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The variation of crack shape factor (a/c) during propagation has an important role on calculation of the stress intensity factor (SIF), where imprecise estimation of this latter can lead us to an inaccurate prediction of failure probabilities. For the case of external cracked surface pipeline carried oil and gas products, such estimation can results undesired fault decisions like excessive repairs action or inspection planning. In this paper, the structural integrity analysis of pipeline with semi elliptical crack on the external surface is evaluated. Reliability calculations expressed in term of reliability index β are carried out based on Monte Carlo simulation and First Order reliability Method (FORM). The crack shape factors are varied to cover a variety of geometries from shallow to deep cracks while fatigue crack growth is assumed in depth direction. For SIF estimation, surface and deep point are considered. Results of the analysis indicate that for a constant crack depth a/t, the reliability index is strongly affected by a/c ratio and the trend is not similar in deep and surface point for different crack shapes.

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