Assessment on failure pressure of high strength pipeline with

corrosion defects
Bin Ma
a,
, Jian Shuai
a
, Dexu Liu
b
, Kui Xu
a
a
China University of Petroleum, Beijing, China
b
Zhongyuan Petroleum Prospecting and Design Institute, Puyang, Henan, China
a r t i c l e i n f o
Article history:
Received 20 December 2012
Received in revised form 28 February 2013
Accepted 31 March 2013
Available online 9 April 2013
Keywords:
Failure Pressure
High strength steel
Full-scale burst test
Pipeline
Finite element analysis
a b s t r a c t
An accurate prediction on the failure pressure of line pipe is very important in the engi-
neering design and integrity assessment of oil and gas transmission pipelines. This paper
analytically investigates the failure pressure of line pipes with or without corrosion defects,
and focus on the high strength steels. Based on von Mises strength failure criterion, a clas-
sic strength failure criterion, the failure pressure of end-capped and defect-free pipe p
M
is
theoretically deduced with the strain hardening material. In order to derive a general solu-
tion for corrosion defect assessment of high strength pipelines, an extensive series of nite
element analyses on various elliptical corrosion defects was performed. Finally, a new for-
mula for predicting the failure pressure of corroded pipe in the material of high strength
steels is formulated, based on the FE models and p
M
, and is validated using 79 groups of
full-scale burst test data, which contain the low, middle and high strength pipeline. The
results indicated that the proposed formula for predicting the failure pressure is closely
matches the experimental data for the high strength steels.
Crown Copyright 2013 Published by Elsevier Ltd. All rights reserved.
1. Introduction
At the present, with the industry developed rapidly, the demand of oil and gas is on the increase, and thus carrying capac-
ity and transport efciency of pipeline has been improved. The important trend of the development to oil and gas pipelines
is: large diameter, transmission by high pressure and high strength steels [1]. And we have to improve the strength and
toughness of the material, considering the structural stability and safety of the pipeline [2]. In the pipeline industry, some
sections of high-pressure pipelines, particularly those with long service histories, may experience corrosion. Accurate pre-
diction of burst pressure for line pipes is crucial in the engineering design and integrity assessment of oil and gas transmis-
sion pipelines. The burst pressure is usually dened as the limit load or failure pressure of a pipe at plastic collapse,
representing the maximum load-bearing capacity of the pipe [3]. In this paper the burst pressure represent the pressure
measured in the actual burst test and the failure pressure represent the prediction maximum pressure at the plastic collapse
stage calculated by the theoretical equation.
The remaining strength of line pipes with corrosion defects is an important project in the oil and gas pipeline industry,
and it has been studied for years, using experimental, numerical, analytic and empirical methods [47]. There are lots of
assessment criteria and methods [8], such as ASME B31G-1984 [9], ASME B31G-1991 [10], ASME B31G-2009 [11], DNV
RP101 [12], PCORRC [13], RSTRENG [14] and so on. However, many experimental data have shown these methods can often
be over conservative to evaluate the pipeline with the materials of high-grade strength steels [15].
1350-6307/$ - see front matter Crown Copyright 2013 Published by Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.engfailanal.2013.03.015

Corresponding author. Tel.: +98 615110284571.

E-mail address: chrismabin@163.com (B. Ma).
Engineering Failure Analysis 32 (2013) 209219
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j our nal homepage: www. el sevi er . com/ l ocat e/ engf ai l anal
The early research on the failure pressure of pipeline ignored the hardening behavior of materials, such as J.B. Choi devel-
oped a limit load solutions for corroded pipelines made of X65 steel, but he did not consider the hardening behavior of mate-
rial [16]. The increase demand of oil and gas require the modern pipeline steels with higher tensile strengths, which have
different strain hardening behavior than the traditional lower-grade strength steels. Xian-Kui rst proposed to consider
the hardening behavior condition [17], but he considered the extensive materials from Grade B to X80 and not the high-
grade strength steel specially. Nonsolution is applied to the whole materials as different strength grade steel has different
properties. This paper adopts the materials of high-grade strength steels such as X70 and X80 and analysis an evaluation
formula to predict the high strength corroded pipeline.
2. Failure pressure of defect-free pipeline
When the line pipe generally approaches failure it comes into plastic collapse stage undergoing large plastic deformation.
The failure analysis of pipeline often adopts two classical strain hardening models, which are the Hollomon (power-law)
model [18] (dened as Eq. (1)) and the RambergOsgood model [19] (dened as Eq. (2)), which are shown as:
r Ke
n
1
e
e
0

r
r
y
a
r
r
y
_ _
n
2
Xian-Kui and Leis [6] rst considered the condition of buried pipeline, thus dene a long, defect-free, thin-wall pipe with
remote capped ends subjected to internal pressure only, and based on the nite strain theory, in the plastic instability stage
the volume incompressibility require e
hh
+ e
aa
+ e
rr
0 and t = 0.5. Based on the Von Mises criterion and the power-law hard-
ening model, he deduced a solution assessing the failure pressure of pipeline without defects, which can be determined by
the condition of dp=d

e 0, and the limit strain

e
limit

n

3
p
, and can be expressed as:
p
M

4

3
p

n1

t
0
D
0
r
0
u
3
In the plastic instability stage, RambergOsgood model can ignore the linear portion, which can express as:
e
e
0
a
r
r
y
_ _
n
4
Nomenclature
r true stress in simple tension
e true strain in simple tension
r
0
engineering stress
e
0
engineering strain
K the strength coefcient
r
u
the true ultimate tensile stress
r
y
the true yield stress
e
0
initial strain, where e
0

ry
E
n the strain hardening exponent
r
0
u
the engineering ultimate tensile stress
e
0
u
the engineering strain value, when r
0
r
0
u
r
1
, r
2
, r
3
principal stresses
e
1
, e
2
, e
3
principal strains
r
hh
, r
aa
, r
rr
hoop, axial, and radial stresses, respectively
e
hh
, e
aa
, e
rr
hoop, axial, and radial strains, respectively
r
M
Mises equivalent stress
t, t
0
instant and original wall thicknesses of the pipe, respectively
d depth of the corrosion defect
L length of the corrosion defect
D, D
0
instant and original average diameters of the pipe, respectively
p
M
failure pressure of defect-free pipeline based on Mises criterion
p
failure
failure pressure of corroded pipeline
E elastic modulus
t Poissons ratio
210 B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219
Base on Eq. (4), the assessment solution which deduced by Xian-Kui can be expressed by:
p
0
M

4

3
p
_ _n1
n

t
0
D
0
r
0
u
5
where the strain hardening exponent n in Eq. (5) is the one in the RambergOsgood model.
3. Non-linear nite element analysis
3.1. material properties
In the FEA simulations there are three kinds of material utilized in the three kinds of pipelines, respectively. Each kind of
pipeline has 60 kinds of volumetric defects with the variations of lengths (from 25 mm to 2000 mm) and depths (from 20% to
60% of wall thickness). In the all calculations, the elastic modulus E = 207 GPa, and the Poisson ratio t = 0.3. The true stress
versus true strain curves for the pipeline materials API X70 and API X80 which were used in our FEA simulations are shown
in Fig. 1. The material parameters are expressed in Table 1.
3.2. FE model generation
For the corroded line pipes, quarter symmetry, three-dimensional (3D) non-linear FE models have been performed using
the commercial software ABAQUS. This approach takes advantage of symmetry to reduce the size of the FE model, thereby
reducing computer processing times. The 3D models were constructed using 20 nodes, reduced integration brick elements
(C3D20R). The elasticplastic nite strain formulation and the modied RIKS algorithm that are built in ABAQUS have been
utilized. There are two layers of elements through the remaining ligament of each corrosion defect.
Many researches (such as Leis and Stephens [20]) have shown that the effect of defect width to the limit pressure is not
signicant. In this paper we investigate the effect of the length and the depth of the corrosion defects to the failure pressure
of corroded pipelines. In order to ignore the effect of the defect width, width is designed to be a constant value. A plastic
collapse FE model is presented for the end-capped pipe with various defects, which contains 195 cases with different mate-
rial, various pipe geometry and defect geometry. In the simulations there were three kinds of pipes with the outside diam-
eter of 1016 mm and 1219 mm, and the nominal wall thicknesses of 14.6 mm, 21 mm and 22 mm using the material API X70
and API X80, respectively. Articial corrosion defects are designed with ten length grades increased from 25 mm to 2000 mm
and ve depth grades increased from 20% to 60% of wall thickness for each of the three pipes above.
Fig. 1. The true stress-true strain curves of API X70 and API X80.
Table 1
Material parameters of API X70 and API X80 in the FEA simulations.
Grade and no. Material model n a r
y
r
u
X70-1 RambergOsgood 12.26 0.5553 508 667
X70-2 11.42 0.6178 523 701
X80 11.19 1.043 524 685
B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219 211
All groove defects were designed to be elliptical shaped bottomed with spherical ends. It is showed in Fig. 2. The geometry
parameters of pipelines and defects are described in Table 2.
3.3. Loading and boundary conditions
This research only considers the condition, in which the buried pipelines subjected to internal pressure only. For each
model the load was applied as a monotonically increasing internal pressure, where pressure loads remain normal to the pipe
internal surface. External loading was not considered.
The symmetry boundary conditions were used to reduce the size of the FE models. Two axes of symmetry were applied to
the quarter models, in the x = 0 and z = 0 planes. The model was not allowed to rotate, or expand or contract axially, however,
was allowed to expand and contract radially. The origin is the center of the cross section of the pipe. The cross section is in
the deepest location of the corroded defect, and the coordinate axis and the loading and boundary conditions of FE models
can be shown in Fig. 2.
3.4. Calculation of FE models
For each model analyzed, the von Mises equivalent stresses were monitored at three points through the highest stress
portion of the ligament of each defect as the internal pressure in the pipe was increased. For the analyses, the failure pressure
Fig. 2. The load and boundary condition of the FE model.
Table 2
Geometry parameters of pipelines and defects in the FEA simulations.
Material Geometric parameters of pipes Geometric parameters of defects
D (mm) t (mm) L (mm) d (mm)
X70-1 1016 14.6 25 2.92
45 4.38
65 5.84
85 7.3
100 8.76
X70-2 1219 21 200 4.2
300 6.3
400 8.4
500 10.5
600 12.6
X80 1320 22 800 4.4
1000 6.6
2000 8.8
11
13.2
212 B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219
was determined when the von Mises equivalent stress of the corresponding point reach the true ultimate tensile strength of
the material, which is in the mid surface of the ligament. As shown in Figs. 3 and 4.
3.5. Effect of defect depth and length
Two parameters of L=

D t
p
and d/t were considered in nite element analyses. The value of d/t was set to 0.2, 0.3, 0.4, 0.5
and 0.6 considering the actual dimensions of pipeline. The value of L=

D t
p
is ranging from 0.15 to 13.69 were considered.
Total of 195 cases were analyzed as summarized in Table 2. Figs. 5 and 6 show the resulting maximum allowable pressure
values vary with the various L=

D t
p
and d/t. The results indicate that the failure pressure of corroded pipes: (a) decreases as
d/t increases for all defects; and when the d/t is small, the pressure decreases slowly; (b) decreases as L=

D t
p
increases for
all defects; and when the L=

D t
p
is small, the pressure decreases slowly; (c) when the defect length is larger than the pipe
diameter, the variation of failure pressure is tiny as L=

D t
p
increases. (d) The variation trend of the failure pressure with the
L=

D t
p
accord with the power index function of e.
4. Failure pressure of corroded pipeline
For RambergOsgood hardening materials under monotonous loading, the deformation theory of plasticity shows that
the stress components are linearly proportional to the applied load, like those in Eq. (3) for defect-free pipes. At the limit
state, it can be assumed that the failure pressure p
failure
of a corroded pipe with a defect is also related to the p
0
M
, and has
the following form:
p
failure
p
0
M
f
d
t
;
L

D t
p
_ _
6
Fig. 3. Von Mises equivalent stress variation through ligament with increasing internal pressure.
Fig. 4. Typical 3D quarter symmetry FE model of a pipeline with an axial groove defect.
B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219 213
where p
0
M
is the failure pressure of defect-free pipeline based on Mises criterion, i.e. Eq. (5). And f is a function of the geom-
etry variables of defects, i.e.
d
t
and
L

Dt
p
. The range of f function is form 01, consider the two bounding cases that involve either
very small or very large corrosion defects on the outside surface of a pipe. First, a sufciently small defect does not
Fig. 5. The variation of the resulting failure pressure with the various of the ratio of d and t.
214 B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219
appreciably affect failure pressure. Hence, the upper bound on practical defect failure, whose failure pressure (denoted as
p
failure
), can be approximated as the failure pressure of defect-free pipe determined by Eq. (5). The lower bound of a very deep
Fig. 6. The variation of the resulting failure pressure with the various ratio of L and sqrt(Dt).
B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219 215
and long defect can be approximated as the failure pressure for the thinner wall pipe. Considering the variation trend of pres-
sure with the d/t and
L

Dt
p
, the function f has a simple form of:
f 1
d
t
1 a exp
b L

D t
p
_ _
1
d
t
_ _
c
_ _
7
where a, b and c are the parameters. Consequently, based on extensive nite element analysis, the expression of failure pres-
sure of corroded pipe is obtained:
p
failure

4

3
p

n1
n

t
0
D
0
r
0
u
1
d
t
1 0:7501 exp
0:4174 L

D t
p
_ _
1
d
t
_ _
0:1151
_ _ _ _
8
5. Full-scale experimental validation
In order to verify the reliability and application elds of this method, 79 groups of full-scale burst tests data (shown as
Table 4) from the published references are collected for pipeline failure pressure prediction. Based on the experimental data,
the failure pressures are calculated using the criteria of B31G, DNV, PCORRC, and the methods by Eq. (8), Xian-Kui and Leis
[6] and Chois [16], and the error between the actual burst pressure and the failure pressure calculated by the methods above
was expressed by Table 3. The pipeline steels contained in Table 3 and Fig. 7 represent grades from X42 to X100, which con-
tains the material of low-, mid- and high-grade strength steels, as shown in Table 4, the low-grade strength steels include the
grades from X42 to X56; the mid-grade strength steels include the grades from X60 and X65; and the high-grade strength
steels include the grades from X80 and X100, which are shown in Table 4.
The comparison results in Table 3 and Fig. 7 indicate that the failure pressure predicted by Eq. (8): (a) is most closest to
the actual burst pressure in the pipeline with high-grade strength steel; (b) and also apply to evaluate the pipeline with mid-
grade strength steel; (c) but is not reliable to evaluate the pipeline with low-grade strength steel.
Table 3
Standard deviation of prediction error among these methods.
Materials
Methods Low strength grade steel Mid strength grade steel High strength grade steel Overall error
p
failure
13.99 8.03 4.95 15.11
B31G 11.45 13.48 15.38 17.80
DNV 16.94 9.40 8.23 15.77
PCORRC 16.68 8.73 8.11 15.75
Zhu Xian-Kui 18.09 9.47 8.30 17.17
Chois 15.30 6.90 6.20 15.05
Fig. 7. Comparison of predicted failure pressure with actual failure pressure by Eq.8
216 B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219
Table 4
Seventy nine groups of full-scale burst tests data.
No. Grade D (mm) t (mm) d (mm) L (mm) r
u
(MPa) Burst pressure (MPa) p
failure
(MPa)
1 X42 273.30 4.95 3.30 182.88 453.86 7.75 7.20
2 X42 272.97 4.67 2.62 48.26 453.86 13.79 11.80
3 X42 273.53 4.78 1.63 30.48 453.86 13.71 14.56
4 X42 273.10 4.88 2.18 101.60 453.86 15.18 11.69
5 X42 273.89 4.93 1.60 45.72 453.86 14.99 14.63
6 X42 274.14 5.00 2.16 124.46 453.86 13.35 11.70
7 X42 274.45 4.57 2.74 66.04 453.86 12.67 10.31
8 X42 274.12 4.98 2.72 38.10 453.86 14.8 13.31
9 X42 274.52 4.83 2.11 157.48 453.86 12.62 10.73
10 X42 529.00 9.00 4.70 350.00 415.00 8.83 7.93
11 X42 529.00 9.00 4.70 160.00 415.00 15.7 9.59
12 X42 529.00 9.00 5.30 150.00 415.00 14.2 9.13
13 X46 323.60 8.51 0.00 0.00 469.29 25.06 26.64
14 X46 323.34 8.64 2.16 63.50 469.29 24.37 23.48
15 X46 323.60 8.64 0.00 0.00 469.29 24.44 27.05
16 X46 323.09 8.59 2.97 203.20 469.29 23.11 19.09
17 X46 324.10 8.53 0.00 0.00 469.29 25.01 26.67
18 X46 323.09 8.64 2.69 60.96 469.29 25.23 22.74
19 X46 321.56 8.33 0.00 0.00 469.29 22.46 26.25
20 X46 323.60 8.74 0.00 0.00 469.29 23.92 27.36
21 X46 324.10 8.43 0.00 0.00 469.29 23.27 26.35
22 X46 323.60 8.61 3.30 144.78 469.29 23.93 19.23
23 X46 323.60 8.64 2.67 127.00 469.29 21.75 21.09
24 X46 323.09 8.53 2.18 50.80 469.29 21.56 23.46
25 X46 323.85 8.64 0.00 0.00 469.29 24.52 27.03
26 X46 323.85 5.08 3.66 99.06 472.39 9.74 8.14
27 X46 863.60 9.63 3.63 213.36 508.02 10.8 9.05
28 X46 863.60 9.47 3.00 185.42 508.02 10.56 9.55
29 X46 863.60 9.37 4.62 91.44 508.02 9.17 9.20
30 X46 273.05 8.26 3.96 241.30 481.13 21.21 18.19
31 X52 273.05 5.23 1.85 408.94 502.27 16.71 13.53
32 X52 273.05 5.26 1.73 139.70 502.27 18.06 15.23
33 X52 273.05 5.28 0.00 0.00 502.27 17.24 21.04
34 X52 611.35 6.55 3.30 901.70 534.53 9.45 6.14
35 X52 612.55 6.43 3.56 1432.56 534.53 7.88 5.40
36 X52 611.51 6.40 2.57 1371.60 534.53 9.81 7.22
37 X56 506.73 5.74 3.02 132.08 587.34 10.73 9.09
38 X56 504.95 5.66 3.25 462.28 587.34 8.05 6.27
39 X56 508.00 5.69 3.76 619.76 587.34 8.58 4.91
40 X56 508.00 5.74 3.84 533.40 587.34 9.89 4.91
41 X56 508.00 5.74 3.05 416.56 587.34 10.91 7.01
42 X56 508.00 5.61 3.35 596.90 587.34 8.05 5.74
43 X56 508.00 5.64 2.46 170.18 587.34 11.51 9.30
44 X60 323.90 9.80 7.08 255.60 542.00 14.4 13.40
45 X60 323.90 9.66 6.76 305.60 542.00 14.07 12.84
46 X60 323.90 9.71 6.93 350.00 542.00 13.58 11.84
47 X60 323.90 9.71 6.91 394.50 542.00 12.84 11.45
48 X60 323.90 9.91 7.31 433.40 542.00 12.13 10.52
49 X60 323.90 9.74 7.02 466.70 542.00 11.92 10.69
50 X60 323.90 9.79 6.99 488.70 542.00 11.91 10.88
51 X60 323.90 9.79 6.99 500.00 542.00 11.99 10.83
52 X60 323.90 9.74 7.14 527.80 542.00 11.3 10.01
53 X60 508.00 6.60 2.62 381.00 598.90 11.3 10.43
54 X60 508.00 6.70 2.66 1016.00 601.00 11.6 10.21
55 X60 508.00 6.40 3.46 899.20 672.50 8 8.19
56 X60 508.00 6.40 2.18 899.20 672.50 11.8 11.74
57 X60 508.00 6.40 3.18 1000.80 672.50 8.4 8.98
58 X60 720.00 8.00 4.30 180.00 535.00 10.3 8.10
59 X60 720.00 8.00 4.40 320.00 535.00 8.83 6.83
60 X60 720.00 8.00 6.20 180.00 535.00 7.55 6.23
61 X65 762.00 17.50 4.40 200.00 600.00 24.11 25.58
62 X65 762.00 17.50 8.80 200.00 600.00 21.76 21.10
63 X65 762.00 17.50 13.10 200.00 600.00 17.15 17.32
64 X65 762.00 17.50 8.80 100.00 600.00 24.3 23.72
65 X65 762.00 17.50 8.80 300.00 600.00 19.08 19.27
66 X65 762.00 17.50 8.80 200.00 600.00 23.42 21.10
67 X65 762.00 17.50 8.80 200.00 600.00 22.64 21.10
68 X80 459 8 3.75 40 731 24.2 22.75
(continued on next page)
B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219 217
6. Conclusions
This paper investigates the prediction method of the failure pressure of the corroded pipeline, which focus on high-grade
strength steels. Based on von Mises strength failure criterion, a formula (denoted as p
0
M
) is theoretically deduced adopting
RambergOsgood hardening stressstrain relation, which was used to evaluate the failure pressure of end-capped and de-
fect-free pipeline.
Extensive FEA simulations were presented in this paper for failure pressures of high-grade strength steel pipelines with
outer corrosion defects. The FEA simulations were to investigate how the depth and length of the corrosion defects inuence
load carrying capacity of the defective pipelines, when the von Mises equivalent stress of the corresponding point reach the
true ultimate tensile strength of the material, where is in the mid surface of the ligament, because of the instability of the
inner surface point. And the FEA results indicate that the failure pressure of corroded pipes: (a) decreases as
d
t
increases for all
defects; and when the
d
t
is small, the pressure decreases slowly; (b) decreases as
L

Dt
p
increases for all defects; and when the
L

Dt
p
is small, the pressure decreases slowly; (c) when the defect length is larger than the pipe diameter, the variation of failure
pressure is tiny as
L

Dt
p
increases. (d) The variation trend of the failure pressure with the
L

Dt
p
accord with the power index func-
tion of e;
The failure pressure prediction formula p
failure
of corroded pipe with defects was determined based on p
M
, and f. f is a func-
tion to express the variation trend of pressure with the
d
t
and
L

Dt
p
. 79 groups of full-scale burst test data were collected to
verify the reliability and application elds of this method. The comparison results indicate that the failure pressure predicted
by Eq. (8): (a) is much closer to the accrual burst pressure in the pipeline with high-grade strength steel; (b) and also apply to
evaluate the pipeline with mid-grade strength steel; (c) but is not reliable to evaluate the pipeline with low-grade strength
steel.
Acknowledgements
The authors are grateful to the Zhongyuan Petroleum Prospecting and Design Institute for its support, through the na-
tional science and technology major project (project number is 2011ZX05017-004-HZ04). Special thanks are due to the
anonymous reviewers for their useful comments and suggestions regarding the present paper.
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Table 4 (continued)
No. Grade D (mm) t (mm) d (mm) L (mm) r
u
(MPa) Burst pressure (MPa) p
failure
(MPa)
69 X80 457 8.1 5.39 39.6 684 22 20.61
70 X80 1219.00 19.89 15.41 605.72 740.00 9.3 9.65
71 X80 1219.00 19.89 7.44 605.72 740.00 17.7 18.28
72 X80 1219.00 19.89 1.77 607.74 740.00 23.3 24.69
73 X80 1219.00 13.79 10.78 588.37 740.00 5.2 5.99
74 X80 1219.00 13.79 5.45 589.40 740.00 12 12.08
75 X80 1219.00 13.79 1.54 586.42 740.00 16.1 16.69
76 X100 1320.00 22.90 11.36 609.03 886.00 19.1 20.14
77 X100 1320.00 22.90 11.45 1109.94 886.00 15.4 15.81
78 X100 1320.00 22.90 11.52 514.98 886.00 19.9 19.76
79 X100 1320.00 22.90 11.45 1012.75 886.00 17 18.06
Note: The data of X46 are form the literatures [21,22]; the data of X52 and X56 are from the literature [23]; the data of X60 and X65 are from the literatures
[2428]; the data of X80 and X100 are from the literature [29,30].
218 B. Ma et al. / Engineering Failure Analysis 32 (2013) 209219
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