances in Welding Technology (ICAWT ’99), Galveston, Texas USA, October 26-28, 1999.

48.

With M. P. H. Brongers, J. A. Beavers and B. S. Delanty, “Influence of Line-Pipe Steel Metallurgy on Ductile Tearing of Stress-Corrosion Cracks During Simulated Hydrostatic Testing," 2000 International Pipeline Conference – Volume 2, ASME International, New York, 2000, pp. 743-756.

49.

With M. P. H. Brongers, J. A. Beavers and B. S. Delanty, “Effect of Hydrostatic Testing on Ductile Tearing of X-65 Linepipe Steel with Stress Corrosion Cracks," Corrosion, Vol. 56, No. 10, 2000, pp. 1050-1058.

50.

C. E. Jaske and J. A. Beavers, "Fitness-For-Service Assessment for Pipelines Subject to SCC," Pipeline Pigging, Integrity Assessment, and Repair Conference, Houston, Texas, February 1-2, 2000.

51.

M. P. Brongers and C. E. Jaske, "Creep-Rupture of Service-Exposed Base Metal and Weldments of Alloy 800H," Aging Management, Component and Piping Analysis, Nondestructive Engineering Monitoring and Diagnostics – 2000, PVP-Vol. 409, ASME International, New York, 2000, pp. 143-153.

52.

C. E. Jaske, "Fatigue Strength Reduction Factors for Welds in Pressure Vessels and Piping," Pressure Vessels and Piping Codes and Standards – 2000, PVP-Vol. 407, ASME International, New York, 2000, pp. 279-297.

53.

C. E. Jaske, "Fatigue Strength Reduction Factors for Welds in Pressure Vessels and Piping," Journal of Pressure Vessel Technology, Vol. 122, No. 3, 2000, pp. 297-304.

54.

C. E. Jaske and R. Viswanathan, "Use of Miniature Specimens for Creep-Crack-Growth Testing," Understanding and Predicting Material Degradation, PVP-Vol. 413, ASME International, New York, 2000, pp. 69-79.

Resume: Carl E. Jaske, Ph.D., P.E. Page 8 Selected Publications (Continued) 55.

C. E. Jaske and R. Viswanathan, "Use of Miniature Specimens for Creep-Crack-Growth Testing," Journal of Engineering Materials and Technology, Vol. 122, No. 3, 2000, pp. 327-332.

56.

C. E. Jaske and John A. Beavers, “Evaluating the Remaining Strength and Life of Pipelines Subject to Local Corrosion or Cracking.” NACE Northern Area Premiere Conference (Corrosion Prevention 2000), Toronto, Ontario, Canada, November 2000.

57.

P. H. Vieth, D. A. Soenjoto, and C. E. Jaske, “Transverse Field Inspection (TFI) Program Results,” 52nd Annual Pipeline Conference, San Antonio, Texas USA, April 17-18, 2001.

58.

C. E. Jaske, “Development of Miniature-Specimen Test Techniques For Measuring Creep-Crack-Growth Behavior,” The 7th International Conference on Creep and Fatigue at Elevated Temperatures, National Institute for Materials Science, Tsukuba, Japan, June 3-8, 2001.

59.

M. P. Brongers, C. J. Maier, C. E. Jaske, P. H. Vieth, M. D. Wright, and R. J. Smyth, “Tests, Field Use Support Compression Sleeve for Seam-Weld Repair,” Oil & Gas Journal, Volume 99.24, pp. 60 – 66, June 11, 2001.

60.

M. P. Brongers, C. J. Maier, C. E. Jaske, P. H. Vieth, M. D. Wright, and R. J. Smyth, “Evaluation and Use of a Steel Compression Sleeve to Repair Longitudinal Seam-Weld Defects,” 52nd Annual Pipeline Conference, San Antonio, TX, April 17 – 18, 2001.

61.

B. E. Shannon and C. E. Jaske, “A Practical Life Assessment Approach For Hydrogen Reformer Tubes,” Proceedings of NACE International Northern Area Conference, Edmonton, Alberta, Canada, February 18-21, 2002.

62.

C. E. Jaske, P. H. Vieth, and J. A. Beavers, “Assessment of Crack-Like Flaws in Pipelines,” Corrosion NACExpo 2002, NACE International, Paper No. 02089, Denver, Colorado (April 2002).

Books and Software C. E. Jaske, J. H. Payer and V. S. Balint, Corrosion Fatigue of Metals in Marine Environments, Battelle Press, Columbus Ohio (1981). C. E. Jaske, Coordinating Editor, Residual-Life Assessment, Nondestructive Examination, and Nuclear Heat Exchanger Materials, PVP-Vol. 98-1, ASME, New York (1985). C. E. Jaske, et al., Editors, Life Extension and Assessment: Nuclear and Fossil Power-Plant Components, PVP-Vol. 138/NDE-Vol. 4, ASME, New York (1988). With W. H. Bamford and R. C. Cipolla, Editors, Service Experience in Operating Plants – 1991, PVP-Vol. 221, ASME, New York (1991). ReHeat12™, pcTUBE™, and CreepLife™ computer programs for life assessment of hightemperature steam pipes, furnace tubes, and pressure vessels.

Resume: Carl E. Jaske, Ph.D., P.E. Page 9 Books and Software (Continued) CorLAS™ computer program for evaluating the effects of corrosion and stress-corrosion cracking on the structural integrity of pipes and vessels.

6141 Avery Road, Dublin, OH 43016-8761 USA TEL 614-761-1214 FAX 614-761-1633

PATRICK H. VIETH Mr. Vieth is Vice President of CC Technologies Services, Inc., (CC Technologies). Mr. Vieth is a Mechanical Engineer and has fifteen years of experience in the field of pressure vessel fracture behavior and defect assessment methods for transmission pipeline systems. Prior to joining CC Technologies, Mr. Vieth held positions with Battelle and Kiefner & Associates, Inc. Mr. Vieth’s expertise is primarily directed toward assisting the operators of transmission pipeline systems with the development and implementation of short-term and long-term pipeline integrity management programs. Specifically, he works with operators to develop programs to reduce the likelihood of failures through in-line inspection, hydrostatic testing, defect assessment, risk assessment, and fitness-for-purpose assessment. Mr. Vieth has been active in research and the development of innovative solutions within the pipeline industry. He was a key-contributor in the validation and implementation of the RSTRENG corrosion assessment method. RSTRENG is recognized within the Federal Code of Federal regulations for transmission pipeline systems as a method for assessing the remaining pressurecarrying capacity of pipe which has sustained wall loss due to corrosion. Mr. Vieth was also a team member that developed a Transverse Field Inspection (TFI) program to address a pipeline operator’s specific integrity concern. The TFI program utilized a new technology to identify longitudinal seam weld defects that could pose an integrity concern to the pipeline operations. Success in the development, validation, and implementation of this TFI program resulted in the Department of Transportation (DOT) Office of Pipeline Safety’s (OPS) acceptance of this program in lieu of mandated hydrostatic testing to verify the integrity of the pipeline system. Mr. Vieth has conducted several full-scale testing programs to evaluate the fracture behavior of defects in pressure vessels. These testing programs were conducted under the sponsorship of the Nuclear Regulatory Commission (NRC) to evaluate the fracture behavior of power plant piping subjected to dynamic loading. Additional full-scale testing programs have been conducted to evaluate the pressure-carrying capacity of defects identified in transmission pipeline systems (natural gas and hazardous liquids) and removed from services. These tests have been used to evaluate the pressure-carrying capacity of pipe sections containing defects such as corrosion-caused metal loss and longitudinal seam weld defects. Education B.S., Mechanical Engineering, The Ohio State University

Resume: Patrick H. Vieth Page 2 Experience Vice President

CC Technologies Services, Inc.

2001 – present

Senior Group Leader

CC Technologies Services, Inc.

1999 – 2001

Manager, Integrity Solutions

Pipeline Integrity International

Senior Mechanical Engineer Associate

Kiefner & Associates, Inc. Worthington, OH

1991 – 1999

Principal Research Scientist

Battelle, Columbus, OH

1985 – 1991

1999

Professional Activities National Association of Corrosion Engineers (NACE), Committee Chairman, T-10E-6 (Defect Assessment) American Society of Mechanical Engineers (ASME), #1271881, Past Chairman – Central Ohio Section of ASME, (1990). Selected Publications Risk Assessment Kiefner, J. F., Vieth, P. H., Orban, J. E., and Feder, P. I., “Methods for Prioritizing Pipeline Maintenance and Rehabilitation,” American Gas Association, Pipeline Research Committee, Catalog No. L51631, September 28, 1990. Corrosion Assessment Kiefner, J. F., and Vieth, P. H., “A Modified Criterion for Evaluating the Remaining Strength of Corroded Pipe,” American Gas Association, Pipeline Research Committee, Catalog No. L51609, December 22, 1989. Vieth, P. H., and Kiefner, J. F., “Database of Corroded Pipe Tests,” American Gas Association, Pipeline Research Committee, Pipeline Research Committee, Catalog No. L51689, April 4, 1989. Kiefner, J. F., and Vieth, P. H., “Evaluating Pipe: New Method Corrects Criterion for Evaluating Corroded Pipe,” Oil and Gas Journal, August 6, 1990. Kiefner, J. F., and Vieth, P. H., “Evaluating Pipe: PC Program Speeds New Criterion for Evaluating Corroded Pipe,” Oil and Gas Journal, August 20, 1990. Vieth, P. H., and Kiefner, J. F., “RSTRENG User’s Manual,” American Gas Association, Pipeline Research Committee, Catalog No. L51688, March 31, 1993. Kiefner, J. F., and Vieth, P. H., “The Remaining Strength of Corroded Pipe,” American Gas Association, Eighth Symposium on Line Pipe Research, Houston, Texas, September 1993. Kiefner, J. F., Vieth, P. H., and Roytman, I., “Continued Validation of RSTRENG,” American Gas Association, Catalog Number L51749, December 1996.

Resume: Patrick H. Vieth Page 3 Selected Publications (continued) Pipeline Failures Vieth, P. H., Roytman, I., Mesloh, R. E., and Kiefner, J. F., “Analysis of DOT Reportable Incidents for Gas Transmission and Gathering Pipelines – 1985 through 1994,” American Gas Association, Pipeline Research Committee. Vieth, P. H., et al., “DOT Incident Data Analysis,” American Gas Association, PRC International, th 9 Symposium on Line Pipe Research, Houston, Texas, September 1996. Vieth, P. H., Maxey, W. A., Mesloh, R. E., Kiefner, J. F., and Williams, G. W., “Investigation of the Failure in GRI’s Pipeline Simulation Facility Flow Loop,” Gas Research Institute, March 15, 1996. In-Line Inspection Vieth, P. H., Ashworth, “In-Line Inspection,” International Pipeline Conference. Vieth, P. H., Rust, S. W., Johnson, E. R., and Cox, M. J., “In-Line Characterization and th Assessment,” American Gas Association, PRC International, 9 Symposium on Line Pipe Research, Houston, Texas, September 1996. Rust, S. W., Vieth, P. H., Johnson, E. R., and Cox, M. J., “Corrosion Pig Performance and Risk Assessment,” Pipes and Pipelines International, Pipeline Pigging Conference, Houston, Texas, February 1996. Vieth, P. H., Rust, S. W., Johnson, E. R., and Cox, M. J., “Corrosion Pig Performance Evaluation,” th American Society of Mechanical Engineers, American Petroleum Institute, 7 Annual Energy Week Conference, Houston, Texas, January 1996. Vieth, P. H., Rust, S. W., Johnson, E. R., and Cox, M. J., “Corrosion Pig Performance Evaluation,” National Association of Corrosion Engineers (NACE), NACE/96, Denver, Colorado, March 1996. Rust, S. W., Vieth, P. H., Johnson, E. R., and Cox, M. J., “Quantitative Corrosion Risk Assessment Based on Pig Data,” National Association of Corrosion Engineers (NACE), NACE/96, Denver, Colorado, March 1996. Flaw Growth Maxey, W. A., Vieth, P. H., and Kiefner, J. F., “An Enhanced Model for Predicting Pipeline Retest Intervals to Control Cyclic-Pressure-Induced Crack Growth,” American Society of Mechanical Engineers (ASME), Offshore Mechanics and Arctic Engineering (OMAE) 1993, Proceedings of the th 12 International Conference, Volume V (Pipeline Technology), 1993. Full-Scale Testing Scott, P., Kramer, G, Vieth, P., Francini, R., and Wilkowski, G., “The Effects of Cyclic Loading During Ductile Tearing on Circumferentially Cracked Pipe – Experimental Results,” ASME PVP Volume 280, June 1994, pp 207-220. Wilkowski, G., Vieth, P., Kramer, G., Marschall, C., and Landow, M., “Results of Separate-Effects Pipe Fracture Experiments,” Post-SMiRT-11 Conference, August 1991, Paper 4.2.

PART II – COST PROPOSAL TP274-3553

UPDATED PIPELINE REPAIR MANUAL PREPARED FOR

PRC INTERNATIONAL Pipeline Materials Committee

PREPARED BY

CC TECHNOLOGIES LABORATORIES, INC. CARL E. JASKE, PH.D., P.E. AUGUST 05, 2002

CC Technologies 6141 AVERY ROAD DUBLIN, OHIO 43016 614.761.1214 • 614.761.1633 fax www.cctechnologies.com

Part II – Cost Proposal

Updated Pipeline Repair Manual

PRCI / GAS TECHNOLOGY INSTITUTE CONTRACT COST ESTIMATE (FOOTNOTE A) Nam e ofO fferor

RFP No./Prp. No.

Page Num ber

Num ber ofPages

CC Technologies Laboratories Inc. Hom e O ffice Address

Nam e ofProposed Project

6141 A very R oad,D ublin O hio 43016

U pdated Pipeline R epair M anual(M aterials Program 1) ProposalN um ber: TP274-3553

Division(s) and Location(s) (w here w ork is to be perform ed)

TotalAm ount ofProposal

$75,000 Estim ated Cost (dollars)

TotalEstim ated Cost Supporting Schedule (dollars) (Footnote B)

1. Direct M aterial a. Purchased Parts

$0

b. InterdivisionalEffort

$0 $0

c. Equipm ent Rental

$200

d. O ther (Supplies and M aterials)

$200 Table 1b

TotalDirect M aterial 2. M aterialO verhead

Rate

10%

$200

x Base $

$20

3. Subcontracted Effort

Subcontractor Cofunding (Footnote D)

$0 Table 1b

Net Subcontracted Effort 4. Direct Labor - Specify

Est.Hours

Rate/Hour

Est.Cost

90

$45

$4,021

Project Engineer

360

$29

$10,494

Technologist

205

$25

$5,176

70

$15

$1,039

Senior G roup Leader

O ffice Staff

TotalDirect Labor

20,730

5. Labor O verhead - Specify

O .H.Rate

Labor O verhead (Fringes) G eneralO verhead

X Base $

$20,730 Table 1b

Est.Cost

40%

$20,730

$8,292

132%

$29,022

$38,309

N on-Labor O verhead

$46,601

TotalLabor & GeneralO verhead 6. SpecialTesting

Table 1b

7. Purchased SpecialEquipm ent

Table 1b

8. Travel

$1,040 Table 1b

G&A on travel

9. Consultants (Identify - Purpose - Rate)

Est.Cost

$0 Table 1b

TotalConsultants

$390 Table 1b

10.O ther Direct Costs

$68,981

11.TotalDirect Cost and O verhead 12.Generaland Adm inistrative Expense Rate

10%

x Base $

1,430 (Cost elem ent no(s).

3, 6, 7, 8,9,& 10)

(Cost elem ent no(s).

)

$143

13.Independent Research and Developm ent Rate

x Base $

$0 $69,124

14.TotalEstim ated Cost (Footnote C)

$5,876

15.Fixed Fee

$75,000

16.TotalEstim ated Cost and Fee 17.Contractor/Third Party Cofunding (Footnote D)

$75,000

18.NetEstim ated Cost and Fee to GRI This proposalreflects our best estim ate as of this date,in accordance w ith the instructions to offerors and the footnotes w hich follow . Typed Nam e and Title N eilG .Thom pson,CEO FO O TNO TES:

Signature

Date 7/31/02

A. The subm ission ofthis form does not constitute an acceptable proposal. Required supporting inform ation m ust also be subm itted. B. For each item ofcost, reference the schedule w hich contains the required supporting data. C. This should be the totalcost ofthe research project. Any contractor cost sharing should be show n on the Line 17 as a reduction from totalcosts. D. This line should contain (I) totalproposed fee,(ii) contractor cofunding,(3) third party cash cofunding,or (iv)be blank,depending on the contract type. Fixed fee should be cofunded before any contractor in-kind cofunding is proposed.

____________________________________________________________________________________ CC Technologies Laboratories, Inc. 1

Part II – Cost Proposal

Updated Pipeline Repair Manual

Table 1b. Cost Detail for Table 1a. (1) LABOR COSTS

Staff Sen Group Leader/Total Project Engineer/Total Technologist/Total Office Staff/Total TOTAL LABOR

Hours Billed 90 360 205 70 725

Average Rate x Infl 5.0% $44.68 $29.15 $25.25 $14.84

Total Labor Charged $4,021.20 $10,494.00 $5,176.25 $1,038.80 $20,730.25

(3) MATERIALS

Item Misc Total Materials

Unit Cost $200.00

Quantity 1

Total Cost $200.00 $200.00

(5) TRAVEL

Trip Project Review Total Travel

No. of Persons

No. of Trips 1

No. of Days 1

2

Airfare $600.00

Subsistence /day $170.00

Rental Car/day $50.00

Trip Cost $1,040.00 $1,040.00

(7) OTHER COSTS

Item Misc/Postage Total Other Costs

Unit Cost $390.00

Quantity 1

Total Cost $390.00 $390.00

____________________________________________________________________________________ CC Technologies Laboratories, Inc. 2

August 12, 2002 VIA FEDERAL EXPRESS PROPOSAL NO. CP052647 Mr. Steve Foh PRCI 1700 South Mount Prospect Des Plaines, IL 60018 Re: Request for Noncompetitive Proposals Dear Steve: Enclosed is our proposal for the project “Stress-Corrosion Crack Extension and Growth Modeling”, which is in response to PRCI RPTG-0320. This effort is offered under the master set of terms and conditions negotiated between PRCI and Battelle on June 30, 2000. Our receipt of authorization under these terms and conditions will allow us to proceed. This offer shall remain valid for a period of sixty (60) days from the date of this letter. If you have any technical questions, please call me at (614) 424-4421, or contact me via email at [email protected]. Questions of a contractual nature should be directed to Ms. LaDonna James, Contracts Department, at (614) 424-5543 or via email address: [email protected]. Sincerely,

Brian N. Leis Research Leader Pipeline Technology Center BNL/cw Enclosure

Christina L. Rotunda Contracting Officer

Stress-Corrosion Crack Extension and Growth Modeling: RPTG-0320 Background As in-line inspection (ILI) becomes available to detect and size SCC, accurate crack growth models will be essential in managing pipeline integrity and setting safe re-inspection intervals. The recent development of validated models to assess severity of single as well as multiple cracks makes it possible to assess pipeline integrity for the configuration of defects as detected – the immediate concern in integrity assessment. However, currently adequate modeling does not exist to project the behavior of SCC as time progresses under generalized loading conditions. Growth of the cracks can occur by SCC, or by stable tearing, depending on the defect size, the pipe hoop stress, and the factors driving SCC. The growth of this cracking is particularly complex for situations where new cracks may initiate within a colony and/or where crack coalescence can occur. In addition to validated models to assess defect criticality for as-detected cracking, a firstgeneration model specific to high pH SCC has been developed to grow such cracks as a function of the service conditions. This model was formulated such that the current cracking response depends on the prior operating and cracking history. This model has since been shown to faithfully recreate field-observed cracking patterns for high pH SCC, and has been used to successfully predict the field response under contract to some member companies. SCCLPM was developed for the PRCI such that the current cracking response depends on the prior operating and cracking history, the algorithms in this model can be reformulated to incorporate cracking as it is found in the field in bell-hole digs or via ILI. Because all modules comprising SCCLPM are generic except for reference to cracking environment in the crack growth module, this model could be simply adapted to address near-neutral cracking by specific changes in this module. Finally, because coalescence and growth by either SCC or stable tearing as currently incorporated do not reflect load history dependence, changes also could be required in this module.

Objective The objective is to generalize modules in SCCLPM that limit its utility in field applications, and extend it to address the apparent physics and electro-chemistry associated with low pH SCC.

Research Approach The success in formulating SCCLPM to deal with high pH SCC suggests use of a similar approach to modular modeling and related strategies with a focus on near-neutral cracking environments, and the extension of the existing modules to assess criticality of field-cracking as identified in bell-holes or ILI. This present model for high pH SCC will be generalized to incorporate the nucleation, growth, and coalescence of stress corrosion cracks, in a format applicable to assessing the stress- and time-dependent response of significant cracking found during in-service inspection. The new formulation will use the past approach, which has proven to be successful in developing the field-validated models for high pH SCC. Current algorithms that model situations where new cracks may initiate within a colony, and crack coalescence will be enhanced to embed stress-

history dependence, while capabilities to handle stress localization, as occurs along weld seams will be refined. The approach to address stress dependence and coalescence will continue use of numerical and phenomenological modeling, as this practice has been effective in dealing with these aspects in developing the model validated for simple laboratory stress histories. To the extent possible, the current growth module for high pH cracking will be redesigned to deal with low pH SCC. This redesign to address low pH SCC will utilize discriminating experiments to isolate and evaluate contributory factors, as this approach worked well in formulating the high pH model.

Proposed Research Key tasks needed to meet the committee’s objectives for a general model of SCC growth including near-neutral cracking involves six tasks to be completed over a two-year period, as follows: Task One – Update Algorithms to Incorporate Pressure (Stress) History This task will begin with a literature evaluation of the changing stress and inelastic strain fields that develop around a crack tip as a function of the normalized far-field stress. Thereafter, selected numerical analyses will be done to address crack configurations typical of those observed in field cracking. Finally, the crack nucleation, growth, and coalescence algorithms will be reformulated to permit input that characterizes the colony of significant cracking found in the field, and develop this cracking subject to the service history typical of the prior use of the pipeline. Task Two – Modify Algorithms to Incorporate Local Stress Raisers At present the evaluation of the localized stress-inelastic strain fields due to stress raisers, such as occurs along a weld toe, is limited to a “patch” applied to address this aspect. This task will begin with a literature evaluation of the change in severity in the stress and inelastic strain fields that occur around a crack tip as a function of local stress raisers, such as a long-seam weld. It is anticipated that selected numerical work will be needed to characterize changes in the local fields as a function of normalized far-field stress for typical weld profiles in line pipe. Thereafter, the current algorithms for stress-localization and environmental focusing will be generalized to facilitate evaluation of situations such as long seam tenting and weld reinforcement effects. Task Three – Modify Algorithms to Assess Severity of Existing Crack Colonies Current crack growth algorithms will be broadened to permit inputs that describe the significant cracking observed in the field, in addition to the present scope wherein such cracking is “nucleated” as a function of prior service history. This task also will generalize the decisionmaking associated with whether cracking occurs by SCC versus stable tearing, depending on the pressure history and current crack morphology. Task Four – Physics and Elector-Chemistry of SCC in Near-Neutral Environments This task begins enhancement of SCCLPM to address near-neutral cracking. The literature developed for the PRCI will be evaluated as will the general literature dealing with the physics and elector-chemistry of SCC of steel in environments comparable to near-neutral conditions.

Central to this is the evaluation of the HELP mechanism and other competing processes that might be postulated to control or contribute to near-neutral pH SCC. Task Five – Discriminating Experiments to Isolate Factors Controlling Near-Neutral SCC This task parallels a comparable effort made in developing SCCLPM for applications to high pH SCC, wherein simple experiments were done to provide go—no go insight into the key factors controlling SCC in that environment. The task will use the results of Task Four as the basis to design discriminating experiments involving mechanisms postulated to explain near-neutral pH SCC. The results of this task will be used to direct the outcome of this project. Task Six – Reporting A report will be prepared that presents the results of each of the tasks following completion of the technical tasks in Year Two. This report is expected to present a generalized model for SCC, including an understanding of the physics and electro-chemistry of near-neutral SCC, which lay the foundation for schemes to reduce unnecessary conservatism in setting re-inspection or rehydrotest intervals, or allow minor SCC to be left in place without immediate remedial action.

Cost, Schedule, and Reporting Completion of the above six tasks for the scope of parameters anticipated is estimated to require a two-year period of performance and a total budget of $250,000.00 split equally over the period of performance. Month after contract

2

4

6

8

10

12

14

16

18

20

22

24

Task One Task Two Task Three Task Four Task Five Task Six - Report Oral Reports

x

x

x

x

x

x

During the course of this research, Battelle will provide quarterly status reports and progress updates at meetings, as indicated in the table.

Expected Deliverables This project is expected to deliver a generalized model for SCC, including an understanding of the physics and electro-chemistry of near-neutral SCC. The model proposed will lay the foundation for schemes to reduce unnecessary conservatism in setting re-inspection or re-hydrotest intervals, or allow minor SCC to be left in place without immediate remedial

action. The final report will summarize the results and underlying methodology and approach taken to obtain results.

Project Organization and Management This project would be completed within Battelle’s Pipeline Technology Center. Battelle has current and recent projects with INGAA/GTI, PRCI, and the industry that involve SCC. This work is useful experience in regard to programs such as this. However, as it is more applications oriented, it does not directly impact the technology development agenda of the present project. The project manager and principal investigator for this effort will be Dr. Brian Leis, who will be assisted by Drs. Robert E. Kurth and Jeffery A. Colwell, and others on the Battelle technical staff including Mr. Thomas P. Forte. All members of this team have contributed to the formulation of SCCLPM and Battelle’s research into SCC. This team has more than 30 years of cumulative experience in this area. While Battelle has extensive experience in high pH SCC, it is possible that Battelle will retain sub-contractors. For example, to ensure that the field aspects for this second year reflect reality, Battelle plans to team with Marr and Associates, where the work will be managed by Mr. James (Jim) Marr. Dr. Leis has worked for hazardous liquids and natural gas transmission pipeline companies and the pipeline industry in the US and internationally in the field of SCC. Drs. Kurth and Colwell and Mr. Forte have ongoing interests into the causes and mitigation of SCC.

August 12, 2002 Via FEDERAL EXPRESS Proposal No. CP052649 Mr. Steve Foh PRCI 1700 South Mount Prospect Des Plaines, IL 60018 Re: Non-competitive Proposals Dear Steve: Enclosed is our proposal for Year Two of the project “SCC Acceptance Criteria”, which will complete PRCI Project PR-003-0046. This effort is offered under the master set of terms and conditions negotiated between PRCI and Battelle on June 30, 2000. Our receipt of authorization under these terms and conditions will allow us to proceed. This offer shall remain valid for a period of sixty (60) days from the date of this letter. If you have any technical questions, please call me at (614) 424-4421, or contact me via email at [email protected]. Questions of a contractual nature should be directed to Ms. LaDonna James, Contracts Department, at (614) 424-5543 or via email address: [email protected]. Sincerely,

Brian N. Leis Research Leader Pipeline Technology Center BNL/cw Enclosure

Christina L. Rotunda Contracting Officer

SCC Acceptance Criteria – Year Two Background When SCC is found, member companies must decide how to continue their pipeline operations without jeopardizing safety. As cost-effective, accurate methods for finding and sizing SCC develop, the number of colonies that must be addressed with regard to safe serviceability increases. This means that pipeline companies will be faced with rehabilitation choices ranging from grind and recoat, through use of a pressure-containing sleeve, and under some circumstances, a cut out. It follows that pipeline companies suffering even limited SCC need to identify rehabilitation options as a function of pipeline service and the nature of the cracking in that joint of pipe. To be practical, rehabilitation options need to be identified in a field setting, which means selecting options is best done in terms of a simple, easy to use, technically defensible, decision tree that could be used by field crews. To be economically viable, such options must recognize that the mere presence of SCC does not in many cases compromise the integrity of the line in the near term. Technically justified criteria that are simple enough to interpret in the field are needed to avoid incurring significant repair costs in situations where there will be no reduction in risk of failure. Much has already been done that contributes to the development of rehabilitation options as a function of pipeline service and the nature of the cracking in that joint of pipe. Criteria are required to determine cracking severity and near-term criticality. Objective Develop rehabilitation options for SCC in the form of a simple, easy to use, technically defensible, decision tree: The work plan to develop rehabilitation options as a function of pipeline service and the nature of the cracking in that joint of pipe involves five tasks. These tasks, which are specific to high pH SCC, include: •

Determine circumferential and axial crack spacings ranging from benign to critical, as a function of service pressure and actual (or specified) mechanical and toughness properties of the steel.

•

Establish field criteria in terms of nomographs and images of crack position to decide which colonies required what type of rehabilitation.

•

Identify field-proven grind and recoat practices, and other such actions.

•

Detail the field-proven repair practices, with independent validation where practical.

•

Report the results. Proposed Research

Year One of this project evaluated crack spacing and assessed apparent severity. This included determination of critical circumferential spacing and the formulation of a simple macro-based

assessment for crack coalescence, which addresses critical axial crack spacing. Year Two continues the development of this work plan. TASK ONE – CRITICAL CRACK SPACING (FOCUS OF YEAR ONE) The objective of this task is to determine circumferential and axial crack spacings for in-service conditions that range from benign to critical. This will be done for service pressures corresponding to 0.5, 0.6, 0.72, and 0.8 times the specified minimum yield stress (SMYS). These cases will be evaluated as a function of the specified or actual mechanical and toughness properties of the steel. This will be accomplished using analytical and experimental results to identify combinations of circumferential crack spacings that range from benign through potentially critical. For potentially critical circumferential crack spacings, the corresponding axial spacings needed to preclude the formation of critical crack lengths will be determined using PRCI-developed analyses methods as a function of the circumferential spacing and the specified or actual estimated mechanical and toughness properties of the steel. TASK 2 – DEVELOP FORMAT FOR FIELD CREWS The objective of this task is to establish simple measurement protocol to determine which colonies are benign versus those that are potentially critical and when they are expected to reach a critical state. This will be done using photographs or printed images of crack arrays that range from benign through critical that can be interpreted by field personnel with minimal engineering support. Factors such as differences in toughness or operating stress will be accounted for in terms of nomographs and selected photographs or images of crack arrays. Decisions as to which colonies require what type of rehabilitation will be based on consideration of the appearance of the colony and spacing of the cracks, the depth of the cracking based on in-the-ditch measurements, the operating pressure, and the permanence of the repair in a framework that could be used by field personnel with minimal engineering support TASK 3 -- FIELD-PROVEN PRACTICES The objective of this task is to identify field-proven practices for rehabilitation of SCC. Companies that routinely rehabilitate SCC will be contacted to compile current practices. These practices and the colonies they have been applied to will be compared with the results of Tasks 1 and 2 to assess the extent of inherent conservatism. TASK 4 -- DETAIL AND VALIDATE REPAIR PRACTICES The objective of this task is to document and validate field-proven repair practices, such as grind and recoat. During the company contacts that underlie Task 3, details on the implementation of field-proven practices for the rehabilitation of SCC will be gathered from companies that routinely rehabilitate SCC. Field-proven practices will be culled from the methods used by companies that experience significant SCC. Criteria used in this selection will include practical aspects and the requirement of long-term success. Such methods will be detailed and evidence of their viability presented in terms of company experience, or analysis when revealed.

TASK 5 – REPORT A report will be prepared that presents rehabilitation options as a function of pipeline service and the nature of the cracking in a joint of pipe, based on a simple easy to use, technically defensible criteria, most likely in the form of a decision tree. Cost, Schedule, and Reporting Completion of the above four tasks comprising Year Two for the scope of parameters anticipated is estimated to require a budget of $75,000.00. The work to meet the Year Two objectives can be completed within a one-year period after contract initiation. Month after contract

1

2

3

4

5

6

7

8

9

10

11

12

Task Two Task Three Task Four Task Five Oral Reports

x

x

x

During the course of this research, Battelle will provide quarterly status reports and progress updates at meetings, as indicated in the table. Based on the scope of this second year of work, a third year will be required to translate the results into simple design guidelines. In addition, selected full-scale testing should be considered. Deliverables The deliverable of this project when completed is an improved understanding of the applicability and reliability of field-proven rehabilitation and repair methods to facilitate cost-effective SCC management strategies based on a sound understanding of SCC significance, for individual cracks and colonies. This deliverable will be presented in a written report that presents the approach as well as the results of the project. Project Organization and Management This project would be completed within Battelle’s Pipeline Technology Center, working in conjunction Marr and Associates. The project manager and principal investigator for this effort will be Dr. Brian Leis, who will be assisted by Dr. Robert Kurth and Mr. Ron Galliher, and others in the Pipeline Technology Center at Battelle, which is organized to meet the needs of the energy pipeline industry. All facilities needed to complete this work are available at Battelle, which has a long history of involvement with research associated with fracture propagation. While Battelle has extensive experience in high pH SCC, to ensure that the field aspects for this

second year reflect reality, Battelle will team with Marr and Associates, where the work will be managed by Mr. James (Jim) Marr. Battelle has current and recent projects with INGAA/GTI, PRCI, and private gas and liquids pipeline companies that involve SCC, although none of this work is directed at the specific objective of this project. Marr and Associates have a long-term international reputation for field services and related support capabilities in regard to SCC detection and rehabilitation. Marr and Associates will work as a sub-contractor to Battelle.

August 2002

SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328)

Confidential

Prepared for: Steve Foh Pipeline Research Council International, Inc. c/o Gas Technology Institute 1700 South Mount Prospect Road Des Plaines Illinois 60018-1804

Prepared by: Mark McQueen (& Steve Matthews) Advantica Technologies Inc. 5177 Richmond Avenue Suite 900 Houston TX 77056 USA Tel: Fax: Email: Website:

Ⓒ 2002 Advantica Technologies Inc. CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

Page 1

713 586 7000 713 586 0604 [email protected] www.advanticatechinc.com

PROPOSAL SUMMARY Proposal:

RPTG 0328

Title: FACTORS INFLUENCING THE RELATIVE SCC SUSCEPTIBLITY OF LINE PIPE. Contractors: Advantica Technologies Inc with EPRG consortium (Advantica, CSM and Corus) working under sub-contract. Type: New. Period: Start date January 2003, duration 24 months. Total estimated cost: US$100,000. Objective: To extend the understanding of the factors controlling low pH SCC initiation, by subjecting a representative range of North American line pipe steels to standardised tests. Incentive: Recent studies by EPRG have enabled the development of standardized procedures for assessing the resistance of line pipe steels to low pH SCC initiation. By applying these procedures to a range of steels from North America, thereby broadening the overall database of information, the key factors determining resistance to SCC will be better understood. Work Plan: TASK 1 – Experimental testing. TASK 2 – Post-test examination TASK 3 – Comparison with other data, reporting Deliverables: Reports documenting • Qualitative assessment and ranking resistance of a typical North American line pipe to low pH SCC initiation. • Comparison with similar results from European line pipe steels.

CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

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TABLE OF CONTENTS PART I TECHNICAL PROPOSAL 1 2

INTRODUCTION & SUMMARY ......................................................................... 5 TECHNICAL DISCUSSION ................................................................................ 5 2.1 objectives ................................................................................................... 5 2.2 scope of work............................................................................................. 6 2.2.1 Test environment .................................................................................. 6 2.2.2 Crack initiation tests.............................................................................. 6 2.2.3 crack propagation tests......................................................................... 6 2.2.4 Reference tests..................................................................................... 7 2.2.5 Test Monitoring ..................................................................................... 7 2.2.6 specimen evaluation ............................................................................. 7 2.2.6.1 Crack Initiation Specimens ............................................................... 7 2.2.6.2 Crack Propagation Specimens ......................................................... 8 2.3 deliverables ................................................................................................ 8 2.4 Schedule ..................................................................................................... 9 3 ADVANTICA INFORMATION........................................................................... 10 PART II COST PROPOSAL

1 2

COSTS ............................................................................................................. 12 COMMERCIAL TERMS.................................................................................... 15

Confidentiality Statement THE INFORMATION CONTAINED IN THIS PROPOSAL IS PROVIDED ON A COMMERCIAL BASIS IN CONFIDENCE AND IS THE PROPERTY OF ADVANTICA TECHNOLOGIES INC. IT MUST NOT BE DISCLOSED TO ANY THIRD PARTY, IS COPYRIGHT, AND MAY NOT BE REPRODUCED IN WHOLE OR IN PART BY ANY MEANS WITHOUT THE APPROVAL IN WRITING OF ADVANTICA TECHNOLOGIES INC.

CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

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PART I TECHNICAL PROPOSAL

1 INTRODUCTION & SUMMARY The issue of low pH SCC is a concern for many pipeline operators in North America and elsewhere. The integrity management of pipelines that are known or suspected to be at risk from SCC requires a quantitative understanding of the time-dependence of crack initiation and growth. This information is essential for reliable assessment of any defects found by inspection during service, and for setting appropriate intervals between re-inspection or re-hydrotesting. While many of the factors determining the extent of low pH SCC found in in-service pipelines are related to operational conditions and the external environment (including cathodic protection and coating quality), the influence of pipe materials and surface conditions has been harder to determine. Recent work conducted by EPRG has indicated that the initiation and early growth of low pH SCC is influenced by the pipe metallurgy; some steels are significantly more resistant than others. In terms of crack initiation, some metallurgical factors (steel microstructure and chemical composition) have been found to play an important role, but there is a need to extend the comparison of crack initiation susceptibility to other line pipe materials and microstructures. In terms of crack propagation, however, the EPRG research has indicated that the rates of crack growth are broadly independent of factors influencing crack initiation. Crack propagation rates and crack morphologies are dominated by the mechanical loading parameters (i.e. average pressure and pressure fluctuations). As a result of this work, standardised procedures have been established for the investigation of low pH SCC crack initiation and propagation; crack initiation using unflattened tensile test pieces subjected to slow cyclic tensile loading, and crack propagation using compact tension (CT) test pieces subjected to similar loading cycles. In particular, the cyclic loading of tensile test specimens has been shown to be suitable for qualitative assessment and ranking of different steels to determine their relative susceptibility to low pH SCC. This program aims to increase the understanding of the metallurgical factors controlling low pH SCC initiation, and their influence on crack propagation by applying these standardised test methodologies to a representative range of North American line pipe steel.

2 TECHNICAL DISCUSSION 2.1

OBJECTIVES

Several aspects of low-pH SCC initiation and growth have been the subject of previous PRCIfunded projects. Despite this work, however, the relative SCC susceptibility of different pipeline steels has not been well documented. Recent EPRG-funded work has identified ways in which this issue can now be addressed. Although the EPRG program has been extended to evaluate a wider range of materials, the testing is inherently slow and limited in extent. The objective of this program is to extend and enlarge this pool of data by conducting a parallel series of tests, using exactly the same laboratory conditions as those used by EPRG, on materials sourced from North America.

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2.2

SCOPE OF WORK

The research program has been formulated based on the assumption that four suitable line pipe materials will be made available for testing, together with materials test certificates detailing mechanical properties (i.e. transverse and longitudinal yield and ultimate tensile strength) and chemical composition. The program costs assume that the line pipe sections required for this project will be supplied free-of-charge. Selection of the test materials will be finalised in conjunction with PRCI Committee Members. The program is designed to evaluate low pH SCC initiation and early crack growth using standardised testing methodologies, under consistent, simulated field conditions and a fixed test duration. 2.2.1 TEST ENVIRONMENT All tests will be carried out at ambient temperature with the specimen mounted in an air tight, sealed chamber containing NS4 solution (classically adopted as representative of the solution found in low pH SCC field studies. The solution will be pre-saturated at atmospheric pressure with a gas mixture of 90% N2 and 10% CO2. Testing will be carried out at the free corrosion potential of the steel in NS4 solution for a duration of 90 days. All cyclic loading will be on the basis of a “sawtooth” cycle, with a 120 minute loading period and a 12 minute unloading period. 2.2.2 CRACK INITIATION TESTS Test specimens will be removed from the pipe longitudinal axis and machined according to a modified (reduced thickness) ASTM E 8M specification for pin-loaded test specimens of 50 mm gauge length. The original uncoated (or coating-free surface) of the pipe material will be preserved. All other machined surfaces will be coated to ensure that only the original pipe surface is in contact with the NS4 solution. Cyclic loading will be between 70% and 90% of the actual (measured) longitudinal yield strength of the pipe material. •

2 tests per pipe material

2.2.3 CRACK PROPAGATION TESTS Test specimens will be reduced thickness Compact Tension (CT) samples, based on ASTM E647 and prepared in the T-L orientation as defined in ASTM E399. All specimens will be fatigue pre-cracked to provide an overall crack depth of 14 mm. Cyclic loading with use a constant R value (Kmin/Kmax) of 0.78 with KImax selected above the likely threshold for low pH SCC (and inferred from previous EPRG test results). •

1 test per pipe material

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2.2.4 REFERENCE TESTS Reference tests will be carried out on identical test specimens to those used in the crack initiation and crack propagation studies. Two types of reference test will be carried out for each material included in the investigation: 1. Crack Initiation Reference – to be tested under identical environmental conditions with no applied stress. • 1 test per pipe material. 2. Crack Propagation Reference – to be tested under cyclic conditions in laboratory air environment. These will be undertaken at a frequency of 0.1 Hz for 50000 cycles. Details of the laboratory environment (i.e. ambient temperature and humidity) will be recorded throughout the test. • 1 test per pipe material 2.2.5 TEST MONITORING The following parameters will be monitored throughout the tests (excluding the control crack propagation tests): • • •

Specimen electrochemical potential – weekly Solution pH – fortnightly Solution conductivity – fortnightly

N.B. Previous experience from EPRG test programs suggests that the amount of crack growth is likely to be beyond the resolution of convential crack growth measurement technology (e.g. clip gauges). It should therefore be recognised that the requirements of ASTM E647 cannot be met. In the case of the crack propagation tests, reliance is placed on the post-test examination of specimens to accurately determine the extent of crack growth. 2.2.6 SPECIMEN EVALUATION 2.2.6.1

Crack Initiation Specimens

The main assessment tool for evidence of crack initiation will be metallographic examination. Following exposure of cyclic loaded and reference specimens, the complete gauge length of will be longitudinally sectioned through the mid-point of the specimen. The sections will then be polished and etched according to standard metallographic procedures. The exposed pipe surface will be examined to determine the morphology and depth of surface features along the gauge length. To determine the probability of low pH SCC crack initiation, the features found on the surface of cyclic loaded specimens will be compared to sections through the reference test specimens and as-received pipe material.

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2.2.6.2

Crack Propagation Specimens

To precisely distinguish the pre-crack, developed during the air pre-cracking phase from the crack growth generated during immersion in NS4 (and the fracture surface following mechanical rupture of the test specimen*), CT specimens will be submitted to the following heat-tinting procedure: •

Immersion of specimens in an acetone bath with ultrasonic treatment for 30 minutes

•

Heat treatment in electric muffle furnace, in air, at 350oC for 1 hour followed by air cooling

* - The mechanical rupture of CT specimens will be carried out using a tensile machine, after immersion into liquid nitrogen

2.3

DELIVERABLES

The results of this program will be collated into a final report, which it is proposed will include (subject to agreement between EPRG and PRCI), a comparison of the data from previous EPRG test programs. This would considerably enhance the value of both EPRG and PRCI research programs, and increase our understanding of the metallurgical factors controlling low pH SCC crack initiation. This research program will provide an increased understanding of the metallurgical parameters influencing the initiation and early growth of low pH SCC, and hence enable improved management of SCC risks in existing pipelines, and better selection of materials for new pipeline construction. The key deliverables from this programme will be as follows: • • •

Standardised and repeatable methodologies for the investigation of low pH crack initiation and propagation. Qualitative assessment and ranking of typical North American line pipe materials to low pH SCC crack initiation Comparative data on the resistance to low pH SCC of typical North American and European line pipe materials.

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2.4

SCHEDULE

The work will be undertaken by Advantica over a 21 month period. A summary of the main tasks of the project and their duration, assuming work commences in Q1 of 2003, is detailed below. Effort requirements are also provide for each task.

PHASE 1

2003 Q1

Q2

2004 Q3

Q4

Q1

Specimen Preparation 0.4 man.mths

Testing

2

5 man.mths

2a

See below

2b

See below

2c

See below

2d

See below

3

Final Report 0.75 man.mths

Phase 1 – Specimen Preparation Duration – Year 1: months 1 to 3 • Delivery of pipe lengths • Handling and storage of pipe lengths • Flame cutting of pipe sections for test specimen stock • Machining of test specimens • Delivery of test specimens Phase 2a – Testing Duration – Year 1: months 4 to 7 • Crack initiation and reference tests: steel No.1 Phase 2b – Testing Duration – Year 1: months 7 to 10 • Crack initiation and reference tests: steel No.2 Phase 2c – Testing Duration – Year 1: months 10 to Year 2: month 2 • Crack initiation and reference tests: steel No.3 CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

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Q2

Q3

Q4

•

Crack propagation & reference tests: steel Nos.1 and 2

Phase 2d – Testing Duration – Year 2: months 3 to 7 • Crack initiation and reference tests: steel No.4 • Crack propagation & reference tests: steel Nos.3 and 4 Phase 3 – Final Report Duration – Year 2: months 8 to 9 • Preparation of Final Report

3 ADVANTICA INFORMATION Advantica is part of the Lattice Group, the UK-based infrastructure technology group that includes the gas pipeline operator Transco, and is a leading supplier of innovative technologies and technical services to the global energy marketplace. Advantica's aim is to be a leading improver of business and operating performance for customers in gas, pipelines and associated industries internationally. Advantica has its origins in the British Gas (BG) group of companies and is now a $100 million business with over 800 skilled staff and centers in Houston, Charlotte and the UK. Advantica has fully equipped in-house facilities to undertake a wide variety of experimental testing programs. These are complemented by a comprehensive suite of state-of-the-art numerical computing and finite element analysis facilities. Advantica is a long established technology supplier to the PRCI member companies and has a substantial track record in the management and execution of major Joint Industry Projects for groups of international gas and oil operators. Advantica has a long history of involvement in line pipe stress corrosion cracking (SCC) research having carried out extensive investigations of the controlling factors and remedies for carbonate-bicarbonate (high-pH) SCC and more recent involvement will all phases of the EPRG low pH SCC program since 1996. Dr Steve Matthews represents Advantica/Transco’s interests on the EPRG Corrosion Technical Committee, through which the EPRG program is managed.

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PART II COST PROPOSAL

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1 COSTS The work described in this proposal will be undertaken on a fixed cost basis. The fixed cost is $100,000 (one hundred thousand US dollars). The total cost is inclusive of labor, computing, consumables, overheads, project management. An allowance for two technical presentations to the Committee has also been included. A cost breakdown of the overall project is summarized in Table 1, with the subcontracted effort requirements detailed in Table 2.

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CONTRACT COST ESTIMATE Name of Offeror Advantica Technologies Inc. Home Office Address 5177 Richmond Avenue, Suite 900 Houston TX 77056

RFP No/Prp No Page Number Number of Pages RPTG-0328 1 2 Name of Proposed Project Factors Influencing the relative SCC Susceptibility of Line Pipe

Division(s) and Location(s) (where work is being performed) Advantica Technology, Spadeadam Test Facility, UK

Total Amount of Proposal $100,000 Estimated Cost (dollars)

Cost Elements 1.

Direct Material a. Purchased Parts b. Interdivisional Effort

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

1,700

c. Equipment Rental/Lease d. Other

600

Total Direct Material 2. 3.

Material Overhead (Rate

2300 % x Base $

)

Subcontracted Effort (Attach Detailed Schedule)

26,046

See Table 2

Subcontractor Cofunding (Footnote D) Net Subcontracted Effort 4.

Est. Hours

Rate/Hour

Manager/Consultant

Direct Labor - Specify

45

195

Est. Cost 8,775

Senior Engineer

218

143

31,174

Engineer

59

109

6,431

Technician

250

69

17,250

O.H. Rate

X Base $

Est. Cost

Total Direct Labor 5.

Labor Overhead - Specify

62083

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

10. Other Direct Costs

2,424

Based on attendance at two project review meetings

5,600

Specimen Machining

11. Total Direct Cost and Overhead 12. General and Administrative Expenses (w/o IR&D) Rate

% of cost element numbers

13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost (Footnote C)

100,076

15. Fixed Fee 16. Total Estimated Cost and Fee

100,029

17. Contractor/Third Party Cofunding (Footnote D) 18. Net PRCI Estimated Cost and Fee

100,076

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title Signature Date Dr Steve Matthews

Table 1 Contract Cost Estimate CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

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CONTRACT COST ESTIMATE (SUBCONTRACTED EFFORT REQUIREMENTS) Name of Offeror Advantica Technologies Inc. Home Office Address 5177 Richmond Avenue, Suite 900 Houston TX 77056

RFP No/Prp No Page Number Number of Pages RPTG-0328 2 2 Name of Proposed Project Factors Influencing the relative SCC Susceptibility of Line Pipe – Subcontracted Effort

Division(s) and Location(s) (where work is being performed) EPRG Contractor Laboratories, UK & Italy

Total Amount of Proposal $26,046 Estimated Cost (dollars)

Cost Elements 1.

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

26,046

CT Crack Propagation Tests

Direct Material a. Purchased Parts b. Interdivisional Effort c. Equipment Rental/Lease d. Other Total Direct Material

2.

Material Overhead (Rate

3.

Subcontracted Effort (Attach Detailed Schedule)

% x Base $

)

Subcontractor Cofunding (Footnote D) Net Subcontracted Effort 4.

Direct Labor - Specify

Est. Hours

Rate/Hour

Est. Cost

Manager/Consultant

10

195

1,950

Senior Engineer

72

143

10,296

Engineer

109

Technician

200

69

13,800

Total Direct Labor 5.

Labor Overhead - Specify

26,046 O.H. Rate

X Base $

Est. Cost

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

10. Other Direct Costs 11. Total Direct Cost and Overhead 12. General and Administrative Expenses (w/o IR&D) Rate

% of cost element numbers

13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost (Footnote C)

26,046

15. Fixed Fee 16. Total Estimated Cost and Fee

26,046

17. Contractor/Third Party Cofunding (Footnote D) 18. Net PRCI Estimated Cost and Fee

26,046

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title Signature Date Dr Steve Matthews 2 August 2002

Table 2 Contract Cost Estimate – Subcontracted Effort Requirements CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

Page 14

2 COMMERCIAL TERMS Terms and conditions for undertaking the proposed work will be consistent with those previously agreed between Advantica Technology Inc. and GTI.

CONFIDENTIAL SCC INITIATION SUSCEPTABILITY RANKING/SCREENING (RPTG-0328) August 2002 Rev 0

Page 15

August 12, 2002 Via FEDERAL EXPRESS Proposal No. CP052723 Mr. Steve Foh PRCI 1700 South Mount Prospect Des Plaines, IL 60018 Re: Proposal for Effect of Operating Practice on SCC Crack Growth Dear Steve: Enclosed is our proposal for the project “Effect of Operating Practice on SCC Crack Growth,” which is PRCI RPTG-0327. This effort is offered under the master set of terms and conditions negotiated between PRCI and Battelle on June 30, 2000. Our receipt of authorization under these terms and conditions will allow us to proceed. This offer shall remain valid for a period of sixty (60) days from the date of this letter. If you have any technical questions, please call me at (614) 424-4421, or contact me via email at [email protected]. Questions of a contractual nature should be directed to Ms. LaDonna James, Contracts Department, at (614) 424-5543 or via email address: [email protected]. Sincerely,

Brian N. Leis Research Leader Pipeline Technology Center BNL/cw Enclosure

Christina L. Rotunda Contracting Officer

Effect of Operating Practice on SCC Crack Growth: RPTG-0327 Background The susceptibility of pipelines prone to SCC is determined by complex interactions between the mechanical, chemical and electrochemical factors that influence the SCC process. While prior experience could help operators plan when control of SCC is implemented, most operators now are subject to other drivers, such as those affected by FERC Order 636 in the US. The frequent and significant pressure and thermal cycles more common in today’s gas pipeline operation can complicate use of past incident and hydrotest experience in SCC management. In turn, this complicates planning maintenance for such lines and establishing a viable plan to return to service in the unlikely event of an incident. The factors influencing SCC nucleation and growth rates have been the subject of many laboratory-based studies, for high pH and low pH crack growth mechanisms. These studies highlight the important role of stress fluctuations in maintaining ‘active’ crack growth, and the tie between large load changes and step changes in growth rate (acceleration or dormancy). Unfortunately, there is no simple way to quantify the tie between laboratory testing conditions and pipeline operation, particularly in regard to factors that influence environmental aggressiveness and line-pipe susceptibility.

Objective The objective is to determine the influences of pipeline operating parameters (pressure, load fluctuations and transients, temperature extremes, etc.) on SCC growth rate and dormancy in a format that will permit generalization to a wide range of pipelines.

Approach There are two keys to meeting the objective. The first is a model that replicates field trends in cracking characteristics (length, depth, aspect ratio, cracking frequency), recreates the effects of loading (dormancy, acceleration), and reflects typical average cracking speeds over the life of a pipeline. The second is SCC field experience via hydrotest or in-service cracking data representing typical prior service over the interval such data were developed. These data are critical as they serve to “calibrate” the model, to make it specific to the pipeline steel susceptibility and right-of-way (RoW) aggressiveness.

Proposed Work The work scope based on this approach involves two major technical tasks, in addition to a reporting task, as follows:

Task One – Recast SCCLPM for User Calibration The objective of this task is to reformulate SCCLPM to permit users to calibrate the model to reflect the pipeline of interest. This involves changes to the input module as well as changes to algorithms that comprise the crack nucleation and crack growth modules. Finally, a module must be developed to process user inputs and permit the user to calibrate SCCLPM consistent with the changes to these modules, which is done as part of Task Two.

Task Two – Develop a User Calibration Module for SCCLPM The objective of this task is to develop a module for SCCLPM that will help the user identify what data are needed to calibrate SCCPLM based on prior historical use of the pipeline. This is a significant task as it requires creation of a graphical user interface and supporting help screens, along with the algorithm to determine the inherent susceptibility of a given pipeline steel subject to the aggressiveness of its RoW. This algorithm will develop the sensitivity of cracking response to loading and related thermal factors. Inputs will require knowledge of typical prior operating histories, as well as prior service experience in terms of incidents, rehabilitation, and so on. This algorithm will express pipeline-specific susceptibility data in a normalized format that is recognized by SCCLPM and serves as a calibration factor. Once calibrated, the reformatted version of SCCLPM will facilitate analysis of future operation relative to prior experience. With this approach, there is no need to explicitly incorporate pipeline-specific interactions between the mechanical, chemical and electrochemical factors influencing the SCC process, as these are implicit in this calibration.

Task Three – Reporting This task develops a written report presenting the approach relating operating parameters to SCC response for high pH cracking. The report will also present an updated version of SCCLPM that includes an algorithm to make it specific to SCC susceptibility through a calibration based on prior SCC experience, the related operational history in the form of typical discharge pressure and temperature, and the distance from the station where prior SCC was experienced. Because of budget limitations, this model will retain the current look and feel of the input and output, although it will be restructured to run under a Windows environment and include a graphical interface to deal with the calibration aspects. The existing users manual will be updated as part of this report to address only the changes made under this project.

Deliverable This project will lead to a written report and updated version of SCCLPM that will facilitate developing pipeline-specific operational strategies to minimize the risk of SCC.

Cost, Schedule, and Reporting Completion of the above three tasks for the work scope outlined is estimated to require a budget of $75,000.00. The work can be completed within a one-year period after contract initiation.

During the course of this research, Battelle will provide quarterly status reports and progress updates at meetings, as indicated in the table. Month after contract

1

2

3

4

5

6

7

8

9

10

11

12

Task One Task Two Task Three Oral Reports

x

x

x

Project Organization and Management This project will be managed within the Pipeline Technology Center at Battelle, which is organized to meet the needs of the energy pipeline industry. All facilities needed to complete this work are available at Battelle, which has a long history of involvement with research associated with fracture propagation. Battelle has current and recent projects with INGAA/GTI and PRCI that involve SCC and has used the suggested approach in work for companies in the US and abroad. Dr. Leis has worked for hazardous liquids and natural gas transmission pipeline companies and the pipeline industry in the US and Internationally. The project manager and principal investigator for this effort will be Dr. Brian Leis, who will be assisted by Dr. Robert Kurth and Mr. Thomas Forte. Dr. Kurth and Mr. Forte have supported work on SCC at Battelle over the last 10 years.

Proposal on Effects of Operating Practice on SCC Crack Growth (Materials Program)

Prepared for the Pipeline Materials Committee of Pipeline Research Council International

August 2002 Submitted by CANMET-Materials Technology Laboratory Natural Resources Canada 568 Booth St. Ottawa, Ontario, Canada

Technical Contacts Dr. William R. Tyson, Group Leader Joining and Structural Integrity Phone: (613) 992-9573 Fax: (613) 992-8735 e-mail: [email protected]

Wenyue Zheng Ph.D., Project Leader-SCC Joining and Structural Integrity Phone: (613) 992-7904 Fax: (613) 992-8735 e-mail: [email protected]

i

TABLE OF CONTENTS

PART 1 - TECHNICAL PROPOSAL

1

INTRODUCTION AND SUMMARY

1

TECHNICAL DISCUSSION

1

OBJECTIVE

1

STATEMENT OF THE PROBLEM

1

BACKGROUND

2

EXPECTED BENEFITS

2

TECHNICAL WORK PLAN

3

Task 1. Review of Existing SCC Data – Correlation of Crack Growth Rates with

3

the Deformation Rate Task 2. Laboratory Validation

3

Deliverables

4

REFERENCES

4

ORGANIZATION INFORMATION

4

MANAGEMENT AND PROJECT TEAM

5

PROJECT SCHEDULE GANTT CHART

6

PART II – COST PROPOSAL

7

TASK AND COST BREAKDOWN

7

PRCI CONTRACT COST ESTIMATE FORM

8

SCHEDULES TO COST ESTIMATE

9

1

PART1 – TECHNICAL PROPOSAL INTRODUCTION AND SUMMARY Oil and gas pipelines are known to be susceptible to stress corrosion cracking in both high and low pH (Near-Neutral pH) environments. Recent evidence suggests that cracks can become ‘dormant’ or inactive after some amount of active growth. On some of the well-examined fracture surfaces, these growth-dormancy-growth transitions are indicated by periodic crack arrest markings [1]. Laboratory studies in this area, using both full-scale pipes and small SCC samples, have shown strong effects of stress fluctuation on crack growth rates as well as on crack initiation [2,3]. It is likely that under normal operating conditions in which the nominal stress at the pipe surface is below the yield point of the steel, the dynamic loading associated with fluctuating stress provides the necessary crack tip strain rate for crack development. The deformation rate of line pipe steel is greatly enhanced by the presence of a cyclic loading component superimposed onto a static load. Under special circumstances, such as in the cases where ground movement (landslide) has caused a substantial amount of loading on the pipe, the net total stress at the pipe surface can exceed the yield point of the material. In this case, instantaneous deformation of the line pipe steel can occur at sufficiently high rate for crack growth. It is well possible that subsequent exhaustion of this creep process leads to a gradual slowing down and eventual arresting of the cracking. In the literature of stress corrosion cracking in many metal/environment systems, the term ‘threshold strain rate’ is often used to describe the critical loading condition that is essential for crack growth/initiation. For line pipe steels in both high pH and low-pH environments, the occurrence of cracking indicates that the operating load conditions in combination with any secondary load are within this critical range. Avoidance of this range can no doubt lead to prolonged service life and improvement of pipeline reliability. Research in fracture mechanics over the past few decades has shown that the crack tip deformation process is governed by the overall crack driving force, often expressed as the J-integral, and the inherent resistance of the material to plastic deformation. Therefore, for a given operating system this critical operating condition would be different for line pipe steels of inherently different properties. As higher grades of steels are used in new pipeline construction, knowledge of whether these new steels perform differently in an SCC environment is of significant value. TECHNICAL DISCUSSION OBJECTIVE: To establish a correlation model that relates the crack growth rate in low-pH or in high-pH environments to the deformation rate, especially the crack tip deformation rate, of the line pipe steel. The ultimate goal of this work is to define the critical loading conditions necessary for SCC to develop so that operating practices can be assessed for the purpose of eventual avoidance of SCC. STATEMENT OF THE PROBLEM Recent lab studies, using both full-scale pipes and small test samples, have shown the effects of various loading parameters such as R, stress level and ∆K on active crack growth. However, loading

2

conditions that cause a dormant crack to re-initiate have not been established. The primary problem in applying data from tests using conventional small specimens such as the CT-type specimen or smooth tensile samples is that the test conditions cannot be readily compared with field operating conditions. In addition, the stress state in a CT specimen and tensile bar is different from that of a crack in a long pipe. The electrochemical effect is also likely different in the sense that the ratio of active crack area to the flat surface in a real pipe is very small; thus, the severity of mechanical loading required to generate cracking may be different from a precracked compact-tension or smooth tensile specimen. BACKGROUND It is known that the cracks on pipelines can become “inactive” after some amount of active growth. In a study of the SCC fracture surface produced by a landslide-induced environmentally assisted failure [1], distinct crack arrest markings were found that indicate the growth-dormancy-growth transitions during the propagation process of the main flaw. In a subsequent review of other SCC failures resulting from axial cracking, such markings on the fracture surface were found to be generally present. As the cracking in both high-pH and low-pH environments is affected by the strain rate of the line pipe steel at the crack tip, it is very likely that the transition between “active” and “inactive” states is related to the changes in the strain (deformation) rate at the crack tip. For a crack in a pipe subject to fluctuating load, the deformation process at the crack tip can be modeled using finite element analysis. The overall crack tip strain rate is governed by the operating conditions (stress level, amplitude of stress fluctuation, etc.) and the material properties such as yield strength and strainhardening coefficient. When the net stress is close to or above the yield point of the steel, deformation by creep can also generate a strain rate in excess of 10-6s-1, sufficient for crack re-initiation. This parameter, the deformation rate at the crack tip, is proposed to be the critical loading parameter for the various types of test specimens and cracked pipelines; it can thus be used as a way of bridging the gap between lab data and field conditions. Over the last several decades, a large amount of research work has been conducted on SCC in high-pH conditions. More recently, SCC data for the cracking in low-pH environments have been published in journals and by research organizations such as PRCI and GTI. In this proposal, we plan perform a thorough state-of-the-art literature review on all the relevant data on pipeline SCC. Effort will be made to correlate the reported crack growth rates with loading conditions for the various types of specimen used. The focus of the this first phase will be on establishing a quantitative model that describes the crack growth rates in terms of the crack tip deformation rate of the respective line pipe materials. In a second stage, laboratory testing will be performed to validate and refine this quantitative model. EXPECTED BENEFITS: 1. An advanced understanding of the conditions leading to cracking and dormancy would facilitate prioritization of the SCC-related maintenance programs for SCC-affected pipelines, thus avoiding unexpected occurrence of SCC failures. 2. Knowing the operating conditions, the level of secondary loading and materials properties, pipeline operator can assess the SCC susceptibility of their system using a quantitative model that relates the general crack growth rates with the crack tip deformation rates. The industry can

3

reduce the maintenance-related down time and reduce the costs of in-line inspection and/or hydrotesting, which are very costly to perform. This model can also be used for service life-time prediction and help pipeline companies in their long-term planning. 3. A quantitative descriptive model that defines the threshold loading conditions for crack reinitiation and propagation would enhance the confidence of pipeline operators in their integrity management practices. 4. Cost savings from the above benefits. TECHNICAL WORK PLAN: Task 1. Review of existing SCC data - correlation of crack growth rates with the deformation rate In this task, existing SCC data from field inspection programs and laboratory research projects will be collected and reviewed. The line pipe steels used, the configuration of the test specimens used and the details of mechanical loading applied will be recorded and evaluated. In the cases where the crack developed from an initially smooth surface, the loading rate used, or the likely strain rate calculated from relevant test data such as the cross-head displacement rates, will be taken as the Base Parameter. In the case where the test specimens contained pre-notch or precracks, the Base Parameter will be the crack-tip opening rate. In many cases, this parameter is not directly available from the reported data as the test loading conditions are usually described by the stress intensity factor, K or ∆K. However, crack tip opening displacement (CTOD) values can be obtained from K or J and the material properties. All CANMET test specimens from past projects are still available and can be used to produce tensile samples for generating the required material properties. A good portion of test data has been generated for the TCPL system (both the former TCPL and the NOVA Gas Transmission segments) and CANMET has access to most of the representative grades of line pipes. Some of the key research labs generating useful data in this area include Waterloo University, Univ. of Alberta, NOVA Chemical Research, CC Technology, Batelle and University of Newcastle upon Tyne. CANMET MTL has collaborated with these organizations for various projects and they will be contacted for data-sharing in the course of this program. The severity of the chemical conditions used will also be recorded and reviewed. The expected outcome of this task is a quantitative model that defines the relation between the crack growth rate and the deformation rate of the line pipe steel. Task 2. Laboratory validation This task is optional. CANMET recommends that this work be done in order to validate the model developed in Task 1. In this task, short pipe sections in the form of pipe sleeves containing multiple pre-cracks, in isolation and within interaction range, will be prepared and installed on long “carrier” pipes. Test cells containing the high-pH solution (the carbonate-bicarbonate solution) or the low-pH solution (the near-neutral-pH solution) will be fixed on top of the test sleeve. By adjusting the preload level in the sleeve and by controlling the load spectrum of the carrier pipe, load level in the test sleeve can be accurately controlled to produce various predefined pressure-time waveforms.

4

A range of loading conditions can be used in the tests to validate the model developed in Task 1. By growing cracks at very slow rates, the threshold loading condition for crack re-initiation can be deduced from the test data. Because pipe sleeves are used instead of full-scale pipe, the overall test time can be much shortened. This task will take place in the second year of this program. Deliverables: The results of Task 1 will be collected into a final report for Task 1. This report will contain a quantitative model that relates general crack growth rates with deformation rates at the crack tip. If Task 2 is requested by PRCI, a second report will be prepared following the completion of Task 2. This report will contain a validation of the model developed in Task 1. REFERENCES: 1.

W. Zheng, R. Sutherby, R. W. Revie, W. R. Tyson and G. Shen, “Stress Corrosion Cracking of Linepipe Steels in Near-Neutral pH Environment: a Review of the Effects of Stress,” in Environmentally Assisted Cracking: Predictive Methods for Risk Assessment and Evaluation of Materials, Equipment, and Structures, ASTM STP 1401 2. Wang, Y.-Z., Revie, R. W., Shehata, M. T., Parkins, R. N., and Krist, K., Initiation of Environment Induced Cracking in Pipeline Steel: Microstructural Correlation, International Pipeline Conference, Calgary, Vol. 1, ASME, New York, 1998, pp. 529-542.

3. Zheng, W., MacLeod, F. A., Revie, R.W., Tyson, W. R., Shen, G., Shehata, M., Roy, G., Kiff, D., and McKinnon, J., Growth of Stress Corrosion Cracks in Pipelines in Near-Neutral pH Environment: The CANMET Full-Scale Tests - Final Report to the CANMET/Industry Consortium, CANMET/MTL, Ottawa, MTL 97-48(CF), 1997.

ORGANIZATION INFORMATION The proposed PRCI project will be carried out in collaboration with PRCI member companies. The CANMET Materials Technology Laboratory (MTL), Canada’s premier metallurgical laboratory, is part of the research and technology development arm of Natural Resources Canada. MTL is the largest research facility in Canada dedicated to metals and other materials. MTL uniquely offers startto-finish capacities encompassing material selection, product design, fabrication and characterization. In over 30 years of research on infrastructure reliability, MTL has addressed metallurgical, mechanical, joining, corrosion and inspection technologies in integrity assessment for pipelines, marine and offshore structures, pressure vessels and power generation plants. MTL is closely involved in management of stress corrosion cracking in pipelines. It administers several research consortia sponsored by the pipeline industry.

5

MANAGEMENT AND PROJECT TEAM Dr. Wenyue Zheng will be the Project Leader, and will perform most of the data collection and review, as well as preparation of the final report. The CANMET Materials Technology Laboratory has a matrix management structure. Dr. Winston Revie, Program Manager, Infrastructure Reliability, will provide overall guidance and direction to the project leader. Dr. William Tyson, Group Leader, Joining and Structural Integrity, will make available to the project leader the resources needed to perform the project. Dr. Gwowu Shen will perform the calculations of mechanical driving force.

Dr. Wenyue Zheng Project Leader Phone: (613) 992-7904 Fax: (613) 992-8735 e-mail: [email protected]

Dr. William R. Tyson Group Leader, Joining & Structural Integrity Phone: (613) 992-9573 Fax: (613) 992-8735 e-mail: [email protected]

Dr. R. Winston Revie Program Manager, Infrastructure Reliability Phone: (613) 992-1703 Fax: (613) 992-8735 e-mail: [email protected]

Dr. G. Shen Research Scientist Phone: (613) 996-4367 Fax: (613) 992-8735 e-mail: [email protected]

Business Contact: Mr. Alan Bowles Manager Business Communication Phone: (613) 995-8814 Fax: (613) 992-8735 e-mail: [email protected]

6

PROJECT SCHEDULE GANTT CHART

START: January 2003

END: December 2003

PROJECT/PHASE DESCRIPTION: Effects of Operating Practice on SCC – Task 1 (Materials Program)

2003 J

TIME FRAME: Months F

M

A

M

J

Task1 - ACTIVITY/TASK Project Leader- Project Management Task 1. Review of existing SCC data

Collection of SCC data from available sources Review of test conditions and test materials Calculation of mechanical driving force Mechanical testing Data analysis and reporting

Task 2 would require an additional year to validate the model developed in Task 1. Task 2 is not shown on the Gantt Chart because it is an optional task.

J

A

S

O

N

D

7

PART II – COST PROPOSAL

TASK AND COST BREAKDOWN TASKS

DESCRIPTION

Task 1

Review of existing SCC data and defining the relation between crack growth rate and the deformation rate. - Collection of SCC data - Review of test conditions and test material properties - Calculation of mechanical driving force - Mechanical testing - Data analysis and reporting Subtotal - Project Management - Travel and accommodation - Special materials and supplies *Total for Task 1 (includes in-kind contributions)

$8,841.60 $30,700.80 $27,098.88 $9,408.00 $34,736.00 $110,785.28 $8,771.28 $6,400.00 $2,560.00 $128,516.48

Laboratory Validation (optional) Total for Task 2 (includes in-kind contributions)

$169,795.20 $169,795.20

Total for Tasks 1 and 2(includes in-kind contributions)

$298,311.68

1.1 1.2 1.3 1.4 1.5

Task 2

___________________ * Funding requested from PRCI is US $56,725.76 for Task 1.

ESTIMATE US $ (including in-kind contributions)

8

PRCI CONTRACT COST ESTIMATE

CONTRACT COST ESTIMATE (FOOTNOTE A) Name of Offeror CANMET-Materials Technology Laboratory Home Office Address 568 Booth St., Ottawa, Ontraio, Canada K1A0G1

RFP No/Prp No

Division(s) and Location(s) (where work is being performed) As above

Total Amount of Proposal

Number of Pages

Name of Proposed Project

Effects of Operating Practice on SCC Crack GrowthTask 1 US$128,516.4860 funding from PRCI + in-kind contributions of US$71,790.48 Estimated Cost (dollars)

Cost Elements 1.

Page Number

Direct Material a. Purchased Parts

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

$2,560.00

b. Interdivisional Effort c. Equipment Rental/Lease d. Other Total Direct Material 2.

Material Overhead (Rate

3.

$2,560.00 % x Base $

)

Subcontracted Effort (Attach Detailed Schedule) Subcontractor Cofunding (Footnote D) Net Subcontracted Effort

4.

Direct Labor - Specify

Est. Hours

Rate/Hour

Est. Cost

91 650 75

$177.28 $144.64 $125.44

$16,132.00 $94,015.00 $9,408.00

O.H. Rate

X Base $

Est. Cost

Professional Level 3 Professional Level 2 Technologist Level 2 Total Direct Labor 5.

Labor Overhead - Specify

Schedule A $122,116.48

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

10.

Other Direct Costs (shipping of materials to be covered by member companies)

11.

Total Direct Cost and Overhead

12.

General and Administrative Expenses (w/o IR&D) Rate

13.

$6,400.00

% of cost element numbers

Independent Research and Development Rate

% of cost element numbers

14.

Total Estimated Cost (Footnote C)

15.

Fixed Fee

16.

Total Estimated Cost and Fee

17.

Contractor/Third Party Cofunding (Footnote D)

18.

Net PRCI Estimated Cost and Fee

$128,516.48 $71,790.48 $56,725.76

Schedule B Schedule C

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes, which follow.

Typed Name and Title Alan Bowles Manager, Business Development

Signature

Date

9

SCHEDULES TO THE CONTRACT COST ESTIMATE SCHEDULE A LABOR RATES In January 2002, the CANMET Materials Technology Laboratory received approval of a revised schedule of charge rates for external clients. These rates had not been revised since they were first implemented ten years ago. Rates listed are those that have been determined to recover the full costs of providing research services without making a profit. These rates include as overhead, costs that are often charged separately by other organizations, such as the use of special equipment, materials, administrative expenses, etc. Since these rates have been determined externally to the CANMET Materials Technology Laboratory (by the Finance Department of Natural Resources Canada) we have not broken them down according to the categories provided in the cost estimate form. Information on this breakdown can be provided upon request. SCHEDULE B IN-KIND CONTRIBUTIONS In-kind contributions are made from two sources. Firstly, the CANMET Materials Technology Laboratory is making an in-kind contribution based upon its labor rates. The value for Task 1 is $33,390.72. This contribution effectively reduces the full cost of labor to nominal costs as follows: Employment Category Professional 3 Professional 2 Technologist 2 Technologist 1

Full Cost Nominal Cost Labor rate in US $/h 177.28 127.36 144.64 104.32 125.44 90.24 93.44 67.20

The second in-kind contribution comes from the Program on Energy Research and development, a sponsor of research at the CANMET Materials Technology Laboratory. The value of this contribution is estimated to be $38,400. Thus the total in-kind contribution is $71,790.72. The Program of Energy Research and Development (PERD) is a federal, interdepartmental program operated by Natural Resources Canada (NRCan). PERD funds research and development designed to ensure a sustainable energy future for Canada in the best interests of both our economy and our environment. It directly supports 40 percent of all non-nuclear energy R&D conducted in Canada by the federal and provincial governments, and is concerned with all aspects of energy supply and use, with the exception of nuclear energy. All costs in this proposal are in US currency. Conversions from calculations in Canadian currency have been made at the rate of Canadian $1.00 = US $0.64. We propose that in the case of currency fluctuations, the cash price in US currency remain fixed and that the amount of the fluctuations be absorbed in the amount of the required in-kind contribution. SCHEDULE C TASK 2 COSTS Costs for Task 2 have not been included in the Cost estimate, which addresses Task 1 only. The total cost for Task 2 would be $169,795.20. For Task 2 the in-kind contribution from labor rates would be $42,713.60 while that from the Program on Energy Research and Development would be $48,000.00. Thus the total in-kind contribution for Task 2 would be $90,713.60. Hence, the net cost to PRCI for Task 2 would be $79,081.60.

Proposal

Remaining Strength of Corroded Pipes Subjected to Biaxial Loads (RPTG-0323)

Submitted to Materials Technical Committee of the Pipeline Research Council International

Prepared by Qishi Chen, Ph.D., P.Eng. tel: 780 450 8989 ext 215 email: [email protected]

Copyright © 2002 C-FER Technologies

August 2002 Project L076

C-FER Technologies

NOTICE Restriction on Disclosure

Information contained in this proposal may not be disclosed, duplicated or used in whole or in part for any purpose other than in evaluation of the Pipeline Research Council International, Inc. (PRCI). In the event that the proposal is not accepted, this proposal document should be returned to C-FER Technologies. This restriction does not limit the use of information contained in the document if it is obtained from another source without restriction.

i

C-FER Technologies

TABLE OF CONTENTS

Notice Table of Contents List of Figures and Tables Executive Summary

i ii iii iv

1.

TERMS OF REFERENCE ................................................................................................... 1

2.

TECHNICAL BACKGROUND............................................................................................. 2

2.1 General 2.2 Previous Work 2.3 Technical Issues 3.

2 2 5

PROPOSED PROGRAM..................................................................................................... 7

3.1 Objective 3.2 Incentive 3.3 Work Plan 3.3.1 Task 1: 3.3.2 Task 2: 3.3.3 Task 3: 3.3.4 Task 4: 3.3.5 Task 5: 3.4 Schedule 3.5 Cost

Review of Previous Research Full-Scale Burst Tests Finite Element Analysis Assessment of Axial Stress Effects Reporting

7 7 7 7 7 8 9 9 9 10

4.

PROJECT TEAM ORGANIZATION AND QUALIFICATIONS ......................................... 11

5.

CORPORATE QUALIFICATIONS .................................................................................... 13

5.1 5.2 6.

Corporate Profile Qualifications Related to the Proposed Project

13 13

REFERENCES .................................................................................................................. 15

APPENDICES

Appendix A

Resumes of Project Team

Appendix B

C-FER’s Structural Testing Facilities

ii

C-FER Technologies

LIST OF FIGURES AND TABLES

Figures

Figure 1 Ruptured Pipe Specimen with Simulated Defect Figure 2 Finite Element Model for the Local Buckling of a Corroded Pipe

Tables

Table 1 Proposed schedule. Table 2 Cost Breakdown by Task (US$)

iii

C-FER Technologies

EXECUTIVE SUMMARY TITLE

Remaining Strength of Corroded Pipes Subjected to Biaxial Loads

CONTRACTOR

C-FER Technologies

NEW PROJECT FUNDING REQUESTED

$120,000

ESTIMATED COMPLETION DATE

December 31, 2003

TOTAL ESTIMATED COST

$120,000

Objective

The objective of the proposed project is to assess the effect of axial stress on the remaining burst capacity of corroded pipes by conducting full-scale tests and finite element analysis. If axial stress effects are found to be significant, the limiting axial stress beyond which standard assessment methods are no longer applicable will be determined, and the currently available predictive methods will be evaluated to identify the most suitable approaches for incorporating axial stress into the prediction of burst pressure. Incentive

Standard methods currently used in the pipeline industry for assessing the burst capacity of corroded pipes (e.g. RSTRENG, B31G), do not take axial stresses into account. This is an important source of uncertainty in integrity assessment for pipelines with metal loss corrosion. The practice of pipeline integrity management can be improved if the effect of axial stress on remaining burst capacity is better understood, and the most appropriate methods for acknowledging the effects of bending and axial loading are identified. Work Plan

It is proposed that the project be carried out with the following tasks: 1. Review of Previous Research. Review existing prediction methods for burst under biaxial stresses and collect test and numerical data produced from previous work. 2. Full-Scale Burst Tests. Develop a test matrix, design and fabricate test set-up and specimens, and conduct full-scale tests of pipes with different types of defects and subject them to different levels of axial stress. 3. Finite Element Analysis. Develop finite element models based on full-scale test results, select parametric cases based on key input variables and perform parametric finite element analysis to numerically expand the experimental database.

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C-FER Technologies Executive Summary

4. Assessment of Axial Stress Effect. Assess the effect of axial stress on the remaining burst capacity, determine limitations of currently available methods and identify methods suitable for biaxial stress applications. 5. Reporting. Prepare project status reports, present project results at two committee meetings and prepare a comprehensive final report.

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1. TERMS OF REFERENCE

This document contains a proposal submitted by C-FER Technologies in response to a Request For Proposal (RFP) issued by the Pipeline Materials Technical Committee of the Pipeline Research Council International, Inc. (PRCI) on the subject of “Remaining Strength of Corroded Pipes Subjected to Biaxial Loads”. The objective of the proposed project is to assess the effect of axial stress on the burst of corroded pipes and to evaluate current assessment methods for their applicability to different axial stress levels. This proposal describes the approach that will be used for this work. It includes a technical background section (Section 2) that describes previous work in this area and the major technical issues related to the proposed project. Section 3 deals with the objective, incentive, proposed tasks, schedule and cost. Section 4 outlines the project management structure and team qualifications, whereas Section 5 summarizes the relevant experience of the proposed team.

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2. TECHNICAL BACKGROUND 2.1 General

Buried onshore pipelines are subjected to hoop (circumferential) stresses primarily related to internal pressure, as well as axial (longitudinal) stresses due to internal pressure, temperature changes and ground movement. For pipes with metal loss corrosion defects, burst under internal pressure is the most common failure mode. The remaining strength of corroded pipes subjected to pressure loading has been extensively researched and standard assessment methods such as RSTRENG (Kiefner and Veith 1989) and ASME B31G (ASME 1991) are readily available. In recent years, these assessment methods have been extended to include complex defect shapes, defect clusters, seam welds, and older pipes with low toughness (e.g. DNV 1999). However, all standard methods that are currently available only consider hoop stresses due to pressure loading. The effect of axial stresses related to bending or axial loads has not been thoroughly investigated. Current standard assessment methods are typically calibrated against burst tests on pipes with closed ends, which results in an axial tensile stress at approximately 50% of the hoop stress. As such, the assessment methods inherently incorporate this assumed axial stress level, despite the fact that axial stress due to internal pressure of buried pipelines is more typically 30% of hoop stress and the total axial stress varies with other factors such as temperature transients and ground movement. 2.2 Previous Work

Current standard assessment methods are based on plastic collapse models similar to the prediction methods developed in the 1970’s for pipes with axial surface flaws (e.g. Kiefner et al. 1973). Tests performed at that time (on pipes with axial surface flaws) suggest that, in comparison to other parameters such as flaw geometries and material properties, burst pressure is not particularly sensitive to the variation of axial stresses. Recent work on this topic was reported by Roberts and Pick (1998), who performed 10 tests of X42 pipe specimens with a 12 inch diameter and a 0.375 inch wall thickness. The circular shaped corrosion defects with diameter of 1.25 inches and a depth of 60-80% of wall thickness were electromechanically simulated. When subjected to different axial stresses, the variation in burst pressure was within 20%. The lowest burst pressure occurred when the ratio between axial stress and critical hoop stress was at − 25% (axial compression) and 125% (axial tension). A correlation between burst pressure and axial stress was found by using the von Mises yield criterion, which predicts that the effective yield stress reaches its maximum when axial stress is 50% of hoop stress and decreases as axial stress deviates from this point. Supplementary finite element analyses (FEA) for similar pipes with similar circular defects were also performed to 2

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Technical Background support the test results. Based on test and analytical results for this particular type of defect, a correction factor was derived using the von Mises yield criterion. Appendix D of DNV’s Recommended Practice F101 (DNV 1999) describes an approach for considering axial stress in the prediction of the remaining strength of corroded pipe. When axial stress is compressive, the approach involves the use of a reduction factor on the burst pressure based on a longitudinal break. For axial tensile stress, the plastic collapse solution of PD6493 for surface circumferential crack-like defects was adopted. Since the approach was not extensively validated, users of Appendix D are cautioned that this methodology serves as an approximation. The above discussions suggest that further tests and analyses are required to determine the true effect of axial stresses. A desired solution for biaxial burst of corroded pipes should be based on: •

effect of axial stress on remaining burst capacity;

•

limiting axial stress for standard assessment methods;

•

failure mechanisms of biaxial burst; and

•

predictive models.

The proposed project will focus on the first two items. If it is proven that axial stress within the practical range has a significant impact on remaining burst capacity, then experimental and analytical results will provide information to further identify failure mechanisms and develop appropriate predictive methods. In addition to burst failure, pipes with high compressive stresses may fail in local buckling or wrinkling. This failure mode has been addressed in another PRCI project entitled “Local Buckling and Collapse of Corroded Pipes” (PR-244-9827). The project has been carried out by C-FER in collaboration with DNV and the University of Alberta. The project involves full-scale tests, finite element analysis, development of predictive equations, and calibration of safety factors. Figure 1 shows a ruptured specimen with a simulated rectangular patch defect. A plot of the finite element model in Figure 2 shows the amplified bulging on the compressive side when a corroded pipe is subjected to internal pressure and bending loads. The work completed so far provided experience in developing test programs and numerical models for line pipes with metal loss corrosion defects.

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Technical Background

Figure 1 Ruptured Pipe Specimen with Simulated Defect

Figure 2 Finite Element Model for the Local Buckling of a Corroded Pipe

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Technical Background 2.3 Technical Issues

This subsection outlines several key factors that need to be considered in designing the experimental program and developing numerical models for the burst of corroded pipes under biaxial stress. The design of the test matrix consists of identifying key parameters, and selecting sampling points and combinations. As suggested in previous work by DNV and the University of Waterloo, axial stress (magnitude, tension vs. compression), and the type (pitting vs. patch, longitudinal vs. circumferential grooves) and geometry of the defect (depth, longitudinal and circumferential dimensions) are potentially key variables for the burst pressure. Other parameters may include pipe diameter, wall thickness and material properties. One possibility for the test matrix involves combining three levels of axial stress and two or three defect geometries, producing a 2x3 or 3x3 matrix that will lead to six or nine tests. The three levels of axial stress may involve an axial tension of 50% hoop stress as the baseline case, an axial compression case, and an axial tension case with tension greater than 50% hoop stress. The second possibility is to design the matrix based on the results of finite element analysis, and then select points for testing. It is suggested that the test program focus on two variables (with the final decision on test parameters being made after a thorough review and preliminary analyses). The effects of other variables such as steel grade, pipe diameter and wall thickness can be further investigated by numerical models that are verified by full-scale tests. Numerical modeling of a burst failure will take into account the secondary effects due to large plastic deformation. For instance, burst failure involving material strength, as well as geometric factors such as the expansion of the circumference and the simultaneous decrease of wall thickness. As a result, internal pressure is applied to a pipe with a larger inside surface and thinner walls than its original configuration. Accordingly, the FEA model will have the following features: •

inelastic material behavior (yielding and strain-hardening);

•

large deformation formulation (equilibrium at every load step is based on increased diameter and decreased wall thickness);

•

deformation dependent pressure load (surface area associated with internal pressure varies with pipe deformation);

•

realistic failure criteria (fracture mechanics based criteria or strain-based criteria); and

•

displacement-controlled solution algorithm (rather than a load-controlled algorithm to capture both the ascending and the descending portions of the response curve and identify the maximum pressure). 5

C-FER Technologies

Technical Background It is proposed that the ABAQUS finite element program be used for this project. ABAQUS is a general-purpose software package with excellent non-linear capabilities. A model based on an appropriate selection of libraries of elements, material models, loading mechanisms and solution algorithms, within ABAQUS, will address the above-mentioned modeling concerns.

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3. PROPOSED PROGRAM 3.1 Objective

The objective of the proposed project is to assess the effect of axial stress on the remaining burst capacity of corroded pipes by conducting full-scale tests and finite element analysis. If such an effect is found to be significant, the limiting axial stress beyond which standard assessment methods are no longer applicable will be determined. Currently available predictive methods will be evaluated to identify the most suitable approaches for incorporating axial stress into the prediction of burst pressure. 3.2 Incentive

Standard methods currently used in the pipeline industry for assessing the burst capacity of corroded pipes do not take axial stress into account. This is an important uncertainty factor in integrity assessment for pipelines with metal loss corrosion. The practice of pipeline integrity management can be improved if the effects of axial stress on the remaining burst capacity is better understood, and the most appropriate methods for incorporating bending and axial loading are identified. 3.3 Work Plan

The proposed objectives can be achieved by carrying out the following five tasks. 3.3.1 Task 1: Review of Previous Research

A review of existing prediction methods for burst under biaxial stresses, such those published by DNV and the University of Waterloo, will be performed. It is believed that most of the relevant information has been gathered by C-FER in the past and is available for this project; but C-FER will seek assistance from organizations like DNV and the University of Waterloo to collect test and numerical data produced from previous work. In addition, a literature search will be conducted to identify and gather new information. 3.3.2 Task 2: Full-Scale Burst Tests

The design, preparation and execution of full-scale burst tests include the following sub-tasks: •

Design of the test matrix

•

Design of test set-up and fabrication of end cap fixtures 7

C-FER Technologies

Proposed Program •

Design and fabrication of test specimens

•

Measurements and preparation of test specimens

•

Design and set-up of a data acquisition system

•

Execution of biaxial burst tests

•

Material tests

•

Data reduction

A test matrix will be designed according to parameters chosen, based on the review of existing information and selected cases of preliminary finite element analysis. The test matrix may consider different axial stresses (magnitude, tension vs. compression), and representative defect types (groove, patch or pitting) and geometries (depth and axial and circumferential dimensions). Test specimens will be manufactured using representative line pipes of a typical steel grade. It is proposed that defects similar to metal loss corrosions be machined using a process that will minimize strain hardening during machining and stress concentration during pressurizing. It is anticipated that six to nine tests will be carried out. The exact number of tests will be determined once the details of test set-up and test specimens are decided. 3.3.3 Task 3: Finite Element Analysis

Following full-scale tests, FEA models will be developed and calibrated for the purpose of parametric analysis. The objective of parametric FEA analysis is to numerically expand the experimental database such that the influence of additional variables can be determined. This task may include the following: •

Development of FEA model

•

Development of failure criteria

•

Calibration of FEA model with full-scale tests

•

Design of parametric analysis cases

•

Parametric FEA analysis

•

Data reduction

In addition to defect types and geometries, and axial stress magnitude, other parameters to be considered may include diameter, wall thickness and material properties such as yield stress, ultimate tensile stress and toughness.

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Proposed Program In order to facilitate the evaluation of axial stress effects, cases with baseline axial stress values will also be analyzed. 3.3.4 Task 4: Assessment of Axial Stress Effects

Based on test and FEA results, the effect of axial stress on remaining burst capacity will be assessed by comparing burst pressures of pipes with identical size, material and defects but different axial stresses. It is expected that the axial stress effect will vary for different pipe sizes, materials and defect combinations. If axial stress is found to be influential on the burst pressure, current assessment methods for corroded pipes will be compared and evaluated to determine their limitations with respect to the range of axial stress within which the assessment results are acceptable. The evaluation will also identify which current methods can be used to assess remaining burst capacity when axial stresses are present. 3.3.5 Task 5: Reporting

Following the reporting guidelines of PRCI, this task includes the preparation of project status reports at the required intervals, two presentations at committee meetings, and preparation of the final report. A comprehensive draft final report documenting the project methodology and conclusions will be prepared and submitted to the committee for review. Copies of the final report will be issued after the committee's comments are incorporated. 3.4 Schedule

As shown in Table 1, it is proposed that the project be completed within one year from the starting date. The draft final report will be submitted at ten months, and the final report will be submitted one month after receiving the client’s comments.

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Proposed Program

Month Task

1

2

3

4

5

6

7

8

9

10

11

12

1. Review of Existing Assessment Methods 2. Full-Scale Biaxial Burst Tests 3. Finite Element Analysis 4. Assessment of Axial Stress Effect 5. Reporting

Table 1 Proposed Schedule

3.5 Cost

We propose to carry out the work for a fixed price of US$120,000. Breakdown of this total cost by task is shown in Table 2. Task

Labour

Materials

Subcontract

Travel

Total

1. Review of Existing Assessment Methods

$3,800

$0

$2,100

$0

$5,900

2. Full-Scale Biaxial Burst Tests

$39,300

$9,800

$9,400

$0

$58,500

3. Finite Element Analysis

$21,100

$4,600

$0

$0

$25,700

4. Assessment of Axial Stress Effect

$11,000

$0

$0

$0

$11,000

5. Reporting

$14,400

$100

$0

$4,400

$18,900

Total

$89,600

$14,500

$11,500

$4,400

$120,000

Table 2 Cost Breakdown by Task (US$)

We propose to invoice PRCI monthly based on the estimated value of the work completed (according to this proposal) up to the end of the previous month.

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4. PROJECT TEAM ORGANIZATION AND QUALIFICATIONS

The proposed project team possesses the technical and managerial qualifications required to complete the project and produce a high quality product. It will consist of Dr. Qishi Chen who will act as project manager and principal investigator, Dr. Tom Zimmerman and Mr. Mark Stephens as senior advisors, and Mr. Chris Timms and Mr. Amir Muradali who will act as project engineers. Other C-FER personnel will contribute to the project as required. Relevant qualifications and experience of the project personnel is summarized below. One-page resumes are included in Appendix A. Qishi Chen, Ph.D., P.Eng. (Project Manager)

Dr. Chen, Principal Research Engineer - Pipeline Technology, will be responsible for managing the project budget and schedule, interacting with the ad hoc group, and preparing the final report. Dr. Chen has fifteen years of engineering experience and has managed projects with individual budgets exceeding $500,000. He is a structural engineer with expertise in numerical analysis, structural testing, structural design and risk and reliability of pipelines. He has been involved in numerous projects related to pipeline reliability including the calibration of reliability levels for limit states design of pipelines, assessment of pipeline failure consequences, and mechanical damage prevention for onshore pipelines. Dr. Chen was project manager and principal investigator for several PRCI projects including “Local Buckling and Collapse of Corroded Pipelines” (PR-244-9827) and “Reliability-based Prevention of Mechanical Damage to Pipelines” (PR-244-9729). Tom Zimmerman, Ph.D., P.Eng. (Senior Advisor)

Dr. Zimmerman, Manager - Special Projects, will advise on fracture mechanics failure criteria. Dr. Zimmerman has twenty years of experience in engineering design and research. His responsibilities during fifteen years at C-FER include: project management, development of work scopes and methodologies, technical direction and review of engineering services, market development, client liaison and long-term strategic core research planning. He managed C-FER's Pipeline and Structures Department from 1990 to 1998. Projects conducted under his leadership include: the development of limit states design procedures for pipelines; an investigation of the structural integrity and buckling behavior of pipelines subjected to extreme ground movements; a full-scale experimental study of the collapse resistance of an ultra-deep water pipeline; and an investigation of the reserve capacity and ultimate strength of stiffened steel plate systems for Arctic offshore structures. Dr. Zimmerman chairs the Canadian Standards Association (CSA) Task Force on Limit States Design of Pipelines and is also a member of an ISO working group that is developing a limit states pipeline design standard. He has led several PRCI projects including PR-244-9517, Limit States Design of Pipelines, and PR-244-9805, Effect of Y/T Ratio on Mechanical Damage Tolerance.

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C-FER Technologies Inc. Project Team Organization and Qualifications Mark Stephens, M.Sc, P.Eng. (Senior Advisor)

Mr. Stephens, Senior Specialist - Pipeline Technology, will advise on current standard assessment methods for corroded pipes and review project results including the final report. Mr. Stephens has nineteen years of experience in the areas of advanced structural analysis, large-scale testing, and risk and reliability of engineering systems with an emphasis on pipelines. Pipeline research projects for which he has been the project manger and/or principal investigator include: the development of risk-based methods and software for the optimization of integrity maintenance activities for transmission pipelines; the development of guidelines for the limit states design of buried pipelines; probabilistic assessments of the fracture initiation and propagation susceptibility of older pipelines; the assessment of the effects of ground movement on the integrity of buried pipelines; and large-scale experimental and analytical investigations of the structural integrity and buckling behavior of pipelines subjected to extreme loads. Mr. Stephens has been actively involved in the development of the sections of the Canadian pipeline code (CSA Z662) pertaining to Risk Assessment and Limit States Design. Chris Timms, B.Sc, P.Eng. (Project Engineer)

Mr. Timms, Research Engineer - Technical Services, will be responsible for the full-scale tests. He comes from a mechanical engineering background with over 10 years of experience covering a wide assortment of technical assignments and research projects. Since joining C-FER in 1991, Mr. Timms has been involved in all phases of many C-FER projects. Frequently, he assumes the role of “design engineer” for large laboratory programs such as the Bluestream and Mardi-Gras pipeline projects. Mr. Timms has also served as project manager for large laboratory programs such as the recently completed TAMSA full-scale pipeline combined load test program. In addition to continued project work, Mr. Timms is currently the primary technical resource to C-FER’s calibration program. Amir Muradali, M.Sc. (Project Engineer)

Mr. Muradali, Research Engineer - Pipeline Technology, will be responsible for the numerical analysis. Mr. Muradali has over five years of wide industry experience. Since joining C-FER, Mr. Muradali has served as project engineer in several pipeline integrity related projects. Recently Mr. Muradali completed an assessment of improved corrosion assessment methods and updated the corrosion model implemented in PIRAMID. Mr. Muradali has an extensive background in numerical modeling. He has taught a course on the fundamentals of finite element analysis at the University of Alberta (Dept. of Mechanical Engineering) and served as project engineer on numerous structural finite element analysis projects.

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5. CORPORATE QUALIFICATIONS 5.1 Corporate Profile

C-FER Technologies was initially established in 1983 to meet the engineering research and innovation needs of the pipeline, and oil and gas industries by developing new technologies to enhance both safety and economics. C-FER conducts theoretical and experimental research in engineering materials and systems, and accesses broad expertise through collaboration with its member companies and other research organizations. Concentrating on research programs that are need-driven, C-FER maintains a strong commitment to meeting the technology needs of its clients and members. A unique laboratory facility, opened in 1990, provides new opportunities for generating maximum return on investment in R&D. The facility includes approximately 5,200 square metres of office and laboratory space, and accommodates up to 85 research and support staff. Experimental equipment in the laboratory is unique in the world, and makes possible the realistic simulation of load, temperature, and other environmental conditions during the testing of components and systems. Appendix B presents summary information of C-FER’s testing facilities. C-FER also maintains a network of powerful engineering workstations for developing software and conducting sophisticated numerical analyses. C-FER’s generic technical expertise and resources are organized in three research departments: Pipeline Technology, Production Technology, and Drilling & Completions Technology. C-FER has a total staff of approximately 45 with diverse technical capabilities in the above areas and an annual budget of approximately $6 million. C-FER’s latest Annual Report and latest organizational chart are already on file at PRCI, and with members of the Committee on Pipeline Design, Construction and Operations. Additional copies can be provided upon request. 5.2 Qualifications Related to the Proposed Project

C-FER has an active research program in the area of pipeline design, testing, analysis and integrity management. The breadth of C-FER’s capabilities in this area is demonstrated by the list of selected projects, which is already on file at PRCI, and with members of the Committee on Pipeline Design, Construction and Operations. Additional copies can be provided upon request. C-FER has had a leading role in developing new technologies to design and assess pipelines with respect to mechanical damage, as evidenced by the following recent projects: •

Local Buckling and Collapse of Corroded Pipelines: The ultimate objective of this three-phase project is to develop local buckling and collapse criteria for onshore and offshore pipelines that have experienced some form of metal-loss corrosion. Phase 1 involved developing finite element models and establishing the relative importance of various 13

C-FER Technologies

Corporate Qualifications corrosion features for these failure modes. Phase 2 focused on large-scale experiments involving the combination of pressure and axial loads. In Phase 3, practical assessment criteria were developed based on test and FEA data. •

High Design Factor for High Strength Pipelines. The purpose of this PRCI project was to evaluate the structural integrity and lifetime benefits of high-strength, high-design-factor pipelines. It involved the assessment of pressure limit for mill and field hydrotests, and in-service reliability associated with manufacturing defects, corrosion and mechanical damage. Lifetime cost-benefits were evaluated by designing a number of typical pipelines and developing appropriate maintenance plans to maintain similar lifetime reliability levels to those achieved by existing pipelines. It was also shown that, for typical Class 1 pipelines, the use of steel grades of up to X80 with a design factor of up to 0.8 has an overall economic advantage.

•

Safe Use of Low Toughness Pipe. The objective of the project is to develop a methodology to evaluate the susceptibility of low toughness pipelines to ductile and brittle propagating fractures and to implement the approach in the form of a user-friendly software program. The methodology will formally account for the uncertainties inherent in data used to estimate the fracture arrest potential and in the arrest prediction models themselves. The added uncertainties associated with parameter estimates obtained from small data sets will also be addressed.

•

Risk-based Maintenance Optimization of Pipelines (PIRAMID). This program is sponsored by thirteen pipeline companies and regulators, and has a budget of C$500,000 per year since 1994. Relevant work carried out under this project is developing limit states functions for all major pipeline failure causes (including burst models for corroded pipes), collecting statistical data on all input parameters and developing approaches to estimate pipeline reliability. The work is coded in an extensive software package (PIRAMID) that stores the attributes of a pipeline system and uses them to determine maintenance priorities and optimize maintenance choices on critical segments.

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6. REFERENCES

ASME 1991. Manual for Determining the Remaining Strength of Corroded Pipeline. ASME B31G. A Supplement to ASME B31 Code for Pressure Piping. American Society of Mechanical Engineers. DNV 1999. Corroded Pipelines. Recommended Practice, RP-F101. Det Norske Veritas. Kiefner, J.F., Maxey, W.A., Eiber, R.J. and Duffy, A.R. 1973. Failure Stress Levels of Flaws in Pressurized Cylinders. Progress in Flaw Growth and Fracture Toughness Testing, ASTM STP 536, American Society for Testing and Materials, pp. 461 - 481. Kiefner, J.F. and Vieth, P.H. 1989. Project PR 3-805: A Modified Criterion for Evaluating the Remaining Strength of Corroded Pipe. A Report for the Pipeline Corrosion Supervisory Committee of the Pipeline Research Committee of the American Gas Association. Roberts, K.A. and Pick, R.J. 1998. Correction for Longitudinal Stress in the Assessment of Corroded Line Pipe. Proceedings of the International Pipeline Conference.

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APPENDIX A – RESUMES OF PROJECT TEAM

A.1

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Appendix A-Resumes of Project Team

Résumé

Qishi Chen C-FER Technologies 2001-present

Principal Research Engineer

1997-2001 1993-1997

Senior Research Engineer Research Engineer

Work History

1990-1993 1986-1990

Research & Teaching Assistant, University of Alberta, Edmonton, Alberta Lecturer (Civil Eng.), Zhejiang University, Hangzhou, China

Education

Ph.D., Civil Engineering, University of Alberta, 1993. M.Sc., Civil Engineering, Zhejiang University, China, 1986. B.Sc., Civil Engineering, Zhejiang University, China, 1983.

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Structure engineering; finite element analysis; structural reliability; risk analysis; design and maintenance of pipelines; structural testing.

Relevant Experience

Over 15 years of experience in engineering design and research and project management. During the past eight years at C-FER, he is primarily involved in projects of pipelines and marine structures. He acted as project manager and/or principal investigator for projects on reliability-based design and maintenance of pipelines, design verification of special structures, large scale testing of stiffened plates, compressive strain limits for buried pipelines, development of pipe-soil interaction models, and implementation of consequence analysis models for hydrocarbon releases from pipelines.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member.

Selected Publications

Chen, Q., DeGeer, D.D., Bjornoy, O., Zhou, J. and Verley, R. 2001. Collapse of Corroded Pipelines. Presented at the 13th Biennial EPRG/PRCI Joint Technical Meeting, April 30 May 3, New Orleans. Chen, Q., Fuglem. M.K., Stephens, M.J. and Zhou, J. 2001. Reliability-based Pipeline Design for Mechanical Damage. Presented at the 13th Biennial EPRG/PRCI Joint Technical Meeting, April 30 - May 3, New Orleans. Nessim, M.A., Fuglem, M.K., Chen, Q. and Odom, T. 2001. Lifetime Benefit of Highstrength, High-design-factor Pipelines. Presented at the 13th Biennial EPRG/PRCI Joint Technical Meeting, April 30 - May 3, New Orleans. Nessim, M.A., Chen, Q., Fuglem, M.K. and Muradali, A. 1999. Hydrotest Requirements for High-Strength, High-Usage-Factor Pipelines. Presented at the Twelfth EPRG/PRCI Joint Meeting, Groningen, The Netherlands, May. Chen, Q. and Nessim, M.A. 1999. Reliability-based Prevention of Mechanical Damage. Presented at the Twelfth EPRG/PRCI Joint Meeting, Groningen, The Netherlands, May Zimmerman, T.J.E., Stephens, M.J., DeGeer, D.D. and Chen, Q. 1995. Compressive Strain Limits for Buried Pipelines. Proceedings of the 1995 Offshore Mechanics and Arctic Engineering Conference, Denmark, June.

A.2

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Appendix A-Resumes of Project Team

Résumé

Tom J.E. Zimmerman C-FER Technologies 1999-present Manager, Special Projects 1998-1999 1990-1998 1989-1990 1988-1989 1985-1988

Manager, Tubulars and Structures Manager, Pipelines and Structures Manager, Offshore and Marine Technology Senior Research Engineer Research Engineer

Work History

1981-1985 Design Engineer, Morrison Hershfield Ltd., Toronto, Ontario 1980-1981 Structural Engineer, Canadian Inst. of Steel Construction, Toronto, Ontario

Education

Ph.D., Civil Engineering, University of Alberta, 1993. M.Sc., Civil Engineering, University of Alberta, 1981. B.Sc., Civil Engineering, University of Alberta, 1978.

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Structural engineering; project management; limit states design; pipeline integrity assessment; design code development; and fracture mechanics.

Relevant Experience

Research and development activities related to down-hole tubulars, pipelines, offshore structures, advanced materials and conventional bridge and building structural systems. Projects include: testing premium connection leakage performance for heavy oil wells; development of limit states design procedures for pipelines; investigation of the collapse behaviour of ultra-deep water pipeline; investigation of the structural integrity and buckling behaviour of pipelines subjected to extreme loads; and strength of stiffened steel plate systems for arctic offshore structures.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member. Subcommittee on Design for CSA Standard Z662-94, Oil and Gas Pipeline Systems: Member (Chairman of Limit States Design Task Force). Technical Committee on Steel Structures for CSA Standard S473, Code for the Design, Construction and Installation of Fixed Offshore Structures: Member; Chairman of the Working Group on Composite Structures. CSCE Technical Committee on Advanced Composite Materials in Bridges and Structures: Member.

Publications

Driver, R.G. and Zimmerman, T.J.E. 1998. A Limit States Approach to the Design of Pipelines for Mechanical Damage. Proceedings of the 17th International Conference on Offshore Mechanics and Arctic Engineering, Paper No. OMAE981017. Zimmerman, T.J.E., Cosham, A., Hopkins, P. and Sanderson, N. 1998. Can Limit States Design Be Used to Design a Pipeline Above 80% SMYS? Proceedings of the 17th International Conference on Offshore Mechanics and Arctic Engineering, Paper No. OMAE98-902.

A.3

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Appendix A-Resumes of Project Team

Résumé

Mark Stephens C-FER Technologies 2000-present Senior Specialist, Pipeline Technology 1998-2000 1993-1998 1988-1993

Research Manager Principal Research Engineer Senior Research Engineer

Work History

1990 Sessional Lecturer (Civil Eng.), University of Alberta, Edmonton 1982-1988 Design Engineer, Lamb McManus Associates Ltd., Edmonton

Education

M.Sc., Civil Engineering, University of Alberta, 1982. B.Sc., Civil Engineering, University of Alberta, 1979.

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Engineering system risk and reliability assessment; pipeline integrity; pipe-soil interaction; large-scale testing, structural analysis and design; and fracture mechanics.

Relevant Experience

Nineteen years of experience in the field of structural analysis, design and research, with a major focus on pipeline integrity maintenance and risk assessment over the past six years. Project manager for and/or principal developer of: failure consequence analysis models, mechanical damage, crack-like defect and ground movement failure prediction models; and risk prioritization tools for onshore and offshore pipeline systems. Project manager and/or principal engineer for other pipeline projects in the areas of ground movement induced damage and susceptibility to both ductile and brittle fracture initiation and propagation. Actively participated in the development of CSA pipeline code appendices on Limit States Design and Risk Assessment. Managed dozens of research projects with budgets to $500,000.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member. Task Force on Risk Assessment, CSA Z662-99, Oil and Gas Pipeline Systems: Member.

Publications

Nessim, M.A., Stephens, M.J. and Zimmerman, T.J.E. 2000. Risk-based Maintenance Planning for Offshore Pipelines. Presented at the 2000 Offshore Technology Conference (OTC), Houston, Texas, May 1-4. Nessim, M.A. and Stephens, M.J. 1998. Managing the Operating Risk Posed by Metal Loss Corrosion and Mechanical Interference. Pipe Line and Gas Industry, Gulf Publishing, Part 1-June and Part 2-August. Nessim, M.A. and Stephens, M.J. 1997. A Risk-based Approach to Managing Pipeline Damage Caused by Metal Loss Corrosion and Mechanical Interference. Proceedings of the Pipeline Week Conference, sponsored by Pipe Line & Gas Industry, Houston. Stephens, M.J. and Nessim, M.A. 1996. Pipeline Maintenance Planning Based on Quantitative Risk Analysis. Proceedings of the International Pipeline Conference, sponsored by the American Society of Mechanical Engineers (ASME), Calgary. Stephens, M.J. and Nessim, M.A. 1995. A Risk-based Approach to Pipeline Integrity Maintnenance Optimization. Proceedings of the 1995 API Pipeline Conference, Dallas, Texas.

A.4

C-FER Technologies

Appendix A-Resumes of Project Team

Résumé

Amir Muradali C-FER Technologies

Work History

2001-present

Research Engineer

1998-1999

Research Engineer

2000 1998 1997

Mechanical Engineer, GKO Engineering, Edmonton, Alberta. Project Analyst, Beta Machinery Analysis, Calgary, Alberta. Private Contract, Mechanical Engineering Department, University of Alberta, Edmonton, Alberta. Teaching Assistant, Mechanical Engineering Department, University of Alberta, Edmonton, Alberta. Research Assistant, Mechanical Engineering Department, University of Alberta, Edmonton, Alberta.

1996 1995 Education

M.Sc., Mechanical Engineering, University of Alberta, 1997. B.Sc., Mechanical Engineering, University of Alberta, 1996 (with Distinction).

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Numerical modeling, pipeline integrity modeling, pipeline corrosion assessment, finite element analysis.

Relevant Experience

Over five years of broad research and consulting experience. Major focus at C-FER is in the area of pipeline risk and reliability engineering. Actively involved in various research projects related to this area and in upgrading/developing failure prediction models for PIRAMID.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member.

Awards

Province of Alberta Graduate Scholarship, 1996-1997. Aga Khan Foundation Scholarship, 1991-1995.

Publications

Muradali, A. and Fyfe, K.R., 1998. A Study of 2D and 3D Barrier Insertion Loss Using Improved Diffraction Based Methods. Applied Acoustics, 53, 49-75. Muradali, A. and Fyfe, K.R., 1998. Accurate Barrier Modeling in the Presence of Atmospheric Effects. Accepted for publication in Applied Acoustics.

Presentations

Muradali, A. and Fyfe, K.R., 1997. Accurate Geometric Modeling of Barrier Attenuation with Atmospheric Effects. Transportation Research Board Summer Conference on Transportation Related Noise and Vibration, Toronto, Ontario. Muradali, A. and Fyfe, K.R., 1996. Single and Parallel Barrier Insertion Loss by Means of Improved Diffraction Based Methods. Canadian Acoustics Association (CAA) Acoustics Week, October, Calgary, Alberta.

A.5

C-FER Technologies

Appendix A-Resumes of Project Team

Résumé

Chris M. Timms C-FER Technologies 1993-present Research Engineer 1991

Research Assistant (co-op term)

Work History

1990 1989 1989

Co-op Student (Transmission Eng.), Northwestern Utilities, Edmonton, AB Co-op Student (Operations Eng.), British Petroleum Res., Edmonton, AB Co-op Student (Field Operator), British Petroleum Resources

Education

B.Sc., Mechanical Engineering, University of Alberta, 1992 with distinction.

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Mechanical design; experimental design; instrumentation; and solid mechanics.

Relevant Experience

Mr. Timms comes from a mechanical engineering background with over 10 years of experience covering a wide assortment of technical assignments and research projects. Since joining C-FER in 1991, Mr. Timms has had involvement in all phases of many C-FER projects. Frequently, he assumes the role of “Design Engineer” for large laboratory programs such as the Bluestream or Mardi Gras pipeline project Mr. Timms has also frequently served as project manager for laboratory programs such as the recently completed TAMSA full-scale pipeline combined load test program. In addition to continued project work, Mr. Timms is currently the primary technical resource to C-FER’s calibration program.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member.

Publications

Timms, C.M. 1999. Testing of Modified 6-5/8 inch API Oilfield Connection. Confidential to Tesco Drilling Technology, C-FER Report 98001.032, June. Timms, C.M. 1996 Additional Testing of Deformation Tubes for the GBS Bearing System. Confidential to Hibernia Management and Development Company Ltd., C-FER Report 95031, January. Timms, C.M. 1995. Testing of Deformation Tubes for the GBS Bearing System. Confidential to Hibernia Management and Development Company Ltd., C-FER Report 95031, August.

A.6

C-FER Technologies

APPENDIX B – C-FER’S STRUCTURAL TESTING FACILITIES

B.1

Tel 780.450.3300

Fax 780.450.3700

www.cfertech.com

200 Karl Clark Road Edmonton, Alberta Canada T6N 1H2

Corporate Profile For over 15 years, C-FER has created innovative technologies and developed new processes for the energy, transportation and manufacturing industries that have reduced costs, increased revenues, extended the life of systems and ensured regulatory compliance. C-FER holds patents and intellectual property rights to dozens of energy industry products and processes — including revolutionary Downhole Oil/Water Separation technology, PC-PUMP® software, CalTranTM software, PIRAMIDTM software and more. C-FER offers state-of-the-art engineering expertise from the ground up, including: project management production engineering experimental design risk and reliability engineering limit states design failure analysis/structural testing

investigative engineering software development computer modeling solid mechanics materials engineering field services prototype design and manufacture One of the keys to successfully bringing new technologies to market lies in the ability to perform tests at full scale, simulated within a controlled environment. C-FER's world-class laboratory services offer a powerful combination of testing and analysis tools designed to accommodate a vast range of applied research to meet energy industry requirements. C-FER has the know-how to make solutions work in the real world. When there is a lot at risk, operators and suppliers alike rely on C-FER’s third party, independent verification methodology. Whether you are pushing the boundaries of technology, optimizing design, or quantifying reliability, C-FER’s expertise and one-ofa-kind facility can meet your performance qualification requirements.

For energy producers who use technology for strategic advantage, C-FER's innovation expertise is a powerful resource for improving profitability and safety. Our know-how extends beyond applied research to include collaboration with manufacturers and service companies to ensure the viable commercialization of new energy industry products and services. For more information on our products and services, visit www.cfertech.com

Facilities and Equipment Extreme Climate Chamber Large temperature-controlled test space (12 m x 12 m x 9 m high), can be partitioned and sub-divided internally Large doors give access to drive-in equipment and 10 t overhead travelling crane Capable of continuous operation at -60°C, with heat load Can be moved to fully envelop the UTS Make-up air and exhaust handling available Special Environments Facility Twin in-ground test chambers provide secondary containment for toxic and flammable gases, with capacity to fully contain explosions Simulation of corrosive and flammable environments, including flow External remote control of test systems Sealable below-ground test vessel, 12 m deep x 2.5 m diameter Deep Well Simulator Cased well bore 0.6 metres (2 feet) in diameter, providing 14 MPa (2,000 psi) containment capacity Control tests on pump systems with full pressure fluid mixing (single and two phase), flowmeters, and tankage Easy access to electric and hydraulic power, fluid handling and instrumentation Accommodates concentric and dual tubing/casing strings Maximum tool string and specimen configuration 46 m (150 ft) in length and 560 mm (22 inches) in diameter Operating temperatures from 20°C (68°F) to 200°C (392°F) Coupled to a flowloop Able to handle a variety of fluids Hyperbaric Pressure Vessel Working pressures to 55 MPa (8,000 psi) 10.7 m (35 ft) long with a 1.22 m (4 ft) diameter Equipped with internal rams and reaction frames to apply tension, compression, torsion and bending loads to specimens while under pressure

Full scale pipeline testing at working pressures, both internally and externally Rapid installation and removal of test specimens and assemblies Internal video monitoring Accommodates hydraulic, electrical, video and instrumentation leads Universal Testing System MTS closed-loop hydraulic system capable of static, cyclic, or impact loads to 15 MN and cyclic to 5 MN Expandable to 25 MN static axial load High strain rate capability Service temperature range -60°C to +40°C Specimen sizes to 6m high x 2m wide x 18m Tubulars Testing System MTS closed-loop hydraulic system capable of applying static loads to 15 MN, cyclic loads to 5 MN Vertically-oriented support shaft with reaction points to induce prescribed curvatures or apply lateral loads Expandable to 25 MN static axial load Specimen sizes to 15 m x 1.5 m diameter Strong Floor and Walls High capacity multi-use reaction floor (22 m x 12 m) Buttressed multi-directional reaction wall (15 m long x 6 m high) for application of multi-directional loading Accommodates large-scale structural assemblies and components with more than 1,300 tie-down locations Serviced by 10 t overhead travelling crane Component Testing Self-contained computer-controlled load and pressure systems for serviceability and proof testing of hoisting equipment, couplings, valves, vessels, etc.

w ww .cferte ch .co m

August 2002

REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323)

Confidential

Prepared for: Steve Foh Pipeline Research Council International, Inc. c/o Gas Technology Institute 1700 South Mount Prospect Road Des Plaines Illinois 60018-1804 USA

Prepared by: Mark McQueen (& Vinod Chauhan, Paul Ng) Advantica Technologies Inc. 5177 Richmond Avenue Suite 900 Houston TX 77056 USA Tel: Fax: Email: Website:

713 586 7000 713 586 0604 [email protected] www.advanticatechinc.com

Sales Opportunity ID: 1001421 Ⓒ 2002 Advantica Technologies Inc.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

Page 1

PROPOSAL SUMMARY Proposal:

RPTG 0323

Title: REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOAD. Contractors: Advantica Technologies Inc. Type: New. Period: Start date January 2003, duration 12 months. Total estimated cost:

US$120,000.

Objective: To extend the assessment methods for corroded pipelines to incorporate the effects of bending and axial loads on internal pressure. Incentive: The recognized methods commonly used for assessing the remaining strength of corroded pipelines are based on pressure loading, and do not address superimposed axial or bend loading. At present the only option is to use sophisticated finite element analysis on a case-by-case basis. Development of a generalised approach will remove an important area of uncertainty in the present methods. Work Plan: TASK 1 – Pipeline external loading case history review. TASK 2 – Evaluation of bounding external loads due to ground movement. TASK 3 – Numerical simulation of corroded pipe subjected to combinations of internal pressure and external loading. TASK 4 – Development of a revised method incorporating combined internal pressure and external loading. Deliverables: A report incorporating: • Review of loading scenarios in onshore pipelines • Numerical simulation and assessment • Development of a new (modified) guidance procedure

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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Table of Contents PART I TECHNICAL PROPOSAL 1 2

3 4 5 6

INTRODUCTION ................................................................................................ 2 TECHNICAL DISCUSSION ................................................................................ 3 2.1 Objective..................................................................................................... 3 2.2 Work to be Performed and Approach ...................................................... 3 2.3 TASK 1 – PIPELINE EXTERNAL LOADING Case History Review ...... 3 2.4 TASK 2 – EVALUATION OF BOUNDING EXTERNAL LOADS DUE TO GROUND MOVEMENT ...................................................................................... 4 2.5 TASK 3 – NUMERICAL SIMULATION of Corroded Pipe SUBJECTED TO COMBINATIONS OF INTERNAL PRESSURE AND EXTERNAL LOADING 4 2.6 TASK 4 – Assessment and Development of A Revised Method TO ASSESS CORROSION METAL LOSS DEFECTS IN PIPELINES SUBJECTED TO COMBINED INTERNAL PRESSURE AND EXTERNAL LOADING ............ 5 SCHEDULE ........................................................................................................ 5 DELIVERABLES ................................................................................................ 5 ADVANTICA INFORMATION............................................................................. 6 REFERENCES ................................................................................................... 8 PART II COST PROPOSAL

1 2

COSTS ............................................................................................................. 10 COMMERCIAL TERMS.................................................................................... 12

Confidentiality Statement THE INFORMATION CONTAINED IN THIS PROPOSAL IS PROVIDED ON A COMMERCIAL BASIS IN CONFIDENCE AND IS THE PROPERTY OF ADVANTICA TECHNOLOGIES INC. IT MUST NOT BE DISCLOSED TO ANY THIRD PARTY, IS COPYRIGHT, AND MAY NOT BE REPRODUCED IN WHOLE OR IN PART BY ANY MEANS WITHOUT THE APPROVAL IN WRITING OF ADVANTICA TECHNOLOGIES INC.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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PART I TECHNICAL PROPOSAL

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

Page 1

1 INTRODUCTION Corrosion metal-loss is one of the major damage mechanisms to transmission pipelines worldwide and particularly in North America. Corrosion metal-loss defects reduce the strength of the damaged pipeline sections from the required levels and introduce localized stress concentrations in the pipeline. Several methods have been developed for assessment of corrosion defects, such as ASME B31G[1], RSTRENG[2, 3] and LPC[4]. All these methods were derived based on experimental tests and theoretical/numerical studies of the failure behavior of corroded pipelines subjected to internal pressure loading. PRCI have recognized the importance of improving corrosion assessment of pipelines and have funded a number of projects with Advantica to improve existing assessment methods. These have included; •

State of the art review of corrosion assessment methods

•

Development of new methods for assessing interacting corrosion defects

(PR 273-9803) (PR 273-9803) (GTI 8549)

•

Assessment of corrosion defects in low toughness pipe

(PR 273-0136)

The available methods for assessing the remaining strength of corroded pipelines assume that the pipeline is subjected to internal pressure loading. However, in reality pipelines could also be subjected to significant external loading. For onshore pipelines, these additional loads could be as a result of ground movement due to landslides, mining subsidence, or earthquakes. Significant bending loads can also be generated in the vicinity of pipe bends or pipe branch connections. In the case of offshore pipelines the formation of free spans may impose significant bending loads. For instance, seabed scour can lead to the development and growth of free spans of pipelines resting on the seabed, particularly if they are not trenched. The formation of free spans combined with sea currents could impose significant external loading on the pipeline. The various external loading mechanisms on a pipeline can produce the following; 1. Tensile or buckling failure of the pipeline due to excessive local displacement 2. Shearing of the pipeline This proposal identifies a programme of work that will allow internal pressure and external loading to be included in the corrosion assessment. Completion of this work will help to remove an important area of uncertainty in the assessment methods currently used by the pipeline industry.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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2 TECHNICAL DISCUSSION The recognized assessment methods[1, 2, 3] commonly used in North America for assessing corroded pipelines assume that the loading is dominated by internal pressure. Only the DnV Guidance Document, RP-F101[5], includes an allowance for assessing corroded pipeline that is also subjected to bending and axial loads. This is because RP-F101 was primarily developed for the assessment of offshore pipelines where it was recognized that bending and axial loading could be significant. This guidance is, however, based on the results of a small number (ten) of full-scale burst tests. Some limited work has also been undertaken by Southwest Research Institute[6]. However, the methods developed to date have not been well validated and it is recognized that further work is now required to develop the methods further. Hence there is a need to establish the influence of external additional loading on the corroded pipeline firstly by defining the limits of applicability of the assessment methods for pressure-only loading and secondly by identifying appropriate methods for cases where significant bending or axial loading is imposed onto the pipeline. The objective of this proposal is to determine bounding external loads that could be realistically imposed onto buried transmission pipelines; these loads could be as a result of ground movement and/or landslides. A non-linear finite element based analysis and assessment will be subsequently undertaken using the Level 3 procedure described in the PRCI Guidance Document[7]. Corrosion metal loss defects of varying depth and length will be analyzed. Both single and interacting defects will be modeled with various combinations of internal pressure, bending and axial loading. A detailed description of the technical proposal follows. 2.1 OBJECTIVE The objective of this proposal is to extend the assessment methods for corroded pipelines subjected to combinations of internal pressure, bending and axial loads. Inclusion of this additional loading will remove an important area of uncertainty in the assessment methods that are currently used within the pipeline industry. 2.2 WORK TO BE PERFORMED AND APPROACH With the budget available, it is recommended that the work to be performed is confined to a detailed analytical investigation as opposed to undertaking test work. The work to be performed has been split into five tasks and will be carried out over a twelve-month period. Details of each task are given below. 2.3 TASK 1 – PIPELINE EXTERNAL LOADING CASE HISTORY REVIEW A review of onshore transmission pipeline case histories involving mining subsidence and/or landslides will be undertaken. The review will concentrate on identifying typical magnitudes of forces and moments imposed on onshore transmission pipelines due to landslides and/or mining subsidence. Any external loading information that is readily available for offshore pipelines will also be reported. CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

Page 3

2.4 TASK 2 – EVALUATION OF BOUNDING EXTERNAL LOADS DUE TO GROUND MOVEMENT A geotechnics assessment will be undertaken for two bounding pipeline geometries and material grades which will be agreed with the Materials Committee. One of the major uncertainties in soil/pipe interaction problem is the determination of the appropriate soil restraint. This is influenced by the pipe size and cover depth, the trench geometry, the pipe coating, the soil properties, and the direction of the restraint. Advantica is the world leader in soil/pipe interaction research[8, 9] and has access to a comprehensive database of pipe backfill properties. Non-linear hyperbolic soil restraints will be determined in all four directions (upward, downward, lateral and axial). This method is superior to the common assumptions of liner and bi-liner elastic soil restraints. Sensitivity studies assuming four bounding soil types and conditions (soft and stiff clay; loose and dense sand) will be investigated. The calculated soil restraints, together with the three dimensional ground movement, will be subsequently input into an in-house analysis program PIPELINE[10]. PIPELINE is a WINDOWS™ based stress analysis program for linear buried pipe systems subjected to internal and external loadings. It is based on the well-known finite difference theory for elastic beam on elastic foundation problems and has an excellent track record in solving practical problems for gas transmission operators. The software has been fully validated against analytical solutions and commercial software[11]. Bounding axial loads and moments will be calculated for two pipeline geometries and material grade to be agreed with the Materials Committee. These loads will be compared with those obtained from published data. A commentary on the relative magnitude of the bounding forces and moments will be given. The bounding forces and moments will be subsequently used in the detailed finite element analysis described below. 2.5 TASK 3 – NUMERICAL SIMULATION OF CORRODED PIPE SUBJECTED TO COMBINATIONS OF INTERNAL PRESSURE AND EXTERNAL LOADING Advantica has already generated a significant number (in excess of seventy-five) of non-linear three dimensional finite element models of interacting corrosion metal loss defects in pipelines as part of Phase 4 of PRCI project PR-273-9803. These models will be modified to incorporate both internal pressure combined with bounding axial forces and moments obtained from the geotechnics assessment. Use of the finite element models already generated by Advantica will be cost efficient and will enable an extensive and comprehensive study to be undertaken. Various combinations of both in plane and out of plane bending moments, axial loading and internal pressure loading will be investigated. Both single defect and combinations of interacting axial/circumferential defects will be investigated. Further non-linear finite element models of elbow geometries will also be generated. The well documented and validated procedure described in section 5 of Ref[7] will be used to derive failure pressures for the cases analyzed.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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A revised failure criterion and guidance for the assessing corroded pipelines subjected to combinations of internal pressure, bending and axial loading will be generated. 2.6 TASK 4 – ASSESSMENT AND DEVELOPMENT OF A REVISED METHOD TO ASSESS CORROSION METAL LOSS DEFECTS IN PIPELINES SUBJECTED TO COMBINED INTERNAL PRESSURE AND EXTERNAL LOADING The results of the finite element analyses will be assessed and failure pressure predictions will be reviewed. The influence of the external loading on the corroded pipeline firstly by defining the limits of applicability of the assessment methods for pressure-only loading and secondly by identifying new and revised methods for cases where significant bending or axial loading is imposed onto the pipeline.

3 SCHEDULE The work will be undertaken by Advantica over a twelve month period. A summary of the main tasks of the project and their duration, assuming work commences in Q1 of 2003, is detailed below. The case history review and Geotechnics assessment is estimated to require approximately one and a half man months of effort. The finite element analysis, assessment, development of new criteria, checking, verification and reporting is estimated to take eight and a half months of effort. 2003 TASK 1

PIPELINE EXTERNAL LOADING CASE HISTORY REVIEW

2

EVALUATION OF BOUNDING EXTERNAL LOADS DUE TO GROUND MOVEMENT

3

4

Q1

Q2

Q3

Q4

NUMERICAL SIMULATION OF CORRODED PIPE SUBJECTED TO COMBINATIONS OF INTERNAL PRESSURE AND EXTERNAL LOADING ASSESSMENT AND DEVELOPMENT OF A REVISED METHOD TO ASSESS CORROSION METAL LOSS DEFECTS IN PIPELINES SUBJECTED TO COMBINED INTERNAL PRESSURE AND EXTERNAL LOADING

Notes: Q is quarter year

4 DELIVERABLES The deliverable will be a verified technical report that detailing the following; •

Review of published literature summarizing the magnitude of loading on onshore transmission pipelines.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

Page 5

•

Geotechnics analysis and assessment to generate bounding forces and moments on onshore transmission pipelines.

•

Numerical simulation and assessment of corrosion metal loss defects in pipelines using the validated procedure described in section 5 of Ref[7] .

•

Description of a new guidance procedure that will allow external loads combined with internal pressure to be considered in the corrosion assessment of pipelines.

5 ADVANTICA INFORMATION Advantica is part of the Lattice Group, the UK-based infrastructure technology group that includes the gas pipeline operator Transco, and is a leading supplier of innovative technologies and technical services to the global energy marketplace. Advantica's aim is to be a leading improver of business and operating performance for customers in gas, pipelines and associated industries internationally. Advantica has its origins in the British Gas (BG) group of companies and is now a $100 million business with over 800 skilled staff and centers in Houston, Charlotte and the UK. Advantica has fully equipped in-house facilities to undertake a wide variety of experimental testing programs. These are complemented by a comprehensive suite of state-of-the-art numerical computing and finite element analysis facilities. Advantica is a long established technology supplier to the PRCI member companies and has a substantial track record in the management and execution of major Joint Industry Projects for groups of international gas and oil operators. Advantica is a recognized leader in the development of assessment methods of corrosion metal loss defects in pipelines. Advantica has led the corrosion Group Sponsored Project and has undertaken a large number of full-scale tests and numerical simulations of corroded pipelines. We, therefore, have access to an extensive database of test/numerical data. The output from this work has been embodied in internationally used standards such as BS 7910[12]. Advantica, together with DnV have also developed the guidance document RP-F101[4] which allows external loading to be incorporated into the corrosion assessment. Advantica is presently undertaking a number of projects on behalf of PRCI. These are to extend methods for assessing metal loss defects in low toughness pipe and to improve the methods for assessing interacting metal loss defects. In particular Advantica now has access to a large library of FE models already generated as part of this latter project will enable Advantica to undertake a detailed and comprehensive assessment of corrosion defects in pipelines subjected to combinations of internal pressure and external loading. Advantica is, therefore, well placed to develop the assessment methods given in Ref [4, 12] . Vinod Chauhan has seventeen years professional experience gained in the oil, gas, nuclear and defence industries. He is a co-author of the pipeline corrosion

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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assessment Guidance Document, Ref[7] and is the principal researcher undertaking the Phase 4 corrosion interaction study on behalf of PRCI. Paul Ng has worked on a wide variety of onshore pipeline geotechnical investigations. Paul has undertaken numerous stress analysis of pipelines subjected to external loads and provided advice on site specific soil restraint parameters. He is a chartered member of the Institution of Civil Engineers, a chartered Member of the Institute of Gas Engineers and Managers, and a member of the Institution of Highways and Transportation. Paul is an active member of the United Kingdom Society of Trenchless Technology and the associate editor of the Trenchless Technology Research Journal.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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6 REFERENCES [1]. Anon. ASME B31G-1991 (revision of ANSI/ASME B31G-1984). ‘Manual for determining the remaining strength of corroded pipelines – a supplement to ASME B31 code for pressure piping’. The American Society of Mechanical Engineers, 1991. [2]. Kiefner, J. F. and Vieth, P. H., ‘A modified criterion for evaluating the remaining strength of corroded pipe’, Final report on PR-3-805 to Pipeline Corrosion Supervisory Committee of the Pipeline Research Committee of the American Gas Association, Battelle, Ohio, 1989. [3]. Vieth, P. H. and Kiefner, J. F., RSTRENG2 user’s manual, Final report on PR218-9205 to Corrosion Supervisory Committee, Pipeline Research Committee, American Gas Association, Kiefner & Associates, Inc., Ohio, 1993. [4]. Anon. ‘DnV Recommended Practice RP-F101: Corroded Pipelines’, Det Norske Veritas, Oslo, 1999 [5]. Fu, B. and Batte, A. D., ‘Advanced methods for the assessment of corrosion in linepipe’, Summary Report OTO 97065, UK Health and Safety Executive, London, 1998. [6]. Smith, M.Q., and Grigory, S.C., ‘New Procedures for the Residual Strength Assessment of Corroded Pipe Subjected to Combined Loads’, ASME International Pipeline Conference, 1996. [7]. Fu, B., Chauhan, V and Jones, L. ‘Guidance for Assessing the Remaining Strength of Corroded Pipeline’, Final Report on PR 273-9803 (Phase-2) to the Material Supervisory Committee Pipeline Research Council International Inc., June 2002. [8]. Ng, P. C. F.; Pyrah, I. C. & Anderson, W. F. (2002). The prediction of ultimate lateral soil pressure on shallow pipelines in trench cohesive backfill. Proceedings of the Eighth International Symposium on Numerical Models in Geomechanics – NUMOG VIII, Rome, Italy, Eds: Pande, G. N. & Pietruszczak, S., 10–12 April 2002, pp. 393-397. Balkema, Lisse. [9]. Ng, P. C. F.; Leach, G. & Harrold, S. (2001). International collaborative research on soil/pipe interaction. Proceedings of the 2001 International Gas Research Conference, IGRC 2001, Amsterdam, Netherlands. 5–8 November 2001. [10]. Ng, P. C. F., Pyrah, I. C. and Anderson, W. F. (1995). Modelling of laterally loaded pipelines using elastic beam on elastic foundation approach. Developments in Computational Techniques for Structural Engineering, Proceedings of the Sixth International Conference on Civil and Structural Engineering Computing, Cambridge, UK, 28–30 August 1995, pp. 71–76. [11]. Ng, P. C. F. (1999). Benchmark Tests for WOMODNT Version 3. Advantica Technologies Ltd., June 1999. [12]. Anon. ‘Guide on Methods for Assessing the Acceptability of Flaws in Metallic Structures’, BS 7910: 1999 (incorporating amendment no. 1), BSi, October 2000.

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PART II COST PROPOSAL

1 COSTS The work described in this proposal will be undertaken on a fixed cost basis. The fixed cost is $120,000. The total cost is inclusive of labor, computing, consumables, overheads, project management. An allowance for one technical presentation to the Committee has also been included. A cost breakdown of the main tasks is summarized in Table 1.

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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CONTRACT COST ESTIMATE

Name of Offeror Advantica Technologies Inc. Home Office Address 5177 Richmond Avenue, Suite 900 Houston, TX 77056 USA Division(s) and Location(s) (where work is being performed) Pipeline Transportation Division, Loughborough, UK

RFP No/Prp No Page Number Number of Pages RPTG 0323 1 1 Name of Proposed Project REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) Total Amount of Proposal $ 104,753 (US) Estimated Cost (dollars)

Cost Elements 1.

Total Estimated Cost (dollars)

Supporting Schedule

Direct Material a. Purchased Parts b. Interdivisional Effort c. Equipment Rental/Lease d. Other (software licence costs)

7,700

Total Direct Material 2. 3.

Material Overhead (Rate

7,700 % x Base $

)

Subcontracted Effort (Attach Detailed Schedule) Subcontractor Cofunding Net Subcontracted Effort

4.

Est. Hours

Rate/Hour

Manager/Consultant

Direct Labor - Specify

65

195

12,675

Senior Engineer

433

143

61,919

Engineer

334

109

36,406

0

69

0

O.H. Rate

X Base $

Est. Cost

Technician

Est. Cost

Total Direct Labor 5.

Labor Overhead - Specify

111,000

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

10. Other Direct Costs 11. Total Direct Cost and Overhead

1,300

Travel & Direct Expenditure

12. General and Administrative Expenses (w/o IR&D) Rate

% of cost element numbers

13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost

120,000

15. Fixed Fee 16. Total Estimated Cost and Fee

120,000

17. Contractor/Third Party Cofunding 18. Net PRCI Estimated Cost and Fee

120,000

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title Signature Date Mr Vinod Chauhan and Dr Paul Ng 2 August 2002

Table 1.

Contract Cost Estimate

CONFIDENTIAL REMAINING STRENGTH OF CORRODED PIPE UNDER BIAXIAL LOADING (RPTG 0323) August 2002 Rev 0

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2 COMMERCIAL TERMS Terms and conditions for undertaking the proposed work will be consistent with those previously agreed between Advantica Technology Inc. and GTI.

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PART I – TECHNICAL PROPOSAL TP296-3442

EXTERNAL MIC GROWTH RATE MODELING

PREPARED FOR

PRC INTERNATIONAL Pipeline Materials Committee

PREPARED BY

CC TECHNOLOGIES LABORATORIES, INC. OLIVER C. MOGHISSI AUGUST 05, 2002

CC Technologies 6141 AVERY ROAD DUBLIN, OHIO 43016 614.761.1214 • 614.761.1633 fax www.cctechnologies.com

Technical Proposal

External MIC Growth Rate Modeling

PROPOSAL SUMMARY

TITLE: External MIC Growth Rate Modeling CONTRACTOR: CC Technologies Laboratories, Inc. NEW PROJECT: FUNDING REQUEST: 2003 PRCI 2004 PRCI Total

$ 75,000 $ 49,500 $ 124,500

OBJECTIVE To measure growth rates of external pipeline MIC under realistic soil conditions through a matrix of laboratory tests.

WORK PLAN The work scope spans over two years. 1. Assemble a matrix of 60 test cells representing a welded pipe sample with crevice under a range of soil, bacteria, and nutrient environments. 2. Allow bacteria to grow and measure corrosion damage after 6, 12, and 18 months. Calculate corrosion rates based on time of exposure and environment to predict realistic MIC rates on buried pipelines.

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TABLE OF CONTENTS

INTRODUCTION............................................................................................................. 1 OBJECTIVE AND SCOPE .............................................................................................. 1 WORK PLAN................................................................................................................... 2 SCHEDULE..................................................................................................................... 5 COSTING AND MANPOWER REQUIREMENTS ........................................................... 6 PROJECT ORGANIZATION AND MANAGEMENT ........................................................ 6 CORPORATE QUALIFICATIONS................................................................................... 7 RELATED PROJECT DESCRIPTIONS .......................................................................... 7 PROFESSIONAL SUMMARIES...................................................................................... 9

FIGURES Figure 1. Test panel with weld and polyolefin crevice. Circle represents test cell containing soil. Panel size is approximately 4 inches................................. 4 Figure 2. Test cell assembly. A cylindrical cell sits on a flat test panel and is filled with soil. The top is sealed. .............................................................................. 5 Figure 3. Project Schedule .............................................................................................. 6

APPENDICIES APPENDIX A

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INTRODUCTION Microbiologically influenced corrosion (MIC) is widely recognized as a contributing factor to pipeline corrosion (internal and external), but agreement does not exist on the growth rate of MIC damage and the influence of metallurgical characteristics. Previous work is limited by several factors and has therefore not provided sufficient information from which to base engineering decisions. Typical and maximum MIC growth rates are not presently known, and it is not presently possible to determine if a particular pipeline or portion of pipeline is more susceptible to MIC than others. This can result in undetected MIC damage, poor scheduling of maintenance or inspection tasks, selection of inappropriate mitigation schemes, or unnecessary corrosion mitigation costs to compensate for lack of information. Agreement does not exist on the influence of metallurgical characteristics on MIC. Field observations and limited laboratory testing have suggested that particular types of weld metal or heat affected zones are more susceptible than the base metal, but clear evidence has not been presented. If it is determined that particular types of weld metal or heat affected zones are more susceptible than the base metal, an operator would examine those areas to determine if a MIC problem exists throughout the system and gauge the effectiveness of mitigation. Otherwise, examination of arbitrary pipe segments may not identify MIC damage occurring in other parts of the system. Knowledge about the rate of MIC at welds may also lead an operator to modify field coating applications at joints or perhaps even the weld procedure of new pipe. Previous work related to MIC of steel components has been limited by several parameters. One significant limitation is that previous work typically has not included long-term exposure of samples having characteristics typical of actual pipelines in MIC environments. The results of some short-term laboratory testing have suggested an influence of metallurgical factors on susceptibility to bacterial colonization and subsequent corrosion. However, the test times have been too short to demonstrate a relationship between metallurgical characteristics and long-term MIC penetration rates. The relationship of colonization rates in short term testing to long-term penetration rates has not been demonstrated. Long-term immersion testing in laboratory experiments has typically not produced results representative of the observed performance of actual pipelines, primarily because it is difficult to establish realistic viable consortia of bacteria, maintain them in the laboratory for long periods of time, and experience accelerated corrosion

OBJECTIVE AND SCOPE To measure growth rates of external pipeline MIC under realistic soil conditions through a matrix of laboratory tests. 1 TP296-3442 CC Technologies Laboratories, Inc.

Technical Proposal

External MIC Growth Rate Modeling

WORK PLAN It is proposed to perform a series of laboratory tests to measure corrosion damage as a function of soil type and microbiological variables. The tests will cover a range of conditions to simulate realistic field conditions, sterile conditions, and environments supplemented with bacteria and/or nutrients.The work scope spans over two years. 1. Assemble a matrix of 60 test cells representing a welded pipe sample with crevice under a range of soil, bacteria, and nutrient environments. 2. Allow bacteria to grow and measure corrosion damage after 6, 12, and 18 months. 3. Calculate corrosion rates based on time of exposure and environment to predict realistic MIC rates on buried pipelines. A schematic of the test panel is shown in Figure 1. The panel will be approximately 4 inches, and cut from a section of pipe so that the weld (ERW is proposed) passes through the middle of the sample. The specimen will be flattened by a press so that a cylindrical test cell can be placed on the surface and sealed. Other than solvent cleaning to remove organics, minimal surface preparation will be conducted to preserve the structure of the surface. If possible, a thin walled pipe sample will be selected allowing weight loss measurements. A small section of polyolefin will be placed on the front of the panel forming a crevice like what might be found under disbonded coating on a field joint. The test cell assembly is shown in Figure 2. A cylinder will be placed on the test panel and sealed with gasket material. The cylinder will be filled with soil, and the top will be sealed with a panel. A small port will be added so that bacteria and/or nutrients can be added during the test. This port will contain a 2 micron filter to prevent the entry of bacteria. For the cells in which bacteria will be introduced, a seal will be used that allows the use of a syringe without contaminating the cell. A total of 60 cells will be constructed according to the test matrix shown inTable 1. . Four soil types will be tested: 4. The first will be soil collected from a pipeline dig site where MIC is suspected to have occurred. This is intended to most closely simulate a field environment known to have the ability to support MIC. 5. Sandy soil will be used to represent a porous and permeable material. 6. Clay will be used to represent a tight material with little void space and poor ability to transport biological or chemical materials. 7. Water will serve as a laboratory control sample. Use of water will allow visual inspection of the test panel throughout the test period. Five

bacteria

related

environments 2

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will

be

tested

for

each

soil

type:

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External MIC Growth Rate Modeling

8. The first environment will be sterile. The test cell and soil will be sterilized by autoclaving, any restoration of water will be sterile, and the cell will be sealed using a 2 micron filter (not allowing bacteria to pass). 9. Fresh native soil will be used as the most natural of environments. Soil samples will be collected from field locations, and no attempt will be made to add bacteria or sterilize. Proper handling procedures (e.g., chilling) will be used to transport the soil so that any native bacteria are not destroyed during transport. 10. Nutrients will be added to the native soils to allow naturally resident bacteria to have access to food. This will simulate a condition of native bacteria with plentiful food source. One drawback to using nutrients is that previous testing has shown that planktonic bacterial growth can be stimulated over the preferred sessile bacteria that attaches to a surface and causes corrosion. 11. A fourth test will have bacteria added without nutrients. This simulates the condition of a natural soil environment and ensures that bacteria associated with corrosion are present. At minimum, the cell will be inoculated with two bacteria. Sulfate reducing bacteria (SRB) will be added because it is most frequently associated with corrosion damage. In addition, a slime former will be added because MIC due to SRB is almost always associated with a biofilm dominated by slime. The slime allows a local environment to exist underneath it so that the anaerobic SRB is isolated from oxygen, and the corrosive metabolic products are concentrated under the film. Inoculation with acid producing bacteria (APB) is also preferred in the test because biofilms associated with corrosion are believed to be a complex matrix of bacteria including APB. 12. The last test cells will be inoculated with bacteria and contain excess nutrients. This environment will ensure bacterial growth in all soil environments. Three cells will be assembled for each environmental combination giving a total of 60 tests. The triplicate cells are intended to allow measurement of corrosion (and bacteria) after three time periods so that corrosion rate can be calculated. It is expected that the corrosion rate will not be constant over the test period. The longest test period will be 18 months. This long period is considered necessary because previous work has shown that the period for bacteria to attach themselves to a metal surface, grow to form a biofilm, and generate corrosive metabolic products can take a period of several months. The first two cells will be disassembled after 6 months and 1 year. Each panel will be evaluated for corrosion and bacterial activity. Corrosion will be measured by pit depth measurements and, if possible, weight loss. Bacteria counts will 3 TP296-3442 CC Technologies Laboratories, Inc.

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External MIC Growth Rate Modeling

be taken and a qualitative characterization of the biofilm will be made. The distribution of all observations will be noted with respect to the bare area and position down the crevice. Table 1. Test Matrix Initially Sterilized

Fresh Native

Nutrient Supplement

Inoculated

Inoculated & Nutrient Supplement

Field Soil

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

Sandy Soil

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

Clay

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

Water

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

6,12,18 mo

Figure 1. Test panel with weld and polyolefin crevice. Circle represents test cell containing soil. Panel size is approximately 4 inches.

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Figure 2. Test cell assembly. A cylindrical cell sits on a flat test panel and is filled with soil. The top is sealed.

DELIVERABLES The final deliverable will be a report documenting the results of the work and summarizing the conclusions. An interim report will be provided at the end of year 1, and quarterly reports will be provided.

SCHEDULE The entire project will be completed within 24-months. Figure 3 gives the project schedule for the individual tasks.

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24

12

18

External MIC Growth Rate Modeling

6

0

Technical Proposal

Months

Collect Materials Assemble Test Cells Run 6 Month Test Interim Report Run 12 Month Test Run 18 Month Test Final Report

Figure 3. Project Schedule

COSTING AND MANPOWER REQUIREMENTS The total project cost over 2 years is $124,500 and is broken down for each year. A detailed cost summary is attached. The Year One cost of the project is $75,000. The manpower requirements are: Senior Group Leader

190 hours

Project Engineer

140 hours

Technologist

260 hours

Office Staff Year 1 Total Labor

40 hours 630 Hours

The Year two cost of the project is $49,500. The manpower requirements are: Senior Group Leader

120 hours

Project Engineer Technologist

80 hours 170 hours

Office Staff Year 2 Total Labor

40 hours 410 Hours

PROJECT ORGANIZATION AND MANAGEMENT The Project Manager and overall project administrator for the proposed project will be Dr. Oliver Moghissi. Dr. Moghissi has experience in managing multi-disciplinary research programs for government and industrial clients (including PRCI) and previous 6 TP296-3442 CC Technologies Laboratories, Inc.

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External MIC Growth Rate Modeling

experience working for a pipeline operating company. Dr. John Beavers will support the project and has a long history with performing successful projects for PRCI and other research organizations. Professional summaries are attached.

CORPORATE QUALIFICATIONS CC Technologies Laboratories, Inc. is a contract research and engineering organization that specializes in corrosion and corrosion control. CC Technologies' philosophy is to provide an organization that can accommodate leading experts in various fields of corrosion in both research and engineering; providing its clients with the highest level of expertise available anywhere in the country. The combination of research and engineering expertise permits CC Technologies to provide research tempered by engineering applicability, and engineering services that are of the highest quality from both practical and fundamental aspects. CC Technologies was started in 1985 and has grown to a staff of over eighty people. The staff includes eight Ph.D. scientists, four M.S. researchers, and fourteen B.S. engineers. On this staff are P.E.s registered in ten states and Canada and NACE Certificated Corrosion Specialists. Degrees earned by the staff include: •

Metallurgical Engineering.

•

Materials Science.

•

Electrical Engineering.

•

Mechanical Engineering.

•

Chemical Engineering.

•

Petroleum Engineering.

•

Theoretical and Applied Mechanics.

•

Aerospace Engineering.

•

Geology.

CC Technologies is a fully equipped corrosion testing and research laboratory specializing in the evaluation of materials properties, materials selection, corrosion, corrosion control, and design and development of instrumentation and engineering software. CC Technologies has continued to grow since its inception in 1985 and now occupies a 21,000-ft2 office and laboratory facility. In addition to numerous laboratory soil cells and soil boxes to perform laboratory tests for underground related projects, CC Technologies has 400-ft of 20-inch diameter pipe buried at it’s facility in Dublin, Ohio, which is instrumented for use on CP related research projects. In addition, there is a full-scale pipe burst facility available for structural analyses involving pipe ruptures.

RELATED PROJECT DESCRIPTIONS CC Technologies Laboratories, Inc. is a contract research and engineering organization that specializes in corrosion and corrosion control. CC Technologies' 7 TP296-3442 CC Technologies Laboratories, Inc.

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External MIC Growth Rate Modeling

philosophy is to provide an organization that can accommodate leading experts in various fields of corrosion in both research and engineering; providing its clients with the highest level of expertise available anywhere in the country. The combination of research and engineering expertise permits CC Technologies to provide research tempered by engineering applicability, and engineering services that are of the highest quality from both practical and fundamental aspects. CC Technologies was started in 1985 and has grown to a staff of over eighty people. The staff includes eight Ph.D. scientists, four M.S. researchers, and fourteen B.S. engineers. On this staff are P.E.s registered in ten states and Canada and NACE Certificated Corrosion Specialists. Degrees earned by the staff include: •

Metallurgical Engineering.

•

Materials Science.

•

Electrical Engineering.

•

Mechanical Engineering.

•

Chemical Engineering.

•

Petroleum Engineering.

•

Theoretical and Applied Mechanics.

•

Aerospace Engineering.

•

Geology.

CC Technologies is a fully equipped corrosion testing and research laboratory specializing in the evaluation of materials properties, materials selection, corrosion, corrosion control, and design and development of instrumentation and engineering software. CC Technologies has continued to grow since its inception in 1985 and now occupies a 21,000-ft2 office and laboratory facility. In addition to numerous laboratory soil cells and soil boxes to perform laboratory tests for underground related projects, CC Technologies has 400-ft of 20-inch diameter pipe buried at it’s facility in Dublin, Ohio, which is instrumented for use on CP related research projects. In addition, there is a full-scale pipe burst facility available for structural analyses involving pipe ruptures.

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PROFESSIONAL SUMMARIES OLIVER C. MOGHISSI, Ph.D. Dr. Moghissi is a Senior Group Leader for CC Technologies Laboratories, Inc. He is a Chemical Engineer with fifteen years experience working on corrosion problems as a researcher, oil and gas technical specialist, and university research assistant. Prior to joining CC Technologies, Dr. Moghissi held positions with Southwest Research Institute and ARCO. His experience includes basic and applied research, laboratory testing, field support and training, interaction with state and federal regulators, and routine technical service. Dr. Moghissi has worked on diverse applications, but his expertise is primarily directed toward technical service in the area of oil and gas production and transportation. Specifically, he conducts applied research, laboratory testing, consulting, and field support to assist with maintaining facility integrity and optimizing corrosion control programs. Dr. Moghissi has experience with internal corrosion of pipelines and production facilities. He cooperated with pipeline operators and regulators to develop a method to assess internal corrosion in gas transmission pipelines (i.e., internal corrosion direct assessment). ICDA is a simple and intuitive method to predict the most likely locations of corrosion along a nominally dry gas pipeline. Dr. Moghissi has supported several other programs on internal pipeline corrosion including the simulation of microbially influence corrosion (MIC) under high pressure, use of financial decision analysis principles to optimize maintenance, and optimizing chemical treatment. While at ARCO, Dr. Moghissi managed a global program to evaluate corrosion inhibitor performance in production facilities. For new facilities, he designed treating/monitoring programs including assessing the fitness of inhibited carbon steel in harsh environments. For existing facilities, he provided on-site trouble shooting, auditing, and reduced cost of chemicals by optimizing product selection, dose, and pricing. Dr. Moghissi has experience with external corrosion control of buried structures. He developed and coordinated laboratory programs to design and implement buried cathodic protection (CP) coupons along the Trans-Alaska Pipeline. He co-developed a disbonded coating coupon to predict when steel under CP may be susceptible to corrosion. He also implemented a technique to remove the effects of Telluric-current interference on a full-line close interval survey of the Trans-Alaska Pipeline. While at Southwest Research Institute, Dr. Moghissi supported a program to evaluate the life of corrosion resistant alloys for high level radioactive waste in a geologic repository (i.e., Yucca Mountain) including development of performance confirmation methods. 9 TP296-3442 CC Technologies Laboratories, Inc.

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External MIC Growth Rate Modeling

Dr. Moghissi has experience with offshore (i.e., seawater) corrosion. He has performed laboratory studies to evaluate the effects of bacteria and shielding on structures under CP, evaluated the use of stainless steels and mitigation schemes, and provided routine technical service for platforms and subsea pipelines. Dr. Moghissi’s dissertation was targeted at mitigating velocity accelerated corrosion of aluminum bronze marine screws (i.e., for propulsion of US Navy vessels). Work included development of transport based mathematical models with numerical solution and regression to electrochemical impedance spectra. Education Ph.D., Chemical Engineering, University of Florida, Gainesville, Florida (1992) M.S., Chemical Engineering, University of Virginia, Charlottesville, Virginia (1989) B.A., Chemistry, University of Virginia, Charlottesville, Virginia (1987) Experience Senior Group Leader Senior Research Engineer Senior Research Engineer 1999

CC Technologies Southwest Research Institute ARCO Exploration and Production Technology ARCO Oil and Gas Company

2002 – Present 1999 – 2002 1992 –

U.S. Army Corps of Engineers

Summer 1984,

Summer

1991 1985 Awards ARCO Outstanding Corporate Technical Achievement Award (1997). ARCO Exploration and Production Technology Award of Excellence for 'Major Impact on Operations' (1996). Professional Activities NACE International • Chairman, Education Committee (1999 – 2001) • Member, Public Affairs Committee (2000 – 2001) • Chairman, TG254 on Pipeline MIC (2001) 10 TP296-3442 CC Technologies Laboratories, Inc.

Technical Proposal • • • • • •

External MIC Growth Rate Modeling

Vice Chairman, Education Committee (1997 – 1998) Chairman, Corrosion Inhibitor Course Development Task Group (1998) Chairman, CP Coupon Course Development (1997 – 1998) Chairman, Basic Corrosion Course Development Task Group (1996 – 1998) Instructor, NACE CP Coupon TechEdge Course (1997) Chairman, North Texas Local Section Membership (1993 – 1995)

Presentations / Publications 1. O. C. Moghissi, L. Norris, P. Dusek, and B. Cookingham, “Internal Corrosion Direct Assessment,’ CORROSION/2002. 2. D. Mauney, O. Moghissi, N. Sridhar, “Internal Corrosion Risk Assessment and Management of Steel Pipelines,” PRCI Final Report, PR 15-9808, 2001. 3. O. Moghissi, N. Sridhar, M. Hill, P. Angell, B. Cookingham, R. Eckert, “Interdependent Effects of Bacteria, Gas Composition, and Water Chemistry on Internal Corrosion of Steel Pipelines,” PRCI Final Report, PR 15-9916, 2001. 4. O. C. Moghissi, “Advances in Corrosion Monitoring for the Pipeline Industry,” Research in Progress Symposium, CORROSION/2001. 5. C. S. Brossia, D. S. Dunn, and O. C. Moghissi, “Approaches to Confirm Waste Package Performance,” The International High-Level Radioactive Waste Management Conference, Las Vegas, NV, 2001. 6. C. S. Brossia, D. S. Dunn, O. C. Moghissi, and N. Sridhar, “Assessment of Methodologies to Confirm Container Performance Model Predictions,” NRC Report 01402.571.030, July 2000. 7. O. C. Moghissi, Y-M Pan, D. D. Daruwalla, J. Weldy, “Ultrafiltration in Low-Activity Waste and High-Level Waste Processes: A Critical Review,” NRC Report 01403.102.00, July 2000. 8. N. Sridhar, D. S. Dunn, C. S. Brossia, and O. C. Moghissi, “Corrosion Monitoring Techniques for Thermally Driven Wet and Dry Conditions,” Paper No. 283, CORROSION/2000. 9. C. S. Brossia, D. S. Dunn, O. C. Moghissi, and N. Sridhar, “Assessment of Methodologies to Confirm Container Performance Model Predictions,” NRC Report 01402.571.030, July 2000. 11 TP296-3442 CC Technologies Laboratories, Inc.

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Presentations / Publications (Continued) 10. O. C. Moghissi, Y-M Pan, D. D. Daruwalla, J. Weldy, “Ultrafiltration in Low-Activity Waste and High-Level Waste Processes: A Critical Review,” NRC Report 01403.102.00, July 2000. 11. N. Sridhar, D. S. Dunn, C. S. Brossia, and O. C. Moghissi, “Corrosion Monitoring Techniques for Thermally Driven Wet and Dry Conditions,” Paper No. 283, CORROSION/2000. 12. O. C. Moghissi and M. Bohon, “Oil and Gas Production internal Corrosion Control,” Tutorials in Corrosion Science & Engineering, AlChE 1999 Annual Meeting, Dallas, TX. 13. C. D. Stears, O. C. Moghissi, L. Bone, “Field Program on CP Coupons,” Materials Performance, Vol. 37, No. 2, 1998. 14. O. C. Moghissi, C. D. Stears, P. Lara, L. Bone, “Laboratory Program on the Use of CP Coupons,” Paper No. 563, CORROSION/97. 15. C. D. Stears, O. C. Moghissi, L. Bone, “Field Program on the Use of CP Coupons,” Paper No. 564, CORROSION/97. 16. R. M. Degerstedt, K. J. Kennelley, P. F. Lara, and O. C. Moghissi, “Acquiring Telluric Nulled Pipe to Soil Potentials on the Trans Alaska Pipeline,” Paper No. 345, CORROSION/95.

17. L. Bone, G. Ruschau, and 0. Moghissi, “Methods to Develop a Performance Envelope for Internal Linings in Oilfield Production Environments,” Paper No. 549, 12th International Corrosion Congress: Corrosion Control for Low Cost Reliability Conference, 1993. 18. P. Agarwal, O. C. Moghissi, M. E. Orazem, and L. H. Garcia-Rubio, “Application of Measurement Models for Analysis of Impedance Spectra,” Corrosion, (1993), Vol. 49, No. 4,278-89. 19. P. Agarwal, O. C. Moghissi, M. E. Orazem, and L. H. Garcia-Rubio, “Application of Measurement Models for Analysis of Impedance Spectra,” Paper No. 227, CORROSION/92. 20. M. E. Orazem, J. M. Esteban, and O. C. Moghissi, “Practical Applications of the Kramers-Kronig Relations,” Paper No. 139, CORROSION/91.

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Presentations / Publications (Continued) 21. O. C. Moghissi and M. E. Orazem, “A Mathematical Model for the Impedance Response of Copper in Alkaline Chloride Solutions,” 179th Electrochemical Society Meeting, 1991. 22. M. E. Orazem, J. M. Esteban, and O. C. Moghissi, “Practical Applications of the Kramers-Kronig Relations,” Corrosion, Vol. 47, No. 4, 1991, pp 248-259. 23. O. C. Moghissi and M. E. Orazem, “An Electrochemical Impedance Study on the Corrosion of Copper and its Aluminum Alloys in Alkaline Chloride Solutions,” CORROSION/90 Research in Progress Symposium.

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JOHN A. BEAVERS, Ph.D. Dr. Beavers is Executive Vice President of CC Technologies Laboratories, Inc. (CC Technologies) a corrosion engineering and research company. He has directed and contributed to numerous research programs on corrosion performance of structural materials. These programs have included failure analyses, critical literature reviews, and laboratory and field evaluations of metallic and non-metallic materials. Dr. Beavers has utilized state-of-the-art electrochemical, surface analytical, and mechanical techniques for evaluation of materials performance for different forms of corrosion. Electrochemical techniques used include potentiodynamic polarization, polarization resistance, electrochemical impedance spectroscopy, electrochemical noise, and galvanic current measurements. Surface analytical techniques used include Auger electron spectroscopy (AES), x-ray photoelectron spectroscopy (XPS), energy dispersive x-ray spectroscopy (EDS), scanning electron microscopy (SEM), transmission electron microscopy (TEM), electron microprobe, and x-ray diffraction. Mechanical techniques used include elastic and plastic fracture mechanics and dynamic mechanical loading techniques such as slow strain rate and low cycle fatigue. A major emphasis of the research of Dr. Beavers has been addressing mechanistic and practical aspects of corrosion and stress corrosion cracking (SCC) on underground structures.

Education B.S., Metallurgical Engineering with Highest Honors (1973), University of Illinois Ph.D., Metallurgical Engineering (1977), University of Illinois Experience Executive VP

CC Technologies Laboratories, Inc.

Senior Scientist

CC Technologies

1987 – 1989

Research Leader

Battelle Memorial Institute (Corrosion Section)

1977 – 1987

Graduate Research

University of Illinois

1973 – 1977 14

TP296-3442 CC Technologies Laboratories, Inc.

1989 – Present

Technical Proposal Assistant

External MIC Growth Rate Modeling Metallurgical Engineering Urbana, Illinois

Professional Organizations NACE International

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Professional Activities Member of Publications Committee, NACE (1982 – 1993) Chairman, Research In Progress Symposium, NACE (1993 – 1994) Chairman of Publications Committee, NACE (1991 – 1992) Member Awards Committee, NACE (1999 – Present) Selected Publications 1. Beavers, J. A. and Garrity, K. C., “100 mV Polarization Criterion and External SCC of Underground Pipelines,” Corrosion NACExpo 2001, NACE International, Paper No. 01592, Houston, Texas (March 2001). 2. Beavers, J. A., Durr, C. L., Delanty, B. S., Owen, D. M., and Sutherby, R. L., “NearNeutral pH SCC: Crack Propagation in Susceptible Soil Environments,” Corrosion NACExpo 2001, NACE International, Paper No. 01217, Houston, Texas (March 2001). 3. Beavers, J. A., Author of Chapters 1, 3, 4, 10, and 16 of Peabody’s Control of Pipeline Corrosion, Second Edition, NACE International, 2001. 4. C. E. Jaske and John A. Beavers, “Evaluating the Remaining Strength and Life of Pipelines Subject to Local Corrosion or Cracking.” NACE Northern Area Premiere Conference (Corrosion Prevention 2000), Toronto, Ontario, Canada, November 2000. 5. Beavers, J. A., Johnson, J. T., and Sutherby, R. L., “Material Factors Influencing the Initiation of Near-Neutral pH SCC on Underground Pipelines,” ASME International, OMAE Division (Calgary Chapter) International Pipeline Conference (IPC 2000), Calgary, Alberta, Canada, October 1 – 5, 2000, ASME Paper No. IPC 0047. 6. Brongers, M. P. H., Beavers, J. A., Jaske, C. E., “Influence Of Metallurgy On Ductile Tearing During Hydrostatic Testing Of Line-Pipe Steels With Stress-Corrosion Cracks,” ASME International, OMAE Division (Calgary Chapter) International Pipeline Conference (IPC 2000), Calgary, Alberta, Canada, October 1 – 5, 2000, ASME Paper No. IPC 0048. 7. Johnson, J. T., Durr, C. L., and Beavers, J. A., “Effects of O2 and CO2 on NearNeutral-pH Stress Corrosion Crack Propagation,” CORROSION/2000, NACE International, Paper No. 00356, Orlando, Florida (March 2000). 16 TP296-3442 CC Technologies Laboratories, Inc.

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Selected Publications (Continued) 8. Brongers, M. P. H., Beavers, J. A., and Jaske, C. E., “Effect of Hydrostatic Testing on Ductile Tearing of X-65 Line–Pipe Steel With Stress Corrosion Cracks,” Corrosion NACExpo 2000, NACE International, Paper No. 00355, Orlando, Florida (March 2000). 9. C. E. Jaske and J. A. Beavers, "Fitness-For-Service Evaluation of Pipelines with Stress-Corrosion Cracks or Local Corrosion," International Conference on Advances in Welding Technology (ICAWT ’99), Galveston, Texas USA, October 26-28, 1999. 10. Beavers, J. A. and Johnson, J. T., “Stress Corrosion Cracking: An Overview Of Field Data Collection,” EPRG / PRCI – 12th Biennial Joint Technical Meeting on Line Pipe Research, Groningen, The Netherlands, May 1999. 11. Beavers, J. A. and C. E. Jaske, “SCC of Underground Pipelines: A History of The Development of Test Techniques,” Corrosion NACExpo 99, NACE International, Paper No. 99142, San Antonio, Texas (April 1999). 12. Jaske, C. E. and J. A. Beavers, “Predicting the Failure and Remaining Life of Gas Pipelines Subject to Stress Corrosion Cracking,” International Gas Research Conference, San Diego, California; November 8 – 11, 1998; Paper TS0-13. 13. Beavers, J. A., Durr, C. L., and Shademan, S. S., “Mechanistic Studies of NearNeutral-pH SCC on Underground Pipelines.” 37th Annual Conference of Metallurgists, Calgary, Alberta, Canada, August 1998. 14. Jaske, C. E. and J. A. Beavers, “Review and Proposed Improvement of a Failure Model for SCC of Pipelines,” International Pipeline Conference, ASME International (OMAE Division) Calgary, Alberta, Canada; June 7 – 11, 1998. 15. J. A. Beavers, C. L. Durr, and B. S. Delanty, “High-pH SCC: Temperature and Potential Dependence for Cracking in Field Environments,” Proceedings for the 3rd International Pipeline Conference, ASME (OMAE Division), Calgary, Alberta, Canada; June 7 – 11, 1998. 16. Kiefner, J. F. and Beavers, J. A., "The History of Stress-Corrosion Cracking in Pipelines in North America," presented at the A.G.A. Operations Conference, Westin Hotel, Seattle, Washington (May 17-19, 1998). 17. Beavers, J. A. and C. L. Durr, “Corrosion of Steel Piling in Nonmarine Applications,” National Cooperative Highway Research Program (NCHRP), Transportation Research Board, National Research Council, National Academy Press, Washington, D.C., Report 408, (1998). 17 TP296-3442 CC Technologies Laboratories, Inc.

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External MIC Growth Rate Modeling

Selected Publications (Continued) 18. Beavers, J. A., C. L. Durr, and N. G. Thompson, “Interpretations Of Potentiodynamic Polarization Curves,” Corrosion NACExpo '98, NACE International, San Diego, CA, Paper No.300, March 1998. 19. Beavers, J. A. and C. E. Jaske, “Near-Neutral pH SCC In Pipelines: Effects Of Pressure Fluctuations On Crack Propagation,” Corrosion NACExpo '98, NACE International, San Diego, CA, Paper No. 257, March 1998. 20. Durr, C. L. and J. A. Beavers, “Techniques For Assessment Of Soil Corrosivity,” Corrosion NACExpo '98, NACE International, San Diego, CA, Paper No. 667, March 1998. 21. Syrett, B. C., A. K. Agrawal, and J. A. Beavers, “Preventing Leakage in the Strand-to-Clip Connection of Water Cooled Generator Stator Windings,” ESKOM/EPRI International Conference on Process Water Treatment and Power Plant Chemistry, Midrand, South Africa (November 1997). 22. Jaske, C. E. and J. A. Beavers, “Fitness-for-Service Evaluation of Pipelines in Ground-Water Environments,” PRCI / EPRG 11th Biennial Joint Technical Meeting on Line Pipe Research; Arlington, Virginia; April 8 – 10, 1997; Paper No. 12. 23. Beavers, J. A. and Thompson, N. G., “Corrosion Beneath Disbonded Coatings: A Review,” CORROSION/96; Denver, Colorado, March 1996, NACE Paper No. 208, and Materials Performance, 36 (4), p. 13 (April 1997). 24. Beavers, J. A. and Harle, B. A., “Mechanisms of High-pH and Near-Neutral-pH SCC of Underground Pipelines,” ASME – International Pipeline Conference; Calgary, Alberta Canada, June 1996, Paper No. IPC 96408. 25. Jaske, C. E., Beavers, J. A., and Harle, B. A., “Effect Of Stress Corrosion Cracking On Integrity And Remaining Life Of Natural Gas Pipelines,”@ CORROSION/96; Denver, Colorado, March 1996, NACE Paper No. 255. 26. Beavers, J. A. and Harle, B. A., “Low-pH Versus High-pH Stress Corrosion Cracking Of Natural Gas Pipelines,” NACE Canadian Region Western Conference in Anchorage, Alaska, February 1996. 27. Beavers, J. A., Thompson, N. G., and Coulson, K. E. W., “Field Studies To Review The Effects Of Surface Preparation On The SCC Susceptibility Of Line-Pipe,” Corrosion Management, August/September 1995.

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External MIC Growth Rate Modeling

Selected Publications (Continued) 28. Beavers, J. A. and Thompson, N. G., “Effects Of Coatings On SCC Of Pipelines: New Developments,” 14th International Conference On Offshore Mechanics and Arctic Engineering (OMAE); Copenhagen, Denmark; June 1995, Paper No. 95-886. 29. Beavers, J. A., Harle, B. A., and Jaske, C. E., “Stress Corrosion Cracking Of Line Pipe Steels In A Low-ph Environment,” The 10th European Pipeline Research Group/American Gas Association Pipeline Research Committee (EPRG/PRC); Cambridge, England; April 1995. 30. Harle, B. A., Beavers, J. A., and Jaske, C. E., “Mechanical And Metallurgical Effects On Low-pH Stress Corrosion Cracking Of Natural Gas Pipelines,” CORROSION/95; Orlando, FL; March 1995, NACE Paper No. 646. 31. Harle, B. A., Beavers, J. A., and Jaske, C. E., “Low-pH Stress Corrosion Cracking Of Natural Gas Pipelines,” CORROSION/94; Baltimore, MD; March 1994, NACE Paper No. 242. 32. Thompson, N. G., Beavers, J. A., and Lawson, Kurt M., “Internal Corrosion Monitoring Of Pipelines,” International Conference and Exhibition on Internal Corrosion And Pipe Protection, Houston, Texas (September 12 – 14, 1994). 33. Beavers, J. A. and Thompson, N. G., “Effects Of Coatings On SCC Of Pipelines: New Developments,” Pipes & Pipelines International, Prevention of Pipeline Corrosion Conference; Houston, TX; October 1994. 34. Beavers, J. A. and Thompson, N. G., “Effects Of Surface Preparation And Coatings On SCC Susceptibility Of Line Pipe; Phase 2 – Field Studies,” 12th International Conference On Offshore Mechanics and Arctic Engineering (OMAE); Glasgow, Scotland; June 1993, Paper No. 93-983. 35. Beavers, J. A., Thompson, N. G., and Silverman, D. C., “Corrosion Engineering Applications Of Electrochemical Techniques: Laboratory Testing,” CORROSION/93, NACE Paper No. 348, March 1993. 36. Beavers, J. A., Thompson, N. G., and Coulson, K. E. W., “Effects Of Surface Preparation And Coatings On SCC Susceptibility Of Line Pipe: Phase 1 – Laboratory Studies,” CORROSION/93, NACE Paper No. 597, March 1993. 37. Durr, C. L. and Beavers, J. A., “Interpretation Of The Polarization Behavior For Copper-Base Alloys In The Tuff Repository,” CORROSION/93, NACE Paper No. 195, March 1993. 19 TP296-3442 CC Technologies Laboratories, Inc.

Technical Proposal

External MIC Growth Rate Modeling

Selected Publications (Continued) 38. Beavers, J. A., Chapter 7, “Stress-Corrosion Cracking of Copper Alloys,” StressCorrosion Cracking, Ed. Russell H. Jones, ASM International, (1992). 39. Beavers, J. A., “Approaches To Life Prediction For High-Level Nuclear Waste Containers In The Tuff Repository,” Symposium on Application of Accelerated Corrosion Tests to Service Life Prediction of Materials, G. Cragnolino, Ed., American Society for Testing and Materials, Philadelphia, 1992. 40. Beavers, J. A., “Limitations Of The Slow-Strain-Rate SCC Test Technique,” ASTM Symposium On Slow-Strain-Rate Testing; Pittsburgh, PA, May 1992. 41. Beavers, J. A. and Durr, C. L., “Stress Corrosion Cracking Studies On Candidate Container Alloys For The Tuff Repository,” NUREG/CR-5710 - May 1992. 42. Durr, C. L. and Beavers, J. A., “Immersion Studies Of Candidate Container Alloys For The Tuff Repository,” CORROSION/92, NACE Paper No. 80, April 1992. 43. Thompson, N. G., Lawson, K. M., and Beavers, J. A., “Area Of Bare Pipe Sampled During A Pipe-To-Soil Potential Measurement,” CORROSION/92, NACE Paper No. 382, April 1992. 44. Beavers, J. A., Thompson, N. G., and Durr, C. L., “Pitting, Galvanic, And Long-Term Corrosion Studies On Candidate Container Alloys For The Tuff Repository,” NUREG/CR-5709 – January 1992. 45. Thompson, N. G., Beavers, J. A., and Durr, C. L., “Potentiodynamic Polarization Studies On Candidate Container Alloys For The Tuff Repository,” NUREG/CR-5708 – January 1992. 46. Beavers, J. A. and Durr, C. L., “Immersion Studies On Candidate Container Alloys For The Tuff Repository,” NUREG/CR-5598 – May 1991. 47. Krause, H. H. and Beavers, J. A., “High Temperature Corrosion Of Stainless Steel By Borate Waste Glass,” CORROSION/91, NACE Paper No. 462, March 1991. 48. Beavers, J. A. and Durr C. L., “Environmental Effects On Corrosion In The Tuff Repository,” NUREG/CR-5435 – February 1990. 49. Agrawal, A. K., Aller, J. E., Hamilton II, A. R., and Beavers, J. A., “Cracking Behavior Of A Cu-Mn Weld Alloy In Phosphoric Acid,” CORROSION/89, NACE Paper No. 101, April 1989. 20 TP296-3442 CC Technologies Laboratories, Inc.

Technical Proposal

External MIC Growth Rate Modeling

Selected Publications (Continued) 50. Christman, T. K., Good, G. W., Beavers, J. A., and Mackenzie, J. D., “Modeling The Growth Of Multiple Stress-Corrosion Cracks In Line Pipe Steels,” NG-18/EPRG Seventh Biennial Joint Technical Meeting On Line Pipe Research, Paper No. 27, (August 29 – Sept. 1, 1988). 51. Christman, T. K. and Beavers, J. A., “The Role Of Environmental Species In Line Pipe Stress Corrosion Cracking,” NG-18/EPRG Seventh Biennial Joint Technical Meeting On Line Pipe Research, Paper No. 29, (August 29 – Sept. 1, 1988). 52. Koch, G. H., Beavers, J. A., Berry, W. E., “Chapter 4 – Marine Corrosion,” Materials for Marine Systems and Structures, D. F. Hasson and C. R. Crowe, Eds., Treatise on Materials Science and Technology, Vol. 28, Academic Press (1988). 53. Thompson, N. G., Lawson, K. M., and Beavers, J. A., “Monitoring Cathodically Protected Concrete Structures with Electrochemical Impedance Techniques,” CORROSION/87, NACE Paper No. 139, (1987). 54. Beavers, J. A. and Thompson, N. G., “Effect of Pit Wall Reactivity on Pit Propagation in Carbon Steel,” Corrosion Journal, 43 (3), p. 185 (March 1987). 55. Beavers, J. A., Thompson, N. G. and Parkins, R. N., “Stress-Corrosion Cracking of Low Strength Carbon Steels in Candidate High-Level Waste Repository Environments,” NUREG/CR-3861, BMI-2147, (Feb. 1987). 56. Han, M. K., Beavers, J. A. and Goins, W., “Stress Corrosion Cracking Failure of Brass Electrical Connectors in an Outdoor Atmospheric Environment,” CORROSION/87, Paper No. 184, NACE, (1987). 57. Beavers, J. A., Christman, T. K. and Parkins, R. N., “Some Effects of Surface Condition on the Stress Corrosion Cracking of Line Pipe Steel,” CORROSION/87, Paper No. 178, NACE, (1987). 58. Beavers, J. A., Koch, G. H. and Berry, W. E., Corrosion of Metals in Marine Environments, MCIC Report 86-50, Metals and Ceramics Information Center, Columbus, Ohio, July 1986. 59. Cialone, H., Beavers, J. A., and Koch, G. H., “Fractographic Features of Stress Corrosion Cracking and Hydrogen Embrittlement,” Microscopy Fractography and Failure Analysis Eds. M. R. Louthan, Jr. and T. A. Place, Virginia Tech Printing Department, Blacksburg, VA, (1986).

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External MIC Growth Rate Modeling

Selected Publications (Continued) 60. Beavers, J. A., and Parkins, R. N., “Standard Test Procedure for Stress-Corrosion Cracking Threshold Stress Determination,” CORROSION/86, Houston, Texas, and Materials Performance, 25 (6), p. 9 (1986). 61. Beavers, J. A., Parkins, R. N., and Thompson, N. G., “Stress-Corrosion Cracking of Low Strength Carbon Steels in Candidate High Level Waste Repository Environments: Environmental Effects,” Nuclear and Chemical Waste Management, Vol. 5, 279-296 (1985). 62. Rosenberg, H. S., Koch, G. H., Kistler, C. W., Jr., and Beavers, J. A., “Performance of Duct and Stack Materials in Wet Scrubbers,” Ninth Symposium on Flue Gas Desulfurization, Cincinnati, Ohio, No. 58 (June 4-7, 1985). 63. Beavers, J. A. and Thompson, N. G., “Electrochemical Studies of the Corrosion Performance of Carbon Steel in Simulated Basalt Repository Environments,” Proceedings of Waste Management ’85 (1985). 64. Beavers, J. A., Agrawal, A. K., Berry, W. E., “Corrosion Related Failures in Feedwater Heaters,” CORROSION/84, New Orleans, Louisiana, Paper No. 169 (1984). 65. Beavers, J. A., Berry, W. E., and Griess, J. C., “Materials Performance in Moist Iodine Vapors at Low Temperatures,” Proceedings of 9th International Congress on Metallic Corrosion, Toronto, Canada, (June 3-7, 1984). 66. Leis, B. N., Rungta, R., Mayfield, M. E. and Beavers, J. A., “Corrosion-Fatigue Crack Initiation in an Iron-Caustic System, ASTM STP 801, p.197, (1983). 67. Koch, G. H. and Beavers, J. A., “The Influence of Scrubber Chemistry on the Corrosion of Alloys in Lime/Limestone Flue Gas Desulfurization Systems,” CORROSION/83, Anaheim, California, Paper No. 186 (1983). 68. Beavers, J. A. and Diegle, R. B., “Corrosion of Iron Aluminum and Copper Base Alloys in Glycols under Simulated Solar Collector Conditions,” Proc. Electrochemical Soc. 1983, 83-1 69. (Proc. Symposium on Corrosion Batteries, Fuel Cells, Corros. Solar Energy Systems) pp. 298-318. 70. Beavers, J. A. and Breeze, G. A., “Inhibiting Steam-Condensate Corrosion of CopperBased Alloys by Hydrazine,” EPRI-NP-2492, 1982.

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External MIC Growth Rate Modeling

Selected Publications (Continued) 71. Koch, G. H., Beavers, J. A., and Syrett, B. C., “Experimental Evaluation of Alloys and Linings in Simulated Duct Environments for a Lime/Limestone Scrubber,” CORROSION/82, Houston, Texas, Paper 197, (1982). 72. Dene, C. E., Syrett, B. C., Koch, G. H., and Beavers, J. A., “Alloys and Coatings for SO2 Scrubbers,” 1982 American Power Conference, Chicago, Illinois (April 1982). 73. Koch, G. H., and Beavers, J. A., “Laboratory and Field Evaluation of Materials for Flue Gas Desulfurization Systems,” Seventh Symposium on Flue Gas Desulfurization, Hollywood, Florida (June 1982). 74. Koch, G. H., Beavers, J. A., Thompson, N. G., and Berry, W. E., “Literature Review of FGD Construction Materials,” EPRI Report CS-2533, (August 1982). 75. Koch, G. H., and Beavers, J. A., “Materials Testing in Simulated Flue Gas Desulfurization Duct Environments,” EPRI Report CS-2537, (August 1982). 76. Beavers, J. A., and Koch, G. H., “Review of Corrosion Related Failures in Flue Gas Desulfurization Systems,” Materials Performance, Vol. 21, October, p. 13 (1982). 77. Koch, G. H., and Beavers, J. A., “Performance of Candidate Materials for Flue Gas Desulfurization Systems,” Proceedings of the Seventh Annual Conference on Materials for Coal Conversion and Utilization, Gaithersburg, Maryland, (October 1982). 78. Beavers, J. A., Berry, W. E., Griess, J. C., and White, R. R., “Corrosion Studies in Fuel Element Reprocessing Environments Containing Nitric Acid,” ORNL/Sub-7237/13 (April 1982). 79. Beavers, J. A., Agrawal, A. K., and Berry, W. E., “Corrosion Related Failures in Feedwater Heaters,” EPRI CS-3184, July 1983. 80. Beavers, J. A., and Diegle, R. B., “The Effect of Degradation of Glycols on Corrosion of Metals Used in Non-Concentrating Solar Collectors,” CORROSION/81, Paper No. 207 (1981). 81. Beavers, J. A., Griess, J. C., and Boyd, W. K., “Stress-Corrosion Cracking of Zirconium in Nitric Acid,” CORROSION/80, Paper No. 238, and Corrosion, 37 (5), p. 292 (May 1981).

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External MIC Growth Rate Modeling

Selected Publications (Continued) 82. Griess, J. C., and Beavers, J. A., “Materials Compatibility in Selected Fuel Element Reprocessing Environments,” Trans. American Nuclear Society, 39 146, Winter Meeting, San Francisco, California (November 29-December 3, 1981).

83. Beavers, J. A., Agrawal, A. K., and Berry, W. E., “Corrosion Related Failures in Power Plant Condensers,” CORROSION/81, Paper No. 17, and Materials Performance, 20 (10), p. 19 (October 1981). 84. Beavers, J. A., Berry, W. E., and Griess, J. C., “Materials Performance in Off-Gas Systems Containing Iodine,” ORNL/Sub-7327/11 (November 1981). 85. Beavers, J. A., Stiegelmeyer, W. N., and Berry, W. E., “Failure Analyses of Corrosion in RAD Waste Systems,” CORROSION/80, Paper No. 261 (1980). 86. Diegle, R. B., Beavers, J. A., and Clifford, J. E., “Corrosion Problems with Aqueous Coolants,” DOE/CS/10510-T11 (1980), NTIS, Energy Res. Abstr. (1980) 5 (21), Abstr. No. 33516. 87. Beavers, J. A., and Pugh, E. N., “The Propagation of Transgranular Stress-Corrosion Cracks in Admiralty Metal,” Metallurgical Transaction, 11 (809) (1980). 88. Beavers, J. A., Agrawal, A. K., and Berry, W. E., “Corrosion Related Failures in Power Plant Condensers@ EPRI NP-1468, (August 1980). 89. Beavers, J. A., Boyd, W. K., Griess, J. C., and Berry W. E., “Materials Compatibility in Hydriodic Acid Solutions,” ORNL/TM-7330 (July 1980). 90. Beavers, J. A., Boyd, W. L., and Berry, W . E., “Materials Performance in Nitric Acid Solutions Containing Fluoride,” ORNL/CFRP-78/7 (January 1979). 91. Beavers, J. A., Boyd, W. K., Griess, J. C., and Berry, W. E., “Selection of Materials for the Iodox Process,” ORNL/Sub-79/77327/1 (December 1979). 92. Nelson, J. L., and Beavers, J. A., “The Application of a Photogrammetric Technique to the Determination of the Orientation of Stress-Corrosion Fractures,” Metallurgical Transactions, 10 (658) (1979). 93. Beavers, J. A., Berry, W. E., and Boyd, W. K., “Selection and Evaluation of Materials for Advanced Fuel Reprocessing Equipment,” ORNL/AFRP-78/1 (August, 1978).

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External MIC Growth Rate Modeling

94. Gabel, H., Beavers, J. A., Woodhouse, J. B., and Pugh, E. N., “The Structure and Composition of Thick Films on Alpha Phase Copper Alloys,” Corrosion, 32 (253) (1976). 95. Beavers, J. A., Rosenburg, I. C., and Pugh, E. N., “The Role of Intergranular Attack in Stress-Corrosion Phenomena,” Tri-Services Conference on Corrosion, Houston, Texas, p. 57 (1972). Patents 1.

“Probe For Monitoring Thompson, N. G., Patent design and measurement corrosion cracking (SCC) vessels.

Stress Corrosion Cracking,” Beavers, J. A. and No. 5.571,143; November 5, 1996. The novel probe methodology provides real-time information on stress in chemical process equipment, pipelines, and other

2.

“Galvanic Corrosion Inhibiting Coupling Interposed Between Two Dissimilar Pipes,” Beavers, J. A.; Patent No. 5,739,424; April 14, 1998. The device mitigates corrosion in piping systems containing dissimilar metal couples without promoting the degradation that is sometime associated with cathodic protection.

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Technical Proposal

External MIC Growth Rate Modeling APPENDIX A

PRC International Project Descriptions Performed by CC Technologies and Staff LIST OF PRCI PROJECTS EXECUTED BY CC TECHNOLOGIES STAFF

26

Technical Proposal

External MIC Growth Rate Modeling PRC International Project Descriptions Performed by CC Technologies and Staff.

Lead Organization/Staff

Manager/ Principal Investigator

Funding PRCI Organization Committee

Project/ Contract

Project Name

Starting Date

No. of Years

Project Description

GRI-81-0125

Corrosion of Underground Pipe

1980

2

GRI project to examine the basic processes of corrosion and cathodic protection. Environmental changes at the steel surface were examined in simulated ground water solutions.

$210,000

Funding Level

CCT Staff

N. G. Thompson

GRI

CCT Staff

T. J. Barlo, N. G. Thompson

PRCI

Corrosion

PR-3-129

Assessment of Criteria for Cathodic Protection of Buried Pipelines

1981

3

PRC International project to examine the requirements to mitigate corrosion on buried steel and to refine the criteria for effective cathodic protection where appropriate. The scope included both laboratory and field evaluations.

$250,000

CCT Staff

N. G. Thompson

PRCI

Corrosion

PR-3-163

Criteria to Stop Active Pit Growth

1981

2

PRC International project to establish the cathodic protection requirement to stop active pitting as compared to mitigate corrosion on bare steel with no on-going pitting.

$150,000

NG-18 Report 136

Effects of Shot Peening and Grit blasting on the StressCorrosion-Cracking Behavior of Line-Pipe Steel

1982

1

PRC International project to demonstrate the beneficial effect of shot peening and grit blasting to SCC susceptibility and to determine the effect of oxidation after blasting.

$60,000

CCT Staff

G. H. Koch, T. J. Barlo

PRCI

Materials

Investigation of Line Pipe that is Highly Resistant to SCC

1983

2

NG-18 Report 146

Test Method for Defining Susceptibility of Line Pipe to SCC

1984

3

GRI-5084-271-1009

Effectiveness of Cathodic Protection (Phases I - IV)

1981

5

Materials

NG-18 Report 148

Effect of Temperature on Stress-Corrosion Cracking of Precracked Line Pipe Steel

1985

1

Materials

NG-18 Report 167

Surface Effects on Stress Corrosion Susceptibility of Line Pipe Steels

1985

2

CCT Staff

J. A. Beavers

AGA

Materials

CCT Staff

J. A. Beavers, G. H. Koch

AGA

Materials

CCT Staff

N. G. Thompson G. T. Ruck

GRI

CCT Staff

G. H. Koch, J. A. Beavers

AGA

CCT Staff

J. A. Beavers

AGA

CC Technologies Laboratories, Inc.

27

PRC International project to investigate the relationship between metallurgical characteristics of line pipe steel and stress corrosion cracking susceptibility. A specific goal of this work was to understand the influence of processing parameters on those characteristics that control SCC susceptibility so that steels can be made consistently resistant to SCC. PRC International project to develop a standardized test method for defining the SCC susceptibility of line pipe steels. Previous studies had identified the optimum environmental conditions and specimen geometry for performing such an evaluation and the aim of the work was to identify the optimum loading conditions and test time. GRI project to develop methodologies and instrumentation to evaluate the effectiveness of a cathodic protection system in mitigating corrosion. A primary focus was to measure the "offpotential" without synchronous interruption. The research resulted in three patents for instrumentation and the commercialization of two instruments. PRC International project to determine the effect of temperature on the KISCC and the effect of temperature and KI on stresscorrosion crack velocity on line pipe steels. This study was initiated to determine whether lowering the temperature of the environment could prevent a stress-corrosion crack from initiating or could stop existing propagating cracks. PRC International project to investigate the surface related factors affecting SCC initiation. Specific goals were to identify those surface factors that affect and control SCC initiation to reduce the variation in the results of SCC tests and to optimize surface properties of operating pipelines.

$130,000

$150,000

$800,000

$50,000

$100,000

Technical Proposal Lead Organization/Staff CCT Staff

Manager/ Principal Investigator

External MIC Growth Rate Modeling Funding PRCI Organization Committee

Project/ Contract

Project Name

Starting Date

No. of Years

Effects of Seasonal Variations on Requirement to Prevent Corrosion in Soils(1985 Annual)

1985

2

Current Requirement Cathodic Protection

1986

2

1988

1

N. G. Thompson

PRCI

Corrosion

PR-3-505

CC Technologies N. G. Thompson

PRCI

Corrosion

PR-186-619

CCT Staff

AGA

Materials

NG-18 Report 186

J. A. Beavers

For

Effect of Loading on the Growth Rates of Deep Stress Corrosion Cracks

CC Technologies N. G. Thompson

PRCI

Corrosion

PR-186-807

Improved Pipe To Soil Potential Survey Methods (Phases I - III)

1988

3

CC Technologies N. G. Thompson

PRCI

Corrosion

PR-186-916

Assessment Of Research On Cathodic Protection Of Buried Pipelines

1989

1

CC Technologies J. A. Beavers

PRCI

Materials

PR-186-917

Assessment of Line Pipe Susceptibility to SCC Under Tape, Enamel, and Fusion Bonded Epoxy Coatings

1989

2

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-006

Causes And Effects Of The Spiking Phenomena

1990

2

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9106

Investigation Of The -0.85 Volt On-Potential Criteria

1991

2

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9126

Evaluation Of Commercial Systems For Measuring Cathodic Protection

1991

2

CC Technologies Laboratories, Inc.

28

Project Description PRC International project to examine effects of seasonal variations on the corrosion behavior of steel in soils and to determine the response of the steel to cathodic protection during seasonal variations. PRC International program to determine the feasibility of using polarization resistance techniques for establishing a current requirement for cathodically protected buried gas pipelines. An instrument was developed for measuring the polarization resistance in the field, free of IR drop. PRC International project to determine the effect of loading parameters on the propagation rates of high pH stress-corrosion cracking. PRC International project to improve the ability to perform and interpret close interval on and off potential surveys for buried piping. A field site of 80 feet of 20 inch bare pipe has been established for which ground level pipe to soil potential measurements can be compared to potentials at the pipe surface. Finite Element Analysis computer modeling also is being performed to establish what area of the pipe is being "sensed" during a ground level pipe to soil potential measurement. PRC International project to provide a critical review of PRCI. funded research and outside research as it relates to the specific goals of PRCI in the general area of cathodic protection. The specific goals were to examine the effects that the research had on the state-of-the-art for cathodic protection and to provide a convenient, comprehensive report that documents and summarizes the accomplishments of research projects relating to the specific goals of PRCI. PRC International project to evaluate the susceptibility of line pipe to stress corrosion cracking (SCC) when coated with polyethylene (PE) tape, coal tar enamel (CTE), and fusion bonded epoxy (FBE) and to establish whether SCC can occur on FBE coated pipelines. PRC International project to establish the cause and effects of the spiking phenomena so as to provide the CP engineer with a standard practice for measuring off-potentials in the presence of the spiking phenomena. PRC International project to investigate the effectiveness of the 0.85 V on-potential criteria. The specific goals were: (1) to establish a substantial database of pipeline inspection reports and soil analyses, and (2) to provide an analysis of the database that will evaluate the effective of the -0.85 V on-potential criterion. PRC International project to provide an evaluation of commercially available cathodic protection survey equipment. The scope of this program included field evaluations, primarily on operation pipelines, examining the equipment's accuracy, reliability, and ease of use.

Funding Level $90,000

$70,000

$70,000

$220,000

$125,000

$150,000

$140,000

$120,000

$80,000

Technical Proposal Lead Organization/Staff

Manager/ Principal Investigator

External MIC Growth Rate Modeling Funding PRCI Organization Committee

Project/ Contract

Project Name

Starting Date

No. of Years

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9105

Multiple Pipelines In The Same Right-of-Way

1991

2

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9220

The Use Of Coupons For Estimating Off-Potentials (Phases I - IV)

1992

8

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9203

Most Accurate Method For Measuring An Off-Potential

1992

2

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9412

Cathodic Protection Stray Current Areas

1994

1

CC Technologies J. A. Beavers

PRCI

Materials

PR-186-9402

Low-pH SCC: Mechanical Effects On Crack Propagation

1994

3

CC Technologies J. A. Beavers

PRCI

Materials

PR-186-9506

An Overview of SCC Field Data Collection

1995

2

In

DC

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9611

Impact of Short-Term Depolarization of Pipelines

1996

2

CC Technologies

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9610

External Corrosion Monitoring Practices

1996

2

CC Technologies Laboratories, Inc.

Control

29

Project Description PRC International project to improve the ability to interpret close interval on- and off-potential surveys in right-of-ways containing multiple pipelines. The specific objectives were to develop a computer model, which could be used to predict interaction between the pipelines, to extend the module to more complex real life pipeline situations, and to provide field verification of the model. PRC International project to establish guidelines for the use of coupons as a monitoring methodology for determining the level of protection on a pipeline. The specific goals are to examine other recent studies utilizing coupons, to expand conditions for operating pipelines for which coupons have been examined, and to verify the accuracy of coupon off-potentials as a function of the level of CP. PRC International project to develop the most accurate method for estimating the polarized potential of a pipeline utilizing interruption. The specific goals of the research were (1) to establish and verify the amount of error introduced by long-line currents when measuring an off-potential and (2) to develop a test protocol for estimating the polarized potential by interruption techniques in view of all possible errors. PRC International project to develop reliable measurement techniques to assess stray current effects, to develop reliable procedures for measuring CP criteria in the presence of stray currents or develop improved CP criteria if necessary, and to identify mitigation procedures and assess their ability to mitigate corrosion in stray current areas. PRC International project to determine the role of hydrotesting on stress corrosion crack growth in a low-pH SCC environment. Crack growth rate measurements were performed on 1/2 T compact type specimens of pipeline steels under cyclic loading conditions in a low-pH environment. An electric potential drop technique was used to monitor crack extension and the data were analyzed using elastic plastic fracture mechanics. PRC International project to establish a standard protocol for the collection of field data on SCC and to train technicians on this protocol. To this end, a manual on field data collection was created. This manual includes an overview of SCC, reviewing mechanisms of SCC and information on conducting an investigative program. PRC International project to examine the effect of repeated depolarization of the pipeline during either interrupted closeinterval-surveys or during longer term interruptions of the CP system due to intentional depolarization to validate a CP criterion or scheduled and unscheduled maintenance. PRC International project to provide recommended practices for corrosion control monitoring for a wide range of pipeline conditions and monitoring scenarios.

Funding Level

$140,000

$800,000

$150,000

$75,000

$240,000

$80,000

$120,000

$90,000

Technical Proposal Lead Organization/Staff

Manager/ Principal Investigator

CC Technologies N. G. Thompson

External MIC Growth Rate Modeling Funding PRCI Organization Committee GRI

Corrosion

Project/ Contract

Project Name

Starting Date

No. of Years

Project Description

GRI-5097-260-3825

Cathodic Protection Requirements for Mitigating Corrosion on Buried Pipelines

1997

4

GRI project to determine the requirements for effective mitigation of corrosion for buried steel and to develop a model based on fundamental mechanisms for cathodic protection of steel in soils.

CC Technologies J. A. Beavers

PRCI

Materials

PR-186-9706

Effects of Fluctuations Propagation

CC Technologies

C. E. Jaske J. A. Beavers

PRCI

Materials

PR-186-9709

CCT Staff

O. C. Moghissi

PRCI

Corrosion

CC Technologies J. A. Beavers

PRCI

CC Technologies J. A. Beavers

PRCI

on

Pressure SCC

1997

2

Integrity and Remaining Life of Pipe with Stress Corrosion Cracking

1997

1

PR 15-9808

Internal Corrosion Risk Assessment and Management of Steel Pipelines

1998

1

Corrosion

PR-186-9807

CP Conditions Conducive to SCC

1998

1

Corrosion

PR-186-9810

Performance of Blistered FBE Coated Pipe

1998

1

1999

1

PRC International project to define the relationship between the nature of pressure fluctuations on gas transmission pipelines and the crack-growth behavior under conditions designed to simulate near-neutral pH SCC. The roles of R ratio (ratio of minimum to maximum cyclic load), frequency, waveform, time, and pressure transients on crack-growth behavior were evaluated. PRC International project to improve the CorLAS(TM) Version 1.0 model for predicting the failure and remaining life of pipelines with stress-corrosion cracks. Improvements were made by (1) adding a tearing instability criterion for toughness-dependent failure, (2) adding improved formulations for computing values of the J integral for surface flaws, (3) incorporating procedures to evaluate flaw Interaction, and (4) validating strain hardening approximations that are used in computing values of plastic J integral. PRC International project to develop Maintenance Optimization Risk Management software to maximize the net present value savings for a series of pipeline segments by scheduling their inspection/ repair/ or replacements. A probabilistic internal corrosion rate prediction model was included. PRC International project to define pipeline conditions where use of the 100 mV polarization criterion may be conducive to possible SCC problems. Each of the controlling conditions for SCC were examined, using a combination of analysis of previous research results, analysis of field data, and laboratory testing. PRC International project to (i) determine the corrosion rate of steel beneath blistered, but holiday-free, FBE coatings under aerated and deaerated conditions, (ii) evaluate the effectiveness of CP through such coatings, and (iii) evaluate the effect of increased levels of CP on the rate of degradation of such coatings. PRC International project to develop a high pressure system to maintain a mixed MIC-biofilm and determine the influence of a consortium of microorganisms on the internal corrosion of steel pipeline exposed to CO2, H2S, and O2 and varied liquid chemistry.

Funding Level $620,000

$160,000

$125,000

$75,000

$100,000

$70,000

GRI

Corrosion

PR 15-9916

Interdependent Effects of Bacteria, Gas Composition, and Water Chemistry on Internal Corrosion of Steel Pipelines

N. G. Thompson K. M. Lawson

PRCI

Corrosion

PR-186-9918

Hot Spot Protection for Impressed Current Systems

1999

2

PRC International project to determine the effectiveness of "hotspot" magnesium anode protection on a pipeline protected by an impressed current CP system.

$120,000

N. G. Thompson M. Yunovich

GRI

Corrosion

GRI-8187

AC Corrosion

2000

2

GRI project to validate whether "AC corrosion" is the cause of corrosion observed on pipelines in high voltage AC corridors and to determine the mechanism of the corrosion observed and monitoring practices and criteria to mitigate the corrosion.

$220,000

CCT Staff

O. C. Moghissi

CC Technologies

CC Technologies

CC Technologies Laboratories, Inc.

30

$100,000

Technical Proposal Lead Organization/Staff

Manager/ Principal Investigator

CC Technologies J. A. Beavers

External MIC Growth Rate Modeling Funding PRCI Organization Committee GRI

Project/ Contract

Project Name

Starting Date

No. of Years

Project Description

GRI-7045

Near-Neutral pH SCC: Dormancy and Re-Initiation of Stress Corrosion Cracks

2000

2

GRI project to identify the environmental and mechanical conditions that lead to dormancy of stress corrosion cracks and reinitiation of previously dormant cracks.

2000

2

PRC International project to establish the specifications and a quality test for the magnesium anodes used in sacrificial anode CP systems that insures the expected anode efficiency used to design the CP system is realized in field installations. PRC International project to develop a standard overall performance test for pipeline coatings, one which correctly ranks coatings and indicates failure modes which are representative of field performance. PRC International project to determine the chemical compatibility of different small area repair patch coatings to the most common mainline coating chemistries by measuring coating-to-coating adhesion. Both initial and long-term adhesion was determined.

Funding Level $200,000

N. G. Thompson CC Technologies M. Yunovich

PRCI

Corrosion

PR-186-0025

Development of Quality & Performance Specifications For Magnesium Anodes

CC Technologies G. R. Ruschau

PRCI

Corrosion

PR-186-0028

Developing Predictive Accelerated Test Methods for Pipeline Coatings

2000

2

CC Technologies G. R. Ruschau

PRCI

Corrosion

PR-186-0029

Compatibility of Repair Coatings to Existing Underground Coatings

2000

1

Seasonal Variations Effects on Free-Corrosion GRI – NRTC Subcontract Potentials/Monitoring CP in High Resistivity Soils

2001

2

GRI project to establish the effect of seasonal variations on operating pipelines and the ability of existing criteria to effectively mitigate corrosion during fluctuating soil conditions.

$100,000

2001

2

GRI project to examine the application of the polarization/depolarization criterion based on fundamental mechanisms and to establish methodology to apply the criterion based on depolarization/repolarization times less than the multiple days necessary with the current practice.

$210,000

2001

1

GRI project to develop a method to assess internal corrosion damage in gas transmission pipelines.

$130,000

2001

1

PRC International project to determine the adhesion of different repair coatings to the various components of a thermite weld, and determine the repair coatings' ability to be applied during a keyhole excavation. The short and long term performance of each was to be determined.

$55,000

2002

1

PRC International project to explore the field-compatible techniques for permanently repairing SCC cracks and colonies without the need for service interruption.

$60,000

CC Technologies / N. G. Thompson NRTC K. M. Lawson

CC Technologies

CCT Staff

N. G. Thompson O. C. Moghissi

O. C. Moghissi

CC Technologies G. R. Ruschau

CC Technologies C. E. Jaske

GRI

GRI

GRI

Corrosion

GRI-8468

Efficient Use of Protection Criteria

GRI-8329

Internal Corrosion Direct Assessment of Gas Transmission Pipelines Methodology

Corrosion

PR-186-0109

GRI

Pipeline Materials

GRI-8511

GRI

CC Technologies J. A. Beavers

GRI

CC Technologies Laboratories, Inc.

Corrosion

PRCI

J. A. Beavers E. B. Clark

CC Technologies

Corrosion

Materials

Cathodic

Coating Compatibility Special Repairs

Permanent Field SCC - Review

for

Repair

of

GRI-8512

In-Situ Pipeline Mechanical Property Characterization

2002

2

GRI-8513

Reliable Diagnosis Of SCC During Field Inspection

2002

1

31

GRI project to identify reliable, field applicable nondestructive test methods that can be used for estimating the yield strength, tensile strength, and fracture toughness of line pipe materials. This will include the proper procedures for using the equipment identified and its limitations. GRI project to prepare a document containing a compilation of types of crack-like MPI or visual indications found on underground transmission pipelines for the purpose of proper interpretation of their type and cause.

$172,000

$440,000

$65,000

$80,000

$65,000

Technical Proposal Lead Organization/Staff

Manager/ Principal Investigator

External MIC Growth Rate Modeling Funding PRCI Organization Committee

Project/ Contract

Project Name

Starting Date

No. of Years

Project Description

Funding Level

CC Technologies N. G. Thompson

PRCI

Corrosion

PR-186-02107

High CP Potential Effects on Pipelines

2002

1

PRC International project to determine the detrimental effects of over protection of the CP system to high potentials sometimes achieved on pipelines.

$80,000

CC Technologies O. C. Moghissi

PRCI

Corrosion

PR-186-02124

Coupons Coatings

2002

2

PRC International project to develop a buried coupon to identify conditions under which disbonded coatings create susceptibility to external corrosion.

$270,000

for

Disbonded

$8,177,000

CC Technologies Laboratories, Inc.

32

PART II – COST PROPOSAL TP296-3442

EXTERNAL MIC GROWTH RATE MODELING 2003 - 2004 PREPARED FOR

PRC INTERNATIONAL Pipeline Materials Committee

PREPARED BY

CC TECHNOLOGIES LABORATORIES, INC. OLIVER C. MOGHISSI AUGUST 05, 2002

CC Technologies 6141 AVERY ROAD DUBLIN, OHIO 43016 614.761.1214 • 614.761.1633 fax www.cctechnologies.com

Part II – Cost Proposal

External MIC Growth Rate Modeling

Table 1a. Cost Summary for 2003 PRCI / GAS TECHNOLOGY INSTITUTE CONTRACT COST ESTIMATE (FOOTNOTE A) Name of Offeror

RFP No./ Prp. No.

Page Number

Number of Pages

CC Technologies Laboratories I nc. Home Office Address

Name of Proposed Project

6141 Avery Road, Dublin Ohio 43016

External MI C Grow th Rate Modeling - Proposal No. TP2743555 ( 2003)

Division(s) and Location(s) (where work is to be performed)

Total Amount of Proposal

$75,000 Estimated Cost (dollars)

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

1. Direct Material a. Purchased Parts

$0

b. I nterdivisional Effort

$0 $0

c. Equipment Rental

$1,000

d. Other (Supplies and Materials)

$1,000 Table 1b

Total Direct Material 2. Material Overhead

Rate

10%

$1,000

x Base $

$100

3. Subcontracted Effort

Subcontractor Cofunding (Footnote D)

$0 Table 1b

Net Subcontracted Effort 4. Direct Labor - Specify

Est. Hours

Rate/ Hour

Est. Cost

Sen Group Leader

190

$44.68

$8,489

Project Engineer

140

$29.15

$4,081

Technologist

260

$25.25

$6,565

40

$14.84

$594

Office Staff

$19,729 Table 1b

Total Direct Labor 5. Labor Overhead - Specify

O.H. Rate

Labor Overhead ( Fringes) General Overhead

X Base $

Est. Cost

40%

$19,729

$7,892

132%

$27,621

$36,459

Non- Labor Overhead

$44,351

Total Labor & General Overhead

$0 Table 1b

6. Special Testing

$0 Table 1b

7. Purchased Special Equipment 8. Travel

$990 Table 1b

G&A on travel

9. Consultants (I dentify - Purpose - Rate)

Est. Cost

$2,400 Table 1b

Total Consultants

$195 Table 1b

10. Other Direct Costs

$68,765

11. Total Direct Cost and Overhead 12. General and Administrative Expense Rate

10%

x Base $

3,585 (Cost element no(s).

3, 6, 7, 8, 9, & 10)

(Cost element no(s).

)

$359

13. I ndependent Research and Development Rate

x Base $

$0 $69,124

14. Total Estimated Cost (Footnote C)

$5,876

15. Fixed Fee

$75,000

16. Total Estimated Cost and Fee 17. Contractor/ Third Party Cofunding (Footnote D)

$75,000

18. Net Estimated Cost and Fee to GRI This proposal reflects our best estimate as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title Neil G. Thompson, CEO FOOTNOTES:

A. B. C. D.

Signature

Date 7/ 31/ 02

The submission of this form does not constitute an acceptable proposal. Required supporting information must also be submitted. For each item of cost, reference the schedule which contains the required supporting data. This should be the total cost of the research project. Any contractor cost sharing should be shown on the Line 17 as a reduction from total costs. This line should contain (I ) total proposed fee, (ii) contractor cofunding, (3) third party cash cofunding, or (iv)be blank, depending on the contract type. Fixed fee should be cofunded before any contractor in-kind cofunding is proposed.

CC Technologies Laboratories, Inc.

1

Part II – Cost Proposal

External MIC Growth Rate Modeling

Table 1b. Cost Detail for Table 1a. (1) LABOR COSTS

Staff Sen Group Leader Project Engineer Technologist Office Staff TOTAL LABOR

Hours Billed 190 140 260 40 630

Average Rate x Infl 5.0% $44.68 $29.15 $25.25 $14.84

Total Labor Charged $8,489.20 $4,081.00 $6,565.00 $593.60 $19,728.80

(3) MATERIALS

Item Misc Total Materials

Unit Cost $1,000.00

Quantity 1

Total Cost $1,000.00 $1,000.00

(4) CONSULTANT

Consultant Microbiologist Total Consultants

Cost Per Hr $50.00

No. of Hours

No. of Persons

No. of Trips

48

Cost $2,400.00 $2,400.00

(5) TRAVEL

Trip Project Review Total Travel

1

No. of Days 1

2

Airfare $550.00

Subsistence /day $170.00

Rental Car/day $50.00

Trip Cost $990.00 $990.00

(7) OTHER COSTS

Item Misc/Postage Total Other Costs

Unit Cost $195.00

CC Technologies Laboratories, Inc.

Quantity 1

Total Cost $195.00 $195.00

2

Part II – Cost Proposal

External MIC Growth Rate Modeling

Table 2a. Cost Summary for 2004 PRCI / GAS TECHNOLOGY INSTITUTE CONTRACT COST ESTIMATE (FOOTNOTE A) Name of Offeror

RFP No./ Prp. No.

Page Number

Number of Pages

CC Technologies Laboratories I nc. Home Office Address

Name of Proposed Project

6141 Avery Road, Dublin Ohio 43016

External MI C Grow th Rate Modeling - Proposal No. TP2743555 ( 2004)

Division(s) and Location(s) (where work is to be performed)

Total Amount of Proposal

$49,500 Estimated Cost (dollars)

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

1. Direct Material a. Purchased Parts

$0

b. I nterdivisional Effort

$0 $0

c. Equipment Rental

$500

d. Other (Supplies and Materials)

$500 Table 2b

Total Direct Material 2. Material Overhead

Rate

10%

$500

x Base $

$50

3. Subcontracted Effort

Subcontractor Cofunding (Footnote D)

$0 Table 2b

Net Subcontracted Effort 4. Direct Labor - Specify

Est. Hours

Sen Group Leader Project Engineer Technologist Office Staff

Rate/ Hour

Est. Cost

120

$45.74

80

$29.84

$5,489 $2,387

170

$25.85

$4,395

40

$15.19

$608 $12,878 Table 2b

Total Direct Labor 5. Labor Overhead - Specify

O.H. Rate

Labor Overhead ( Fringes) General Overhead

X Base $

Est. Cost

40%

$12,878

$5,151

132%

$18,029

$23,799

Non- Labor Overhead

$28,950

Total Labor & General Overhead

$0 Table 2b

6. Special Testing

$0 Table 2b

7. Purchased Special Equipment 8. Travel

$1,040 Table 2b

G&A on travel

9. Consultants (I dentify - Purpose - Rate)

Est. Cost

$1,600 Table 2b

Total Consultants

$309 Table 2b

10. Other Direct Costs

$45,327

11. Total Direct Cost and Overhead 12. General and Administrative Expense Rate

10%

x Base $

2,949 (Cost element no(s).

3, 6, 7, 8, 9, & 10)

(Cost element no(s).

)

$295

13. I ndependent Research and Development Rate

x Base $

$0 $45,622

14. Total Estimated Cost (Footnote C)

$3,878

15. Fixed Fee

$49,500

16. Total Estimated Cost and Fee 17. Contractor/ Third Party Cofunding (Footnote D)

$49,500

18. Net Estimated Cost and Fee to GRI This proposal reflects our best estimate as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title Neil G. Thompson, CEO FOOTNOTES:

A. B. C. D.

Signature

Date 7/ 31/ 02

The submission of this form does not constitute an acceptable proposal. Required supporting information must also be submitted. For each item of cost, reference the schedule which contains the required supporting data. This should be the total cost of the research project. Any contractor cost sharing should be shown on the Line 17 as a reduction from total costs. This line should contain (I ) total proposed fee, (ii) contractor cofunding, (3) third party cash cofunding, or (iv)be blank, depending on the contract type. Fixed fee should be cofunded before any contractor in-kind cofunding is proposed.

CC Technologies Laboratories, Inc.

3

Part II – Cost Proposal

External MIC Growth Rate Modeling

Table 2b. Cost Detail for Table 2a.

(1) LABOR COSTS

Staff Sen Group Leader/Total Project Engineer/Total Technologist/Total Office Staff/Total TOTAL LABOR

Hours Billed 120 80 170 40 410

Average Rate x Infl 7.5% $45.74 $29.84 $25.85 $15.19

Total Labor Charged $5,488.80 $2,387.20 $4,394.50 $607.60 $12,878.10

(3) MATERIALS

Item Misc Total Materials

Unit Cost $500.00

Quantity 1

Total Cost $500.00 $500.00

(4) CONSULTANT

Consultant Microbiologist Total Consultants

Cost Per Hr $50.00

No. of Hours

No. of Persons

No. of Trips

32

Cost $1,600.00 $1,600.00

(5) TRAVEL

Trip Project Review Total Travel

1

No. of Days 1

2

Airfare $600.00

Subsistence /day $170.00

Rental Car/day $50.00

Trip Cost $1,040.00 $1,040.00

(7) OTHER COSTS

Item Misc/Postage Total Other Costs

Unit Cost $309.00

CC Technologies Laboratories, Inc.

Quantity 1

Total Cost $309.00 $309.00

4

Proposal

Direct Assessment Approaches to Mechanical Damage (RPTG-0321)

Submitted to Materials Technical Committee of the Pipeline Research Council International

Prepared by Maher A. Nessim, Ph.D., P.Eng. tel: 780 450 8989 ext 207 email: [email protected]

Copyright © 2002 C-FER Technologies

August 2002 Project L074

C-FER Technologies

NOTICE Restriction on Disclosure

Information contained in this proposal may not be disclosed, duplicated or used in whole or in part for any purpose other than in evaluation of the Pipeline Research Council International, Inc. (PRCI). In the event that the proposal is not accepted, this proposal document should be returned to C-FER Technologies. This restriction does not limit the use of information contained in the document if it is obtained from another source without restriction.

i

C-FER Technologies

TABLE OF CONTENTS

Notice Table of Contents List of Figures and Tables Executive Summary

i ii iii iv

1.

TERMS OF REFERENCE ................................................................................................... 1

2.

TECHNICAL BACKGROUND............................................................................................. 2

2.1 General 2.2 Previous Work 2.3 Proposed Framework 2.4 Technical Issues 3.

2 2 2 4

PROPOSED PROGRAM..................................................................................................... 5

3.1 Objective and Scope 3.2 Incentive 3.3 Work Plan 3.3.1 Task 1: Finalize Project Plan 3.3.2 Task 2: Investigate Methodologies for Identifying Likely Damage Sites 3.3.3 Task 3: Develop Reliability Evaluation Model 3.3.4 Task 4: Develop Decision Models 3.3.5 Task 5: Assess Overall Methodology 3.3.6 Task 6: Preparation of Deliverables and Reporting 3.4 Schedule 3.5 Cost

5 5 6 6 6 6 7 7 8 8 9

4.

PROJECT TEAM ORGANIZATION AND QUALIFICATIONS ......................................... 10

5.

CORPORATE QUALIFICATIONS .................................................................................... 11

5.1 5.2

Corporate Profile Qualifications Related to the Proposed Project

11 11

APPENDICES

Appendix A

Resumes of Project Team

ii

C-FER Technologies

LIST OF FIGURES AND TABLES

Figures

Figure 1

Overview of Direct Assessment Methodology

Tables

Table 1

Proposed Schedule

Table 2

Cost Breakdown by Task (US$)

iii

C-FER Technologies

EXECUTIVE SUMMARY TITLE

Direct Assessment Approaches to Mechanical Damage

CONTRACTOR

C-FER Technologies

NEW PROJECT FUNDING REQUESTED

PRCI

$150,000

ESTIMATED COMPLETION DATE

December 31, 2004

TOTAL ESTIMATED COST

PRCI

2003 - 2004

$150,000

Objective

The objective of the proposed project is to develop a methodology for direct assessment of pipelines with respect to mechanical damage. The project will focus on in-service mechanical damage, which is defined as dent and gouge features that occur due to equipment impact during the service life of the pipeline (other damage such as dents occurring during construction is not included). Incentive

Mechanical damage is the most common cause of pipeline failures and is responsible for a significant proportion of ruptures and large leaks. Although the majority of mechanical damage failures occur at or immediately after the damage incident, delayed failures can occur due to the fatigue growth of gouge defects. Such damage features can be identified by in-line inspection or eliminated through hydrostatic testing; however, there is no economical way to assess integrity for pipelines that are not amenable to these methods. The development of such a methodology will enable operators to cost-effectively manage the integrity of old pipelines with respect to mechanical damage.

Framework

The proposed basic direct assessment methodology for in-service mechanical damage is demonstrated in Figure 1. The first step is to define likely damage sites based on the best available method and select the most critical damage sites for excavation. These sites are then excavated and any necessary repairs carried out. Based on the information obtained from the damage site identification analysis and the excavations, the integrity of the pipeline can be evaluated. If the integrity is adequate the process is terminated. If the integrity is not adequate, one must determine whether or not the direct assessment method is sufficiently promising to warrant further excavations. If further excavations are to be undertaken, the information from previous excavations is used to update the site selection method before the new excavation site locations are defined. This creates an iterative process that should be continued until sufficient confidence is achieved in the integrity of the line, or the assessment method is shown to be ineffective. iv

C-FER Technologies Executive Summary Define Likely Damage Sites

Select Excavation Sites

Update Likely Damage Site Selection Model

Excavate and Repair Critical Sites

Evaluate Pipeline Integrity

Yes

No Promising ?

Adequate ?

Yes

No End

Figure 1 Overview of Direct Assessment Methodology

Work Plan

Tasks that will be carried out to achieve the project objectives are as follows: 1. Finalize Project Plan. The project plan will be finalized based on the comments of the project ad hoc committee and the results of a literature review. 2. Investigate Methodologies for Identifying Likely Damage Sites. Produce a listing of possible methods of identifying likely damage sites, a summary of all available information relating to their potential accuracy, and a proposed approach to characterize their accuracy. Approaches that will be considered include coating damage surveys supplemented by other information (such as clock position of the coating damage) and damage susceptibility models (such as the fault tree model developed by C-FER). 3. Develop Reliability Evaluation Model. Develop a model to calculate reliability taking into account the additional uncertainties resulting from the use of indirect information (e.g. from v

C-FER Technologies Executive Summary

ground surveys) and limited excavation information. Define the reliability levels that must be met to demonstrate adequate integrity. 4. Develop Decision Models. Develop a model that uses accumulated excavation data to determine whether additional excavations should be undertaken for cases that do not meet the target reliability with the amount of data available. Where additional excavations are required, update the model used to select initial damage sites using the information from previous excavations. Demonstrate the model by realistic example cases. 5. Assess Overall Methodology. Use a suitable test case to demonstrate and assess the integrated methodology, and define bounds within which it could be successfully implemented. Use sensitivity analyses to investigate the conditions under which a direct assessment approach can be successfully used. Determine the required accuracy of the damage location method and evaluate the methods proposed in Task 2 against these requirements. Develop project conclusions and recommendations based on the results. 6. Present findings at two committee meetings, deliver quarterly project updates, and prepare a comprehensive final report.

vi

C-FER Technologies

1. TERMS OF REFERENCE

This document contains a proposal submitted by C-FER Technologies in response to a Request For Proposal (RFP) issued by PRCI on the subject of “Direct Assessment Methods for Mechanical Damage”. The objective of the proposed project is to develop methods to assess integrity with respect to in-service mechanical damage for pipelines that are not amenable to in-line inspection or hydrostatic testing. This proposal describes the approach that will be used for this work. It includes a technical background section (Section 2) that describes previous work on direct assessment and the major technical issues involved in implementing it for in-service mechanical damage. Section 3 deals with the objective, incentive, proposed tasks, schedule and cost. Section 4 outlines the project management structure and team qualifications, while Section 5 summarizes the relevant experience of the proposed team.

1

C-FER Technologies

2. TECHNICAL BACKGROUND 2.1 General

With growing emphasis on pipeline safety over the past few years, there has been an increasing demand for effective ways to demonstrate and maintain pipeline integrity. The main tools used for this purpose are In-Line Inspection (ILI) and hydrostatic testing, but these methods are not always viable. For example, hydrostatic testing is not practical for lines with no supply redundancy. Similarly, some pipelines that are not fitted with launch/receive facilities, or have sharp bends or small diameter valves that cannot be negotiated by an inspection tool. Direct assessment methods, which infer the condition of the pipeline from information that can be obtained from sources other than an in-line inspection, have been developed as an alternative integrity management approach for pipelines that are not amenable to ILI or hydrostatic testing. 2.2 Previous Work

Ongoing work by Battelle on direct assessment is focused on external corrosion. The information used in the assessment is obtained from ground surveys (such as close interval and direct current voltage gradient surveys) and bell hole excavations. Ground surveys detect areas of coating damage and determine the condition of the cathodic protection system. The information from ground surveys typically provides 100% coverage of the pipeline, but is indirect in the sense that it provides the location of potential rather than actual areas of corrosion. Direct information is then obtained from excavations, in which the defects in the excavated sections are located and accurately measured. Battelle suggests that confidence in the model can be developed by correlating the excavation information to the survey data and repeating the process until the model predictions compare favourably to the excavation findings. This methodology is still under development, requiring further validation with actual pipeline data. Although not referred to as direct assessment, a similar methodology has been used for some years to manage SCC damage. In this context, potential defect locations are identified using a susceptibility model that is based on coating type, soil type, topography and drainage. The most susceptible locations are excavated to locate and repair any existing defects. Confidence in the susceptibility model improves as more excavations are undertaken, allowing better correlation between reality and model results. The susceptibility models used in this case are largely line-specific and proprietary. 2.3 Proposed Framework

The proposed basic direct assessment methodology for in-service mechanical damage is demonstrated in Figure 1. The first step is to define likely damage sites based on the best available method and select the most critical damage sites for excavation. These sites would then be excavated and any necessary repairs carried out. Based on the information obtained from the 2

C-FER Technologies

Technical Background damage site identification analysis and the excavations, the integrity of the pipeline can be evaluated. If the integrity is adequate the process is terminated. If the integrity is not adequate, one must determine whether or not the direct assessment method is sufficiently promising to warrant further excavations. If further excavations are to be undertaken, the information from previous excavations is used to update the site selection method before the new excavation site locations are defined. This creates an iterative process that should be continued until sufficient confidence is achieved in the integrity of the line, or the assessment method shown to be ineffective.

Define Likely Damage Sites

Select Excavation Sites

Update Likely Damage Site Selection Model

Excavate and Repair Critical Sites

Evaluate Pipeline Integrity

Yes

No Promising ?

Adequate ?

Yes

No End

Figure 1 Overview of Direct Assessment Methodology

It is noted that an in-line inspection can be represented by a single pass through the steps shown in Figure 1. Only one pass is required for an accurate ILI tool, because the results of the first excavation are likely to match the tool data. This suggests that the efficiency of direct assessment depends largely on the ability of the initial damage site definition method to identify critical defect locations. If the method is perfect, critical defects will be identified in the first pass, leading to complete confidence in the integrity of the pipeline. In the other extreme, if a method of identifying defect locations is not available, the initial excavation sites will be selected 3

C-FER Technologies

Technical Background randomly and a significant pipeline length may need to be excavated in order to demonstrate integrity with sufficient confidence. In general, the number of iterations required and the length of pipeline excavated is a function of the accuracy of the defect identification method. 2.4 Technical Issues

Based on the discussion in Section 2.3, the technical issues involved in developing a direct assessment method for mechanical damage are as follows: 1. Identification of likely damage sites. As argued earlier, the effectiveness of direct assessment is highly dependent on the accuracy of the method used to identify likely damage sites. There are currently no recognized methods to locate mechanical damage features, and therefore a methodology needs to be developed for this purpose. 2. Characterizing integrity based on incomplete information. In a direct assessment situation integrity assessment is affected by two sources of uncertainty. The first source is the basic uncertainty resulting from variability in material properties, dimensions and loading. This uncertainty affects all pipelines regardless of the assessment methodology. The second source is the incompleteness of available information (referred to here as measurement uncertainty). This relates to the fact that the assessment is being made using a combination of indirect information (e.g. CIS data for external corrosion) and incomplete direct information (i.e. from selected excavations). While basic uncertainty cannot be reduced because it relates to intrinsic variability in loading and manufacturing processes, measurement uncertainty can be reduced by carrying out more excavations and improving the methods used to predict damage locations. The integrity measure used should be capable of incorporating the impact of these two sources of uncertainty. 3. Measuring the effectiveness of direct assessment. The RFP states that direct assessment methods should be as effective as in-line inspection and hydrostatic testing. The effectiveness of direct assessment can be measured by the level of confidence in the reliability estimates obtained using the information available for the assessment. If an adequate reliability estimate is demonstrated with a high level of confidence, the assessment is successful. On the other hand, if it is demonstrated that there is a low chance of achieving the desired level of confidence with a reasonable amount of further excavations, then the direct assessment approach may be deemed unsuccessful. To make these determinations, a methodology is required to estimate the level of confidence in calculated reliability as a function of the accuracy of the method used to identify initial damage sites and the total length of pipeline excavated. While the first issue mentioned above is unique to mechanical damage, the other two relate to direct assessment methodology in general. Therefore, some of the project results will be applicable to direct assessments related to other failure causes such as corrosion and SCC.

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3. PROPOSED PROGRAM 3.1 Objective and Scope

The objective of the proposed project is to develop a methodology for direct assessment of pipelines with respect to mechanical damage. The project will focus on in-service mechanical damage, which is defined as dent and gouge features that occur due to equipment impact during the service life of the pipeline (other damage such as dents occurring during construction is not included). The focus areas of the project will be as follows: 1. Develop a direct assessment framework for mechanical damage (see Section 2.3). 2. Develop models to address the individual components of the framework (Section 2.4). 3. Use the models in 2, to assess the feasibility of the framework and define the bounds within which the methodology is likely to be successful (e.g. What is the required accuracy of the method used to identify damage locations for a specific pipeline?). To develop a fully functional methodology, a specific method to identify damage locations must be selected and its accuracy characterized and validated using excavation data. This activity cannot be undertaken under the current project, as it requires a significant level of effort. The project will identify promising methods and make recommendations on how to characterize, quantify and validate their accuracy. 3.2 Incentive

Mechanical damage is the most common cause of pipeline failures and is responsible for a significant proportion of ruptures and large leaks. Although the majority of mechanical damage failures occur at or immediately after the damage incident, delayed failures can occur due to the fatigue growth of gouge defects. Such damage features can be identified by in-line inspection or eliminated through hydrostatic testing; however, there is no economical way to assess integrity for pipelines that are not amenable to these methods. The development of such a methodology will enable operators to cost-effectively manage the integrity of old pipelines with respect to mechanical damage.

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Proposed Program 3.3 Work Plan 3.3.1 Task 1: Finalize Project Plan

The project ad hoc committee will be contacted to obtain comments on the project scope and approach. A literature search will also be carried out to ensure that all published relevant information is obtained. Any required adjustments to the project plan will be made at this stage. 3.3.2 Task 2: Investigate Methodologies for Identifying Likely Damage Sites

This task will produce a listing of possible methods of identifying likely damage sites, a summary of all available information relating to their potential accuracy, and a proposed approach to characterize their accuracy. Approaches that will be considered include: •

Modified coating damage surveys. Since most mechanical damage events result in a coating holiday, coating damage surveys are likely to identify in-service mechanical damage sites. This method however, cannot directly distinguish between coating holidays resulting from mechanical damage and those resulting from other causes. Methods that could be considered to make this distinction include the clock position (mechanical damage is likely to occur near he top of the pipe) and the characteristics of the signal obtained.

•

Damage susceptibility model. Damage susceptibility is dependent on the hit rate and the potential for damage given a hit. The hit rate is a function of such pipeline attributes as land use, burial depth, one-call system, surveillance interval, right-of-way condition, and excavation procedures. The potential for damage given a hit is a function of the pipe wall thickness, grade and pressure. Excavations could be initially directed to sections with the highest damage potential. Damage susceptibility characterization will utilize a fault tree model previously developed and calibrated by C-FER for PRCI. The model calculates the likelihood of an impact in a specific location, allowing initial excavations to be targeted to more susceptible locations.

Information for this task will be collected from the literature and from informal discussions with member companies. Information on mechanical damage features found during excavations aimed to corrosion or SCC repair will be especially valuable. 3.3.3 Task 3: Develop Reliability Evaluation Model

This task will develop the measures that will be used to characterize pipeline integrity based on the information obtained from a direct assessment, and the criteria that must be met to demonstrate adequate integrity. To address the second issue discussed in Section 2.4, integrity of a given pipeline will be characterized by its reliability, defined as the probability that it will not fail for a period of one 6

C-FER Technologies

Proposed Program year (reliability = 1 – annual failure rate). Bayesian methods will be used to estimate reliability, because they combine the effect of basic uncertainty and measurement uncertainty into the reliability estimate. The resulting estimate incorporates a degree of conservatism commensurate with the level of measurement uncertainty associated with the information used in the assessment. In addition, the model will update the reliability based on new information obtained from subsequent excavations. A reliability-based criterion will be defined, against which the calculated reliability can be evaluated. Confidence in the calculated reliability level (as determined by the quality of the damage site selection model and the total length of pipeline excavated) will be considered in the criteria. The model will be tested and demonstrated by realistic example cases that will be included in the project report. The basic reliability calculation will utilize the PRISM software, which has been developed by C-FER to calculate the reliability of pipelines with respect to a number of failure modes including mechanical damage. Adjustments to the model will be made to account for measurement uncertainty. 3.3.4 Task 4: Develop Decision Models

This task will develop a model that uses accumulated excavation data to determine whether additional excavations should be undertaken for cases that do not meet the target reliability with the amount of data available. This choice will be based on the probability that additional excavations will be successful in demonstrating adequate reliability. Should further excavations be required, the effectiveness of the model used to select initial damage sites will be updated using the information from previous excavations. The model will be tested and demonstrated by realistic example cases that will be included in the project report. C-FER has developed a similar model and software for PRCI to address sampling strategies for low toughness pipelines. The same general approach will be utilized in this work. 3.3.5 Task 5: Assess Overall Methodology

The purpose of this task is to demonstrate and assess the overall methodology, and define bounds within which it could be successfully implemented. This will be achieved by selecting and analyzing a realistic case study. Ideally, the case study would be based on an actual pipeline for which a coating survey (e.g. DCVG), in-line inspection (MFL and/or geometry tool) and some verification excavations have been carried out. If this information cannot be provided by any of the member companies, a hypothetical but realistic example will be developed. The models developed in Tasks 2 through 4 will be integrated and used to analyze the test case as an example application. To examine the direct assessment approach, the case study will be analyzed as a non-piggable pipeline. The success of the method will be evaluated by comparing 7

C-FER Technologies

Proposed Program the reliability estimates and recommended actions to those based on the more accurate ILI information. Variations in key parameters will be made to investigate the conditions under which a direct assessment approach can be successfully used. Parameters that could be considered include wall thickness, location and condition of the pipeline. Since the success of direct assessment is dependent on the accuracy of the method used to identify likely damage locations, and since the development of a reliable method might still be on-going after completion of this project (see Section 3.1), an analysis of the required accuracy of the damage location method will be undertaken. Existing and proposed damage location methods analyzed in Task 2 will be evaluated against these requirements in order to develop an assessment of the likely success of different methods. This assessment will be used to develop a set of final conclusions and recommendations that reflect the findings of the work. 3.3.6 Task 6: Preparation of Deliverables and Reporting

This task will cover preparation of the project deliverables that include the following: •

Quarterly progress reports.

•

A comprehensive draft final report documenting the research work, the direct assessment methodology and the project conclusions/recommendations.

•

Presentations at two committee meetings. The timing of the presentations will be finalized in discussion with the PRCI representative.

3.4 Schedule

The proposed project schedule is shown in Table 1 (on a quarterly basis). The total duration of the project is assumed to be 2 years.

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Proposed Program Quarter Task

1

2

3

4

5

6

7

8

1. Project Plan 2. Damage Site Identification 3. Reliability Evaluation Model 4. Decision Model 5. Methodology Assessment 6. Reporting

Draft Report Final Report

Table 1 Proposed Schedule

3.5 Cost

We propose to carry out the work for a fixed price of US$150,000. Breakdown of this total cost by task is shown in Table 2. Task 1. Project Plan

Labour

Travel

Total

$5,800

$5,800

2. Damage Site Identification

$34,000

$34,000

3. Reliability Evaluation Model

$14,500

$14,500

4. Decision Model

$24,200

$24,200

5. Methodology Assessment

$42,500

$42,500

6. Reporting

$24,400

$4,600

$29,000

$145,400

$4,600

$150,000

Total

Table 2 Cost Breakdown by Task (US$)

We propose to invoice PRCI monthly, based on the estimated value of the work completed (according to this proposal) up to the end of the previous month.

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4. PROJECT TEAM ORGANIZATION AND QUALIFICATIONS

The proposed project team possesses the technical and managerial qualifications required to complete the project and produce a high quality product. It will consist of Dr. Maher Nessim who will act as project manager and principal investigator, and Dr. Mark Fuglem and Mr. Amir Muradali who will act as project engineers. Other C-FER personnel will contribute to the project as required. Relevant qualifications and experience of the project personnel is summarized below. One-page resumes are included in Appendix A. Maher Nessim (Project Manager and Principal Investigator)

Maher Nessim, Ph.D., P.Eng., Manager - Pipeline Technology, will act as project manager and principal investigator. He will be responsible for the final quality of the project deliverables. Dr. Nessim has over 20 years of experience in engineering research, consulting and management. His main areas of expertise are risk management and reliability-based engineering, applied to a variety of engineering systems including offshore structures, ships, buildings, nuclear facilities, and bridges. His work has had a special focus on pipeline integrity problems over the past few years. He has been involved in a number of research projects funded by the Pipeline Materials Committee and the Onshore and Offshore Design Committee of PRCI, and has been co-manager of C-FER’s multi-year joint industry project on Risk-based Optimization of Pipeline Integrity Maintenance Activities. Mark Fuglem (Project Engineer)

Mark Fuglem, Ph.D., Research Scientist – Pipeline Technology, will act as a project engineer. Dr. Fuglem has over 15 years of experience in research related to the oil and gas industry with a strong emphasis on reliability-based design. Recent work includes development for PRCI of a pipeline design method to ensure adequate reliability with respect to mechanical damage, reliability-based design of large diameter pipelines subject to mechanical damage and corrosion, and optimization of sampling procedures to ensure adequate fracture arrest capabilities for old pipe given measurement and sampling uncertainty. Amir Muradali (Project Engineer)

Amir Muradali, M.Sc., P.Eng., Research Engineer - Pipeline Technology, will act as a project engineer. Mr. Muradali has over five years of experience in engineering research and consulting. His main focus recently at C-FER has been working with improved corrosion assessment methods, crack assessment and propagation prediction methods, as well as conducting risk analysis for pipelines.

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5. CORPORATE QUALIFICATIONS 5.1 Corporate Profile

C-FER Technologies was initially established in 1983 to meet the engineering research and innovation needs of the pipeline, and oil and gas industries by developing new technologies to enhance both safety and economics. C-FER conducts theoretical and experimental research in engineering materials and systems, and accesses broad expertise through collaboration with its member companies and other research organizations. Concentrating on research programs that are need-driven, C-FER maintains a strong commitment to meeting the technology needs of its clients and members. A unique laboratory facility, opened in 1990, provides new opportunities for generating maximum return on investment in R & D. The facility includes approximately 5,200 square metres of office and laboratory space, and accommodates up to 85 research and support staff. Experimental equipment in the laboratory is unique in the world, and makes possible the realistic simulation of load, temperature, and other environmental conditions during the testing of components and systems. C-FER also maintains a network of powerful engineering workstations for developing software and conducting sophisticated numerical analyses. C-FER’s generic technical expertise and resources are organized in three research departments: Pipeline Technology, Production Technology, and Drilling & Completions Technology. C-FER has a total staff of approximately 45 with diverse technical capabilities in the above areas and an annual budget of approximately $6 million. C-FER’s latest Annual Report and latest organizational chart are already on file at PRCI, and with members of the Committee on Pipeline Design, Construction and Operations. Additional copies can be provided upon request. 5.2 Qualifications Related to the Proposed Project

C-FER has an active research program in the area of pipeline design, testing, analysis and integrity management. The breadth of C-FER’s capabilities in this area is demonstrated by the list of selected projects, which is already on file at PRCI, and with members of the Committee on Pipeline Design, Construction and Operations. Additional copies can be provided upon request. C-FER has had a leading role in developing new technologies to design and assess pipelines with respect to mechanical damage, as evidenced by the following recent projects: •

Effectiveness of Mechanical Damage Prevention Methods (PRCI, US$56,000, 1997 - 1999). Development of a model to assess the effectiveness of various damage preventions methods. Developed a fault tree model to estimate the likelihood of damage as a function of location and carried out an industry survey to obtain the data required to quantify the model.

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Corporate Qualifications •

Design for Mechanical Damage (PRCI, US$75,000, 1999 – 2000). Development of a reliability-based approach to design pipeline against mechanical damage and assessment of the implications on pipeline wall thicknesses.

•

Effectiveness of New Prevention Technologies for Mechanical Damage (PRCI US$80,000, on-going). The objective of this project is to evaluate the effectiveness, cost-benefit and technical feasibility of new technologies that are being proposed to prevent mechanical damage to pipelines, and to develop recommendations regarding the most effective path to further development and implementation of these new technologies. Effectiveness of each technology will be measured by the associated potential reduction in failure incidents and will be evaluated using reliability models developed by C-FER in previous PRCI projects.

•

Risk-based Maintenance Optimization of Pipelines. This program is sponsored by twelve pipeline companies and regulators, and has a budget of C$500,000 per year since 1994. Relevant work carried out under this project included developing models to calculate reliability with respect to mechanical damage (both immediate and delayed failures) and models to evaluate integrity and reliability based on ground survey and excavation methods.

Other recent project that are relevant to this proposal include: •

Safe Use of Low Toughness Pipe (PRCI US$105,000, on-going). Development of a model to assess the integrity of low toughness pipe based on information form a limited number of toughness tests. Developed a model and software tool optimize the sampling process using an iterative approach similar to the one proposed in this project.

•

Guidelines for Reliability-based Design (BP and TCPL, C$350,000, 2001 - 2001). Development of guidelines and a software tool for the application of reliability based design to onshore pipelines. The project developed the PRISM software, which will be used as the primary tool of reliability calculation in this project. Also developed a set of reliability targets that can be used to evaluate the integrity of pipelines in various location classes.

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APPENDIX A – RESUMES OF PROJECT TEAM

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Appendix A-Resumes of Project Team

Résumé

Maher A. Nessim C-FER Technologies 2000-present Manager, Pipeline Technology and Chief Engineer 1999-2000 1998-1999 1993-1998 1989-1993

Vice President and General Manager General Manager, Research and Technology Manager, Engineering Systems Technology Manager, Safety and Risk Technology

Work History

1985-1989 1983-1985 1979-1983 1978-1979

Senior Research Engineer, Det Norske Veritas (Canada), Calgary, Alberta Research Engineer, Det Norske Veritas (Canada), Calgary, Alberta Teaching Assistant (Civil Eng.), University of Calgary, Calgary, Alberta Instructor (Civil Eng.), Cairo University, Egypt

Education

Ph.D., Structural Engineering, University of Calgary, 1983. B.Sc., Civil Engineering, Cairo University, Egypt, 1976.

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Risk and reliability analysis; decision theory, probabilistic methods and statistical analysis; structural engineering; arctic and ice engineering; and pipeline design and maintenance.

Relevant Experience

Over twenty years of experience in engineering design, research and management. During the past fifteen years his technical work focused on risk and reliability analysis and its applications to a variety of engineering systems. Over the past eight years he has led C-FER’s efforts in this area, developing proposal and project ideas, interacting with C-FER’s members and clients, and supervising up to ten highly qualified professionals.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member. Institute for Risk Research, University of Waterloo, Ontario: Member Advisory Committee, International Workshops on the Reliability of Offshore Operations: Member, March 1991. CSA Technical Committee on "General Requirements, Design Criteria, the Environment and Loads - S471", Part I of the Code for Fixed Offshore Structures: Member, 1990 - present.

Awards

National Science and Engineering Research Council of Canada's Industrial Research Fellowship, 1984 - 1987, DNV (Canada) Ltd. Issac Walton Killam Memorial Scholarship, 1981 - 1983 University of Calgary. Robert Paugh Memorial Bursary, 1980, University of Calgary.

Publications

Nessim, M.A. and Zimmerman, T.J.E. 1999. Is Limit States Design a Probabilistic Design Method? Risk Based and Limit State Design and Operation of Pipelines, Oslo, Norway, October. Chen, Q. and Nessim, M.A. 1999. Reliability-based Prevention of Mechanical Damage. Presented at the Twelfth EPRG/PRCI Joint Meeting, Groningen, The Netherlands, May

A.2

C-FER Technologies

Appendix A-Resumes of Project Team

Résumé

Mark K. Fuglem C-FER Technologies 1998-present

Research Scientist

Work History

1998 1993-1998 1991-1998 1988-1991 1986-1988 1981-1986

Research Engineer, C-CORE, St. John’s Research and Project Engineer, Mem. Univ. of Nfld, St. John’s Project Engineer (Consultant), Ian Jordaan & Assoc., St. John’s Research Scientist, C-CORE, St. John’s Applied Mathematician, HydroQual Consultants, Calgary Programmer Analyst, Petro-Canada, Calgary

Education

Ph.D., Ocean Engineering, Memorial University of Newfoundland, 1998. B.Sc., Computer Science, University of Calgary, 1981. B.Sc., Math-Physics, Carleton University, 1979 (Honours).

Expertise

Reliability-based design, decision-making, risk analysis, and engineering economics.

Relevant Experience

Over 15 years of experience in research related to the oil and gas industry. Dr. Fuglem has been responsible for the development and application of probabilistic methods applied to pipeline reliability, ice keel impacts with pipelines, ice strengthening of offshore structures, production downtime, arctic shipping regulations, offshore transportation of crude oil, iceberg trajectory forecasting, and analysis of the reliability of offshore standby vessel systems.

Awards

Atlantic Accord Career Development Award Memorial Graduate Student Support, Memorial University of Newfoundland C-CORE Graduate Fellowship

Publications

Chen, Q., Fuglem. M.K., Stephens, M.J. and Zhou, J. 2001. Reliability-based Pipeline Design for Mechanical Damage. Presented at the 13th Biennial EPRG/PRCI Joint Technical Meeting, April 30 - May 3, New Orleans. Nessim, M.A., Fuglem, M.K., Chen, Q. and Odom, T. 2001. Lifetime Benefit of Highstrength, High-design-factor Pipelines. Presented at the 13th Biennial EPRG/PRCI Joint Technical Meeting, April 30 - May 3, New Orleans. Nessim, M.A., Chen, Q., Fuglem, M.K. and Muradali, A. 1999. Hydrotest Requirements for High-Strength, High-Usage-Factor Pipelines. Presented at the Twelfth EPRG/PRCI Joint Meeting, Groningen, The Netherlands, May. Fuglem, M.K. and Jordaan, I.J. 1998. Estimation of Maximum Bow Force for Arctic Vessels. 14th International Symposium on Ice (IAHR).

Consulting and Internal Reports

Fuglem, M.K., Chen, Q., and Stephens, M.J. 2001. Pipeline Design for Mechanical Damage. Submitted to the Pipeline Research Committee International, Pipeline Design, Construction and Operations Technical Committee, Project PR-244-9910, C-FER Report 99024, October. Nessim, M.A., Fuglem, M.K., Chen, Q., and Muradali, A.M. 2001. Influence of Higher Design Factor on Structural Integrity of X70 and X80 Pipelines. Submitted to the Pipeline Research Committee International, Materials Technical Committee, Project PR-244-9806, C-FER Report 98056, August.

A.3

C-FER Technologies

Appendix A-Resumes of Project Team

Résumé

Amir Muradali C-FER Technologies

Work History

2001-present 1998-1999

Research Engineer Research Engineer

2000 1998 1997

Mechanical Engineer, GKO Engineering, Edmonton, Alberta. Project Analyst, Beta Machinery Analysis, Calgary, Alberta. Private Contract, Mechanical Engineering Department, University of Alberta, Edmonton, Alberta. Teaching Assistant, Mechanical Engineering Department, University of Alberta, Edmonton, Alberta. Research Assistant, Mechanical Engineering Department, University of Alberta, Edmonton, Alberta.

1996 1995 Education

M.Sc., Mechanical Engineering, University of Alberta, 1997. B.Sc., Mechanical Engineering, University of Alberta, 1996 (with Distinction).

Professional Accreditation

P.Eng., Registered Professional Engineer in Alberta.

Expertise

Numerical modeling, pipeline integrity modeling, pipeline corrosion assessment, finite element analysis.

Relevant Experience

Over five years of broad research and consulting experience. Major focus at C-FER is in the area of pipeline risk and reliability engineering. Actively involved in various research projects related to this area and in upgrading/developing failure prediction models for PIRAMID.

Professional Activities

Association of Professional Engineers, Geologists and Geophysicists of Alberta (APEGGA): Member.

Awards

Province of Alberta Graduate Scholarship, 1996-1997. Aga Khan Foundation Scholarship, 1991-1995.

Publications

Muradali, A. and Fyfe, K.R., 1998. A Study of 2D and 3D Barrier Insertion Loss Using Improved Diffraction Based Methods. Applied Acoustics, 53, 49-75.

Presentations

Muradali, A. and Fyfe, K.R., 1998. Accurate Barrier Modeling in the Presence of Atmospheric Effects. Accepted for publication in Applied Acoustics. Muradali, A. and Fyfe, K.R., 1997. Accurate Geometric Modeling of Barrier Attenuation with Atmospheric Effects. Transportation Research Board Summer Conference on Transportation Related Noise and Vibration, Toronto, Ontario. Muradali, A. and Fyfe, K.R., 1996. Single and Parallel Barrier Insertion Loss by Means of Improved Diffraction Based Methods. Canadian Acoustics Association (CAA) Acoustics Week, October, Calgary, Alberta.

A.4

August 2002

DIRECT ASSESSMENT APPROACHES TO MECHANICAL DAMAGE (RPTG 0321)

Confidential

Prepared for: Steve Foh Pipeline Research Council International, Inc. c/o Gas Technology Institute 1700 South Mount Prospect Road Des Plaines Illinois 60018-1804 USA

Prepared by: Mark McQueen (& Robert Owen) Advantica Technologies Inc. 5177 Richmond Avenue Suite 900 Houston TX 77056 USA Tel: Fax: Email: Website:

713 586 7000 713 586 0604 [email protected]

www.advanticatechinc.com

Sales Opportunity ID: 1001421 Ⓒ 2002 Advantica Technologies Ltd CONFIDENTIAL Rev 0

DIRECT ASSESSMENT APPROACHES TO MECHANICAL DAMAGE (RPTG 0321)

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PROPOSAL SUMMARY Proposal:

RPTG 0321

Title: DIRECT ASSESSMENT APPROACHES TO MECHANICAL DAMAGE. Contractors: Advantica Technologies Inc. Type: New. Period: Start date January 2003, duration 24 months. Total estimated cost:

US$150,000.

Objective: To develop a quantifiable and validated basis for utilizing Direct Assessment methods for addressing time-independent mechanical damage, focusing particularly on delayed failure. Incentive: Direct Assessment methods are being developed for application to pipelines that are not amenable to hydrostatic testing or pigging, in line with emerging legislative requirements for managing pipeline integrity. At present the focus is on corrosion, but mechanical damage is the most frequent cause of failure and delayed failure has resulted in several recent high-profile incidents. Work Plan: TASK 1 – Overall framework development. TASK 2 – Reliability assessment. TASK 3 – Validation. TASK 4 – Standardized procedure. Deliverables: A report setting out a standardized and validated procedure, supported by documented technical justification.

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TABLE OF CONTENTS PART I TECHNICAL PROPOSAL 1 2

INTRODUCTION ................................................................................................ 5 TECHNICAL DISCUSSION ................................................................................ 5 2.1 Objectives................................................................................................... 5 2.2 Approach .................................................................................................... 5 2.3 WORK TO BE PERFORMED...................................................................... 6 3 SCHEDULE ........................................................................................................ 7 4 DELIVERABLES ................................................................................................ 7 5 ADVANTICA INFORMATION............................................................................. 7 PART I TECHNICAL PROPOSAL 1 2

COSTS ............................................................................................................. 10 COMMERCIAL TERMS.................................................................................... 12

Confidentiality Statement THE INFORMATION CONTAINED IN THIS PROPOSAL IS PROVIDED ON A COMMERCIAL BASIS IN CONFIDENCE AND IS THE PROPERTY OF ADVANTICA TECHNOLOGIES LIMITED. IT MUST NOT BE DISCLOSED TO ANY THIRD PARTY, IS COPYRIGHT, AND MAY NOT BE REPRODUCED IN WHOLE OR IN PART BY ANY MEANS WITHOUT THE APPROVAL IN WRITING OF ADVANTICA TECHNOLOGIES LIMITED.

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PART I TECHNICAL PROPOSAL

1 INTRODUCTION Mechanical interference is the most frequent cause of failure in high-pressure gas transmission pipelines. Whilst in most instances leaks or ruptures occur almost immediately, delayed failures also result from subsequent further damage development, usually in the form of cracks extending or linking the prior damage. Such damage can sometimes be identified and managed using regular hydrostatic testing or in-line inspection; however there are many pipelines for which such approaches are extremely difficult and/or expensive. Direct assessment (DA) methodologies are being developed for application to pipelines that are not amenable to pigging or hydrotesting, in line with the requirements for managing the integrity of gas pipelines (e.g. ASME B31.8 supplement). The primary focus of DA is currently on in-service corrosion; however, it is also potentially applicable to the management of other forms of in-service damage, including mechanical damage, for which specific tools and methods are necessary in order to characterize and assess the significance of the damage found. It will be necessary to demonstrate that these tools and methods are as effective as those based on pigging or hydrotesting in eliminating the risk of failure. A primary concern for delayed failure is unreported mechanical damage. Unreported damage can result from previous mechanical interference, vandalism or earth movement and may incorporate several features including denting, buckling, coating damage/removal, metal gouging or removal, residual stresses, cold working and surface cracking. Whilst the DOT failure statistics for gas pipelines show that less than 5% of reportable incidences are due to delayed failures, they nevertheless can be extremely costly to the industry when they occur, and play an important role in influencing public perceptions of pipeline safety.

2 TECHNICAL DISCUSSION 2.1

OBJECTIVES

The overall objectives of the proposed program of work are to deliver a quantifiable and validated basis for incorporating DA methods into the integrity management methodology for addressing time-independent mechanical damage threats to natural gas pipelines, focusing particularly on those that are potentially responsible for delayed failure. The methodology will be compatible with the requirements of ASME B31.8. 2.2

APPROACH

The approach to integrity management in ASME B31.8 incorporates both prescriptive and performance-based methods. The performance-based method requires additional knowledge of the pipeline to undertake data-intensive risk assessment, but allows more options for inspection intervals, inspection tools, mitigation and prevention methods.

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DA utilizes a structured process through which the operator is able to integrate knowledge of the physical characteristics and operating history of a pipeline segment with the results of inspection, examination and evaluation in order to determine integrity. The process for external threats typically has four components: preassessment, inspection, evaluation and post-assessment. DA can be employed as part of either a prescriptive or a performance-based integrity management methodology. Advantica’s approach will be firstly, to develop the overall framework for a structured approach to the threat of mechanical damage, incorporating DA methods within a performance-based integrity management methodology as outlined in ASME B31.8. It is expected that the framework will be very similar to that developed by NACE for external corrosion; indeed, many of the mechanical damage occurrences will be detected in the first instance by application of the NACE External Corrosion Direct Assessment methods. The assessment part of the framework will incorporate the results from a substantial body of work undertaken previously by PRCI, API, EPRG and GRI on aspects of mechanical damage. The second task will be to conduct a critical review/gap analysis to quantify/demonstrate how the weakest links in the methodology can be improved to deliver a reliable overall assessment, consistent with DA approaches for other forms of in-service damage (NACE, INGAA, ASME etc.) In the third task topic-specific detailed analysis will be supported as necessary by selected experimental testing of methods, inspection tools or integrity assessment (defect significance), in order to establish and validate a basis for applying DA. It is expected that a main focus of testing will be on the accuracy, repeatability and overall reliability of the individual steps in the assessment process. The final task will be to draft a standardized process incorporating the validated methods, in a format consistent with other DA methodologies (e.g. NACE). 2.3

WORK TO BE PERFORMED

The specific activities included in each of these tasks are as follows: Task 1

Overall framework development • • • •

Task 2

Reliability assessment •

CONFIDENTIAL Rev 0

Review current status of DA methods, legislative requirements. Review recent data and trends in damage frequency, type, causes, severity, consequences. Review information on reliability of inspection, examination and interrogation techniques. Develop linked suite of assessment algothrims and criteria compatible with prescriptive and performance-based approaches for DA.

Assess reliability of each element in the assessment methodology.

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• • • • Task 3

Validation • •

Task 4

Evaluate consequences of uncertainties/inaccuracies in input data. Identify and quantify benefits of changing the frequency of inspection/examination. Identify potential ‘weak points’ in the approach. Develop a strategy for validating the methodology.

Optimize performance of ‘weak links’ in methodology, based on analysis/experimental assessment of specific methods and tools. Conduct overall validation exercise on selected line with a known history of mechanical damage (preferably including comparison with hydrostatic testing or pigging approach).

Standardized procedure • •

Draft finalized methodology incorporating optimized methods and procedures, in a format compatible with industry-wide developments in DA methods. Finalize methodology based on feedback from members.

3 SCHEDULE The work will be undertaken by Advantica over a 24-month period. defined above will be completed as follows: Task 1. Task 2. Task 3. Task 4.

Overall Framework development Reliability assessment Validation Standardized procedure

The tasks

Months 1-8 Months 9-12 Months 13-20 Months 21-24

4 DELIVERABLES The outcome of this project will be a standardized and validated basis for utilizing DA methods to address time-independent mechanical damage threats, focusing particularly on those that are potentially responsible for delayed failure. The deliverable will be a report documenting the methodology and procedures, supported by technical justification. The methodology will be compatible with the requirements of ASME B31.8.

5 ADVANTICA INFORMATION Advantica is part of the Lattice Group, the UK-based infrastructure technology group that includes the gas pipeline operator Transco, and is a leading provider of consultancy and technical solutions for improved business and operating

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performance for customers in gas, pipelines and associated industries worldwide. Advantica has its origins in the British Gas (BG) group of companies and is now a $150 million business with over 800 skilled staff and centers in Houston, Charlotte and the UK. Advantica is a long-established technology supplier to the PRCI member companies and brings an important end-user operator perspective to their research programs. Of particular relevance, Advantica recently undertook a peer review of a GRI-funded project at SwRI on development of methods for assessing mechanical damage, and is assisting the INGAA Direct Assessment Task Group in the development and validation of direct assessment methods for external corrosion. Advantica staff have for many years played an active role in the direction and execution of EPRG’s projects on integrity management. Robert Owen is the Company’s member of the European Gas Pipeline Incident Data Group (EGIG), responsible for analyzing trends in pipeline incident frequencies and causes throughout Western Europe.

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PART II COST PROPOSAL

1 COSTS The work described in this proposal will be undertaken on a fixed cost basis of $150,000 (one hundred and fifty thousand US dollars). The total cost is inclusive of labor, computing, consumables, overheads and project management. A breakdown of costs is given in Table 1

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CONTRACT COST ESTIMATE

Name of Offeror Advantica Technologies Inc. Home Office Address 5177 Richmond Avenue, Suite 900 Houston, TX 77056 USA Division(s) and Location(s) (where work is being performed) Pipeline Transportation Division, Loughborough, UK

RFP No/Prp No Page Number Number of Pages RPTG 0321 1 1 Name of Proposed Project DIRECT ASSESSMENT APPROACHES TO MECHANICAL DAMAGE (RTPG 0321) Total Amount of Proposal $ 150,000 (US) Estimated Cost (dollars)

Cost Elements 1.

Total Estimated Cost (dollars)

Supporting Schedule

Direct Material a. Purchased Parts b. Interdivisional Effort c. Equipment Rental/Lease d. Other (software licence costs) Total Direct Material

2.

Material Overhead (Rate

3.

Subcontracted Effort (Attach Detailed Schedule)

% x Base $

)

Subcontractor Cofunding Net Subcontracted Effort 4.

Est. Hours

Rate/Hour

Manager/Consultant

Direct Labor - Specify

50

195

Est. Cost 9,750

Senior Engineer

500

143

71,500

Engineer

500

109

54,500

Technician

60

69

4,140

O.H. Rate

X Base $

Est. Cost

Total Direct Labor 5.

Labor Overhead - Specify

139,890

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

10. Other Direct Costs

10,110

11. Total Direct Cost and Overhead 12. General and Administrative Expenses (w/o IR&D) Rate

% of cost element numbers

13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost

100,000

15. Fixed Fee 16. Total Estimated Cost and Fee

100,000

17. Contractor/Third Party Cofunding 18. Net PRCI Estimated Cost and Fee

100,000

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow. nd Typed Name and Title R. Owen Signature Date 2 Aug 2002

Table 1.

Contract Cost Estimate

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2 COMMERCIAL TERMS Terms and conditions for undertaking the proposed work will be consistent with those previously agreed between Advantica Technology Inc. and GTI.

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MECHANICAL DAMAGE DIRECT ASSESSMENT - RPTG-0321 PART 1 – TECHNICAL PROPOSAL August 5, 2002

Submitted to: Steve Foh Gas Technology Institute 1700 South Mount Prospect Road Des Plaines, IL 60018

Submitted by: BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8

BMT FTL Contact: L. Blair Carroll, P. Eng. Tel: 613-592-2830, Ext 242 Fax: 613-592-4950 e-mail: [email protected]

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

Author: Principal Researcher: Name of Organization: Project Type:

L. Blair Carroll L. Blair Carroll / Robert Lazor BMT Fleet Technology Limited (BMT FTL) New

1) Statement of the Problem (What is to be solved): There are a number of tools and methods available for characterizing and assessing the structural significance of corrosion or cracking that are not directly applicable to mechanical damage. Such a tool for direct assessment will require the ability to combine the relative impact of several features of the mechanical damage, which include associated pipe deformation, gouging and the presence of other localized effects such as weld seams or corrosion. A mechanical damage assessment methodology will require consideration of stress analysis techniques, materials damage models and fracture mechanics based algorithms.

2) Background (What is the historical data): A significant amount of research effort has been attributed to denting and mechanical damage. Programs of note include the API 1156 study and the GRI-97/0413 study. In conjunction with industry support, BMT Fleet Technology has developed a Dent Assessment Model aimed at evaluating the impact of the presence of dents on the integrity of a pipeline. The model incorporates finite element analysis of the dented pipe geometry and a fracture mechanics based fatigue crack growth algorithm, and is currently being used in an industry consortium to develop a dent criticality criteria that can be applied to dents found in-service (in-line inspection) or during excavation programs. Phase I of this project was completed in May 2002 and Phase II will commence in Fall 2002. Part of the Phase II project scope will consider the impact of localized effects including gouging and weld seams.

i

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

3) Proposed Research Action Plan (How will the problem be solved): In order to develop an assessment model, several areas of investigation will be required: Year 1 - Task 1 - Assessment of Pipe Deformation on the Integrity of the Pipeline This work was developed in Phase I of the industry consortium project at BMT FTL and will be further developed in Phase II. The dent ranking criteria developed in the Phase I project was a function of pipe and dent geometry and pipeline operating conditions and was used to develop a relative ranking of the severity of a list of dents. The Phase II work will carry this forward to assign residual lives to a dented pipe segment. Year 1 - Task 2 - Modeling the Impact of Line Strike Material Damage This phase of the project will first require a review of all available literature to determine the extent of the past projects related to characterizing the severity and failure modes for mechanical damage. This work is scheduled as part of the Phase II industry consortium project and can be carried further in conjunction with the funding proposed by PRCI. The next stage of this work will involve numerical modeling of mechanical damage in pipelines to obtain a calibrated model to predict the morphology of mechanical damage features and their effects on localized stress distributions. The LS Dyna finite element analysis package is well suited for modeling impact, contact and material cold working and will be used in this phase of the analysis process. The conclusions will be added to the dent characterization criteria to expand the methodology beyond smooth dents to dents with associated material damage. Year 1 - Task 3 - Consideration of Other Localized Effects The dent characterization model will be further modified to account for the impact of additional features which may be associated with mechanical damage (metal loss, cracking, weld seams) and can further impact the integrity of the pipeline. Numerical modeling will be validated using the published results from full-scale trials. Year 2 - Task 4 - Further Model Validation and Implementation. As a further measure of the validity of the model, the funding made available in Year 2 will be used to conduct further testing to ensure that all appropriate information is available when validating the model. Any shortcomings in available published data will be identified during Year 1.

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Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

4) Expected Deliverables (List Specifically what PRCI will get out of the work): A validated and robust methodology for characterizing the impact of mechanical damage on the integrity of a pipeline. The methodology will be developed using numerical modeling, but will be adapted so that it can be applied without the need for detailed numerical analysis. A set of guidelines with examples of how the methodology can be applied to various forms of data, whether it was collected using in-line inspection tools or during field excavation. A report documenting the results of the modeling processes.

5) Resource Requirements (total cost, year-by-year breakdown, capital costs vs. overhead, and outside resources to be used): It is anticipated that the total expenditures required to complete this work will be in the order of $460,000 USD and will be broken down as follows: In-kind contributions: • $100,000: Initial development of the BMT FTL Dent Assessment Model • $100,000: Phase I work of the dent characterization consortium project • $60,000: Contribution of the Phase II work from the dent characterization consortium project supported by the consortium members • $50,000: Licensing fees for FEA modeling packages covered by BMT FTL.

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Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

6) Organization Information (Describe major business of contractor, facilities available for use in this project, related concurrent/recent projects): BMT FTL provides engineering research and services to the pipeline industry in the welding, materials characterization, and damage tolerance (ECA) areas of interest. Research efforts at BMT FTL have resulted in the development of dent and buckle/wrinkle assessment models. These tools support the integrity assessment of mechanically damaged pipes segments. Beyond the assessment of dents and wrinkles, the metallurgical, mechanical testing, welding and numerical simulation labs at BMT FTL have been involved in the following related projects: • Development of a hot tap tee design model • Development and calibration of pipeline pressure retaining sleeve design models • Development of fatigue and fracture analysis tools and courses for industry

7) Contractor Contacts: Mr. L. Blair Carroll Materials Technology Centre BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8 Tel: 613-592-2830 Fax: 613-592-4950 E-mail: [email protected] Internet: www.fleetech.com

Mr. Robert B. Lazor Materials Technology Centre BMT Fleet Technology Limited Box 82057, 2037-111 Street Edmonton, Alberta Canada Tel: 780-465-0077 Fax: 780-465-0085 E-mail: [email protected] Internet: www.fleetech.com

8) Alternative Funding Sources: The proposed program will be subsidised and progress facilitated through: • the use of pre-existing mechanical damage (dent and wrinkle) modeling tools developed under separate contracts, • the use of previously completed full-scale trial data to validate the numerical modeling tools, • the use of previously developed pipeline operation characterization techniques and tools • the use of previously collected and characterised pipeline material and operational data. Co-operative funding will also be sought from on-going parallel industry group sponsored projects to subsidise the work in this project.

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BMT FTL Document Quality Control Data Sheet Report:

Mechanical Damage Direct Assessment – RPTG-0321 –

Project No.

5561P

Date:

5 August 2002

Prepared by: L. Blair Carroll, Project Engineer

Reviewed by: R. B. Lazor, Manager BMT FTL Western Canada Office

Approved by:

A. Dinovitzer, Vice-President

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TABLE OF CONTENTS Page

1.

INTRODUCTION.................................................................................................................. 1 1.1 Proposal Layout/Administrative Details ...................................................................................1 1.2 Background and Incentives .....................................................................................................1 1.2.1 Project Objective ..................................................................................................................2

2.

WORK PLAN........................................................................................................................ 2 2.1 Overview ..................................................................................................................................2 2.2 Scope of Work .........................................................................................................................2 2.2.1 Task 1 – Literature Review ..................................................................................................2 2.2.2 Task 2 – Formalization of Pipeline Specific Parameters .....................................................2 2.2.3 Task 3 – Formalization of Inspection Information Parameters ............................................4 2.2.4 Task 4 – Evaluation of Model on Test Sections...................................................................4 2.2.5 Task 5 – Final Report...........................................................................................................6 2.3 References...............................................................................................................................6

3.

PROJECT TEAM AND QUALIFICATIONS.......................................................................... 7 3.1 3.2

4.

Project Team............................................................................................................................7 Related Projects ......................................................................................................................8

PROJECT MANAGEMENT.................................................................................................. 9 4.1

Project Schedule......................................................................................................................9

APPENDICES APPENDIX A: RESUMES APPENDIX B: CORPORATE CAPABILITIES

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LIST OF FIGURES AND TABLES

Figure 2.1: Figure 2.2: Figure 3.1: Figure 4.1: Figure 4.2:

BMT Fleet Technology Dent Assessment Modeling Process [3]...............................................5 Effect of D/t on Remaining Life Estimates for Dented Pipe [2] ..................................................6 Proposed Project Team and Additional Available Staff .............................................................8 Project Management Control ...................................................................................................10 Example of Weekly Project Cost Summary Sheet...................................................................11

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INTRODUCTION

In this section we describe the proposal layout, provide our understanding of the need for the project, its objectives and summarize the technical approach proposed for the project.

1.1

Proposal Layout/Administrative Details

This proposal is prepared in response to PRCI Request for Proposal No. RPTG-0321. It is submitted by BMT Fleet Technology Limited (BMT FTL) of Kanata, Ontario, who will act as the prime contractor. The proposal is presented in two parts contained in one volume: • •

Part I - Technical and Management Proposal, and Part II - Price Proposal

The proposal includes a copy of the pre-proposal submitted by BMT FTL as a summary of the following information: Section 1 2 3 4

1.2

Contents Proposal Summary (PRCI Pre-Proposal) Proposal Introduction and Technical Summary Details of the Technical Approach by Task Project Team Qualifications Project Management Approach

Background and Incentives

With the increased emphasis placed upon pipeline integrity management programs, new approaches to detecting and repairing pipeline flaws have been, and continue to be, developed. Current requirements placed on pipeline operators mandate the inspection of pipeline systems on regular intervals via either pressure testing or in-line inspection. Unfortunately, a large percentage of pipeline systems are neither equipped to allow the passage of in-line inspection tools, nor can one readily isolate the lines for hydrostatic testing. Furthermore, many pipelines provide single product sources so downtime related to in-line inspections and pressure testing would result in significant disruption for the end user of the product. In an effort to address these issues, new processes are under development to mitigate corrosion and stress corrosion cracking related degradation process using the concept of ‘Direct Assessment’. Some of the recent developments include: • • •

NACE International has implemented working groups to develop recommend practices for Direct Assessment Procedures related to external corrosion (TG-041); The draft version of the revised ASME B31.8 contains summary information to address internal corrosion direct assessment approaches; Formalized procedures are being developed to address Direct Assessment methodologies to mitigate stress corrosion cracking [1].

Each of the above utilizes databases of information collected on pipeline systems combined with known features of the degradation mechanism to predict the most probable locations the of degradation on a pipeline. After these locations are identified, exploratory excavation programs are planned to assess the current condition of the pipeline and address long-term integrity concerns. The methodologies essentially employ four categories of data: 1. Pipeline specific: material properties, pipe geometry, coating type, operating pressure history, past excavation history, failure history, etc. 2. Inspection information: closed spaced CP surveys, etc.

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3. Environmental: soil type along right of way, drainage, etc. 4. Degradation mechanism specific Overlaying the four categories of data in a risk-based approach, models can be developed to highlight the most probable locations of the damage along a pipeline right of way. The prevention of mechanical damage related failures using direct assessment type methodologies have not been formalized. Unlike corrosion or environmental cracking, the environmental and degradation specific degradation data is not applicable. It is proposed that pipeline specific and inspection information can be used to develop a direct assessment approach to mitigate mechanical damage on a pipeline system.

1.2.1

Project Objective

The work proposed in this document will seek to develop a recommended practice based upon direct assessment concepts to address mechanical damage concerns on a pipeline system that cannot be inspected using applicable ILI technologies or be easily pressure tested. The process will incorporate pipeline specific data, land use information, inspection results and operating history details.

2.

WORK PLAN

2.1

Overview

This proposal includes the technical experience and expertise of personnel at BMT Fleet Technology Limited (BMT FTL) in the development of techniques to determine the damage tolerance of, or significance of damage to, pipeline systems. The full-scale evaluation of the range of mechanical damage induced failure modes proposed in this project would be a monumental task financially, therefore a numerical modeling approach has been proposed. The scope of the model development is limited by previous work completed by the staff at FTL. The six tasks proposed for this work are summarized in Figure 1.9 and the section that follow provide detailed descriptions of the work to be carried out in this project. These tasks include a first year of model refinement and validation followed by their application to develop damage acceptance criteria.

2.2

Scope of Work

2.2.1

Task 1 – Literature Review

An extensive literature summary will be compiled to identify key elements contributing to mechanical damage related failures using several data sources, which include available regulatory agency or operating company failure reports, and sponsor company maintenance excavation histories. This information gathering phase of the project will summarize failure mechanisms associated with mechanical damage, and also to develop statistics related to pipe contact incidents by third parties that had not failed. The focus will be to identify common occurrences associated with the failures that may lead to previously unanticipated elements of a direct assessment procedure. It is proposed that the elements will be subdivided into two primary categories: • Pipeline Specific Parameters • Inspection Information Parameters

2.2.2

Task 2 – Formalization of Pipeline Specific Parameters

The pipeline specific parameters identified from Task 1 will be assessed as to their potential use in a direct assessment methodology. It is anticipated that the weighting applied to the different parameters will address both the contribution to the possibility of failure and also their usefulness

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in a direct assessment approach. It is anticipated that the following pipeline specific parameters will be included in the methodology: • Pipe material properties: The material properties may impact the potential for mechanical damage related failures. If a pipeline was constructed over a series of several years, different pipe material may have been used to construct different segments of the pipeline. Older lower toughness pipe would have a higher risk of failure from mechanical damage. Additionally, the consequences of a failure in low toughness pipe could be more severe than in high toughness pipe since resulting fractures could be larger and run for longer distances before arresting. • Pipe geometry: The pipe D/t ratio influences the risk of a failure on a pipeline. If the diameter and wall thickness changes along a pipeline then certain areas may be more susceptible to failure than others. Larger diameter pipe also is more likely to be struck during excavation because of its greater size. • Pipe manufacturing process: If pipe from different sources and/or manufacturing practices was used to construct a pipeline, the end result could have similar results on the risk of failure as the material properties since the two are related. If a mix of low frequency ERW pipe and DSAW pipe were used then mechanical damage associated with LFERW welds would have a higher potential for failure because of the low toughness traditionally associated with the fusion line of this welding process. • Land use: Land use in the vicinity of a pipeline can identify regions with a higher likelihood for the presence of mechanical damage. Pipelines running through farmers’ fields, for instance, have a higher probability of a line strike than a pipeline running through a wilderness area. Pipelines near residential areas would similarly have a higher likelihood and consequence of failure than a pipeline in a remote location. Recent development and changes in class location would be additional factors to consider. Separate risk and consequence indices would have to be applied. • Historical Failure Data: Some regions may have experienced a higher number of mechanical damage failures than others. Factors affecting this could be related to work conducted around the pipeline right of way. If for instance several failures occurred in an area where a particular contractor was working and the entire region was not excavated and visually inspected, then there is a potential for additional line strikes in the same region. • Pipeline Route: Pipelines routed through areas with deep clay soil layers would be less likely to have dents resulting from pipe laying or in-service dents resulting from pipe movement than pipelines routed through regions where the bedrock is nearer to the surface. The soil could also include large boulders, which are known to be associated with pipe deformation. • Pipeline Operating Pressure History and Pressure Profile: For time dependent failures related to mechanical damage, fatigue crack growth is likely a contributor to the failure process. Operating pressure data from the pipeline system can be analyzed to identify regions with the potential for the highest fatigue crack growth rates. The pipeline specific parameters could be used to rank the highest risk locations along a pipeline right of way using a pipeline indexing measure, Ip, of the form:

I P = f (Risk Parameters ) + f (Consequence Parameters) The functions applied to the risk and consequence parameters could include weighting features that would be applied to the individual parameter.

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To address issues related to the pipe material and pipe geometry parameters, BMT Fleet Technology Limited can draw upon the results of its two-year industry sponsored project to develop a pipeline dent characterization criteria [2]. The project was undertaken to address shortcomings in current industry codes when assessing the need to repair dented pipeline segments and utilizes the BMT Fleet Technology Limited Dent Assessment Model [3]. The model is illustrated schematically in Figure 2.1. It first uses pipe material properties and geometry, then dent geometry and the pipeline operating pressure history to predict the remaining life of a dented pipeline section. The model has been validated using full-scale test data from the API 1156 [4] and GRI-97/0413 [5] studies. In general, codes specify that dents with depths less than 6% of the pipeline OD do not require repair if no secondary effects are present (weld seams, corrosion, etc.). Operating experience for several liquid pipeline operators in North America have indicated that dent failures can occur at dent depths as small as 2-3% of the OD. These incidents suggest that the dent shape and pipe geometry may be more important than dent depth when assessing the likelihood of a failure. The group sponsored project has successfully demonstrated trends based upon pipe and dent geometry measures when quantifying the lives of a series of simulated dents generated using the BMT FTL Dent Assessment Model (Figure 2.2). It is proposed that an approach using the dent assessment criteria could be used to develop the risk functions required for the pipe material and geometry parameters used in the direct assessment methodology.

2.2.3

Task 3 – Formalization of Inspection Information Parameters

Inspection methods which could assist in developing a direct assessment process for mechanical damage include: • Visual inspection (aerial surveys): Regular pipeline right of way aerial surveys can provide information on encroachment on the pipeline since the time of construction. It can also be used as a tool to identify unreported construction activity. • Close-spaced CP surveys: While mechanical damage alone would not be affected by the CP applied to the pipeline system, data from CP surveys could indicate regions of coating damage. This information combined with known locations of pipeline excavation work could suggest that the coating damage was due to line strikes. Both of the inspection parameters could be formulated to give an inspection risk based index:

I I = f (RiskParameters )

After completion of Task 3, the total risk of a mechanical damage based failure at a location could be characterized using the equation:

I = f (I P + I I )

2.2.4

Task 4 – Evaluation of Model on Test Sections

It is proposed that a validation of the risk index be conducted using data from several actual operating pipeline systems known to have had mechanical damage defects or failures. The data could be supplied by PRCI member companies and the work conducted at the BMT Fleet Technology facilities or a representative from BMT Fleet Technology could travel to an operating company’s offices to gather the required information. The data required will likely include, but not necessarily be limited to: • Pipeline route sheets • Construction details of the pipeline, such as daily log books • Operating pressure data • Aerial photographs • Reported construction activity along the right of way • Land use information • CP survey data Locations of specific mechanical damage flaws or failures should be withheld until after the assessments have been completed. The results of the assessments would then be compared to

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the operators’ experience along the pipe sections. The results will be confirmation of the validity of the direct assessment process.

Figure 2.1: BMT Fleet Technology Dent Assessment Modeling Process [3]

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Figure 2.2: Effect of D/t on Remaining Life Estimates for Dented Pipe [2] 2.2.5

Task 5 – Final Report

The outcome of the project will be documented in a final report that will include a discussion of the theory behind each parameter used and the sources of information utilized. The results of the validation trial and the process required to conduct a direct assessment survey of a pipeline system will be documented.

2.3

References

1. Beavers, J., “SCC Direct Assessment”, NACE Pipeline Integrity Management Seminar, January, 2002. 2. Dinovitzer, A., Lazor, R., Carroll, L.B., Zhou, J., McCarver, F., Ironside, S., Raghu, D., and Keith, K., “Geometric Dent Characterization”, pending publication at IPC 2002. 3. Dinovitzer, A., Lazor, R., & R. Walker, “A Pipeline Dent Assessment Model”, OMAE’99. 4. Alexander, C.R., & J.F. Kiefner, “Effects of Smooth and Rock Dents on Liquid Petroleum Pipelines”, American Petroleum Institute, API Publication 1156, November 1997. 5. Gas Research Institute, “Evaluation of a Composite System for Repair of Mechanical Damage in Gas Transmission Lines”, GRI-97/0413, December 1998.

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PROJECT TEAM AND QUALIFICATIONS

BMT Fleet Technology Limited offers multi-disciplinary solutions to applied engineering and research projects. The Materials Technology Center has a history of providing engineering services to pipeline companies in the fields of pipeline integrity, damage tolerance, structural reliability, risk assessment and welding engineering.

3.1

Project Team

The BMT Fleet Technology Limited personnel proposed for this project provide over 20 years of combined experience working on pipeline integrity and damage tolerance issues. Resumes for the primary project team members are provided in Appendix A and brief biographies are provided below: Robert B. Lazor, MASc., P. Eng. – Project Manager Robert Lazor is a Principal Engineer with BMT Fleet Technology Limited and the Manager of the Western Canada office. One of his primary functions is to provide consulting services to pipeline companies in the area of damage tolerance and pipeline integrity. Prior to joining BMT Fleet Technology, Robert worked for 10 years in the Technical Services and Pipeline Integrity Departments at Enbridge Pipelines Inc. where he was responsible for developing, updating and implementing pipeline inspection and repair procedures. L. Blair Carroll, M.Eng., P. Eng. - Principal Investigator Blair Carroll is an Intermediate Engineer with BMT Fleet Technology Limited working in the Materials Technology Center. A key role for Blair is the development and implementation of damage tolerance criteria and procedures. He is extensively involved in the application of the BMT Fleet Technology Dent Assessment Model and other structural analysis and defect assessment projects. His previous employment experience included two years with the Pipeline Integrity Department of Enbridge Pipelines Inc. There he was charged with selecting and implementing inspection procedures and damage tolerance criteria and instructing engineering and field personnel in the practical application of the protocols. Aaron S. Dinovitzer, MAsc., P.Eng. – Structural Analysis Specialist Aaron is an Executive Engineer with BMT Fleet Technology Limited and the Manager of the Materials Technology Center. Aaron’s expertise in structural analysis, damage tolerance and risk and reliability will provide guidance to the project team in the development of appropriate risk and consequence criteria for the direct assessment process. He has been working in the area of structural integrity and damage tolerance analysis in which he has led the development of a number of pipeline ECA tools and techniques. His recent areas of development have included industry-sponsored projects on the development and extension of the BMT FTL dent assessment model discussed in Section 2, and a pipeline wrinkle model. Mr. Dinovitzer's experience in advanced numerical modeling, experimental program oversight and project management will be an asset to the team. Figure 3.1 shows the project team proposed for this project. The number of individuals has been kept small to ensure continuity and familiarity with the project; however, where potential conflicts with other work could affect the availability of project team members, alternative BMT FTL staff have been listed in Figure 3.1.

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Project Technical Committee Robert Lazor - Project Manager - Technical and Management Lead - Pipeline Operations Blair Carroll – Senior Mechanical Engineer - Numerical Modeling and Failure Analysis Aaron Dinovitzer – Principal Engineer - Numerical Modeling / Structural Analysis Additional Available FTL Staff: - N. Pussegoda – Senior Metallurgist (Failure Mechanisms) - A. Fredj – Senior Engineer (Numerical Modeling) - M. Avsare - Mech Eng (Numerical Modeling) - S Tiku - Met. Eng. (Fatigue and Fracture) - B. Xu (Numerical Modeling)

Figure 3.1: Proposed Project Team and Additional Available Staff 3.2

Related Projects

The following is a list of current or past projects undertaken by BMT Fleet Technology Limited related to the tasks proposed in this project: • • • • • • • • •

Development of a Pipeline Dent Characterization Criteria – the criteria was developed under an industry-sponsored project utilizing pipe geometry and material properties, dent profile information and pipeline operating history. Further work is ongoing. Review of Damage Tolerance and Repair Guidelines for Pipeline Companies. Development of a Pipeline Dent Assessment Model - incorporating finite element analysis and a fracture mechanics based fatigue crack growth algorithm to predict the remaining useful life of dented pipe in oil and gas transmission pipelines. Structural integrity analysis of pipeline repair sleeve and Stopple Tee fillet welds, including fatigue and fracture analysis of flaws in the weld toe and root regions. Performed reliability-based structural optimization - identifying optimal structural material properties based on probabilistic fracture mechanics. The optimal material selection problem has been formulated to produce maximum reliability and minimum cost solutions. The Review of Strain-Based Pipeline Design - reviewed and compared existing strainbased pipeline design criteria contained in design standards and research projects. The Development of Rational Criteria for Strain Limits in Pipeline Welds - investigated and developed preliminary strain criteria for the assessment of pipeline weld integrity. Development of Pipeline Limit States Design Material Partial Safety Factor - material property partial safety factors proposed for the limit states design standard were reviewed based on the material property data collected in previous work. Risk based review of proposed designs for the Liberty Pipeline System.

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PROJECT MANAGEMENT

Program management is an important component in the successful completion of this study. This requires that both the technical and financial aspects of the project be closely monitored and controlled. BMT Fleet Technology Limited has managed research and development contracts up to $1,000,000 in value and typically is managing some twenty-five contracts at any one time. The Company has standardized internal procedures for effective management of the programs and these are schematically shown in Figure 4.1. The overall management of this program will be handled by Mr. Aaron Dinovitzer, a Vice President at BMT Fleet Technology Limited. He will be responsible for ensuring that the project work is performed in a timely fashion and within the projected costs. Financial control is exercised through the computer generated and weekly updated cost summaries (Figure 4.2). He will also be authorizing the payment for costs related to this project. The technical monitoring will be carried out by internal meetings of the BMT FTL staff involved in the project at no longer than two-week intervals. Ms. Colleen Seabrook, Assistant Treasurer, will be available to address contractual and financial questions.

4.1

Project Schedule

It is anticipated that the work can be completed in a 24-month period from the time that the project is awarded. Quarterly progress reports will be issued throughout the duration of the project with an interim report after 12 months. BMT Fleet Technology personnel can be made available to provide presentations at PRCI meetings following submission of the interim and final reports. The proposed completion dates for each task are listed below: Tasks 1

2

3 4

5

6

7

8

Months 9 10 11 12 13 14 15

16

17 18 19 20 21 22 23 24

Task 1 Task 2 Interim Report Task 3 Task 4 Draft Final Report Final Report

• • • • • • •

Task 1: Task 2: Interim Report: Task 3: Task 4: Draft Final Report: Final Report:

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Month 4 Month 10 Month 12 Month 14 Month 18 Month 22 Month 24

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Figure 4.1: Project Management Control

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Figure 4.2: Example of Weekly Project Cost Summary Sheet

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Appendix A • Project Team Resumes

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ROBERT B. LAZOR, P. Eng. MANAGER, WESTERN CANADA

ACADEMIC BACKGROUND BASc, (Mechanical Engineering), University of Waterloo, Waterloo, ON MASc, (Mechanical Engineering), University of Waterloo, Waterloo, ON

PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, Edmonton, Manager, Western Canada, March 2000-Present – Responsibilities include increasing awareness of FTL’s capabilities in the Energy sector. This involves identifying opportunities for the company as a whole, building industry contacts, and providing engineering services related to pipeline repair methods and reliability, engineering critical assessments, welding engineering, material selection, and failure investigations. ENBRIDGE PIPELINES INC., Engineering Specialist-Technical Services, 1992-1997; Engineering Specialist-Pipeline Integrity, 1997-1999 – Responsible for failure investigations, defect assessment procedures, welding procedure approvals, team leadership, representation on CSA Materials Subcommittee, custodian of Operations & Maintenance Procedures Manual. ! Resolved technical issues relating to design, integrity evaluations, and repair procedures of Company facilities. ! Provided advice to Operations and Engineering on the selection of materials for Company facilities, non-conformance issues, and revised Company specifications to ensure compliance with industry standards and regulations. ! Collected Company comments relating to the proposed Onshore Pipeline Regulations and made these known to the National Energy Board staff as part of an industry committee. ! Reviewed the fracture design methodology of the Alliance Pipeline to satisfy corporate interests and concerns for the technical viability of the project. ! Developed a database of corporate pipe inventory, including material properties, which provided the ability to establish internal inspection intervals. ! Supervised co-workers to resolve issues related to internal inspection of pipelines and the capabilities of the inspection technologies. ! Analyzed the life cycle costs of fittings and flanges and determined the competitive bidding process, rather than a sole source supplier was more effective. ! Developed Company practices for hydrostatic testing and provided assistance in field during hydrostatic testing as needed. ENBRIDGE PIPELINES INC., Senior Engineer, Quality Assurance, 1998-1992 – Responsible for projects to support Operations and Engineering related to welding and material selection and represented Company on industry committees. ! Developed company program to address stress corrosion cracking to comply with National Energy Board requirements. ! nvestigated plant failures and developed recommendations and action plans for preventing similar failures. ! Initiated storage system for hydrostatic test results, mill test reports, and nondestructive examination reports to comply with regulatory requirements. ! Created Industry standard for qualification of nondestructive examination technicians for fillet weld inspections.

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Reviewed manufacturers’ quality assurance programs and prepared list of approved manufacturers for material purchases. Advised Operations on welder training requirements and arranged instruction program with local college. Contributed to CSA Standards regarding pipeline maintenance welding and repair methods.

WELDING INSTITUTE OF CANADA, Scientific Officer, 1979-1982; Group Leader, Materials Technology, 1982-1988 – Supervised a specialized technical staff of two engineers and three technicians in the execution of research contracts, failure investigations, and routine mechanical testing. ! Liaised with government and industry groups to develop and implement research programs to address timely issues related to welding metallurgy, thermal and residual stresses, and fracture design concepts for welded structures. ! Developed weldability test that is currently used throughout the pipeline industry to establish preheat temperatures for pipeline construction. ! Instructed at seminars and developed materials for home study welding metallurgy courses. WESTINGHOUSE CANADA LIMITED, Junior Project Engineer, 1975-1976 – Designed modifications and calculated new operating characteristics for changing the operation of industrial gas turbines to operate on both gas and oil. Required the development of new operating manuals and the preparation of design drawings. ONTARIO MALLEABLE IRON, Junior Project Engineer, 1974-1975 – Completed projects related to plant maintenance, which involved material procurement, liaison between contractors and plant departments, and the preparation of design drawings.

PROFESSIONAL AFFILIATIONS Council Member, ASM International Weldability Committee, Welding Research Council International Institute of Welding CSA Task Force on Fracture Toughness CSA Subcommittee on Materials CSA Task Force on Joining APEGGA Career Counselling Committee API Mechanical Damage Task Force

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L. BLAIR CARROLL, M. ENG., P. ENG PROJECT ENGINEER ACADEMIC BACKGROUND Master of Engineering (Mechanical Engineering – Nondestructive Examination), Memorial University of Newfoundland, St. John’s, NF, 1998 Bachelor of Engineering (Mechanical Engineering), Memorial University of Newfoundland, St. John’s, NF, 1995

PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, Project Engineer-Materials and Structures, June 2000 to Present – Responsibilities include: # FEA analysis # Engineering critical assessment and damage tolerance # Assisting with failure investigations # ILI data analysis and in-field defect assessment services for pipeline operators # Assisting with structural analysis for pipelines risk and reliability projects # Evaluation of pipeline repair techniques ENBRIDGE PIPELINES INC. Edmonton, Alberta, Canada , Pipeline Integrity Engineer, April 1998 to June 2000 – Responsibilities included: # Performance evaluation of in-line inspection crack detection tools; # Updated pipeline inspection procedures, maintenance manuals, engineering standards and material specifications; # Stress corrosion cracking management program; # Coordinated failure investigations; # Welding procedure review and upkeep; # Technical resource for defect assessment and repair programs; # Technical resource on codes and standards for operations personnel. RTD QUALITY SERVICES, LTD. Edmonton, Alberta, Corrosion Engineer, July 1997 to April 1998 – Responsibilities included: # Evaluation of ACFM technology for company inspection procedures; # Technical resource for field NDT inspectors; # Corrosion ECA’s. FISHERIES AND MARINE INSTITUTE OF MEMORIAL UNIVERSITY OF NEWFOUNDLAND St. John's, NF, Part-Time Instructor, May 1995 to April 1997 Instructed theory of machines and engineering mechanics. CENTRE FOR COLD OCEANS RESOURCES ENGINEERING (C-CORE), St. John's, NF, Part-Time Research Assistant, December 1995 to March 1996 Responsibilities included: # Lab and field testing for a Canadian Coast Guard project investigating the properties of synthetic fibre mooring lines for buoy systems. DEUTAG DRILLING, Bad Bentheim, Germany, Co-Op Student, Sept. 1994 to Dec. 1994 # Performed design reviews for drilling rigs systems including mud recycling systems and automated drill pipe handling equipment

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HELSINKI UNIVERSITY OF TECHNOLOGY, Helsinki, Finland, Co-Op Student, January 1994 to April 1994 – # Assisted with data analysis of scale model testing of an ice breaker hull design; assisted with testing of mechanical properties of ice sheet formulations for model ship testing NORWEGIAN CONTRACTORS a.s, Hinna, Norway, Co-Op Student, June 1993 to September 1993 # Assisted with welding procedure qualification tests (carbon steel and titanium); # Assisted with NDT inspections; # Conducted quality control inspections of piping systems. PROFESSIONAL AFFILIATIONS 2001-Present Treasurer, National Capitol Section of the National Association of Corrosion Engineers 2001 Member, Professional Engineers of Ontario 1999-Present P. Eng., Association of Professional Engineers, Geologists and Geophysicists of Alberta 1999 Stress Corrosion Cracking Session Chair, Banff 99 Pipeline Workshop 1998-Present Enbridge representative to the CEPA Pipeline Integrity Working Group

Personal/Professional Development 2000 1999 1999 1998 1998 1998 1998

ANSYS Finite Element Modeling Course British Standards, BS 7910 Course, Structural Integrity Training CASTI CSA Z662 Course, Oil and Gas Pipeline Systems Skill Paths Team Management Course Kiefner & Associates 1-Day Corrosion Assessment Workshop O.H. & S. First Aider I CASTI ASME Section IX Welding Codes and Metallurgy Course

PUBLICATIONS Thesis: L.B. Carroll, Investigation into the Detection and Classification of Defect Colonies using ACFM Technology, Faculty of Engineering and Applied Science, Memorial University of Newfoundland, St. John’s, Newfoundland, Canada, October, 1998. Conference Papers: Carroll, L.B. and M.S. Madi, “Crack Detection Program on the Cromer to Gretna, Manitoba Section of Enbridge Pipelines Inc. Line 3”, 2000 ASME International Pipeline Conference, Oct. 15, Calgary, Alberta, Canada, Proceedings of the International Pipeline Conference 2000, Vol. 2, ASME, New York, pp. 1435-1438. Carroll, L.B., Monahan, C.C., and R.G. Gosine, “An automated ACFM peak detection algorithm with potential for locating SCC clusters on transmission pipelines”, 1998 ASME International Pipeline Conference, June 7-11, Calgary, Alberta, Proceedings of the International Pipeline Conference 1998, Vol. 1, ASME, New York, pp. 335-340. Kania, R., and L.B. Carroll, “Non-Destructive Techniques for Measurement and Assessment of Corrosion Damage on Pipelines”, 1998 ASME International Pipeline Conference, June 7-11, Calgary, Alberta, Proceedings of the International Pipeline Conference 1998, Vol. 1, ASME, New York, pp. 309-313. Carroll, L.B., and C.C. Monahan, "Detection and classification of crack colonies using ACFM technology - Phase I," 1997 ASME Pressure Vessels and Piping Conference, July 27-31, Orlando, Florida, NDE Performance Demonstration, Planning and Research, PVP-Vol. 352, NDEVol. 16, M.M. Behravesh, M.P. Jones, and C.C. Monahan, Eds., ASME, New York, pp. 57-64.

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Timco, G.W., Irani, M.B., Funke, E R., English, L.A., Carroll, L.B., and J.C. Chao, (1993), "Ice Load Distribution on a Faceted Conical Structure", Proceedings of the 12th International Conference on Port and Ocean Engineering under Arctic Conditions (POAC '93), Hamburg, Volume 2, pp. 607 - 616. Journal Articles: Carroll, L.B., and M. Madi, “PIPELINE INSPECTION – Conclusion: ILI tool detects cracks, SCC in Canadian liquids line,” Oil & Gas Journal, Vol. 99, Issue 19, May 7, 2001. Contract Reports: K. Klein, C. Monahan, M. Nahon, R. Driscoll, and B. Carroll, "Investigation of Synthetic Fiber Rope Moorings for Canadian Coast Guard Navigation Buoys," Contract Report for Canadian Coast Guard, Transport Canada, C-CORE Publication 96-

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AARON S. DINOVITZER PRINCIPAL ENGINEER ACADEMIC BACKGROUND University of Waterloo, Waterloo, MASc., Civil Engineering, 1992. Research Assistant, 1990-92, Involved in design approach development to minimise the effects of local buckling on cold formed steel sections. Studied probabilistic (reliabilitybased) design and optimisation with the goal of comparing it to deterministic approaches. MASc. thesis: "Probabilistic and Deterministic Structural Optimisation". University of Waterloo, Waterloo, BASc., Civil Engineering, 1990. Course of study focused on structural mechanics and design. Awarded undergraduate research assistantship for study of structural optimisation.

PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present - Contribute expertise and support to projects involved in the fields of structural design/analysis, reliability and risk, assessment, Welding Engineering, numerical and analytical modeling and mechanics. Research and develop structural and reliability-based analysis and modeling techniques for research projects involving structural design criteria, fracture mechanics, finite element analysis and closed form solutions for plate and shell behaviour. Involved in the design and analysis of welded structures for the pipeline, marine, defence and resource sectors. Recent projects include: Development of rational material strain limits for pipelines: This project funded by the Canadian pipeline industry investigated and developed strain based pipeline analysis criteria. A probabilistic approach has been used to illustrate the conservatism associated with the current design approaches that neglect the effects of material ductility. Development of a combined hydrogen/thermal diffusion model to evaluate the potential for delayed cracking in pipeline welds. Based on a description of essential multi-pass welding procedure parameters the model develops a time history of thermal and hydrogen diffusion to illustrate the potential for delayed cracking and allow the optimisation of the welding procedure to reduce the risk of delayed cracking. Development of refit specifications including welding procedures to add a self unloading system to a bulk carries. Finite element analysis to illustrate the effects of the addition of a deck mounted self unloading system to a bulker. Detailed analyses including analysis of doubler plate system including slot welds were completed to illustrate integrity of welded connections. With this information design modifications and details of the self unloading system were design and modified based on further finite element modeling. FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present Review existing design of Canadian Coast Guard 47’ Aluminium Motorised Lifeboat to identify compatible aluminium alloys for repairs in Canada. This study demonstrated the feasibility of making repairs with more readily available and less expensive high strength aluminium alloys. T he review included fatigue buckling and ultimate strength checks of the as welded structural system. In addition, promising repair welding procedures were developed. Review and demonstration of strain-based limit states design criteria for pipeline design. In this project the merits of strain-based (post-yield) design criteria were examined and demonstrated through a series of pipeline design examples. Development and presentation of a Fatigue Resistant Detail Design Guide for Ship Structures. In this project, a design guide was developed to present procedures used to characterise the long term statistical nature of wave induced ship loads and to design

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structural connections with specified fatigue lives. These approaches were presented and demonstrated in a short course on fatigue and fracture for ship structures. Reliability-Based Structural Optimisation: In a project funded by CANMET (EMR) techniques for identifying the optimal match of pipeline weld and base material properties based on probabilistic fracture mechanics were developed. The optimal material selection problem has been formulated to produce maximum reliability and minimum cost solutions. Development of a non-linear finite element modeling system which evaluates the effects of dents on the fatigue performance of a pipeline. This modeling project included the development of a FE based software suite which incorporated inspection based dent configuration data, a client supplied operational loading profile and an a parametric description of the structure linked to an automated model meshing system. Corrosion, crack like flaws and weld seams may be superimposed on the dent in the assessment process. An assessment of ice loading on hydroelectric dams, for the Canadian Electrical Association, was performed as par of a larger dam safety program. In this project, finite element modeling was used to assess the magnitude of the loads generated due to the constrained daily expansion of the reservoir's winter ice cover. Development of a risk based maintenance management system for the Canadian Navy Ship Structural Integrity Programme (SSIP). This approach optimally allocated inspection and repair resources in a continuously updating management system. FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present Development of Risk-Based inspection tools for Transport Canada Marine Safety to allocate resources, manage inspection time and rationalised the regulatory enforcement decision process. Developed a finite element model to assess the structural behaviour source of cracks in a longitudinal bulkhead of a tanker structure. By identifying the sloshing induced buckling mode that was present a structural modification was developed and designed using FEA. The results of this FEA were compiled and submitted and approved by ABS. Characterisation and modeling of behind-armour ballistic debris to identify the post penetration vulnerability of armoured vehicles. The vulnerability/lethality model being developed in this project, for the Department of National Defence, employs aspects of the shot conditions and the mechanics of penetration in a probabilistic framework to predict the mass and velocity distribution of behind-armour debris clouds. The development of a symbolic finite element analysis approach for reliability analysis: In this year and a half long project for the Canadian Defence Research Establishment Atlantic (DREA), an automated approach to the algebraic solution of a finite element structural analysis problems is being developed for use in reliability analysis. High strength buoy mooring chain selection based on a comparison of chain residual strength and service loads. This project, for the Canadian Coast Guard, identifies chains that provide a required level of safety against failure at the end of a five year service life. This design project involved the development of a semi-empirical corrosion/wear model and a mechanics based analytical degraded chain ultimate strength model. The development of conceptual designs for a lightweight ceramic/FRP composite armour system to provide ballistic protection for light armoured vehicle weapon stations. In this material selection and geometric design project, for DVEM 2-5, Mr. Dinovitzer employed analytical ballistic modeling techniques to identify the ceramic and FRP material components which provided the required levels of ballistic protection and minimised the overall turret weight. Global Stress Concentrations in Ship Structural Details: This project, funded by the Canadian Navy, includes the identification of stress distributions in structural details, through finite element analysis, for fatigue life estimation. Development of Tripping and Buckling Criteria of Framing for Ice Strengthening: In this project, criteria were developed for the Canadian Arctic Shipping Pollution Prevention Regulations (CASPPR) to ensure the adequacy of stiffeners in ice strengthened vessels.

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Development of a Materials Property Database for Reliability Analysis: In this project, for the U.S. Ship Structures Committee, a uniform format for collecting and processing material property data was developed for use in reliability-based design. The material property database developed in this project is being considered by the ASTM for adoption as a standard data reporting format. Development and evaluation of existing analysis approaches for buckling of partially stiffened plate elements. Recommendations on optimal section configuration and buckling analysis approaches resulted in changes to the Canadian handbook of steel construction and the Canadian cold formed steel design standard. Engineering Critical Assessment / Fitness-For-Purpose Investigations Loading, structural analysis and fracture mechanics expertise has been used to assess the significance of structural damage and weld flaws to determine the root cause of a failure. These accident reconstruction, failure analysis, fitness for purpose or ECA projects include: - Reconstruction of tractor trailer accident - ECA investigation of pipeline girth weld defects - Pre-Inspection ECA of weld defects for petro-chemical plant reactors and piping - Determination of chain lashing failure mechanics - Rail car fatigue and fracture failure investigation - Marine structure fatigue cracking damage tolerance investigation

PROFESSIONAL SOCIETIES / AFFILIATIONS Association of Professional Engineers of Ontario, Member Society of Naval Architects and Marine Engineers, Member Certified Design Welding Engineer Canadian Society of Civil Engineering, Associate Member American Society of Civil Engineers, Associate Member Society of Reliability Engineers, Vice President (Ottawa Chapter) Institute for Risk Research, Member Member of CSA-Z662 Pipeline Risk Assessment Working Group Member of CSA-Z662 Pipeline Limit States Design Technical Committee

PUBLICATIONS A.S. Dinovitzer, "Optimization of Cold Formed Steel C-Sections", published in Canadian Journal of Civil Engineering, February 1992. A.S. Dinovitzer, M. Sohrabpour, R.M. Schuster, "Observations and Comments Pertaining to CAN/CSA-S136-M89", presented at the 11th International Specialty Conference on Cold Formed Steel, Recent Developments in Cold Formed Steel Design and Construction, St. Louis, Missouri, October 1992. M.Z. Cohn, A.S. Dinovitzer, "Applications of Structural Optimization", ASCE, Journal of Structural Engineering, Vol 120, No. 2, February 1994. A.S. Dinovitzer, M. Szymczak, “Characterization of Behind-Armour Debris”, 16th International Ballistics Symposium, Ballistics’96, San Francisco, Sept. 1996. B. Graville, A.S. Dinovitzer, “Strain-Based Failure Criteria for Part Wall Defects in Pipes”, 8th International Conference on Pressure Vessel Technology, ICPVT-8, Montreal, July 1996. A.S. Dinovitzer, “Reliability Based Optimal Material Selection”, Managing Pipeline Integrity: An Issues Workshop on Pipeline Lifecycle, Banff, Alberta, June 1994. G. Comfort, R. Abdelnour, Y. Gong, A. Dinovitzer, “Poussee Statique des Glaces Sur les Ouvrages Hydroelectriques”, November 1996. A.S. Dinovitzer, R. Basu, LCDr K. Holt, “A Hybrid Approach to Warship Maintenance Management”, Accepted for presentation at the SNAME Annual General Meeting October 1997.

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A.S. Dinovitzer, M. Szymczak, D. Erickson, “Fragmentation of Targets During Ballistic Penetration Events”, to apear in the International Journal of Impact Engineering. A.S. Dinovitzer, R. Silberhorn, J.L. Rene, “The Mooring Selection Guide (MSG) Software”, Accepted for presentation at Oceans’97. A.S. Dinovitzer, M.Szymczak, T. Brown, “Behind-Armour Debris Modeling”, 17th International Symposium on Ballistics, 1998. A.S. Dinovitzer, B. Graville, A. Glover, “Strain-Based Failure Criteria for Sharp Part Wall Defects in Pipelines”, International Pipeline Conference, 1998. A.S. Dinovitzer, R. Smith, “Strain-Based Pipeline Design Criteria Review”, International Pipeline Conference, 1998. A.S. Dinovitzer, R. Lazor, R. Walker, C. Bayley, “A Pipeline Dent Assessment Model”, paper to be presented at OMAE’99. A.S. Dinovitzer, I. Konuk, R. Smith, B. Xu, “Pipeline Limit States Design”, paper to be presented at OMAE’99. D. Heath, N. Pegg, A. Dinovitze, R. Walker, “Detail Analysis of Ship Structures”, paper to be presented at Canadian HydroMechanics Conference, 1999.

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APPENDIX B BMT FLEET TECHNOLOGY LIMITED CORPORATE CAPABILITIES

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BMT Fleet Technology Limited has been engaged in the business of contract Research and Development for more than twenty seven years now. During this time period, hundreds of contracts, several of these in the $300,000 to $500,000 range, have been successfully completed for clients, both in Canada and in the United States. BMT FTL has been involved in marine engineering and structures research since its inception 25 years ago. Since the addition of the Materials Technology Division in the mid-80s, BMT FTL has been applying its quite unique combination of structures and materials expertise to welded structures in other industries. In the context of the pipeline industry, numerous investigations undertaken to date have dealt with pipeline girth weld fracture toughness, line pipe steel weldability, studies in support of Standards development, and failure analysis. The investigations undertaken by the Materials Technology Division are about evenly divided between experimental and analytical projects. The former have dealt mainly with welding procedure development and weldability studies, and fracture and fatigue performance of steels and welded joints; the latter with structural reliability, engineering critical assessment, optimization and analytical model development. RECENT BMT FTL PROJECTS In the recent past, BMT FTL staff has completed a wide range of projects including the following projects, presented as an example of the types of work completed at BMT FTL: • Welding Related Projects • Repair welding of stiffeners to hull plating in low temperature marine environments (water backing) without preheat; • Armour steel repair procedure development and implementation in a battlefield tank; • Repair welding procedure development and instructions for aluminum alloy mantlets, medium girder bridge, and armoured vehicle launched bridge; • Hardfacing repair welding of gas turbine blades; • Simulation of reheated heat affected zone cracking in repaired girth welds; • Development of a Multi-Pass Weld Procedure Delayed Cracking Risk Assessment Software • Pipeline Design and Fitness-for-Service • Risk evaluation of concept designs for the Liberty Pipeline; • Development of pipeline dent assessment model • Strain-Based Corrosion Damage Assessment Technique • Development of Strain-Based Planar (Crack-Like) Defect Assessment Technique • Development of Multi-Pass Weld Delayed Hydrogen Cracking Prediction Software • Preliminary development of a CTOA Based Model to Predict the Potential for Long Running Ductile Fracture Events • Review of Strain-Based Pipeline Design Criteria, including sample applications • Probabilistic Modeling, and Risk Assessment • Reliability-based calibration of CSA Z662 Limit States Design Appendix • Reliability based optimal material selection for pipeline girth welds • Development of Risk-Based Structural Inspection Management Tools • Development of Risk-Based Maintenance Management System • Material Properties • Development of an Interim Measure of Ductile Fracture • Assessment of a Two Specimen Approach for the Measurement of CTOA Ductile Toughness • Development of Pipeline Material Property Database for Reliability Analysis

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FACILITIES The sections that follow provide a brief overview of the facilities and equipment available in the Materials and Welding Division at Fleet Technology Limited. The facilities and equipment available at FTL are more than adequate to perform the proposed project. In addition to the facilities listed, in the sections that follow, the Systems Division of Fleet Technology Limited which performs software development and field instrumentation can provide assistance in the data recording requirements for the experimental part of this project. Metallurgical • Optical microscopes and stereoscope • Hitachi scanning electron microscope equipped with Ortec EDX system • Specimen preparation facilities: • metallurgical cut off wheel • small diamond saw • mounting press • automatic grinding and polishing facilities • Vickers and Rockwell hardness machines • Lietz micro-hardness unit Welding & Machining • Automatic oxy fuel and plasma cutting equipment • Fully equipped welding facility for SMAW, GTAW, P-GTAW, GMAW, P-GMAW, FCAW, MCAW and SAW • Welding parameter high speed data acquisition system • High temperature electric furnace accommodating material up to 600 x 600 mm in size. • Induma 2045 horizontal universal milling machine • Lagun FCM-20W horizontal universal milling machine • Churchill NB horizontal grinder with magnetic chuck • 3 ton overhead crane, 2 ton forklift • Colchester Master 2500 lathe • Drill press NIDER • Belt and disc grinder • Cutting & machining tools Mechanical Testing • Granite table for distortion measurements • 900KN (200 kips) horizontal servo-hydraulic test machine • 1360KN (300 kips) Baldwin universal tensile testing machine for tension, compression and fracture toughness testing • 640KN (150 kips), 250KN (50 kips), 100KN (20 kips) and 25KN (5 kips) servo-hydraulic fatigue, fracture toughness, and crack arrest materials testing • CVN testing machine (325J capacity) along with broaching equipment Numerical Modeling • Finite element modeling / Structural Analysis services with both ANSYS and Algor • linear and non-linear structural analysis • impact and vibration analysis • heat transfer and fluid flow analysis • structural contact and friction modeling • Fracture mechanics, stress & strain life based fatigue and fracture modeling • Computational fluid dynamics (CFD) services with Flowtran • Reliability and risk assessment software • Weld preheat calculator and delayed cracking (hydrogen embrittlement) risk evaluator • Other proprietary modeling and simulation software modules for design and analysis

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MECHANICAL DAMAGE DIRECT ASSESSMENT - RPTG-0321 PART II – COST PROPOSAL August 5, 2002

Submitted to: Steve Foh Gas Technology Institute 1700 South Mount Prospect Road Des Plaines, IL 60018

Submitted by: BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8

BMT FTL Contact: L. Blair Carroll Tel: 613-592-2830, Ext 242 Fax: 613-592-4950 e-mail: [email protected]

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Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

Author: Principal Researcher: Name of Organization: Project Type:

L. Blair Carroll L. Blair Carroll / Robert Lazor BMT Fleet Technology Limited (BMT FTL) New

9) Statement of the Problem (What is to be solved): There are a number of tools and methods available for characterizing and assessing the structural significance of corrosion or cracking that are not directly applicable to mechanical damage. Such a tool for direct assessment will require the ability to combine the relative impact of several features of the mechanical damage, which include associated pipe deformation, gouging and the presence of other localized effects such as weld seams or corrosion. A mechanical damage assessment methodology will require consideration of stress analysis techniques, materials damage models and fracture mechanics based algorithms.

10) Background (What is the historical data): A significant amount of research effort has been attributed to denting and mechanical damage. Programs of note include the API 1156 study and the GRI-97/0413 study. In conjunction with industry support, BMT Fleet Technology has developed a Dent Assessment Model aimed at evaluating the impact of the presence of dents on the integrity of a pipeline. The model incorporates finite element analysis of the dented pipe geometry and a fracture mechanics based fatigue crack growth algorithm, and is currently being used in an industry consortium to develop a dent criticality criteria that can be applied to dents found in-service (in-line inspection) or during excavation programs. Phase I of this project was completed in May 2002 and Phase II will commence in Fall 2002. Part of the Phase II project scope will consider the impact of localized effects including gouging and weld seams.

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Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

11) Proposed Research Action Plan (How will the problem be solved): In order to develop an assessment model, several areas of investigation will be required: Year 1 - Task 1 - Assessment of Pipe Deformation on the Integrity of the Pipeline This work was developed in Phase I of the industry consortium project at BMT FTL and will be further developed in Phase II. The dent ranking criteria developed in the Phase I project was a function of pipe and dent geometry and pipeline operating conditions and was used to develop a relative ranking of the severity of a list of dents. The Phase II work will carry this forward to assign residual lives to a dented pipe segment. Year 1 - Task 2 - Modeling the Impact of Line Strike Material Damage This phase of the project will first require a review of all available literature to determine the extent of the past projects related to characterizing the severity and failure modes for mechanical damage. This work is scheduled as part of the Phase II industry consortium project and can be carried further in conjunction with the funding proposed by PRCI. The next stage of this work will involve numerical modeling of mechanical damage in pipelines to obtain a calibrated model to predict the morphology of mechanical damage features and their effects on localized stress distributions. The LS Dyna finite element analysis package is well suited for modeling impact, contact and material cold working and will be used in this phase of the analysis process. The conclusions will be added to the dent characterization criteria to expand the methodology beyond smooth dents to dents with associated material damage. Year 1 - Task 3 - Consideration of Other Localized Effects The dent characterization model will be further modified to account for the impact of additional features which may be associated with mechanical damage (metal loss, cracking, weld seams) and can further impact the integrity of the pipeline. Numerical modeling will be validated using the published results from full-scale trials. Year 2 - Task 4 - Further Model Validation and Implementation. As a further measure of the validity of the model, the funding made available in Year 2 will be used to conduct further testing to ensure that all appropriate information is available when validating the model. Any shortcomings in available published data will be identified during Year 1.

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Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

12) Expected Deliverables (List Specifically what PRCI will get out of the work): A validated and robust methodology for characterizing the impact of mechanical damage on the integrity of a pipeline. The methodology will be developed using numerical modeling, but will be adapted so that it can be applied without the need for detailed numerical analysis. A set of guidelines with examples of how the methodology can be applied to various forms of data, whether it was collected using in-line inspection tools or during field excavation. A report documenting the results of the modeling processes.

13) Resource Requirements (total cost, year-by-year breakdown, capital costs vs. overhead, and outside resources to be used): It is anticipated that the total expenditures required to complete this work will be in the order of $460,000 USD and will be broken down as follows: In-kind contributions: $100,000: Initial development of the BMT FTL Dent Assessment Model $100,000: Phase I work of the dent characterization consortium project $60,000: Contribution of the Phase II work from the dent characterization consortium project supported by the consortium members $50,000: Licensing fees for FEA modeling packages covered by BMT FTL PRCI Committee Contributions: Year 1: $75,000 – Tasks 1, 2, and 3 described above Year 2: $75,000 – Task 4 described above (as required)

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Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage Direct Assessment - RPTG-0321 -

14) Organization Information (Describe major business of contractor, facilities available for use in this project, related concurrent/recent projects): BMT FTL provides engineering research and services to the pipeline industry in the welding, materials characterization, and damage tolerance (ECA) areas of interest. Research efforts at BMT FTL have resulted in the development of dent and buckle/wrinkle assessment models. These tools support the integrity assessment of mechanically damaged pipes segments. Beyond the assessment of dents and wrinkles, the metallurgical, mechanical testing, welding and numerical simulation labs at BMT FTL have been involved in the following related projects: • Development of a hot tap tee design model • Development and calibration of pipeline pressure retaining sleeve design models • Development of fatigue and fracture analysis tools and courses for industry 15) Contractor Contacts: Mr. L. Blair Carroll Materials Technology Centre BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8 Tel: 613-592-2830 Fax: 613-592-4950 E-mail: [email protected] Internet: www.fleetech.com

Mr. Robert B. Lazor Materials Technology Centre BMT Fleet Technology Limited Box 82057, 2037-111 Street Edmonton, Alberta Canada Tel: 780-465-0077 Fax: 780-465-0085 E-mail: [email protected] Internet: www.fleetech.com

16) Alternative Funding Sources: The proposed program will be subsidised and progress facilitated through: • the use of pre-existing mechanical damage (dent and wrinkle) modeling tools developed under separate contracts, • the use of previously completed full-scale trial data to validate the numerical modeling tools, • the use of previously developed pipeline operation characterization techniques and tools • the use of previously collected and characterised pipeline material and operational data. Co-operative funding will also be sought from on-going parallel industry group sponsored projects to subsidise the work in this project.

iv

BMT FLEET TECHNOLOGY LIMITED

5561P

BMT FTL Document Quality Control Data Sheet Report:

Mechanical Damage Direct Assessment – RPTG-0321 –

Project No.

5561P

Date:

5 August 2002

Prepared by:

L. Blair Carroll, Project Engineer

Reviewed by:

R. B. Lazor, Manager, BMT FTL Western Canada Office

Approved by:

A. Dinovitzer, Vice-President

v

BMT FLEET TECHNOLOGY LIMITED

5561P

TABLE OF CONTENTS

5.

COST AND SCHEDULE ...................................................................................................... 1 5.1 Business Management - General Information .........................................................................1 5.1.1 General Corporate Information ............................................................................................1 5.1.2 Financial Management for Projects .....................................................................................1 5.2 Project Cost Estimate ..............................................................................................................1 5.2 Project Schedule..................................................................... Error! Bookmark not defined.

6.

CONTRACTING DETAILS................................................................................................... 3

LIST OF FIGURES AND TABLES Table 5.1: Detailed Cost Estimate (with travel required for Task 4)............ Error! Bookmark not defined.

vi

BMT FLEET TECHNOLOGY LIMITED

5.

COST AND SCHEDULE

5.1

Business Management - General Information

5.1.1

General Corporate Information

5561P

The project will be carried out by BMT Fleet Technology Limited, which has offices in Kanata (head office) and Edmonton, as follows: BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8 BMT Fleet Technology Limited PO Box 82057, 2037-111 Street Edmonton, Alta. T6J 7E6

5.1.2

Financial Management for Projects

The Project Manager is responsible for the financial performance of a contract. Notifications or other communication concerning invoices for the project should be sent to BMT FTL’s Accounting Office to the attention of: Mrs. Colleen Seabrook, Assistant Treasurer BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8

5.2

Project Cost Estimate

The cost associated with the completion of this project is $150,000 (USD). The estimated cost of the project would be reduced by $14,000 to $134,000.00 if the work is completed entirely at BMT Fleet Technology facilities. The detailed cost breakdown includes a 15% fee on labour only. The rates are calculated from: Salary + (Salary x Overhead) 1867.75 where 1867.75 hours is the 2002/2003 working year for an employee with ten days vacation. These rates do not include fee. The rates are better than those offered our most favored commercial client. The Government overhead rate for FY02/03 is 130%.

Mechanical Damage Direct Assessment

1

BMT FLEET TECHNOLOGY LIMITED

5561P

Table 5.1: Detailed Cost Estimate (with travel required for Task 4) 1 day is 7.75 hours 2003 Rates TASK 1 LABOUR HOUR DAY Executive Engineers $90.00 $697.50 1 Princ. Engrs/PMs $75.00 $581.25 15 Intermediate Engrs. $52.00 $403.00 40 Project Engrs. $45.00 $348.75 5 Admin/support $32.00 $248.00 0 TOTAL ESTIMATED COST OF LABOUR $27,280 SUBCONTRACTORS

TOTAL ESTIMATED COST OF SUBCONTRACTS CHARGES FOR FTL EQUIPMENT ANSYS

$0

TOTAL ESTIMATED EQUIPMENT CHARGES RENTAL OF EQUIPMENT

$0

TOTAL ESTIMATED RENTALS

TASK 2 2 15 40 0 0 $26,234

$0

TASK 3 2 15 35 0 2 $24,715

$0

DAYS BY TASK TASK 4 TASK 5 2 15 40 5 0 $27,978

$0

1 3 5 1 3 $5,549

Tot

TOTAL COST

8 63 160 11 5 111,755

$5,580 $36,619 $64,480 $3,836 $1,240 $111,755

$0

$0 $0 $0 $0

$0

$3,750 $0 $3,750

$0

$0 $0 $0 $0 $0 $0 $0 $0

$3,750

$0

$3,750

$0

$0

$0

$0

$0

MATERIALS AND SUPPLIES

TOTAL MATERIALS TRAVEL AND LIVING PRIME CONTRACTOR SUBCONTRACTORS TOTAL ESTIMATED COST OF TRAVEL OTHER EXPENSES COMMUNICATIONS/COURIER REPRODUCTION SHIPPING TOTAL ESTIMATED EXPENSES % FEE

On labour On Subcontractors On Travel & Living On materials/ Expenses

15% 0% 0% 0% TOTAL PROFIT

$0

$0

$0

$0

$0

$0

$0

$1,500

$14,000

$1,500

$1,500

$14,000

$1,500

$17,000 $0 $17,000

$0

$200 $500 $0 $700

$200 $500 $0

$0

$0

$700

4092 0 0 0 $4,092

3935 0 0 0 $3,935

3707 0 0 0 $3,707

4197 0 0 0 $4,197

PROJECT TOTAL

$31,372

$33,919

$29,922

$46,874

$7,881

% OF TOTAL

20.92%

22.62%

19.95%

31.26%

5.26%

Mechanical Damage Direct Assessment

832 0 0 0 $832

$16,763 $0 $0 $0 $16,763 $149,968

1.00

2

BMT FLEET TECHNOLOGY LIMITED

6.

5561P

CONTRACTING DETAILS

The PRCI Contract Cost Estimate Form has been completed. For the purposes of PRCI, we have extracted overhead (130%) from our current rates (Table 5.1) for the Contract Cost Estimate Form.

Mechanical Damage Direct Assessment

3

BMT FLEET TECHNOLOGY LIMITED 5561P

PRCI CONTRACT COST ESTIMATE FORM

CONTRACT COST ESTIMATE (FOOTNOTE A) Name of Offeror BMT Fleet Technology Limited Home Office Address 311 Legget Drive Kanata, Ontario, Canada K2K 1Z8 Division(s) and Location(s) (where work is being performed) Home Office: Kanata, ON Western Canada Office: Edmonton, Alberta, Canada

RFP No/Prp No Page Number RPTG-0321 Name of Proposed Project Mechanical Damage Direct Assessment Total Amount of Proposal $ 150,000.00 Estimated Cost (dollars)

Cost Elements 1.

Number of Pages

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

Direct Material a. Purchased Parts b. Interdivisional Effort c. Equipment Rental/Lease d. Other (ANSYS Lease)

$3,750

Total Direct Material

$3,750

2.

Material Overhead (Rate

0 % x Base $

3.

Subcontracted Effort (Attach Detailed Schedule)

4.

Direct Labor - Specify

)

0

Net Subcontracted Effort Est. Hours

Rate/Hour

Est. Cost

Executive Engineer

62

$39.00

$2,418.00

Principal Engineer

488.25

$32.60

$15,916.95

Intermediate Engineer

1240

$22.60

$28,024.00

Project Engineer

85.25

$19.56

$1,667.49

Support

38.75

$13.91

$539.00

O.H. Rate

X Base $

Est. Cost

130%

$48,565.44

$63,135.00

Total Direct Labor 5.

Labor Overhead - Specify

$48,565.44

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

$63,135.00

$17,000

10. Other Direct Costs 11. Total Direct Cost and Overhead

$700 $133,150

12. General and Administrative Expenses (w/o IR&D) Rate 15 % of cost element numbers 13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost (Footnote C) 15. Fixed Fee 16.

$16,795

Total Estimated Cost and Fee

17. Contractor/Third Party Cofunding (Footnote D) 18. Net PRCI Estimated Cost and Fee

$150,000

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow.

Mechanical Damage Direct Assessment

BMT FLEET TECHNOLOGY LIMITED 5561P Typed Name and Title

Signature

Date 5 August 2002

A.S. Dinovitzer, Vice-President

Footnotes:

A. The submission of this form does not constitute an acceptable proposal. Required supporting information must also be submitted. B. For appropriate items of cost, reference the schedule that contains the required supporting data. Generally, supply supporting information for cost elements that are extraordinary (subcontracts or special

testing costs above 25% of total costs, large equipment items, etc.). C. This should be the total cost of the research project. Any contractor cofunding should be shown on line 17 as a reduction from total costs.

D. This line should include (1) total fixed fee, (2) contractor cofunding, (3) third party cash cofunding, or (4) be blank, depending on the contract type. Fixed fee should be cofunded before any contractor in-kind cofunding is proposed.

Mechanical Damage Direct Assessment

August 12, 2002 FEDERAL EXPRESS Proposal No. CP052763 Mr. Steve Foh PRCI 1700 South Mount Prospect Des Plaines, IL 60018 Re: PRCI Request for Competed Proposals Dear Steve: Enclosed is our proposal for the project “Mechanical Damage at Welds”, which is PRCI RPTG0326. This effort is offered under the master set of terms and conditions negotiated between PRCI and Battelle on June 30, 2000. Our receipt of authorization under these terms and conditions will allow us to proceed. This offer shall remain valid for a period of sixty (60) days from the date of this letter. If you have any technical questions, please call me at (614) 424-4421, or contact me via email at [email protected]. Questions of a contractual nature should be directed to Ms. LaDonna James, Contracts Department, at (614) 424-5543 or via email address: [email protected]. Sincerely,

Brian N. Leis Research Leader Pipeline Technology Center BNL/cw Enclosure

Christina L. Rotunda Contracting Officer

Mechanical Damage at Welds: RPTG-0326 Background Mechanical damage due to external interference is consistently a significant threat to the integrity of natural gas pipelines. As for corrosion and other types of defects, present guidance and procedures for assessing the significance of mechanical damage does not address the weld zone. Yet because construction practices often place the weld seam in the upper third of the pipe’s circumference, damage due to agriculture or civil engineering activities is likely to occur in the vicinity of the seam weld. Because guidance and procedures for assessing the significance of mechanical damage do not reference weld seams, even minor evidence of damage must be completely removed. An assessment method or guidance specifically addressing welds and mechanical damage would help to focus rehabilitation time and resources. This would limit the cost of removing damage that lacks clear benefit, and thus be a valuable addition to damage assessment and repair manuals like that written by Keifner, jointly with Battelle authorship. This manual, or the one dealing with dent assessment for the pipe body1 written by Rosenfield of Keifner and Associates under PRCI and GTI funding, could be revised or updated to identify circumstances where minor mechanical damage on weld seams could be left in place without repair or rehabilitation. Objective The objective is to develop criteria defining when mechanical damage on weld seams could be left without repair or rehabilitation. Approach Whether mechanical damage could be left without repair or rehabilitation depends on the severity of the damage and the resistance of the line pipe local to the damage. Damage on weld seams is complicated by the nature of the seam welding and the thermal-mechanical history associated with it. It follows that a one-size-fits-all criterion must reflect the worst-case seam weld and the thermal-mechanical history associated with it, as well as the least resistant type of secure weld. Because damage can vary from dents through severe gouges and their combination, it will be necessary to define circumstances where minor damage can remain relative to plain dents. It follows that developing criteria to define when mechanical damage on weld seams could be left without repair or rehabilitation requires a sound technical basis, in either full-scale testing or in validated models and analysis, or their combination. Battelle’s approach to develop criteria defining when mechanical damage on weld seams could be left in place will be based on continuing extensive full-scale testing and analysis work at Battelle for the DOT involving simple dents and dent and gouge combinations, along with the modeling and analysis recently completed for PRCI, and some related full-scale testing done for other clients, including dents on welds. 1

This manual written by Mr. Mike Rosenfield was developed for eventual inclusion within ASME B31.8, but is still in review, with no clear path forward yet.

Essential differences between current code guidance for the pipe body and the present approach are inclusion of a weld seam and the need to make better decisions than that based on dent depth. Guidance and procedures for assessing the significance of such mechanical damage would be developed relative to dents that encompass welds. Mechanics analysis will be done evaluating dent depth coupled with a local measure of curvature, which controls local strain, with the focus on plain dents. Situations leading to failure controlled by toughness as well as plastic collapse will be considered, as in cases where no defects are present and toughness is adequate (based on mill or other reliable data), such that much larger dents will be tolerable. Analysis to determine local strains and stresses, including the effects of weld geometry, will be coupled with material properties for weld seams. Defects due to the joining practice will be considered. Specifically, Battelle will use parametric analysis to determine acceptable dent profiles as a function of line pipe long seam type, pipe grade and geometry, and operating pressure. Where feasible, Battelle will use the current DOT full-scale test results as well as prior Battelle database and testing by others to validate the new criteria. Proposed Work Scope Five technical tasks are needed to meet the objectives of this project, which will culminate in a reporting task, as outlined in the ensuing paragraphs. Task One – Quantify Curvature as Function of Dent Depth and Shape The objective of this task is to relate field measures of dent geometry to local curvature, which serves as a measure of local bending strain. This task involves parametric analysis done as a function of dent depth and the extent of denting along and across the pipeline (i.e., dent profile), to relate curvature to dent depth and profile (i.e., dent geometry). Task Two – Quantify Residual Stress due to Welding The objective of this task is to estimate the residual stress that might be present in the vicinity of the long-seam weld. This estimate will be based on results of the very extensive evaluation of weld-related residual stresses developed in making line pipe and in constructing pipelines, which was done as part of PR-3-9523 / Phase II (Hydrotest Benefits and Alternatives Project) recently completed by Battelle. These results reflect the thermal history in forming a double-submergedarc weld (DSAW) long seam and a multi-pass girth weld in different line pipe geometries and grades, and so should provide a viable measure of residual stresses for many applications. This task will search and organize project file data to serve as the basis to estimate the residual stress that might be present in the vicinity of the long-seam weld. Task Three – Properties to Assess Integrity The objective of this task is to develop data typical of weld seam properties as a function of pipe grade, seam type, and line pipe vintage and supplier, for use in integrity assessment. This task will use data developed for failure controlled by both fracture and plastic collapse as part of GRI Project Number 8521 dealing with Corrosion on Welds. To the extent possible, those data will

be supplemented with data for weld seam types for which fracture data are not yet available but could be generated as part of the data mining done as part of RPTG-0362. Key concerns for this project include data describing fracture and strain-limited failure. Available data will be organized to quantify fracture and flow behavior of weld seams as a function of pipe grade, seam type, and line pipe vintage and supplier. Task Four – Assess Integrity as a Function of Curvature The objective of this task is to evaluate the integrity of dents as a function of dent geometry, leading to criteria defining when mechanical damage on weld seams could be left without repair or rehabilitation as a function of dent geometry, weld type (and shape where important), pipe grade, seam type, and line pipe vintage and supplier. Specifically, the parametric analysis of Task One will be used to determine curvatures that are acceptable as a function of percent SMYS, seam type, pipe grade, and toughness inferred via line pipe vintage and supplier unless otherwise known. Membrane strain will be added to curvature-induced strain to estimate maximum local stress. This local stress will be increased by a shape-determined stress concentration factor to account for weld profile as appropriate and added to the worst-case residual stress, with the result compared to the API 5L minimum ultimate tensile stress (UTS). In all cases, the focus is plain dents. Criteria for failure controlled by plastic collapse then will be determined for selected factors of safety for defect-free weld seams. Where defects are present, these criteria would serve as input to a plastic-collapse based engineering critical assessment (ECA), which would depend on the nature of the defect and other details specific to each application. Criteria for failure controlled by toughness also will be developed, with toughness for present purposes being expressed as both plateau energy and a limiting strain. Criteria for dents on defect-free seams will be expressed as a function of critical strain. Criteria for welds with defects will be determined for worst-case defect location and orientation considering the largest size likely to be missed by appropriate inspection and expressed as a function of toughness. Task Five –Validate the Criteria The objective of this task is to locate and organize incident, open literature, and other results that can be used to validate criteria developed to justify leaving selected plain dents on weld seams in operation. Battelle’s archives, as well as the DOT incident database, will be considered in this task. Task Six– Reporting A summary report describing the procedures and work scope will be provided culminating in an assessment methodology and guidance specifically addressing the interaction of welds with plain-dent mechanical damage. This deliverable will be in written and graphical format suitable for incorporation in pipeline damage assessment and repair manuals.

Deliverable The deliverable is an assessment methodology and guidance specifically addressing the interaction of welds with plain-dent mechanical damage. This should eliminate the necessity to remove all such damage and will provide technical justification for selecting less expensive options for repair / refurbishment. While not considered as part of this project, it would be appropriate to prepare a section on “Guidance for the User” when incorporating this deliverable into a handbook on repair and rehabilitation procedures. This would consider factors like field measurements and inspection, appropriate line pipe properties for toughness and critical strain, and what constitutes a plain dent. Consideration of gouge-like mechanical damage also could be considered in future but is outside the present scope. Cost, Schedule, and Reporting The above six tasks can be completed and reported within a twelve month period of performance, for a budget estimated at $100,000. There are no capital purchases planned. During the course of this research, Battelle will provide quarterly status reports and progress updates to the ad hoc team leader or oral briefings as appropriate. Month after contract

1

2

3

4

5

6

7

8

9

10

11

12

Task One Task Two Task Three Task Four Task Five Task Six Project Organization and Management This project will be managed within the Pipeline Technology Center at Battelle, which is organized to meet the needs of the energy pipeline industry. All facilities needed to complete this work are available at Battelle, where assessing the severity of mechanical damage has been a research concern for several decades. Battelle has current and recent projects with INGAA/GTI, DOT, and PRCI that involve mechanical damage, and the development of failure criteria for use in pipeline applications. We also are currently under contract to several US and International pipeline companies in projects whose work scope involves mechanical damage severity. The project manager and principal investigator for this effort will be Dr. Brian Leis, who will be assisted by Dr. Xiankui Zhu, Mr. Ron Galliher, and others on the Battelle technical staff. Dr. Leis has worked for hazardous liquids and natural gas transmission pipeline companies and the pipeline industry in the US and Internationally. Mr. Galliher has extensive experience with

stress analysis and failure, having worked such problems for industry companies in prior employment with Battelle, as well as since re-joining Battelle’s Pipeline Technology Center within the last year. Dr. Zhu has extensive experience in stress analysis, fracture theory, and failure of structural systems, including pipelines. His experience comes from years of working such problems for industry companies prior to his employment with Battelle. This type of work has been his full-time responsibility since joining Battelle’s Pipeline Technology Center within the last year.

August 2002

MECHANICAL DAMAGE ON WELDS (RPTG 0326)

Confidential

Prepared for: Steve Foh Pipeline Research Council International, Inc. c/o Gas Technology Institute 1700 South Mount Prospect Road Des Plaines Illinois 60018-1804 USA

Sales Opportunity ID: 1001421 Ⓒ 2002 Advantica Technologies Inc.

Mechanical damage at welds

30 July 2002

Rev 0

Prepared by: Mark McQueen (& Robert Owen) Advantica Technologies Inc. 5177 Richmond Avenue, Suite 900 Houston, TX 77056 USA Tel: Fax: Email: Website:

713 586 7000 713 586 0604 [email protected] www.advanticatech.com

PROPOSAL SUMMARY Proposal:

RPTG 0326

Title: MECHANICAL DAMAGE ON WELDS. Contractors: Advantica Technologies Inc. Type: New. Period: Start date January 2003, duration 24 months. Total estimated cost:

US$150,000.

Objective: To develop damage assessment procedures for mechanical damage occurring on welds. Incentive: Mechanical damage due to external interference is a significant threat to the integrity of pipelines. At present, guidance and procedures for assessing the significance of mechanical damage do not explicitly address the weld zone, and in some instances specifically exclude it. An assessment methodology incorporating interactions with welds will provide a valuable and effective addition to pipeline damage assessment and repair manuals, leading to reductions in repair costs. Work Plan: TASK 1 – 3 Member survey, literature review and establishment of priorities/scenarios. TASK 4 – Finite element modeling, small scale experiments. TASK 5-7 – Ring tension testing, comparison with models. TASK 8 – Development of preliminary assessment procedure. Deliverables: Reports on Damage scenarios and priorities Experimental testing and theoretical modeling. Preliminary assessment guidance procedure.

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TABLE OF CONTENTS PART I TECHNICAL PROPOSAL 1 2

INTRODUCTION ................................................................................................ 2 TECHNICAL DISCUSSION ................................................................................ 2 2.1 OBJECTIVE................................................................................................. 2 2.2 WORK TO BE PERFORMED AND APPROACH........................................ 2 3 SCHEDULE ........................................................................................................ 4 4 DELIVERABLES ................................................................................................ 5 5 ADVANTICA INFORMATION............................................................................. 6 PART II COST PROPOSAL 1 2

COSTS ............................................................................................................... 8 COMMERCIAL TERMS.................................................................................... 10

Confidentiality Statement THE INFORMATION CONTAINED IN THIS PROPOSAL IS PROVIDED ON A COMMERCIAL BASIS IN CONFIDENCE AND IS THE PROPERTY OF ADVANTICA TECHNOLOGIES INC. IT MUST NOT BE DISCLOSED TO ANY THIRD PARTY, IS COPYRIGHT, AND MAY NOT BE REPRODUCED IN WHOLE OR IN PART BY ANY MEANS WITHOUT THE APPROVAL IN WRITING OF ADVANTICA TECHNOLOGIES INC.

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PART I TECHNICAL PROPOSAL

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1 INTRODUCTION Mechanical damage due to external interference is a significant threat to the integrity of pipelines. Damage due to mechanised plant, associated for example with agriculture or civil engineering activities, can occur in the vicinity of the seam and girth welds. At present the guidance and procedures for assessing the significance of mechanical damage do not explicitly address the weld zone and may, as in the original B31.G specifically exclude damage to the weld. It is assumed that the welds and their HAZ have less tolerance to damage than parent plate. Often any mechanical damage at welds (including ovalization, dents, buckling etc) is repaired or completely removed. An assessment methodology and guidance specifically incorporating the interaction of welds with mechanical damage will provide a valuable and effective addition to overall pipeline damage assessment and repair manuals, leading to a reduction in repair costs.

2 TECHNICAL DISCUSSION 2.1 OBJECTIVE The objective of this programme of work is to develop damage assessment procedures for mechanical damage occurring on welds. This will be achieved through the following programme of work. 2.2 WORK TO BE PERFORMED AND APPROACH Damage assessments procedures for damage to linepipe material are fairly well developed, at least at the screening level. Such procedures typically cover damage such as; •

Gouges

•

Spalling or cracks

•

Smooth dent

•

Kinked dent

•

Smooth dent and gouge

•

Smooth dent and spalling or smooth dent and cracks

•

General corrosion

•

Pitting corrosion

•

Stress corrosion cracking

•

Arc strikes

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However, there is little historical data available on the mechanical damage behavior of welds. The Battelle work which led to the development of B31.G and RSTRENG included limited testing of welds, but this did not consider mechanical damage. There is some data on the fatigue of dents in welds (PRCI, Battelle, Tokyo Gas etc). A particular concern is the possibility of tearing at the weld toes due to high strain concentrations, coupled with the difficulty of detecting small amounts of tearing at the toe, particularly on the inner surface. In addition, there may be a loss of toughness due to the plastic strain occurring during the damage process. As the welds are usually of lower toughness than the parent plate, a further loss of toughness could reduce defect tolerance to unacceptable levels. However, there is little data available to show whether these concerns are real. This has led to a conservative approach being used of repairing or removing mechanical damage at welds. The programme of work to address these issues will be split over two years. Year 1 will comprise of the following activities. PRCI member companies will be surveyed to confirm priorities for the assessment of mechanical damage at welds, for example static loading or fatigue loading, the type of mechanical damage of greatest concern and the welds to be considered (seam or girth, weld processes). Information will also be sought from other industry contacts, for example through EPRG. A review of previous work on mechanical damage at welds in pipelines (eg by PRCI, EPRG, DOT, API) will be undertaken to ensure that all of the limited available data are considered. This will also include methods of predicting local strains during denting and subsequent pressurization, as this will provide information on the likely strains, which will be imposed on a weld. Data on the high strain performance of welds will also be obtained, as this may give guidelines on the amount of strain that can be tolerated. Modelling and/or small scale tests will be carried out to clarify some aspects of the findings. It is expected that this will investigate the local damage mechanisms at the weld, and the stress and strain intensifying effects of damage. The exact extent of this will be determined by the review and member company survey, but it could include investigations of: •

The effect of pre-strain on weld material properties will be measured by straining welds and then measuring the toughness to determine the reduction as a function of pre-strain.

•

The effects of local damage at the weld through pre-strain and tearing at the weld toe will be investigated by straining coupons containing transverse welds to various levels of strain and then sectioning the welds to determine if local tearing has occurred at the toe, and if so to quantify the extent.

•

Predictions of the combined stress or strain raising effect of dent and weld combination, through finite element analysis.

•

Effect of spring back after denting through finite element analysis and rerounding due to pressure loading, again using finite element analysis.

•

Residual stresses in dented pipe.

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Note, however, that not all of the above are included within the allocated budget, the investigation will focus on those parameters considered to be of greatest importance.

Year 2 will comprise of the following activities. Based on the findings from Year 1 a program of tests on damaged welds will be specified to be carried out using Advantica’s ring tension facility. Use of ring tension testing will provide the greatest amount of test performance data. Ring tension testing has been extensively used by EPRG, PRCI and others for assessing the significance of a wide variety of damage and developing guidance for damage management. Using ring tension tests, data can be generated over a range of diameters and thicknesses at a significantly reduced cost compared with that for full vessel testing. The specific pipe geometries, weld geometries and damage parameters to be tested will be based on the results from the survey and year 1 studies, and agreed with the PRCI Ad Hoc committee. Damage such as dents or gouges will be introduced on welds before testing; the rings will then be pressurized to failure. Ring tension tests can be used directly to assess damaged seam welds. To test damaged girth welds, a girth weld procedure will be used to make axial welds between two pipe half sections, which will then be sliced into rings, damaged and tested. The test results will be compared with predictions from the theoretical models and a preliminary assessment procedure developed for mechanically damaged welds. Recommendations will be made for a future work programme to enhance the assessment procedure for mechanical damage at welds.

3 SCHEDULE The work will be undertaken by Advantica over a two year period. A summary of the main tasks of the project and their duration, assuming work commences in Q1 of 2003, is detailed below.

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TASK 1

Member survey

2

Literature review

3

Report on review and member priorities

4#

Finite element modelling studies and/or small scale testing

5

Ring tension testing - damage on seam welds

6

Ring tension testing - damage on girth welds

7

Comparison of experimental results with theoretical models

8

Report on preliminary assessment procedure for mechanical damage on welds and recommendations for future work

2003 Q1

Q2

2004 Q3

Q4

Q1

Q2

Q3

Q4

Note: # The exact nature of item 4 will be depend on the member survey and literature review.

4 DELIVERABLES The deliverables at the end of the first year will be: •

Report on review of mechanical damage at welds and priorities for assessment.

•

Interim report on experimental testing and theoretical modelling approaches.

The deliverable at the end of the second year will be:

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•

Report on preliminary guidance for the assessment of mechanical damage found in the vicinity of welds and recommendations for future work to enhance the assessment procedure.

5 ADVANTICA INFORMATION Advantica is part of the Lattice Group, the UK-based infrastructure technology group that includes the gas pipeline operator Transco, and is a leading supplier of innovative technologies and technical services to the global energy marketplace. Advantica's aim is to be a leading improver of business and operating performance for customers in gas, pipelines and associated industries internationally. Advantica has its origins in the British Gas (BG) group of companies and is now a $100 million business with over 800 skilled staff, who have developed proven solutions for the oil and gas industry. Advantica has undertaken considerable research in the area of pipeline damage assessment including experimental, analytical and numerical analyses of damage arising from external interference. This has included the development of and provision of support to the Transco damage assessment procedures for the inspection and repair of damaged steel pipelines. This has been supported by ring tension and full scale vessel pressure burst tests. Advantica developed the semiempirical fracture mechanics based methodology for calculating the failure strength of dent-gouge defects (Otherwise known as the British Gas dent-gouge failure model. This model is included in the EPRG guidance). Advantica is currently performing research in this area, specifically, including the response of X80 grade steels to dent-gouge damage. Advantica has previously undertaken work relevant to this proposal. Advantica performed a review of existing fitness-for-purpose methods for damaged pipelines for the European Pipelines Research Group, and a review of work undertaken on GRI project 6026, ‘Assessment of criteria for mechanical damage in gas transmission pipelines’.

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30 July 2002

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PART II COST PROPOSAL

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1 COSTS The work described in this proposal will be undertaken on a fixed price basis. The fixed price is $150,000 (one hundred and fifty thousand US dollars). The total cost is inclusive of labor, computing, consumables, overheads and project management. A breakdown of costs is shown in Table 1.

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Table 1 Contract Cost Estimate Form CONTRACT COST ESTIMATE

Name of Offeror Advantica Technologies Inc.

RFP No/Prp No RPTG 0326

Home Office Address 5177 Richmond Avenue, Suite 900 Houston, TX 77056 USA

Name of Proposed Project Mechanical damage on welds

Division(s) and Location(s) (where work is being performed) Pipeline Transportation Division, Loughborough, UK.

Total Amount of Proposal $150,000 (US) Estimated Cost (dollars)

Cost Elements 1.

Page Number 1

Total Estimated Cost (dollars)

Number of Pages 1

Supporting Schedule

Direct Material a. Purchased Parts b. Interdivisional Effort c. Equipment Rental/Lease d. Other Total Direct Material

2. 3.

Material Overhead (Rate

% x Base $

)

Subcontracted Effort (Attach Detailed Schedule) Subcontractor Cofunding Net Subcontracted Effort

4.

Direct Labor - Specify

Est. Hours

Rate/Hour

Manager

41

195

Est. Cost 7995

Officer

328

143

46904

Staff

220

109

23980

Technician

349

69

24081

O.H. Rate

X Base $

Est. Cost

Total Direct Labor 5.

Labor Overhead - Specify

102960

Total Labor Overhead 6.

Special Testing (mainly ring tension testing and material property testing)

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

10. Other Direct Costs

45500

1540

11. Total Direct Cost and Overhead 12. General and Administrative Expenses (w/o IR&D) Rate

% of cost element numbers

13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost

150,000

15. Fixed Fee 16. Total Estimated Cost and Fee

150,000

17. Contractor/Third Party Cofunding 18. Net PRCI Estimated Cost and Fee

150,000

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title Signature Date Mr Robert Owen 2 August 2002

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2 COMMERCIAL TERMS Terms and conditions for undertaking the proposed work will be consistent with those previously agreed between Advantica Technology Inc. and GTI.

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MECHANICAL DAMAGE AT WELDS - RPTG-0326 PART I – TECHNICAL PROPOSAL

August 5, 2002

Submitted to: Steve Foh Gas Technology Institute 1700 South Mount Prospect Road Des Plaines, IL 60018

Submitted by: BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8

BMT FTL Contact: Aaron Dinovitzer Phone: 613-592-2830 ext 203 Fax: 613-592-4950 e-mail: [email protected]

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

Author: Principal Researcher: Name of Organization: Project Type:

Aaron Dinovitzer Aaron Dinovitzer / Robert Lazor BMT Fleet Technology Limited (FTL) New

1) Statement of the Problem (What is to be solved): In general, pipeline design standards require the repair of dents with depths exceeding 6% of the pipeline's outside diameter and the repair of all dents or signs of mechanical damage that interact with weld seams. This cautious damage disposition approach is based upon numerical and full-scale trials that demonstrate the significant impact that weld seams have on the life of the mechanically damaged pipe segments. It is noted, however, that recent advances in the understanding of mechanical damage failure suggests that the regulatory requirements could be made less restrictive by considering the: - relatively smooth pressure history (low fluctuation) of gas transmission lines, - the type and extent of the mechanical damage, and - position of the weld with respect to the mechanical damage 2) Background (What is the historical data): FTL has developed a pipeline dent assessment model, which uses the actual dent profile and in-service pressure history as inputs to a non-linear pipe finite element model with a fracture mechanics crack growth algorithm. This dent assessment approach has been calibrated using smooth dent full-scale trial data and some cases that have included localized effects (corrosion, gouges and weld seams). The BMT FTL model considers the weld profile, material properties and residual stress field. The BMT FTL model agrees with full-scale trials and operating experience, demonstrating that gas transmission line pressure fluctuations are benign in terms of crack growth, thus reducing the risk of mechanical damage failure. Additional BMT FTL model studies demonstrated that mechanical damage/weld interaction severity is significantly affected by mechanical damage form and position with respect to the weld seam.

i

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

3) Proposed Research Action Plan (How will the problem be solved): The proposed project includes 6 tasks as follows: Task 1 - Dent Model Demonstration and Calibration While the dent model has been widely validated for smooth dents its validation for interaction with welds has not been as rigorous. This task will complete the dent model validation for welds and take the opportunity to demonstrate the model. Task 2 - Wrinkle Model Demonstration and Calibration The wrinkle model has been developed and demonstrated to agree well with fullscale trials, however, it has only considered the effect of weld seams on the development of the wrinkle not the through life integrity. This task will focus on the extension of the wrinkle through life integrity assessment and comparison with fullscale experimental data for validation. Task 3 - Development of Dent and Ovality Criteria This task will use the BMT FTL dent assessment model to simulate dent and ovality mechanical damage interaction with weld seams. A range of pipe geometries and mechanical damages will be considered along with a range of weld qualities (profiles) and mechanical properties. The results of this sensitivity analysis will be a conservative guidance note for the disposition of dents and ovality interacting with longitudinal and girth weld seams. Task 4 - Development of Wrinkle Criteria This task will use the BMT FTL wrinkle and buckle model to simulate mechanical damage interaction with weld seams. A range of pipe geometries and mechanical damages will be considered along with a range of weld qualities (profiles) and properties. The results of this sensitivity analysis will be a conservative guidance note for the disposition of wrinkles or buckles interacting with longitudinal and girth weld seams. Task 5 - Development of Other Criteria This task will consider the interaction of other forms of mechanically induced damage (e.g. gouges, localized corrosion due to coating damage) and weld seams. A range of mechanical damage forms will be used to understand the sensitivity of pipeline welds to these forms of damage and thus develop guidance for their assessment. Task 6 - Project Reporting In this task the results of the calibration and analysis will be reported along with a description of the BMT FTL dent and wrinkle models. The report will outline the mechanical damage guidance developed in this project, in addition, the databases of dent full-scale trials will be provided.

ii

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

4) Expected Deliverables ( List Specifically what PRCI will get out of the work): It is proposed to develop a guidance note demonstrating the conditions under which mechanical damage interaction with weld seams is acceptable. This guidance note will consider the operational characteristics of the pipeline and the characteristics of the mechanical damage and weld seam. It is expected that the analysis results will develop separate criteria to consider each form of mechanical damage (ovalization, dents, buckling, etc.). The recommendations will be in the form non-dimensional damage characteristic limits similar to those being developed using the BMT FTL model for the assessment of smooth dents and those containing localized effects.

5) Resource Requirements (total cost, year-by-year breakdown, capital costs vs. overhead, and outside resources to be used): The FTL project team will bring databases of experimental results containing some 197 smooth dent tests and 100+ dent trials with localized effects. In addition, BMT FTL will seek to secure a similar database of buckle and wrinkle full-scale test results. Previous BMT FTL Dent and Wrinkle model development will be used and with the permission of the current dent geometric characterization project sponsor group, related analytic results could be made available.

iii

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

6) Organization Information (Describe major business of contractor, facilities available for use in this project, related concurrent/recent projects): FTL provides engineering research and services to the pipeline industry in the welding, materials characterization, and damage tolerance (ECA) areas of interest. Research efforts at FTL have resulted in the development of dent and buckle/wrinkle assessment models. These tools support the integrity assessment of mechanically damaged pipes segments. Beyond the assessment of dents and wrinkles the metallurgical, mechanical testing, welding and numerical simulation labs at FTL have been involved in the following related projects: - Development of a hot tap tee design model - Development and calibration of pipeline pressure retaining sleeve design models - Development of fatigue and fracture analysis tools and courses for industry

7) Contractor Contacts: Mr. Aaron Dinovitzer Materials Technology Centre Fleet Technology Limited Kanata, Ontario Canada K2K 1Z8 Tel: 613-592-2830 Fax: 613-592-4950 E-mail: [email protected] Internet: www.fleetech.com

Mr. R. Lazor Materials Technology Centre Fleet Technology Limited Edmonton, Alberta Canada Tel: 780-465-0077 Fax: E-mail: [email protected] Internet: www.fleetech.com

8) Alternative Funding Sources: The proposed program will be subsidised and progress facilitated through: - the use of pre-existing mechanical damage (dent and wrinkle) modelling tools developed under separate contracts, - the use of previously completed full-scale trial data to validate the numerical modeling tools, - the use of previously developed pipeline operation characterization techniques and tools - the use of previously collected and characterized pipeline material and operational data. Co-operative funding will also be sought from on-going parallel industry group sponsored projects to subsidise the work in this project.

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BMT FTL Document Quality Control Data Sheet Report:

Mechanical Damage at Welds - RPTG-0326 -

Project No.

5563P

Date:

5 August 2002

Prepared by: A. Dinovitzer, Vice President - Principal Engineer

Reviewed by: R. Lazor - Manager BMT FTL Western Canada Office

Approved by:

A. Dinovitzer, Vice-President

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TABLE OF CONTENTS Page

1.

INTRODUCTION......................................................................................................1 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.3 1.4

2.

Proposal Layout / Administrative Details .................................................................................1 Background and Incentives .....................................................................................................1 FTL Dent Assessment Model ..............................................................................................3 FTL Buckle/Wrinkle Assessment Model..............................................................................5 Gouge Assessment .............................................................................................................8 Ovality Induced Failure........................................................................................................9 Project Objectives..................................................................................................................10 Project Technical Approach Summary ..................................................................................10

WORK PLAN .........................................................................................................12 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.4

Overview ................................................................................................................................12 Scope of Work .......................................................................................................................12 Task 1 - Dent Model Demonstration and Calibration ........................................................12 Task 2 - Wrinkle Model Demonstration and Calibration....................................................12 Task 3 - Development of Dent and Ovality Criteria...........................................................13 Task 4 - Development of Wrinkle Criteria .........................................................................13 Task 5 - Development of Other Criteria ............................................................................14 Task 6 - Reporting & Project Management .......................................................................14 Expected Project Deliverables...............................................................................................15 References.............................................................................................................................15

3.

PROJECT TEAM AND QUALIFICATIONS.............................................................16

4.

PROJECT MANAGEMENT....................................................................................18

APPENDICES APPENDIX A: RESUMES APPENDIX B: CORPORATE CAPABILITIES

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LIST OF FIGURES AND TABLES Page Figure 1.1: Figure 1.2: Figure 1.3: Figure 1.4: Figure 1.5: Figure 1.6: Figure 1.7: Figure 1.8: Figure 1.9: Figure 3.1: Figure 4.1:

Pipeline Dent Assessment Model Overview ..............................................................4 Agreement of FTL Dent Assessment Model with Full Scale Trial Results .................5 Effect of Girth Weld Position on Dent Fatigue Life.....................................................5 Sample Buckled Pipe Geometry ................................................................................6 Sample Wrinkled Pipe Geometry ...............................................................................7 Comparison of FTL Buckle Model with Full Scale Trial Results.................................8 Predicted Pipe Rerounding ........................................................................................9 Pipe Cross Section Damage Modes / Limit States ....................................................9 Project Technical Scope Summary ..........................................................................11 Proposed Project Team and Additional Available Staff............................................16 Project Management Control ...................................................................................19

Table 2.1: Expected Project Deliverables ...................................................................................15

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1.

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INTRODUCTION

In this section we describe the proposal layout, provide our understanding of the need for the project, it’s objectives and summarise the technical approach proposed for the project. 1.1

Proposal Layout / Administrative Details

This proposal is prepared in response to PRCI Request for Proposal No. RPTG-0326. It is submitted by BMT Fleet Technology Limited (BMT FTL) of Kanata, Ontario, who will act as the prime contractor. The proposal is presented in two parts contained in one volume: - Part I - Technical and Management Proposal, and - Part II - Price Proposal The proposal includes a copy of the pre-proposal submitted by FTL as a summary of the the following information: Section 1 2 3 4 1.2

Contents Proposal Summary (PRCI Pre-Proposal) Proposal Introduction and Technical Summary Details of the Technical Approach by Task Project Team Qualifications Project Management Approach

Background and Incentives

Failures in transmission pipelines are often the result of mechanical damage. The US DOT has indicated that 20 to 40 percent of the serious pipeline incidents in any given year are related to mechanical damage. This damage is due to third party activities, mishandling during construction, pipeline bedding material consolidation, or ground movement. Damage usually takes the form of a dent with an associated gouge. In many instances, the dent has re-bounded such that it is not noticeable and inspection reports simply report the existence of a gouge. It is postulated that, aside from puncture, mechanical damage to a pipeline can cause a number of types of damage that may be characterised as deformation or metallurgical/metal loss related including: Deformation - Dents - Ovality - Wrinklling or Buckling

Mechanical Damage at Welds

Metallurgical/Metal Loss - Coating Damage - Gouge

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These forms of mechanical damage may be coincident (i.e., a gouge in a dent) and are of concern due to their potential for promoting failure. The significance of these forms of damage may be identified in terms of their post damage service life or damage accumulation rate, where critical amounts of damage may accumulate: •

Immediately after damage formation (e.g., a gouge formed by excavation equipment that will fail as the pipe re-bounds with the removal of the indentor (excavator tooth)), and

•

Gradual damage accumulation due to post damage formation loading events (e.g., cyclic re-rounding of dent due to pipeline internal pressure fluctuations, or environmentally induced cyclic axial and flexural loads applied to a buckle or wrinkle caused by seasonal ground movements).

In general, pipeline design standards require the repair of dents with depths exceeding 6% of the pipeline's outside diameter and the repair of all dents or signs of mechanical damage that interact with weld seams. This cautious damage disposition approach is based upon numerical and full-scale trials [1, 2, 3, 4 and 5] that demonstrate the significant impact that weld seams have on the life of the mechanically damaged pipe segments. Weld seams are considered less damage tolerant than the line pipe base material due to: •

the range of weldment mechanical properties – weldments contain weld metal and heat affected zone materials that are not as well defined as standardised grades of linepipe base materials,

•

potential for weld faults promoting failure – welds have a greater potential to contain fabrication faults (lack of fusion, inclusions, hydrogen cracks, undercut/overlap, etc.) than the linepipe base material,

•

weld geometry stress concentration effects – even welds without flaws contain notches at their weld toes that reduce their effective fatigue lives, and

•

weld residual stress fields – while the weld and fabrication residual stresses, of greater magnitude in and immediately adjacent to weld seams, have only a secondary effect on fatigue crack growth, they promote fracture in welded connections.

It is noted, however, that recent advances in the understanding of mechanical damage failure suggests that the regulatory requirements could be made less restrictive for gas pipelines by considering the: • relatively smooth pressure history (low fluctuation) of gas transmission lines, • type and extent of the mechanical damage, and • position of the weld with respect to the mechanical damage.

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1.2.1

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FTL Dent Assessment Model

FTL has developed a pipeline dent assessment model, which uses the actual dent profile and in-service pressure history as inputs to a non-linear pipe finite element model with a fracture mechanics crack growth algorithm. This approach would be useful in evaluating the gradual accumulation of damage at a mechanical damage site. This dent assessment approach has been calibrated using smooth dent full-scale trial data and some cases that have included localized effects (corrosion, gouges and weld seams). The FTL model considers the weld profile, material properties and residual stress field. A pictorial overview of the input data and analysis procedure is provided in Figure 1.1. The application of this approach relies strictly on well-defined parameters including: •

pipe characteristics (e.g., dimensions and mechanical properties),

•

a dent description which may consist of a 3-dimensional dent profile from in-line inspection (ILI),

•

details of pre-existing localized effects such as planar flaws (e.g., cracks), volumetric flaws (e.g., corrosion) and weld seams, and

•

a description of the operating conditions including the pipeline fluid pressure or load history as well as indenter contact condition (e.g., is the dent stabilized by the indentor remaining in contact with the pipe).

The FTL dent assessment model [6,7,8,9,10] was developed to study dented pipeline segments and provide a practical technique to predict their service life. The model considers the dent shape and line pressure history in a non-linear finite element analysis combined with fracture mechanics based crack growth analysis techniques. The predictions of this model have been validated through comparison with full-scale dent fatigue trials [3, 4 and 5]. Limited validation was completed on the model’s predictions when considering localized effects. Figure 1.2 illustrates the agreement achieved for the FTL dent life assessment model with full-scale trial results for a range of dent depths and shapes. Since some of the information above may not be available, representative data based on field experience, engineering judgement and modeling studies is used. Once the required assessment information is provided, a four node quadrilateral shell element non-linear finite element model is generated. The surface of the pipe model is deformed to comply with the dent profile. The deformed pipe geometry is then subjected to a representative pressure history to calculate the mean and cyclic stresses resulting from the line pressure history. Linear elastic fracture mechanics is applied to the cyclic stress data to track the growth of a fatigue crack through the pipe wall. The results provide a prediction of the residual safe operating life of a dented pipe segment, enabling the operator to make an informed maintenance decision. The FTL model agrees with full-scale trials and operating experience, demonstrating that gas transmission line pressure fluctuations are benign in terms of crack growth, thus reducing the risk of mechanical damage failure. Additional FTL model studies demonstrated that mechanical damage/weld interaction severity is significantly affected by mechanical damage form and position with respect to the weld seam. However, it is noted that these results indicated that the significance of the interaction between a weld seam and a dent is significantly related to their relative position. Figure 1.3 illustrates the significance of girth weld position relative to a smooth dent in terms service life. This effect is significant when considering high resolution in-line inspection that can identify the relative location of a weld within a mechanical damage zone.

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Figure 1.1: Pipeline Dent Assessment Model Overview

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Model Cycles to Failure

60000 6% 12% 6% 12% 18% 18% 24%12% 18% 12%

45000 30000 15000

4" Dome 8" Dome Long Bar

0 0

4" Double Dome 8" Double Dome

15000 30000 Trial Cycle to Failure

45000

60000

Figure 1.2: Agreement of FTL Dent Assessment Model with Full Scale Trial Results

1

Crack Dpeth (a/t)

0.8

Location 1 0.6

Location 2 0.4

No Weld Location 1 Location 2 Location 3

0.2

Pipe Long. Axis Location 3

0 0

100 200 300 Years to 95% Through Crack

Figure 1.3: Effect of Girth Weld Position on Dent Fatigue Life 1.2.2

FTL Buckle/Wrinkle Assessment Model

Similar on-going research and development efforts at FTL have developed a numerical model to predict the formation and behaviour of pipeline buckles and wrinkles. A buckle (see Figure 1.4) forms in an unpressurised pipeline due to a combination of axial, flexural and lateral loads, whereas, a wrinkle (Figure 1.5) forms in a pipeline under similar applied loading conditions if a significant internal pressure is present. While a buckle or a wrinkle may form in the absence of a lateral load (mechanically applied loads or construction loads) their formation is facilitated by the application of lateral loads. The buckle wrinkle formation and life assessment model considers the continued growth and damage accumulation of the buckle and wrinkle. The model was developed to simulate the behaviour of a pipe before during and after the formation of a buckle / wrinkle to support a damage tolerance assessment approach. The results of the work completed previously at FTL have developed a technique capable of considering: Mechanical Damage at Welds

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BMT FLEET TECHNOLOGY LIMITED

• • • • • •

5563P

internal pressure (static or cyclic), axial loads (due to thermal or ground movement) lateral loads (due to mechanical damage or rock contact) flexural loads (due to pipe curvature or ground movement) pipe imperfections (out of roundness, weld seams, ovality or wall thickness), and residual stresses (from welds or construction).

510

500

490

Pipe Diameter (mm)

480

470

460

450

440

430

420

410 -800

-700

-600

-500

-400

-300

-200

-100 0 100 Pipe Length (mm)

200

300

400

500

600

700

800

Figure 1.4: Sample Buckled Pipe Geometry

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335

330

Pipe Diameter (mm)

325

320

315

310

305 -400

-300

-200

-100

0 Pipe Length (mm)

100

200

300

400

Figure 1.5: Sample Wrinkled Pipe Geometry When compared with full-scale trials, the wrinkle assessment model has demonstrated good agreement as shown in Figure 1.6 that illustrates the agreement of the “Fleet LS-Dyna” model with the “Experimental” trial results.

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800 Fleet LS-DYNA UGA508- Experimental

700 FEM-Bai & Hauch ABAQUS FEM-Mohareb et al.

End Moment (KN-m)

600

FEM-Bruschi et al. ABAQUS

500

400

300

200

100

0 0

5

10

15

20

25 30 Curvature(1000/m)

35

40

45

50

Figure 1.6: Comparison of FTL Buckle Model with Full Scale Trial Results While the dent assessment model discussed in the previous section considered linear elastic cyclic behaviour using fracture mechanics to estimate crack growth rate, the wrinkle damage accumulation process can include both elastic and plastic deformations thus a strain life approach is used to estimate its service life. Thus, this approach considers the gradual accumulation of damage in a buckle or a wrinkle using a Miner’s damage accumulation model based upon a strain life approach. 1.2.3

Gouge Assessment

Mechanical damage in the form of a gouge, formed on a weld seam, holds the potential to fail immediately after the indenter load is removed and pipe re-bounds occurs. This failure mode occurring immediately after damage formation is a result of: • • •

metal loss at the gouge causing high net section stresses cracking in the root of the gouge (in pressure/heat induced brittle martensite layer caused by gouging friction), and plastic deformation involved in dent rebound.

Field experience and experimental trials have noted that once indenters are removed from contact with the pipe wall, dent rebound can be significant. Mechanical damage with dent depth to pipe diameter ratios of twelve percent have been seen to rebound to 2 or 3 percent deep dents with the removal of the indenter. The FTL dent assessment model has been used to explore this behaviour as shown in Figure 1.7 below for two different pipe geometries. This figure relates the initial dent depth to the rebounded dent depth for two 30-inch diameter pipe wall thickness. The indenters in these examples are spherical objects with a diameter of one third of the pipe diameter.

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Figure 1.7: Predicted Pipe Rerounding In studying the immediate mechanical damage failure mode, similar numerical modeling techniques used in the dent assessment model may be used. In this work, the gouged pipe wall thickness reduction is considered explicitly in the non-linear finite element model, and the nonlinear stress and strain state are considered to evaluate the potential for failure due to low cycle fatigue (one cycle) or fracture (plastic collapse or fracture). 1.2.4

Ovality Induced Failure

While ovality is predominantly considered a serviceability limit state in that it can either impede pipeline fluid flow or preclude in-line inspection, pipe ovality caused by either bending or lateral loads has been shown to produce significant circumferential stresses 90 degrees away from the point of load application along the pipe circumference or at the bending neutral axis. The effect of this ovality due to bending or a concentrated load can promote failure of the pipe section in the modes shown in Figure 1.8.

+

Excessive Tensile Strains Local Buckling Curvature Reversal/Denting Figure 1.8: Pipe Cross Section Damage Modes / Limit States The tensile strains developed on the side of a pipe subjected to soil pressures and bending induced ovality include axial and bending components as shown in Figure 1.8. The side wall tensile strains (first limit state in Figure 1.8) may estimated by first calculating the ovality induced by the bending strain [11]:

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Ovality =

5563P

D max − D min D no min al

2   D 0  D 0   εb  + f0  = 2 0.061 +      120 t  t

where: D0 = pipe diameter t = wall thickness f0 = original ovality (0.5%) εb = bending strain

and the maximum bending strain in the side wall of the pipe may be estimated as:

εO =

 t  1 − 1  D  (1 − Oval) 2 

Alternatively, the ovality induced stresses and strains may be estimated numerically considering the contributions of lateral loads, buckling and dent formation, as described in the previous sections. The resulting stress or strain state could be used to define critical long seam flaws that may be supported in a weld of a given fracture toughness. 1.3

Project Objectives

The primary objective of this research project is: “to develop a guidance note describing the conditions under which the interaction of mechanical damage and weld seams could be tolerated”. The desired project result will be sought through the refinement and application of existing engineering tools developed at FTL. To accomplish the above objective a two-step research and development plan is presented in the sections that follow. The two steps correspond to model development/validation (year 1) and application (year 2). In the development of the proposed guidance notes, the following project technical or subobjectives have been defined: • • • 1.4

to describe and demonstrate conservative validation results for each of the engineering models applied in deriving the guidance notes, to perform sensitivity studies to demonstrate the sensitivity of weld seams to mechanical damage, to characterise the operational conditions, mechanical damage forms and extents that are of significance for gas pipelines

Project Technical Approach Summary

The proposed project includes five technical tasks in addition to the administrative and reporting actions related to a sixth task. The technical scope of work is divided into two steps completed in the first and second years of the project. The project scope of work in terms of tasks is outlined in Figure 1.9 along with a brief description of their objectives. A more detailed description of each task in terms of its objective, approach and expected results is provided in Section 2.

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FIRST YEAR ACTIVITIES

1) Dent Model Calibration & Demonstration Complete dent model validation with localised effects (gouge, weld, corrosion). Describe modeling techniques and demonstration sample applications. 2) Wrinkle Model Calibration & Demonstration Complete wrinkle model validation with localised effects (gouge, weld, corrosion). Describe modeling techniques and demonstration sample applications.

5563P

SECOND YEAR ACTIVITIES 3) Development of Dent & Ovality Criteria Apply models to explore failure sensitivity and develop guidance note or criteria for acceptance of dents and ovality interacting with welds. 4) Development of Wrinkle Criteria Apply model to explore failure sensitivity and develop guidance note or criteria for acceptance of buckles or wrinkles interacting with welds.

5) Development of Other Criteria Apply models to explore failure sensitivity and develop guidance note or criteria for acceptance of gouges and corrosion interacting with welds. 6) Project Reporting General task to keep Project Technical Committee informed of project technical and financial status / progress and produce final report and presentation. Figure 1.9: Project Technical Scope Summary

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2.

WORK PLAN

2.1

Overview

5563P

This proposal includes the technical experience and expertise of personnel at BMT Fleet Technology Limited (BMT FTL) in the development of techniques to determine the damage tolerance of, or significance of damage to, pipeline systems. The full-scale evaluation of the range of mechanical damage induced failure modes proposed in this project would be a monumental task financially, therefore a numerical modelling approach has been proposed. The scope of the model development is limited by previous work completed by the staff at FTL. The six tasks proposed for this work are summarised in Figure 1.9 and the section that follow provide detailed descriptions of the work to be carried out in this project. These tasks include a first year of model refinement and validation followed by their application to develop damage acceptance criteria. 2.2

Scope of Work

2.2.1

Task 1 - Dent Model Demonstration and Calibration

Objective: The objective of this task is to complete the validation of the FTL dent assessment model considering localised effects. Approach: While the dent model has been widely validated for smooth dents its validation for interaction with welds and gouges has not been as rigorous. This task will complete the dent model validation for welds and gouges and take the opportunity to demonstrate the model. The validation will compare the model behaviour and life predictions with full-scale trial results. The BMT FTL database of full scale trial results including several hundred test will be reviewed with the technical committee to identify a representative sample for use as the basis of the validation. It is proposed at this time that the validation efforts will consider up to twenty full-scale trials in addition to the work already completed for smooth dents and those with localised effects (welds, corrosion and gouges). The details of the modeling technique as well as the results of the validation effort will be reported at the end of this task. This report will also include a copy of the BMT FTL full-scale trial dent experimentation database. It is expected that the report will comment on the level of conservatism of the model when considering each localised effect combination. Result: Completion of this task will produce a validated dent assessment model capable of conservatively predicting the service life of dented pipe segments interacting with localised effects such as welds, gouges and corrosion features. 2.2.2

Task 2 - Wrinkle Model Demonstration and Calibration

Objective: The objective of this task is to complete the validation of the FTL wrinkle and buckle model considering the effects of local weld seams and gouges. Approach: The wrinkle model has been developed and demonstrated to agree well with full-scale trials, however, it has only considered the effect of weld seams on the development of the wrinkle not the through life integrity. This task will focus on the extension of the wrinkle through life integrity assessment and comparison with full-scale experimental data for validation. The data for full-scale validation is available to the project team based upon trials. The BMT FTL database of full-scale trial results available will be reviewed with the technical committee to identify a representative sample for use as the basis of the validation. It is proposed at this time that the validation efforts will consider up to ten full-scale trials in addition to the work already completed. Full scale-trial data including gouges is not available at this time, however, if additional data becomes available, these results will be modeled.

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The effects of a weld seam and gouge will be considered on the life of static wrinkle. It is proposed that the scope of this task will not consider buckle or wrinkle growth but will consider the effects of internal pressure fluctuations. The details of the modeling technique as well as the results of the validation effort will be reported at the end of this task. This report will also include a copy of the BMT FTL full-scale trial wrinkle experimentation database. It is expected that the report will comment on the level of conservatism of the model when considering each localised effect combination. Result: Completion of this task will produce a validated pipeline wrinkle and buckle assessment model capable of conservatively predicting the service life of wrinkled or buckled pipe segments interacting with welds and gouges considering the effects of line pressure fluctuations. 2.2.3

Task 3 - Development of Dent and Ovality Criteria

Objective: The objective of this task is to develop criteria for accepting dent and ovality mechanical damage interacting with a weld seam. Approach: This task will use the BMT FTL dent assessment model to simulate dent and ovality mechanical damage interaction with girth and longitudinal weld seams. A range of pipe geometries and mechanical damages will be considered along with a range of weld qualities (profiles) and mechanical properties. In addition, the effect of weld location and pressure history will be considered in this sensitivity study. Pressure time history data, available at FTL or additional data provided by PRCI companies, collected from SCADA reports at compressor stations will be characterised using BMT FTL proprietary software to demonstrate mechanical damage life sensitivity to operational conditions. It is expected that the sensitivity studies will consider at least forty mechanical damage scenarios to identify trends in the damage life expectancy. The results of this sensitivity analysis will be a conservative guidance note for the disposition of dents and ovality interacting with longitudinal and girth weld seams. The details of the sensitivity studies as well and the resulting trends will be reported at the end of this task. It is expected that the report will comment on the level of conservatism of the results and any concerns or restrictions in applying the results. Result: Completion of this task will produce guidance notes or damage acceptance criteria that may be applied to dent and ovality mechanical damage interacting with weld seams. 2.2.4

Task 4 - Development of Wrinkle Criteria

Objective: The objective of this task to develop criteria for accepting buckles and wrinkles interacting with weld seams. Approach: This task will use the FTL wrinkle and buckle model to simulate mechanical damage interaction with weld seams. A range of pipe geometries and mechanical damages will be considered along with a range of weld qualities (profiles) and properties. In addition, the effect of weld location and pressure history will be considered in this sensitivity study. As in the previous task collected pressure time history will be used to demonstrate service life sensitivity to operational conditions. It is expected that the sensitivity studies will consider at least forty mechanical damage scenarios to identify trends in the damage life expectancy. The results of this sensitivity analysis will be a conservative guidance note for the disposition of buckles and wrinkles interacting with longitudinal and girth weld seams.

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The details of the sensitivity studies as well and the resulting trends will be reported at the end of this task. It is expected that the report will comment on the level of conservatism of the results and any concerns or restrictions in applying the results. Result: Completion of this task will produce guidance notes or damage acceptance criteria that may be applied to wrinkle or buckling promoted by mechanical damage interacting with weld seams. 2.2.5

Task 5 - Development of Other Criteria

Objective: The objective of this task will be to explore the effects of gouges and corrosion damage interacting with weld seams. Approach: This task will consider the interaction of other forms of mechanically induced damage (e.g., gouges, localized corrosion due to coating damage) and weld seams. This task will consider both the immediate failure and gradual damage accumulation modes of failure discussed in Section 1. A range of mechanical damage forms in dented and undented pipe segments will be used to understand the sensitivity of pipeline welds to these forms of damage and thus develop guidance for their assessment. It is expected that the sensitivity studies will consider at least forty mechanical damage scenarios to identify trends in the damage life expectancy. The results of this sensitivity analysis will be a conservative guidance note for the disposition of combinations of dents, gouges and corrosion interacting with longitudinal and girth weld seams. It is noted that the effects of corrosion features alone will not be dealt with in this project as their behaviour has been explored in previous PRCI projects. The details of the sensitivity studies as well and the resulting trends will be reported at the end of this task. It is expected that the report will comment on the level of conservatism of the results and any concerns or restrictions in applying the results. Result: Completion of this task will produce guidance notes or damage acceptance criteria that may be applied to gouges and corrosion features at weld seams without the presence of a dent. 2.2.6

Task 6 - Reporting & Project Management

Objective: The objective of this task is to keep the project technical committee up to date on the project status and disseminate the results of the project. Approach: In this task the results of the calibration and analysis will be reported along with a description of the FTL dent and wrinkle models. The report will outline the mechanical damage guidance developed in this project, in addition, the databases of dent full-scale trials will be provided. This task includes all of the reporting and project management duties required by the second phase of the project. This effort includes the production of Quarterly Progress reports outlining the project financial and technical status, Task reports outlining the results of each major task and a Year 2 Final Report. The task budget also allows for a Progress Meeting and a Final Project Meeting. These meetings will be coordinated with PRCI to coincide with committee meetings or other major industry technical events to facilitate attendance. Quarterly, Task and Draft and Final reports will be produced in pdf format suitable for webposting and electronic download. The report delivery schedule is outlined in Section 6. Project meeting dates, invoicing and reporting will be coordinated by the Fleet Technology Limited Project Manager. Mechanical Damage at Welds

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Result: Completion of this task will ensure that the Project Technical Committee is kept appraised of project progress and the technical advances from this project are documented and disseminated. 2.3

Expected Project Deliverables

With the completion of each task a report will be assembled describing the work completed. These reports will be delivered as interim reports along with quarterly letter progress reports and the project final report. A listing of the expected project deliverables are outlined Table 2.1. Each deliverable is related to a project task along with its approximate delivery date relative to the project start date. Table 2.1: Expected Project Deliverables Deliverable Task Dent Model Validation Interim Report 1 Wrinkle and Buckle Model Validation Interim Report 2 Dent and Ovality Acceptance Criteria Interim Report 3 Wrinkle and Buckle Acceptance Criteria Interim Report 4 Other Mechanical Damage Acceptance Criteria Interim Report 5 Draft Project Final Report 6 Project Final Report 6 Quarterly Project Progress Reports 6 2.4

Delivery Date 4 Months 12 Months 15 Months 18 Months 22 Months 23 Months 24 Months Every 4 Months

References

1) Fowler, J.R., Alexander, C.R., Kovach, P.J., Connelly, L.M., 1995, “Fatigue Life of Pipelines with Dents and Gouges Subjected to Cyclic Internal Pressure”, PD Vol. 69, Pipeline Engineering, ASME. 2) Alexander, C.R., & J.F. Kiefner, “Effects of Smooth and Rock Dents on Liquid Petroleum Pipelines”, American Petroleum Institute, API Publication 1156, November 1997. 3) Kiefner, J.F. and Alexander, C.R., , “Effects of Smooth and Rock Dents on Liquid Petroleum Pipelines (Phase II)”, American Petroleum Institute, Addendum to API Publication 1156, October 1999. 4) Wang, K.C. and Smith, E.D., “The Effect of Mechanical Damage on Fracture Initiation in Line Pipe: Part 1 – Dents”, Report ERP/PMRL 82-11(TR), Physical Metallurgy Research Laboratories, CANMET, January 1982. 5) Evaluation of a Composite System for Repair of Mechanical Damage in Gas Transmission Lines, GRI, Dec. 1998, GRI-97/0413. 6) Fleet Technology Limited, “Pipe Dent ECA Process Development”, report prepared for Interprovincial Pipe Line Inc., Nov. 1997. 7) Dinovitzer, A., Lazor, R., Walker, R., 1999, “A Pipeline Dent Assessment Model”, OMAE’99. 8) Dinovitzer,A., Bhatia,A., Walker,R., Lazor,R., “A Pipeline Dent Assessment Model Considering Localised Effects”, IPC 2000, pg 735. 9) Fleet Technology Limited, “Pipe Dent ECA Process Extension”, report prepared for Enbridge Pipe Line Inc., Nov. 1998. 10 Fleet Technology Limited, “Calibration of the Pipe Dent Assessment Model”, report prepared for Enbridge Pipe Line Inc., May 2000. 11) Murray,N.W., Bilston,P., “Rational Acceptance Limits for Field Bends in Oil or Gas Pipelines”, International Pipeline Conference, Calgary, Alberta, 1992.

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PROJECT TEAM AND QUALIFICATIONS

The proposed project scope requires a multi-disciplinary project team including welding engineering, stress analysis, metallurgy and numerical modeling skills. This multidisciplinary project team is available within the proposed BMT Fleet Technology Limited project team. Figure 8 outlines the project team proposed for this project. The project team has been kept small to ensure continuity and familiarity with the project. It is noted that potential conflicts with other work could reduce the availability of project team members. For this reason available replacement FTL staff have also been listed in Figure 3.1. Project Technical Committee Aaron Dinovitzer - Project Manager - Technical and Management Lead Robert Lazor – Principal Engineer – Pipeline Operations Nick Pussegoda - Senior Metallurgist - Failure Mechanisms Blair Carroll – Senior Mechanical Engineer - Numerical Modeling and Failure Analysis Stephanie Verbit – Project Mechanical Engineer - Data Reduction / Fatigue and Fracture Analysis Abdelfettah Fredj – Senior Engineer - Numerical Modelling Additional Available FTL Staff: - R. Lazor - Mech. Eng (Project Manager) - M. Avsare - Mech Eng (Numerical Modelling) - S Tiku - Met. Eng. (Fatigue and Fracture) - B. Xu (numerical Modelling) Figure 3.1: Proposed Project Team and Additional Available Staff The project manager designated for this project is Mr. Aaron Dinovitzer, a Principal Engineer and Vice President at Fleet Technology Limited. Mr. Dinovitzer holds a MASc in Civil Engineering, specializing in structural optimisation and design, and is a CWB certified Welding Engineer for Steel and Aluminium. He has been working in the area of structural integrity and damage tolerance analysis in which he has lead the development of a number of pipeline ECA tools and techniques. His recent areas of development have involved the development and extension of the FTL dent assessment and wrinkle models. Mr. Dinovitzer's experience in advanced numerical modelling, experimental program oversight and project management will be an asset to the team. Mr. Dinovitzer will be assisted in this project primarily by:

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Dr. Nick Pussegoda has a Bachelor’s degree in Mechanical Engineering and Ph.D. in Physical and Mechanical Metallurgy. His experience base comprises both research, teaching and practical consulting and failure analysis. Prior to joining BMT Fleet Technology, he has worked on projects related to microstructure and properties of dual phase steels, hydrogen embrittlement in steels, and rolling schedules for micro-alloyed steels. At BMT Fleet Technology, in addition to being a team member for several of the interdisciplinary projects, he has been project manager and/or principal investigator for projects involving the hardware and software development for dynamic fracture toughness testing, fracture toughness of deformed plate steels, and CTOD and crack arrest toughness testing of weld metals and HAZ. Dr. Pussegoda leads BMT FTL’s experimental programs and is intimately involved in BMT FTL’s work in failure investigations and metallurgy. Robert B. Lazor has a Bachelor’s and Master’s degrees in Mechanical Engineering, with specialization in Materials Science and Welding. Robert is a Principal Engineer with BMT Fleet Technology Limited and the Manager of the Western Canada office. One of his primary functions is to provide consulting services to pipeline companies in the area of damage tolerance and pipeline integrity. Prior to joining BMT Fleet Technology, Robert, work for 10 years in the Technical Services and Pipeline Integrity Departments at Enbridge Pipelines Inc. where he was responsible for developing, updating and implementing pipeline inspection and repair procedures. L. Blair Carroll has a Bachelor’s and Master’s degree in Engineering from Memorial University, with expertise in ultrasonic examination. Recently Blair has been an Intermediate Engineer with BMT Fleet Technology Limited working in the Materials Technology Center. A key role for Blair has been the development and implementation of damage tolerance criteria and procedures. He is extensively involved in the application of the BMT Fleet Technology Dent Assessment Model and other structural analysis and defect assessment projects. His previous employment experience included 2 years with the Pipeline Integrity Department of Enbridge Pipelines Inc. There he was charged with selecting and implementing inspection procedures and damage tolerance criteria and instructing engineering and field personnel in the practical application of the protocols. The resumes of the above named individuals are included in Appendix A.

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PROJECT MANAGEMENT

Program management is an important component in the successful completion of this study. This requires that both the technical and financial aspects of the project be closely monitored and controlled. Fleet Technology Limited has managed research and development contracts up to $1,000,000 in value and typically is managing some twenty-five contracts at any one time. The Company has standardised internal procedures for effective management of the programs and these are schematically shown in Figure 4.1. The overall management of this program will be handled by Mr. Aaron Dinovitzer, a Vice President at Fleet Technology Limited. He will be responsible for ensuring that the project work is performed in a timely fashion and within the projected costs. Financial control is exercised through the computer generated and weekly updated cost summaries (Figure 4.2). He will also be authorising the payment for costs related to this project. The technical monitoring will be carried out by internal meetings of the FTL staff involved in the project at no longer than two-week intervals. Ms. Colleen Seabrook, Assistant Treasurer, will be available to address contractual and financial questions.

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Figure 4.1: Project Management Control

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Figure 4.2: Example of Weekly Project Cost Summary Sheet

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APPENDIX A PROJECT TEAM RESUMES

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AARON S. DINOVITZER PRINCIPAL ENGINEER - VICE PRESIDENT ACADEMIC BACKGROUND University of Waterloo, Waterloo, MASc., Civil Engineering, 1992. Research Assistant, 1990-92, Involved in design approach development to minimise the effects of local buckling on cold formed steel sections. Studied probabilistic (reliabilitybased) design and optimisation with the goal of comparing it to deterministic approaches. MASc. thesis: "Probabilistic and Deterministic Structural Optimisation". University of Waterloo, Waterloo, BASc., Civil Engineering, 1990. Course of study focused on structural mechanics and design. Awarded undergraduate research assistantship for study of structural optimisation. PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present - Contribute expertise and support to projects involved in the fields of structural design / analysis, reliability & risk, assessment, Welding Engineering, numerical and analytical modelling and mechanics. Research and develop structural and reliability-based analysis and modelling techniques for research projects involving structural design criteria, fracture mechanics, finite element analysis and closed form solutions for plate and shell behaviour. Involved in the design and analysis of welded structures for the pipeline, marine, defence and resource sectors. Recent projects include: Development of rational material strain limits for pipelines: This project funded by the Canadian pipeline industry investigated and developed strain based pipeline analysis criteria. A probabilistic approach has been used to illustrate the conservatism associated with the current design approaches which neglect the effects of material ductility. Development of a combined hydrogen/thermal diffusion model to evaluate the potential for delayed cracking in pipeline welds. Based on a description of essential multi-pass welding procedure parameters the model develops a time history of thermal and hydrogen diffusion to illustrate the potential for delayed cracking and allow the optimisation of the welding procedure to reduce the risk of delayed cracking. Development of refit specifications including welding procedures to add a self unloading system to a bulk carries. Finite element analysis to illustrate the effects of the addition of a deck mounted self unloading system to a bulker. Detailed analyses including analysis of doubler plate system including slot welds were completed to illustrate integrity of welded connections. With this information design modifications and details of the self unloading system were design and modified based on further finite element modelling. ...2/

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A.S. DINOVITZER Page 2 PROFESSIONAL EXPERIENCE (continued) FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present Review existing design of Canadian Coast Guard 47’ Aluminium Motorised Lifeboat to identify compatible aluminium alloys for repairs in Canada. This study demonstrated the feasibility of making repairs with more readily available and less expensive high strength aluminium alloys. The review included fatigue buckling and ultimate strength checks of the as welded structural system. In addition, promising repair welding procedures were developed. Review and demonstration of strain-based limit states design criteria for pipeline design. In this project the merits of strain-based (post-yield) design criteria were examined and demonstrated through a series of pipeline design examples. Development and presentation of a Fatigue Resistant Detail Design Guide for Ship Structures. In this project, a design guide was developed to present procedures used to characterise the long term statistical nature of wave induced ship loads and to design structural connections with specified fatigue lives. These approaches were presented and demonstrated in a short course on fatigue and fracture for ship structures. Reliability-Based Structural Optimisation: In a project funded by CANMET (EMR) techniques for identifying the optimal match of pipeline weld and base material properties based on probabilistic fracture mechanics were developed. The optimal material selection problem has been formulated to produce maximum reliability and minimum cost solutions. Development of a non-linear finite element modelling system which evaluates the effects of dents on the fatigue performance of a pipeline. This modelling project included the development of a FE based software suite which incorporated inspection based dent configuration data, a client supplied operational loading profile and an a parametric description of the structure linked to an automated model meshing system. Corrosion, crack like flaws and weld seams may be superimposed on the dent in the assessment process. An assessment of ice loading on hydroelectric dams, for the Canadian Electrical Association, was performed as par of a larger dam safety program. In this project finite element modelling was used to assess the magnitude of the loads generated due to the constrained daily expansion of the reservoir's winter ice cover. Development of a risk based maintenance management system for the Canadian Navy Ship Structural Integrity Programme (SSIP). This approach optimally allocated inspection and repair resources in a continuously updating management system.

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A.S. DINOVITZER Page 3 PROFESSIONAL EXPERIENCE (continued) FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present Development of Risk-Based inspection tools for Transport Canada Marine Safety to allocate resources, manage inspection time and rationalised the regulatory enforcement decision process. Developed a finite element model to assess the structural behaviour source of cracks in a longitudinal bulkhead of a tanker structure. By identifying the sloshing induced buckling mode which was present a structural modification was developed and designed using FEA. The results of this FEA were compiled and submitted and approved by ABS. Characterisation and modelling of behind-armour ballistic debris to identify the post penetration vulnerability of armoured vehicles. The vulnerability/lethality model being developed in this project, for the Department of National Defence, employs aspects of the shot conditions and the mechanics of penetration in a probabilistic framework to predict the mass and velocity distribution of behind-armour debris clouds. The development of a symbolic finite element analysis approach for reliability analysis: In this year and a half long project, for the Canadian Defence Research Establishment Atlantic (DREA), an automated approach to the algebraic solution of a finite element structural analysis problems is being developed for use in reliability analysis. High strength buoy mooring chain selection based on a comparison of chain residual strength and service loads. This project, for the Canadian Coast Guard, identifies chains which provide a required level of safety against failure at the end of a five year service life. This design project involved the development of a semi-empirical corrosion/wear model and a mechanics based analytical degraded chain ultimate strength model. The development of conceptual designs for a lightweight ceramic/FRP composite armour system to provide ballistic protection for light armoured vehicle weapon stations. In this material selection and geometric design project, for DVEM 2-5, Mr. Dinovitzer employed analytical ballistic modelling techniques to identify the ceramic and FRP material components which provided the required levels of ballistic protection and minimised the overall turret weight. Global Stress Concentrations in Ship Structural Details: This project funded by the Canadian Navy includes the identification of stress distributions in structural details, through finite element analysis, for fatigue life estimation.

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A.S. DINOVITZER Page 4 PROFESSIONAL EXPERIENCE (continued) FLEET TECHNOLOGY LIMITED, Project Engineer, 1992-Present Development of Tripping and Buckling Criteria of Framing for Ice Strengthening: In this project criteria were developed for the Canadian Arctic Shipping Pollution Prevention Regulations (CASPPR) to ensure the adequacy of stiffeners in ice strengthened vessels. Development of a Materials Property Database for Reliability Analysis: In this project, for the U.S. Ship Structures Committee, a uniform format for collecting and processing material property data was developed for use in reliability-based design. The material property database developed in this project is being considered by the ASTM for adoption as a standard data reporting format. Development and evaluation of existing analysis approaches for buckling of partially stiffened plate elements: Recommendations on optimal section configuration and buckling analysis approaches resulted in changes to the Canadian handbook of steel construction and the Canadian cold formed steel design standard. Engineering Critical Assessment / Fitness-For-Purpose Investigations Loading, structural analysis and fracture mechanics expertise has been used to assess the significance of structural damage and weld flaws to determine the root cause of a failure. These accident reconstruction, failure analysis, fitness for purpose or ECA projects include: - Reconstruction of tractor trailer accident - Bridge girder damage tolerance analysis - ECA investigation of pipeline girth weld defects - Pre-Inspection ECA of weld defects for petro-chemical plant reactors and piping - Determination of chain lashing failure mechanics - Rail car fatigue and fracture failure investigation - Marine structure fatigue cracking damage tolerance investigation

PROFESSIONAL SOCIETIES / AFFILIATIONS Association of Professional Engineers of Ontario, Member Society of Naval Architects and Marine Engineers, Member CWB Certified Design, Procedures and Practice Welding Engineer Canadian Society of Civil Engineering, Associate Member American Society of Civil Engineers, Associate Member Society of Reliability Engineers, Vice President (Ottawa Chapter) Institute for Risk Research, Member Member of CSA-Z662 Pipeline Risk Assessment Working Group Member of CSA-Z662 Pipeline Limit States Design Technical Committee ...5/

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A.S. DINOVITZER Page 5 PUBLICATIONS A.S. Dinovitzer, "Optimization of Cold Formed Steel C-Sections", published in Canadian Journal of Civil Engineering, February 1992. A.S. Dinovitzer, M. Sohrabpour, R.M. Schuster, "Observations and Comments Pertaining to CAN/CSA-S136-M89", presented at the 11th International Specialty Conference on Cold Formed Steel, Recent Developments in Cold Formed Steel Design and Construction, St. Louis, Missouri, October 1992. M.Z. Cohn, A.S. Dinovitzer, "Applications of Structural Optimization", ASCE, Journal of Structural Engineering, Vol 120, No. 2, February 1994. A.S. Dinovitzer, M. Szymczak, “Characterization of Behind-Armour Debris”, 16th International Ballistics Symposium, Ballistics’96, San Francisco, Sept. 1996. B. Graville, A.S. Dinovitzer, “Strain-Based Failure Criteria for Part Wall Defects in Pipes”, 8th International Conference on Pressure Vessel Technology, ICPVT-8, Montreal, July 1996. A.S. Dinovitzer, “Reliability Based Optimal Material Selection”, Managing Pipeline Integrity: An Issues Workshop on Pipeline Lifecycle, Banff, Alberta, June 1994. G. Comfort, R. Abdelnour, Y. Gong, A. Dinovitzer, “Poussee Statique des Glaces Sur les Ouvrages Hydroelectriques”, November 1996. A.S. Dinovitzer, R. Basu, LCDr K. Holt, “A Hybrid Approach to Warship Maintenance Management”, SNAME Annual General Meeting October 1997. A.S. Dinovitzer, M. Szymczak, D. Erickson, “Fragmentation of Targets During Ballistic Penetration Events”, International Journal of Impact Engineering, 1997. A.S. Dinovitzer, R. Silberhorn, J.L. Rene, “The Mooring Selection Guide (MSG) Software”, Accepted for presentation at Oceans’97. Comfort, G., Singh, S., and Dinovitzer, A., 1997, "Limit-Force Ice Loads and their Significance to Offshore Structures in the Beaufort Sea.", ISOPE. A.S. Dinovitzer, M.Szymczak, T. Brown, “Behind-Armour Debris Modelling”, 17th International Symposium on Ballistics, 1998. A.S. Dinovitzer, B. Graville, A. Glover, “Strain-Based Failure Criteria for Sharp Part Wall Defects in Pipelines”, International Pipeline Conference, 1998. A.S. Dinovitzer, R. Smith, “Strain-Based Pipeline Design Criteria Review”, International Pipeline Conference, 1998. A.S. Dinovitzer, R. Lazor, R. Walker, C. Bayley, “A Pipeline Dent Assessment Model”, OMAE’99, St. John’s Nfld, 1999. A.S. Dinovitzer, I. Konuk, R. Smith, B. Xu, “Pipeline Limit States Design”, OMAE’99, St. John’s Nfld, 1999. D. Heath, N. Pegg, A. Dinovitzer, R. Walker, “Detail Analysis of Ship Structures”, Canadian HydroMechanics Conference, St. John’s Nfld, 1999. A.S. Dinovitzer, “Risk-Based Inspection Targeting System for Small Vessels”, Canadian Passenger Vessel Association Conference, Kingston Ontario, 1999.

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ROBERT B. LAZOR, P. Eng. ACADEMIC BACKGROUND BASc, (Mechanical Engineering), University of Waterloo, Waterloo, ON MASc, (Mechanical Engineering), University of Waterloo, Waterloo, ON PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, Edmonton, Manager, Western Canada, March 2000-Present – Responsibilities include building industry contacts and providing engineering services related to welding engineering services, pipeline repair methods and reliability, engineering critical assessments, material selection, and failure investigations. Designated as Canadian Welding Bureau certified engineer for welding design and welding procedures and practices. Familiar with ASME and CSA welding and design requirements for piping and related equipment. ENBRIDGE PIPELINES INC., Engineering Specialist-Technical Services, 19921997; Engineering Specialist-Pipeline Integrity, 1997-1999 – Responsible for failure investigations, defect assessment procedures, welding procedure approvals, team leadership, representation on CSA Materials Subcommittee, custodian of Operations & Maintenance Procedures Manual. ! Resolved technical issues relating to design, integrity evaluations, and repair procedures of Company facilities. This often involved designing welded assemblies for repair of damaged pipe and components and to design branch connections for new facilities. The designs followed CSA Z662 and ASME B31.4 standards. ! Provided advice to Operations and Engineering on the selection of materials for Company facilities, non-conformance issues, and revised Company specifications to ensure compliance with industry standards and regulations. ! Collected Company comments relating to the proposed Onshore Pipeline Regulations and made these known to the National Energy Board staff as part of an industry committee. ! Reviewed the fracture design methodology of the Alliance Pipeline to satisfy corporate interests and concerns for the technical viability of the project. ! Developed a database of corporate pipe inventory, including material properties, which provided the ability to establish internal inspection intervals. ! Supervised co-workers to resolve issues related to internal inspection of pipelines and the capabilities of the inspection technologies. ! Analyzed the life cycle costs of fittings and flanges and determined the competitive bidding process, rather than a sole source supplier was more effective. ! Developed Company practices for hydrostatic testing and provided assistance in field during hydrostatic testing as needed. ! Maintained company operating manual for welding, revising as needed and providing advice to welders and engineering as required. Attended pipeline maintenance supervisors meetings to answer questions related to welding procedures. ! Acted as the corporate contact for welding procedure review and approval for all contractors working on Enbridge facilities, either maintenance or new construction.

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ENBRIDGE PIPELINES INC., Senior Engineer, Quality Assurance, 1998-1992 – Responsible for projects to support Operations and Engineering related to welding and material selection and represented Company on industry committees. ! Developed company response to National Energy Board concerns related to fillet weld failures as a result of fillet welding to in-service pipelines. This involved developing welding procedure specifications and nondestructive inspection techniques, qualification of inspectors, design of repair sleeve configurations and summarizing results for presentation to industry groups. ! Developed company program to address stress corrosion cracking to comply with National Energy Board requirements. ! Represented company on CSA Task Force on Joining and Task Force on Fracture Toughness. On the Joining TF, I was the secretary and was primarily responsible for amalgamating Z183 and Z184 clauses related to joining, eventually becoming CSA Z662. A major effort was required on my part to address the sections on joining of piping with unequal wall thickness. ! Investigated plant failures and developed recommendations and action plans for preventing similar failures. For example, following two failures of booster pump cans, a fatigue study of the failed weld configuration showed that it had been operating at 3/4 of the maximum allowable stress. The connection was redesigned to 1/3 of the allowable stress and all of the cans similar to the ones that had failed have been repaired. ! Initiated storage system for hydrostatic test results, mill test reports, and nondestructive examination reports to comply with regulatory requirements. ! Created Industry standard for qualification of nondestructive examination technicians for fillet weld inspections. The standard is referenced in CSA Z662 as a recommended test procedure to demonstrate the competency of NDE inspectors. ! Reviewed manufacturers’ quality assurance programs and prepared list of approved manufacturers for material purchases. ! Advised Operations on welder training requirements and arranged instruction program with local college. In addition, attended yearly welder performance qualification testing to supervise testing and to respond to questions from the welders and supervisors. Usually provided short seminars on issues such as hydrogen-induced cracking, practices for welding in liquid-filled pipelines under operating conditions, or NDE techniques to measure remaining wall thickness in pipe. ! Contributed to CSA Standards regarding pipeline maintenance welding and repair methods. WELDING INSTITUTE OF CANADA, Scientific Officer, 1979-1982; Group Leader, Materials Technology, 1982-1988 – Supervised a specialized technical staff of two engineers and three technicians in the execution of research contracts, failure investigations, and routine mechanical testing. ! !

Developed and implemented research programs to address timely issues related to welding metallurgy, thermal and residual stresses, and fracture design concepts for welded structures. Developed the WIC weldability test that is currently used throughout the pipeline industry to establish preheat temperatures for linepipe purchase specifications and pipeline construction.

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! !

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! ! ! !

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Resolved inquiries from member companies on a wide range of problems related to welding and material selection, often as a follow-on activity from failure investigations. Recommended and supervised material testing requirements in accordance with design standards and codes. Undertook specific projects related to welded construction for buildings such as penetration characteristics of flare bevel groove welds, and penetration of arc spot welds used for attaching galvanized sheeting to structural members. Conducted several studies related to determine weld contraction in pipeline girth welds, working with other researchers who complemented the studies with measurements of residual stresses using blind hole drilling and neutron diffraction techniques. Examined the use of several NDE techniques for non-radiographic inspection of pipeline girth welds. This involved making the defects in the welds, organizing the inspections, destructive examination to confirm the defect sizes, and preparation of the final report. Worked on many projects related to welding metallurgy and how properties are affected by changes in welding conditions and stress relief. The main sponsorship was from the pipeline industry, looking to improve the girth weld toughness. Investigated the influence of baseplate composition, welding conditions, and stress relief treatments on the susceptibility of submerged arc strip cladding to weld overlay disbanding. Instructed at seminars and developed materials for WIC modular welding metallurgy courses. These modules are recommended reference materials for persons preparing to take the CWB examinations. Participated actively on Welding Research Council, International Institute of Welding Assembly, and was a contributing author for the Metals Handbook. Was a member of the CSA W48 Filler Metal Committee and one of my related responsibilities at WIC was to conduct weld metal hydrogen testing of consumables. This testing supported many research projects related to hydrogen-induced cracking.

WESTINGHOUSE CANADA LIMITED, Junior Project Engineer, 1975-1976 – Designed modifications and calculated new operating characteristics for changing the operation of industrial gas turbines to operate on both gas and oil. Required the development of new operating manuals and the preparation of design drawings. ONTARIO MALLEABLE IRON, Junior Project Engineer, 1974-1975 – Completed projects related to plant maintenance, which involved material procurement, liaison between contractors and plant departments, and the preparation of design drawings. PROFESSIONAL AFFILIATIONS (Past and Present) ASM International, Council Member Welding Research Council, Weldability Committee International Institute of Welding CSA Task Force on Fracture Toughness CSA Subcommittee on Materials CSA Filler Metals Committee CSA Task Force on Joining APEGGA Career Counselling Committee API Mechanical Damage Task Force

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PUBLICATIONS R.B. Lazor and H.W. Kerr, “The Effects of Nickel and Titanium on Submerged Arc Welds in HSLA Steels”, Pipeline and Energy Plant Piping: Design and Technology, Pergamon Press, 1980, p 141. R.B. Lazor and B.A. Graville, “Effect of Microalloying on Weld Cracking in Low Carbon Steels”, ibid, p. 247. R.B. Lazor, R.D. McDonald, and A.G. Glover, “Properties of Welds in Thick Section NbContaining Steels”, Welding in Energy-Related Projects, Pergamon Press, 1984, p. 1. J.T. Bowker, R.B. Lazor and A.G. Glover, “The Structure and Toughness of the Weld and HeatAffected Zone of a C-Mn-V Steel”, HSLA Steels Technology and Applications, American Society for Metals, 1984, p 679. B.G. Kenny, H.W. Kerr, R.B. Lazor, and B.A. Graville, “Ferrite Transformation Characteristics and CCT Diagrams in Weld Metals, Metal Construction, Vol 17(6), 1985, p 374. T.W. Lau, J.T. Bowker, and R.B. Lazor, “First Report on HAZ Study”, Welding for Challenging Environments, Pergamon Press, 1986, p 167. K.S. Ko and R.B. Lazor, “Flare Groove Welds in Hollow Structural Steels”, IIW Commission XVE, 1983. R.B. Lazor, R.H. Legget, and A.G. Glover, “Experimental Stress Analysis of Pipeline Girth Welds”, 6th Biennial Joint Technical Meeting on Line Pipe Research(AGA NG-18/EPRG), Camogli, Italy, 1985. A.G. Glover and R.B. Lazor, “The Role of Residual Stresses in Fracture of Pipeline Girth Welds”, 7th Biennial Joint Technical Meeting on Line Pipe Research (AGA NG-18/EPRG), July 1988. A.G. Glover and R.B. Lazor, “Metallurgical Factors in Fracture Toughness”, World Materials Congress, Calgary, 1988. T.M. Holden, J.H. Root, R.R. Hosbons, K.G. Leewis, an R.B. Lazor, “Neutron Diffraction Measurements of Axial Residual Strain Near Cracks in Typical Pipeline Girth Welds”, The Canadian Fracture Conference 21, April 24-26, 1990. J.F. Keifner, W.A. Maxey, J.D. Smith, and R.B. Lazor, “Validating the Serviceability of IPL’s Line 13, Calgary, 1996. R.J. Pick, D.S. Cronin, F.E. Nippard, and R.B. Lazor, “The Influence of Weld Geometry on the Fatigue Life of a 864 mm Diameter Line Pipe”, Pressure Vessel Technology, Montreal, 1996. A. Dinovitzer, R.B. Lazor, R. Walker and C. Bayley, “A Pipeline Dent Assessment Model”, Offshore Mechanics and Engineering, St. John’s, NF, 1999. A. Dinovitzer, A. Bhatia, R. Walker and R.B. Lazor, “A Pipeline Dent Assessment Model Considering Localized Effects”, International Pipeline Conference 2000, Calgary, AB, ASME International, 2000.

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Presentations ! New Problems in the Welding of Steels for Major Structures, CIM Conference, August 1982. ! Arc Burns in Pipeline Steels, 64th Annual AWS Convention, Philadelphia, PA, 1983. ! Properties and Problems in Structural Steel Welds, ibid. ! A Restraint Test for Developing Girth Weld Procedures, ASM Metals Congress, Detroit, 1984.Heat-Affected Zone Toughness in C/Mn Steels, ASTM Committee on Effect of Temperature on the Properties of Metals, May 1984. ! Heat-Affected Zone Toughness on Bean-on-Plate Welds in Titanium Steels, CCIIW Working Group, Commission IX/X, May 1984. ! Weld Overlay Techniques, WIC Calgary Chapter Seminar on Improved Welding Productivity, February, 1985.

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L. BLAIR CARROLL, M. ENG., P. ENG PROJECT ENGINEER ACADEMIC BACKGROUND Master of Engineering (Mechanical Engineering – Nondestructive Examination), Memorial University of Newfoundland, St. John’s, NF, 1998 Bachelor of Engineering (Mechanical Engineering), Memorial University of Newfoundland, St. John’s, NF, 1995 PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, Project Engineer-Materials and Structures, June 2000 to Present – Responsibilities include: # Assisting with pipeline related risk and reliability projects # Data analysis and in-field assessment services for pipeline operators # Evaluation of pipeline repair techniques # Failure analysis ENBRIDGE PIPELINES INC. Edmonton, AB, Canada , Pipeline Integrity Engineer, April 1998 to June 2000 – Responsibilities included: # Updated pipeline inspection procedures, maintenance manuals, engineering standards and material specifications; # Technical resource on codes and standards for operations personnel. PROFESSIONAL AFFILIATIONS 2001-Present Treasurer, National Capitol Section of the National Association of Corrosion Engineers 2001 Member, Professional Engineers of Ontario 1999-Present P. Eng., Association of Professional Engineers, Geologists and Geophysicists of Alberta 1999 Stress Corrosion Cracking Session Chair, Banff 99 Pipeline Workshop 1998-Present Enbridge representative to the CEPA Pipeline Integrity Working Group Personal/Professional Development 2000 1999 1999 1998 1998

ANSYS Finite Element Modeling Course British Standards, BS 7910 Course, Structural Integrity Training CASTI CSA Z662 Course, Oil and Gas Pipeline Systems Skill Paths Team Management Course Transportation of Dangerous Goods

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L. BLAIR CARROLL (Page 2) PUBLICATIONS Thesis: L.B. Carroll, Investigation into the Detection and Classification of Defect Colonies using ACFM Technology, Faculty of Engineering and Applied Science, Memorial University of Newfoundland, St. John’s, Newfoundland, Canada, October, 1998. Conference Papers: Carroll, L.B. and M.S. Madi, “Crack Detection Program on the Cromer to Gretna, Manitoba Section of Enbridge Pipelines Inc. Line 3”, 2000 ASME International Pipeline Conference, Oct. 1-5, Calgary, Alberta, Canada, Proceedings of the International Pipeline Conference 2000, Vol. 2, ASME, New York, pp. 1435-1438. Carroll, L.B., Monahan, C.C., and R.G. Gosine, “An automated ACFM peak detection algorithm with potential for locating SCC clusters on transmission pipelines”, 1998 ASME International Pipeline Conference, June 7-11, Calgary, Alberta, Proceedings of the International Pipeline Conference 1998, Vol. 1, ASME, New York, pp. 335-340. Kania, R., and L.B. Carroll, “Non-Destructive Techniques for Measurement and Assessment of Corrosion Damage on Pipelines”, 1998 ASME International Pipeline Conference, June 7-11, Calgary, Alberta, Proceedings of the International Pipeline Conference 1998, Vol. 1, ASME, New York, pp. 309-313. Carroll, L.B., and C.C. Monahan, "Detection and classification of crack colonies using ACFM technology - Phase I," 1997 ASME Pressure Vessels and Piping Conference, July 27-31, Orlando, Florida, NDE Performance Demonstration, Planning and Research, PVP-Vol. 352, NDE-Vol. 16, M.M. Behravesh, M.P. Jones, and C.C. Monahan, Eds., ASME, New York, pp. 5764. Timco, G.W., Irani, M.B., Funke, E R., English, L.A., Carroll, L.B., and J.C. Chao, (1993), "Ice Load Distribution on a Faceted Conical Structure", Proceedings of the 12th International Conference on Port and Ocean Engineering under Arctic Conditions (POAC '93), Hamburg, Volume 2, pp. 607 - 616. Journal Articles: Carroll, L.B., and M. Madi, “PIPELINE INSPECTION – Conclusion: ILI tool detects cracks, SCC in Canadian liquids line,” Oil & Gas Journal, Vol. 99, Issue 19, May 7, 2001. Contract Reports: K. Klein, C. Monahan, M. Nahon, R. Driscoll, and B. Carroll, "Investigation of Synthetic Fiber Rope Moorings for Canadian Coast Guard Navigation Buoys," Contract Report for Canadian Coast Guard, Transport Canada, C-CORE Publication 96-

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LAKSHMAN N. (NICK) PUSSEGODA SENIOR METALLURGICAL ENGINEER ACADEMIC BACKGROUND University of Canterbury, New Zealand, PhD (Metallurgical Engineering), 1978 University of Ceylon, BSc (Eng) (Hons), (Mechanical Engineering), 1970 PROFESSIONAL EXPERIENCE FLEET TECHNOLOGY LIMITED, 1990-Present - As Senior Metallurgical Engineer, responsible for management of projects up to $200,000 in value. Principal Investigator for projects associated with performance of materials in engineering applications such as marine structures, pipe lines, utilities and other land based structures. The projects involve strength, toughness of steels and their weldments as well as corrosion of the joints and degradation of composites. In the case of strength and toughness, over 20 years of experience has been obtained in the analysis of results in relation to the steel and weld joint microstructure. On the corrosion side, attack on the material and weld in the field has been simulated in the laboratory. Failure investigations have been performed on pipes, machine components and materials handling equipment that have suffered degradation during service and automotive components to name a few. McGILL UNIVERSITY, Department of Metallurgical Engineering, Visiting Professor, July 1988-September 1990 - Performed research and development on the simulation of industrial rolling leading to optimization of the rolling process, and designing of steel alloys to achieve the required microstructure and mechanical properties, in collaboration with steel industry. UNIVERSITY OF PERADENIYA, SRI LANKA, Department of Mechanical Engineering, Associate Professor, May 1981-June 1988 - Teaching metallurgy and design for mechanical engineering students, collaborating with metal working industries through student projects and funded research and development projects. Consulting services for the Bureau of Standards, metal and chemical processing industry, and design and consulting engineering organizations. Served as a Board Member in the Ceylon State Hardware Corporation. CANMET (Metals Technology Laboratories), Ottawa, Visiting Fellow, November 1978March 1981 - Research on problems associated with fabrication and performance of metal products for the oil and gas industry, and on production of new high strength automotive materials. UNIVERSITY OF CATERBURY, New Zealand, Graduate Student, March 1975-July 1978 - Research on production of reinforcing bar to be used in earthquake resistant structural design. Proposed new specifications for reinforcing in earthquake resistant structural design. .../2

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L.N. PUSSEGODA Page 2 PROFESSIONAL EXPERIENCE (continued) UNIVERSITY OF PERADENIYA, SRI LANKA, Department of Mechanical Engineering, Assistant Lecturer, February 1972-February 1975 - Teaching mechanics and design for mechanical engineering students and supervision of student vacation projects performed in industry. SRI LANKA TRANSPORT BOARD, SRI LANKA, Mechanical Engineer, August 1971January 1972 - Completed an industrial training program. UNIVERSITY OF PERADENIYA, SRI LANKA, Department of Engineering Mathematics, Instructor, August 1970-July 1971 - Correcting student assignments, worked on a project on application statistical methods on quality control of batch-produced components. MAJOR ACHIEVEMENTS $

Visiting fellowship awarded by NSERC and EMR, Canada, to work at the Metals Technology Laboratories, CANMET (1978-1981).

$

A number of research grants awarded by Natural Resources, Energy and Science Authority (NARESA) of Sri Lanka (1982-1988).

$

Physical and engineering sciences merit award by NARESA of Sri Lanka.

$

Merit promotion from Lecturer to Associate Professor (bypassing Senior Lecturer) by University of Peradeniya, Sri Lanka, in December, 1985.

$

United States Patent - "Seamless Steel Tube Manufacture", (co-inventors P.J. Hunt, J.J. Jonas, S. Yue and G.E. Ruddle), Patent No. 5,186,769, Feb. 16, 1993.

PROFESSIONAL SOCIETIES Member, Professional Engineers of Ontario. Member, E8 committee, ASTM, USA Member, ASM International Corporate Member, Institution of Engineers of Sri Lanka ../3

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L.N. PUSSEGODA Page 3 PUBLICATIONS Papers in Refereed Journals "Strain Age Embrittlement of Reinforcing Steels", (co-author with L.A. Erasmus), New Zealand Eng., V32, 1977, pp. 178-83. "Safe Bend Radii for Deformed Reinforcing Bar to Avoid Failure by Strain Age Embrittlement", (co-author with L.A. Erasmus), New Zealand Eng., V33, 1978, pp 170-177. "The Strain Aging Characteristics of Reinforcing Steel with a Range of Vanadium Contents", (co-author with L.A. Erasmus), Metall. Trans., V11A, 1980, pp 231-37. "Hydrogen Embrittlement of HSLA Direct Quenched Steel and Its Simulated HAZ Microstructures", (co-author with W.R. Tyson), Can. Metall. Q., V20, 1981, pp 407-19. "Sensitivity of Electroslag Weld Metal to Hydrogen", (Co-author with W.R. Tyson), Welding Journal, V60, 1981, pp 252S-57S. "Cleavage Fracture of Bent Reinforcing Bar", Met. Technol., V9, 1982, pp 312-16. "Strength and Ductility of Reinforcing Bar", Engineer, 1982/83, V1, pp 8-19. "Grain Size Dependence of Yield and Flow Stresses of a Fe-Mn-Si Alloy", (co-author with W.R. Tyson), Scripta Metall. V18, 1984, pp 241-45. "Comparison of Two Methods of Cold Work to Increase Strength of Hot Rolled Reinforcing Bar", Met. Technol. V11, 1984, pp 207-210. "Segregation of Manganese During Intercritical Annealing of Dual Phase Steels", (coauthor with W.R. Tyson, P. Wycliffe and G.R. Purdy), Metall. Trans., V15A, 1984, pp. 1449502. "Modelling of Dual Phase Steel from Its Ferrite and Martensite Constituents", (co-author with W.R. Tyson), Can. Metall. Q., V24, 1984, pp 341-47. "The Role of Mechanical Properties of Metals in Engineering Design", Engineer, March 1985, pp. 26-33. "Testing of Welds in Ferrous Metals", (co-author with C.B. Ratnayake and A. Alvapillai), Engineering, September 1985, pp 25-29. .../4

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L.N. PUSSEGODA Page 4 PUBLICATIONS (continued) Papers in Refereed Journals (continued) "Comparison of Two Methods of Cold Work to Increase Strength of Hot Rolled Reinforcing Bar - A Further Study", (co-author with K.E.D. Sumanasiri), Can. Metall., V17, 1988, pp 197-203. "Estimates of Yield Strength Changes due to Dislocation Pinning and Internal Stress Relaxation During Aging of a Ferrite-Martensite Dual-Phase Steel", (co-authored with W.R. Tyson), Mat. Sci. Eng., VA111, 1989, pp. L9-L11. "Laboratory Simulation of Seamless Tube Piercing and Rolling Using Dynamic Recrystallization Schedules", (co-author with S. Yue, and J.J. Jonas), Metall. Trans., V15A, 1984, pp. 1449-502. "Simulation of Seamless Tube Rolling Process", (co-author with R. Barbosa, S. Yue, J.J. Jonas and P.J. Hunt), J. Materials Processing Technol., V25, 1991, pp 69-90. "Effect of Intermediate Cooling on Grain Refinement and Precipitation During Rolling of Seamless Tubes", (co-authored with S. Yue and J.J. Jonas), Mat. Sci. Technol. V7, 1991, pp. 278-288. "Comparison of Dynamic Recrystallization and Conventional Controlled Rolling Schedules by Laboratory Simulation", (co-authored with J.J. Jones), ISIJ International, V31, 1991, pp. 278-288. "Design of Dynamic Recrystallization Controlled Rolling Schedules for Seamless Tube Rolling", (co-authored with P.D. Hodgson and J.J. Jonas), Mat. Sci. Technol., V8, 1992, pp. 63-71. “Strain rate effects on fracture toughness of ship plate steels” (co authored with L. Malik, R. Bouchard & W.R. Tyson), Jour. Offshore Mechanics & Engineering, Transaction of ASME, v. 118, (1996), pp. 127-134. “Crack arrest toughness of a HAZ containing LBZ’s” (co authored with L. Malik, B.A. Graville & W.R. Tyson), Jour. Offshore Mechanics & Engineering, Transaction of ASME, v. 118, (1996), pp. 292-299. “Effects of plastic deformation on fracture toughness of ship plate steels” (co authored with L. Malik & W.R. Tyson), Can. Metallurgical Q, v. 36, (1997), pp. 39-47. “Measurement of crack arrest fracture toughness of a ship steel plate” (co authored with L. Malik, & J. Morrison), Jour.of Testing & Evaluation, JTEVA, v.26, (1998), pp.187-197. .../5

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L.N. PUSSEGODA Page 5 PUBLICATIONS (continued) Papers in Refereed Conference Proceedings "The Effect of Titanium on the Strain Aging Characteristics of a C-Mn Structural Steel", (coauthored with L.A. Erasmus), Proc. 6th Australasian Conf. on Mechanics of Structures and Materials, Christchurch, New Zealand, 1977, pp. 445-51. "Relationship between Microstructure and Hydrogen Susceptibility of Some Low Carbon Steels", (co-authored with W.R. Tyson), in I.M. Bernstein and A.W. Thompson (eds.), Hydrogen Effect in Metals, Metallurgical Society of AIME, Warrendale, PA, 1981, pp. 34960. "Processing, Properties and Modelling of Experimental Batch Annealed C-Mn Dual Phase Steels", (co-authored with A. Crawley, C.M. Mitchell, M. Shehata and W.R. Tyson), in R.A. Kot and B.L. Bramfitt (eds), Fundamentals of Dual Phase Steels, Metallurgical Society of AIME, Warrendale, PA, 1981, pp 181-97. "An Improved Locally Produced Mammoty", (co-authored with S. Thayalan and G. Jesuthasan), Trans. Inst. of Engineers, Sri Lanka, 1984, pp 63-67. "Metallurgy of Soil Working Tools for Agriculture", Proc. National Symposium for Agriculture, The Institution of Engineers, Colombo, Sri Lanka, 1985. "Results of Tensile Test of Reinforcing Bar - A Case Study", (co-authored with H.B. Maliyasena), Trans. Inst. of Engineers, Sri Lanka, 1986, pp 124-29. "Effect of Aging on Yield and Flow Stresses of C-Mn Dual Phase Steel", (co-authored with W.R. Tyson), Proc. Australasian Conf. "Materials for Industrial Development", Christchurch, New Zealand, 1987, pp 159-63. "Optimization of Hot Rolling Parameters for Improving the Mechanical Properties of Microalloyed Steels", (co-authored with S. Yue and J.J. Jonas), Professor E.O.E. Pereria Commemoration Vol., Inst. Engineers S.L., Colombo, Sri Lanka, 1991, pp 169-176. "Development of Dynamic Recrystallization Controlled Rolling Schedules During Seamless Tub Rolling", (co-authored with S. Yue, J.J. Jonas and P.J. Hunt) in HSLA Steels: Processing, Properties and Applications, Eds. G. Tither and Z. Shouhua, The Minerals, Metals & Materials Soc., 1992, pp. 159-163. "Fracture Toughness Properties of Cast Aluminum Alloys for Line Hardware", (co-authored with L. Malik, G. Bellamy and H.J. Houston), Proc. Ann. Conf. Canadian Electrical Association, Transmission Section, E&O Division, March 1992. .../6

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L.N. PUSSEGODA Page 6 PUBLICATIONS (continued) Papers in Refereed Conference Proceedings(continued) "Significance of Local Brittle Zones in Weld Heat Affected Zones: Wide Plate Test", (coauthored with L. Malik, M. Chambers, U. Mohaupt, B.A. Graville, W.R. Tyson and P.W. Marshall), in Offshore Mechanics and Arctic Engineering, 1992, VIII, Part A, ASME, NY, pp 41-52. “Toughness of Damaged Plate”, (co-authored with W.R. Tyson. L. Malik, G.C.J Carpenter, M. Charest, B.A. Graville, and P.W. Marshall), in “Inelasticity and Damage in Solids Subject to Microstructural Change”, Sept. 1996, St. John’s, New Foundland, Canada. “Investigation on a Damaged Propeller”, (co-authored with L. Malik), Proc. Analysis InService Failures and Advances in Microstructural Characterization, 31st Ann. Convention of the IMS, (in press) “Prediction of Maximum Time for Delayed Cracking in a Ssimulated Girth Weld Repair’, (coauthored with L. Malik, B.A. Graville, and A.G. Glover), Proc. Int. Pipeline Conf. 1998, v.1, ASME, N.Y., pp. 513-520 “Interim Approach to Determine Ductile Fracture Arrest Toughness – Progress”, (coauthored with L. Malik, and B.A. Graville,), Proc. EPRG/PRCI 12th Biennial Joint Technical Meeting on Pipeline Research, Groningen, The Netherlands, May 17-21, 1999, Paper 15. REPORTS About 100 reports have been prepared. In most cases, these have been for documenting the findings from funded projects. The next major portion is failure analysis reports. PRESENTATIONS More than 60 presentations have been made at conferences, seminars, technical meetings and delivery of reports to clients in the case of funded projects. They have been in the following countries: Australia, Belgium, Canada, Germany, India, Italy, The Netherlands, New Zealand, Sri Lanka, United Kingdom and the USA.

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APPENDIX B BMT FLEET TECHNOLOGY LIMITED CORPORATE CAPABILITIES

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BMT Fleet Technology Limited has been engaged in the business of contract Research and Development for more than twenty seven years now. During this time period, hundreds of contracts, several of these in the $300,000 to $500,000 range, have been successfully completed for clients, both in Canada and in the United States. BMT FTL has been involved in marine engineering and structures research since its inception 25 years ago. Since the addition of the Materials Technology Division in the mid-80s, BMT FTL has been applying its quite unique combination of structures and materials expertise to welded structures in other industries. In the context of the pipeline industry, numerous investigations undertaken to date have dealt with pipeline girth weld fracture toughness, line pipe steel weldability, studies in support of Standards development, and failure analysis. The investigations undertaken by the Materials Technology Division are about evenly divided between experimental and analytical projects. The former have dealt mainly with welding procedure development and weldability studies, and fracture and fatigue performance of steels and welded joints; the latter with structural reliability, engineering critical assessment, optimisation and analytical model development. RECENT BMT FTL PROJECTS In the recent past, staff have completed a wide range of projects including the following projects, presented as an example of the types of work completed at BMT FTL: • Welding Related Projects • Repair welding of stiffeners to hull plating in low temperature marine environments (water backing) without preheat; • Armour steel repair procedure development and implementation in a battlefield tank; • Repair welding procedure development and instructions for aluminum alloy mantlets, medium girder bridge, and armoured vehicle launched bridge; • Hardfacing repair welding of gas turbine blades; • Simulation of reheated heat affected zone cracking in repaired girth welds; • Development of a Multi-Pass Weld Procedure Delayed Cracking Risk Assessment Software • Pipeline Design and Fitness-for-Service • Risk evaluation of concept designs for the Liberty Pipeline; • Development of pipeline dent assessment model • Strain-Based Corrosion Damage Assessment Technique • Development of Strain-Based Planar (Crack-Like) Defect Assessment Technique • Development of Multi-Pass Weld Delayed Hydrogen Cracking Prediction Software • Preliminary development of a CTOA Based Model to Predict the Potential for Long Running Ductile Fracture Events • Review of Strain-Based Pipeline Design Criteria, including sample applications • Probabilistic Modelling, and Risk Assessment • Reliability-based calibration of CSA Z662 Limit States Design Appendix • Reliability based optimal material selection for pipeline girth welds • Development of Risk-Based Structural Inspection Management Tools • Development of Risk-Based Maintenance Management System • Material Properties • Development of an Interim Measure of Ductile Fracture • Assessment of a Two Specimen Approach for the Measurement of CTOA Ductile Toughness • Development of Pipeline Material Property Database for Reliability Analysis

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FACILITIES The sections that follow provide a brief overview of the facilities and equipment available in the Materials and Welding Division at BMT Fleet Technology Limited. The facilities and equipment available are more than adequate to perform the proposed project. In addition to the facilities listed, in the sections that follow, the Systems Division of BMT Fleet Technology Limited which performs software development and field instrumentation can provide assistance in the data recording requirements for the experimental part of this project. Metallurgical • Optical microscopes and stereoscope • Hitachi scanning electron microscope equipped with Ortec EDX system • Specimen preparation facilities: • metallurgical cut off wheel • small diamond saw • mounting press • automatic grinding and polishing facilities • Vickers and Rockwell hardness machines • Lietz micro-hardness unit Welding & Machining • Automatic oxy fuel and plasma cutting equipment • Fully equipped welding facility for SMAW, GTAW, P-GTAW, GMAW, P-GMAW, FCAW, MCAW and SAW • Welding parameter high speed data acquisition system • High temperature electric furnace accommodating material up to 600 x 600 mm in size. • Induma 2045 horizontal universal milling machine • Lagun FCM-20W horizontal universal milling machine • Churchill NB horizontal grinder with magnetic chuck • 3 ton overhead crane, 2 ton forklift • Colchester Master 2500 lathe • Drill press NIDER • Belt and disc grinder • Cutting & machining tools Mechanical Testing • Granite table for distortion measurements • 900KN (200 kips) horizontal servo-hydraulic test machine • 1360KN (300 kips) Baldwin universal tensile testing machine for tension, compression and fracture toughness testing • 640KN (150 kips), 250KN (50 kips), 100KN (20 kips) and 25KN (5 kips) servo-hydraulic fatigue, fracture toughness, and crack arrest materials testing • CVN testing machine (325J capacity) along with broaching equipment Numerical Modeling • Finite element modelling / Structural Analysis services with both ANSYS and Algor • linear and non-linear structural analysis • impact and vibration analysis • heat transfer and fluid flow analysis • structural contact and friction modelling • Fracture mechanics, stress & strain life based fatigue and fracture modeling • Computational fluid dynamics (CFD) services with Flowtran • Reliability and risk assessment software • Weld preheat calculator and delayed cracking (hydrogen embrittlement) risk evaluator • Other proprietary modelling and simulation software modules for design and analysis

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MECHANICAL DAMAGE AT WELDS - RPTG-0326 PART II – COST PROPOSAL

August 5, 2002

Submitted to:

Steve Foh Gas Technology Institute 1700 South Mount Prospect Road Des Plaines, IL 60018

Submitted by: BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Mechanical Damage at Welds

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Canada

K2K 1Z8

BMT FTL Contact: Aaron Dinovitzer Phone: 613-592-2830 ext 203 Fax: 613-592-4950 e-mail: [email protected]

Mechanical Damage at Welds

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

Author: Principal Researcher: Name of Organization: Project Type:

Aaron Dinovitzer Aaron Dinovitzer / Robert Lazor BMT Fleet Technology Limited (FTL) New

9) Statement of the Problem (What is to be solved): In general, pipeline design standards require the repair of dents with depths exceeding 6% of the pipeline's outside diameter and the repair of all dents or signs of mechanical damage that interact with weld seams. This cautious damage disposition approach is based upon numerical and full-scale trials that demonstrate the significant impact that weld seams have on the life of the mechanically damaged pipe segments. It is noted, however, that recent advances in the understanding of mechanical damage failure suggests that the regulatory requirements could be made less restrictive by considering the: - relatively smooth pressure history (low fluctuation) of gas transmission lines, - the type and extent of the mechanical damage, and - position of the weld with respect to the mechanical damage 10) Background (What is the historical data): FTL has developed a pipeline dent assessment model, which uses the actual dent profile and in-service pressure history as inputs to a non-linear pipe finite element model with a fracture mechanics crack growth algorithm. This dent assessment approach has been calibrated using smooth dent full-scale trial data and some cases that have included localized effects (corrosion, gouges and weld seams). The BMT FTL model considers the weld profile, material properties and residual stress field. The BMT FTL model agrees with full-scale trials and operating experience, demonstrating that gas transmission line pressure fluctuations are benign in terms of crack growth, thus reducing the risk of mechanical damage failure. Additional BMT FTL model studies demonstrated that mechanical damage/weld interaction severity is significantly affected by mechanical damage form and position with respect to the weld seam.

i

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

11) Proposed Research Action Plan (How will the problem be solved): The proposed project includes 6 tasks as follows: Task 1 - Dent Model Demonstration and Calibration While the dent model has been widely validated for smooth dents its validation for interaction with welds has not been as rigorous. This task will complete the dent model validation for welds and take the opportunity to demonstrate the model. Task 2 - Wrinkle Model Demonstration and Calibration The wrinkle model has been developed and demonstrated to agree well with fullscale trials, however, it has only considered the effect of weld seams on the development of the wrinkle not the through life integrity. This task will focus on the extension of the wrinkle through life integrity assessment and comparison with fullscale experimental data for validation. Task 3 - Development of Dent and Ovality Criteria This task will use the BMT FTL dent assessment model to simulate dent and ovality mechanical damage interaction with weld seams. A range of pipe geometries and mechanical damages will be considered along with a range of weld qualities (profiles) and mechanical properties. The results of this sensitivity analysis will be a conservative guidance note for the disposition of dents and ovality interacting with longitudinal and girth weld seams. Task 4 - Development of Wrinkle Criteria This task will use the BMT FTL wrinkle and buckle model to simulate mechanical damage interaction with weld seams. A range of pipe geometries and mechanical damages will be considered along with a range of weld qualities (profiles) and properties. The results of this sensitivity analysis will be a conservative guidance note for the disposition of wrinkles or buckles interacting with longitudinal and girth weld seams. Task 5 - Development of Other Criteria This task will consider the interaction of other forms of mechanically induced damage (e.g. gouges, localized corrosion due to coating damage) and weld seams. A range of mechanical damage forms will be used to understand the sensitivity of pipeline welds to these forms of damage and thus develop guidance for their assessment. Task 6 - Project Reporting In this task the results of the calibration and analysis will be reported along with a description of the BMT FTL dent and wrinkle models. The report will outline the mechanical damage guidance developed in this project, in addition, the databases of dent full-scale trials will be provided.

ii

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

12) Expected Deliverables ( List Specifically what PRCI will get out of the work): It is proposed to develop a guidance note demonstrating the conditions under which mechanical damage interaction with weld seams is acceptable. This guidance note will consider the operational characteristics of the pipeline and the characteristics of the mechanical damage and weld seam. It is expected that the analysis results will develop separate criteria to consider each form of mechanical damage (ovalization, dents, buckling, etc.). The recommendations will be in the form non-dimensional damage characteristic limits similar to those being developed using the BMT FTL model for the assessment of smooth dents and those containing localized effects.

13) Resource Requirements (total cost, year-by-year breakdown, capital costs vs. overhead, and outside resources to be used): The FTL project team will bring databases of experimental results containing some 197 smooth dent tests and 100+ dent trials with localized effects. In addition, BMT FTL will seek to secure a similar database of buckle and wrinkle full-scale test results. Previous BMT FTL Dent and Wrinkle model development will be used and with the permission of the current dent geometric characterization project sponsor group, related analytic results could be made available.

iii

Project Summary Committee:

Pipeline Materials

Project Title:

Mechanical Damage at Welds - RPTG-0326 -

14) Organization Information (Describe major business of contractor, facilities available for use in this project, related concurrent/recent projects): FTL provides engineering research and services to the pipeline industry in the welding, materials characterization, and damage tolerance (ECA) areas of interest. Research efforts at FTL have resulted in the development of dent and buckle/wrinkle assessment models. These tools support the integrity assessment of mechanically damaged pipes segments. Beyond the assessment of dents and wrinkles the metallurgical, mechanical testing, welding and numerical simulation labs at FTL have been involved in the following related projects: - Development of a hot tap tee design model - Development and calibration of pipeline pressure retaining sleeve design models - Development of fatigue and fracture analysis tools and courses for industry

15) Contractor Contacts: Mr. Aaron Dinovitzer Materials Technology Centre Fleet Technology Limited Kanata, Ontario Canada K2K 1Z8 Tel: 613-592-2830 Fax: 613-592-4950 E-mail: [email protected] Internet: www.fleetech.com

Mr. R. Lazor Materials Technology Centre Fleet Technology Limited Edmonton, Alberta Canada Tel: 780-465-0077 Fax: E-mail: [email protected] Internet: www.fleetech.com

16) Alternative Funding Sources: The proposed program will be subsidised and progress facilitated through: - the use of pre-existing mechanical damage (dent and wrinkle) modelling tools developed under separate contracts, - the use of previously completed full-scale trial data to validate the numerical modeling tools, - the use of previously developed pipeline operation characterization techniques and tools - the use of previously collected and characterized pipeline material and operational data. Co-operative funding will also be sought from on-going parallel industry group sponsored projects to subsidise the work in this project.

iv

BMT FLEET TECHNOLOGY LIMITED

5563P

BMT FTL DOCUMENT QUALITY CONTROL DATA SHEET

Report:

Mechanical Damage at Welds - RPTG-0326 -

Project No.

5563P

Date:

5 August 2002

Prepared by: A. Dinovitzer, Vice President - Principal Engineer

Reviewed by: R. Lazor - Manager BMT FTL Western Canada Office

Approved by:

A. Dinovitzer, Vice-President

Mechanical Damage at Welds

v

BMT FLEET TECHNOLOGY LIMITED

5563P

TABLE OF CONTENTS Page

5.

COST AND SCHEDULE ..........................................................................................1 5.1 Business Management - General Information .......................................................... 1 5.1.1 General Corporate Information ............................................................................. 1 5.1.2 Financial Management for Projects ...................................................................... 1 5.2 Project Cost .............................................................................................................. 1 5.3 Project Schedule....................................................................................................... 5

6.

CONTRACTING DETAILS .......................................................................................6

Mechanical Damage at Welds

vi

BMT FLEET TECHNOLOGY LIMITED

5563P

LIST OF FIGURES AND TABLES

Figure 5.1: Contract Plan and Report Form ................................................................................ 5

Table 5.1: Detailed Task Cost Breakdown .................................................................................. 3

Mechanical Damage at Welds

vii

BMT FLEET TECHNOLOGY LIMITED

5.

5563P

COST AND SCHEDULE

5.1

Business Management - General Information

5.1.1

General Corporate Information

The project will be carried out by BMT Fleet Technology Limited, which has offices in Kanata (head office) and Edmonton, as follows: BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8

BMT Fleet Technology Limited PO Box 82057, 2037-111 Street Edmonton, Alta. T6J 7E6

5.1.2

Financial Management for Projects

The Project Manager is responsible for the financial performance of a contract. Notifications or other communication concerning invoices for the project should be sent to BMT FTL’s Accounting Office to the attention of:

Mrs. Colleen Seabrook, Assistant Treasurer BMT Fleet Technology Limited 311 Legget Drive Kanata, Ontario Canada K2K 1Z8

5.2

Project Cost

The total cost of the project is a fixed price of $150,000 US. This project cost includes:

Rates calculated from:

Salary + (Salary x Overhead)

Mechanical Damage at Welds

1

BMT FLEET TECHNOLOGY LIMITED

5563P

1867.75

where 1867.75 hours is the 2002/2003 working year for an employee with ten days vacation. These rates do not include fee. The rates are better than those offered our most favored commercial client.

The Government overhead rate for FY02/03 is 130%.

Mechanical Damage at Welds

2

BMT FLEET TECHNOLOGY LIMITED

5563P

Table 5.1: Detailed Task Cost Breakdown 1 day is

7.75

LABOUR

2002

Rates

HOUR

DAY

Executive Engineers

hours

DAYS TASK

TASK 1

BY

Tot

TASK 2 TASK 3 TASK 4 TASK 5 TASK 6

TOTAL

COST

$90.00 $697.50

2

6

2

2

2

9

23

$16,043

Princ. Engrs/PMs $75.00 $581.25

11

6

12

11

12

4

56

$32,550

Intermediate Engrs.

$52.00 $403.00

20

21

19.5

19

19.5

3

102

$41,106

Project Engrs.

$45.00 $348.75

10

35

10

10

10

3

78

$27,203

Admin/support

$32.00 $248.00

0

2

0

0

0

2

4

$992

TOTAL ESTIMATED COST OF LABOUR

$19,336 $28,838 $19,71 $18,933 $19,716 $11,354 6

$117,893

CHARGES FOR FTL EQUIPMENT ANSYS

$1,000

$1,000 $1,000 $1,000 $1,000

TOTAL EQUIPMENT CHARGES

$1,000

$1,000 $1,000 $1,000 $1,000

MATERIALS AND SUPPLIES

$500

$5,000 $0

$500

$5,000 $1,000

TRAVEL AND LIVING PRIME CONTRACTOR

$1,250

$1,250 $1,250 $1,250 $1,250 $1,250

$7,500

TOTAL ESTIMATED COST OF TRAVEL

$1,250

$1,250 $1,250 $1,250 $1,250 $1,250

$7,500

OTHER EXPENSES COMMUNICATIONS/COURIER REPRODUCTION TOTAL ESTIMATED EXPENSES FEE

$400

$400

$500

$500

$0

$0

$0

$900

$0

$0

$900

% On labour

15%

2900

4326

2957

2840

2957

1703

$17,684

On Travel & Living

0%

0

0

0

0

0

0

$0

On materials/ Expenses

0%

0

0

0

0

0

0

$0

Mechanical Damage at Welds

3

BMT FLEET TECHNOLOGY LIMITED

TOTAL PROFIT

5563P

$4,326 $2,957 $2,840 $2,957 $1,703

$17,684

PROJECT TOTAL

$24,987 $35,913 $24,92 $24,923 $24,923 $14,307 3

$149,977

% OF TOTAL

16.66% 23.95% 16.62% 16.62% 16.62%

Mechanical Damage at Welds

$2,900

9.54%

1.00

4

BMT FLEET TECHNOLOGY LIMITED

5.3

5563P

Project Schedule

Subject to contract, the project will commence on 1st January 2003 and is due for completion on the 31st of December 2004.

Figure 5.1: Contract Plan and Report Form

Each invoice will be accompanied by a quarterly report as shown in the contract plan and report form above. Payment will be due within 30 days from date of invoice.

Mechanical Damage at Welds

5

BMT FLEET TECHNOLOGY LIMITED

6.

5563P

CONTRACTING DETAILS

The PRCI Contract Cost Estimate Form has been completed. For the purposes of PRCI, we have extracted overhead (130%) from our current rates (Table 5.1) for the Contract Cost Estimate Form.

Mechanical Damage at Welds

6

BMT FLEET TECHNOLOGY LIMITED

5563P

PRCI CONTRACT COST ESTIMATE FORM

CONTRACT COST ESTIMATE (FOOTNOTE A)

Name of Offeror

RFP No/Prp No

Page Number

BMT Fleet Technology Limited

RPTG-0326

Home Office Address

Name of Proposed Project

311 Legget Drive

Mechanical Damage Direct Assessment

Number of Pages

Kanata, Ontario, Canada K2K 1Z8 Division(s) and Location(s) (where work is being performed)

Total Amount of Proposal

Home Office: Kanata, ON

$ 150,000.00

Western Canada Office: Edmonton, Alberta, Canada Estimated Cost Cost Elements

(dollars)

Total Estimated Cost (dollars)

Supporting Schedule (Footnote B)

1.

Direct Material a. Purchased Parts b. Interdivisional Effort c. Equipment Rental/Lease d. Other (ANSYS Lease)

$5,000

Total Direct Material

$5,000

2.

Material Overhead (Rate

0 % x Base $

3.

Subcontracted Effort (Attach Detailed Schedule)

)

0

Net Subcontracted Effort 4.

Direct Labor - Specify

Est. Hours

Rate/Hour

Est. Cost

Executive Engineer

178.25

$39.13

$6,975.22

Principal Engineer

434

$32.61

$14,152.17

Intermediate Engineer

790.5

$22.61

$17,872.17

Project Engineer

604.5

$19.57

$11,827.39

31

$13.91

$431.30

Support Total Direct Labor

Mechanical Damage at Welds

$51,258.25

1

BMT FLEET TECHNOLOGY LIMITED

5.

Labor Overhead - Specify

5563P

O.H. Rate

X Base $

Est. Cost

130 %

$51,258.25

$66,635.73

Total Labor Overhead 6.

Special Testing

7.

Purchased Special Equipment

8.

Travel

9.

Consultants (Attach Detailed Schedule)

$66,635.73

$7,500.00

10. Other Direct Costs

$6,900.00

11. Total Direct Cost and Overhead 12. General and Administrative Expenses (w/o IR&D) Rate

% of cost element numbers

13. Independent Research and Development Rate

% of cost element numbers

14. Total Estimated Cost (Footnote C) 15. Fixed Fee

$17,684.10

16. Total Estimated Cost and Fee

$149,978.00

17. Contractor/Third Party Cofunding (Footnote D) 18. Net PRCI Estimated Cost and Fee

$149,978.00

This proposal reflects our best estimates as of this date, in accordance with the instructions to offerors and the footnotes which follow. Typed Name and Title

Signature

Date 5 August 2002

A. Dinovitzer

Footnotes: A. The submission of this form does not constitute an acceptable proposal.

Required supporting

information must also be submitted. B. For appropriate items of cost, reference the schedule that contains the required supporting data. Generally, supply supporting information for cost elements that are extraordinary (subcontracts or special testing costs above 25% of total costs, large equipment items, etc.). C. This should be the total cost of the research project. Any contractor cofunding should be shown on line 17 as a reduction from total costs.

D. This line should include (1) total fixed fee, (2) contractor cofunding, (3) third party cash cofunding, or (4) be blank, depending on the contract type. Fixed fee should be cofunded before any contractor in-kind cofunding is proposed.

Mechanical Damage at Welds

2

PART I – TECHNICAL PROPOSAL T 274-3553

UPDATED PIPELINE REPAIR MANUAL

PREPARED FOR

PRC INTERNATIONAL Pipeline Materials Committee

PREPARED BY

CC TECHNOLOGIES LABORATORIES, INC. CARL E. JASKE, PH.D., P.E. AUGUST 1, 2002

CC Technologies 6141 AVERY ROAD DUBLIN, OHIO 43016 614.761.1214 • 614.761.1633 fax www.cctechnologies.com

SUMMARY The objective of the proposed project is to develop and produce an update of PRCI Pipeline Repair Manual, PR-218-9307 (AGA L51716), which was published 1994. It will discuss response to anomaly or defect discovery, review repair methods, identify appropriate repairs for various types of defects, and provide generic guidelines for use of various repair methods taking into account current codes and regulations. CC Technologies will review existing and emerging pipeline repair technologies and evaluate them in comparison with those in the current repair manual. Then, the Manual will be revised to add and update the information on repair technologies. The review will be based on published literature, vendor literature, and industry experience. Methods for evaluating cost versus effectiveness of repair techniques will be included. The final product will be an updated printed and electronic Pipeline Repair Manual. The electronic version will be indexed and in Adobe Acrobat format and will include both written descriptions and illustrations of various repair methods. The Manual will include a generic repair procedure that can be used to upgrade or develop a company’s repair procedures. The generic procedure will be provided in an electronic, as well as printed, format so that an operator can easily tailor it for specific company use.

ii

CONTENTS INTRODUCTION............................................................................................................. 1 TECHNICAL DISCUSSION............................................................................................. 1 Objectives .................................................................................................................. 2 Work to Be Performed ............................................................................................... 2 Approach ................................................................................................................... 3 End Product ............................................................................................................... 3 Schedule.................................................................................................................... 4 Manpower Requirements........................................................................................... 4 SUPPORTING DATA ...................................................................................................... 4 Organization Information............................................................................................ 4 Corporate Qualifications ............................................................................................ 5 Related Project Descriptions...................................................................................... 5 Facilities..................................................................................................................... 9 CONTRACT REQUIREMENTS ...................................................................................... 9

iii

APPENDICES Appendix A – Résumés

iv

Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

INTRODUCTION The current PRCI Pipeline Repair Manual, PR-218-9307 (AGA L51716), was published in 1994. The Manual first discusses how an operator should respond to the discovery of an anomaly or defect. It then reviews various repair methods that are available and identifies appropriate repairs for the various types of defects. Finally, it provides a set of generic guidelines for use of the various repair methods. It is based on the state-of-the-art, accepted repair techniques, codes, and regulations in existence at the time of its development and has become an important benchmark for the development of pipeline damage assessment and repair strategies throughout the natural gas pipeline industry. Since its publication, there have been significant changes in codes and regulations as well as major advances in repair technology. U.S. DOT Regulations have been revised to accept new methods of permanent pipeline repair and to provide criteria for pipeline repair. GRI has completed extensive studies of reinforced composite repairs; the repair materials and procedures are now commercially available to pipeline operators. Others have developed similar composite repair methods. PRCI has developed new methods for in-service repair of pipelines by welding, and the in-service welding requirements of API and ASME Codes have been revised. Several pipeline operators have extensively evaluated the use of steel compression sleeves for repairing crack-like defects. Operators have also modified procedures for the application of standard steel sleeves and developed methods for improving and quantifying load transfer from the sleeve to the carrier pipe. Complete replacement of damaged pipeline segments with new sections of pipe is an obvious repair procedure. However, the replacement approach requires the pipeline segment to be taken out of service during the repair. Repairs that can be implemented without a service outage are preferred because they are less costly to implement than those that require pipeline shutdown and they do not significantly impact gas supply. The repair methods must satisfy the requirements of applicable codes, such as ASME B31.8, and regulations, such as CFR Title 49, Part 192. Because of these significant changes and developments in the gas pipeline industry, it is necessary to update the Pipeline Repair Manual to incorporate new information and include the best and most cost-effective practices that are available worldwide.

TECHNICAL DISCUSSION The project objectives, work to be performed, technical approach, end product, schedule, and manpower requirements are discussed in this section of the proposal.

CC Technologies Laboratories, Inc.

1

Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

Objectives The objective of the proposed work is to develop and produce an updated PRCI Pipeline Repair Manual. The Manual will be in both printed and electronic versions. Work to Be Performed CC Technologies proposes to achieve the project objective by thoroughly reviewing both existing and emerging pipeline repair technologies and then evaluating them in comparison with those described in the current Pipeline Repair Manual. Based on the comparative evaluations, areas of outdated or missing information will be identified. The Manual then will be revised and expanded as required to update and add its contents. There will be three steps in the review phase of the work. The first step will be a review and evaluation of the published literature on pipeline repair techniques. The literature review will concentrate on publications produced since 1994, when the current Pipeline Repair Manual was issued. The second step will be a review and evaluation of vendor publications and literature on repair techniques. We will contact vendors to make sure that we have the latest information on their products. The list of vendors contacted and incorporated into the manual will include linked Internet addresses for their web sites to facilitate use of the list. The third step will be a review and evaluation of industry experience with repair techniques for similar applications. Operators will be contacted and interviewed to obtain their experience and recommendations. We also will consider offshore repair techniques that have on-shore applications. Since we are doing similar reviews on our current PRCI project on Permanent Field Repair of SCC (GRI Contract Number 8511), we will expand that work to cover all types of anomalies and defects. CC Technologies’ extensive experience in pipeline integrity management uniquely qualifies us to undertake the proposed work. One particularly important topic is methods for evaluating the effectiveness versus cost of various repair techniques, especially for crack-like anomalies or defects where past repairs have often been replacement of pipe sections. Some repair techniques will either reduce the flaw severity or reduce the stress in the carrier pipe. Use of these techniques requires models for predicting the conditions for which no additional damage would be expected to occur. The models and their use will be included with the discussion of each repair applicable technique. Examples will be presented to illustrate their use in typical applications. As indicated above, CC Technologies will contact pipeline operators to obtain information on their experience with repairs. Much of this information is available in our files from past projects, and it will only be necessary to obtain permission to use it in the proposed research. This work has been for both U.S. and Canadian companies.

CC Technologies Laboratories, Inc.

2

Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

The final product will be an updated printed and electronic Pipeline Repair Manual. The electronic version will be indexed in Adobe Acrobat format, so it can be easily and readily used in the field. The Manual will include both written descriptions and illustrations of various repair methods, organized in a modular fashion to facilitate their use. It also will include a generic repair procedure that can be used to upgrade or develop a company’s repair procedures. The generic procedure will be provided in an electronic, as well as printed, format so that an operator can easily tailor it for specific company use. The electronic version will include an interactive interface to facilitate input of the information that is typically operator dependent. Approach We will prepare a written review of the recently published literature (since 1994) on pipeline repair methods and incorporate the results into the updated Repair Manual. We already have much of the relevant literature in our files from recent and current projects, so we will just make sure that no recent information is excluded. For example, we will review the proceedings of the ASME International Pipeline Conference (IPC) that is to be held in Calgary, September 29 through October 3, 2002. We also will prepare a written synopsis of vendor information on various applicable repair techniques. Again, we have most of the relevant information in our files, so we will only need to contact the vendors to obtain any recent updates on their products and repair methods. CC Technologies will contact pipeline operators to obtain information on their experience with repairs. Much of this information is available in our files from past industrial projects. In these cases, it will only be necessary to obtain permission to use that information on the proposed research. This includes work for both United States and Canadian companies that have addressed repairs of various types of defects in operating pipelines. Once the information has been collected, we will evaluate and compare it with that in the current Manual. Areas of the Manual where revisions and additions are required will be identified. Based on these results, the Manual will be updated. End Product This project will produce an updated printed and electronic PRCI Pipeline Repair Manual. The electronic version will facilitate field use and development of company specific procedures. The discussion of response to discovery of an anomaly or defect will take into account current codes and regulations. A summary table and flowchart of various repair options will be produced. It will indicate the types of anomalies or defects that can be repaired by each technique and the advantages and disadvantages of each

CC Technologies Laboratories, Inc.

3

Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

technique, including relative costs. The techniques to be included are pipe removal and replacement, grinding of metal, deposition of weld metal, steel sleeves, composite reinforcement, mechanical clamps, and hot taps. Methods of evaluating the effect of metal removal will be included in the discussion of grinding. Acceptable procedures for in-service welding will be presented. For reinforcement repairs, methods of determining load transfer will be presented. The generic repair procedure will incorporate the new and improved techniques. Schedule The proposed project will be completed within one year of the receipt of the contract. Manpower Requirements CC Technologies estimates that the following hours of manpower will be required to complete the proposed work: • • • •

Senior Group Leader Project Engineer Technologist Office Staff/Total

90 360 205 70

No subcontractors will be used. Based on the above requirements, the estimated project cost is $75,000. A detailed cost breakdown is given in Part II – Cost Proposal.

SUPPORTING DATA Supporting data on CC Technologies are included in this section of the proposal. They include organizational information, a discussion of corporate qualifications, descriptions of related past projects, and a description of available facilities. Organization Information CC Technologies is an engineering and research firm specializing in corrosion control, corrosion monitoring, and materials evaluation. We have laboratories in Columbus, Ohio and Calgary, Alberta, with a staff that includes Ph.D. scientists and engineers in a number of relevant fields including corrosion, metallurgical, mechanical, and welding engineering. Dr. Carl E. Jaske, P.E. will be the Principal Investigator on the proposed project. His resume is given in Appendix A. Dr. Jaske has conducted numerous investigations of pipeline and equipment mechanical integrity and fitness for service. His work includes studies of SCC, fatigue, fracture, and creep, as well as development of the CorLAS computer program for the assessment of crack-like flaws in pipelines. In addition, CC Technologies Laboratories, Inc.

4

Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

Dr. Jaske has worked with pipeline operators in the development of pipeline repair manuals and procedures, including innovative procedures for application to crack-like flaws. Mr. Patrick H. Vieth of CC Technologies will serve as a technical advisor. Mr. Vieth is well known for his pipeline integrity work. Resumes are given in Appendix A. Corporate Qualifications CC Technologies is a contract research and engineering organization that specializes in corrosion control, metallurgy, and structural integrity. The combination of research and engineering experience permits CC Technologies to provide our clients with research results that are tempered by engineering applicability and engineering services that are of the highest quality from both practical and fundamental aspects. CC Technologies is highly qualified to perform the proposed research program. Since its inception in 1985, CC Technologies has grown to a staff of over ninety people that includes Ph.D. scientists, M.S. researchers, and B.S. engineers. Degrees earned by the staff cover a range of relevant disciplines, including, Metallurgical Engineering, Materials Science, Mechanical Engineering, Theoretical and Applied Mechanics, Chemical Engineering, Electrical Engineering, and Civil Engineering, and Geology. The highly qualified staff at CC Technologies has performed research for PRCI, GRI, and individual pipeline companies on underground corrosion, cathodic protection, and stress corrosion cracking since inception of the company in 1985. Related Project Descriptions Presented below is a list of projects that were performed by members of the CC Technologies’ staff and are specifically related to the proposed project. Highlighted for each project description are the accomplishments of the particular project, the client, and the principal investigator. Permanent Field Repair of SCC – Review. This research project is exploring the fieldcompatible techniques for permanently repairing SCC cracks and colonies without the need for service interruption. A review report is being prepared. C. E. Jaske – PRCI (GRI Contract No. 8511), One year, 2002 Evaluation And Use Of A Steel Compression Sleeve To Repair Longitudinal Seam-Weld Defects. An engineering evaluation of a steel compression sleeve as a means to repair longitudinal seam-weld defects in pipelines was performed. The technique was used in a subsequent field program in which more than 200 such repair sleeves were installed on an operating crude oil pipeline. The steel compression sleeve evaluated has been commercially available since 1994 and has been installed on NPS 6 to NPS 42 pipelines in Canada and Mexico; primarily as a means to repair stress CC Technologies Laboratories, Inc.

5

Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

corrosion cracking, corrosion, and dents. The field program undertaken in 2000 represents the first use of this repair sleeve in the United States. C. E. Jaske – Industrial Client, One year, 2000 Compression Sleeve Repair of Gas Pipeline. CC Technologies developed a simplified model for evaluating the effectiveness of compression steel sleeves. It included the effect of load transfer between the sleeve and carrier pipe as a function of internal pressure, filler material, and sleeve temperature. The model was validated by finite-element stress analysis and strain-gage measurements on test sleeve installations. TransCanada Pipelines Sleeve Repair of Crack-Like Defects in ERW Seams in an Oil Pipeline. CC Technologies performed an engineering critical assessment (ECA) to develop guidelines for repair of crack-like defects in ERW seams in an oil pipeline. The evaluation included the detection capabilities of in-line inspection, the possibility of fatigue crack propagation, and the potential of fracture. Industrial Client Pipeline Repair Manual. CC Technologies developed a pipeline repair manual for the operator of an oil pipeline. The manual included procedures for various repair options that can be implemented depending on the type of defect encountered. The manual was approved by the U.S. DOT. Industrial Client Compression Sleeve Repair of Oil Pipeline. CC Technologies helped implement the first US use of a steel compression sleeve for pipeline repair. The method can be used to permanently repair longitudinal defects on an operating pipeline, including crack-like defects in ERW seams. The method is non-intrusive and requires no welding to the carrier pipe. In comparison with a Type B sleeve, which relies on tapping through the pipe and the sleeve to reduce hoop stress, the steel sleeve applies compression to the carrier pipe to reduce the hoop stress and prevent crack growth. Evaluation of the sleeve included measuring mechanical properties of the three different steels, modeling of the stresses in the carrier pipe and in the sleeve, and full-scale burst and fatigue testing. AEC Pipelines Ltd.'s Platte Pipeline Environmentally Assisted Cracking Low-pH SCC: Mechanical Effects on Crack Propagation The objective of this PRCI program was to determine the effects of mechanical factors such as hydrotesting on low-pH stress corrosion crack growth. All testing was performed in a low-pH (nearneutral-pH) electrolyte (NS4 solution) under cyclic load conditions on pre-cracked specimens of one X-65 line pipe steel. The cyclic load conditions in the testing were related to field conditions using the J-integral parameter. Crack growth was initiated in specimens under cyclic load conditions. Once steady state crack growth had been

CC Technologies Laboratories, Inc.

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Updated Pipeline Repair Manual

achieved, a typical hydrostatic test sequence was applied to the specimen. The initial cyclic load conditions were then reapplied to the specimen and crack growth was monitored to evaluate the effect of the hydrostatic testing on the rate of crack growth. It was found that some crack extension occurred during the simulated hydrostatic test sequence but the hydrostatic testing also promoted a decrease in the cracking velocity. The magnitude of the crack extension was slightly greater than that observed upon reloading, following unloading of the specimens. It was concluded that hydrostatic testing is no more harmful than simple depressurization of a pipeline. J. A. Beavers – CC Technologies, PRC International, 1994 – 1996 Investigations of Propagation of Low-pH SCC The objectives of this research for TransCanada Pipelines included: (1) to develop a laboratory technique to simulate the propagation of low-pH SCC, (2) to estimate rates of crack propagation, and (3) to evaluate the effects of environmental and metallurgical factors such as welding and pipe steel grade on crack growth rates. In this research, CC Technologies was one of the first laboratories to reproduce this form of cracking in the laboratory. An experimental technique that utilizes pre-crack compact type specimens was developed in the laboratory studies. The crack propagation rate information generated in the research has been utilized to assist TCPL in establishing safe hydrostatic testing intervals. The studies of metallurgical factors have demonstrated that some weld structures exhibit much higher crack propagation rates than the wrought steel. J. A. Beavers – TransCanada Pipelines Ltd., 1992 – 1997 Assessment Of Line Pipe Susceptibility To Stress Corrosion Cracking Under Tape, Enamel And Fusion Bonded Epoxy Coatings. The objectives of this PRC program were to evaluate the susceptibility of line pipe to stress corrosion cracking (SCC) when coated with polyethylene (PE) tape, coal tar enamel (CTE), and fusion bonded epoxy (FBE) and to establish whether SCC can occur on FBE coated pipelines. The program was divided into two tasks: Task 1 - Coating Characterization, and Task 2 - SCC Testing. The purposes of Task 1 were: (1) to establish a standard specimen geometry, incorporating a disbonded coating, for electrochemical and SCC tests, (2) to evaluate the effect of coating type on the potential gradients beneath a disbonded coating, and (3) to correlate the testing described above with standard industrial tests for coating evaluation. In Task 1, electrochemical impedance spectroscopy (EIS) and other electrochemical techniques were used for coating characterization. The purpose of Task 2 was to evaluate the individual and combined roles of surface preparation and cathodic protection shielding on SCC susceptibility. Two types of SCC tests were performed. Tapered Tensile SCC tests are being performed on uncoated specimens of line pipe steel to evaluate the role of surface preparation alone on SCC surface susceptibility. Cyclic load SCC tests were performed on coated straight-sided tensile specimens to evaluate the roles of cathodic protection shielding and surface preparation on SCC susceptibility. J. A. Beavers – CCT, American Gas Association (1989-1991). Investigation Of Line Pipe Steel That Is Highly Resistant To SCC. Principal Investigator on a Pipeline Research Committee of the American Gas Association

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Updated Pipeline Repair Manual

(A.G.A.) program in which the relationship between metallurgical characteristics of line pipe steel and stress corrosion cracking susceptibility was investigated. The goal of this work was to understand the influence of processing parameters on those characteristics that control SCC susceptibility so that steels can be made consistently resistant to SCC. Experimental techniques used included potentiodynamic polarization, slow strain rate and constant load and fracture mechanics tests. J. A. Beavers - CCT, Client: American Gas Association (1983-1984). Test Method For Defining Susceptibility Of Line Pipe Steels To SCC. Principal Investigator on an A.G.A. program in which a standardized test method for defining the SCC susceptibility of line pipe steels was developed. Previous studies had identified the optimum environmental conditions and specimen geometry for performing such an evaluation and the aim of the work was to identify the optimum loading conditions and test time. J. A. Beavers - CCT, Client: American Gas Association (1984-1986). Modeling Of Stress-Corrosion Crack Initiation And Propagation. Program Manager of a program in which the initiation and propagation of stress-corrosion cracking in natural gas pipelines were being modeled. The goals of the research included the development of a methodology to estimate hydrostatic retest frequencies in operating pipelines and the development of SCC resistant steels. J. A. Beavers - CCT, Industrial Client (1986). Surface Related Factors Affecting Stress-Corrosion Cracking. Principal Investigator of an A.G.A. program to investigate the surface related factors affecting SCC initiation. The objective of the research was to identify those surface factors that affect and control SCC initiation to reduce the variation in the results of SCC tests and to optimize surface properties of operating pipelines. J. A. Beavers - CCT, Client: The American Gas Association (1985). Limitations Of The Slow Strain Rate Test For Stress Corrosion Cracking Testing. Materials Technology Institute of the Chemical Process Industries (MTI) Report Number 61. The overall objective of the program, which was performed for MTI, was to determine if SSR testing methods yield useful data in predicting SCC susceptibility of metals used in the Chemical Process Industry (CPI). The specific objectives of the Year 1 research were to identify the alloy-environment systems in which the SSR technique produces anomalous SCC results, identify which test variables must be controlled to make the SSR test results applicable to the CPI, identify the limitations of the SSR test technique, and identify what further program support is needed to resolve unanswered questions. The open literature was surveyed and contacts were made within the industry by means of a questionnaire and follow-up telephone calls. J. A. Beavers and G. H. Koch, Client: MTI. (1990) Stress Corrosion Cracking Of Low Strength Carbon Steels In Candidate High Level Waste Repository Environments. Nuclear Regulatory Commission Report NUREG/CR-3861, February 1987. Co-authors on a report of a literature survey

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Part I – Technical Proposal (TP 274-3553)

Updated Pipeline Repair Manual

performed to identify the potential stress corrosion cracking agents for low strength carbon and low alloy steels in repository environments. It was found that a number of potent cracking agents are present, but stress corrosion cracking is relatively unlikely in the bulk repository environments because of the low concentration of these species. J. A. Beavers, N. G. Thompson - CCT, Client: Nuclear Regulatory Comm. (1985-1986). Stress Corrosion Cracking Environments. A series of programs to establish the likely stress corrosion cracking environment containing CO2 for buried gas pipelines. The work includes examining changes to the environment at the pipe surface and beneath a coating during cathodic protection in the presence of CO2. J. A. Beavers - CCT, Industrial Client (1988). Estimating Intervals For Hydrostatic Retesting. Developed a Monte Carlo type model for estimating the safe time between hydrotests for a pipeline in which stress corrosion cracks are propagating. J. A. Beavers - CCT, Industrial Client (1987). Facilities CC Technologies is a fully equipped corrosion testing and research laboratory specializing in the evaluation of materials properties, materials selection, corrosion, corrosion control, and design and development of instrumentation and engineering software. CC Technologies has continued to grow since its inception in 1985 and has more than 25,000 square feet of space in its current office and laboratory facility.

CONTRACT REQUIREMENTS CC Technologies accepts the terms and conditions of its current standard contract agreements with PRC International. This same type of contract is proposed for this work.

CC Technologies Laboratories, Inc.

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APPENDIX A Résumés

6141 Avery Road, Dublin, OH 43016-8761 USA TEL 614-761-1214 FAX 614-761-1633

CARL E. JASKE, Ph.D., P.E. Dr. Jaske is Senior Group Leader of Materials Engineering and Research for CC Technologies. He is leading work in the areas of mechanical integrity, fitness-for-service, and remaining-life assessment of structures and equipment. He has developed the www.Fitness4Service.com web site and a short course on the API 579 Fitness-For-Service recommended practice. His work includes projects on fatigue, corrosion-fatigue, creep, creep-crack growth, hightemperature properties, in-service aging, and failure analysis of structural materials. These projects typically incorporate both analytical assessments and experimental evaluations of failure lives and material damage. Much of his work has been concerned with relating the physical metallurgy of carbon steels, low-alloy steels, stainless steels, and heat-resistant alloys to their mechanical properties and in-service aging. This research includes wrought products, castings, and weldments. Dr. Jaske has evaluated the effects of elevated temperatures and corrosive environments on mechanical properties of materials. He has developed and applied fracture-mechanics approaches for assessing creep, fatigue, and stress-corrosion cracking degradation and failure of engineering components, such as in-service pressure vessels and piping. He has served on industry and government advisory groups for life extension and remaining life assessment of key engineering equipment and facilities. Also, he has developed computer programs for life assessment of welded steam pipes, reformer furnace tubes, and pressure vessels. A major portion of Dr. Jaske’s work, since joining CC Technologies in 1990, has addressed the mechanical integrity of oil and gas pipelines. He developed a model for predicting the failure and remaining life of pipelines with local defects, including crack-like flaws, and commercialized the CorLAS computer program to make the model easily usable by engineers. His work on pipelines includes evaluations of stress-corrosion cracks, corrosion flaws, weld defects, dents, gouges, and dents with corrosion. He utilizes inspection and operational data to predict failures and remaining service life and advises companies on implementing and maintaining appropriate integrity programs. Education B.S., B.S., M.S., Ph.D.,

Liberal Arts and Sciences (Mathematics) with High Honors, University of Illinois General Engineering with Highest Honors, University of Illinois Theoretical and Applied Mechanics, University of Illinois Metallurgical Engineering, The Ohio State University

Experience Senior Group Leader Senior Research Scientist

CC Technologies Battelle Memorial Institute

1991 – Present 1967 – 1990

Resume: Carl E. Jaske, Ph.D., P.E. Page 2 Professional Organizations Fellow, American Society of Mechanical Engineers (ASME) Member, American Society for Testing and Materials (ASTM) Member, NACE International Professional Activities Program Chair, ASME Pipeline Systems Subdivision Associate Editor, Journal of Pressure Vessel Technology Past Chair, ASME Pressure Vessels and Piping (PVP) Division Past Chair of Central Ohio Section of ASME Technical Program Chairman (1992) and General Chairman (1993) of ASME PVP Conferences API Working Group on Pipeline Integrity Management Standard ASME Boiler and Pressure Vessel Code Committee, Subgroup on Fatigue Strength ASTM Committee E8 on Fatigue and Fracture Short Courses/Forums/Tutorials ASME Short Course on API-579 Fitness-For-Service Evaluation of Vessels, Tanks, and Piping ASME Short Course on Assessment of Material Aging and Prediction of Remaining Life Developer of NDE Demonstration Forum, 1996-2001 ASME PVP Conferences Tutorial on Remaining Life Prediction, 1987 PVP Conference Tutorial on Assessment of Material Degradation in Service, 1989 PVP Conference Tutorial on Life Extension and Remaining Life Assessment, 1995 PVP Conference Engineering Registration Dr. Jaske is a Registered Professional Engineer in the States of Ohio and Alaska. Relevant Experience Integrity of Oil and Gas Pipelines. Performed numerous projects on evaluating the integrity of oil and gas pipelines, including failure analyses. The CorLAS computer program was developed to predict the failure of pipelines with local defects, including crack-like flaws. An independent evaluation of available models for assessing SCC flaws showed that CorLAS gave the most accurate predictions of fourteen actual Canadian pipeline failures. Other projects include evaluation of stresses during hot tapping, assessment of dents and gouges, and predictions of remaining fatigue life. Fatigue Strength Reduction Factors for Welds. Completed an interpretative review of fatigue strength reduction and stress concentration factors for welds in pressure vessels and piping for the Welding Research Council (Bulletin 432, June 1998). Available procedures for evaluating the fatigue strength of welded structures were reviewed and evaluated. Guidelines for developing weld-joint fatigue strength reduction factors were developed. Aging of Nuclear Power Plant Components. Participated in the U.S. Nuclear Regulatory Commission's Nuclear Plant Aging Research (NPAR) program to help develop methodology for residual-life assessment of key safety-related nuclear-plant components, including evaluation of the thermal embrittlement of cast stainless steels.

Resume: Carl E. Jaske, Ph.D., P.E. Page 3 Relevant Experience (Continued) Remaining Life Assessment. Conducted numerous projects to assess the remaining life of operating equipment in industrial plants. This work included testing and examination of material samples and analytical calculations. Examples of equipment that have been evaluated include steam-turbine rotors, steam pipes, reformer furnace tubes, headers, superheater and reheater tubes, and pressure vessels. Creep-Fatigue Crack Growth. Developed a fracture-mechanics model and life-assessment approach for creep-fatigue crack growth interaction effects and performed creep, low-cycle fatigue, and creep-fatigue crack propagation experiments on Type 316 Stainless Steel. Creep Fracture and Creep-Fatigue Life of Welded Steam Lines. Developed personal computer codes to help assess the remaining creep and creep-fatigue life and the potential for unstable fracture of 2-1/4Cr-1Mo and 1-1/4Cr-1/2Mo welded steam pipes, including seamwelded hot reheat steam lines. Failure Analyses. Performed failure analyses of various components used in industrial equipment, including the failure of a large motor shaft, the failure of a generator rotor, the failure of a mold used for casting bronze alloys, steam pipe failures, and failures of fired furnace tubes. Long-Life Corrosion Fatigue Evaluation for the Development of Alloys Used in PaperMaking Equipment. Performed long-life (107 to 109 cycles to failure) corrosion-fatigue studies of cast alloys--bronze, martensitic stainless steel, austenitic stainless steel, and duplex stainless steel--in white water (low pH, chloride, sulfate, thiosulfate) environments; to realistically simulate expected service conditions, tests have been performed at low stresses for periods of several months to more than one year. Selected Publications 1.

C. E. Jaske and H. Mindlin, “Elevated-Temperature Low-Cycle Fatigue Behavior of 21/4Cr-1Mo and 1Cr-1Mo-1/4V Steels,” 2-1/4 Chrome 1 Molybdenum Steel in Pressure Vessels and Piping, ASME, New York (1971), pp. 137-210.

2.

C. E. Jaske, et al., “Combined Low-Cycle Fatigue and Stress-Relaxation Behavior of Alloy 800 and Type 304 Stainless Steel at Elevated Temperature,” Fatigue at Elevated Temperatures, STP 520, ASTM, Philadelphia (1973), pp. 365-376.

3.

C. E. Jaske, et al., “Development of Elevated-Temperature Fatigue Design Information for Type 316 Stainless Steel,” Paper C163/73, International conference on Creep and Fatigue in Elevated-Temperature Applications, Conference Publication 13, I. Mech. E., London (1973), pp. 163.1-163.7.

4.

C. E. Jaske, “Thermal-Mechanical, Low-Cycle Fatigue of AISI 1010 Steel,” Thermal Fatigue of Materials and Components, STP 612, ASTM, Philadelphia (1976), pp. 170198.

5.

C. E. Jaske, “Low-Cycle Fatigue of AISI 1010 Steel at Temperatures Up to 1200°F (649°C),” Journal of Pressure Vessel Technology, Vol. 99, No. 3 (1977), pp. 423-443.

6.

C. E. Jaske and W. J. O'Donnell, “Fatigue Design Criteria for Pressure Vessel Alloys,” Journal of Pressure Vessel Technology, Vol. 99, No. 4 (1977), pp. 584-592.

Resume: Carl E. Jaske, Ph.D., P.E. Page 4 Selected Publications (Continued) 7.

C. E. Jaske, “Corrosion Fatigue of Structural Steels in Seawater and for Offshore Applications,” Corrosion-Fatigue Technology, STP 642, ASTM, Philadelphia (1978), pp. 19-47.

8.

C. E. Jaske and J. A. Begley, “An Approach to Assessing Creep/Fatigue Crack Growth,” Ductility and Toughness Considerations in Elevated Temperature Service, MPC-8, ASME, New York (1978), pp. 391-409.

9.

C. E. Jaske and N. D. Frey, “Long-Life of Type 316 Stainless Steel at Temperatures up to 593°C,” Journal of Engineering Materials and Technology, Vol. 104, No. 2 (1982), pp. 137-144.

10.

C. E. Jaske, et al., “Predict Reformer Furnace Tube Life,” Hydrocarbon Processing, Vol. 62, No. 1 (1983), pp. 63-68.

11.

C. E. Jaske, “Creep-Fatigue-Crack Growth in Type 316 Stainless Steel,” Advances in Life Prediction Methods, ASME, New York (1983), pp. 93-103.

12.

With F. A. Simonen, “A Computational Model for Predicting the Life of Tubes Used in Petrochemical Heater Service,” Journal of Pressure Vessel Technology, Vol. 107, No. 3 (1985), pp. 239-246.

13.

C. E. Jaske, “Long-Term Creep-Crack Growth Behavior of Type 316 Stainless Steel,” Fracture Mechanics: Eighteenth Symposium, STP 945, ASTM, Philadelphia (1988), pp. 867-877.

14.

C. E. Jaske and A. P. Castillo, “Corrosion Fatigue of Cast Suction-Roll Alloys in Simulated Paper-Making Environments,” Materials Performance, Vol. 26, No. 4 (1987), pp. 37-43.

15.

C. E. Jaske, “Techniques for Examination and Metallurgical Damage Assessment of Pressure Vessels,” Performance and Evaluation of Light Water Reactor Pressure Vessels, ASME, New York (1987), pp. 103-114.

16.

C. E. Jaske and R. W. Swindeman, “Long-Term Creep and Creep-Crack-Growth Behavior of 9Cr-1Mo-V-Nb Steel,” Advances in Materials Technology for Fossil Power Plants, ASM International, Metals Park, Ohio (1987), pp. 251-258.

17.

C. E. Jaske, “Life Assessment of Hot Reheat Steam Pipe,” Paper 2.9.2, Proc, International Conference on Life Extension and Assessment, Volume II, The Hague, Netherlands (June 13-15, 1988), pp. 185-193 [also in the Journal of Pressure Vessel Technology, Vol. 112, No. 1 (1990), pp. 20-27.]

18.

C. E. Jaske, “Fatigue Curve Needs for Higher Strength 2-1/4Cr-1Mo Steel for Petroleum Process Vessels,” Fatigue Initiation, Propagation, and Analysis for Code Construction, MPC Vol. 29, ASME, New York (1988), pp. 181-195 [also in the Journal of Pressure Vessel Technology, Vol. 112, No. 4 (1990), pp. 323-332.]

Resume: Carl E. Jaske, Ph.D., P.E. Page 5 Selected Publications (Continued) 19.

C. E. Jaske and V. N. Shah, “Life Assessment Procedure for LWR Cast Stainless Steel Components,” Proceedings of the Fourth International Symposium on Environmental Degradation of Materials in Nuclear Power Systems-Water Reactors, National Association of Corrosion Engineers, Houston, Texas (1990), pp. 3-66 to 3-83.

20.

C. E. Jaske and V. N. Shah, “Life Assessment Procedures for Major LWR Components: Cast Stainless Steel Components,” NUREG/CR-5314, EGG-2562, Vol. 3 (October, 1990).

21.

With B. S. Majumdar and M. P. Manahan, “Creep Crack Growth Characterization of Type 316 Stainless Steel Using Miniature Specimens,” International Journal of Fracture, Vol. 47 (1991), pp. 127-144.

22.

C. E. Jaske and R. Viswanathan, “Predict Remaining Life of Equipment for High Temperature-Pressure Service,” Paper Number 213, Corrosion 90, Las Vegas, Nevada (April 23-27, 1990).

23.

C. E. Jaske and R. Viswanathan, “Remaining-Life Prediction for Equipment in HighTemperature/Pressure Service,” Materials Performance, Vol. 30, No. 4 (1991), pp. 6167.

24.

With A. P. Castillo and G. M. Michel, “Sandusky Alloy 86, A New Suction Roll Shell Material with Improved Corrosion-Fatigue Strength in Corrosive White Waters,” presented at the 24th EUCEPA Technical Conference, SPCI 90 International Exhibition, Stockholm, Sweden (May 7-10, 1990).

25.

With B. S. Majumdar, “Creep-Fatigue Crack Growth in 9Cr-1Mo-V-Nb Steel,” presented at the 1991 ASME Pressure Vessel and Piping Conference, San Diego, California (June 23 – 27, 1991).

26.

C. E. Jaske and F. A. Simonen, “Creep-Rupture Properties For Use In The Life Assessment Of Fired Heater Tubes,” Proceedings of the First International Conference On Heat-Resistant Materials, ASM International (1991), pp. 485-493.

27.

With G. H. Koch, “Prediction of Remaining Life of Equipment Operating in Corrosive Environments,” NACE Conference on Life Prediction of Corrodible Structures, Cambridge, UK (September 23-26, 1991) and Kauai, Hawaii (November 5-8, 1991).

28.

C. E. Jaske and G. H. Koch, “Failure and Damage Mechanisms – Embrittlement, Corrosion, Fatigue, and Creep,” Technology for the 90’s, ASME, New York (July, 1993), pp., 7-39.

29.

C. E. Jaske, “Review of Materials Property Relationships for Use in Computerized Life Assessment,” Fourth International Symposium of the Computerization and Use of Materials Property Data, ASTM, Gaithersburg, Maryland (October 6-8, 1993).

30.

C. E. Jaske, “Life Prediction in High-Temperature Structural Materials,” Fatigue and Fracture of Aerospace Structural Materials, AD-Vol. 36, ASME, New York (1993), pp. 59-71.

Resume: Carl E. Jaske, Ph.D., P.E. Page 6 Selected Publications (Continued) 31.

C. E. Jaske, “The Effects of High-Temperature Exposure on the Properties of HeatResistant Alloys,” Paper No. 397, Corrosion 94, Baltimore (February 28-March 4, 1994).

32.

C. E. Jaske, “Remaining Life Evaluation of Pressure Vessels and Piping – General Approach and Case Histories,” 3rd International Conference & Exhibition on Improving Reliability in Petroleum Refineries and Chemical Plants, Houston (November 15-18, 1994).

33.

C. E. Jaske, “Review of Materials Property Relationships for Use in Computerized Life Assessment,” Computerization and Networking of Materials Databases, STP 1257, ASTM, Philadelphia (1995), pp. 194-208.

34.

With B. A. Harle and J. A. Beavers, “Mechanical and Metallurgical Effects on Low-pH Stress Corrosion Cracking of Natural Gas Pipelines,” Paper No. 646, Corrosion 95, NACE International, Houston (1995).

35.

C. E. Jaske and R. Viswanathan, “Properties of Cr-Mo Steels after Long-Term HighTemperature Service,” Service Experience, Structural Integrity, Severe Accidents, and Erosion in Nuclear and Fossil Plants, PVP-Vol. 303, ASME, New York (1995), pp. 235-245.

36.

C. E. Jaske, “Remaining Life Assessment of High-Temperature Components,” HeatResistant Materials II, Proceedings of the 2nd International Conference on HeatResistant Materials, ASM International, Materials Park, Ohio (1995), pp. 405-412.

37.

C. E. Jaske, J. A. Beavers, and N. G. Thompson, “Improving Plant Reliability Through Corrosion Monitoring,” Fourth International Conference on Process Plant Reliability, Gulf Publishing Company, Houston (November 14-17, 1995).

38.

C. E. Jaske and J. A. Beavers “Effect of Corrosion and Stress-Corrosion Cracking on Pipe Integrity and Remaining Life,” Proceedings of the Second International Symposium on the Mechanical Integrity of Process Piping, MTI Publication No. 48, Materials Technology Institute of the Chemical Process Industries, Inc., St. Louis (1996), pp. 287-297.

39.

C. E. Jaske, J. A. Beavers, and B. A. Harle, “Effect of Stress Corrosion Cracking on Integrity and Remaining Life of Natural Gas Pipelines,” Corrosion 96, Denver, Colorado, March 1996, NACE Paper No. 255.

40.

C. E. Jaske and J. A. Beavers, “Fitness-for-Service Evaluation of Pipelines in GroundWater Environments,” PRCI / EPRG 11th Biennial Joint Technical Meeting on Line Pipe Research; Arlington, Virginia; April 8 – 10, 1997; Paper No. 12.

41.

J. A. Beavers and C. E. Jaske, “Near-Neutral pH SCC In Pipelines: Effects Of Pressure Fluctuations On Crack Propagation,” Corrosion NACExpo 98, NACE International, Paper No. 98257, San Diego, California (March 1998).

42.

C. E. Jaske and J. A. Beavers, “Review and Proposed Improvement of a Failure Model for SCC of Pipelines,” International Pipeline Conference — Volume 1, ASME International, New York, 1998, pp. 439-445.

Resume: Carl E. Jaske, Ph.D., P.E. Page 7 Selected Publications (Continued) 43.

C. E. Jaske, “Interpretive Review of Weld Fatigue-Strength-Reduction and StressConcentration Factors," Fatigue Strength Reduction and Stress Concentration Factors for Welds in Pressure Vessels and Piping, WRC Bulletin 432, Welding Research Council, Inc., New York, June, 1998.

44.

C. E. Jaske, “Integrity and Remaining Life of High-Temperature Equipment,” CIM Symposium on Materials for Resource Recovery and Transport, Calgary, Alberta, Canada, August 16 – 19, 1998.

45.

C. E. Jaske and J. A. Beavers, “Predicting the Failure and Remaining Life of Gas Pipelines Subject to Stress Corrosion Cracking,” International Gas Research Conference, San Diego, California; November 8 – 11, 1998; Paper TS0-13.

46.

J. A. Beavers and C. E. Jaske, “SCC of Underground Pipelines: A History of The Development of Test Techniques,” Corrosion NACExpo 99, NACE International, Paper No. 99142, San Antonio, Texas (April 1999).

47.

C. E. Jaske and J. A. Beavers, "Fitness-For-Service Evaluation of Pipelines with StressCorrosion Cracks or Local Corrosion," International Conference on Advances in Welding Technology (ICAWT ’99), Galveston, Texas USA, October 26-28, 1999.

48.

With M. P. H. Brongers, J. A. Beavers and B. S. Delanty, “Influence of Line-Pipe Steel Metallurgy on Ductile Tearing of Stress-Corrosion Cracks During Simulated Hydrostatic Testing," 2000 International Pipeline Conference – Volume 2, ASME International, New York, 2000, pp. 743-756.

49.

With M. P. H. Brongers, J. A. Beavers and B. S. Delanty, “Effect of Hydrostatic Testing on Ductile Tearing of X-65 Linepipe Steel with Stress Corrosion Cracks," Corrosion, Vol. 56, No. 10, 2000, pp. 1050-1058.

50.

C. E. Jaske and J. A. Beavers, "Fitness-For-Service Assessment for Pipelines Subject to SCC," Pipeline Pigging, Integrity Assessment, and Repair Conference, Houston, Texas, February 1-2, 2000.

51.

M. P. Brongers and C. E. Jaske, "Creep-Rupture of Service-Exposed Base Metal and Weldments of Alloy 800H," Aging Management, Component and Piping Analysis, Nondestructive Engineering Monitoring and Diagnostics – 2000, PVP-Vol. 409, ASME International, New York, 2000, pp. 143-153.

52.

C. E. Jaske, "Fatigue Strength Reduction Factors for Welds in Pressure Vessels and Piping," Pressure Vessels and Piping Codes and Standards – 2000, PVP-Vol. 407, ASME International, New York, 2000, pp. 279-297.

53.

C. E. Jaske, "Fatigue Strength Reduction Factors for Welds in Pressure Vessels and Piping," Journal of Pressure Vessel Technology, Vol. 122, No. 3, 2000, pp. 297-304.

54.

C. E. Jaske and R. Viswanathan, "Use of Miniature Specimens for Creep-Crack-Growth Testing," Understanding and Predicting Material Degradation, PVP-Vol. 413, ASME International, New York, 2000, pp. 69-79.

Resume: Carl E. Jaske, Ph.D., P.E. Page 8 Selected Publications (Continued) 55.

C. E. Jaske and R. Viswanathan, "Use of Miniature Specimens for Creep-Crack-Growth Testing," Journal of Engineering Materials and Technology, Vol. 122, No. 3, 2000, pp. 327-332.

56.

C. E. Jaske and John A. Beavers, “Evaluating the Remaining Strength and Life of Pipelines Subject to Local Corrosion or Cracking.” NACE Northern Area Premiere Conference (Corrosion Prevention 2000), Toronto, Ontario, Canada, November 2000.

57.

P. H. Vieth, D. A. Soenjoto, and C. E. Jaske, “Transverse Field Inspection (TFI) Program Results,” 52nd Annual Pipeline Conference, San Antonio, Texas USA, April 17-18, 2001.

58.

C. E. Jaske, “Development of Miniature-Specimen Test Techniques For Measuring Creep-Crack-Growth Behavior,” The 7th International Conference on Creep and Fatigue at Elevated Temperatures, National Institute for Materials Science, Tsukuba, Japan, June 3-8, 2001.

59.

M. P. Brongers, C. J. Maier, C. E. Jaske, P. H. Vieth, M. D. Wright, and R. J. Smyth, “Tests, Field Use Support Compression Sleeve for Seam-Weld Repair,” Oil & Gas Journal, Volume 99.24, pp. 60 – 66, June 11, 2001.

60.

M. P. Brongers, C. J. Maier, C. E. Jaske, P. H. Vieth, M. D. Wright, and R. J. Smyth, “Evaluation and Use of a Steel Compression Sleeve to Repair Longitudinal Seam-Weld Defects,” 52nd Annual Pipeline Conference, San Antonio, TX, April 17 – 18, 2001.

61.

B. E. Shannon and C. E. Jaske, “A Practical Life Assessment Approach For Hydrogen Reformer Tubes,” Proceedings of NACE International Northern Area Conference, Edmonton, Alberta, Canada, February 18-21, 2002.

62.

C. E. Jaske, P. H. Vieth, and J. A. Beavers, “Assessment of Crack-Like Flaws in Pipelines,” Corrosion NACExpo 2002, NACE International, Paper No. 02089, Denver, Colorado (April 2002).

Books and Software C. E. Jaske, J. H. Payer and V. S. Balint, Corrosion Fatigue of Metals in Marine Environments, Battelle Press, Columbus Ohio (1981). C. E. Jaske, Coordinating Editor, Residual-Life Assessment, Nondestructive Examination, and Nuclear Heat Exchanger Materials, PVP-Vol. 98-1, ASME, New York (1985). C. E. Jaske, et al., Editors, Life Extension and Assessment: Nuclear and Fossil Power-Plant Components, PVP-Vol. 138/NDE-Vol. 4, ASME, New York (1988). With W. H. Bamford and R. C. Cipolla, Editors, Service Experience in Operating Plants – 1991, PVP-Vol. 221, ASME, New York (1991). ReHeat12™, pcTUBE™, and CreepLife™ computer programs for life assessment of hightemperature steam pipes, furnace tubes, and pressure vessels.

Resume: Carl E. Jaske, Ph.D., P.E. Page 9 Books and Software (Continued) CorLAS™ computer program for evaluating the effects of corrosion and stress-corrosion cracking on the structural integrity of pipes and vessels.

6141 Avery Road, Dublin, OH 43016-8761 USA TEL 614-761-1214 FAX 614-761-1633

PATRICK H. VIETH Mr. Vieth is Vice President of CC Technologies Services, Inc., (CC Technologies). Mr. Vieth is a Mechanical Engineer and has fifteen years of experience in the field of pressure vessel fracture behavior and defect assessment methods for transmission pipeline systems. Prior to joining CC Technologies, Mr. Vieth held positions with Battelle and Kiefner & Associates, Inc. Mr. Vieth’s expertise is primarily directed toward assisting the operators of transmission pipeline systems with the development and implementation of short-term and long-term pipeline integrity management programs. Specifically, he works with operators to develop programs to reduce the likelihood of failures through in-line inspection, hydrostatic testing, defect assessment, risk assessment, and fitness-for-purpose assessment. Mr. Vieth has been active in research and the development of innovative solutions within the pipeline industry. He was a key-contributor in the validation and implementation of the RSTRENG corrosion assessment method. RSTRENG is recognized within the Federal Code of Federal regulations for transmission pipeline systems as a method for assessing the remaining pressurecarrying capacity of pipe which has sustained wall loss due to corrosion. Mr. Vieth was also a team member that developed a Transverse Field Inspection (TFI) program to address a pipeline operator’s specific integrity concern. The TFI program utilized a new technology to identify longitudinal seam weld defects that could pose an integrity concern to the pipeline operations. Success in the development, validation, and implementation of this TFI program resulted in the Department of Transportation (DOT) Office of Pipeline Safety’s (OPS) acceptance of this program in lieu of mandated hydrostatic testing to verify the integrity of the pipeline system. Mr. Vieth has conducted several full-scale testing programs to evaluate the fracture behavior of defects in pressure vessels. These testing programs were conducted under the sponsorship of the Nuclear Regulatory Commission (NRC) to evaluate the fracture behavior of power plant piping subjected to dynamic loading. Additional full-scale testing programs have been conducted to evaluate the pressure-carrying capacity of defects identified in transmission pipeline systems (natural gas and hazardous liquids) and removed from services. These tests have been used to evaluate the pressure-carrying capacity of pipe sections containing defects such as corrosion-caused metal loss and longitudinal seam weld defects. Education B.S., Mechanical Engineering, The Ohio State University

Resume: Patrick H. Vieth Page 2 Experience Vice President

CC Technologies Services, Inc.

2001 – present

Senior Group Leader

CC Technologies Services, Inc.

1999 – 2001

Manager, Integrity Solutions

Pipeline Integrity International

Senior Mechanical Engineer Associate

Kiefner & Associates, Inc. Worthington, OH

1991 – 1999

Principal Research Scientist

Battelle, Columbus, OH

1985 – 1991

1999

Professional Activities National Association of Corrosion Engineers (NACE), Committee Chairman, T-10E-6 (Defect Assessment) American Society of Mechanical Engineers (ASME), #1271881, Past Chairman – Central Ohio Section of ASME, (1990). Selected Publications Risk Assessment Kiefner, J. F., Vieth, P. H., Orban, J. E., and Feder, P. I., “Methods for Prioritizing Pipeline Maintenance and Rehabilitation,” American Gas Association, Pipeline Research Committee, Catalog No. L51631, September 28, 1990. Corrosion Assessment Kiefner, J. F., and Vieth, P. H., “A Modified Criterion for Evaluating the Remaining Strength of Corroded Pipe,” American Gas Association, Pipeline Research Committee, Catalog No. L51609, December 22, 1989. Vieth, P. H., and Kiefner, J. F., “Database of Corroded Pipe Tests,” American Gas Association, Pipeline Research Committee, Pipeline Research Committee, Catalog No. L51689, April 4, 1989. Kiefner, J. F., and Vieth, P. H., “Evaluating Pipe: New Method Corrects Criterion for Evaluating Corroded Pipe,” Oil and Gas Journal, August 6, 1990. Kiefner, J. F., and Vieth, P. H., “Evaluating Pipe: PC Program Speeds New Criterion for Evaluating Corroded Pipe,” Oil and Gas Journal, August 20, 1990. Vieth, P. H., and Kiefner, J. F., “RSTRENG User’s Manual,” American Gas Association, Pipeline Research Committee, Catalog No. L51688, March 31, 1993. Kiefner, J. F., and Vieth, P. H., “The Remaining Strength of Corroded Pipe,” American Gas Association, Eighth Symposium on Line Pipe Research, Houston, Texas, September 1993. Kiefner, J. F., Vieth, P. H., and Roytman, I., “Continued Validation of RSTRENG,” American Gas Association, Catalog Number L51749, December 1996.

Resume: Patrick H. Vieth Page 3 Selected Publications (continued) Pipeline Failures Vieth, P. H., Roytman, I., Mesloh, R. E., and Kiefner, J. F., “Analysis of DOT Reportable Incidents for Gas Transmission and Gathering Pipelines – 1985 through 1994,” American Gas Association, Pipeline Research Committee. Vieth, P. H., et al., “DOT Incident Data Analysis,” American Gas Association, PRC International, th 9 Symposium on Line Pipe Research, Houston, Texas, September 1996. Vieth, P. H., Maxey, W. A., Mesloh, R. E., Kiefner, J. F., and Williams, G. W., “Investigation of the Failure in GRI’s Pipeline Simulation Facility Flow Loop,” Gas Research Institute, March 15, 1996. In-Line Inspection Vieth, P. H., Ashworth, “In-Line Inspection,” International Pipeline Conference. Vieth, P. H., Rust, S. W., Johnson, E. R., and Cox, M. J., “In-Line Characterization and th Assessment,” American Gas Association, PRC International, 9 Symposium on Line Pipe Research, Houston, Texas, September 1996. Rust, S. W., Vieth, P. H., Johnson, E. R., and Cox, M. J., “Corrosion Pig Performance and Risk Assessment,” Pipes and Pipelines International, Pipeline Pigging Conference, Houston, Texas, February 1996. Vieth, P. H., Rust, S. W., Johnson, E. R., and Cox, M. J., “Corrosion Pig Performance Evaluation,” th American Society of Mechanical Engineers, American Petroleum Institute, 7 Annual Energy Week Conference, Houston, Texas, January 1996. Vieth, P. H., Rust, S. W., Johnson, E. R., and Cox, M. J., “Corrosion Pig Performance Evaluation,” National Association of Corrosion Engineers (NACE), NACE/96, Denver, Colorado, March 1996. Rust, S. W., Vieth, P. H., Johnson, E. R., and Cox, M. J., “Quantitative Corrosion Risk Assessment Based on Pig Data,” National Association of Corrosion Engineers (NACE), NACE/96, Denver, Colorado, March 1996. Flaw Growth Maxey, W. A., Vieth, P. H., and Kiefner, J. F., “An Enhanced Model for Predicting Pipeline Retest Intervals to Control Cyclic-Pressure-Induced Crack Growth,” American Society of Mechanical Engineers (ASME), Offshore Mechanics and Arctic Engineering (OMAE) 1993, Proceedings of the th 12 International Conference, Volume V (Pipeline Technology), 1993. Full-Scale Testing Scott, P., Kramer, G, Vieth, P., Francini, R., and Wilkowski, G., “The Effects of Cyclic Loading During Ductile Tearing on Circumferentially Cracked Pipe – Experimental Results,” ASME PVP Volume 280, June 1994, pp 207-220. Wilkowski, G., Vieth, P., Kramer, G., Marschall, C., and Landow, M., “Results of Separate-Effects Pipe Fracture Experiments,” Post-SMiRT-11 Conference, August 1991, Paper 4.2.

PART II – COST PROPOSAL TP274-3553

UPDATED PIPELINE REPAIR MANUAL PREPARED FOR

PRC INTERNATIONAL Pipeline Materials Committee

PREPARED BY

CC TECHNOLOGIES LABORATORIES, INC. CARL E. JASKE, PH.D., P.E. AUGUST 05, 2002

CC Technologies 6141 AVERY ROAD DUBLIN, OHIO 43016 614.761.1214 • 614.761.1633 fax www.cctechnologies.com

Part II – Cost Proposal

Updated Pipeline Repair Manual

PRCI / GAS TECHNOLOGY INSTITUTE CONTRACT COST ESTIMATE (FOOTNOTE A) Nam e ofO fferor

RFP No./Prp. No.

Page Num ber

Num ber ofPages

CC Technologies Laboratories Inc. Hom e O ffice Address

Nam e ofProposed Project

6141 A very R oad,D ublin O hio 43016

U pdated Pipeline R epair M anual(M aterials Program 1) ProposalN um ber: TP274-3553

Division(s) and Location(s) (w here w ork is to be perform ed)

TotalAm ount ofProposal

$75,000 Estim ated Cost (dollars)

TotalEstim ated Cost Supporting Schedule (dollars) (Footnote B)

1. Direct M aterial a. Purchased Parts

$0

b. InterdivisionalEffort

$0 $0

c. Equipm ent Rental

$200

d. O ther (Supplies and M aterials)

$200 Table 1b

TotalDirect M aterial 2. M aterialO verhead

Rate

10%

$200

x Base $

$20

3. Subcontracted Effort

Subcontractor Cofunding (Footnote D)

$0 Table 1b

Net Subcontracted Effort 4. Direct Labor - Specify

Est.Hours

Rate/Hour

Est.Cost

90

$45

$4,021

Project Engineer

360

$29

$10,494

Technologist

205

$25

$5,176

70

$15

$1,039

Senior G roup Leader

O ffice Staff

TotalDirect Labor

20,730

5. Labor O verhead - Specify

O .H.Rate

Labor O verhead (Fringes) G eneralO verhead

X Base $

$20,730 Table 1b

Est.Cost

40%

$20,730

$8,292

132%

$29,022

$38,309

N on-Labor O verhead

$46,601

TotalLabor & GeneralO verhead 6. SpecialTesting

Table 1b

7. Purchased SpecialEquipm ent

Table 1b

8. Travel

$1,040 Table 1b

G&A on travel

9. Consultants (Identify - Purpose - Rate)

Est.Cost

$0 Table 1b

TotalConsultants

$390 Table 1b

10.O ther Direct Costs

$68,981

11.TotalDirect Cost and O verhead 12.Generaland Adm inistrative Expense Rate

10%

x Base $

1,430 (Cost elem ent no(s).

3, 6, 7, 8,9,& 10)

(Cost elem ent no(s).

)

$143

13.Independent Research and Developm ent Rate

x Base $

$0 $69,124

14.TotalEstim ated Cost (Footnote C)

$5,876

15.Fixed Fee

$75,000

16.TotalEstim ated Cost and Fee 17.Contractor/Third Party Cofunding (Footnote D)

$75,000

18.NetEstim ated Cost and Fee to GRI This proposalreflects our best estim ate as of this date,in accordance w ith the instructions to offerors and the footnotes w hich follow . Typed Nam e and Title N eilG .Thom pson,CEO FO O TNO TES:

Signature

Date 7/31/02

A. The subm ission ofthis form does not constitute an acceptable proposal. Required supporting inform ation m ust also be subm itted. B. For each item ofcost, reference the schedule w hich contains the required supporting data. C. This should be the totalcost ofthe research project. Any contractor cost sharing should be show n on the Line 17 as a reduction from totalcosts. D. This line should contain (I) totalproposed fee,(ii) contractor cofunding,(3) third party cash cofunding,or (iv)be blank,depending on the contract type. Fixed fee should be cofunded before any contractor in-kind cofunding is proposed.

____________________________________________________________________________________ CC Technologies Laboratories, Inc. 1

Part II – Cost Proposal

Updated Pipeline Repair Manual

Table 1b. Cost Detail for Table 1a. (1) LABOR COSTS

Staff Sen Group Leader/Total Project Engineer/Total Technologist/Total Office Staff/Total TOTAL LABOR

Hours Billed 90 360 205 70 725

Average Rate x Infl 5.0% $44.68 $29.15 $25.25 $14.84

Total Labor Charged $4,021.20 $10,494.00 $5,176.25 $1,038.80 $20,730.25

(3) MATERIALS

Item Misc Total Materials

Unit Cost $200.00

Quantity 1

Total Cost $200.00 $200.00

(5) TRAVEL

Trip Project Review Total Travel

No. of Persons

No. of Trips 1

No. of Days 1

2

Airfare $600.00

Subsistence /day $170.00

Rental Car/day $50.00

Trip Cost $1,040.00 $1,040.00

(7) OTHER COSTS

Item Misc/Postage Total Other Costs

Unit Cost $390.00

Quantity 1

Total Cost $390.00 $390.00

____________________________________________________________________________________ CC Technologies Laboratories, Inc. 2