Elastic–plastic J and COD estimation schemes for 90° elbow with throughwall circumferential crack at intrados under in-plane opening moment

Leak-before-break (LBB) assessment of primary heat transport piping of nuclear reactors involves detailed fracture assessment of pipes and elbows with postulated throughwall cracks. Fracture assessment requires the calculation of elastic–plastic J-integral and crack opening displacement (COD)¹ for these piping components. Analytical estimation schemes to evaluate elastic–plastic J-integral and COD simplify the calculations. These types of estimation schemes are available for pipes with various crack configurations subjected to different types of loading. However, such schemes for elbow (or pipe bend), which is one of the important components for LBB analyses, is very meager. Recently, elastic–plastic J and COD estimation scheme has been developed for throughwall circumferentially cracked elbow subjected to closing bending moment. However, it is well known that the elbow deformation characteristics are distinctly different for closing and opening bending modes because the ovalisation patterns of elbow cross section are different under these two modes. Development of elastic–plastic J and COD estimation scheme for an elbow with throughwall circumferential crack at intrados subjected to opening bending moment forms the objective of the present paper. Experimental validation of proposed J-estimation scheme has been provided by comparing the crack initiation, unstable ductile tearing loads and crack extension at instability with the test data. The COD estimation scheme has been validated by comparing the COD of test data with the predictions of the proposed scheme.     

Finite volume method and multigrid acceleration in modelling of rapid crack propagation in full-scale pipe test

Rapid Crack Propagation (RCP) along pressurised plastic pipes is by far the most dangerous pipe failure mode. Despite the economic benefits offered by increasing pipe size and operating pressure, both strategies increase the risk and the potential consequences of RCP. It is therefore extremely important to account for RCP in establishing the safe operational conditions. Combined experimental-numerical study is the only reliable approach of addressing the problem, and extensive research is undertaken by various fracture groups (e.g. Southwest Research Institute – USA, Imperial College – UK). This paper presents numerical results from finite volume modelling of full-scale test on medium density polyethylene gas pressurised pipes. The crack speed and pressure profile are prescribed in the analysis. Both steady-state and transient RCPs are considered, and the comparison between the two shown. The steady-state results are efficiently achieved employing a full multigrid acceleration technique, where sets of progressively finer grids are used in V-cycles. Also, the effect of inelastic behaviour of polyethylene on RCP results is demonstrated.     

Pipe-defect assessment based on the limit analysis, failure-assessment diagram, and subcritical crack growth

We analyze the serviceability of a pipe containing a defect by the following three methods: limit analysis, failure-assessment diagram, and subcritical crack growth. The use of the proposed complex approach is explained by the fact that, despite the plasticity of pipe steels, they can suffer quasibrittle fracture (under the conditions of plane deformation) or fail as a result of plastic collapse. Moreover, the final fracture of a pipe with defect is preceded by the stage of stable crack growth. Therefore, in analyzing the serviceability of the pipe, one should also take into account the “leak-before-break” criterion. To take into account all these circumstances, it is necessary to use the indicated three methods, as in the case of evaluation of the serviceability of a pipe of API X52 steel containing a surface semielliptic notch. Defects of this sort reflect the influence of the surface gouges and dents responsible for the failures of pipes under the action of internal pressure. Published in Fizyko-Khimichna Mekhanika Materialiv, Vol. 42, No. 1, pp. 119–127, January–February, 2006.     

Application of volumetric method to the assessment of damage induced by action of foreign object on gas pipes

Gas pipes are submitted to three major types of damage: damages induced by impact of foreign objects, pits and craters produced by corrosion, weld defects produced during manufacturing. Damages induced by impact of foreign objects are considered as the most important problem for the gas pipes reliability and lead to dents, gouges or notches at the pipe failure. Geometrical effect of gauges or notches on brittle or elastoplastic failure of pipes submitted to internal pressure can be treated by the volumetric method. The volumetric method has been applied to a gas pipe submitted to internal pressure and exhibiting a longitudinal external and surface notch. We introduced a special procedure SINTAP, which allows one to compute the safety factor value. __________ Translated from Problemy Prochnosti, No. 4, pp. 109–117, July–August, 2006.     

Failure resistance of drilling rig casing pipes with an axial crack

Working conditions of casing pipes in drilling rigs can significantly influence the initiation and development of damage in the material, and therefore also the safe service of the entire system. In this work, an integrity assessment of a pipe with initial defect (machined surface crack) is presented. The position of this defect is on the external surface; unlike transport pipes, where internal surface is often endangered due to the contact with the fluid, casing pipes are also often exposed to damages at the external surface. A pipe segment exposed to internal pressure is examined experimentally and numerically, using the finite element method. Experimental setup included tracking of crack mouth opening displacement (CMOD) values, as well as J integral. Criteria for pipe failure are determined on the finite element (FE) models of the pipe; fracture initiation and plastic collapse are considered as failure mechanisms. Several 3D models with different crack sizes are evaluated. 2D plane strain models are also examined, to determine the applicability limits of this simplified approach. Integrity assessment criteria for the analysed geometries are discussed. Assessment of fracture resistance of the pipeline material is also considered in this work. Besides the standard SENB specimens, Ring specimens cut from the pipe are tested, and the results are compared. Both specimen geometries are modelled using local approach to fracture, by application of the micromechanical Complete Gurson model (CGM), developed by Z.L. Zhang. It is shown that the Ring specimens have similar fracture conditions under bending load as SENB specimens. Since they are much simpler to fabricate from the pipe than standard specimens, it is concluded that they can be used for assessment of fracture of the pipes with axial cracks.     

In-service degradation of gas trunk pipeline X52 steel

We study the mechanical and corrosion-mechanical properties and the behavior of hydrogen in X52 steel in the intact state and after operation for 30 yr. It is shown that the long-term operation of gas mains made of this steel is accompanied by the degradation of the metal in the bulk of the pipe wall. This is manifested, first of all, in the decrease in impact toughness, relative narrowing ψ, fracture toughness, and corrosion-cracking resistance. It is shown that the in-service embrittlement of the metal is characterized by the presence of two anomalies in its mechanical behavior, namely, its brittle fracture resistance decreases parallel with the drop of hardness and the decrease in ψ is accompanied by the increase in relative elongation. The characteristics of crack growth resistance are especially sensitive to the in-service degradation of the material. The detection of degradation is more efficient under the action of embrittling factors, such as the severe stress-strain states, low testing temperatures, and the presence of corrosive media. In general, the degradation is more pronounced for the bottom part of the operating pipes, which is explained by the negative effect of hydrogen penetrating into the metal from the transported media. A hypothesis is advanced concerning the microdamage of operating steel as the principal factor of degradation of pipes as a result of long-term operation. Note that the results of investigation of hydrogen permeability and the temperature dependences of the extraction of hydrogen from the metals in different states are in good agreement with the proposed hypothesis. Published in Fizyko-Khimichna Mekhanika Materialiv, Vol. 44, No. 1, pp. 88–99, January–February, 2008.     

Diagnosis of the load-carrying capacity of pipes containing a longitudinal crack when loaded by an axial force and internal pressure

A method is developed for evaluating the load-carrying capacity and safe life of pipes with a through longitudinal crack when loaded by an axial force and internal pressure. The method is based on the use of previously developed nomograms of strain and limit load. The first nomogram is calculated on the basis of constitutive relations of the theory of plasticity, while the second is calculated in accordance with a fracture criterion for biaxial loading. The proposed method makes it possible to determine one of three parameters — critical crack length, limiting pressure, or limiting axial load — without preliminary calculations if the other two parameters are already known. As an example, nomograms are presented for a steel 15G2 pipe having a diameter of 1420 mm and wall thickness of 21.5 mm and containing a longitudinal crack. Translated from Problemy Prochnosti, No. 12, pp. 16–23, December, 1994.     

An updated continuum damage model to investigate fracture process of structures in DBTT region

In the Ductile–Brittle Transition Temperature (DBTT) region, it is not realistic to take unique fracture stress or fracture strain as the fracture criterion to investigate the fracture properties. In this paper, an updated continuum damage model was proposed, in which the fracture energy density, a function of the stress triaxiality, temperature and strain rate in the transition region was taken as the critical damage factor. Uniaxial tension tests were carried out to get the basic material properties at different temperatures, to calibrate the fracture model constants and verify the validity of the damage model. The fracture behaviour of pipes with penetrating cracks under the internal pressure was experimentally investigated with the load–deflection curves and the crack propagation length captured from tests. The J–R curves were obtained from the testing results for different temperatures. Based on the Finite Element Analyses (FEA) with the proposed fracture criterion of the updated continuum damage model, the loading level of pipes with penetrating cracks were estimated and compared with the experimental results. Meanwhile the fracture processes of the pipeline structures in the transition region were reproduced. The experimental and numerical results agreed very well in present calculations. It has been shown that the fracture process in the transition region strongly depends on both the stress and strain states, and could be effectively predicted using the continuum damage model.     

The work of fracture in uniaxial and biaxial oriented unplasticised polyvinylchloride pipes

In oriented unplasticised polyvinylchloride (uPVC) pipes, cracks propagate tangentially rather than through the wall as in conventional pipe. Notched impact, a modified peel test and the specific work of fracture approach have been used to measure fracture toughness of a conventionally extruded, a uniaxially oriented and a biaxially oriented uPVC pipe in different directions. The different failure mode for the oriented pipes was found to result from an order of magnitude increase in the fracture toughness for cracks propagating perpendicular to the orientation direction. Differences in the fracture toughness between the oriented pipes were also related to their molecular orientation.     

Residual stress-strain state of the collector assembly of a steam generator in the process of press-fitting of heat-exchange pipes

The influence technological heredity connected with the manufacturing process on the strength and service life of the assembly of joints of the collector and heat exchange pipes of a steam generator proves to be one of the main causes of premature failures of steam generators of water-cooled reactors of nuclear power plants. We present the results of a numerical simulation of the process of press-fitting of heat-exchange pipes in the collector. We determine the residual stress-strain state of the collector assembly depending on the basic technological parameters of press-fitting (the initial gap between the pipe and the collector, the pressure of hydraulic press-fitting, and the boundaries of the region of application of pressure) and strength characteristics of the materials of the collector and pipes. We also estimate the influence of the additional mechanical flaring of pipes and redistribution of local stresses in the course of consecutive hydraulic press-fitting on the level of residual stresses in the collector assembly. Institute for Problems of Strength, National Academy of Sciences of Ukraine, Kiev, Ukraine. Translated from Problemy Prochnosti, No. 2, pp. 66 – 86, March – April, 1998.     

Fatigue crack growth of filament wound GRP pipes with a surface crack under cyclic internal pressure

In this study, fatigue damage behavior of (±75₃) filament wound composite pipes with a surface crack under alternating internal pressure was investigated. The specimens were tested at room temperature and exposed to open ended fatigue tests in which the pipe can be deformed freely in the axial direction. The tests were carried out in accordance with the ASTM D-2992 standard. The alternating internal pressure was generated by conventional hydraulic oil. The low cycle tests were performed with 0.42 Hz frequency and R = 0.05 stress ratio. Glass reinforced polymer pipes (GRP) are made of E-glass/epoxy and have (±75₃) configuration. Surface cracks were machined in the axial direction of the pipes which have depth-to-thickness ratios a/t = 0.25–0.38–0.50 and depth to length ratio of a/c = 0.2. Tests were performed at three different loads of 50%, 40%, and 30% of ultimate hoop stress strength of unnotched pipes. The failure behavior of GRP pipes during the test was observed and fatigue test results were presented by means of (S–N) curves and delamination damage zone area-cycle (A–N) curves.     

Rapid crack propagation in polyethylene pipe: combined effect of strain rate and temperature on fracture toughness

The need to predict the mechanical behaviour of polymers is motivated by the increasing use of these materials in structural applications. In order to consider safety in the design of engineering components, the question of a criterion for rapid crack propagation has been investigated in a medium density polyethylene (MDPE) used to extrude pipes for gas distribution. Work on the strain rate–temperature equivalence (ε ↔ T) was performed to study the yield stress, σs, as a function of ε and T. A shifting procedure enabled a behavioural master curve, σs versus 1/(aTε) to be drawn, where aT is the shift factor. Both cracked-ring and Charpy specimens were tested to characterize the fracture toughness KIC(T) of the MDPE. The values of the KIC(T) based on linear elastic fracture mechanics are superposed to form a fracture toughness master curve: KIC versus 1/(aTε). This revised version was published online in November 2006 with corrections to the Cover Date.     

Ductile fracture of a pipe with a rectangular three-dimensional defect

A model is constructed to describe the ductile fracture of a pipe with a rectangular three-dimensional defect. Upper and lower bounds are obtained for the burst pressure. The first is calculated for a rectangular crack, while the second is calculated for an axisymmetric three-dimensional defect. It is shown that if the half-width of the defect b₀ is equal to 2(Rt_n)^1/2 — where R is the radius of the pipe and t_n is the net thickness of the pipe wall—then the defect can be regarded as axisymmetric. Calculated values of burst pressure are compared with literature data from full-scale tests of pipes. The results can be used to analyze actual defects in pipelines (pitting, etc.), as well as in conducting full- scale tests of pipes and pressure vessels.Translated from Problemy Prochnosti, No. 9, pp. 55–66, September, 1995.     

A physical probabilistic model to predict failure rates in buried PVC pipelines

For older water pipeline materials such as cast iron and asbestos cement, future pipe failure rates can be extrapolated from large volumes of existing historical failure data held by water utilities. However, for newer pipeline materials such as polyvinyl chloride (PVC), only limited failure data exists and confident forecasts of future pipe failures cannot be made from historical data alone. To solve this problem, this paper presents a physical probabilistic model, which has been developed to estimate failure rates in buried PVC pipelines as they age. The model assumes that under in-service operating conditions, crack initiation can occur from inherent defects located in the pipe wall. Linear elastic fracture mechanics theory is used to predict the time to brittle fracture for pipes with internal defects subjected to combined internal pressure and soil deflection loading together with through-wall residual stress. To include uncertainty in the failure process, inherent defect size is treated as a stochastic variable, and modelled with an appropriate probability distribution. Microscopic examination of fracture surfaces from field failures in Australian PVC pipes suggests that the 2-parameter Weibull distribution can be applied. Monte Carlo simulation is then used to estimate lifetime probability distributions for pipes with internal defects, subjected to typical operating conditions. As with inherent defect size, the 2-parameter Weibull distribution is shown to be appropriate to model uncertainty in predicted pipe lifetime. The Weibull hazard function for pipe lifetime is then used to estimate the expected failure rate (per pipe length/per year) as a function of pipe age. To validate the model, predicted failure rates are compared to aggregated failure data from 17 UK water utilities obtained from the United Kingdom Water Industry Research (UKWIR) National Mains Failure Database. In the absence of actual operating pressure data in the UKWIR database, typical values from Australian water utilities were assumed to apply. While the physical probabilistic failure model shows good agreement with data recorded by UK water utilities, actual operating pressures from the UK is required to complete the model validation.     

Investigation of the development of localized corrosion-induced defects of welded pipes of elements of the water-steam channels of thermal electric power plants

We propose a method for the evaluation and perform prognostic assessments of the maximum depth of corrosion-induced defects in the components of combined circular welded joints of the pipes. The method is based on the use of fundamental electrochemical parameters of the materials of welded joints obtained by standard potentiometric methods and the developed numerical-analytic procedure of determination of the density of corrosion current on the inner surface of the pipe in which the analyzed combined welded joint is regarded as a three-electrode electrochemical system. __________ Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 42, No. 4, pp. 17–25, July–August, 2006.     

Analysis of pipeline fracture by fast crack propagation

An analysis is presented of the influence of wave processes in gases and in a pipeline wall on extended fracture by fast crack propagation. The influence of design and technological parameters of the pipeline and of the pipe metal fracture toughness on the extent of fracture is shown. Translated from Problemy Prochnosti, No. 2, pp. 119–125, March, 1997.     

Measurement of Specific Fracture Energy and Surface Tension of Brittle Materials in Powder Form

Studies of the influence of specimen geometry and size–effect on the K _R –curves and the related fracture parameters were carried out by the authors (Kumar and Barai 2008b). The present paper is a supplementary contribution and reports interesting results related to the effect of the loading condition and size–effect studies on the K _R –curves associated with the cohesive stress distribution for complete fracture process, the double–K fracture parameters, the CTOD–curves and the process zone length using two different loading conditions (i.e., three–point bending test and four–point bending test). The laboratory size specimen with initial–notch length/depth ratios 0.3 and 0.5 are considered in the work. The load–crack opening displacement curves for these loading conditions are obtained using well known version of fictitious crack model.     

客车空调压缩机排气管路失效分析与结构改进

采用ANSYS Workbench软件对客车空调压缩机排气管路进行失效分析和结构改进。以3种典型管路为研究对象,在压缩机端施加位移载荷进行管路失效分析,模拟结果与管路实际断裂位置一致。通过添加弯头、调整管路角度以及增加不锈钢波纹管长度等改进措施,可以降低管路的最大等效应力,延长管路的使用寿命。     

Analytical solution of the Brazier problem for thin-wall pipes with initial cross-sectional shape imperfection in the case of action of pressure

An analytical method is proposed for the solution of geometrically nonlinear Brazier problem for thin-mall pipes with initial cross-sectional shape imperfection in the case of action of pressure. Geometrical equations relating displacement components to strains and equilibrium equations taking into account change in the curvature of pipe cross section and axis have been derived. A solution in a first approximation for dimensionless flexibility parameter is presented, the exactness of which is illustrated by numerous examples. For the case of joint action of external bending moment and pressure, a limit curve of the critical moment value as a function of pressure value has been obtained. __________ Translated from Problemy Prochnosti, No. 3, pp. 100–123, May–June, 2008.