Stress Distribution and Mechanical Modeling of Double-Layer Pipelines Coupled with Temperature Stress and Internal Pressure

In deepwater oil and gas transportation, Pipe-in-Pipe (PIP) systems are an effective solution for mitigating external loads while preserving internal thermal integrity. A finite element model with ITT elements and nonlinear spring contacts was developed in ABAQUS to simulate thermal expansion and contraction under extreme conditions. The coupled mechanical response of double-layer pipelines under non-uniform temperature fields and internal pressure was analyzed, focusing on stress distribution and deformation coordination between the inner and outer pipes. The inner pipe primarily sustains compressive or tensile stress depending on the thermal load direction, while the outer pipe experiences opposing stresses due to mechanical coupling. Distinct stress transfer zones are present near the pipe ends, governed by pipe-soil interaction and internal bending moments. The proposed model for double-layer pipelines under coupled thermal and internal pressure loads demonstrates a prediction accuracy within 5% as compared with benchmark numerical solutions. The simulations capture axial stress variations of up to 68% between extreme thermal expansion and contraction scenarios, with radial deformation ranging from 0.9 mm to 3.4 mm. These findings provide valuable insights into the safe and efficient design of subsea PIP systems, particularly for optimizing material selection and structural configuration in high-temperature, high-pressure environments.