Stress Intensity Factors for Pressurized Pipes with an Internal Crack: The Prediction Model Based on an Artificial Neural Network

During pipeline operation, internal cracks may occur. The severity around the crack tip can be quantified by the stress intensity factor (KI), which is a linear–elastic fracture mechanics parameter. For pressurized pipes featuring infinitely long internal surface cracks, KI can be interpolated from a function considering pressure, geometry, and crack size, as presented in API 579-1/ASME FFS-1. To enhance KI prediction accuracy, an artificial neural network (ANN) model was developed for such pressurized pipes. Predictions from the ANN model and API 579-1/ASME FFS-1 were compared with precise finite element analysis (FEA). The ANN model with an eight-neuron sub-layer outperformed others, displaying the lowest mean squared error (MSE) and minimal validation discrepancies. Nonlinear validation data improved both MSE and testing performance compared to uniform validation. The ANN model accurately predicted normalized KI, with differences of 2.2% or lower when compared to FEA results. Conversely, API 579-1/ASME FFS-1′s bilinear interpolation predicted inaccurately, exhibiting disparities of up to 4.3% within the linear zone and 24% within the nonlinearity zone. Additionally, the ANN model effectively forecasted the critical crack size (aC), differing by 0.59% from FEA, while API 579-1/ASME FFS-1′s bilinear interpolation underestimated aC by 4.13%. In summary, the developed ANN model offers accurate forecasts of normalized KI and critical crack size for pressurized pipes, providing valuable insights for structural assessments in critical engineering applications.