Use of Full-Scale Destructive Testing As a Means for Managing Mechanical Integrity

Abstract Full-scale destructive testing is an effective means for evaluating the mechanical integrity of pipeline and piping systems. Typically, inspection technologies provide the first source of data from which critical integrity management decisions are made. The resulting inspection data are then processed and utilized in a variety of ways, including finite element analysis, fracture mechanics, and risk-based software packages that all involve some form of numerical modeling. While there is no doubt that numerical modeling plays a critical and essential role in managing the structural integrity of aging assets, the increased use of full-scale testing could greatly enhance industry s ability to more accurately evaluate the threats associated with anomalies of various forms. The fundamental goal of any full-scale test is to simulate real-world conditions and establish a true limit state condition by applying simulated loads that could lead to failure. These include various means of loading including bending, axial tension / compression, elevated temperature conditions, cyclic pressure testing, and burst testing. Further, full-scale testing is an ideal means for validating repair technologies, including composite repair systems. This paper provides several case studies on the full-scale assessment of dents, crack-like features in seam welds, and simulated bending associated with external loads, as well as the assessment of repair technologies including composites. The goal of this paper is to provide readers with a better understanding on the benefits associated with full-scale testing, while at the same time presenting various options available for testing that include the fabrication of specialized fixtures and equipment to achieve desired loading conditions.