Recommendations on X80 steel for the design of hydrogen gas transmission pipelines

By limiting the pipes thickness necessary to sustain high pressure, high-strength steels could prove economically relevant for transmitting large gas quantities in pipelines on long distance. Up to now, the existing hydrogen pipelines have used lower-strength steels to avoid any hydrogen embrittlement. The CATHY-GDF project, funded by the French National Agency for Research, explored the ability of an industrial X80 grade for the transmission of pressurized hydrogen gas in large diameter pipelines. This project has developed experimental facilities to test the material under hydrogen gas pressure. Indeed, tensile, toughness, crack propagation and disc rupture tests have been performed. From these results, the effect of hydrogen pressure on the size of some critical defects has been analyzed allowing proposing some recommendations on the design of X80 pipe for hydrogen transport. Cost of Hydrogen transport could be several times higher than natural gas one for a given energy amount. Moreover, building hydrogen pipeline using high grade steels could induce a 10 to 40% cost benefit instead of using low grade steels, despite their lower hydrogen susceptibility.     

From the perspective of new technology of blending hydrogen into natural gas pipelines transmission: Mechanism,experimental study,and suggestions for further work of hydrogen embrittlement in high-strength pipeline steels

Blending hydrogen into high-strength pipeline steels for high-pressure transmission may cause materials' hydrogen embrittlement (HE) failure. Although the hydrogen-induced failure of metallic materials has been studied for a long time, the process of hydrogen into the materials, hydrogen-induced delayed failure, and dynamic mechanisms of high-strength pipeline steels under high pressure have not been fully understood. This paper aims to provide a detailed review of the latest research on the hydrogen-induced failure of high-strength pipeline steels in hydrogen-blended natural gas transmission. First, introduced the typical hydrogen blending natural gas pipeline transmission projects and their associated research conclusions. Then, described the physical process of the HE in high-strength pipeline steels and the principle, development, and latest research progress of typical hydrogen embrittlement mechanisms in detail. Third, reviewed the research methods and progress of experimental and theoretical simulations for the HE in steels, including hydrogen permeation (HP) experiments, hydrogen content measurements, hydrogen distribution detection, mechanical property tests, and molecular dynamics simulations. The shortcomings of existing experimental and theoretical simulation methods in the hydrogen-induced analysis of high-strength natural gas pipeline steels under high pressure are discussed. Finally, the future research directions and challenges of this problem are proposed from three aspects: the multimechanism synergy mechanism, the improvement of experimental methods, and the establishment of a new interatomic multiscale model.     

Hydrogen related degradation in pipeline steel: A review

To support our increasing energy demand, steel pipelines are deployed in transporting oil and natural gas resources for long distances. However, numerous steel structures experience catastrophic failures due to the evolution of hydrogen from their service environments initiated by corrosion reactions and/or cathodic protection. This process results in deleterious effect on the mechanical strength of these ferrous steel structures and their principal components. The major sources of hydrogen in offshore/subsea pipeline installations are moisture as well as molecular water reduction resulting from cathodic protection. Hydrogen induced cracking comes into effect as a synergy of hydrogen concentration and stress level on susceptible steel materials, leading to severe hydrogen embrittlement (HE) scenarios. This usually manifests in the form of induced-crack episodes, e.g., hydrogen induced cracking (HIC), stress-oriented hydrogen induced cracking (SOHIC) and sulfide stress corrosion cracking (SSCC). In this work, we have outlined sources of hydrogen attack as well as their induced failure mechanisms. Several past and recent studies supporting them have also been highlighted in line with understanding of the effect of hydrogen on pipeline steel failure. Different experimental techniques such as Devanathan–Stachurski method, thermal desorption spectrometry, hydrogen microprint technique, electrochemical impedance spectroscopy and electrochemical noise have proven to be useful in investigating hydrogen damage in pipeline steels. This has also necessitated our coverage of relatively comprehensive assessments of the effect of hydrogen on contemporary high-strength pipeline steel processed by thermomechanical controlled rolling. The effect of HE on cleavage planes and/or grain boundaries has prompted in depth crystallographic texture analysis within this work as a very important parameter influencing the corrosion behavior of pipeline steels. More information regarding microstructure and grain boundary interaction effects have been presented as well as the mechanisms of crack interaction with microstructure. Since hydrogen degradation is accompanied by other corrosion-related causes, this review also addresses key corrosion causes affecting offshore pipeline structures fabricated from steel. We have enlisted and extensively discussed several recent corrosion mitigation trials and performance tests in various media at different thermal and pressure conditions.     

The synergistic effects of hydrogen embrittlement and transient gas flow conditions on integrity assessment of a precracked steel pipeline

We are reporting in this study the hydrogen permeation in the lattice structure of a steel pipeline designed for natural gas transportation by investigating the influence of blending gaseous hydrogen into natural gas flow and resulted internal pressure values on the structural integrity of cracked pipes. The presence of cracks may provoke pipeline failure and hydrogen leakage. The auto-ignition of hydrogen leaks, although been small, leads to a flame difficult to be seen. The latter makes such a phenomenon extremely dangerous as explosions became very likely to happen. In this paper, a reliable method is presented that can be used to predict the acceptable defect in order to reduce risks caused by pipe failure due to hydrogen embrittlement. The presented model takes into account the synergistic effects of transient gas flow conditions in pipelines and hydrogen embrittlement of steel material due to pressurized hydrogen gas permeation. It is found that blending hydrogen gas into natural gas pipelines increases the internal load on the pipeline walls due to overpressure values that may be reached in a transient gas flow regime. Also, the interaction between transient hydrogen gas flow and embrittlement of API 5L X52 steel pipeline was investigated using Failure Assessment Diagram (FAD) and the results have shown that transient flow enhances pipeline failure due to hydrogen permeation. It was shown that hydrogen embrittlement of steel pipelines in contact with the hydrogen environment, together with the transient gas flow and significantly increased transient pressure values, also increases the probability of failure of a cracked pipeline. Such a situation threatens the integrity of high stress pipelines, especially under the real working conditions of hydrogen gas transportation.     

Feasibility analysis of blending hydrogen into natural gas networks

Hydrogen fuel has the potential to mitigate the negative effects of greenhouse gases and climate change by neutralizing carbon emissions. Transporting large volume of hydrogen through pipelines needs hydrogen-specific infrastructure such as hydrogen pipelines and compressors, which can become an economic barrier. Thus, the idea of blending hydrogen into existing natural gas pipelines arises as a potential alternative for transporting hydrogen economically by using existing natural gas grids. However, there are several potential issues that must be considered when blending hydrogen into natural gas pipelines. Hydrogen has different physical and chemical properties from natural gas, including a smaller size and lighter weight, which require higher operating pressures to deliver the same amount of energy as natural gas. Additionally, hydrogen's small molecular size and lower ignition energy make it more likely to permeate through pipeline materials and seals, leading to degradation, and its wider flammability limits make it a safety hazard when leaks occur. In this study, we investigate these potential issues through simulation and technical surveys. We develop a gas hydraulic model to simulate the physical characteristics of a transmission and a distribution pipeline. This model is used throughout the study to visualize the potential impacts of switching from natural gas to hydrogen, and to investigate potential problems and solutions. Furthermore, we develop a Real-Time Transient Model (RTTM) to address the compatibility of current computational pipeline monitoring (CPM) based leak detection methods with blended hydrogen. Finally, we suggest the optimal hydrogen concentration for this model, and investigate the amount of carbon reduction that could be achieved, while considering the energy needs of the system.     

Time development of new hydrogen transmission pipeline networks for France

The development of a hydrogen economy will need a transportation infrastructure to deliver hydrogen from production sites to end users. For the specific case of hydrogen, pipelines networks compete with other hydrogen carriers: compressed gas trucks and liquid cryogenic trucks. In this paper, we deal with the determination of the temporal deployment of a new hydrogen transportation infrastructure. Starting from the expected final horizon pipelines network, we propose a backward heuristic approach. The proposed approach is illustrated on a French regional hydrogen transportation network tacking into account two scenarios for hydrogen penetration into the fuel markets. We showed that for the mid term perspective and low market share, the trucks are the most economical options. However, for the long term, the pipeline option is considered as an economical viable option as soon as the hydrogen energy market share for the car fueling market reaches 10%.     

Damage associated with interactions between microstructural characteristics and hydrogen/methane gas mixtures of pipeline steels

There is no common standard for blended hydrogen use in the natural gas grid; hydrogen content is generally based on delivery systems and end-use applications. The need for a quantitative evaluation of hydrogen-natural gas mixtures related to the mechanical performance of materials is becoming increasingly evident to obtain long lifetime, safe, and reliable pipeline structures. This study attempts to provide experimental data on the effect of H₂ concentration in a methane/hydrogen (CH₄/H₂) gas mixture used in hydrogen transportation. The mechanical performance under various blended hydrogen concentrations was compared for three pipeline steels, API X42, X65, and X70. X65 exhibited the highest risk of hydrogen-assisted crack initiation in the CH₄/H₂ gas mixture in which brittle fractures were observed even at 1% H₂. The X42 and X70 samples exhibited a significant change in their fracture mechanism in a 30% H₂ gas mixture condition; however, their ductility remained unchanged. There was an insignificant difference in the hydrogen embrittlement indices of the three steels under 10 MPa of hydrogen gas. The coexistence of delamination along with the ferrite/pearlite interface, heterogeneous deformation in the radial direction, and abundance of nonmetallic MnS inclusions in the X65 sample may induce a high stress triaxiality at the gauge length at the beginning of the slow strain rate tensile process, thereby facilitating efficient hydrogen diffusion.     

Multidimensional risk assessment and categorization of hydrogen pipelines

The use of hydrogen has been shown to be an efficient form of producing energy and meeting society's demands for energy. In this perspective, pipelines are known as the safest and most economical transportation mode for hydrogen. However, accidents in this type of structure lead to multiple consequences of losses such as those related to people, the environment and properties. From this perspective, decision-makers are required to tackle the likelihood of these and to make suitable decisions that can prevent accidents from happening. Multicriteria methods have played an important role in addressing multiple risk problems when there is a need to assign priorities to risk-based decisions. This paper puts forward a multidimensional risk model to categorize hydrogen pipeline sections according to levels of risks based on Utility Theory and the ELECTRE TRI method. A probabilistic modeling is proposed so as to incorporate elements of risk analysis into the evaluation of situations such as accidental scenarios, their probabilities and consequences. An application of the model is presented for a hydrogen pipeline. The results demonstrate that measures to prevent and mitigate risks can be sharpened by taking into account the human, environmental and financial risks dimensions of impacts. Thus, the sections of the pipeline studied are sorted into categories of risks, where 4 out of 10 sections are assigned to the high-risk category, 1 to the medium-risk category, and 5 sections to the low-risk category. A local sensitivity analysis was conducted which varied the weights of the dimensions. Varying the weights by 20% showed that the risk of 3 sections increases to the medium-risk category and 1 section changes to the high-risk one. Moreover, this paper indicates visualization tools that are efficient at communicating information on the levels of risk and the categories of the sections, thus contributing to assessing models that categorize risk in hydrogen pipelines. By doing so this paper supports the process of prioritizing resources for pipeline sections, the aim being to minimize multiple losses.     

An MILP model for the reformation of natural gas pipeline networks with hydrogen injection

A mixed integer linear programming (MILP) model is proposed for the reformation of natural gas pipelines. The model is based on the topology of existing pipelines, the load and pressure at each node and the design factors of the region and minimizes the annual substitution depreciation cost of pipelines, the annual construction depreciation cost of compressor stations and the operating cost of existing compressor stations. Considering the nonlinear pressure drop equations, the model is linearized by a piecewise method and solved by the Gurobi optimizer. Two cases of natural gas pipeline networks with hydrogen injection are presented. Several adjustments are applied to the original natural gas pipeline network to ensure that our design scheme can satisfy the safety and economic requirements of gas transportation. Thus, this work is likely to serve as a decision-support tool for the reformation of pipeline networks with hydrogen injection.     

Point-to-point transportation: The economics of hydrogen export

Hydrogen transport over long distances is a critical cost component, and it can involve many complex pathways. We have developed a model and an associated framework that can be used to determine the cost of transport methods for both land and land-and-sea scenarios. The model assesses the transportation of liquid and gaseous hydrogen by truck, rail, and barge; as well as gaseous hydrogen pipelines. Our results show that for large scale and long-distance hydrogen transport, the only feasible gaseous hydrogen transport option are pipelines. For example, a well-planned pipeline can keep hydrogen transportation costs below $3 per kg for distances up to 7000 km so long as the demand is greater than 150 tonnes per day. Liquid hydrogen transport is feasible and efficient for long distance transport, especially when used alongside rail travel providing less than 50 tonnes per day.     

氢气管输技术研究进展

利用现有“全国一张网”的天然气管道设施,将氢气掺入天然气管道输送,可有效解决中国氢气规模化输送难题。该文综述目前关于氢气管道输送的研究成果,总结氢气管道建设现状;分析输氢工艺安全性,阐述管线泄漏的危害性及防护措施,分别讨论高压输送管道、中低压配送管道和管道焊缝的相容性;归纳目前的燃气互换性方法及设备适应性。指出了目前氢气管输面临的问题：掺氢比例等参数对氢气渗透、聚集、泄漏、喷射火灾等安全问题的影响尚不明确;氢气与典型管材的相容性研究不足;缺少纯氢和掺氢管道输送技术相关标准规范体系。     

Assigning priorities to actions in a pipeline transporting hydrogen based on a multicriteria decision model

Nowadays there is a pressing need to implement changes in the global energy structure, such that it incorporates new features and changes the way that we use fossil fuels. In this scenario, hydrogen is projected as the fuel of the future. Among the possible modes that can be used for its transportation, the pipeline is singled out as it is the safest and the most economically viable means of transporting large quantities of the gas. However, accidents to pipelines have been recorded and they often result in catastrophic consequences for society. In this context, this paper proposes novelties in multidimensional risk assessment for the transportation of hydrogen by pipeline. Thus, a multicriteria decision model is proposed, using multiattribute utility theory, which incorporates the behavior of a decision maker and considers three dimensions of risk assessment: the human, financial and environmental dimensions. By taking these into consideration, the decision maker may well get precious and differentiated information about the risk management of pipelines.     

Failure analysis of corroded high-strength pipeline subject to hydrogen damage based on FEM and GA-BP neural network

The pipeline is a major approach to achieving large-scale hydrogen transportation. Hydrogen damage can deteriorate the material performance of the pipe steel, like ductility and plasticity reduction. Corrosion is dominating damage that impairs a pipeline's bearing capacity and structural reliability. However, previous research barely investigated the effect of hydrogen damage on failure behaviors, residual strength and interacting effect between adjacent corrosions of corroded high-strength pipelines transporting hydrogen. Besides, hardly any burst pressure model considers hydrogen damage. In this paper, several approaches, including the finite element method (FEM), regression analysis, the orthogonal test method, and the artificial neural network method, are applied to fill the gap. First, a series of finite element models with different geometric features and hydrogen damage is established to investigate the effects of hydrogen damage and corrosion on failure behaviors and residual strength. The results show that hydrogen damage can change the corroded pipeline's failure behaviors and reduce the residual strength. Second, based on the simulation results and regression analysis, a new burst model is developed to consider the hydrogen damage and improve the estimation accuracy. Third, based on the genetic algorithm (GA), a GA-BP neural network is established and trained for accurate and efficient residual strength estimation considering hydrogen damage. Furthermore, an orthogonal test is designed and performed to investigate the effects of critical parameters on the burst pressure of the corroded pipeline after hydrogen damage. The results indicate that hydrogen damage and corrosion length have similar contributions to the residual strength. Finally, the simulation results of pipelines with multiple corrosions show that hydrogen damage has a significant impact on the interacting effect between adjacent corrosions. The results obtained are valuable for further integrity management of steel pipelines carrying hydrogen.     

Large-scale long-distance land-based hydrogen transportation systems: A comparative techno-economic and greenhouse gas emission assessment

Interest in hydrogen as an energy carrier is growing as countries look to reduce greenhouse gas (GHG) emissions in hard-to-abate sectors. Previous works have focused on hydrogen production, well-to-wheel analysis of fuel cell vehicles, and vehicle refuelling costs and emissions. These studies use high-level estimates for the hydrogen transportation systems that lack sufficient granularity for techno-economic and GHG emissions analysis. In this work, we assess and compare the unit costs and emission footprints (direct and indirect) of 32 systems for hydrogen transportation. Process-based models were used to examine the transportation of pure hydrogen (hydrogen pipeline and truck transport of gaseous and liquified hydrogen), hydrogen-natural gas blends (pipeline), ammonia (pipeline), and liquid organic hydrogen carriers (pipeline and rail). We used sensitivity and uncertainty analyses to determine the parameters impacting the cost and emission estimates. At 1000 km, the pure hydrogen pipelines have a levelized cost of $0.66/kg H₂ and a GHG footprint of 595 gCO₂eq/kg H₂. At 1000 km, ammonia, liquid organic hydrogen carrier, and truck transport scenarios are more than twice as expensive as pure hydrogen pipeline and hythane, and more than 1.5 times as expensive at 3000 km. The GHG emission footprints of pure hydrogen pipeline transport and ammonia transport are comparable, whereas all other transport systems are more than twice as high. These results may be informative for government agencies developing policies around clean hydrogen internationally.     

The development of natural gas and hydrogen pipeline capital cost estimating equations

Natural gas pipeline cost data collected by the Oil and Gas Journal (O&GJ) [1] for interstate pipelines constructed from 1980 through 2017 were used to develop capital cost estimating equations that are a function of pipeline diameter, length, and U.S. region. Equations were developed for material, labor, miscellaneous, and right-of-way costs, the four cost components in the O&GJ data, for six different regions of the United States (U.S.). Each equation is a function of pipeline diameter and length.Adjustment mechanisms were then developed for converting the natural gas pipeline equations into equations for estimating the costs of hydrogen pipelines. These adjustments were based in part on an analysis completed by the National Institute for Standards and Technology (NIST) [2,3]. The results of this work were used to update cost models in the Hydrogen Delivery Scenario Analysis Model (HDSAM) [4], developed by Argonne National Laboratory for the U.S. Department of Energy's Hydrogen Program. Our analysis shows a wide range of pipeline cost across different U.S. regions, especially with respect to labor and right-of-way costs. The developed cost formulas for hydrogen pipelines are both important and timely as hydrogen is being considered as a zero-carbon energy carrier with the potential to decarbonize all energy sectors, and the cost of hydrogen transportation is essential for techno-economic analysis of its potential use in these sectors.     

Evaluation of hydrogen induced cracking behavior of API X70 pipeline steel at different heat treatments

The microstructure of API X70 pipeline steel was modified by applying different heat treatments including water-quenched, water-sprayed, and water-quenched and tempered. Hydrogen induced cracking behavior was investigated on the X70 steel at these heat treatments. Two test methods, Japanese Industrial Standard (JIS) and vacuum thermal desorption, were used to release hydrogen from reversible and irreversible traps. The experimental results showed that the highest amount of discharged hydrogen in reversible and irreversible traps was related to the water-sprayed and as-received steels. The hydrogen discharged content from reversible traps reached to a saturation level after 8 h of charging, and it decreased considerably when the steels were charged for 15 h and 24 h. Hydrogen discharge tests proved that a higher amount of hydrogen inside steel is not a reliable measure for HIC evaluation. HIC test results also document that the water-quenched steel with agglomerated martensite particles had the highest susceptibility to HIC. Texture study results show that a low fraction of important texture components, such as {023}, {321} and {332}, cannot be reliably used to evaluate HIC. As a result, a novel method of manufacturing of pipeline steels with an optimized texture is required to increase safety and reliability of transportation of sour gas and oil.     

Non-contact,nondestructive hydrogen and microstructural assessment of steel welds

Nondestructive low-frequency impedance has been developed to determine hydrogen content in operating pipeline steel and weldments through a structural coating. A low frequency impedance measurement is similar to a resistivity measurement with a depth function due to the sensor coil reactance. Resistivity introduces variability in impedance measurements because resistivity is a function of the conductivity of the material, the depth of the measurement, and the alloy content. The conductivity, based on the free electron model, is a function of the electronic effective mass, the electron concentration, and the dominating scattering mechanisms, which is altered by such factors as inclusions, microstructure, temperature, and strain. Each of these variables must be separated out to obtain a hydrogen content measurement in operating pipelines (with a structural coating) using low frequency impedance. Techniques used to separate out the variables associated with operating pipeline steels are presented. The use of real-time low frequency impedance measurements to monitor hydrogen content as it diffuses out of a steel weldment is presented and discussed.     

Overview of the DOE hydrogen safety,codes and standards program,part 3: Advances in research and development to enhance the scientific basis for hydrogen regulations,codes and standards

Hydrogen fuels are being deployed around the world as an alternative to traditional petrol and battery technologies. As with all fuels, regulations, codes and standards are a necessary component of the safe deployment of hydrogen technologies. There has been a focused effort in the international hydrogen community to develop codes and standards based on strong scientific principles to accommodate the relatively rapid deployment of hydrogen-energy systems. The need for science-based codes and standards has revealed the need to advance our scientific understanding of hydrogen in engineering environments. This brief review describes research and development activities with emphasis on scientific advances that have aided the advancement of hydrogen regulations, codes and standards for hydrogen technologies in four key areas: (1) the physics of high-pressure hydrogen releases (called hydrogen behavior); (2) quantitative risk assessment; (3) hydrogen compatibility of materials; and (4) hydrogen fuel quality.     

Permeation barriers for hydrogen embrittlement prevention in metals – A review on mechanisms,materials suitability and efficiency

To develop large-scale use of hydrogen as an environmentally sensible alternative to fossil energy sources, the design of safe and innovative storage and transportation infrastructure is a crucial issue. In direct contact with the high-pressure hydrogen, structural materials, especially traditional alloys, are indeed susceptible to degradation of their mechanical properties due to the diffusion of hydrogen atoms into their atomic lattice structure. This phenomenon leads to materials' embrittlement and results in severe damage to the employed components. Therefore, the prevention of hydrogen atom diffusion is one key consideration to avoid its adverse effects on materials' mechanical properties. This paper aims to review the mechanisms and factors responsible for the hydrogen embrittlement phenomenon. The main specifications to fulfill while selecting appropriate materials are hence considered for hydrogen energy uses. Finally, the effective surface modification solutions are reviewed for implementation as a permeation barrier to protect the structural materials from hydrogen degradation.