PTC 2009 Mueller-Syring

4th Pipeline Technology Conference 2009
Preparing for the Hydrogen Economy by Using the Existing Natural Gas System as a Catalyst // Project Contract No.: SES6/CT/2004/502661
Integrity Management for

Pipelines Transporting
Hydrogen – Natural
Gas Mixtures
Pipeline Technology Conference 2009
Hannover, Germany
22-23 April 2009
NATURALHY is an Integrated Project funded by the European Commission’s Sixth Framework Programme (2002-2006) for research, technological development and demonstration (RTD)
NATURALHY Aims
“Preparing for the hydrogen economy by

using the existing natural gas system as a
catalyst”
To define conditions under which hydrogen can
be added to natural gas in the existing system
To assess the “greening of gas”options
To develop membranes for hydrogen separation
NATURALHY is an Integrated Project funded by the European Commission’s Sixth Framework Programme (2002-2006) for research, technological development and demonstration (RTD) 2
NATURALHY Key figures
39 European partners
Integrated Project within EC’s FP6
Project budget: 17.3 M€; EC grant: 11 M€
Start 1 May 2004, duration 51/2 years
Recognised by the International Partnership
of the Hydrogen Economy
NATURALHY Contents
8 work packages
Life Cycle and Socio-Economic Assessment
Safety
Durability
Integrity
End use
Decision support tool
Dissemination
Project management
Motivation for Integrity

Management
Start
Objectives of WP4
Preventing incidents caused

by hydrogen addition
Source: GE-PII
Objectives of WP4
Determine when and how to inspect and repair hydrogen

transportation pipelines
Providing a specification for an integrity management tool

(IMT)
Developing a software able to calculate the POF of

pipelines considering real pipe data or statistical
distributions (defects, material data)
Investigating the effect of hydrogen addition on the costs

for the integrity management
Defect description
Inventory of defects present in NG pipelines
Manufacturing, corrosion,
3rd party damage, cracks
Expert judgment on the

expected hydrogen effect
Figure 2 : Lack of penetration

Figure 1 : Shrinkage groove
Figure 4 : Cracks
Figure 3 : Root concavity
Defect description
Axial cracks are most severe
Circumferential cracks (e.g. in weld area)

are more common but less severe
Other defects must introduce plastic

deformation at the inner pipe wall in order
to be critical
Defect Criticality
Aim
Determining relevant defects and their critical

size in pipelines transporting hydrogen
Sensitivity Analysis Probability of Failure

(POF) Model
Will be updated using the
final material data from Final version expected
WP3 for May 2009
Defect Criticality
Sensitivity analysis
Cracks have been identified as the most critical
defects (in presence of hydrogen)
Cracks are not in the main focus of the
currently applied inspection technologies (NG)
The available technologies can not be applied
without modification
• Improvement of inspection and monitoring tools is
needed (updated specifications will be elaborated)
Defect Criticality
Sensitivity Analysis
The impact of pure hydrogen on the critical initial crack depth is
significant, but for 50% per volume H2 the impact is much reduced
(600 mm in diameter and 10 mm wall thickness)
For a life of 20 years

100% NG 8.5 mm
50% H2 6 mm
100% H2 4.7 mm
For a life of 60 years
100% NG 8.2 mm
50% H2 5.1 mm
100% H2 3.1 mm
Defect Criticality
100% H2
Life 60 years
Critical initial
defect depths
and lengths for
an X70
pipeline in
relation to
internal
pressure
changes
Defect Criticality
50% H2/NG Critical initia llength vs. pressure and crack length
Mixture 10
Life 60 years 9
Critical initial length (mm)
Critical initial 7
defect depths 6
and lengths for 5
an X70 4
pipeline in 3
relation to 0
internal
In
te
rn
pressure
al
5
pr
es
300
su
250
changes
200
re
100 150
(M
10
0 50
P
a)
gth mm
Cr ack len
Defect Criticality
Probability Of Failure (POF) tool

Is being used to compute the impact of hydrogen on
pipeline defects
The POF calculation incorporates
• Impact of hydrogen on the material properties (toughness and
fatigue)
• Effect of inspection interval shortening and improvement of
inspection tool performance
• Repair strategy
Defect Criticality
POF tool covers

Corrosion Defects
Third Party Damage
Differentiation of faliure mode for crack like defects into
the classifications required for safety assessment
• Pinhole defects, holes, ruptures
Results of the POF tool for non location specific defects

will be used for high level models (safety, DST)
Location specific calculations can be used for IM
Defect Criticality
Selected results (POF tool)
Defect Criticality
Fatigue data based on tests in gaseous conditions at a

pressure of 65 bar
Defect Criticality
Cumulative probability of failure (including both

leakage and rupture) for an X52 pipeline with one
crack within 50 years; gas pressure=60bar
1,00E+00
1,00E-01
1,00E-02
1,00E-03
1,00E-04
1,00E-05
1,00E-06
1,00E-07
Natural 100% 50%
Gas Hydrogen Natural
gas/50%
Hydrogen
Current inspection performance
Inline Inspection
Detection of metal loss is state of the art
Cracks are only surveyed for oil pipelines by

ultrasonic tools
Couplant-free devices, which are suitable for NG

pipelines, are in their development phase
Adoption of existing tools might be an option
Current inspection performance
Non-intrusive technologies
• A quantitative determination of the metal loss is not

possible
• The technologies require often a lot of expertise

from the operator
• There is a need to enhance the accuracy and the

quality of the results
Inspection improvements
Aim
Elaborating updated specifications for

inspection tools
• Cracks and crack like defects
• Defect sizes and their POD
Identification of candidates in NDE technologies
MFL3.0 and TRIAX inspection tools have been tested against

their suitability to detect crack like defects
Test were performed by GEPII and the spool with artificial

defects was build by GDF SUEZ
Pipe Body Crack-like defects
MFL3.0 and TRIAX inspection tools show nearly the same performance
All defects have been detected
Defect detection and sizing is difficult in weld areas
Very good detection and acceptable sizing performance for the pipe body area
The performance exceeds partly the specification of MFL tools
But it is recommended to use the TRIAX tool

• Better signal range
• Can inspect down to zero speed
• Better sizing for corrosion defects
Metal loss and circumferential crack like defects can be inspected in one run
Repair adaptations
Aim
Investigation of the suitability of currently used

repair methods for the hydrogen service
Repair adaptations
In none of the specimen cold cracks were observed
Coarse grained HAZ: Max. hardness = 375 HV5

Weld metal: hardness = 230 HV5
4 specimen welded 4 specimen charged with Reference

and charged with H2 H2 for 7 d at 65 bar
for 7 d at 65 bar welded immediately
afterwards
Repair adaptations
Explanation
Hydrogen, introduced by welding, is
magnitudes higher (factor of 1000)
than that introduced by gaseous H2
Wall thickness of pipelines is thin => lower
stresses than in thick materials
Repair adaptations
Metallic and composite sleeves showed a good

performance for natural gas/hydrogen mixtures
Long term behaviour have to be investigated (not

in the scope of Naturalhy)
Repair adaptations
Weld repair,
Clock spring and
Metallic sleeve repair

are suitable technologies
for the hydrogen service
Resource allocation
Aim
To establish a functional specification for a cost
optimisation tool
The considering costs for inspection and repair
Developing the needed cost optimisation formulas as

basis for the Decision Support Tool and operators
Resource allocation
Costs considered
Pipeline monitoring
In line Inspection (ILI) cost
• Future cost of the next inspection based on the cost of the last inspection
– Costs of the preparation and analysis of the inspection
– Costs of the preparation of the installations
– Costs of the inline inspection run
Repair program
Comprises Excavation, defect characterization, defect assessment, repair

and restoration of the site
Resource allocation
Section 1 Section 2 Section 3 Section 4 Section 5
Excavation, external coating rehabilitation, backfilling of the dig,
restoration of the site (EXC)
Number of excavations (Difficult access, difficult to excavate) Nb EXC DADE 0 2 2 3 3
Number of excavations (Difficult access, easy to excavate) Nb EXC DAEE 2 3 2 0 3

Number of excavations (Easy access, difficult to excavate) Nb EXC EAD E 2 3 4 0 3
Number of excavations (Easy access, easy to excavate) Nb EXC EAEE 1 2 0 2 3
CostEXC (€) 45000 110000 100000 70000 135000
Cost of Defect characterization (DCH)

CostDC H for all defects (€) 6350 15700 11360 7600 20640
Cost of Repair
Cost of one repair by composite sleeves (CS)
Cost of one repair by CS (€) (from details) 5834 6044 5351 5834 5911
Medium cost of one repair by composite sleeve (€) (already performed on
6000 6000 6000 6000 6000
the pipeline)
Cost of one repair by metallic sleeves (MS)
Medium cost of one repair by metallic sleeve (€) (already performed on the
5000 5000 5000 5000 5000
pipeline)
Cost of one repair by hot-tapping
Medium cost of one repair by hot tapping (€) (already performed on the
10000 10000 10000 10000 10000
pipeline)
Cost of one repair by cut out and replace
Medium cost of one repair by cut out and replace (€) (already performed on
20000 20000 20000 20000 20000
the pipeline)
Medium cost of repair for one defect on the section Costrepdef 8100 10900 9000 7650 6000
Cost of repair for all defects on the section (€) 40500 109000 72000 38250 72000
TOTAL COST OF REPAIR PROGRAM AT THE PRESENT YEAR

presentyear 91850 234700 183360 115850 227640
32
Cost allrepairNATURALHY is (€)an Integrated Project funded by the European Commission’s Sixth Framework Programme (2002-2006) for research, technological development and demonstration (RTD)
Integrity Management Tool
Aim
To establish a functional specification for an Integrity

management Tool that enables taking account of
hydrogen addition
• Including:
– calculation of inspection and repair deadlines
– determining cost optimal maintenance programme
Definition of pipeline properties Covered by

IMT
Definition of defect properties
specification
but results of
Definition of limit state functions
POF tool will
be used
Evaluation of pipeline reliability/POF
Determination of reinspection deadline Covered by
IMT
Repair deadlines specification
and resource
Minimising maintenance costs allocation
results
Output
Partners in WP4
BP
IGDAS
CMI ISQ
DBI (lead) TUBITAK
Gasunie Statoil
GDF SUEZ Total
GE PII TNO
Thank you for your attention
Gert Müller-Syring
gert.mueller-syring@dbi-gut.de
NATURALHY is an Integrated Project funded by the European Commission’s Sixth Framework Programme (2002-2006) for research, technological development and demonstration (RTD)

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4th Pipeline Technology Conference 2009

Integrity Management for

 “Preparing for the hydrogen economy by

NATURALHY Key figures

Motivation for Integrity

Preventing incidents caused

 Determine when and how to inspect and repair hydrogen

 Providing a specification for an integrity management tool

 Developing a software able to calculate the POF of

 Investigating the effect of hydrogen addition on the costs

 Inventory of defects present in NG pipelines

 Expert judgment on the

Figure 2 : Lack of penetration

 Axial cracks are most severe

 Circumferential cracks (e.g. in weld area)

 Other defects must introduce plastic

 Determining relevant defects and their critical

Sensitivity Analysis Probability of Failure

 For a life of 20 years

and lengths for 5

 Probability Of Failure (POF) tool

 POF tool covers

 Results of the POF tool for non location specific defects

 Selected results (POF tool)

Fatigue data based on tests in gaseous conditions at a

 Cumulative probability of failure (including both

Current inspection performance

 Detection of metal loss is state of the art

 Cracks are only surveyed for oil pipelines by

 Couplant-free devices, which are suitable for NG

 Adoption of existing tools might be an option

Current inspection performance

• A quantitative determination of the metal loss is not

• The technologies require often a lot of expertise

• There is a need to enhance the accuracy and the

 Elaborating updated specifications for

• Cracks and crack like defects

• Defect sizes and their POD

 Identification of candidates in NDE technologies

 MFL3.0 and TRIAX inspection tools have been tested against

 Test were performed by GEPII and the spool with artificial

 Pipe Body Crack-like defects

 All defects have been detected

 Defect detection and sizing is difficult in weld areas

 The performance exceeds partly the specification of MFL tools

 But it is recommended to use the TRIAX tool

• Can inspect down to zero speed

• Better sizing for corrosion defects

 Investigation of the suitability of currently used

Coarse grained HAZ: Max. hardness = 375 HV5

4 specimen welded 4 specimen charged with Reference

 Metallic and composite sleeves showed a good

 Long term behaviour have to be investigated (not

 Clock spring and

 Metallic sleeve repair

 The considering costs for inspection and repair

 Developing the needed cost optimisation formulas as

 In line Inspection (ILI) cost

– Costs of the preparation and analysis of the inspection

– Costs of the preparation of the installations

– Costs of the inline inspection run

 Comprises Excavation, defect characterization, defect assessment, repair

Number of excavations (Difficult access, difficult to excavate) Nb EXC DADE 0 2 2 3 3

Number of excavations (Difficult access, easy to excavate) Nb EXC DAEE 2 3 2 0 3

“Preparing for the hydrogen economy by

Determine when and how to inspect and repair hydrogen

Providing a specification for an integrity management tool

Developing a software able to calculate the POF of

Investigating the effect of hydrogen addition on the costs

Inventory of defects present in NG pipelines

Expert judgment on the

Axial cracks are most severe

Circumferential cracks (e.g. in weld area)

Other defects must introduce plastic

Determining relevant defects and their critical

For a life of 20 years

Probability Of Failure (POF) tool

POF tool covers

Results of the POF tool for non location specific defects

Selected results (POF tool)

Cumulative probability of failure (including both

Detection of metal loss is state of the art

Cracks are only surveyed for oil pipelines by

Couplant-free devices, which are suitable for NG

Adoption of existing tools might be an option

Elaborating updated specifications for

Identification of candidates in NDE technologies

MFL3.0 and TRIAX inspection tools have been tested against

Test were performed by GEPII and the spool with artificial

Pipe Body Crack-like defects

All defects have been detected

Defect detection and sizing is difficult in weld areas

The performance exceeds partly the specification of MFL tools

But it is recommended to use the TRIAX tool

Investigation of the suitability of currently used

Metallic and composite sleeves showed a good

Long term behaviour have to be investigated (not

Clock spring and

Metallic sleeve repair

The considering costs for inspection and repair

Developing the needed cost optimisation formulas as

In line Inspection (ILI) cost

Comprises Excavation, defect characterization, defect assessment, repair

To establish a functional specification for an Integrity

Definition of pipeline properties Covered by

DBI (lead) TUBITAK

GDF SUEZ Total