Automated finite element analysis of burst capacity for corroded pipelines

Accurate prediction of pipeline burst pressure is critical for ensuring the safe and efficient operation of energy pipelines. Conventional empirical solutions compromise burst pressure prediction accuracy for complex corrosion with irregular profiles or multiple defects, leading to unnecessary repairs. Albeit significantly more accurate, the three-dimensional finite element modeling requires substantial efforts, which limits its use in pipeline burst pressure assessment. This paper presents an innovative automated finite element method (FEM) for elastic-plastic analysis of corroded pipelines, applicable to both straight pipelines and pipeline elbows. The method integrates MATLAB and ANSYS to automate key manual steps, including defect geometry reconstruction, mesh generation, and post-processing analysis for the burst pressure prediction of pipelines containing both semi-elliptically idealized and realistic corrosion defects. Validation against full-scale burst test data demonstrates excellent
agreement, with the developed FEM accurately predicting the burst capacity for corroded straight pipelines and elbows. The method developed will greatly reduce manual efforts for finite element modeling and facilitate pipeline assessment of complex irregular corrosion defects.