V. P. Larionov Institute of Physical and Technical Problems of the North, Siberian Branch of the Russian Academy of Sciences, Yakutsk, Russia
V. V. Lepov, Dr. Eng., Chief Researcher, Full Member of the Academy of Sciences of the Republic of Sakha (Yakutia), e-mail: wisecold@mail.ru

N. I. Golikov, Dr. Eng., Chief Researcher, e-mail: n.i.golikov@mail.ru
Ya. M. Andreev, Cand. Eng., Senior Researcher, e-mail: yakovmich@yandex.ru
E. S. Lukin, Cand. Eng., Acting Director, e-mail: lukin@iptpn.ysn.ru

Yakutsk Scientific Center, Siberian Branch of the Russian Academy of Sciences, Yakutsk, Russia
S. O. Semenov, Junior Researcher, e-mail: semens1993@mail.ru
L. A. Prokopyev, Researcher, e-mail: l.prokopyev@yandex.ru

The basis for a comprehensive system for ensuring the reliability and safety of welded pipelines is the computational and experimental support for monitoring their technical condition using a system-structural approach. The article presents the results of multi-scale modeling of the failure process of a welded pipeline wall made of low-alloy grade 09G2S steel, an analysis of the biaxial stress state, and a computational validation for the leak-before-break criterion, widely used in the industry. The macroscopic level is represented by a computational analysis of the stress-strain state of a longitudinally welded pipe 530×7 mm with a semi-elliptical surface crack in the ANSYS environment. The mesolevel is represented by crack growth modeling within the SmartCrack algorithm using macromodeling parameters. The microlevel is represented by stochastic modeling of the growth of microcracks of an acceptable size according to physical concepts of preferential crack propagation along grain boundaries and defects. The analysis of the results indicates a significant safety margin during the operation of pipelines made of low-alloy high-strength steel 09G2S. However, a significant influence of residual stresses on the stress intensity factor, T-stress, and biaxiality coefficient is revealed. The conducted computational estimates correlate with experimental data from instrumental measurements. The developed method enables a more accurate prediction of the development of crack-like defects and an assessment of the residual service life of structures, including the with leak-before-break criterion. The obtained results are fundamental for the numerical prediction of the stages preceding crack formation and primary leakage based on the percolation criterion. These results are applicable for improving nondestructive testing methods, substantiating the sizes of permissible defects, developing weld repair technologies, and improving the operational safety of metal structures operating in the extreme climatic conditions of northeastern Russia.

This work was performed using the scientific equipment of the Shared Research Center of the Yakutsk Scientific Center of the Siberian Branch of the Russian Academy of Sciences. The application of multi-level modeling and stochastic calculation of crack growth at the micro level were carried out with the support of the Russian Science Foundation (grant 24-21-20122 https://rscf.ru/project/24-21-20122).

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