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Pneumatic and Hydrostatic (HT) Test Report (All data required for ASME B31) TEST NUMBER: 01 PROJECT NO: 1 PAGE 1 OF: 1 PROJECT NAME: Pneumatic and hydrostatic tests for Experimental Piping System TEST INFORMATION SYSTEM DESCRIPTIONS: This structure will be solely used in the lab of Cranfield University UK and just for the purpose of research works (structural pipeline integrity) DESCRIPTION OF TEST BOUNDARIES: The test was carried out in an isolated area (closed warehouse) for safety reasons. DESIGN TEMPERATURE: 148.9º C DESIGN PRESSURE: 45.17 Bar TEST METHOD: [√ ] HYDROSTATIC: 68 Bar [√ ] PNEUMATIC: 14 Bar TEST FLUID: Normal water 220 APPLICABLE CODE: N.A TEST REQUIREMENTS (FOR HT) REQ TEST PRESSURE: 68.10 Bar TEST FLUID TEMPERATURE: 27º C REQ TEST DURATION: 30 mins (HT) AMBIENT TEMPERATURE: 27º C TEST RESULTS TEST DATE : 7 AUG 2009 START TIME [√ ] AM [ ] PM (PNEUMATIC TEST) 12:30 FINISH TIME [√ ] AM [ ] PM 05:40 TEST DATE: 7 AUG 2009 START TIME [√ ] AM [ ] PM (HYDROTEST) 07:10 FINISH TIME [√ ] AM [ ] PM 07:40 ACTUAL GAUGE PRESSURE 68 Psig (Bar) TEST EQUIPMENT TYPE RANGE CAL DATE CAL DUE Pressure Gauge - Parker 0 - 70 Bar (New-Factory setting) N.A (Brand new) REMARKS: Pneumatic: Leaks at nipple joints / blind flanges. Immediate reworks were carried out using SMAW and Dye Penetration (NDT) at the weldment. Hydrostatic: The result was O.K and successful. No indication of water leakage especially at the welding areas No plastic deformation occurred during and after the test. TEST ACCEPTANCE CARRIED OUT BY: DATE: (Ir Mahadi Abd Murad) APPROVED BY: (Prof Engr Dr Feargal Peter Brennan) 07-Aug-09 DATE: 25–Sept-09
Photos of the Design and Build of the piping system Figure 1: Shop drawings were displayed in the workshop for references – Design Stage Figure 3: A dial gauge used in controlling the tolerance – before, during and after defect machining Figure 5: Welding works on all five pipe segments using simple and reliable jig and fixture. 221 Figure 2: Materials used such as 300 Lbs Weld Neck and Blind Flanges Figure 4: The defect length of 40 mm and depth of 3.75 ± 0.25 mm were measured using a digital calliper – Final profile of artificial corrosion Figure 6: A pipeline was properly tightened prior to Hydrostatic Test
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CRANFIELD UNIVERSITY MAHADI ABD MUR
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ABSTRACT One of the most common pro
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TABLE OF CONTENTS ABSTRACT ........
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3.7.1 Introduction ................
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5.6 Summary and Conclusions .......
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Figure 3.1: Schematic diagram of th
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Figure 5.4: The average temperature
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NOMENCLATURES ACFM Alternating Curr
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1 INTRODUCTION One of the most comm
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1.1 Objectives Knowing this backgro
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The methodology of this integrated
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Chapter 6 contains the summary and
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period of the major part of the exi
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Figure 2.2: Reported interest in de
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Figure 2.4: Dent damage caused by v
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presented current practices, recent
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Energy Workforce Sdn Bhd (2011) cla
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available provides real time detect
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2.3.3 Reliability Analysis of Infor
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Figure 2.9: Pipeline failure probab
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2.3.3.1 NDT Reliability and POD cur
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increase in the yield limit of stee
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the SCC assessment in their integri
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Manufacturers such as Walkers Techn
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Company L.P, 2005); Aquawrap ® pro
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monitoring, inspection, and damage
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2.6.2 Aims of Structural Health Mon
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Figure 2.16: Application fields and
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egistered by the piezoelectric sens
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discretization error. Round-off err
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notches and Neuber‘s is better fo
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maximum local stress at discontinui
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De Carvalho (2005) concludes that t
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accurate simulation of loading espe
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Based on the above facts, the opera
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3 FINITE ELEMENT ANALYSIS (FEA) IN
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Figure 3.2: Schematic diagram of th
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In this modelling work (i.e. compos
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This partition toolset also helps u
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Figure 3.6: Mesh control using Swee
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Figure 3.7: Schematic representatio
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discretization. Therefore, in this
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According to Staten et al. (2010b),
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3.5 The influence of pressure on th
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each pressure value remains constan
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Axial Stress, σa (S22) was referre
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Figure 3.14 shows a graph of analyt
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the notch defect is found to be in
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One of the contributions of this st
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Table 3.4: Convergence tests on var
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Figures 3.16 and 3.17 show that the
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Figure 3.20 shows that as the relat
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3.7.4 Concluding Remarks A biaxial
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yarns change and lateral contact be
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For predicting E2 and Gl2, a number
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Where: Ar = weight of one sheet of
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Where; The Stiffness matrix is trad
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simulations for the hoop strain at
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Figure 3.24: Finding the hoop stres
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Table 3.8: The effect of repair len
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four up to 18 layers. In this study
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hoop and axial stress concentration
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Table 3.11: Predicted Elastic Const
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Table 3.13: Axial Stress v/s L/W ra
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Hoop Stress (MPa) Figure 3.3: Hoop
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However, Frost (2008) and Alexander
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Table 3.17: Ratio of Axial Stress N
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axial load (e.g. buried pipelines t
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3.10 Numerical Strain Analysis of C
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Figure 3.36 shows the contours befo
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Stress Concentration Factor 2 1.8 1
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In fact, for Notch 40 with 18 plies
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this second approach (i.e. the expe
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4.2.2 Strain Gauge Selection and Cr
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Finally, a method used to calculate
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Where, and are the maximum and mini
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should be between 20 and 28 bar and
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welded weld neck flange at both end
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Figure 4.7: Sensor and heating elem
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Figure 4.9: A summary of data acqui
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One of the objectives of doing this
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Figure 4.14: A schematic diagram of
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Table 4.1: Strain gauge readings at
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microstrain 3.00E-04 2.50E-04 2.00E
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However, the axial load transfer is
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Mircostrain 500 450 400 350 300 250
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Since the defect is not a flat notc
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Again, the epoxy resin plays a sign
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Table 4.4: Study at the defect area
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Mircostrain 300 250 200 150 100 50
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Mircostrain 600 500 400 300 200 100
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14.25% in hoop strain and 23.5% in
Page 189 and 190: consideration for the selection of
Page 191 and 192: 5.4 Methodology of Thermal Expansio
Page 193 and 194: Figure 5.1: Some preventive measure
Page 195 and 196: 5.4.1 The Fundamentals of the Therm
Page 197 and 198: 5.5 Analysis of Results 5.5.1 The t
Page 199 and 200: Thermal Output (strain ) 0.0002 0.0
Page 201 and 202: (Strain ,ε) Figure 5.12: Coefficie
Page 203 and 204: (Strain ,ε) 0.0002 0.00018 0.00016
Page 205 and 206: Table 5.1: The strain readings afte
Page 207 and 208: maximum shear strain increase as th
Page 209 and 210: The above results show that shear s
Page 211 and 212: shear strains becomes more stable a
Page 213 and 214: for future safe design and operatio
Page 215 and 216: has been fully cured. Poor surface
Page 217 and 218: 6.3 Primary PhD Achievements The ea
Page 219 and 220: In Chapter 5, the CTE was determine
Page 221 and 222: ASM International (2002), "Thermal
Page 223 and 224: Bucinell, R. B. (2001), Calculating
Page 225 and 226: Proceedings of OMAE'01 20th Interna
Page 227 and 228: Greenwood, R. (2002), UKOPA Pipelin
Page 229 and 230: Kotrechko, S. A., Krasovskii, A. Y.
Page 231 and 232: Mousavi, S. E., Xiao, H. and Sukuma
Page 233 and 234: Raju, I. S. and Newman, J. C. (1986
Page 235 and 236: Tennyson, R. C. and Mufti, A. A. (2
Page 237 and 238: Xue, L., Widera, G. E. O. and Sang,
Page 239: General Technical Specifications: T
Page 243 and 244: Composite Installation Process usin
Page 245 and 246: APPENDIX 3 - STRAIN GAUGE INSTALLAT
Page 247 and 248: Figure 7: Mylar tape was stuck onto
Page 249 and 250: Figure 19: Repeating the above proc
Page 251: 2) Electrical Insulation Test Resul
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