Development of a Blade Toughness Meter (BTM) for In-Situ Pipe Toughness Measurement

Overview

Main Objective

The project will produce a validated and complete instrument specification capable of delivering accurate and reliable fracture toughness data when deployed commercially by performing finite element simulations, field trials, and third-party validation tests. These specifications will include hardware and software, testing procedures, and the requirements for the training and certification program of end users. This project will also increase the accuracy and reduce the material removal associated with the field procedure.

Public Abstract

Non-destructive evaluation (NDE) methods for pipe toughness determination have been sought after for decades. Accurate toughness data is crucial for analyzing the critical crack size that could cause failure at maximum allowable operating pressure (MAOP) and for conducting fitness-for-service evaluations on cracks found during inspections. In the absence of pre-existing material toughness data, operators may resort to using conservative estimates, performing cut-outs for laboratory testing, or relying on industry-accepted data, such as that collected through nondestructive testing methods. In 2022, Massachusetts Materials Technologies (MMT) developed the method of planing-induced microfracture. A specialized blade featuring a central opening cuts a thin layer of material from the surface, and the uncut material at the central opening deforms and creates a microfracture. The microfracture response is used to correlate with the material's toughness.

The current state of the technology is a proof of concept where the prototype instrument, called the Blade Toughness Meter (BTM), can be attached onto a pipe and perform testing on cutouts for laboratory or warehouse settings. Preliminary validation where the results from destructive fracture toughness testing are compared with the results from the BTM has shown a prediction accuracy of approximately ±20%.

This project aims to perform the other necessary research and development to advance the current BTM prototype into a technology offering that will be safe and reliable for the intended use on energy transmission pipelines. These tasks include development of finite element models to improve accuracy and safety, improving understanding and addressing challenges arising from differences between laboratory test temperatures in comparison to field test temperatures, developing robust hardware, software, and test procedures along with associated training methodologies, and third-party validation of the resulting technologies. The success of the project will provide the industry a valuable instrument for in-ditch, nondestructive pipe toughness determination and ultimately enhance the safety of pipeline assets.

Anticipated Results: The project will produce a validated and complete instrument specification capable of delivering accurate and reliable data when deployed commercially. These specifications will include hardware and software, testing procedures, and the requirements for the training and certification program of end users. This project will also increase the accuracy and reduce the material removal associated with the field procedure.

Potential Impact on Safety: The BTM instrument developed in this project will allow pipeline operators to obtain critical data from in-situ toughness testing of their assets without interrupting the pipeline service. It will significantly lower the cost and effort required to obtain valuable fracture toughness data, data that will enhance integrity management and pipeline safety

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