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Integrity assessment is used to ensure reliability operation of a pressurized equipment containing defects. Based on data of cylindrical shell dimensions, operation conditions, material properties and crack dimensions, an assessment can be carried out, using either Level 1, Level 2 or Level 3 procedure. Assessment using Level 3 procedure within the code requires a finite element simulation in order to generate both the evaluation point and the failure assessment diagram (FAD) that serves as the acceptance criteria. The purpose of this paper is to provide the numerical data which are used for integrity assessment of a pressure vessel containing crack. Here, a parametric study has been carried out to generate such result for the cases of longitudinal crack defect in a cylindrical shell for a number of common cases, in terms of thickness-to-radius ratio, crack size ratio and crack aspect ratio.

The evaluation of stress intensity factor is determined through J-integral parameter found using a finite element analysis with a specially meshed strategy incorporating the crack. A comparison is made against stress intensity factor provided by the code.

A good agreement is obtained with percent error of 2.13 percent for low aspect ratio crack, and 0.57 percent for high aspect ratio crack. Furthermore, a study has been carried out using the methodology for 160 cases, covering both cases already available in the code and other cases of crack in cylindrical shells. The result can be used as a complement to the existing tabular data available in the code for Level 2 assessment, to be used for integrity analysis of damaged cylindrical shells based on the FAD criteria.

The result can be used as a complement to the existing tabular data available in the API 579 code for Level 2 assessment, to be used for integrity analysis of damaged cylindrical shells based on the FAD criteria. New equations were generated based on finite element analysis and can be used for Level 3 assessment of the code.

The purpose of this paper is to develop basic principles of deterministic structural integrity assessment of a component with a crack- or notch-like defect by including safety factors against fracture and plastic collapse in criteria equations of linear and nonlinear fracture mechanics.

The safety factors against fracture are calculated by demanding that the applied critical stress should not be less than the yield stress of the material for a component with a crack or a notch of the acceptable size. Structural integrity assessment of the engineering components damaged by crack- or notch-like defects is discussed from view point of the failure assessment diagram (FAD). The methodology of the FAD has been employed for the structural integrity analysis and assessment of acceptable sizes of throw-thickness notch in a plate under tension and surface longitudinal notch-like defects in a pressure vessel.

Basic equations have been presented to calculate the safety factor against fracture for critical values of the stress intensity factor, crack tip opening displacement (CTOD), the J-integral and the FAD as well as to estimate an acceptable (safe) region for an engineering component with a crack- or notch-like defect of the acceptable size. It was shown that safety factors against fracture depend on both the safety factor against plastic collapse and employed fracture mechanics criterion. The effect of crack/notch tip constraint is incorporated into criteria equations for the calculation of safety factors against fracture.

The deterministic method of fracture mechanics is recommended for structural integrity assessment of a component with a crack- or notch-like defect by including safety factors against fracture and plastic collapse in criteria equations of linear and nonlinear fracture mechanics.

The purpose of this paper is to validate the strain-based failure assessment diagram (SB-FAD) approach for surface cracks in components subjected to displacement controlled boundary conditions.

Numerical analyses are performed for several crack geometries and materials representative for aerospace applications. The performance of the SB-FAD is judged by comparing numerically calculated J-integrals to respective analytical estimates, using both Options 1 and 2 approximations.

In the most cases, both Options 1 and 2 SB-FAD method results in reasonably conservative J-estimates. Exceptions are for surface cracks in a pressurized vessel made of a material with low-strain hardening, for which Option 2 assessment produces non-conservative results. In contrast, Option 1 assessment is conservative for all geometries considered. In general, Option 1 results in a considerable overestimation of the crack driving force, whereas Option 2 produces rather accurate results in many cases.

The results demonstrate both the potential of the SB-FAD method and needs for its further improvements.

The purpose of this paper is to present and validate a methodology for the structural integrity assessment of components containing a variety of stress risers and subjected to static conditions.

The methodology is based on the use of the apparent fracture toughness prediction provided by the theory of critical distances (in this case, the line method), together with a well‐known, widely‐used engineering tool in structural integrity assessments: failure assessment diagrams. In order to validate the proposed methodology, an experimental programme has been conducted, testing 38 specimens made of aluminium alloy Al7075‐T651, each of them containing a certain stress riser. The comparison between the experimental results and the corresponding predictions provided by the proposed assessment methodology has also allowed the situations for which the theory of critical distances provides accurate predictions to be defined.

The results show that the methodology provides accurate results as long as the Neuber number, defined as the notch radius divided by the critical distance (L), is sufficiently low. In order to extend the validity to situations where the Neuber number is higher, it is necessary to calibrate L by using notched specimens with similar radii to those found in the defects being analysed.

The present study is part of Virginia Madrazo's doctoral thesis, an original research work.

The purpose of this paper is to present a methodology for assessing the structural integrity of a tie member from a bucket-wheel excavator, ESRC 470 model, which was in operation for about 20 years. The tie member is made of S355J2N structural steel. Following the period of operation, the occurrence of microcracks which can propagate by fatigue is almost inevitable. It is therefore necessary to analyze the structural integrity and the remaining life of the component analyzed.

In principle, the assessment methodology is based on three steps: first, the evaluation of mechanical properties of the material component; second, a BEM analysis using FRANC 3D software package to estimate the evolution of the stress intensity factor based on crack length and applied stress; third, risk factor estimation and remaining fatigue life predictions based on failure assessment diagram and fatigue damage tolerance concept.

Following the evaluation procedure were made predictions of failure risk factor and remaining fatigue life function of crack length and variable stress range, for a high level of confidence.

As results of this analysis was implemented a program for verification and inspection of the tie member for the loading state and development of small cracks during operation.

The purpose of this paper is to compare different existing assessment procedures for their limitations and applicable areas.

Procedures have been studied in-depth along with their criterion for applications.

The study shows applicability of different procedures along with their limitations and future scope.

The paper provides starting point for performing damage assessment based on relevant procedures.

This paper aims to solve the problem that pipes conveying fluid are faced with severe reliability failures under the complicated working environment.

This paper proposes a dynamic reliability and variance-based global sensitivity analysis (GSA) strategy with non-probabilistic convex model for pipes conveying fluid based on the first passage principle failure mechanism. To illustrate the influence of input uncertainty on output uncertainty of non-probability, the main index and the total index of variance-based GSA analysis are used. Furthermore, considering the efficiency of traditional simulation method, an active learning Kriging surrogate model is introduced to estimate the dynamic reliability and GSA indices of the structure system under random vibration.

The variance-based GSA analysis can measure the effect of input variables of convex model on the dynamic reliability, which provides useful reference and guidance for the design and optimization of pipes conveying fluid. For designers, the rankings and values of main and total indices have essential guiding role in engineering practice.

The effectiveness of the proposed method to calculate the dynamic reliability and sensitivity of pipes conveying fluid while ensuring the calculation accuracy and efficiency in the meantime.

The purpose of this study is to develop an efficient numerical procedure for simulating the effect of printing orientation, as one of the primary sources of anisotropy in 3D-printed components, on their fracture properties.

The extended finite element method and the cohesive zone model (XFEM-CZM) are used to develop subroutines for fracture simulation. The ability of two prevalent models, i.e. the continuous-varying fracture properties (CVF) model and the weak plane model (WPM), and a combination of both models (WPM-CVF) are evaluated to capture fracture behavior of the additively manufactured samples. These models are based on the non-local and local forms of the anisotropic maximum tangential stress criterion. The numerical models are assessed by comparing their results with experimental outcomes of 16 different configurations of polycarbonate samples printed using the material extrusion technique.

The results demonstrate that the CVF exaggerates the level of anisotropy, and the WPM cannot detect the mild anisotropy of 3D-printed parts, while the WPM-CVF produces the best results. Additionally, the non-local scheme outperforms the local approach in terms of finite element analysis performance, such as mesh dependency, robustness, etc.

This paper provides a method for modeling anisotropic fracture in 3D-printed objects. A new damage model based on a combination of two prevalent models is offered. Moreover, the developed subroutines for implementing the non-local anisotropic fracture criterion enable a reliable crack propagation simulation in media with varying degrees of complication, such as anisotropy.

This paper aims to present the approximate limit pressure solutions for thin-walled shape-imperfect 90° pipe bends. Limit pressure was determined by finite element (FE) limit analysis with the consideration of small geometry change effects.

The limit pressure of 90° pipe bends with ovality and thinning has been evaluated by geometric linear FE approach. Internal pressure was applied to the inner surface of the FE pipe bend models. When von-Mises stress equals or just exceeds the yield strength of the material, the corresponding pressure was considered as the limit pressure for all models. The current FE methodology was evaluated by the theoretical solution which has been published in the literature.

Ovality and thinning produced a significant effect on thin-walled pipe bends. The ovality weakened pipe bend performance at any constant thinning, while thinning improved the performance of the bend portion at any constant ovality. The limit pressure of pipe bends under internal pressure increased with an increase in the bend ratio and decreased with an increase in the pipe ratio. With a simultaneous increment in bend radius and reduction in wall thickness, there was a reduction in limit pressure. A new closed-form empirical solution was proposed to evaluate limit pressure, which was validated with published experimental data.

The influences of structural deformation (ovality and thinning) in the limit pressure analysis of 90° pipe bends have not been investigated and reported.

Asset intensive process industries are under immense pressure to achieve promised return on investments and production targets. This can be accomplished by ensuring the highest level of availability, reliability and utilization of the critical equipment in processing facilities. In order to achieve designed availability, asset characterization and maintainability play a vital role. The most appropriate and effective way to characterize the assets in a processing facility is based on risk and consequence of failure. The paper aims to discuss these issues.

In this research, a risk-based stochastic modeling approach using a Markov decision process is investigated to assess a processing unit's availability, which is referred as the risk-based availability Markov model (RBAMM). RBAMM will not only provide a realistic and effective way to identify critical assets in a plant but also a method to estimate availability for efficient planning purposes and resource optimization.

A unique risk matrix and methodology is proposed to determine the critical equipment with direct impact on the availability, reliability and safety of the process. A functional block diagram is then developed using critical equipment to perform efficient modeling. A Markov process is utilized to establish state diagrams and create steady-state equations to calculate the availability of the process. RBAMM is applied to natural gas absorption process to validate the proposed methodology. In the conclusion, other benefits and limitations of the proposed methodology are discussed.

A new risk-based methodology integrated with Markov model application of the methodology is demonstrated using a real-life application.