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Assessing the Secondary Stress in a Pipe System with Circumferential Surface Crack Using Finite Element Modeling


 In flaw evaluation criteria, the design limits for the secondary stresses are frequently different than the primary stresses. The evaluation procedure for primary stresses is load-controlled based which is independent of pipe deformation. The evaluation procedures for secondary stresses are displacement controlled which are dependent on pipe deformation. In this work, the secondary stress reduction factor was determined for a representative pipe system with multiple crack sizes, crack locations, and loading conditions. Nonlinear finite element (FE) analyses of a whole uncracked-pipe system were performed using ABAQUS® under various loading combinations to determine the critical locations for cracks in the pipe system. Next, FE analyses of the cracked-pipe system were carried out using cracked-pipe element - a methodology developed by the authors. Cracked-pipe system analyses were conducted for two loading conditions - one producing contained plasticity or single-hinge system and the other producing larger plasticity in the pipe system. Several analyses were conducted for each loading conditions with a combination of two crack sizes at two key locations. Secondary stress reduction factors were then calculated for both loading conditions in the pipe system. Finally, the margin in secondary stress was assessed for the pipe system by comparing the secondary stress reduction factors with that for straight pipe sections (determined for experimental bend tests) as well as with the recommended equivalent PRF and the equivalent ASME secondary stress correction factors.