Analytical solution for stress, strain and plastic instability of pressurized pipes with volumetric flaws

The mechanical behavior of internally pressurized pipes with volumetric flaws is analyzed. The two possible modes of circumferentially straining the pipe wall are identified and associated to hypothesized geometries. The radial deformation that takes place by bending the pipe wall is studied by means of axisymmetric flaws and the membrane strain developed by unequal hoop deformation is analyzed with the help of narrow axial flaws. Linear elastic shell solutions for stress and strain are developed, the plastic behavior is studied and the maximum hoop stress at the flaw is related to the undamaged pipe hoop stress by means of stress concentration factors. The stress concentration factors are employed to obtain equations predicting the pressure at which the pipe fails by plastic instability for both types of flaw. These analytical solutions are validated by comparison with burst tests on 3″ diameter pipes and finite element simulations. Forty-one burst tests were carried out and two materials with very dissimilar plastic behavior, carbon steel and austenitic stainless steel, were used in the experiments. Both the analytical and the numerical predictions showed good correlation with the experimentally observed burst pressures.

► An analytical model for the burst of a pipe with a volumetric flaw is developed. ► Deformation, strain and stress are modeled in the elastic and plastic domains. ► The model is comprehensively validated by experiments and numerical simulations. ► The burst pressure model’s accuracy is equivalent to finite element simulations.