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The purpose of this paper is to investigate the application of reliability engineering to oil and gas (O&G) pipeline systems with the aim of identifying means through which reliability engineering can be used to improve pipeline integrity, specifically with regard to man-made incidents (e.g. material/weld/equipment failure, corrosion, incorrect operation and excavation damages).

A literature review was carried out on the application of reliability tools to O&G pipeline systems and four case studies are presented as examples of how reliability engineering can help to improve pipeline integrity. The scope of the paper is narrowed to four stages of the pipeline life cycle; the decommissioning stage is not part of this research. A survey was also carried out using a questionnaire to check the level of application of reliability tools in the O&G industry.

Data from survey and literature show that a reliability-centred approach can be applied and will improve pipeline reliability where applied; however, there are several hindrances to the effective application of reliability tools, the current methods are time based and focus mainly on design against failure rather than design for reliability.

The tools identified do not cover the decommissioning of the pipeline system. Research validation sample size can be broadened to include more pipeline stakeholders/professionals. Pipeline integrity management systems are proprietary information and permission is required from stakeholders to do a detailed practical study.

This paper proposes the minimum applied reliability tools for application during the design, operation and maintenance phases targeted at the O&G industry. Critically, this paper provides a case for an integrated approach to applying reliability and maintenance tools that are required to reduce pipeline failure incidents in the O&G industry.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

This study aims to analyze the factors, evaluation techniques of the durability of existing railway engineering.

China has built a railway network of over 150,000 km. Ensuring the safety of the existing railway engineering is of great significance for maintaining normal railway operation order. However, railway engineering is a strip structure that crosses multiple complex environments. And railway engineering will withstand high-frequency impact loads from trains. The above factors have led to differences in the deterioration characteristics and maintenance strategies of railway engineering compared to conventional concrete structures. Therefore, it is very important to analyze the key factors that affect the durability of railway structures and propose technologies for durability evaluation.

The factors that affect the durability and reliability of railway engineering are mainly divided into three categories: material factors, environmental factors and load factors. Among them, material factors also include influencing factors, such as raw materials, mix proportions and so on. Environmental factors vary depending on the service environment of railway engineering, and the durability and deterioration of concrete have different failure mechanisms. Load factors include static load and train dynamic load. The on-site rapid detection methods for five common diseases in railway engineering are also proposed in this paper. These methods can quickly evaluate the durability of existing railway engineering concrete.

The research can provide some new evaluation techniques and methods for the durability of existing railway engineering.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

Porous implant surface is shown to facilitate bone in-growth and cell attachment, improving overall osteointegration, while providing adequate mechanical integrity. Recently, biodegradable material possessing such superior properties has been the focus with an aim of revolutionizing implant’s design, material and performance. This paper aims to present a comprehensive investigation into the design and development of low elastic modulus porous biodegradable Mg-3Si-5HA composite by mechanical alloying and spark plasma sintering (MA-SPS) technique.

This paper presents a comprehensive investigation into the design and development of low elastic modulus porous biodegradable Mg-3Si-5HA composite by MA-SPS technique. As the key alloying elements, HA powders with an appropriate proportion weight 5 and 10 are mixed with the base elemental magnesium (Mg) particles to form the composites of potentially variable porosity and mechanical property. The aim is to investigate the performance of the synthesized composites of Mg-3Si together with HA in terms of mechanical integrity hardness and Young’s moduli corrosion resistance and in-vitro bioactivity.

Mechanical and surface characterization results indicate that alloying of Si leads to the formation of fine Mg2 Si eutectic dense structure, hence increasing hardness while reducing the ductility of the composite. On the other hand, the allying of HA in Mg-3Si matrix leads to the formation of structural porosity (5-13 per cent), thus resulting in low Young’s moduli. It is hypothesized that biocompatible phases formed within the composite enhanced the corrosion performance and bio-mechanical integrity of the composite. The degradation rate of Mg-3Si composite was reduced from 2.05 mm/year to 1.19 mm/year by the alloying of HA elements. Moreover, the fabricated composites showed an excellent bioactivity and offered a channel/interface to MG-63 cells for attachment, proliferation and differentiation.

Overall, the findings suggest that the Mg-3Si-HA composite fabricated by MA and plasma sintering may be considered as a potential biodegradable material for orthopedic application.

Purpose – The purpose of this study is to develop a numerical framework to predict the time-dependent probability of failure of a bridge subjected to multiple vehicle impacts. Specially, this study focuses on investigating the inter-relationship between changes in life-cycle parameters (e.g., damage size caused by vehicle impact, loss of initial structural capacity, and threshold intervention) and bridges probability of failure.

Design/Methodology/Approach – The numerical procedure using MATLAB program is developed to compute the probability failure of a bridge. First, the importance and characteristics of life-cycle analysis is described. Then, model for damage accumulation and life cycle as a result of heavy vehicle impacts is discussed. Finally, the probability of failure of a bridge subjected to vehicle impacts as a result of change in life-cycle parameters is presented.

Findings – The results of study show that damage size caused by both vehicle impacts and loss of initial structural capacity have a great impact on the long-term safety of bridges. In addition, the probability of failure of a bridge under different threshold limits indicates that the structural intervention (e.g., repair or maintenance) should be undertaken to extend the service life of a bridge.

Research Limitations/Implications – The damage sizes caused by heavy vehicle impacts are based on simple assumptions. It is suggested that there would be a further study to estimate the magnitude of bridge damage as a result of vehicle impact using the full-scale impact test or computational simulation.

Practical Implications – This will allow much better predictions for residual life of bridges which could potentially be used to support decisions on health and maintenance of bridges.

Originality/Value – The life-cycle performance for assessing the time-dependent probability of failure of bridges subjected to multiple vehicle impact has not been fully discussed so far.

The combined effects of several complex phenomena cause the deterioration of elements in steel hydraulic structures (SHSs) within the US lock system: corrosion, cracking and fatigue, impact and overloads. Predicting the future condition state of these structures by the use of current condition state inspection data can be achieved through the probabilistic chain deterioration model. The purpose of this study is to derive the transition probability matrix using final elements modeling of a miter gate.

If predicted accurately, this information would yield benefits in determining the need for rehabilitation or replacement of SHS. However, because of the complexity and difficulties on obtaining sufficient inspection data, there is a lack of available condition states needed to formulate proper transition probability matrices for each deterioration case.

This study focuses on using a three-dimensional explicit finite element analysis (FEM) of a miter gate that has been fully validated with experimental data to derive the transition probability matrix when the loss of flexural capacity in a corroded member is simulated.

New methodology using computational mechanics to derive the transition probability matrices of navigation steel structures has been presented.

The difficulty of deriving the transition probability matrix to perform a Markovian analysis increases when limited amount of inspection data is available. The used state of practice FEM to derive the transition probability matrix is not just necessary but also essential when the need for proper maintenance is required but limited amount of the condition of the structural system is unknown.

For many decades, it has been recognized that maintenance activities should be adapted to the specific usage of a system. For that reason, many advanced policies have been developed, such as condition-based and load-based maintenance policies. However, these policies require advanced monitoring techniques and rather detailed understanding of the failure behavior, which requires the support of an OEM or expert, prohibiting application by an operator in many cases. The present work proposes a maintenance policy that relieves the high (technical) demands set by these existing policies and provides a more accurate specification of the required (dynamic) maintenance interval than traditional usage-based maintenance.

The methodology followed starts with a review and critical assessment of existing maintenance policies, which are classified according to six different aspects. Based on the need for a technically less demanding policy that appears from this comparison, a new policy is developed. The consecutive steps required for this functional usage profiles based maintenance policy are then critically discussed: usage profile definition, monitoring, profile severity quantification and the possible extension to the fleet level. After the description of the proposed policy, it is demonstrated in three case studies on real systems.

A maintenance policy based on a simple usage registration procedure appears to be feasible, which enables a significantly more efficient maintenance process than the traditional usage-based policies. This is demonstrated by the policy proposed here.

The proposed maintenance policy based on functional usage profiles offers the operators of fleets of systems the opportunity to increase the efficiency and effectiveness of their maintenance process, without the need for a high investment in advanced monitoring systems and in experts interpreting the results.

The original contribution of this work is the explicit definition of a new maintenance policy, which combines the benefits of considering the effects of usage or environment severity with a limited investment in monitoring technology.

Terrestrial laser scanning (TLS) point clouds have been widely used in deformation measurement for structures. However, reliability and accuracy of resulting deformation estimation strongly depends on quality of each step of a workflow, which are not fully addressed. This study aims to give insight error of these steps, and results of the study would be guidelines for a practical community to either develop a new workflow or refine an existing one of deformation estimation based on TLS point clouds. Thus, the main contributions of the paper are investigating point cloud registration error affecting resulting deformation estimation, identifying an appropriate segmentation method used to extract data points of a deformed surface, investigating a methodology to determine an un-deformed or a reference surface for estimating deformation, and proposing a methodology to minimize the impact of outlier, noisy data and/or mixed pixels on deformation estimation.

In practice, the quality of data point clouds and of surface extraction strongly impacts on resulting deformation estimation based on laser scanning point clouds, which can cause an incorrect decision on the state of the structure if uncertainty is available. In an effort to have more comprehensive insight into those impacts, this study addresses four issues: data errors due to data registration from multiple scanning stations (Issue 1), methods used to extract point clouds of structure surfaces (Issue 2), selection of the reference surface S_ref to measure deformation (Issue 3), and available outlier and/or mixed pixels (Issue 4). This investigation demonstrates through estimating deformation of the bridge abutment, building and an oil storage tank.

The study shows that both random sample consensus (RANSAC) and region growing–based methods [a cell-based/voxel-based region growing (CRG/VRG)] can be extracted data points of surfaces, but RANSAC is only applicable for a primary primitive surface (e.g. a plane in this study) subjected to a small deformation (case study 2 and 3) and cannot eliminate mixed pixels. On another hand, CRG and VRG impose a suitable method applied for deformed, free-form surfaces. In addition, in practice, a reference surface of a structure is mostly not available. The use of a fitting plane based on a point cloud of a current surface would cause unrealistic and inaccurate deformation because outlier data points and data points of damaged areas affect an accuracy of the fitting plane. This study would recommend the use of a reference surface determined based on a design concept/specification. A smoothing method with a spatial interval can be effectively minimize, negative impact of outlier, noisy data and/or mixed pixels on deformation estimation.

Due to difficulty in logistics, an independent measurement cannot be established to assess the deformation accuracy based on TLS data point cloud in the case studies of this research. However, common laser scanners using the time-of-flight or phase-shift principle provide point clouds with accuracy in the order of 1–6 mm, while the point clouds of triangulation scanners have sub-millimetre accuracy.

This study aims to give insight error of these steps, and the results of the study would be guidelines for a practical community to either develop a new workflow or refine an existing one of deformation estimation based on TLS point clouds.

The results of this study would provide guidelines for a practical community to either develop a new workflow or refine an existing one of deformation estimation based on TLS point clouds. A low-cost method can be applied for deformation analysis of the structure.

Although a large amount of the studies used laser scanning to measure structure deformation in the last two decades, the methods mainly applied were to measure change between two states (or epochs) of the structure surface and focused on quantifying deformation-based TLS point clouds. Those studies proved that a laser scanner could be an alternative unit to acquire spatial information for deformation monitoring. However, there are still challenges in establishing an appropriate procedure to collect a high quality of point clouds and develop methods to interpret the point clouds to obtain reliable and accurate deformation, when uncertainty, including data quality and reference information, is available. Therefore, this study demonstrates the impact of data quality in a term of point cloud registration error, selected methods for extracting point clouds of surfaces, identifying reference information, and available outlier, noisy data and/or mixed pixels on deformation estimation.

Large displacement misalignment under the action of active faults can cause complex three-dimensional deformation in subway tunnels, resulting in severe damage, distortion and misalignment. There is no developed system of fortification and related codes to follow. There are scientific problems and technical challenges in this field that have never been encountered in past research and practices.

This paper adopted a self-designed large-scale active fault dislocation simulation loading system to conduct a similar model test of the tunnel under active fault dislocation based on the open-cut tunnel project of the Urumqi Rail Transit Line 2, which passes through the Jiujiawan normal fault. The test simulated the subway tunnel passing through the normal fault, which is inclined at 60°. This research compared and analyzed the differences in mechanical behavior between two types of lining section: the open-cut double-line box tunnel and the modified double-line box arch tunnel. The structural response and failure characteristics of the open-cut segmented lining of the tunnel under the stick-slip part of the normal fault were studied.

The results indicated that the double-line box arch tunnel improved the shear and longitudinal bending performance. Longitudinal cracks were mainly distributed in the baseplate, wall foot and arch foot, and the crack position was basically consistent with the longitudinal distribution of surrounding rock pressure. This indicated that the longitudinal cracks were due to the large local load of the cross-section of the structure, leading to an excessive local bending moment of the structure, which resulted in large eccentric failure of the lining and formation of longitudinal cracks. Compared with the ordinary box section tunnel, the improved double-line box arch tunnel significantly reduced the destroyed and damage areas of the hanging wall and footwall. The damage area and crack length were reduced by 39 and 59.3%, respectively. This indicates that the improved double-line box arch tunnel had good anti-sliding performance.

This paper adopted a self-designed large-scale active fault dislocation simulation loading system to conduct a similar model test of the tunnel under active fault dislocation. This system increased the similarity ratio of the test model, improved the dislocation loading rate and optimized the simulation scheme of the segmented flexible lining and other key factors affecting the test. It is of great scientific significance and engineering value to investigate the structure of subway tunnels under active fault misalignment, to study its force characteristics and damage modes, and to provide a technical reserve for the design and construction of subway tunnels through active faults.