A fully coupled fluid-structure interaction simulation of three-dimensional dynamic ductile fracture in a steel pipeline

Long running fractures in high-pressure pipelines transporting hazardous fluid are catastrophic events resulting in pipeline damage and posing safety and environmental risks. Therefore, the ductile fracture propagation control is an essential element of the pipeline design. In this study, a coupled fluid-structure interaction modelling is used to simulate the dynamic ductile fractures in steel pipelines. The proposed model couples a fluid dynamics model describing the pipeline decompression and the fracture mechanics of the deforming pipeline exposed to internal and back-fill pressures. To simulate the state of the flow in a rupturing pipeline, a compressible one-dimensional computational fluid dynamics model is applied, where the fluid properties are evaluated using a rigorous thermodynamic model. The ductile failure of the steel pipeline is described as an extension of the modified Bai-Wierzbicki model implemented in a finite element code. The proposed methodology has successfully been applied to simulate a full-scale pipeline burst test performed by British Gas Company, which involved rupture of a buried X70 steel pipeline, initially filled with rich natural gas at 11.6 MPa and −5 °C.