Burst Pressure Prediction for Small-Diameter Thin-Walled Steel Pipes

Research Context and Motivation

Xu Yan, Liu Yinglai, Nie Xianghui, Feng Zhenjun, Wang Gaofeng, and Li Liang from the Petroleum Pipeline Engineering Technology Research Institute of CNPC and Beijing Longshengtaike Petroleum Pipe Technology Co., Ltd. conducted hydrostatic burst pressure tests on small-diameter thin-walled steel pipes commonly used in oil and gas transmission systems. Published in Oil and Gas Storage and Transportation (Volume 36, Issue 11, 2017, pages 1265–1269), this work addresses the critical need for accurate burst pressure prediction in pipeline engineering design and integrity assessment.

Comparative Analysis of Prediction Methods

The study evaluates several established burst pressure prediction formulas and compares their accuracy against experimental results using deviation analysis:

The key finding is that the Tresca (maximum shear stress) yield criterion provides more accurate burst pressure predictions for small-diameter thin-walled pipes than the Von Mises criterion. This result is significant because the conventional wisdom in general mechanics favors the Von Mises criterion for ductile materials under multiaxial stress states.

Technical Interpretation

The superior performance of the Tresca criterion for thin-walled pipe burst prediction can be attributed to the specific stress state at failure. In small-diameter thin-walled pipes under internal pressure, the hoop stress dominates, and the failure mechanism involves plastic yielding that initiates at the maximum shear stress location. The Tresca criterion, which identifies failure based on the maximum shear stress reaching a critical value, more accurately captures this failure mode than the Von Mises criterion, which averages the stress state over all orientations.

The geometric characteristics of small-diameter thin-walled pipes—specifically the high D/t ratio and small absolute dimensions—create a stress distribution that deviates from the assumptions underlying the Von Mises-based formulas. The Tresca criterion's simplicity and direct physical interpretation of shear-driven yielding make it particularly well-suited for this geometry.

Engineering Practice and Integrity Assessment

Accurate burst pressure prediction is essential for pipeline engineering design, integrity assessment, and operational safety. The study recommends using the Tresca-based formula in conjunction with ASME, Barlow OD, Barlow ID, max shear stress, and Turner formulas for comprehensive prediction, as these methods collectively provide the strongest applicability for small-diameter thin-walled pipe configurations.

For pipeline operators and steel pipe manufacturers, these findings have direct implications for design margins, pressure testing protocols, and remaining life assessment of in-service pipelines. The use of the Von Mises criterion for burst pressure prediction may lead to non-conservative estimates for small-diameter thin-walled pipes, potentially compromising safety.

Study Insights and Recommendations

This research provides a clear and practical recommendation for the prediction of burst pressure in small-diameter thin-walled steel pipes used in oil and gas transmission. The superior accuracy of the Tresca-based approach, combined with the complementary use of multiple prediction formulas, offers a robust methodology for engineering applications. Steel pipe manufacturers should consider incorporating these findings into their product qualification testing protocols, and pipeline integrity engineers should adopt the Tresca criterion as the primary basis for burst pressure assessment of small-diameter thin-walled pipe segments. The practical impact of this work extends to improved pipeline safety, optimized design margins, and more reliable integrity management decisions across the oil and gas industry.