Effect of integrating polymeric pipes on the pressure evolution and failure assessment in cast iron branched networks

Abstract Pressure response and structural integrity assessment of cast iron and HDPE pipes were investigated in this study. The failure analysis of pipes in a branched network was considered taking into consideration the maximum stress generated by hydraulic transient events and the presence of an initial external semi-elliptical defect. The numerical study was conducted based on a developed non-conventional transient solver that incorporates the viscoelasticity of polymeric pipes. Considering the replacement of pipes located in sensitive zones with high-density polyethylene (HDPE) pipes, the pressure evolution of the network was evaluated for different network states at different locations. The integration of polymeric pipes in the originally cast-iron network provided remarkable pressure wave damping and dispersing in some locations. Since the failure of pipes with a corrosion crater is likely to occur when the admissible stress is reached, a structural integrity analysis was conducted. Failure Assessment Diagram (FAD) using the SINTAP code was considered to calculate the safety factors for cast iron pipes with different metallic-plastic combinations, whereas a semi-empirical model that calculates the J-integral is used for HDPE pipes. The results of this study conclude that high attention should be paid when a longitudinal crack is located in the pipelines. It may be possible for integrated polymeric pipes to alleviate the risk of failure in the network. However, under large crack geometries, additional measures should be taken.