Open Access

ARTICLE

A Method for Preventing Crack Propagation in a Steel Gas Conduit Reinforced with Composite Overlays

Nurlan Zhangabay^1,*, Ulanbator Suleimenov¹, Marco Bonopera^2,*, Ulzhan Ibraimova¹, Shairbek Yeshimbetov³

1 Department of Architecture and Urban Planning, Mukhtar Auezov South Kazakhstan University, Tauke Khan av., 5, Shymkent, 160012, Kazakhstan
2 Department of Architecture and Industrial Design, University of Campania “Luigi Vanvitelli”, Via San Lorenzo ad Septimum, Aversa, 81031, Italy
3 Department of Scientific and Innovative Work, Peoples’ Friendship University named after Academician A. Kuatbekov, Tole bi str., 32B1, Shymkent, 160011, Kazakhstan

* Corresponding Authors: Nurlan Zhangabay. Email: ; Marco Bonopera. Email:

(This article belongs to the Special Issue: Intelligent Fault Diagnosis and Health Monitoring for Pipelines)

Structural Durability & Health Monitoring 2025, 19(4), 773-787. https://doi.org/10.32604/sdhm.2025.064980

Received 28 February 2025; Accepted 26 May 2025; Issue published 30 June 2025

Abstract

This research presents a numerical simulation methodology for optimizing circular composite overlays’ dimensions and pressure characteristics with orthotropic mechanical properties, specifically, for metal conduits with temperature-dependent elastoplastic behavior. The primary objective of the proposed method is to prevent crack propagation during pressure surges from operational to critical levels. This study examines the “Beineu-Bozoy-Shymkent” steel gas conduit, examining its performance across a temperature range of −40 to +50°C. This work builds on prior research on extended avalanche destruction in steel gas conduits and crack propagation prevention techniques. The analysis was conducted using a dynamic finite-element approach with the ANSYS-19.2/Explicit Dynamics software. Simulations of unprotected conduits revealed that increasing gas-dynamic pressure can convert a partial-depth crack into a through-crack, extending longitudinally to approximately seven times its initial length. Notably, at T = +50°C, the developed crack length was 1.2% longer than that at T = −40°C, highlighting the temperature sensitivity of crack progression. The modeling results indicate that crack propagation can be effectively controlled using a circular composite overlay with a thickness between 37.5% and 50% of the crack depth and a length approximately five times that of the initial crack, centered symmetrically over the crack. In addition, preliminary stress analysis indicated that limiting the overlay-induced pressure to 5% of the operational pressure effectively arrested crack growth without generating significant stress concentrations near the overlay boundaries, thereby preventing conduit integrity.

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Keywords

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