Cracked Pipes Research Articles

Application of ANN Concepts for Prediction of Crack Growth and Remaining Life of Circumferentially Cracked Piping Components under Different Loading Scenarios

This paper presents the details of Artificial Neural Network (ANN) based models to predict crack depth and remaining life of circumferentially part-through cracked piping components used in the nuclear industry. Crack growth data from experimental studies on (i) straight pipes made up of SA 312 Type 304LN stainless steel having part-through circumferential notch under combined bending and torsion and (ii) dissimilar metal pipe weld joints having circumferential through-wall crack in the weld were used. The dissimilar metal pipe weld joint is made up of SA312 Type 304LN austenitic stainless steel and SA508 Gr. 3 Cl. 1 low alloy carbon steel and joined by Nickel-rich Inconel alloy weld. About 75% of the mixed experimental data has been used for development of model and the remaining data for validation. For the development of ANN model, (i) back propagation technique (ii) sigmoidal transfer functions and (iii) Levenberg-Marquardt algorithm are used. The maximum percentage difference observed between the predicted and the experimental results for crack depth and remaining life was 19.59% and 15.78% respectively. The efficiency of the developed model was verified using several statistical parameters. The developed models are useful for the structural integrity assessment of piping components under different loading scenarios.

Model-based PD neural network control for pipe crack sealing manipulator

This study focuses on the control of a pipe crack sealing manipulator (PCSM) for concrete pipe crack sealing, with the capability to maneuver through horizontal and vertical pipes. This PCSM is a tree-type robot with five different branches. Observation and simulation studies indicate that only the fifth branch of the PCSM effectively executed the repair operation. However, in real application, the movement of these links is hindered by disturbances and uncertainties, preventing them from behaving as intended. Hence, a robust control scheme is essential to effectively manage the links of a pipe crack sealing manipulator. To address this need, this study introduces a Model-based PD neural network control (MBPDNNC) algorithm, which is then compared against modal-based PD (MBPD), Sliding mode control (SMC) with constant plus proportional rate reaching Law (CPPRL), and super twisting SMC (STSMC). The simulation study reveals that MBPDNN is characterized by greater accuracy and less chattering compared to the contrast control methods. The main contribution of this work is the compensation of disturbance by updating the weight by using the Radial basis function neural network (RBFNN). Through observation, it is evident that the neural network yields more promising results in the presence of disturbances and uncertainties.

Lightweight Sewer Pipe Crack Detection Method Based on Amphibious Robot and Improved YOLOv8n.

Aiming at the problem of difficult crack detection in underground urban sewage pipelines, a lightweight sewage pipeline crack detection method based on sewage pipeline robots and improved YOLOv8n is proposed. The method uses pipeline robots as the equipment carrier to move rapidly and collect high-definition data of apparent diseases in sewage pipelines with both water and sludge media. The lightweight RGCSPELAN module is introduced to reduce the number of parameters while ensuring the detection performance. First, we replaced the lightweight detection head Detect_LADH to reduce the number of parameters and improve the feature extraction of modeled cracks. Finally, we added the LSKA module to the SPPF module to improve the robustness of YOLOv8n. Compared with YOLOv5n, YOLOv6n, YOLOv8n, RT-DETRr18, YOLOv9t, and YOLOv10n, the improved YOLOv8n has a smaller number of parameters of only 1.6 M. The FPS index reaches 261, which is good for real-time detection, and at the same time, the model also has a good detection accuracy. The validation of sewage pipe crack detection through real scenarios proves the feasibility of the proposed method, which has good results in targeting both small and long cracks. It shows potential in improving the safety maintenance, detection efficiency, and cost-effectiveness of urban sewage pipes.

Underground concrete pipe crack damage monitoring by the fuzzy analysis of microseism

Abstract Underground concrete pipe is critical for the safety of the urban infrastructure. Crack would lead to the accidents such as fluid spillage, ground subsidence, as well as waterlogging. Thus, it is of great significance to measure and monitor the crack of pipeline. In this research, a fuzzy monitoring method of the concrete pipe crack damage based on the microseism signal GMM (Gaussian Mixed Model) analysis was proposed. First, the multi parameters of microseism signal were extracted. Then, CRITIC (Criteria Importance Through Intercriteria Correlation) weight vector was constructed using the importance information of parameters. Further, the GMM membership matrix was created by the similarity of the probability density distribution. The crack condition was assessed by means of the fuzzy calculation between the weight vector and membership matrix. The experiment indicated that the proposed method could monitor and assess the different crack conditions in real time.

Machine learning supported ultrasonic testing for characterization of cracks in polyethylene pipes

This study aims to develop a machine learning supported ultrasonic guided wave testing (UGWT) for detection and characterization of cracks in polyethylene (PE) pipes used for natural gas distribution. Ultrasonic testing is conducted to investigate the wave-crack interaction and determine damping properties of PE pipes. Finite element models are further built with material properties fine-tuned by wave attenuation experiments combined with cross-correlation analysis between the simulated and experimental signals. A synthetic database is populated using sensed signals over a wide range of crack geometries from numerical simulations. Finally, support vector machine (SVM) models are developed with different feature selections for classification of crack geometry and the accuracy is evaluated using both simulated and experimental cases. The findings demonstrate the potential of locating the circumferential position of crack with the ring-focusing method and classifying crack geometry in PE pipes using SVM model with central frequency features.

Numerical Finite Element Analysis of Cracked Stainless-Steel Pipe Repaired by GFRP in a Moist Environment

Numerical Finite Element Analysis of Cracked Stainless-Steel Pipe Repaired by GFRP in a Moist Environment

Spectral element-finite element modeling and dynamic analysis of a fluid-delivering cracked pipe subjected to both pulsation and base excitations

Previous studies on cracked pipes have predominantly focused on single excitation, but in practical engineering, pipe systems often experience a combined effect of fluid pulsation and base excitations, which can potentially trigger more complex dynamic behaviors. Moreover, the solid finite element (FE) models are generally adopted to simulate the breathing effect and stress singularity, but the solution efficiency is unacceptable. Therefore, this study presents a spectral element-finite element (SE-FE) method to construct the dynamic models of the fluid-delivering cracked pipes (FDCPs), which combines the efficiency of spectral element (SE) with the adaptability of FE. Furthermore, a fluid pulsation model is constructed using measured data. Specifically, dynamic models of intact and cracked pipe segments are constructed using SE and FE, respectively, and interface coupling is achieved by the penalty function method. Subsequently, an experimental system for fluid pulsation excitation is established, and then a fluid pulsation model is constructed. Finally, the dynamic behaviors of a FDCP under compound excitation are analyzed. The results show that the fluid pulsation in the FDCP is higher than that in the intact pipe due to the breathing effect. Moreover, the beat vibration will be triggered when the pulsation frequency approaches the base excitation frequency. This study can provide a better understanding for the dynamic behaviors of FDCP, thereby providing a reference for crack damage detection.

Leakage Quantification in Metallic Pipes under Different Corrosion Exposure Times

The combined effects of aqueous corrosion, stress factors, and seeded cracks on leakage in cast iron pipes have not been thoroughly examined due to the complexity and difficulty in predicting their interactions. This study seeks to address this gap by investigating the interdependencies between corrosion, stress, and cracks in cast iron pipes to optimise the material selection and design in corrosive environments. Leakage experiments were conducted under simulated localised corrosive conditions and internal pressure, revealing that leakage increased from 0 to 25 mL with crack sizes of 0.5 mm, 0.8 mm, 1 mm, and 1.2 mm, along with corrosion times of 0, 120, 160, and 200 h, and varying stress levels. An empirical model was developed using a curve-fitting approach to map the relationships among corrosion time, crack propagation, and leakage amount. The results demonstrate that the interaction between corrosion, stress, and crack propagation was complex and nonlinear, and the leakage amount increased from 0.7 to 0.10 mm every 15 min, as evidenced by SEM microstructure images and empirical data.

Dynamic analysis of cracked pipe elbows: Numerical and experimental studies

This study aims to investigate the dynamic behaviors of fluid-delivering cracked pipe elbows (FDCPEs), thereby providing theoretical and methodological guidance for vibration-based crack detection in pipe elbows. Specifically, an efficient spectral element-finite element (SE-FE) based modeling method for the FDCPEs is proposed firstly, which considers fluid-structure coupling and breathing effect. For the SE-FE method, the spectral element (SE) and finite element (FE) are constructed to simulate the healthy straight segments and cracked elbows of the pipe, respectively, and a penalty function method is adopted to simulate interface coupling and breathing effects. Furthermore, the computational accuracy and efficiency of the SE-FE method are verified through numerical and experimental studies. Finally, the effects of the elbow and crack parameters on the dynamic behaviors of FDCPE are analyzed. The results indicate that changes in the bending radius and angle may trigger frequency veering behaviors, leading to in-plane and out-plane vibration mode switching. Moreover, the even-mode harmonics of the stress responses can effectively detect cracks in the elbow. Most importantly, the strength of nonlinearity at different measuring locations can be used to predict the crack location and size.

Influence of shielding gas flow on the TIG welding process using stainless steel 304 material

A common issue encountered with main heat exchanger equipment is improper operation, which can lead to the development of cracks in the stainless-steel pipes. The welding process alters the metal microstructure in the heat-affected zone, thereby affecting the mechanical properties of the welded joint. To mitigate this issue, TIG welding with argon shielding gas is employed. This method helps prevent oxidation and ensures the formation of a stable welding arc in 304 stainless steel, which is renowned for its excellent mechanical properties and corrosion resistance. The objective of this study is to evaluate the impact of variations in shielding gas flow on the mechanical properties of 304 stainless steel plates during the TIG welding process. The aim is to determine the optimal settings for producing robust and long-lasting welded joints. To assess the hardness of the welded joints, we employed a Brinell-type Hardness Tester FB-3000LC machine. A Brinell steel ball indenter measuring 5 mm on the HBW scale and applying a load of 125 Kgf was utilized. At a protective gas flow rate of 8 L/min, the average tensile stress was 44.72 N/mm², strain was 0.177, modulus of elasticity was 2518 MPa, and hardness was 99.712 HBW. Increasing the gas flow rate to 13 L/min resulted in an average tensile stress of 47.50 N/mm², strain of 0.189, elastic modulus of 2525 MPa, and hardness of 105.522 HBW. Further increasing the gas flow rate to 18 L/min led to an average tensile stress of 49.69 N/mm², strain of 0.192, modulus of elasticity of 2597 MPa, and hardness of 106.704 HBW. Based on the research findings, it was observed that the weld area exhibited an increase in hardness values due to the heat generated during the welding process. The use of protective gas flow during welding is deemed effective in producing well-formed welded joints, as it prevents fractures from occurring within the weld area during the tensile test process. The choice of protective gas is determined by the dimensions of the material plate.

Engineering estimate of plastic collapse loads for cracked pipe bends under in-plane and out-of-plane bending

Nuclear power plant piping systems frequently encounter complex loads due to factors like internal pressure, self-weight, structural supports, and operational conditions. Within these systems, pipe bends play a crucial role in releasing energy through deformation. Cracks pose a risk to the integrity of the system, necessitating the calculation of the plastic collapse load for cracked pipe bends. This study presents estimations for the plastic collapse load of cracked pipe bends under pure out-of-plane bending moments and simultaneous in-plane and out-of-plane bending moments. Cracks located in the intrados, extrados, and crown of pipe bends were considered. The estimations for plastic collapse load are proposed based on the observed similarity between plastic collapse load and plastic deformation under both in-plane and out-of-plane bending conditions. For combined in-plane and out-of-plane bending moment conditions, circular and parabolic relationships have been proposed for a straightforward plastic collapse load prediction. Additionally, the estimations for plastic collapse loads were derived from the results of finite element analysis conducted on crack-free pipe bends, demonstrating its applicability to cracked pipe bends as well.

Numerical Simulation and ANN Prediction of Crack Problems within Corrosion Defects.

Buried pipelines are widely used, so it is necessary to analyze and study their fracture characteristics. The locations of corrosion defects on the pipe are more susceptible to fracture under the influence of internal pressure generated during material transportation. In the open literature, a large number of studies have been conducted on the failure pressure or residual strength of corroded pipelines. On this basis, this study conducts a fracture analysis on buried pipelines with corrosion areas under seismic loads. The extended finite element method was used to model and analyze the buried pipeline under seismic load, and it was found that the stress value at the crack tip was maximum when the circumferential angle of the crack was near 5° in the corrosion area. The changes in the stress field at the crack tip in the corrosion zone of the pipeline under different loads were compared. Based on the BP algorithm, a neural network model that can predict the stress field at the pipe crack tip is established. The neural network is trained using numerical model data, and a prediction model with a prediction error of less than 10% is constructed. The crack tip characteristics were further studied using the BP neural network model, and it was determined that the tip stress fluctuation range is between 450 MPa and 500 MPa. The neural network model is optimized based on the GA algorithm, which solves the problem of convergence difficulties and improves the prediction accuracy. According to the prediction results, it is found that when the internal pressure increases, the corrosion depth will significantly affect the crack tip stress field. The maximum error of the optimized neural network is 5.32%. The calculation data of the optimized neural network model were compared with the calculation data of other models, and it was determined that GA-BPNN has better adaptability in this research problem.

Load-independent creep constraint analysis and solutions for surface cracks in pressurized pipes

Using load-independent creep constraint parameters Q* and Qm*, the variations of crack front stress field and constraint level are analyzed for various crack sizes of pipelines containing internal surface cracks under high temperature conditions. The results show that the trends of stress changes in the axial and circumferential internal surface crack front for different crack sizes are similar. For axial internal surface cracks, when the crack depth to length ratio a/c is the same, the maximum values of crack front Q* and Qm* are shifted from the deepest part of the crack (2Φ/π = 1) to the vicinity of the free surface (2Φ/π = 0.2) as the crack depth a/t increases. As for the circumferential inner surface cracks, when the crack depth a/t exceeds 0.2, the locations where the maximum values of crack fronts Q* and Qm* appear are mainly concentrated in the deepest part of the crack (2Φ/π = 1). Based on the calculation results of the constraint parameters, the empirical formulas for the engineering calculation of the relationship between the average constraint parameters (Qavg* and Qm‐avg*) and the crack size are obtained by fitting.

Nonlinear dynamic modeling and analysis of the fluid-transporting cracked pipe using the hybrid semi-analytical and finite element method

The fatigue cracks may develop in the pipe systems due to long-term cyclic loading, which may cause catastrophic accidents. The finite element method (FEM) is usually adopted to simulate the stress singularity and breathing effect, resulting in expensive computational costs. Therefore, in this paper, an efficient hybrid semi-analytical and finite element (SA-FE) method is proposed to study the nonlinear dynamic characteristics of the fluid-transporting cracked pipe (FTCP) considering the breathing effect. Furthermore, the crack sensitivity parameters are obtained through bending-bending and bending-axial vibration analysis. For the SA-FE method, the semi-analytical method (SAM) and FEM are separately used to construct the dynamic models of the non-cracked and cracked regions, and the connection at the interface is performed by constraint equations. Subsequently, the validity of the modeling method is substantiated through both FEM and experimental tests. Finally, the effects of crack and fluid parameters on the dynamic characteristics of the FTCP are analyzed. The results indicate that changes in crack positions may trigger different-order mode switching, and continuous switching may occur between higher-order modes. In addition, the bending-bending and bending-axial coupling responses can effectively detect crack failures of the FTCP with varying levels of damage. The proposed model can offer valuable insights for fault diagnosis and health monitoring of FTCP.

Numerical analysis of pressure variation and gas load effects in the refrigeration system for household refrigerators

Insufficient air evacuation from a refrigeration system prior to refrigerant charging can lead to an increased non-condensable gas concentration, negatively impacting system performance. Despite its critical importance, literature on refrigeration system vacuuming procedures is notably lacking. This study developed numerical methods and constitutive models to assess gas load, validated against measured pressures using experimental setups. The model developed can be extended and applied to a wide range of vacuum systems. Examining the vacuuming process in a household refrigerator, a connected vacuum pump expedited the process, revealing higher pressures in the capillary tube and condenser outlet due to low flow conductance. The rate of pressure increase attributable to the gas load from outgassing and degassing remained below 0.6 %, deemed negligible during vacuum pump operation. A 24-hour simulation post-vacuum pump cessation showcased pressure equalization and subsequent rise due to outgassing and degassing, resulting in a 201 % increase in pressure within the compressor’s internal space connected to the process pipe. The pressure increase in the compressor attributable to outgassing amounted to 140 %, surpassing the 59 % from degassing. Notably, assuming a 3 μm crack in the process pipe led to a continuous increase in refrigerator system pressure over 24 h. Leakage significantly increases the amount of non-condensable gases inside the system, potentially leading to increased energy consumption and deterioration in system performance.

Numerical investigation of the instability of dry granular bed induced by water leakage

AbstractUnderground pipe defects or cracks under transport infrastructure can cause water leakage to upper soil layers (e.g. subgrade and capping), inducing local cavities or even failure of overlying road/railway formation. Although numerous studies on the instability of granular beds induced by injected water have been conducted, most of them focused on the behaviour of saturated granular beds, while research on dry granular beds is still limited. This paper aims to address this gap using a numerical model coupling volume of fluid method with discrete element method. We observed that dry granular beds go through three distinct regimes as water jet velocity increases including stationary, stable deformation with heave and fluidisation. However, the flow velocities required to deform and fluidise dry granular beds are significantly higher than those required for saturated beds. Increasing granular bed thickness can alter its failure mechanism from full depth to localised erosion, leading to cavity formation around pipe cracks prior to the bed fluidisation. The gravitational and frictional components of granular mass are identified as two main resisting forces of dry granular beds against water jet force, evidenced by the increase of critical jet velocities as particle density and friction coefficient increase. Nevertheless, the moblised zone of granular mass is practically independent of both the buried depth of dry granular beds.

Failure analysis of S30408 pipe cracking and preventive measures

BACKGROUND: The feed pipeline made from 30408 stainless steel of a new unit leaked during the air pressure test. OBJECTIVE: The present work aims to examine the specific cause of pipeline cracking, and providing effective approaches to avoid similar failures. METHODS: Macroscopic inspections of the cracked pipe defects were made on site immediately after leakage. Mechanical properties and hardness of specimens machined from the failed pipe were tested. In addition, microscopic analyses including material composition, microstructure observation and crack morphologies of the failed part were performed to get detail information. Composition of the feed raw material was also analyzed to identify whether it had been contaminated by corrosive elements or not. RESULTS: No impurity composition was found in the feed raw material. The element constituents, yield strength, tensile strength and hardness of the cracked pipe fulfill standard requirements. A number of scratches and defects with a size of several microns were found on the inner wall of the leaked pipe, and they were believed to be formed at the perforation step during pipeline processing. Liquation cracks were found at the pipeline butt weld joint, and they laid hidden dangers for the safety and steady operation of the pipeline. CONCLUSION: The overall analysis results indicated the pipeline leakage during air pressure test was caused by cracks initiated around inner wall defects, which sabotaged the bearing capacity of the pipe by wall thickness reduction and stress concentration. Therefore, improving the inner wall surface quality at the perforation step may help to avoid such failure. The metallurgical effect and weld stress caused during the welding process promoted the initiation and propagation of liquation cracks. The tendency of welding hot crack formation could be reduced by taking strict composition control of the welding rod and adopting reasonable welding parameters.

Using J-integral analysis to predict the failure of HDPE pipes under crack face load and internal pressure

Cracks in pipes used for water transfer have been identified as a significant contributor to water loss and potential failures. To assess fracture behavior, the J-integral was computed for 3D finite element HDPE pipes (DN 355) with axial internal and external cracks (with a/ c and a/ t ratios of 0.5) subjected to a range of internal pressure (16–30 bar) and crack face load condition. Four ratios of a/ c ranging from 0.3 to 0.9 (with an increment of 0.2) were examined with the internal crack. Results indicate that under face crack loading, the external axial crack exhibits a higher J-integral intensity than the internal axial crack. J-integral values greater than 8.4 kJ/m2 were found to lead to pipe failure, with higher internal pressures (25–30 bar for external crack, and 30 bar for internal pressure). Moreover, the a/ c ratio plays a significant role in influencing the distribution of J-integral along internal crack arc length. For pipes of DN 355 size with axial cracks, internal pressure exceeding 20 bar is not recommended. These findings underscore the importance of considering J-integral values in pipe design to prevent failure.

IDENTIFICATION OF WAVY FLOW SUB-REGIMES USING POWER SPECTRUM OF LASER DOPPLER VELOCIMETRY SIGNALS

The formation of a slug happens when the roll waves on the interface of two-phase flow undergo constructive interference. Slug flowing with high momentum results in flow-accelerated corrosion (FAC) leading to cracks in pipes. The leakages from such cracks are hazardous to industry. In order to avoid such hazards, a detailed analysis is required for the transition of smooth stratified flow to slug flow. This transition happens through different wavy flow sub-regimes. Previous studies in literature used visual observation and image processing to determine sub-regimes of wavy flow. However, visual observation alone is not sufficient to differentiate between the different sub-regimes of wavy flow. In the present study the power spectrum of the velocity signals measured using laser Doppler velocimetry (LDV) is used in addition to visual observations to develop a precise wavy-flow sub-regime map. Experiments are conducted in a two-phase flow test rig by varying liquid superficial Reynolds number in the range of 1685 and 6830 and gas superficial Reynolds number between 393 and 9824. The transition to wavy flow is observed much earlier in the present study compared to that reported in literature based solely on visualization methods. The present paper successfully utilized power spectrum analysis to accurately and precisely categorize wavy flow sub-regimes, including the creation of a flow subregime map demarcating "3D large-amplitude waves (3DLA)," "2D small-amplitude waves (2DSA)," "3D small-amplitude waves (3DSA)," and "2D large-amplitude waves (2DLA)." The modified flow-pattern map developed based on power-spectrum analysis of velocity signals and the flow visualization is compared with the flow-pattern maps available in literature.

Fracture investigation at 300oC on carbon-steel and austenitic stainless-steel pipes of NPPs under cyclic loads

The Leak-Before-Break (LBB) of high enthalpy piping of Indian NPPs require fracture stability demonstration of pipelines with postulated cracks under design basis earthquake loads. Earlier large number of cyclic fracture and corresponding monotonic fracture tests on large sized pipe components were conducted at room temperature. In current program, monotonic/cyclic fracture experiments are extended to reactor operating temperature (300 oC). The aim of this study is to demonstrate the structural integrity of SA333Gr6 piping and Stainless Steel (SS) 304LN welds under monotonic/cyclic loading which simulates extreme earthquake events and operating temperatures. Total six pipes/pipe welds of carbon steel (8-inch NB ~219 mm outer diameter and 19 mm thick) and SS304LN (12-inch NB~324 mm and outer diameter ~25 mm thick) with through-wall cracks have been tested under four-point bending. Two monotonic fracture tests have been conducted at 300 oC under monotonic loadings. Different experimental results like LLD (Load Line Displacement), Total Load, CMOD (crack mouth opening displacement), Crack Growth values have been obtained. Based on this data the load carrying capacity are obtained for both 8-inch and 12-inch cracked pipes. The cyclic fracture tests have also been conducted at 300 oC under fully reversing cyclic loading on four pipes. Three 8-inch SA333Gr6 pipes have been tested under different magnitude of peak load values. Similarly, one 12-inch SS pipe is also tested under cyclic loading. For carbon steel pipes, the reduction in load capacity is slightly higher under cyclic loadings at 300 oC compared to that at room temperature. However, for stainless steel pipes the load reduction factor at 300 oC is in good agreement with that at room temperature.