Corrosion Fatigue Failure of a Gray Cast Iron Water Main

Cullin, Matthew; Petersen, Todd; Paris, Anthony J.

doi:10.1061/(asce)ps.1949-1204.0000188

Cited by 8 publications

(5 citation statements)

References 10 publications

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“…Most of the area of the fracture surface contained orange brown coloured corrosion products that were most likely generated after the pipe burst event. The existence of dual corrosion phases in failed CI pipes have also been observed in other studies, highlighting that fracture may have grown over a period of time prior to final catastrophic fracture (Makar 2000;Rajani et al 2012;Cullin et al 2014).…”

Section: Metallurgical Analysissupporting

confidence: 77%

“…The longitudinal barrel fracture is the predominant failure mode for large diameter CI pipes and is caused by local stress concentrations and hoop stresses produced by internal pressures (Makar 2000). Fatigue from cyclic internal pressures is considered as a mechanism to propagate existing cracks in pressurised pipe barrels (Cullin et al 2014;Rathnayaka et al 2016). Hence, the effects of internal pressures on fractured pipes requires detailed analysis.…”

Section: Introductionmentioning

confidence: 99%

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Leak-before-break in cast iron mains: a failure analysis of a catastrophic pipe burst on Harris Street, Sydney

Jiang

Robert

Hutchinson

et al. 2017

Water Practice and Technology

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This article analyses the failure of a 500 mm-diameter cast iron (CI) water pipe that catastrophically fractured in Sydney in 2013. According to metallurgical analysis and finite element simulation, a longitudinal pre-existing crack initiated from the adjacent bell-joint and eventually propagated to a critical length in the pipe barrel over a certain period. There was evidence of leakage prior to the burst incident but information was inconclusive whether it was exactly from this pipe. Fatigue caused by cyclic internal pressure was considered as the predominant factor in leading to crack growth. A numerical model was developed to describe crack growth behaviour using Paris' law, and metallurgical analysis and mechanical tests were conducted to support this investigation. Based on the field evidence and simulation results, the leak-before-break approach might be applicable in CI pipes to avoid severe consequences of trunk main bursts.

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Section: Metallurgical Analysissupporting

confidence: 77%

Section: Introductionmentioning

confidence: 99%

Leak-before-break in cast iron mains: a failure analysis of a catastrophic pipe burst on Harris Street, Sydney

Jiang

Robert

Hutchinson

et al. 2017

Water Practice and Technology

View full text Add to dashboard Cite

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“…This claim must be further investigated and validated, since corrosion in cast iron can dramatically reduce the required minimum value of water pressure fluctuations to produce corrosion fatigue. Example of a reported case of a most likely failure due to corrosion fatigue was reported in [29]. In addition, previous studies that have correlated the effect of water pressure daily range as a proxy for water pressure fluctuations have shown positive correlations for reducing pressure range and reduction of pipe breaks, including pipes of high stress intensity threshold such as cast iron pipes [35], [36].…”

Section: Discussionmentioning

confidence: 97%

High resolution water pressure monitoring for the assessment of fatigue damage in water distribution pipes

Jara-Arriagada,

Stoianov

2022

Proceedings - 2nd International Join Conference on Water Distribution System Analysis (WDSA)& Computing and Control in the

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In the last decade, the increasing implementation of high frequency monitoring has shown that water distribution networks are frequently affected by pressure transients. In some instances, even thousands of cyclic loadings can be exerted on pipes posing a risk of fatigue damage. High frequency monitoring, which can be as high as 128 samples per second, allows the capturing of extremely rapid transient events, otherwise undetectable using normal 15 min telemetry monitoring. Thus, providing a precise picture and awareness of the full dynamic activity in a pipe. However, despite this new awareness of a possible fatigue risk on pipes, current research has not be able to show to the extent of the relevance of this risk. Main limiting factors of previous published research have been short high frequency monitoring periods, limiting the generalisation of previous findings, and few mechanistic analysis utilising measured data. To address these issues, this work presents the analysis and evaluation of several months to years of high frequency monitoring water pressure data at various locations in operating water distribution networks. We have obtained extensive time series datasets with highly detailed information of transient events, and utilised this information together with knowledge of fracture mechanics to assess the extent of fatigue damage on pipes. In order to perform the analyses, our time series data were converted into tuples of number of cycles and magnitude by utilising a rainflow cycle counting algorithm. This algorithm allows the counting of full cyclic loadings and their magnitude in an spectral loading history. Such information can then be utilised for fatigue analysis. In particular, we have used theory of fatigue crack propagation to assess number of cycles to failure. Results from this research suggest evidence that at some logging locations, and depending on the pipe material, and current deterioration state, fatigue damage due constant cyclic loadings can be a main trigger causing pipe breaks. In particular we have estimated examples that show that up to tens of years of pipe life could be extended if pressure transient activity were reduced. Therefore, the need for further monitoring, analysis and reduction of water pressure transients is critical to increase the life of our water supply infrastructure.

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“…Makar et al 84 discovered longitudinal fractures in large diameter CI water mains caused by circumferential stresses caused by internal pressure. These fractures allow for pitting corrosion nucleation 85 . According to Ratnayake et al 86 , corrosion and cracks on the internal surfaces of water pipelines are related and primarily cause internal pressure loading.…”

Section: Physical Factorsmentioning

confidence: 99%

Analysis and ranking of corrosion causes for water pipelines: a critical review

Hussein Farh,

Ben Seghier,

Taiwo

et al. 2023

npj Clean Water

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Corrosion is still the most common contributor to failures in Water Distribution Networks (WDNs), causing detrimental techno-socio-economic impacts. Although the corrosion process has been the subject of several studies, factors influencing this process remain a source of contention due to the complexity of the process and its influence by the surrounding environment. Considering the prior reviews, this comprehensive review is considered an early attempt to thoroughly cover the most influential corrosion factors in water pipelines. Corrosion factors have been classified into three main categories: 1) environmental factors; soil factors, external factors, and stray current factors; 2) pipe-related factors, and 3) operational factors. A fault tree analysis diagram was used to map, discuss, and analyze all significant corrosion causes of the buried water pipelines to facilitate easy visualization from basic factors to their intermediate and parent factors. Furthermore, the techno-socio-economic impacts of corrosion on water pipelines and beyond are appropriately addressed to demonstrate the issue’s multi-dimensional importance. The research is expanded to rank these factors using the fuzzy analytical hierarchy process to provide a better understanding of the currently focused research investigation and to enable the extraction of gaps and existing limitations in scholarly literature. The findings revealed that water quality is the most investigated factor, followed by electrical infrastructure and soil quality. Conversely, operational factors exhibit the greatest relative weight (0.428), followed by environmental factors (0.337). These findings highlight areas where further research is needed, and the article proposes potential directions for future studies to address these gaps.

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Corrosion Fatigue Failure of a Gray Cast Iron Water Main

Cited by 8 publications

References 10 publications

Leak-before-break in cast iron mains: a failure analysis of a catastrophic pipe burst on Harris Street, Sydney

Leak-before-break in cast iron mains: a failure analysis of a catastrophic pipe burst on Harris Street, Sydney

High resolution water pressure monitoring for the assessment of fatigue damage in water distribution pipes

Analysis and ranking of corrosion causes for water pipelines: a critical review

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