Failure Analysis of Girth Weld Cracking in Gas Transmission Pipelines Subjected to Ground Subsidence and Traffic Loads

Girth welds are weak points in pipelines, and failures occur frequently. In a gas transmission pipeline, a girth weld experienced cracking, prompting a failure analysis using experimental methods and finite element analysis (FEA). Experimental results showed that X-ray non-destructive testing (NDT) revealed cracks, porosity, and lack of fusion in the girth weld. However, the hardness and microstructure of the material showed no abnormalities. During operation, the pipeline experienced an increase in soil cover and was subjected to ground subsidence and vehicle loads. Finite element analysis was conducted on the defective girth weld under different conditions, including varying soil cover depths, different levels of subsidence, and varying vehicle loads, to examine the pipeline's stress response. The results indicated that the combination of soil cover, subsidence, and vehicle loads led to pipeline failure, whereas none of these factors alone was sufficient to cause girth weld failure. To prevent such failures from occurring again, the following measures are recommended: strengthen on-site welding quality control of girth welds, conduct inspections for defects in girth welds of in-service pipelines, and promptly address any defects that exceed acceptable limits.