Fatigue Life of Long-Distance Natural Gas Pipelines with Internal Corrosion Defects Under Random Pressure Fluctuations

Long-distance natural gas pipelines with internal corrosion defects are susceptible to fatigue failure under operational pressure fluctuations, posing significant risks to infrastructure integrity and safety. To address this, the present study employs a finite element methodology, utilizing Ansys Workbench to model pipelines of various specifications with parametrically defined corrosion defects, and nCode DesignLife to predict fatigue life based on Miner’s linear cumulative damage theory. The S-N curve for X70 steel was directly adopted, while a power-function model was fitted for X80 steel based on standards. A cleaned real-world pressure-time history was used as the load spectrum. Parametric analysis reveals that defect depth is the most influential factor, with a depth coefficient increase from 0.05 to 0.25, reducing fatigue life by up to 67.5%, while the influence of defect width is minimal. An empirical formula for fatigue life prediction was subsequently developed via multiple linear regression, demonstrating good agreement with simulation results and providing a practical tool for the residual life assessment and maintenance planning of in-service pipelines.