The consequences of a dynamic fracture in a gas-transmission pipeline require that pipelines be designed to avoid such incidents at a high level of certainty. For this reason, the related phenomonology has been studied since the early 1970s when the possibility of a dynamic ductile fracture was recognized. Full-scale experiments were done to characterize the fracture and gas dynamics associated with this process and empirical models were developed as a means to represent these experiments in a design or analysis setting. Such experiments focused on pure methane gas, and in the early days used steels with toughnesses less than 100 J, consistent with the steel making capabilities of the 1970s. Subsequently, interest shifted to larger diameter, higher pressure, higher BTU “rich” gases requiring higher toughness steels. The full-scale tests conducted to validate the arrest toughness levels determined that these empirical models were non-conservative. This paper presents a relationship between the dynamic crack propagation resistance and the apparent crack propagation resistance as measured by Charpy vee-notch (CVN) test specimens. This relationship is used in conjunction with the existing Battelle empirical criterion for dynamic-fracture arrest to determine the apparent toughness required to arrest a propagating ductile fracture in gas-transmission pipelines. The validity of this relationship is illustrated by successful predictions of arrest toughness in pipelines under a range of conditions including rich gases and high-toughness steels, including those showing a rising upper-shelf behavior.

The ductile fracture toughness of steel is used to assess the ability of a pipeline to resist long running ductile fractures in a burst event. With the introduction of modern low carbon clean steels with ultra high toughness, conventional measures of ductile fracture toughness (standard Charpy and DWTT energy) are under review, and alternatives are being studied. The crack tip opening angle (CTOA) was investigated to evaluate its appropriateness as a measure of modern pipeline steel ductile fracture toughness. At first, fracture mechanics tests at quasi-static rate were analyzed to examine the constancy of CTOA with crack growth. The results of this initial review are based on four pipeline steels with a range of ductile fracture toughness. The CTOA values are also compared with appropriate parameters from conventional tests to examine potential relationships that may be used to indicate the relative resistance of pipeline steels to ductile fracture propagation. The final objective is to compare CTOA values determined by the simple two specimen method and those developed through a formal fracture mechanics based technique.

The control of propagating ductile (or tearing) fracture is a fundamental requirement in the fracture control design of pipelines. The Battelle two-curve method developed in the early 1970s still forms the basis of the analytical framework used throughout the industry. GASDECOM is typically used for calculating decompression speed, and idealizes the decompression process as isentropic and one-dimensional, taking no account of frictional effects. While this approximation appears not to have been a major issue for large-diameter pipes and for moderate pressures (up to 12 MPa), there have been several recent full-scale burst tests at higher pressures and smaller diameters for which the measured decompression velocity has deviated progressively from the predicted values, in general towards lower velocities. The present research was focused on determining whether pipe diameter was a major factor that could limit the applicability of frictionless models such as GASDECOM. Since potential diameter effects are primarily related to wall friction, which in turn is related to the ratio of surface roughness to diameter, an experimental approach was developed based on keeping the diameter constant, at a sufficiently small value to allow for an economical experimental arrangement, and varying the internal roughness. A series of tests covering a range of nominal initial pressures from 10 to 21 MPa, and involving a very lean gas and three progressively richer compositions, were conducted using two specialized high pressure shock tubes (42 m long, I.D. = 38.1 mm). The first is honed to an extremely smooth surface finish, in order to minimize frictional effects and better simulate the behaviour of larger-diameter pipelines, while the second has a higher internal surface roughness. The results show that decompression wave speeds in the rough tube are consistently slower than those in the smooth tube under the same conditions of mixture composition and initial pressure & temperature. Preliminary analysis based on perturbation theory and the fundamental momentum equation indicates that the primary reason for the slower decompression wave speed in the rough tube is the higher spatial gradient of pressure pertaining to the decompression wave dynamics, particularly at lower pressure ratios and higher gas velocities. The magnitude of the effect of the slower decompression speed on arrest toughness was then evaluated by a comparison involving several hypothetical pipeline designs, and was found to be potentially significant for pipe sizes DN450 and smaller.

This paper reviews the fracture control plan for the Alliance Pipeline, which is planned for operation in 2000. This natural-gas pipeline is 2627 km (1858 miles) long, running from British Columbia, Canada to Illinois, USA. Interest in the fracture control for this pipeline results from its design, which is based on transporting a rich natural gas (up to 15% ethane, 3% propane) at a relatively high pressure 12,000 kPa (1740 psi). This break from traditional pressures and lean gases, which frequently are constrained by incremental expansion, is more efficient and more economical than previous natural gas pipelines. Use of higher pressures and rich gas requires adequate fracture control for the line pipe, fittings, and valves. This fracture control has been achieved for the Alliance Pipeline by specifying high-toughness steels, in terms of both fracture-initiation and fracture-propagation resistance for the line pipe, fittings and heavy wall components. While beneficial from an economics viewpoint, the need for higher toughnesses raised concern over the validity of the fracture control plan, which was based on existing and new technology. The concern focused on fracture arrest using high toughness steels. The concern was associated with characterizing fracture arrest resistance using Charpy V-notch impact toughness, the most commonly used method to measure fracture arrest resistance. Developments were undertaken to address problems associated with the use of higher-toughness steel and these were validated with full-scale pipe burst tests to demonstrate the viability of the fracture control plan. The solution involved extending existing methods to address much higher toughness steels, which provided a significantly improved correlation between fracture arrest predictions and experimental results. In the burst tests, data was collected to validate the Alliance design and also to extend the database of fracture arrest data to assist future pipelines. Data such as the pressure between the pipe and soil as the gas escapes from the pipe, the sound levels in the atmosphere, the movement and strains in the pipe ahead of the running fracture were instrumented in the test and the available results are presented.

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