1. Research Needs on SCC of Pipelines Raymond R. Fessler Stress-Corrosion Cracking (SCC) Workshop DOT/RSPA Houston, TX December 2, 2003

2. Status of SCC Remains an industry-wide concern SCC is being managed –Probability of failures is low Much lower than would be expected if it were not being managed Probably never will be zero –Integrity of P/L can be assured Cost of SCC management is very high

3. SCC Gap Analysis What opportunities are there to decrease the probability of SCC failures and reduce the cost of SCC management? What research is needed to take advantages of those opportunities?

4. STRUCTURE FOR SCC GAP ANALYSIS 1.1. Assess Risk 1.2.1. Locate 1.2.2. Treat 1.2. Locate SCC and treat 1.3. Change operating practices 1. Existing pipeline 2.1.1. Initiation 2.1.2. Threshold 2.1.3. Growth 2.1. Select resistant steel 2.2. Select effective coating 2.3. Design operating conditions 2. New (future) pipeline Manage high-pH and near-neutral-pH SCC

5. Criteria for Recommending Research Understanding is not high Probability of success is reasonable Potential benefits far exceed cost of research

6. Incentives for Additional R&D Improve effectiveness and reduce costs of –Hydrostatic retesting –ILI –Direct Assessment Make future pipelines more resistant to SCC

7. Objectives for Future R&D Optimize hydrotesting and ILI intervals –Justify on basis of crack growth rate –Extend intervals by reducing crack growth rate through operating practices –Prioritize areas –Optimize procedures Develop ILI for gas pipelines

8. Objectives for Future R&D (cont.) Validate Direct Assessment for SCC Develop direct-examination sizing techniques Develop simple-to-use ECA methods Validate new repair methods for SCC Develop resistant steels

9. R&D Approaches Optimize inspection intervals –Improve crack-growth models –Improve site-selection models ILI –Develop technologies –Develop commercial tools Direct Assessment –Field Validation Sizing techniques –Develop & qualify commercial tools ECA methods –Develop simple tool (RSTRENG for SCC) Resistant steels –Evaluate current steels –Understand relationships between composition, structure, properties, & performance

10. Crack-Growth Models

11. Several crack-growth models –Leis (Battelle) probabilistic model for high-pH SCC –Rainbow P/L Model for near-neutral-pH SCC –Beaver’s/Lambert’s superposition model All are based on simplified assumptions about growth rate of single crack Some consider interactions between cracks Each has benefits and limitations At least two should be examined and developed more fully

12. Site-Selection Models

13. Difficult to evaluate effectiveness –Limited data –Few “control experiments” –Proprietary algorithms –Continual refinements Phenomenological rather than scientific

14. Site-Selection Models (continued) Mixed industry experience –Geographically specific –More reliable with tape than asphalt –Interdependent factors (e.g., coating type and soil resistivity) Opportunities –Develop scientific basis –High pH vs. near-neutral-pH –Improved soils module Accelerating & Inhibiting factors –Incorporate operating history & coating –Combine industry data

15. In-Line Inspection (ILI)

16. No satisfactory commercially available tool for gas pipelines –Liquid-coupled UT too cumbersome and expensive –Elastic wave has inadequate discrimination –EMAT remains to be demonstrated Too early to judge other technologies, but probably long shots –Circumferential MFL –Rotating magnetic-field probe –Gas-coupled UT

17. In-Line Inspection (continued) Role of PRCI –Support field validations –Develop/encourage/test new technologies Role of vendors: Develop commercial tools Role of DOT Protection of proprietary ideas Assurance of adequate market

18. SCC Direct Assessment (Covered in other presentations)

19. SCC Direct-Examination Sizing Techniques (Covered in other presentations)

20. Resistant Steels

21. Resistant Steels: R&D Approaches & Issues Empirical approach –Test current and new steels Fundamental approach –Relate SCC susceptibility to micro-plastic behavior, microstructure, composition, processing Issues –Large effort required –Proper coatings and surface preparation provide significant benefit

22. Speculative Budget Projections

23. Summary of Opportunities for Gov’t/Industry Cooperation Optimize testing/inspection intervals –Crack-growth models –Site-selection models ILI for SCC –Practical technologies for gas lines Direct-examination sizing and ECA of SCC Resistant-steel development