Prediction of remaining strength of corroded pressurised pipelines

In this paper a deterministic model is developed which can be used to evaluate the remaining strength of corroded steel pipeline over time. This model also can be used to evaluate the maximum allowable failure pressure of corroded pipelines. The motivation for the development of the model is that during in-service conditions the strength of pressurised pipelines may be impaired, for example, from the failure of the protective coatings, paint surfaces or cathodic protection or as a result of externally applied mechanical damage or as a result of ageing (e.g. fatigue). Any of these may lead to the initiation of corrosion at the damaged area if it is not repaired. Once initiated, corrosion increases gradually both in extent and depth with increased exposure period. This results in the reduction of the remaining strength and hence a reduction in the carrying capacity of a pipeline. It also creates uncertainty about the future capacity. The proposed model is related to accepted methods for estimating the remaining strength of pipelines, but uses a simple corrosion model to estimate future remaining life. A sensitivity analysis can be used to investigate the effect of corrosion parameters on the pipeline carrying capacity. A simple example is given to illustrate the approach.     

Reliability of pipelines with corrosion defects

This paper aims at assessing the reliability of pipelines with corrosion defects subjected to internal pressure using the first-order reliability method (FORM). The limit-state function is defined based on the results of a series of small-scale experiments and three-dimensional non-linear finite element analysis of the burst pressure of intact and corroded pipelines. A sensitivity analysis is performed for different levels of corrosion damage to identify the influence of the various parameters in the probability of burst collapse of corroded and intact pipes. The Monte Carlo simulation method is used to assess the uncertainty of the estimates of the burst pressure of corroded pipelines. The results of the reliability, sensitivity and uncertainty analysis are compared with results obtained from codes currently used in practice.     

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.     

Failure pressure analysis of hydrogen storage pipeline under low temperature and high pressure

Low temperature and high pressure line pipes are widely used in hydrogen storage, air separation plant, liquefied natural gas (LNG) transportation etc. The material properties of pipes at low temperature are different from those at room temperature. If the medium in the pipe is corrosive, it will cause the pipe wall thickness to decrease. However, the failure pressure of the corroded hydrogen storage pipeline at extremely low temperature is lacking of adequate understanding. In this paper, we provided a novel failure pressure equation of the mild steel line pipe with corrosion defects at extremely low temperature. Firstly, a mechanical model of the line pipe with corrosion defects is established. And then, an analytical solution of the mechanical model is obtained based on elastic theory. Next, a failure pressure equation of the corroded hydrogen storage pipeline at extremely low temperature is developed. In the end, the accuracy of the failure pressure equation is verified by comparing with finite element method (FEM). The results suggest that the calculated value of the failure pressure equation is consistent with that of FEM. This paper provides a theoretical basis for the safety assessment of low temperature hydrogen storage pipeline. The new equation presented in this paper can provide useful guidance for the design of low temperature and high pressure pipelines.     

Failure assessments of corroded pipelines with axial defects using stress-based criteria: Numerical studies and verification analyses

Conventional procedures used to assess the integrity of corroded piping systems with axial defects generally employ simplified failure criteria based upon a plastic collapse failure mechanism incorporating the tensile properties of the pipe material. These methods establish acceptance criteria for defects based on limited experimental data for low strength structural steels which do not necessarily address specific requirements for the high grade steels currently used. For these cases, failure assessments may be overly conservative or provide significant scatter in their predictions, which lead to unnecessary repair or replacement of in-service pipelines. Motivated by these observations, this study examines the applicability of a stress-based criterion based upon plastic instability analysis to predict the failure pressure of corroded pipelines with axial defects. A central focus is to gain additional insight into effects of defect geometry and material properties on the attainment of a local limit load to support the development of stress-based burst strength criteria. The work provides an extensive body of results which lend further support to adopt failure criteria for corroded pipelines based upon ligament instability analyses. A verification study conducted on burst testing of large-diameter pipe specimens with different defect length shows the effectiveness of a stress-based criterion using local ligament instability in burst pressure predictions, even though the adopted burst criterion exhibits a potential dependence on defect geometry and possibly on material's strain hardening capacity. Overall, the results presented here suggests that use of stress-based criteria based upon plastic instability analysis of the defect ligament is a valid engineering tool for integrity assessments of pipelines with axial corroded defects.     

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.     

Prediction of the failure pressure for complex corrosion defects

A new method for predicting the failure pressure of corrosion defects in pipelines has been developed. The failure pressure of a plain pipe represents an upper limit for the failure pressure of a pipe with a corrosion defect. The failure pressure of a uniform depth, infinitely long groove, where the depth is equal to the maximum depth of the corrosion defect, represents a lower limit for the failure pressure of a pipe with a natural corrosion defect. The predicted failure pressure can be calculated from these limits using the weighted depth difference (WDD) method, which accounts for the defect geometry and any interaction with adjacent defects. The WDD method has been validated using the results of 40 burst tests of pipe sections containing real corrosion defects. The results indicate that this method provides more accurate burst pressure predictions than the currently accepted corrosion defect assessment procedures.     

Effect of spatial correlation on the failure probability of pipelines under corrosion

Corrosion in pipelines has been probabilistically modeled. However, the potential effect of spatial correlation of corrosion defects, in several segments of a pipeline, on its failure probability has not received much attention.In this paper, several degrees of spatial correlation are assumed for the corrosion in determined segments of a pipeline and their effects on the global reliability are examined.The pipeline is assumed to be a series system. The failure mode is considered to be controlled by the stresses due to internal pressure and the presence of corrosion. Component reliability is calculated by First Order Second Moment approximations. First order bounds are used to define the limits for the global failure probability by assuming first, either no correlation (independent pipeline segments) and, secondly, perfect correlation between segments.Then, second order bounds are estimated to improve the calculation of the failure probability by including the correlation coefficients mentioned above.The correlation degree between failure modes at two pipeline segments increases with the degree of correlation of the corrosion initial depths located at these segments. Also, for a correlation coefficient between corrosion depths larger than 0.6, its contribution to the correlation between failure modes becomes significant and, therefore, should be accounted for.When the specific correlation degree between corrosion defects at adjacent pipeline segments is considered in the calculation of an example pipeline failure probability, this probability is narrowly bounded between 0.58 and 0.59, as compared to the usual practice where this correlation is assumed to be either 0 or 1 for which the failure probability is bounded between 0.49 and 0.79.The formulation may be used to set optimal maintenance schedules for pipelines under corrosion.     

Assessment of the flexural capacity of corroded steel pipes

Flexural capacity of corroded pipes can be determined analytically assuming a full plastic failure mode for the pipe. A set of generalized solutions for flexural capacity of the pipe can be developed if the shape of the corrosion is known a priori. The generalized solutions derived in this paper are able to account for the simultaneous action of internal pressure and axial force. For practical purposes, the generalized solutions thus derived are simplified into approximate closed-form equations using three idealized corrosion shapes, namely, constant-depth, elliptical, and parabolic corrosions. Numerical examples indicate that the closed-form approximate solutions provide good comparison with the generalized solutions. The closed-form approximate solutions are subsequently compared to experimental results from full-size tests of pipes with different corrosion depth and width. Parameter study conducted as part of this paper indicates that the shape of a corrosion defect has significant influence on the flexural capacity of the corroded pipes.     

Review on optimization design,failure analysis and non-destructive testing of composite hydrogen storage vessel

Composite hydrogen storage vessels have been increasingly applied to hydrogen fuel cell vehicles. This review focuses on optimization design, failure analysis and nondestructive testing for enhancing the safety of composites hydrogen storage vessels in service. The optimization designs of the composite vessel components help to improve the durability and strength of composite vessels subjected to burst pressure and fatigue loads. In complex service environments, composite vessels may suffer from various failure forms (burst failure, fatigue failure and impact failure) which involve different damage processes and influence factors. More importantly, this review discusses the applications of acoustic emission, digital image correlation, optical fiber in studying the residual performance (burst pressure and fatigue life) and damage modes of the composite vessel. It is expected that the combination of nondestructive testing techniques plays an increasingly important role in developing the composite vessel for structural health monitoring.     

A study of decrease burst strength on compressed-hydrogen containers by drop test

We investigate an initial burst pressure and residual burst pressure at the end of life (EOL) of compressed hydrogen containers and report that a container damage caused by a drop test has a large influence on burst pressure. The container damage induced through hydraulic sequential tests is investigated using nondestructive evaluations to clarify a strength decreasing mechanism. An ultrasonic flaw detection analysis is conducted before and after the drop test and indicated that the damage occurred at the cylindrical and dome parts of the container after the drop test. An X-ray computed tomography imaging identifies a delamination inside laminated structure made of carbon fiber reinforced plastics (CFRP) layer, with some degree of delamination reaching the end boss of the container. Results suggest that a load profile fluctuates in the CFRP layer at the dome part and that a burst strength of the dome part decreases.     

雅克拉污水处理站污水管线腐蚀分析及治理建议

雅克拉污水处理站设计处理污水量为500m3/d,来水主要包括雅克拉站污水、YK12井单井流程污水和大涝坝站污水,处理后出水达到A3标准。污水站自2008年投运至今,污水处理管线及储罐本体累计穿孔40次,主要集中在提升泵进口管线、接收罐进口管线和弯头,频繁更换金属管线和管件,腐蚀治理费用已达27.2万元。影响腐蚀的因素包括污水pH值、矿化度、溶解氧浓度、流体间歇性高流速冲刷、管线材质和加注药剂等。对腐蚀因素进行分析后,建议将污水站低压金属管线更换为非金属管线,玻璃钢管线连接、玻璃钢管线与阀门连接采用承插式连接;将接收罐进口弯头更换为抗冲刷的改型弯头;增设除氧剂加注流程,降低溶解氧浓度;对加注药剂进行改性处理,减缓其对污水管线的腐蚀;在沉降罐开罐检查、处理时,将沉降罐中心筒更换为耐腐蚀材质或有涂层处理的中心筒。     

Time-dependent corrosion behavior of electroless Ni–P coating in H2S/Cl− environment

As a mature technology, electroless Ni–P alloy coating is widely applied in the protection of chemical equipment and pipelines owing to its excellent corrosion resistance, but its application and long-term service evaluation in the field of high-sulfur oil and gas are rare. Therefore, the time-dependent corrosion behavior of Ni–P coating, which was plated on the L360 steel surface, was investigated in a saturated H₂S medium by the method of surface analysis. The results indicate that Ni–P coating with a thickness of about 52.6 μm could significantly reduce the corrosion rate compared with uncoated pipeline steel. This is related to the structure of the dense, protective film on the surface. The uncoated pipeline steel suffered local corrosion during the immersion process, and then it developed into uniform corrosion with the formation of a large number of corrosion products. In comparison, Ni–P coatings corroded relatively mildly with only a thin corroded layer. However, during prolonged corrosion testing, the corrosive medium penetrated the coating/substrate interface at inherent defects, leading to severe local corrosion of the substrate.     

Options of natural gas pipeline reassignment for hydrogen: Cost assessment for a Germany case study

The uncertain role of the natural gas infrastructure in the decarbonized energy system and the limitations of hydrogen blending raise the question of whether natural gas pipelines can be economically utilized for the transport of hydrogen. To investigate this question, this study derives cost functions for the selected pipeline reassignment methods. By applying geospatial hydrogen supply chain modeling, the technical and economic potential of natural gas pipeline reassignment during a hydrogen market introduction is assessed.The results of this study show a technically viable potential of more than 80% of the analyzed representative German pipeline network. By comparing the derived pipeline cost functions, it could be derived that pipeline reassignment can reduce the hydrogen transmission costs by more than 60%. Finally, a countrywide analysis of pipeline availability constraints for the year 2030 shows a cost reduction of the transmission system by 30% in comparison to a newly built hydrogen pipeline system.     

Analysis of hazard area associated with hydrogen gas transmission pipelines

Hydrogen is considered to be the most important future energy carrier in many applications reducing significantly greenhouse gas emissions, but the safety issues associated with hydrogen applications need to be investigated and fully understood to be applicable as the carrier. Generally, the locations of hydrogen production and consumption are different. Hydrogen must be transported from the point of production to the point of use. Pipeline delivery is cheaper than all other methods for large quantities of hydrogen. The rupture of a hydrogen pipeline can lead to outcomes that can pose a significant threat to people and property in the immediate vicinity of the failure point. In this work, a simplified equation of hazard analysis is proposed for the pipeline transporting hydrogen, which relates the diameter, the operating pressure and the length of the pipeline to the size of the affected area in the event of a failure of the pipeline. The dominant hazards are thermal radiation from sustained fire and shock pressure from gas cloud explosion. For a transmission pipeline of hydrogen gas, the hazard area from the fire is slightly larger than by the other event. The hazard area is directly proportional to the operating pressure raised to the power one-half, and to the pipeline diameter. This simplified equation to estimate the hazard area will be a useful tool for safety management of hydrogen gas transmission pipelines.     

Hydrogen permeation and distribution at a high-strength X80 steel weld under stressing conditions and the implication on pipeline failure

Hydrogen permeation and distribution at pipeline welds is critical to integrity maintenance of the pipelines, especially for those made of high-strength steels. The situation becomes even more important under stressing conditions. In this work, metallographic characterization and micro-hardness measurements were conducted at an X80 steel weld. Potentiodynamic polarization and electrochemical hydrogen permeation testing were performance at various zones at the weld, along with numerical modeling of hydrogen distribution at the zones. The X80 steel contains a microstructure of bainite bundles and polygonal ferrite. There are more polygonal ferrite, fewer bainite and some segregated cementite at heat-affected zone (HAZ). The weld metal is featured with acicular ferrite and some grain boundary ferrite. HAZ softening occurs at the weld. The hardness of the weld metal, HAZ and base steel is about 290, 248 and 261 HV_0.2, respectively. There is the greatest corrosion current density, i.e., corrosion rate, at HAZ under both elastic and plastic stresses. An applied stress further increases the corrosion current density. Under the plastic stress of 1.1σ_ys (σ_ys is yield strength), the corrosion current densities of HAZ, base steel and weld metal are 41.04, 17.03 and 25.49 μA/cm², respectively. There are always the greatest hydrogen trapping density and the smallest hydrogen diffusivity at HAZ. Hydrogen, once penetrating the welded steel, tends to accumulate at the HAZ, compared with other two zones. When the welded steel is under stresses, especially a plastic stress (i.e., 1.1σ_ys), the hydrogen diffusivity and permeability decrease, while the subsurface hydrogen concentration and hydrogen trapping density increase remarkably. Plastic deformation favors the hydrogen permeation and trapping at weld, especially the HAZ, to elevate the susceptibility to hydrogen damage. The hydrogen distribution at different welding zones can be evaluated and determined by a developed modeling method.     

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.     

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.     

Acoustic emission characteristics of used 70 MPa type IV hydrogen storage tanks during hydrostatic burst tests

Currently, the periodic inspection of composite tanks is typically achieved via hydrostatic test combined with internal and external visual inspections. Acoustic emission (AE) technology demonstrates a promising nondestructive testing method for damage mode identification and damage assessment. This study focuses on AE signals characteristics and evolution behaviors for used 70 MPa Type IV hydrogen storage tanks during hydrostatic burst tests. AE-based tensile tests for epoxy resin specimen and carbon fiber tow were implemented to obtain characteristics of matrix cracking and fiber breakage. Then, broad-band AE sensors were used to capture AE signals during multi-step loading tests and hydrostatic burst tests. K-means ++ algorithm and wavelet packet transform are performed to cluster AE signals and verify the validity. Combining with tensile tests, three clusters are manifested via matrix cracking, fiber/matrix debonding and fiber breakage according to amplitude, duration, counts and absolute energy. The number of three clustering signals increases with the increase of pressure, showing accumulated and aggravated damage. The sudden appearance of a large number of fiber breakage signals during hydrostatic burst tests suggests that the composite tank structure is becoming mechanically unstable, namely the impending burst failure of the tank.