Comprehensive Data Model to Characterize Long Term Integrity and Process Parameter Interactions Governing the Butt Fusion Process
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Comprehensive Data Model to Characterize Long Term Integrity and Process Parameter Interactions Governing the Butt Fusion Process

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  • Abstract:
    Since 2007, NYSEARCH and TEJ Group have been performing comprehensive technical work to better understand the thermal and mechanical interactions governing the integrity of heat fusion joints in order to establish the necessary foundations or criterion for the continued development of advanced NDE technologies in a phased approach. Given the numerous variables and inherent complexities associated with the heat fusion joining process, the objective of the Phase I portion of the overall program was to utilize a hybrid approach to analyze the interactions for the respective fusion process parameters and evaluate the efficacy of various short-term and long-term tests to characterize the long-term strength of butt fusion joints subjected to combined loading while in-service. Leveraging the understanding from Phase I, the objective of Phase II was to develop a statistical data model for the butt fusion process taking into account various process parameters of interest using a novel test methodology (i.e. whole pipe creep rupture test) as a measure of long term strength. This report presents a summary of the key finding from the Phase II portion of the program including: (1) There are strong interactions two-way interactive affects between respective fusion process variables; and (2) The data demonstrates that the overall fusion process can be optimized by establishing distinct limits for the respective fusion process variables. The most important finding from this study is that the heater iron temperature needs be oriented towards higher heater iron temperature ranges. In addition, the results demonstrate that interfacial pressure has a second order influence on the overall strength and integrity of the joint – a point which was also observed in the Phase I portion of the program.
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