UpDate Pipeline Repair Manual

8/16/2019 UpDate Pipeline Repair Manual

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PART I – TECHNICAL PROPOSAL

T 274-3553

UPDATED PIPELINE REPAIR MANUAL

PREPARED FOR

PRC I NTERNATIONALPipeline Materials Committee

PREPARED B Y

CC TECHNOLOGIES LABORATORIES, INC.

CARL E. JASKE, PH.D., P.E.

AUGUST 1, 2002

CC Technologies6141 AVERY ROAD

DUBLIN, OHIO 43016

614.761.1214 • 614.761.1633 faxwww.cctechnologies.com


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ii

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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iii

CONTENTS

INTRODUCTION............................................................................................................. 1

TECHNICAL DISCUSSION............................................................................................. 1Objectives .................................................................................................................. 2Work to Be Performed ............................................................................................... 2

Approach ................................................................................................................... 3End Product ............................................................................................................... 3Schedule.................................................................................................................... 4Manpower Requirements........................................................................................... 4

SUPPORTING DATA...................................................................................................... 4Organization Information............................................................................................ 4Corporate Qualifications ............................................................................................ 5

Related Project Descriptions...................................................................................... 5Facilities..................................................................................................................... 9

CONTRACT REQUIREMENTS ...................................................................................... 9


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APPENDICES

Appendix A – Résumés


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Part I – Technical Proposal (TP 274-3553) Updated Pipeline Repair Manual

CC Technologies Laboratories, Inc. 1

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, itprovides 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 nowcommercially 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 pipelinesegment 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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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.


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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 anelectronic, 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 willreview 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


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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 field-compatible techniques for permanently repairing SCC cracks and colonies without theneed 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 ameans to repair longitudinal seam-weld defects in pipelines was performed. Thetechnique 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 sleeveevaluated has been commercially available since 1994 and has been installed on NPS6 to NPS 42 pipelines in Canada and Mexico; primarily as a means to repair stress


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corrosion cracking, corrosion, and dents. The field program undertaken in 2000represents 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. Itincluded 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 byfinite-element stress analysis and strain-gage measurements on test sleeveinstallations.TransCanada Pipelines

Sleeve Repair of Crack-Like Defects in ERW Seams in an Oil Pipeline.CC Technologies performed an engineering critical assessment (ECA) to developguidelines for repair of crack-like defects in ERW seams in an oil pipeline. Theevaluation 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 theoperator of an oil pipeline. The manual included procedures for various repair optionsthat can be implemented depending on the type of defect encountered. The manualwas approved by the U.S. DOT.Industrial Client

Compression Sleeve Repair of Oil Pipeline. CC Technologies helped implement thefirst US use of a steel compression sleeve for pipeline repair. The method can be usedto permanently repair longitudinal defects on an operating pipeline, including crack-likedefects in ERW seams. The method is non-intrusive and requires no welding to thecarrier pipe. In comparison with a Type B sleeve, which relies on tapping through thepipe and the sleeve to reduce hoop stress, the steel sleeve applies compression to thecarrier pipe to reduce the hoop stress and prevent crack growth. Evaluation of thesleeve included measuring mechanical properties of the three different steels, modelingof the stresses in the carrier pipe and in the sleeve, and full-scale burst and fatiguetesting.

AEC Pipelines Ltd.'s Platte Pipeline

Environmentally Assisted Cracking

Low-pH SCC: Mechanical Effects on Crack Propagation The objective of this PRCIprogram was to determine the effects of mechanical factors such as hydrotesting onlow-pH stress corrosion crack growth. All testing was performed in a low-pH (near-neutral-pH) electrolyte (NS4 solution) under cyclic load conditions on pre-crackedspecimens of one X-65 line pipe steel. The cyclic load conditions in the testing wererelated to field conditions using the J-integral parameter. Crack growth was initiated inspecimens under cyclic load conditions. Once steady state crack growth had been


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achieved, a typical hydrostatic test sequence was applied to the specimen. The initialcyclic load conditions were then reapplied to the specimen and crack growth wasmonitored to evaluate the effect of the hydrostatic testing on the rate of crack growth. Itwas found that some crack extension occurred during the simulated hydrostatic testsequence but the hydrostatic testing also promoted a decrease in the cracking velocity.

The magnitude of the crack extension was slightly greater than that observed uponreloading, following unloading of the specimens. It was concluded that hydrostatictesting 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 thepropagation of low-pH SCC, (2) to estimate rates of crack propagation, and (3) toevaluate the effects of environmental and metallurgical factors such as welding and pipesteel grade on crack growth rates. In this research, CC Technologies was one of thefirst laboratories to reproduce this form of cracking in the laboratory. An experimental

technique that utilizes pre-crack compact type specimens was developed in thelaboratory studies. The crack propagation rate information generated in the researchhas been utilized to assist TCPL in establishing safe hydrostatic testing intervals. Thestudies of metallurgical factors have demonstrated that some weld structures exhibitmuch 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 PRCprogram were to evaluate the susceptibility of line pipe to stress corrosion cracking(SCC) when coated with polyethylene (PE) tape, coal tar enamel (CTE), and fusionbonded 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 specimengeometry, incorporating a disbonded coating, for electrochemical and SCC tests, (2) toevaluate the effect of coating type on the potential gradients beneath a disbondedcoating, and (3) to correlate the testing described above with standard industrial testsfor coating evaluation. In Task 1, electrochemical impedance spectroscopy (EIS) andother electrochemical techniques were used for coating characterization. The purposeof Task 2 was to evaluate the individual and combined roles of surface preparation andcathodic protection shielding on SCC susceptibility. Two types of SCC tests wereperformed. Tapered Tensile SCC tests are being performed on uncoated specimens of line pipe steel to evaluate the role of surface preparation alone on SCC surfacesusceptibility. Cyclic load SCC tests were performed on coated straight-sided tensilespecimens to evaluate the roles of cathodic protection shielding and surface preparationon SCC susceptibility.J. A. Beavers – CCT, American Gas Association (1989-1991).

Investigation Of Line Pipe Steel That Is Highly Resistant To SCC . PrincipalInvestigator 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 linepipe steel and stress corrosion cracking susceptibility was investigated. The goal of thiswork was to understand the influence of processing parameters on those characteristicsthat 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 . PrincipalInvestigator on an A.G.A. program in which a standardized test method for defining theSCC susceptibility of line pipe steels was developed. Previous studies had identifiedthe optimum environmental conditions and specimen geometry for performing such anevaluation and the aim of the work was to identify the optimum loading conditions andtest 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 innatural gas pipelines were being modeled. The goals of the research included thedevelopment of a methodology to estimate hydrostatic retest frequencies in operatingpipelines and the development of SCC resistant steels.J. A. Beavers - CCT, Industrial Client (1986).

Surface Related Factors Affecting Stress-Corrosion Cracking . PrincipalInvestigator of an A.G.A. program to investigate the surface related factors affectingSCC initiation. The objective of the research was to identify those surface factors thataffect and control SCC initiation to reduce the variation in the results of SCC tests andto 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) ReportNumber 61. The overall objective of the program, which was performed for MTI, was todetermine if SSR testing methods yield useful data in predicting SCC susceptibility of metals used in the Chemical Process Industry (CPI). The specific objectives of theYear 1 research were to identify the alloy-environment systems in which the SSRtechnique produces anomalous SCC results, identify which test variables must becontrolled 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 resolveunanswered questions. The open literature was surveyed and contacts were madewithin 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 HighLevel Waste Repository Environments. Nuclear Regulatory Commission ReportNUREG/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 strengthcarbon 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 inthe 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 thelikely stress corrosion cracking environment containing CO2 for buried gas pipelines.The work includes examining changes to the environment at the pipe surface andbeneath 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 typemodel for estimating the safe time between hydrotests for a pipeline in which stresscorrosion 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 contractagreements with PRC I nternational. This same type of contract is proposed for this

work.


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APPENDIX A

Résumés


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6141 Avery Road, Dublin, OH 43016-8761 USATEL 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-lifeassessment of structures and equipment. He has developed the www.Fitness4Service.comweb site and a short course on the API 579 Fitness-For-Service recommended practice. Hiswork includes projects on fatigue, corrosion-fatigue, creep, creep-crack growth, high-temperature properties, in-service aging, and failure analysis of structural materials. Theseprojects typically incorporate both analytical assessments and experimental evaluations of failure lives and material damage. Much of his work has been concerned with relating thephysical metallurgy of carbon steels, low-alloy steels, stainless steels, and heat-resistant alloysto 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 onmechanical properties of materials. He has developed and applied fracture-mechanicsapproaches for assessing creep, fatigue, and stress-corrosion cracking degradation and failureof engineering components, such as in-service pressure vessels and piping. He has served onindustry and government advisory groups for life extension and remaining life assessment of key engineering equipment and facilities. Also, he has developed computer programs for lifeassessment 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 themechanical integrity of oil and gas pipelines. He developed a model for predicting the failureand remaining life of pipelines with local defects, including crack-like flaws, and commercializedthe CorLAS computer program to make the model easily usable by engineers. His work onpipelines includes evaluations of stress-corrosion cracks, corrosion flaws, weld defects, dents,gouges, and dents with corrosion. He utilizes inspection and operational data to predict failuresand remaining service life and advises companies on implementing and maintaining appropriateintegrity programs.

Education

B.S., Liberal Arts and Sciences (Mathematics) with High Honors, University of IllinoisB.S., General Engineering with Highest Honors, University of IllinoisM.S., Theoretical and Applied Mechanics, University of IllinoisPh.D., Metallurgical Engineering, The Ohio State University

Experience

Senior Group Leader CC Technologies 1991 – PresentSenior Research Scientist Battelle Memorial Institute 1967 – 1990


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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) DivisionPast Chair of Central Ohio Section of ASMETechnical 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 LifeDeveloper of NDE Demonstration Forum, 1996-2001 ASME PVP ConferencesTutorial on Remaining Life Prediction, 1987 PVP ConferenceTutorial on Assessment of Material Degradation in Service, 1989 PVP ConferenceTutorial 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 wasdeveloped to predict the failure of pipelines with local defects, including crack-like flaws. Anindependent evaluation of available models for assessing SCC flaws showed that CorLASgave the most accurate predictions of fourteen actual Canadian pipeline failures. Other projectsinclude evaluation of stresses during hot tapping, assessment of dents and gouges, andpredictions 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 evaluatingthe 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 RegulatoryCommission'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.


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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 materialsamples 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-assessmentapproach for creep-fatigue crack growth interaction effects and performed creep, low-cyclefatigue, and creep-fatigue crack propagation experiments on Type 316 Stainless Steel.

Creep Fracture and Creep-Fatigue Life of Welded Steam Lines. Developed personalcomputer 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 seam-welded hot reheat steam lines.

Failure Analyses. Performed failure analyses of various components used in industrialequipment, including the failure of a large motor shaft, the failure of a generator rotor, the failureof 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 Paper- Making Equipment . Performed long-life (107 to 109 cycles to failure) corrosion-fatigue studiesof cast alloys--bronze, martensitic stainless steel, austenitic stainless steel, and duplex stainlesssteel--in white water (low pH, chloride, sulfate, thiosulfate) environments; to realistically simulateexpected service conditions, tests have been performed at low stresses for periods of severalmonths to more than one year.

Selected Publications

1. C. E. Jaske and H. Mindlin, “Elevated-Temperature Low-Cycle Fatigue Behavior of 2-1/4Cr-1Mo and 1Cr-1Mo-1/4V Steels,” 2-1/4 Chrome 1 Molybdenum Steel in PressureVessels 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 ElevatedTemperatures, STP 520, ASTM, Philadelphia (1973), pp. 365-376.

3. C. E. Jaske, et al., “Development of Elevated-Temperature Fatigue Design Informationfor Type 316 Stainless Steel,” Paper C163/73, International conference on Creep andFatigue 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,” ThermalFatigue of Materials and Components, STP 612, ASTM, Philadelphia (1976), pp. 170-198.

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.


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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 upto 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 inLife Prediction Methods, ASME, New York (1983), pp. 93-103.

12. With F. A. Simonen, “A Computational Model for Predicting the Life of Tubes Used inPetrochemical 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 PressureVessels, ASME, New York (1987), pp. 103-114.

16. C. E. Jaske and R. W. Swindeman, “Long-Term Creep and Creep-Crack-GrowthBehavior 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 VesselTechnology, Vol. 112, No. 1 (1990), pp. 20-27.]

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


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19. C. E. Jaske and V. N. Shah, “Life Assessment Procedure for LWR Cast Stainless SteelComponents,” Proceedings of the Fourth International Symposium on EnvironmentalDegradation 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 HighTemperature-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 High-Temperature/Pressure Service,” Materials Performance, Vol. 30, No. 4 (1991), pp. 61-67.

24. With A. P. Castillo and G. M. Michel, “Sandusky Alloy 86, A New Suction Roll ShellMaterial 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 (June23 – 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 ConferenceOn Heat-Resistant Materials, ASM International (1991), pp. 485-493.

27. With G. H. Koch, “Prediction of Remaining Life of Equipment Operating in CorrosiveEnvironments,” 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 andFracture of Aerospace Structural Materials, AD-Vol. 36, ASME, New York (1993),pp. 59-71.


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31. C. E. Jaske, “The Effects of High-Temperature Exposure on the Properties of Heat-Resistant 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 ImprovingReliability 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-pHStress 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 High-Temperature Service,” Service Experience, Structural Integrity, Severe Accidents, andErosion 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,” Heat-Resistant Materials II, Proceedings of the 2nd International Conference on Heat-Resistant Materials, ASM International, Materials Park, Ohio (1995), pp. 405-412.

37. C. E. Jaske, J. A. Beavers, and N. G. Thompson, “Improving Plant Reliability ThroughCorrosion 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 onPipe Integrity and Remaining Life,” Proceedings of the Second International Symposiumon the Mechanical Integrity of Process Piping, MTI Publication No. 48, MaterialsTechnology 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 onIntegrity 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 Ground-Water Environments,” PRCI / EPRG 11th Biennial Joint Technical Meeting on Line PipeResearch; 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 PressureFluctuations 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 Modelfor SCC of Pipelines,” International Pipeline Conference — Volume 1, ASMEInternational, New York, 1998, pp. 439-445.


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43. C. E. Jaske, “Interpretive Review of Weld Fatigue-Strength-Reduction and Stress-Concentration Factors," Fatigue Strength Reduction and Stress Concentration Factorsfor 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,” CIMSymposium 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 GasPipelines Subject to Stress Corrosion Cracking,” International Gas ResearchConference, 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 TheDevelopment 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 Stress-Corrosion Cracks or Local Corrosion," International Conference on Advances in WeldingTechnology (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 SteelMetallurgy on Ductile Tearing of Stress-Corrosion Cracks During Simulated HydrostaticTesting," 2000 International Pipeline Conference – Volume 2, ASME International, NewYork, 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 toSCC," 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 andWeldments of Alloy 800H," Aging Management, Component and Piping Analysis,Nondestructive Engineering Monitoring and Diagnostics – 2000, PVP-Vol. 409, ASMEInternational, New York, 2000, pp. 143-153.

52. C. E. Jaske, "Fatigue Strength Reduction Factors for Welds in Pressure Vessels andPiping," 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 andPiping," 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-GrowthTesting," Understanding and Predicting Material Degradation, PVP-Vol. 413, ASMEInternational, New York, 2000, pp. 69-79.


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55. C. E. Jaske and R. Viswanathan, "Use of Miniature Specimens for Creep-Crack-GrowthTesting," 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 PremiereConference (Corrosion Prevention 2000 ), Toronto, Ontario, Canada, November 2000.

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

58. C. E. Jaske, “Development of Miniature-Specimen Test Techniques For MeasuringCreep-Crack-Growth Behavior,” The 7th International Conference on Creep and Fatigueat 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 & GasJournal, 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-WeldDefects,” 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 HydrogenReformer 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 inPipelines,” 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, andNuclear 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-PlantComponents, 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 high-temperature steam pipes, furnace tubes, and pressure vessels.


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Books and Software (Continued)

CorLAS™ computer program for evaluating the effects of corrosion and stress-corrosion crackingon the structural integrity of pipes and vessels.


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6141 Avery Road, Dublin, OH 43016-8761 USATEL 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 aMechanical Engineer and has fifteen years of experience in the field of pressure vessel fracturebehavior and defect assessment methods for transmission pipeline systems. Prior to joiningCC Technologies, Mr. Vieth held positions with Battelle and Kiefner & Associates, Inc.

Mr. Vieth’s expertise is primarily directed toward assisting the operators of transmission pipelinesystems with the development and implementation of short-term and long-term pipeline integritymanagement programs. Specifically, he works with operators to develop programs to reduce thelikelihood of failures through in-line inspection, hydrostatic testing, defect assessment, riskassessment, and fitness-for-purpose assessment.

Mr. Vieth has been active in research and the development of innovative solutions within thepipeline industry. He was a key-contributor in the validation and implementation of the RSTRENGcorrosion assessment method. RSTRENG is recognized within the Federal Code of Federalregulations for transmission pipeline systems as a method for assessing the remaining pressure-carrying 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 toaddress a pipeline operator’s specific integrity concern. The TFI program utilized a newtechnology to identify longitudinal seam weld defects that could pose an integrity concern to thepipeline operations. Success in the development, validation, and implementation of this TFIprogram 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 thepipeline 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 pipingsubjected to dynamic loading.

Additional full-scale testing programs have been conducted to evaluate the pressure-carryingcapacity 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-carryingcapacity of pipe sections containing defects such as corrosion-caused metal loss and longitudinalseam weld defects.

Education

B.S., Mechanical Engineering, The Ohio State University


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Resume: Patrick H. ViethPage 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 I nternational,

9th

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 theFailure 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

Assessment,” American Gas Association, PRC I nternational, 9th

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,”

American Society of Mechanical Engineers, American Petroleum Institute, 7th

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 MechanicalEngineers (ASME), Offshore Mechanics and Arctic Engineering (OMAE) 1993, Proceedings of the

12th

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 LoadingDuring Ductile Tearing on Circumferentially Cracked Pipe – Experimental Results,” ASME PVPVolume 280, June 1994, pp 207-220.

Wilkowski, G., Vieth, P., Kramer, G., Marschall, C., and Landow, M., “Results of Separate-EffectsPipe Fracture Experiments,” Post-SMiRT-11 Conference, August 1991, Paper 4.2.


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PART II – COST PROPOSALTP274-3553

UPDATED PIPELINE REPAIR MANUAL

PREPARED FOR

PRC I NTERNATIONALPipeline Materials Committee

PREPARED B Y

CC TECHNOLOGIES LABORATORIES, INC.

CARL E. JASKE, PH.D., P.E.

AUGUST 05, 2002

CC Technologies6141 AVERY ROAD

DUBLIN, OHIO 43016

614.761.1214 • 614.761.1633 faxwww.cctechnologies.com


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Part II – Cost Proposal Updated Pipeline Repair Manual

____________________________________________________________________________________CC Technologies Laboratories, Inc. 1

PRCI / GAS TECHNOLOGY INSTITUTE CONTRACT COST ESTIMATE (FOOTNOTE A)

Nam e of Offeror RFP No./Prp. No. Page Num ber Num ber of Pages

CC Technologies Laboratories Inc.

Hom e Office Address Nam e of Proposed Project

6141 Avery Road, Dublin O hio 43016

Division(s) and Location(s) (w here w ork is to be perform ed) Total Am ount of Proposal

$75,000

Estim ated Cost

(dollars)

Total Estim ated Cost

(dollars)

Supporting Schedule

(Footnote B)

1. Direct Material

a. Purchased Parts $0

b. Interdivisional Effort $0

c. Equipm ent Rental $0

d. Other (Supplies and M aterials) $200

Total Direct Material $200 Table 1b

2. M aterial Overhead Rate 10% x Base $ $200 $20

3. Subcontracted Effort

Subcontractor Cofunding (Footnote D)

Net Subcontracted Effort $0 Table 1b

4. Direct Labor - Specify Est. Hours Rate/Hour Est. Cost

Senior Group Leader 90 $45 $4,021

Project Engineer 360 $29 $10,494

Technologist 205 $25 $5,176

Office Staff 70 $15 $1,039

Total Direct Labor 20,730 $20,730 Table 1b

5. Labor Overhead - Specify O.H. Rate X Base $ Est. Cost

Labor Overhead (Fringes) 40% $20,730 $8,292

General Overhead 132% $29,022 $38,309

Non-Labor Overhead

Total Labor & General Overhead $46,601

6. Special Testing Table 1b

7. Purchased Special Equipm ent Table 1b

8. Travel G&A on travel $1,040 Table 1b

9. Consultants (Identify - Purpose - Rate) Est. Cost

Total Consultants $0 Table 1b

10. Other Direct Costs $390 Table 1b

11. Total Direct Cost and Overhead $68,981

12. General and Adm inistrative Expense

Rate 10% x Base $ 1,430 (Cost elem ent no(s). 3, 6, 7, 8, 9, & 10) $143

13. Independent Research and Developm ent

Rate x Base $ (Cost elem ent no(s). ) $0

14. Total Estim ated Cost (Footnote C) $69,124

15. Fixed Fee

$5,87616. Total Estim ated Cost and Fee $75,000

17. Contractor/Third Party Cofunding (Footnote D)

18. Net Estim ated Cost and Fee to GRI $75,000

This proposal reflects our best estim ate as of this date, in accordance w ith the instructions to offerors and the footnotes which follow .

Typed Nam e and Title Signature Date

Neil G. Thom pson, CEO 7/31/02

FOOTNOTES: A. The subm ission of this form does not constitute an acceptable proposal. Required supporting information m ust also be subm itted.

B. For each item of cost, reference the schedule w hich contains the required supporting data.

C. 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.

D. 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.

Updated Pipeline R epair M anual (M aterials Program 1)

Proposal Num ber: TP274-3553


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Part II – Cost Proposal Updated Pipeline Repair Manual

____________________________________________________________________________________CC Technologies Laboratories, Inc. 2

Table 1b. Cost Detail for Table 1a.

(1) LABOR COSTS

Average Total

Hours Rate x Infl Labor

Staff Billed 5.0% Charged

Sen Group Leader/Total 90 $44.68 $4,021.20

Project Engineer/Total 360 $29.15 $10,494.00

Technologist/Total 205 $25.25 $5,176.25

Office Staff/Total 70 $14.84 $1,038.80

TOTAL LABOR 725 $20,730.25

(3) MATERIALS

Unit Total

Item Cost Quantity Cost

Misc $200.00 1 $200.00

Total Materials $200.00

(5) TRAVEL

No. of No. of No. of Subsistence Rental Trip

Trip Persons Trips Days Airfare /day Car/day Cost

Project Review 1 1 2 $600.00 $170.00 $50.00 $1,040.00

Total Travel $1,040.00

(7) OTHER COSTS

Unit Total

Item Cost Quantity Cost

Misc/Postage $390.00 1 $390.00Total Other Costs $390.00


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August 12, 2002

VIA FEDERAL EXPRESS

PROPOSAL NO. CP052647

Mr. Steve FohPRCI1700 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 GrowthModeling”, which is in response to PRCI RPTG-0320.

This effort is offered under the master set of terms and conditions negotiated between PRCI andBattelle 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 [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 Christina L. RotundaResearch Leader Contracting OfficerPipeline Technology Center

BNL/cwEnclosure

mailto:[email protected]:[email protected]:[email protected]:[email protected]


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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 multiplecracks 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 notexist 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 particularlycomplex for situations where new cracks may initiate within a colony and/or where crackcoalescence can occur.

In addition to validated models to assess defect criticality for as-detected cracking, a first-generation 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 responsedepends on the prior operating and cracking history. This model has since been shown tofaithfully recreate field-observed cracking patterns for high pH SCC, and has been used tosuccessfully 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 toincorporate cracking as it is found in the field in bell-hole digs or via ILI. Because all modulescomprising SCCLPM are generic except for reference to cracking environment in the crackgrowth module, this model could be simply adapted to address near-neutral cracking by specificchanges in this module. Finally, because coalescence and growth by either SCC or stable tearingas currently incorporated do not reflect load history dependence, changes also could be requiredin this module.

Objective

The objective is to generalize modules in SCCLPM that limit its utility in field applications, andextend 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 similarapproach to modular modeling and related strategies with a focus on near-neutral crackingenvironments, 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- andtime-dependent response of significant cracking found during in-service inspection. The newformulation will use the past approach, which has proven to be successful in developing thefield-validated models for high pH SCC. Current algorithms that model situations where newcracks may initiate within a colony, and crack coalescence will be enhanced to embed stress-


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history dependence, while capabilities to handle stress localization, as occurs along weld seamswill be refined. The approach to address stress dependence and coalescence will continue use ofnumerical and phenomenological modeling, as this practice has been effective in dealing withthese aspects in developing the model validated for simple laboratory stress histories. To theextent 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 toisolate 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 growthincluding near-neutral cracking involves six tasks to be completed over a two-year period, asfollows:

Task One – Update Algorithms to Incorporate Pressure (Stress) History

This task will begin with a literature evaluation of the changing stress and inelastic strain fieldsthat 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 thoseobserved in field cracking. Finally, the crack nucleation, growth, and coalescence algorithmswill be reformulated to permit input that characterizes the colony of significant cracking found inthe 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 asoccurs 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 fieldsthat occur around a crack tip as a function of local stress raisers, such as a long-seam weld. It isanticipated that selected numerical work will be needed to characterize changes in the local fieldsas a function of normalized far-field stress for typical weld profiles in line pipe. Thereafter, thecurrent algorithms for stress-localization and environmental focusing will be generalized tofacilitate 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 significantcracking 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 decision-

making 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 literaturedeveloped for the PRCI will be evaluated as will the general literature dealing with the physicsand elector-chemistry of SCC of steel in environments comparable to near-neutral conditions.


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Central to this is the evaluation of the HELP mechanism and other competing processes thatmight 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 factorscontrolling SCC in that environment. The task will use the results of Task Four as the basis todesign discriminating experiments involving mechanisms postulated to explain near-neutral pHSCC. 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 ofthe 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 laythe 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.

Cost, Schedule, and Reporting

Completion of the above six tasks for the scope of parameters anticipated is estimated to requirea two-year period of performance and a total budget of $250,000.00 split equally over the periodof performance.

Month aftercontract

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 anunderstanding of the physics and electro-chemistry of near-neutral SCC. The model proposedwill lay the foundation for schemes to reduce unnecessary conservatism in setting re-inspectionor re-hydrotest intervals, or allow minor SCC to be left in place without immediate remedial


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action. The final report will summarize the results and underlying methodology and approachtaken 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. Thiswork is useful experience in regard to programs such as this. However, as it is more applicationsoriented, 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 beassisted by Drs. Robert E. Kurth and Jeffery A. Colwell, and others on the Battelle technical staffincluding Mr. Thomas P. Forte. All members of this team have contributed to the formulation ofSCCLPM and Battelle’s research into SCC. This team has more than 30 years of cumulativeexperience in this area. While Battelle has extensive experience in high pH SCC, it is possiblethat Battelle will retain sub-contractors. For example, to ensure that the field aspects for thissecond 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 andthe pipeline industry in the US and internationally in the field of SCC. Drs. Kurth and Colwelland Mr. Forte have ongoing interests into the causes and mitigation of SCC.


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August 12, 2002

Via FEDERAL EXPRESS

Proposal No. CP052649

Mr. Steve FohPRCI1700 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 willcomplete PRCI Project PR-003-0046.

This effort is offered under the master set of terms and conditions negotiated between PRCI andBattelle 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 [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 Christina L. RotundaResearch Leader Contracting OfficerPipeline Technology Center

BNL/cwEnclosure

mailto:[email protected]:[email protected]:[email protected]:[email protected]


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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 SCCdevelop, the number of colonies that must be addressed with regard to safe serviceabilityincreases. This means that pipeline companies will be faced with rehabilitation choices rangingfrom grind and recoat, through use of a pressure-containing sleeve, and under somecircumstances, a cut out. It follows that pipeline companies suffering even limited SCC need toidentify rehabilitation options as a function of pipeline service and the nature of the cracking inthat joint of pipe.

To be practical, rehabilitation options need to be identified in a field setting, which meansselecting options is best done in terms of a simple, easy to use, technically defensible, decisiontree that could be used by field crews. To be economically viable, such options must recognizethat 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 areneeded to avoid incurring significant repair costs in situations where there will be no reduction inrisk of failure.

Much has already been done that contributes to the development of rehabilitation options as afunction of pipeline service and the nature of the cracking in that joint of pipe. Criteria arerequired to determine cracking severity and near-term criticality.

Objective

Develop rehabilitation options for SCC in the form of a simple, easy to use, technicallydefensible, 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. Thesetasks, which are specific to high pH SCC, include:

• Determine circumferential and axial crack spacings ranging from benign to critical, as afunction 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 decidewhich 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 includeddetermination of critical circumferential spacing and the formulation of a simple macro-based


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assessment for crack coalescence, which addresses critical axial crack spacing. Year Twocontinues 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-serviceconditions that range from benign to critical. This will be done for service pressurescorresponding 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 toidentify combinations of circumferential crack spacings that range from benign through potentially critical. For potentially critical circumferential crack spacings, the correspondingaxial spacings needed to preclude the formation of critical crack lengths will be determined usingPRCI-developed analyses methods as a function of the circumferential spacing and the specifiedor 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 whichcolonies are benign versus those that are potentially critical and when they are expected to reacha critical state. This will be done using photographs or printed images of crack arrays that rangefrom benign through critical that can be interpreted by field personnel with minimal engineeringsupport. Factors such as differences in toughness or operating stress will be accounted for interms of nomographs and selected photographs or images of crack arrays. Decisions as to whichcolonies require what type of rehabilitation will be based on consideration of the appearance ofthe colony and spacing of the cracks, the depth of the cracking based on in-the-ditchmeasurements, 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 1and 2 to assess the extent of inherent conservatism.

TASK 4 -- DETAIL AND VALIDATE R EPAIR PRACTICES

The objective of this task is to document and validate field-proven repair practices, such as grindand recoat. During the company contacts that underlie Task 3, details on the implementation offield-proven practices for the rehabilitation of SCC will be gathered from companies thatroutinely rehabilitate SCC. Field-proven practices will be culled from the methods used bycompanies that experience significant SCC. Criteria used in this selection will include practicalaspects and the requirement of long-term success. Such methods will be detailed and evidenceof their viability presented in terms of company experience, or analysis when revealed.


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TASK 5 – R EPORT

A report will be prepared that presents rehabilitation options as a function of pipeline service andthe nature of the cracking in a joint of pipe, based on a simple easy to use, technically defensiblecriteria, 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 anticipatedis 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 aftercontract

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 ofwork, a third year will be required to translate the results into simple design guidelines. Inaddition, selected full-scale testing should be considered.

Deliverables

The deliverable of this project when completed is an improved understanding of the applicabilityand reliability of field-proven rehabilitation and repair methods to facilitate cost-effective SCCmanagement strategies based on a sound understanding of SCC significance, for individualcracks and colonies. This deliverable will be presented in a written report that presents theapproach as well as the results of the project.

Project Organization and Management

This project would be completed within Battelle’s Pipeline Technology Center, working inconjunction Marr and Associates. The project manager and principal investigator for this effortwill be Dr. Brian Leis, who will be assisted by Dr. Robert Kurth and Mr. Ron Galliher, andothers in the Pipeline Technology Center at Battelle, which is organized to meet the needs of theenergy 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


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second year reflect reality, Battelle will team with Marr and Associates, where the work will bemanaged 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 specificobjective 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 andAssociates will work as a sub-contractor to Battelle.


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August 2002

SCC INITIATION SUSCEPTABILITYRANKING/SCREENING

(RPTG-0328)

Confidential

Prepared by:Mark McQueen (& Steve Matthews)Advantica Technologies Inc.5177 Richmond Avenue

Suite 900HoustonTX 77056USA

Tel: 713 586 7000Fax: 713 586 0604Email: [email protected]: www.advanticatechinc.com

Prepared for:Steve FohPipeline Research CouncilInternational, Inc.

c/o Gas Technology Institute1700 South Mount Prospect RoadDes PlainesIllinois 60018-1804

2002 Advantica Technologies Inc.

http://www.advanticatechinc.com/http://www.advanticatechinc.com/


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PROPOSAL SUMMARY

Proposal: RPTG 0328

Title: FACTORS INFLUENCING THE RELATIVE SCC SUSCEPTIBLITY OF LINEPIPE.

Contractors: Advantica Technologies Inc with EPRG consortium (Advantica, CSMand 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, bysubjecting a representative range of North American line pipe steels to standardisedtests.

Incentive:Recent studies by EPRG have enabled the development of standardized proceduresfor assessing the resistance of line pipe steels to low pH SCC initiation. By applyingthese procedures to a range of steels from North America, thereby broadening the

overall database of information, the key factors determining resistance to SCC willbe better understood.

Work Plan:TASK 1 – Experimental testing.TASK 2 – Post-test examinationTASK 3 – Comparison with other data, reporting

Deliverables:Reports documenting

• Qualitative assessment and ranking resistance of a typical North Americanline pipe to low pH SCC initiation.

• Comparison with similar results from European line pipe steels.


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TABLE OF CONTENTSPART I

TECHNICAL PROPOSAL

1

INTRODUCTION & SUMMARY ......................................................................... 5

2 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 IICOST PROPOSAL

1 COSTS ...................................................................................................

Documents

UpDate Pipeline Repair Manual