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. 2022 Jan 27;22(3):986.
doi: 10.3390/s22030986.

A Crack Propagation Method for Pipelines with Interacting Corrosion and Crack Defects

Mingjiang Xie  1 , Yifei Wang  1 , Weinan Xiong  2 , Jianli Zhao  1 , Xianjun Pei  1
Affiliations

A Crack Propagation Method for Pipelines with Interacting Corrosion and Crack Defects

Mingjiang Xie et al. Sensors (Basel). .

Abstract

Corrosion and crack defects often exist at the same time in pipelines. The interaction impact between these defects could potentially affect the growth of the fatigue crack. In this paper, a crack propagation method is proposed for pipelines with interacting corrosion and crack defects. The finite element models are built to obtain the Stress Intensity Factors (SIFs) for fatigue crack. SIF interaction impact ratio is introduced to describe the interaction effect of corrosion on fatigue crack. Two approaches based on extreme gradient boosting (XGBoost) are proposed in this paper to predict the SIF interaction impact ratio at the deepest point of the crack defect for pipelines with interacting corrosion and crack defects. Crack size, corrosion size and the axial distance between these two defects are the factors that have an impact on the growth of the fatigue crack, and so they are considered as the input of XGBoost models. Based on the synthetic samples from finite element modeling, it has been proved that the proposed approaches can effectively predict the SIF interaction impact ratio with relatively high accuracy. The crack propagation models are built based on the proposed XGBoost models, Paris' law and corrosion growth model. Sensitivity analyses regarding corrosion initial depth and axial distance between defects are performed. The proposed method can support pipeline integrity management by linking the crack propagation model with corrosion size, crack size and the axial distance. The problem of how the interaction between corrosion and crack defects impacts crack defect growth is investigated.

Keywords: XGBoost; corrosion; fatigue crack; finite element; pipeline; stress intensity factor.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Geometric modeling of corroded pipeline.
Figure 2
Figure 2
The grid division of pipeline. (a) Partial refinement of corrosion defect grid. (b) Partial refinement of grid at crack.
Figure 3
Figure 3
Comparison of pipeline SIF results.
Figure 4
Figure 4
An example of CARTs.
Figure 5
Figure 5
Objective function of the example in Figure 4.
Figure 6
Figure 6
The procedure of the proposed algorithm.
Figure 7
Figure 7
Prediction results of SIF interaction impact ratio based on approach 1.
Figure 8
Figure 8
Prediction results of SIF interaction impact ratio based on approach 1. Corrosion depth d: (a) 4 mm; (b) 6 mm; (c) 10 mm; (d) Comparison results for different corrosion depths when crack depth a is 6 mm.
Figure 8
Figure 8
Prediction results of SIF interaction impact ratio based on approach 1. Corrosion depth d: (a) 4 mm; (b) 6 mm; (c) 10 mm; (d) Comparison results for different corrosion depths when crack depth a is 6 mm.
Figure 9
Figure 9
Prediction results of SIF values without considering interaction impact based on approach 2.
Figure 10
Figure 10
Prediction results of SIF values considering interaction impact based on approach 2.
Figure 11
Figure 11
Prediction results of SIF interaction impact ratio based on approach 2.
Figure 12
Figure 12
The comparison of SIF results based on approach 2. Corrosion depth d: (a) 4 mm; (b) 6 mm; (c) 10 mm; (d) Comparison results for different corrosion depths when crack depth a is 6 mm.
Figure 13
Figure 13
Investigations of the interaction impact on crack depth growth for different axial distances. Axial distance: (a) 150 mm; (b) 200 mm; (c) 300 mm; (d) 500 mm.
Figure 14
Figure 14
Crack depth growth curves for different distances based on approach 2.
Figure 15
Figure 15
Investigations of the interaction impact on crack depth growth. Corrosion initial depth: (a) 2 mm; (b) 4 mm; (c) 6 mm; (d) 8 mm.
Figure 15
Figure 15
Investigations of the interaction impact on crack depth growth. Corrosion initial depth: (a) 2 mm; (b) 4 mm; (c) 6 mm; (d) 8 mm.
Figure 16
Figure 16
Crack depth growth curves for different corrosion initial depths based on approach 2.
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