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Cranfield University Mahadi Abd Murad an Integrated CRANFIELD UNIVERSITY MAHADI ABD MURAD AN INTEGRATED STRUCTURAL HEALTH MONITORING APPROACH TO COMPOSITE-BASED PIPELINE REPAIR SCHOOL OF ENGINEERING Offshore, Process and Energy Engineering Department PhD (Full Time) Academic Year: 2008-2011 Supervisor: Professor Feargal Brennan June 2011 CRANFIELD UNIVERSITY SCHOOL OF ENGINEERING Offshore, Process and Energy Engineering Department PhD (Full Time) Academic Year: 2008-2011 MAHADI ABD MURAD AN INTEGRATED STRUCTURAL HEALTH MONITORING APPROACH TO COMPOSITE-BASED PIPELINE REPAIR Supervisor: Professor Feargal Brennan June 2011 This thesis is submitted in partial fulfilment of the requirements for the degree of PhD © Cranfield University 2011. All rights reserved. No part of this publication may be reproduced without the written permission of the copyright owner. ABSTRACT One of the most common problems in the structural integrity of industrial pipelines is external corrosion. Composite materials have been accepted as a repair option to restore the original strength of the effected damaged section but the approach to analyse how well the composite repair has influenced the stress and strain distributions between the reinforced steel and the reinforcing composite is yet to be determined. This approach is required since it can increase the confidence level among pipeline operators or manufacturers in terms of the composite repair solution that they have chosen or offered. The aim of this study was to develop an integrated approach that could provide a complete methodology to assess the integrity of pipeline systems, especially in quantifying the level of reinforcement provided by the repair in the elastic working region. This cannot be achieved by the traditional method that only relies on classical mechanics derived from strength of materials and compatibility relations. To fulfil this aim, efforts included the simulation of a fibre glass composite repair system using finite element analysis (ABAQUS) software, design and fabrication of the pressure and temperature test rig, installation of fibre glass composite material, and data acquisition. The arc-shaped notch defect that has never been studied before was chosen in the study of stress concentration and bonding integrity of the composite repair system and further validated experimentally using the test rig. The numerical results of this work demonstrated different stress concentration values as the arc-shaped defect size increased. With a proper test plan, the optimum repair system that contains variable lengths of the arc-shaped defect and different lengths as well as thicknesses of the composite material was achieved in the stress distribution study. The bonding integrity via strain distribution study was further validated experimentally. The experimental pressure test results showed some good agreement, especially in the hoop load transfer and limitations of the simulation works were adequately addressed. The experimental temperature results managed to show how the thermal strain behaved in the anisotropic Triaxial Woven Fibre composite repair system. This approach is useful for a better acquisition of information that enables the diagnosis and prognosis of the pipeline repair system prior to installation on site. The novelty of this technique is in its ability to analyse the load transfer in a composite repair system in a more efficient way which can save time and cost. iv ACKNOWLEDGEMENTS First and foremost, I would like to thank God, for having made everything possible. You have given me the power to believe in my passion and pursue my goals. I could never have done this without the faith I have in you, the Almighty. I would like to express my immense gratitude to my Supervisor, Professor Feargal Brennan for his precious guidance and help, and for the endless generosity and kindness with which those were offered. To my wonderful wife, Nur Sufiza Ahmad, I can barely find the words to express all the continuous love and support you have given me. I also would like to thank my beautiful daughter, Nurdina Sufia and handsome sons, Amirul Haris and Amirul Haikal for your wonderful patience and understanding. To all my family and extended family members, thank you for your continuous support and I love you all always. I also would like to express my sincere gratitude to Professor Simon Frost for his useful advice and Walker Technical Resources Ltd in Aberdeen Scotland for sponsoring Technowrap composite materials in this research work. Special thanks to my head of department, Associate Professor Azhar Mahmud, and my colleagues and students at Universiti Kuala Lumpur Malaysia for giving their full support to successfully complete the fabrication of the experimental test rig within a month! Last but not least, I also would like to take this opportunity thank my colleagues and other staff at Cranfield University for their continuous support during the period of my PhD studies. Payam, Dr Iberahin, Wilson, Jian and Philip, your constructive support, help and friendship have made an enormous impact on my work. Thank you very much. v TABLE OF CONTENTS ABSTRACT .................................................................................................................... iv ACKNOWLEDGEMENTS ............................................................................................. v TABLE OF CONTENTS ............................................................................................... vii LIST OF FIGURES ....................................................................................................... xiii LIST OF TABLES ....................................................................................................... xvii NOMENCLATURES .................................................................................................. xviii 1 INTRODUCTION ..................................................................................................... 1 1.1 Objectives .......................................................................................................... 3 1.2 Contributions of the Work ................................................................................. 4 1.3 Summary and Layout of the Thesis ................................................................... 6 2 LITERATURE REVIEW ON STRUCTURAL INTEGRITY ................................. 8 2.1 Introduction ........................................................................................................ 8 2.2 Pipeline damage scenario ................................................................................... 8 2.3 Condition Assessment of Ageing Pipelines ..................................................... 14 2.3.1 Pipeline Inspection Technology ............................................................... 15 2.3.1.1 Risk Based Inspection (RBI) ............................................................. 17 2.3.2 Pipeline Monitoring .................................................................................. 18 2.3.3 Reliability Analysis of Information .......................................................... 21 2.3.3.1 NDT Reliability and POD curves...................................................... 25 2.4 Maintenance Strategy....................................................................................... 26 2.5 Corrective and Preventive Actions .................................................................. 28 2.5.1 Composite Repair ..................................................................................... 30 2.6 Structural Health Monitoring (SHM) ............................................................... 34 2.6.1 Definitions ................................................................................................ 34 2.6.2 Aims of Structural Health Monitoring (SHM) ......................................... 37 vii 2.6.3 Optical Fibre Sensor (OFS) ...................................................................... 37 2.6.4 SHM using Electrical Strain Gauges ........................................................ 40 2.7 Introduction to Finite Element Analysis (FEA) ............................................... 42 2.7.1 Stress Concentration Factor (SCF) and Stress Intensity Factor (SIF) Measurement in Pipeline .......................................................................... 45 2.8 Experimental Approach ................................................................................... 49 2.9 Why is SHM important in the composite repair? ............................................ 51 2.10 Summary and Conclusions .............................................................................. 53 3 FINITE ELEMENT ANALYSIS (FEA) IN THE COMPOSITE BASED PIPELINE REPAIR ................................................................................................................... 55 3.1 Introduction ...................................................................................................... 55 3.2 Objectives ........................................................................................................ 55 3.3 Model and Other Parameters Selection............................................................ 56 3.4 Fundamentals of Modelling in Finite Element Analysis ................................. 57 3.4.1 Element type selection .............................................................................. 57 3.4.2 Mesh refinement ....................................................................................... 60 3.4.3 Types of Algorithms
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