Shuxin Zhang

Permanent ground deformation caused by fault movement threatens the safe operation of buried pipelines. Accurate fragility assessment of buried pipelines subjected to faulting is essential for pipeline design and risk management. However, buried pipelines exhibit nonlinear mechanical responses due to the coupled effects of multiple factors. Moreover, the effects of key parameters remain insufficiently quantified, limiting the accuracy and engineering applicability of existing fragility assessments. In this study, a three-dimensional finite element model incorporating large deformation and nonlinear pipe–soil interaction is developed and validated against representative experimental data. Using this model, numerical simulations are performed for 352 parameter combinations covering fault type, dip angle, burial depth, soil type, and pipe material. Nonlinear regression of the simulation results yielded predictive models for pipeline peak axial strain under normal-slip and reverse-slip faulting. A fragility framework is then established with fault displacement as the intensity measure, and fragility curves are derived for both faulting modes. The predicted peak axial strains agree with the finite element results: 78.6% (normal-slip) and 72.5% (reverse-slip) of predictions fall within ±20% error. The fragility curves enable quantitative estimation of fault-displacement thresholds. In the case study, the intact-to-damage displacement threshold is approximately 0.6 m for normal-slip faults but approximately 0.2 m for reverse-slip faults, indicating a higher failure likelihood under reverse-slip faulting. Within the investigated parameter ranges, the fault dip angle is the most significant factor affecting the pipeline failure probability for both normal-slip and reverse-slip faulting. Sandy soil and greater burial depth substantially increase the probability of moderate-to-severe damage, whereas higher steel grade increases the displacement threshold for transition from intact to failure. This study provides a rapid quantitative tool and a theoretical basis for pipeline design and risk quantification of buried pipelines in fault zones.

Light hydrocarbon fuels are widely utilized in industrial production and transportation due to their high calorific value and clean combustion characteristics. Compared to traditional oil tanker transportation, pipelines not only reduce transportation costs but also minimize environmental impact. To understand the leakage and diffusion law of light hydrocarbon pipelines, this paper takes light hydrocarbon pipelines as the research object, establishes the conceptual model of the process of light hydrocarbon leakage and diffusion, divides the four major processes of leakage and diffusion, analyzes the relevant theory, and deduces a formula. The numerical model of pipeline–air–soil leakage and diffusion was established to analyze the whole process of light hydrocarbon leakage and diffusion. The diffusion behavior of individual hydrocarbon components is examined, along with a comparative analysis between multi-component and single-component leakage scenarios. Simulation results reveal that the leakage process comprises three stages: an initial rapid diffusion phase, a transitional phase where a stable region begins to form, and a final stage where the diffusion pattern stabilizes around 800 s. C3 and C5 exhibit the largest diffusion ranges among gaseous and liquid hydrocarbons, respectively. In multi-component systems, the vaporization sequence suppresses the overall diffusion range compared to single-component cases, though gas-phase hydrocarbons tend to accumulate near the leakage source. Understanding the leakage and diffusion behavior of light hydrocarbon pipelines is crucial for energy security. By accurately modeling these processes, we can determine the impact zones of potential pipeline failures and establish appropriate safety buffers. This proactive approach not only safeguards human life and the environment but also ensures the reliable and uninterrupted delivery of energy resources. Consequently, such research is instrumental in fortifying the resilience and dependability of energy infrastructure.

X80 steel pipelines are widely used in oil and gas transportation, and the quality and fracture behavior of the girth weld have an important influence on the safety and performance of the pipeline. This study presents a comprehensive investigation into the microstructure, mechanical properties, and fracture characteristics of X80 steel welded joints. Through microstructure analysis and mechanical testing, the hardness, impact, and tensile properties of the base metal, heat-affected zone, and weld zone are evaluated. Digital Image Correlation (DIC) technology is employed to scrutinize the strain behavior under quasi-static tensile tests for both smooth and notched round bar specimens, providing a detailed strain distribution analysis. The findings indicate that, while X80 welded joints are well-formed without significant defects, the hardness and impact properties vary across different zones, with the base metal exhibiting the highest impact toughness and the weld zone the lowest. Notched tensile tests reveal that the presence and geometry of notches significantly alter the stress state and deformation characteristics, influencing the fracture mode. The DIC analysis further elucidates the strain concentration and localization behavior in the weld zone, highlighting the importance of notch size in determining the load-bearing capacity and ductility of the welded joints. This study contributes to a deeper understanding of the fracture mechanics in X80 pipeline girth welds and offers valuable insights for the optimization of welding practices and the assessment of pipeline integrity.

Girth welds are weak points in pipelines, and failures occur frequently. In a gas transmission pipeline, a girth weld experienced cracking, prompting a failure analysis using experimental methods and finite element analysis (FEA). Experimental results showed that X-ray non-destructive testing (NDT) revealed cracks, porosity, and lack of fusion in the girth weld. However, the hardness and microstructure of the material showed no abnormalities. During operation, the pipeline experienced an increase in soil cover and was subjected to ground subsidence and vehicle loads. Finite element analysis was conducted on the defective girth weld under different conditions, including varying soil cover depths, different levels of subsidence, and varying vehicle loads, to examine the pipeline’s stress response. The results indicated that the combination of soil cover, subsidence, and vehicle loads led to pipeline failure, whereas none of these factors alone was sufficient to cause girth weld failure. To prevent such failures from occurring again, the following measures are recommended: strengthen on-site welding quality control of girth welds, conduct inspections for defects in girth welds of in-service pipelines, and promptly address any defects that exceed acceptable limits.

With green and low-carbon developments in oil fields, an increasing amount of repaired oil tubing is being used as oil and gas transmission pipelines in China. However, due to differences in manufacturing standards between oil tubing and transmission pipelines, there are inevitably some issues during their use. This paper investigates a case of cracking failure in repaired oil tubing used as a gathering and transportation pipeline. The failure occurred after eight months of operation and was characterized by a circumferential crack at the male thread end of the tubing joint. To determine the root cause of the failure, a series of experiments were conducted on the oil tubing. The experiments included visual inspection, chemical composition analysis, mechanical properties testing, hardness testing, metallographic examination, and microstructure analysis. The results revealed that the thread of the cracked tubing was not tightened to the specified position; the connection between the tubing and the coupling was welded in a circumferential direction; and cracks occurred in the heat-affected zone of the weld. Chemical composition, tensile performance, and the Charpy impact of the tubing meet the requirements of API 5CT for P110 material, and no abnormalities were found in the metallographic structure. The microstructure at the weld toe of the fracture is martensite, and the hardness is 476 HV10. Based on the thermal simulation verification test, when the material of the tubing cools from 1200 °C, which is located in the coarse HAZ temperature zone, the base metal transforms into martensite with a little granular bainite, exhibiting its highest hardness value at 371 HV10, which is higher than the allowable hardness for carbon steel and indicates the material has poor weldability. The reasons for the cracking and failure of the tubing are that the P110 repaired tubing has a high carbon equivalent and poor weldability. During the welding process, martensitic structure was formed at the weld toe, and cold cracks appeared in the heat-affected zone, resulting in failure. To avoid the reoccurrence of such failure, recommendations are proposed.

During well repair operations in an oil field, a Φ73.02 mm×5.51 mm N80 grade flat oil pipe with a circular hole was found. The depth of the well is between 550 meters to 2100 meters, with a usage cycle of 120 days. In order to figure out the root cause of the circular hole failure, a series of experiments were carried out. The chemical composition, yield strength, tensile strength, and elongation of the oil pipe meet the requirements of API SPEC 5CT-2018 standard. The microstructure of the oil pipe matrix consists of ferrite and pearlite, and there are no obvious cracks. The grain size of the material is all above 8.5 levels, and there are no coarse grains or non-metallic inclusions exceeding the standard. The perforation of the oil pipe is caused by internal corrosion, mainly due to CO2 corrosion and dissolved oxygen corrosion. The coexistence of Ca2+ and Mg2+ ions, iron bacteria, and corrosive bacteria in the wellbore fluid can lead to scale deposition inside the pipe, causing under-deposit corrosion, and the accelerating effect of Cl ions on corrosion ultimately leads to perforation of the pipe.

The use of duplex stainless steel (DSS) in various fields is promising due to its excellent anti-corrosion properties, but traditional welding can lead to the formation of unfavorable phases that deteriorate its quality. This study aimed to use the rotary friction weld (RFW) technique to prevent the formation of harmful phases in the welding of an S32205 alloy pipe. The welding parameters used included a rotating speed of 20 m/s, a friction pressure of 10 MPa, a friction time of 30 s, and a forging pressure of 30 MPa. The microstructure and mechanical properties of the resulting RFWed joint were investigated. The results revealed that the weld zone exhibited a microstructure consisting of ferrite and austenite phases, with no deleterious phase detected. The ferrite content was measured to be 53.3%, 54.5%, and 68.7% in the base metal, thermomechanical affected zone (TMAZ), and weld, respectively, owing to the rapid cooling rate in the RFW process, which prevented any harmful phase formation in the weld zone. Furthermore, the RFW process successfully produced an ultrafine grain with a ferrite/austenite grain size of 0.40 μm and 0.41 μm, respectively. The weld zone and TMAZ contained more low-angle grain boundaries (LAGBs) compared to the base metal, which was attributed to the dynamic recovery (DRV) within a grain. The high heating and cooling rates and short welding time of the RFW process did not allow sufficient time for the dynamic recrystallization of the microstructure in the weld zone. However, a slight increase in the ferrite content in the weld zone resulted in grain refinement and an increase in the dislocation density, resulting in a slight increase in the 358 HV0.2 hardness and 823 MPa tensile strength of the weld zone. This study offers a novel approach for obtaining ultrafine grain duplex stainless steel pipes with exceptional mechanical properties through the application of RFW.

T-joint welding is a key manufacturing process of large storage tanks. However, complex residual stresses are generated and have a great effect on the structural integrity of storage tanks. The high residual stress caused by welding and the discontinuous structure may result in tank cracking and failure. In this work, the residual stress distributions on the inner surface, outer surface, and thickness direction of the T-joint were investigated by using the finite element method and indentation test method. The effect of local PWHT with different heating temperatures, heating rates, and heating widths on the residual stress distribution was also discussed. Results show that the residual stress of the T-shaped joint is high due to the serious structure discontinuity, multi-layer welding, and high strength. Among all the stresses, the circumferential residual stress is the highest and most concentrated in the outer weld connected with the annular plate. The residual stress gradually decreases with the increase in the heat treatment temperature. When the heating rate is less than 106 °C/h, the residual stress gradually decreases with the decrease in the heating rate. The large thermal deformation caused by heat treatment can be simultaneously avoided by heating the inside and outside of the T-joint. The residual stress decreases with the decrease in the width of the heating zone. The residual stress can be regulated by using a smaller width in the heating zone. An optimized heat treatment scheme with a heating temperature of 700 °C, heating rate of 56 °C/h, and heating width of 200 mm was proposed, which has a good ability to control residual stresses and improve the quality of the T-joint. It also has a good application in engineering.

The acoustic emission testing standards ASTM E1930, BS EN 15856, JB/T 10764 and Q/SY GD 0211 for atmospheric storage tank are compared and analysed. Combined with production practice, the revision direction and reference suggestions of acoustic emission testing standards for atmospheric tank were proposed.