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The effects of mechanical factors on crack growth behavior during the second stage of high pH stress corrosion cracking in pipeline steel were investigated by applying several loading scenarios on compact tension (CT) specimens. The main mechanism for stage 2 of intergranular crack propagation is anodic dissolution ahead of the crack tip which is highly dependent on crack-tip strain rate. The maximum and minimum crack growth rates were 3 × 10−7 mm/s and 1 × 10−7 mm/s, respectively. It was observed that several factors such as mean stress intensity factor, amplitude, and frequency of loading cycles determine the crack-tip strain rate. Low R-ratio cycles, particularly high-frequency ones, enhance secondary crack initiation, and crack coalescence on the free surface. This mechanism accelerates crack advance on the free surface which is accompanied with an increase in mechanical driving force for crack propagation in the thickness direction. These findings have implications for pipeline operators and could be used to increase the lifespan of the cracked pipelines at stage 2. For those pipelines, any loading condition that increases the strain rate ahead of the crack tip enhances anodic dissolution and is detrimental. Additionally, secondary crack initiation and coalescence could be minimized by avoiding internal pressure fluctuation, particularly rapid large pressure fluctuations.

Crack propagation in near neutral pH (NNpH) environment causes significant threat to pipeline integrity. Internal pressure fluctuations during pipeline operation create variable amplitude loading condition that can propagate corrosion fatigue cracks in NNpH environments. This study is aimed at understanding the effect of load interaction due to mean load pressure fluctuations on crack propagation in pipeline steel under NNpH conditions. The loading condition involved underload followed by an overload at set intervals among minor cycles. The effect of minor cycles, magnitude of overload, and NNpH environment were considered and compared to control test in air. Results showed optimum reduction in crack growth rate at low magnitude of overload in mean load pressure fluctuation. Mini striations observed on fracture surface suggest the contributions of minor cycles to crack propagation due to load interaction. Significant increase in crack growth at high magnitude of overload in NNpH environment indicates the influence of hydrogen.

Pipelines are designed to operate below a maximum operating pressure in service. However, there are pressure fluctuations during operation. The presence of pressure fluctuations creates a drive for crack growth in steel pipes. In order to prevent catastrophic failure of pipelines, there is need for better understanding of the contribution of pressure fluctuations to crack growth rate in steel pipelines. Analysis of pressure fluctuation data in oil and gas pipelines shows that there are different types of fluctuations in a pipe due to friction loss with distance from the pump or compressor station. All these fluctuation types show a form of variable amplitude loading classified in this research as underload, mean load and overload. Studies of some structural systems shows that underload can cause acceleration of crack growth while retardation of crack growth is observed after an overload. This research aims to apply pressure fluctuations to manage integrity of steel pipelines through a novel approach of load sequence involving underload and overload in near neutral pH environment. Clear knowledge of the effect of load interaction involving load sequence of underload and overload is vital to control crack growth in steel pipelines under near neutral pH environment. The result of crack growth rate under different load sequence on X65 steel indicate that increase in overload ratio of 2, 3 and 4 caused an increase in crack growth rate of 1.68E−3, 1.89E−3 and 2.31E−3 mm/block respectively. These results are compared with results from other tests under variable amplitude without load sequence. Analyses were carried out on the morphology of the crack tip and the fracture surface after the test.