Objective Natural gas pipeline failures pose significant risks to energy transportation, public safety, and the environment. However, there remains a lack of comprehensive understanding of the failure mechanisms and patterns affecting these pipelines. By analyzing cross-national data differences, elucidating cause-effect relationships, and examining the spatio-temporal evolution of pipeline failures, as well as assessing the impact of multi-factor interactions on pipeline integrity, this research aims to provide theoretical and technical support for optimizing pipeline safety management systems.

Methods Using pipeline accident data from the US Pipeline and Hazardous Materials Safety Administration (PHMSA), the European Gas Pipeline Incident Data Group (EGIG), the Canada Energy Regulator (CER), and China, a standardized classification system with six categories—including corrosion, material defects, and third-party damage—was applied for multidimensional analysis. The classification methods and influencing factors of natural gas pipeline failures were systematically reviewed. Statistical analysis, case studies, and other approaches were employed to thoroughly investigate the interactions among various factors and their impact mechanisms on pipeline failures.

Results The causes of natural gas pipeline failures vary across countries and regions, primarily involving materials and equipment, corrosion, and third-party damage. The United States and Canada share similar accident profiles, dominated by material, welding, and equipment failures. Europe experiences more third-party damage, while gas theft by puncturing pipelines is notably prevalent in China. Corrosion remains a common risk worldwide. Although technological advances and strengthened management have significantly reduced accident rates, pipeline aging remains a persistent challenge. Natural gas pipeline failures result from the combined effects of technology, management, and environmental factors. Their development follows distinct spatio-temporal patterns, generally conforming to a “bathtub curve” over time and being significantly influenced spatially by geography, pipeline design parameters, and social activities.

Conclusion Effective prevention and control of natural gas pipeline failures require a comprehensive approach that considers multiple factors and their coupling. Implementing targeted, integrated, and multi-level safety management strategies is essential to enhance pipeline safety and support the sustainable development of the natural gas industry.