Four Point Fatigue Testing of Pressurized Composites

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Four-Point Fatigue Testing of Pressurized Composite Pipe
Article in Journal of Pressure Vessel Technology · June 2009

DOI: 10.1115/1.3008036
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D. P. Gerrard
Baker Oil Tools,
Four-Point Fatigue Testing of
Houston, TX 77044
e-mail: dave_errard@bakeroiltools.com Pressurized Composite Pipe
R. J. Scavuzzo This technical paper presents a comparative study of the fatigue strength of high-pressure
Professor Emeritus
Fellow ASME composite pipes and high-pressure composite pipes containing joints. The test specimens
e-mail: rscavuzzo@uakron.edu used in this experimental investigation were exposed to cyclic bending stresses and to
cyclic bending stresses in combination with constant or cyclic internal pressures gener-
T. S. Srivatsan ated by water, brine, and crude oil. The extrinsic influence of elevated temperature on
Professor fatigue performance was also examined. A new four-point bending fatigue machine was
Fellow ASME developed at the University of Akron to accomplish the testing. For each test specimen,
e-mail: tsrivatsan@uakron two types of failure were distinctly observed. After a number of repeated cycles, the fluid
under internal pressure began to gradually leak through the fine microscopic cracks in
Department of Mechanical Engineering, the matrix. The fine microscopic cracks were oriented in the circumferential direction of
The University of Akron, the pipe. However, despite the occurrence of “weeping failure” of the pipe, internal
Akron, OH 44325-3904 pressure could be easily maintained. After about 10–100 times the number of cycles
required for “weeping,” the fiber reinforcements of the pipe gradually fractured and the
T. S. Miner internal pressure could no longer be maintained. The loss of pressure is referred to as
National Feed Screw Machining and Welding “pipe failure.” In these tests, the primary parameter controlling failure was orientation
Engineers, Inc., of the fiber reinforcements in the body of the pipe. Those fibers aligned along the pipe
Massillon, OH 44647 axis revealed a substantial improvement in cyclic fatigue resistance. The existence of a
e-mail: tminer@nfm.net joint in the test specimen showed secondary importance while contributing to degrada-
tion of the fatigue resistance of the specimen. Both types of failure were found to be
Olagoke Olabisi dependent on temperature, over the range tested 共22– 66° C, and also dependent on the
Director type of internal liquid used. The specimens tested using crude oil at 66° C as the internal
Internal Corrosion Engineering, fluid revealed the lowest fatigue resistance. 关DOI: 10.1115/1.3008036兴
Corporate Engineering Department,
Corrpro Companies, Inc.,
Houston, TX 77040
e-mail: oolabisi@corrpro.com
1 Introduction reinforced piping, while the standard ASTM D2143-94 关5兴 con-
centrates on the cyclic fatigue of the composite pipe. None of the
The primary objective of the research endeavor described in
existing standards address the condition of simultaneous bending
this paper was to compare the fatigue strength of epoxy fiberglass
and cyclic fatigue described in this technical paper. In this study,
composite pipes, with and without pipe joints, provided by two
an attempt is made to apply the concepts outlined in Ref. 关4兴 to the
independent vendors. The pipe specimens provided by the two
data sets generated in this study. The results are presented and
vendors are henceforth referred to in this technical manuscript as
discussed in Sec. 4.8.
共a兲 Manufacturer A and 共b兲 Manufacturer B. All of the pipes were
In this project, a confidentiality agreement was signed in which
rated at 2000 psi 共13.8 MPa兲. A chosen composite pipe was sub- the pipe vendors could not be disclosed. In fact, initially, compos-
ject to two types of fatigue loading: ite pipes were tested, and the sources of the pipe were unknown.
共a兲 cyclic bending with a constant internal pressure However, as the project proceeded, the vendor names were deter-
共b兲 cyclic bending with cyclic internal pressure 共for this cy- mined from packing slips, etc., by the authors, but the names
clic loading, peak bending stresses were in-phase with cannot be published. It is safe to say that the pipes were supplied
the stresses arising from internal pressure兲 by two prominent suppliers, except for one special pipe design
discussed below, which was much stronger in fatigue than the
These tests were conducted at both ambient 共22° C兲 and el- other pipes tested. It is felt by the authors that the fatigue data
evated 共66° C兲 temperatures using three different fluids 共共i兲 water, developed are useful to designers using composite pipes, espe-
共ii兲 brine, and 共iii兲 crude oil兲. The mechanical response of the cially considering the three internal pipe fluids and variations in
composite specimens to include failure behavior was recorded for test temperatures. In the Appendix, photographs of the pipes and
all of the different test conditions. Several ASTM standards exist some of the joints and joint failures are presented.
for the thermoplastic pipe 关1–3兴, reinforced thermoplastic pipe
关2,3兴, and fiberglass 共glass-fiber-reinforced thermosetting resin兲
pipe 关3–5兴. The ASTM Standard D2992-96 is widely accepted and 2 The Experimental Apparatus
used for obtaining the hydrostatic pressures for fiberglass-
2.1 The Four-Point Bending Fatigue Test Machine. A new
four-point bending test machine, shown in Fig. 1, was designed,
Contributed by the Pressure Vessel and Piping Division of ASME for publication
in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received August 6,
constructed, instrumented, and calibrated at the University of Ak-
2007; final manuscript received May 12, 2008; published online April 7, 2009. Re- ron for the purpose of this program. The machine provides the
view conducted by Edward A. Rodriguez. following testing capabilities:
Journal of Pressure Vessel Technology Copyright © 2009 by ASME JUNE 2009, Vol. 131 / 031402-1
Downloaded 22 Feb 2011 to 155.246.64.39. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm
is viewed by the machine operator through two polycarbonate
windows 共the first is located on the side and the other at the top of
a steel enclosure兲, which safely covers the moving parts of the
machine and the pressurized specimen during testing.
2.2 Instrumentation. The key measurements made on the
pipe specimens were
共i兲 force from the load cell
共ii兲 internal pipe pressure
共iii兲 temperature of the internal fluid
共iv兲 strains measured with strain gauges
共v兲 cycle counter
The strain gauges acquired from Micro-measurements Inc. 共di-

vision of Vishay Intertechnology, Malvern, PA兲共Type CEA-O6-
187UW-350兲 were used in all of the mechanical tests. They were
Fig. 1 Side view of the four-point fatigue test machine devel- placed axially at the center of the pipe 共or near joint edges兲 and
oped for this project oriented along the axis of the pipe. They were placed both at the
top and bottom of the pipe circumference in order to sense the
largest level of bending strain. It is worth noting that for cyclic
共i兲 controlled cyclic displacements up to approximately 6 in. tests the temperature compensation characteristics of the gauge
共bending force up to 22,000 lb 共97,500 N兲兲 with controlled were not needed to obtain alternating range strains. All of the data,
internal pipe flow except cycle count, were recorded on a PC using 共a兲 Data Window
Pro+ and 共b兲 an analog to digital 共A-D兲 board, i.e., Model DI-400
共a兲 cyclic pressure 共0 – 1500 psi 共0 to 10.3 MPa兲兲
from Dataq Instruments, Inc. 共Akron, OH兲 The strains were also
共b兲 internal flow to 8.5 gal/ min 共32.2 L/min兲 recorded on the PC using an Omega A-D conversion board.
共c兲 controlled temperature of the internal fluid 共room tem-
perature to 200° F 共93.3° C兲兲 3 Pipe Specimens
共ii兲 strain, temperature, force, and displacement measure- Both vendors were invited to provide their best designs for the
ments. test program. Manufacturer A provided a pipe having winding
共iii兲 specimen lengths up to 12 ft 共3.66 m兲 patterns quite different from their standard catalog variety. The
共iv兲 adaptable for other fatigue-critical applications besides primary purpose was to improve performance throughout the test-
piping ing program. All but one of the pipes provided by Manufacturer B
was of the standard catalog design. This one special pipe is re-
Two hydraulic systems are housed in the base of the machine. One ferred to as Pipe B5. Detailed engineering data on the pipes made
system, through a double-shafted cylinder, drives a system of sup- available by the two vendors were not provided due to the propri-
ports, linkages, and rotating yokes to create a state of pure four- etary nature of the intrinsic details pertaining to processing and
point bending on the specimen. The four yokes that hold the preparation of the pipes. The exact matrix materials, the fiber
specimen are held in a vertical position with a steel bar. The bar is characteristics, the number of plies, and the angle of the plies
used during specimen installation to ensure an alignment of the were also not known. The two manufacturers 共Manufacturer A and
test specimen with the test fixture. The two center yokes are Manufacturer B兲 supplied a total of 57 pipe specimens. All speci-
hinged to a short beam supported by the hydraulic cylinder. The mens were between 11 ft 共280 mm兲 and 12 ft 共305 mm兲 long.
displacement limits of the hydraulic cylinder are controlled using Both plain straight pipes and pipes having joints at their midlength
contact switches. The positions of the contact switches are fixed were supplied in the following numbers:
during a test. Thus, the value of bending deflection is held con-
stant during the cyclic bending. • Manufacturer A plain pipe: 9
Since strains in the pipe specimens are almost linearly related to • Manufacturer A joined pipe: 13
deflection, the displacement controlled test machine can be con- • Manufacturer B plain pipe: 9
sidered to be a cyclic strain test in lieu of a constant force. The • Manufacturer B plain pipe 共blue matrix兲: 1
pipe initially behaves in a linear manner until cycling begins to • Manufacturer B joined pipe type A: 13
crack the matrix. Epoxy is a brittle material, so there is no plastic • Manufacturer B joined pipe type B: 13
regime in bending. A load cell mounted between the hydraulic • total: 58
cylinder and the center box measures the total force exerted by the
Although both vendors use a threaded pipe joint, the design of
cylinder. The two outer yokes that fix the test specimen onto the
the joints was quite different. In the design of Manufacturer A,
large beam are also hinged.
one side of the pipe was tapered while the other side was straight.
The central section of the composite pipe, between the two
Female threads were cut into the tapered section, and male threads
inner yokes, is subjected to a constant bending moment across its
were cut into the straight section. There are two O-rings on either
length. The distance between the two center yokes is 3 ft
end of the threads. The straight section is threaded onto the ta-
共914 mm兲 and the distance between the outer yoke and the inner
pered section to form the pipe joint of Manufacturer A. The de-
yoke is 3.5 ft 共1071 mm兲. The hydraulic system effectively con- flection experienced by the threaded joint due to rigid body rota-
trols the temperature, flow, and pressure of the internal fluid 共wa- tion during loading is substantial and could not be easily
ter, brine, and crude兲. It consists of several key components, and observed. Since the pipe is loaded in four-point bending, the cen-
these include the following: 共i兲 an insulated fluid reservoir, 共ii兲 ter of the pipe has a uniform moment over this region. Both of the
stainless steel pump, 共iii兲 pressure sensor, 共iv兲 electronic actuated pipe joints provided by Manufacturer B when tested used a collar
relief valve, 共v兲 thermocouple control circuit, and 共vi兲 heat having straight threaded female pipe connections on both sides.
exchanger. Two types of joints were made available by Manufacturer B:
When a specimen fractures, the loss of internal fluid pressure is
detected by the pressure sensor, which signals a series of relays 共a兲 joints having a 206 mm long collar 共type A兲
and shuts the machine down. During a test, the onset of weeping 共b兲 joints having a 267 mm long collar 共type B兲
031402-2 / Vol. 131, JUNE 2009 Transactions of the ASME
Fig. 2 Measured loads versus deflections „actual data… and linear lines based on the initial stiffness used in Markl calcu-
lations for two Manufacturer B specimens
The collar thickness of both designs was 1 in. 共25 mm兲. One forces used in the conventional Markl method are higher
thread was the standard thread 共Type A兲 while the other 共known as in magnitude than the actual values shown in Fig. 2.
Type B兲 was optimized for field applications were only a short
assembly time is required. Further, in the design of Manufacturer The variation of load ratio 共F / F0兲 as a function of number of
B, two of the pipes that threaded onto the coupling did not have a cycles is shown in Fig. 3, where F is the peak force at a given
constant outer diameter. The diameter was thinner outside of the cycle and F0 is the peak force at the initial cycle. The pipe stiff-
center and was subjected to a uniform moment by the fatigue ness decreases as the bending fatigue progresses leading to a no-
machine. In some cases, failure of the pipes due to fatigue ticeable differential between the Markl stress and the actual stress.
occurred at the thinner section outside of the yoke located at the There occurs a 50% drop in peak force, or pipe stiffness, at
strategic center. Manufacturer B provided one plain pipe having a 10,000 cycles.
blue matrix material instead of the brownish epoxy material used
for all of the other pipe specimens. The stiffness of this pipe was 4.1 Weeping Failures. The weeping failures of all pipe speci-
higher, by over a factor of two, than the other plain pipes provided mens provided by the two vendors are shown in Fig. 4 as the
by Manufacturer B. Fatigue properties of this specimen are quite variation of stress with cycles to failure 共N兲. In this figure, the
similar to those of the pipe specimens provided by Manufacturer pipe of Manufacturer B began to weep at fewer cycles when com-
A. pared to the pipe of Manufacturer A at a specified stress level. A
similar comparison of pipe failure data having the same trends is
4 Results shown in Fig. 5. The data for pipes provided by Manufacturer B
Extremely useful data sets were obtained from 52 of the 58 for the various test conditions, are labeled and shown in Fig. 6.
specimens. The stresses were calculated using two different ap- The test data have a lower bound for the cyclic pressure with the
proaches: heated crude oil at 150° F 共66° C兲. As observed from these data,
the heated crude oil at a constant pressure at 1000 psi 共6.9 MPa兲
共a兲 In the first approach, the alternating force was used to
generates results quite similar to those for pipes with a cyclic
calculate an alternating bending stress. Since the forces
internal pressure.
gradually decrease with cycles, an initial force is used to
determine the initial stress. The fatigue curves are shown The data for pipes provided by Manufacturer A are plotted
with the bending stress as the ordinate. against stress range and shown in Fig. 7. The lowest stress value
共b兲 In the second approach, the stresses were calculated us- for a given initial stress range occurs for a cyclic pressure at
ing the method of Markl. This approach is used in ASME 150° F 共66° C兲 and for the crude oil. However, the test results are
codes for metal piping. In this procedure, the force is not significantly different from the case of a constant pressure of
based on an initial stuffiness. The forces are calculated by 1000 psi 共6.9 MPa兲. The weeping failure data and pipe failure
multiplying the stiffness with the specified deflection 共D兲. data as a functions of measured alternating strains are shown in
The force is then used to calculate the stresses are based Figs. 8 and 9. The trends are quite similar to the variation of
on the initial stiffnesses times the displacements. The alternating stress with cycles to failure 共N兲.
Journal of Pressure Vessel Technology JUNE 2009, Vol. 131 / 031402-3
Fig. 3 Load ratio „force, F/„initial force, F0…… as a function of cycles. The reduction of force with cycles approaches a factor
of 2.
4.2 Pipe Failure. A comparison of the pipe failure data for all expected, the plain pipe revealed a noticeably better fatigue resis-
specimens is shown in Fig. 5. At a given stress level, the pipes tance, i.e., life than the pipe containing joints. The least-squares
provided by Manufacturer A had a longer fatigue life. Also, as straight line for the plain pipes of Manufacturer A has a slope that
Fig. 4 Comparisons of Manufacturer A and Manufacturer B pipe weeping failures
Fig. 5 Comparisons of Manufacturer A and Manufacturer B pipe failures
Fig. 6 Manufacturer B weeping failure data for various test conditions „alternating stress versus cycles to failure…
Fig. 7 Manufacturer A weeping failure data for various test conditions „alternating stress versus cycles to failure…
Fig. 8 Initial alternating strain versus cycles to failure for pipe weeping failure data
Fig. 9 Initial alternating strain versus cycles to failure for pipe failure data
is different from the other least-squares fits. The test data point at 4.5 Markl Bending Stresses. The Markl stresses were calcu-
100 cycles does affect the slope. Additional test data are needed lated by multiplying the prescribed peak displacements with the
so as to make these curves similar. Other comparisons for both initial stiffness. This type of stress calculation results in noticeably
weeping and pipe failure are shown in Figs. 8 and 9. higher stresses than those based on the measured forces from the
load cell. The data are plotted and shown in Fig. 13 for the case of
4.3 Weeping Failure Versus Pipe Failures. The cycles re- weeping failure and Fig. 14 for pipe failure.
quired for the initiation of weeping failure in the pipe specimens
of Manufacturer A pipe specimens 共Fig. 10兲 are compared with 4.6 Effect of Temperature. The intrinsic effects of increasing
the pipe specimens provided by Manufacturer B in Fig. 11. Weep- the temperature of the circulating fluid from room temperature
ing is initiated prior to a complete failure of the composite pipe. In 共=72 ° F or 22° C兲 to 150° F 共66° C兲 for the pipes provided by
the high cycle region, the difference approaches a factor of 100 Manufacturer A are shown in 共a兲 Fig. 15 for the case of weeping
for cycles greater than 2000 cycles. In the low cycle region 共N failure and 共b兲 Fig. 16 for pipe failure. Similar data for the pipes
⬍ 100兲, the factor is reduced to about 10. This observation is provided by Manufacturer B are plotted in 共i兲 Fig. 17 for weeping
depicted in Fig. 12 in which the log of the ratio of cycles of failure failure and 共ii兲 Fig. 18 for the total pipe failure. A comparison of
to cycles to weep is plotted as a function of cycles. This log ratio the pipes provided by the two manufacturers is shown in Figs.
varies from 1 to 2 or from 10 to 100 cycles. There is one point 19–22. All of the gathered test data indicate a marginal reduction
located at 32,000 cycles, which has a log ratio of 2.45, or a factor in fatigue strength of the composite pipe when the temperature is
of 280, on cycles. For this case, failure of the composite pipe will increased over the chosen temperature range.
occur at 280 times the cycles required to initiate weeping failure. 4.7 Calculations of the Thermal Stress. There are a number
4.4 Pipe Stiffness. The stiffness of the pipe varies with cycles of different types of thermal stresses that can be developed in a
since the force required for a given deflection gradually decreases composite pipe arising from 共i兲 end constraints, 共ii兲 changes in
with time 共as shown in Fig. 3兲. The alternating stresses used to pipe thickness, 共iii兲 connections to nozzles or flanges, and 共iv兲
obtain the various graphical representations are based on an initial thermal shock. For the epoxy matrices, these stresses will add to
measured stiffness. This pipe stiffness changes during fatigue test- operational stress and tend to reduce fatigue strength. Considering
ing because of the continual cracking of the epoxy matrix. Thus, the axial load in the pipe by a change in the internal fluid tem-
the stiffness continually decreases until final pipe failure. All perature, which is the predominate loading in the test equipment
graphical representations of stress with cycles use the initial stiff- as the temperature is increased, the axial stress is approximately
ness 共to include the Markl stress calculations兲. The stiffness of the
␴ = − 共E␣⌬T兲共1兲
plain pipe provided by Manufacturer B is lower than the stiffness
of the pipe provided by Manufacturer A by a factor of about 1.5. Overall, thermal stresses, in a completely constrained piping sys-
The stiffness of the Manufacturer B pipe specimen 共B5兲 is much tem, or those caused by thermal shock are bounded by Eq. 共1兲:
greater than the standard pipe of Manufacturer B by approxi- E ⫽ the elastic modulus
mately a factor of 2. ␣= ⫽ the coefficient of thermal expansion
Fig. 10 Initial alternating stress versus cycles to both weeping failure and pipe failure for Manufacturer A pipe
Fig. 11 Initial alternating stress versus cycles to both weeping failure and pipe failure for Manufacturer B pipes
Fig. 12 Log of the ratio of cycles to pipe failure to cycles to weeping failure. Most data indicate that pipe failure is from 10
to 100 times the cycles to initiate weeping.
Fig. 13 Comparisons of Manufacturer A and Manufacturer B pipe weeping failures plotted against Markl stresses
Fig. 14 Comparisons of Manufacturer A and Manufacturer B pipe failures plotted against Markl stresses
⌬T ⫽ temperature change the axial stresses are zero. The restraints at each end of the pipe
The appropriate physical coefficients for 共i兲 Manufacturer A are take the axial forces and not the walls of the pipe. In the fatigue
EA = 12.7 GPa and ␣ = 2.57⫻ 10−5 m / m / ° C, and those for 共ii兲 machine used, the fluid flows through holes located at the end
Manufacturer B are EB = 13.6 GPa and ␣ = 1.58⫻ 10−5 m / m / ° C. caps. Throttling the flow upstream of the exit end cap develops an
Using the equation and considering a temperature change of internal pipe pressure of up to 1000 psi 共6.89 MPa兲. This pressure
+70° C, the thermal stress in a pipe provided by Manufacturer A is acts on the end caps, and the end conditions approach the free-end
−22.8 MPa 共−3300 psi兲, while the thermal stress in a pipe pro- described in the ASTM Standard. However, because of the pres-
vided by Manufacturer B is −15.0 MPa 共=2200 psi兲. It should be ence of the flow holes, the axial stresses are significantly lower
noted that the stress equation does not take into account intercom- than those for a completely capped end condition.
posite stresses between the matrix and fibers or between the lami- Two types of loading conditions are addressed in the referenced
nates. Additional study and detailed pipe information are required standard:
to determine such intercomposite stresses. For a thermal shock, 共1兲 hydraulic design stress 共HDS兲.
the thermal stress on the inside wall of the pipe is increased by 共2兲 long-term hydraulic strength 共LTHS兲.
1 / 共1 − ␷兲, where ␷ is Poisson’s ratio. However, the pipes in this
test program were not subjected to thermal shock. The HDS is the maximum tensile 共hoop兲 stress in the wall that
There are many types of thermal stresses that are dependent on can be applied cyclically, or continuously, to a piping component
design. However, an upper bound of the thermal stresses is esti- with a high degree of certainty that failure will not occur. The
mated by assuming the pipe to be completely constrained. For LTHS is the maximum tensile 共hoop兲 stress in the wall under
example, a buried pipe that cannot expand along its length would cyclic loading conditions that will cause failure after a specified
develop stresses based on the equation shown. However, the number of cycles. In this analysis, the ASTM Standard method
stresses would be larger should the pipe tend to either buckle or used to determine the LTHS is applied to the cyclic axial stresses
bend. Equation 共1兲 also provides an upper bound for thermal even though cyclic or constant hoop stresses are present. The axial
shock. stresses associated with the bending fatigue stresses far exceed the
4.8 ASTM D2992 Calculations. Contained in this section is average hoop stresses developed due to an internal pressure of
the description of the statistical methods described in ASTM 1000 psi 共6.89 MPa兲. For the pipe provided by Manufacturer A,
D2992 关4兴 as applied to the data presented above. This ASTM the hoop stress on the wall of the pipe arising from an internal
Standard considers two types of loads: 共i兲 a hydrostatic internal pressure alone is Shoop = 6600 psi 共45.5 MPa兲,
pressure and 共ii兲 a cyclic internal pressure. Further, two types of
pipe end conditions are also considered: 共a兲 free-ended pipe and P共D − d兲
Shoop = = 6600 psi 共2兲
共b兲 restrained ended pipe. 2tr
In a pipe having free-ends, the pipe has end caps, and the axial
stresses arising from internal pressure are approximately one-half where
of the hoop stresses. However, for the restrained end condition, P ⫽ pipe maximum internal pressure 共1000 psi兲
Fig. 15 Comparisons of Manufacturer A weeping failure data at room temperature and 150° F „66° C… plotted against
stresses
Fig. 16 Comparisons of Manufacturer A pipe failure data at room temperature and 150° F „66° C… plotted against stresses
Fig. 17 Comparisons of Manufacturer B weeping failure data at room temperature and 150° F „66° C… plotted against
alternating stresses
Fig. 18 Comparisons of Manufacturer B pipe failure data at room temperature and 150° F „66° C… plotted against alternating
stresses
Fig. 19 Comparisons of Manufacturer A and Manufacturer B weeping failures at room temperature plotted against alter-
nating stresses
Fig. 20 Comparisons of Manufacturer A and Manufacturer B weeping failures at 150° F „66° C… plotted against alternating
stresses
Fig. 21 Comparisons of Manufacturer A and Manufacturer B pipe failures at room temperature plotted against alternating
stresses
Fig. 22 Comparisons of Manufacturer A and Manufacturer B pipe failures at 150° F „66° C… plotted against alternating
stresses
Fig. 23 Regression analysis of log alternating stress versus log cycles to weeping based on ASTM D 2992
D ⫽ outside diameter 共7.10 in.兲 whichever is less. Except for Figs. 23 and 24, the regression equa-
tr ⫽ pipe wall thickness 共0.5 in.兲 tions depicted in the figures were generated using the expression
The cyclic axial bending stresses vary from ⫾9000 psi to of Excel©,
⫾ 25000 psi 共62– 172 MPa兲. Thus, the cyclic axial stresses domi- Y = A loge共N兲 + B = A ln共N兲 + B 共4兲
nate in causing failure. In some tests, the internal pressure was
also cycled as well as the axial stresses. The cyclic pressure de- where
creases the strength of the composite pipe when compared to the Y ⫽ alternating axial bending stress 共psi兲
bending fatigue using a constant pressure. However, to apply the A , B ⫽ constants determined by regression
LTHS, the cyclic alternating axial bending stresses, defined in this N ⫽ cycles to failure
context to be one-half of the stress range, or the alternating stress, In Table 1, the ASTM regression method is compared with the
is used rather than the hoop stresses. In the fatigued pipe speci- linear log regression calculated using Excel©: As seen from Table
mens, fine microscopic cracks in the brittle epoxy appeared during 1, for the weeping data, the ASTM method is far more conserva-
the test. In the ASTM Standard used, failure is defined as the tive when compared to the linear log regression.
transmission of test fluid through the body of the specimen,
whether it be through the independent or conjoint and mutually 5 Conclusions
interactive influences of 共a兲 a wall fracture, 共b兲 localized leaking, The following are the essential findings of this comprehensive
and 共c兲 weeping at a distance greater than one diameter from the experimental investigation on composite pipes:
end. A LTHS analysis of the ASTM document provides a linear
equation on a log-log plot, 1. Two types of failure were observed: 共i兲 a weeping failure
with a small leak through the matrix that is caused by a
y = ax + b 共3兲 fatigue fracture of the reinforcing fibers and 共ii兲 a failure that
where results in a loss of internal pressure and, usually, a large
y ⫽ log 共axial alternating bending stress amplitude tearing failure of the pipe wall.
x ⫽ log 共cycles to failure 2. The pipe of Manufacturer A had a greater resistance to bend-
a , b ⫽ constants determined by regression analysis. ing fatigue and internal pressure than the standard pipe of
The results are presented in Fig. 23 for weeping failure and Fig. Manufacturer B. The one specially wound Manufacturer B
24 for pipe failure In both cases, all fatigue test data were col- specimen 共B5兲 had fatigue strength characteristics similar to
lected on the Manufacturer A and Manufacturer B pipe specimens. the specially wound Manufacturer A specimens. Since bend-
Two regression analyses were performed to obtain Eq. 共3兲 for each ing stress in the walls of the composite pipe can develop at
vendor for both failure modes. The resultant four equations are flanges and other connections in a pipe due to transient ther-
plotted in the two graphs. The results are accurate to about mal effects, the general conclusion reached in these cyclic
100,000 cycles. Above this value the results are expected to be bending cyclic pressure tests can also be applied to other
conservative. Additional testing is recommended if this range is to loads on the composite pipe.
be extended up to 107 cycles. The equations are based on a re- 3. The effect of increasing temperature from room temperature
gression analysis of the measured data. The design curves must be 共22° C兲 to 66° C is to marginally reduce cyclic strength.
below this regression curve. The fatigue design curves of Section 4. The effect of cyclic pressure loading from 400 psi
3 of the ASME Boiler and Pressure Code are based on reducing 共2.7 MPa兲 to 1000 psi 共6.0 MPa兲 is not large for these
the “best-fit” curve by a factor of 2 on stress or 20 on cycles, specimens since they are rated at 2000 psi 共13.4 MPa兲. If the
Fig. 24 Regression analysis of log alternating stress versus log cycles to pipe failure based on ASTM D 2992
cyclic pressure were to increase its range to the maximum Cyclic bending stresses in the pipe wall can develop from many
design value, the effect could be significant and noticeable. sources during startup or shutdown. At flanges and other pipe
5. Heated pressurized crude oil circulating through the pipe connections, local bending stresses will develop in the pipe walls
causes slightly lower fatigue strength than brine. However, from the internal pressure. All these factors must be considered to
tests were not run using heated water. It is believed that this obtain a leak-proof piping system. Composite piping systems in
reduction is caused by the corrosive elements and com- service should be examined to evaluate the significance of bend-
pounds in the oil but no tests were done to explore this ing fatigue and local pipe wall bending stresses on pipe perfor-
reduction. mance.
6. Pipe fracture had a fatigue life of 10–100 times the initiation
of a weeping failure. Acknowledgment
It may be possible to use a more ductile matrix material to avoid The authors gratefully acknowledge the support of Saudi Ara-
cracking in the pipes and initiating early weeping failures. After a bian Ministry of Petroleum and Mineral Resources and Saudi Ara-
relatively few cycles, the cracks in the pipes collate to form a bian Oil Company 共Saudi Aramco兲. The authors also acknowledge
small leak. Even though fibers in the pipe have not failed and support of this research by The University of Akron.
pressure of the internal fluid can be maintained, there occurs a
leak. A more ductile matrix material could aid in improving the Appendix
overall performance of the pipe. The fatigue tests were run at
about 3 s / cycle or 20 cycles/ min. A slower cyclic rate may then Photographs of the pipe specimens, joints, and failures are de-
allow solvents to cause more damage to the matrix fibers. picted in Figs. 25–30.
Table 1 Comparison of regression methods
Manufacturer A weeping data

N ASTM ASTM method Appendix 1 method
Cycles ASTM log ASTM stress, psi stress, psi
300 4.0916 12348 13309

50 4.2389 17333 17567
4500 3.8689 7395 6874
Manufacturer B weeping data

N ASTM ASTM Appendix 1 method
Cycles ASTM log ASTM stress stress, psi
300 3.9421 8753 9253

50 4.0471 11146 11256
4500 3.7835 6074 6226 Fig. 25 A straight pipe without a joint being tested in the test
machine „Fig. 1…
Fig. 26 Some of the pipe specimens to be tested Fig. 29 Testing of a typical screw-type pipe joint. Water drops
on the plastic window are indicative of small cracks through
the pipe epoxy matrix while maintaining pressure.
Fig. 27 Failure of a straight pipe without a joint. The pressure

stopped the machine, but the failure there was complete rip-
ping of the composite pipe.
Fig. 30 Thread slip failure of a typical screw-type pipe joint
References
关1兴 ASTM D 2837-92, 1992, “Standard Test Method for Obtaining Hydrostatic
Design Basis for Thermoplastic Pipe Materials,” ASTM, Philadelphia, Ap-
proved: June 15.
关2兴 ASTM D 1598-86, 1986, “Standard Test Method for Time-to-Failure of Plastic
Pipe Under Constant Internal Pressure,” ASTM, Philadelphia, Approved: Feb-
ruary 28.
关3兴 ASTM F 948-94, 1994, “Standard Test Method for Time-to-Failure of Plastic
Piping Systems and Components Under Constant Internal Pressure With
Flow,” ASTM, Philadelphia, Approved: Apri1 15.
关4兴 ASTM D 2992-96, 1996, “Standard Practice for Obtaining Hydrostatic or
Pressure Design Basis for ‘Fiberglass’ 共Glass-Fiber-Reinforced Thermosetting-
Resin兲 Pipe Fittings,” ASTM, Philadelphia, Approved: Apri1 10.
关5兴 ASTM D 2143-94, 1994, “Standard Test Method for Cyclic Pressure Strength
of Reinforced, Thermosetting Plastic Pipe,” ASTM, Philadelphia, Approved:
Fig. 28 Typical screw-type pipe joint December 15.
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Four-Point Fatigue Testing of Pressurized Composite Pipe

Article in Journal of Pressure Vessel Technology · June 2009

T. S. Srivatsan Olagoke Olabisi

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Journal of Pressure Vessel Technology JUNE 2009, Vol. 131 / 031402-3

Fig. 4 Comparisons of Manufacturer A and Manufacturer B pipe weeping failures

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Table 1 Comparison of regression methods

Manufacturer A weeping data

300 4.0916 12348 13309

Manufacturer B weeping data

300 3.9421 8753 9253

031402-16 / Vol. 131, JUNE 2009 Transactions of the ASME

Fig. 27 Failure of a straight pipe without a joint. The pressure

Journal of Pressure Vessel Technology JUNE 2009, Vol. 131 / 031402-17

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