Research Papers: Piper and Riser Technology

Numerical Simulation of JCO-E Pipe Manufacturing Process and Its Effect on the External Pressure Capacity of the Pipe1

[+] Author and Article Information
Konstantinos Antoniou

Department of Mechanical Engineering,
University of Thessaly,
Volos 38334, Greece
e-mail: konsanto@uth.gr

Giannoula Chatzopoulou

Department of Mechanical Engineering,
University of Thessaly,
Volos 38334, Greece
e-mail: gihatzop@uth.gr

Spyros A. Karamanos

Department of Mechanical Engineering,
University of Thessaly,
Volos 38334, Greece;
School of Engineering,
The University of Edinburgh,
Scotland EH9 3FG, UK
e-mail: skara@mie.uth.gr

Athanasios Tazedakis

Corinth Pipeworks S. A.,
Thisvi 32001, Greece
e-mail: atazedakis@cpw.vionet.gr

Christos Palagas

Corinth Pipeworks S. A.,
Thisvi 32001, Greece
e-mail: cpalagas@cpw.vionet.gr

Efthimios Dourdounis

Corinth Pipeworks S. A.,
Thisvi 32001, Greece
e-mail: edourdounis@cpw.vionet.gr

1Presented at the ASME 36th International Conference on Ocean, Offshore & Arctic Engineering OMAE2017, Trondheim, Norway, June 25-30, 2017. Paper No. OMAE2017-61540.

2Corresponding author.

Contributed by the Ocean, Offshore, and Arctic Engineering Division of ASME for publication in the JOURNAL OF OFFSHORE MECHANICS AND ARCTIC ENGINEERING. Manuscript received January 17, 2018; final manuscript received July 5, 2018; published online August 13, 2018. Assoc. Editor: Sheng Bao.

J. Offshore Mech. Arct. Eng 141(1), 011704 (Aug 13, 2018) (10 pages) Paper No: OMAE-18-1008; doi: 10.1115/1.4040801 History: Received January 17, 2018; Revised July 05, 2018

Large-diameter thick-walled steel pipes during their installation in deep-water are subjected to external pressure, which may trigger structural instability due to pipe ovalization, with detrimental effects. The resistance of offshore pipes against this instability is affected by local geometric deviations and residual stresses, introduced by the line pipe manufacturing process. In the present paper, the JCO-E pipe manufacturing process, a commonly adopted process for producing large-diameter pipes of significant thickness, is examined. The study examines the effect of JCO-E line pipe manufacturing process on the external pressure resistance of offshore pipes, candidates for deepwater applications using nonlinear finite element simulation tools. The cold bending induced by the JCO forming process as well as the subsequent welding and expansion (E) operations are simulated rigorously. Subsequently, the application of external pressure is modeled until structural instability (collapse) is detected. Both the JCO-E manufacturing process and the external pressure response of the pipe, are modeled using a two-dimensional (2D) generalized plane strain model, together with a coupled thermo-mechanical model for simulating the welding process.

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Fig. 1

Schematic representation of the subsequent phases of JCO-E manufacturing process: (a) crimping, (b) J-shape, (c) C-shape, (d) O-shape and welding, and (e) expansion

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Fig. 2

(a) Metallography of SAW weld of a 22.2 mm thick X-70 line pipe provided by Corinth Pipeworks S.A. and (b) schematic representation of the two different geometry configurations, used in the model for the weld part

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Fig. 3

Test and material modeling for uniaxial X-70 stress–strain behavior [5]

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Fig. 4

The dependence of stress–strain curve on temperature for the material of the weld part

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Fig. 5

Numerical simulation of the crimping and JCO forming process; 9 punching steps

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Fig. 6

Distribution of temperature and von Mises stress after the first and second welding pass; 9 punching steps

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Fig. 7

Numerical results for the von Mises stress after cooling of the second pass and the expansion stage; 9 punching steps

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Fig. 8

Variation of the induced (permanent) hoop expansion strain εE in terms of the expansion displacement value uE of the formed JCO-E pipe

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Fig. 9

Ovality parameter in terms of permanent expansion hoop strain

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Fig. 10

Deformed plate at the end of the C and O phase: (a) 15 punching steps and (b) 19 punching steps

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Fig. 11

Effect of the expansion hoop strain εE on the average thickness taverage of the JCO pipe

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Fig. 12:

Compression hoop stress–strain response of pipe at “intrados” and “extrados”; nonhomogeneity of mechanical properties across the thickness of the pipe

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Fig. 13

Axial tensile and hoop compression stress–strain response of JCO-E; anisotropy of the mechanical properties in the axial and hoop direction

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Fig. 14

Ultimate capacity of JCO-E pipes under external pressure for different values of expansion hoop strain: (a) using the present analysis that includes thermomechanical simulation of welding process and (b) using a purely mechanical model that accounts only for the forming process

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Fig. 15

Collapse pressure of JCO-E pipe under external pressure for different values of expansion hoop strain for the two different configurations of the weld part

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Fig. 16

Variation of collapse pressure of JCO-E pipes in terms of expansion hoop strain, for the three cases of punching steps

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Fig. 17

Calculated pressure-ovalization response of JCO-E pipes subjected to external pressure, considering the optimum expansion hoop strain for each case

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Fig. 18

Deformed configuration of the pipe under external pressure for the case of 9 punching steps and zero expansion (JCO case): (a) cross-sectional shape at three stages of deformation and (b) distribution of von Mises stress and cross-sectional configuration at post-buckling stage corresponding to ovalization Δ = 17.2%

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Fig. 19

The effect of initial ovalization on the collapse pressure of 9 punching steps JCO-E and comparison with the collapse pressure of an equivalent seamless pipe



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