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| Reference Number | NIA_CAD0103 | |
| Title | Hydrogen Environment Testing of Girth Welds | |
| Status | Started | |
| Energy Categories | Hydrogen and Fuel Cells (Hydrogen, Hydrogen transport and distribution) 100%; | |
| Research Types | Applied Research and Development 100% | |
| Science and Technology Fields | ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering) 100% | |
| UKERC Cross Cutting Characterisation | Not Cross-cutting 100% | |
| Principal Investigator |
Project Contact No email address given Cadent Gas |
|
| Award Type | Network Innovation Allowance | |
| Funding Source | Ofgem | |
| Start Date | 01 April 2024 | |
| End Date | 31 March 2025 | |
| Duration | ENA months | |
| Total Grant Value | £504,000 | |
| Industrial Sectors | Energy | |
| Region | London | |
| Programme | Network Innovation Allowance | |
| Investigators | Principal Investigator | Project Contact , Cadent Gas (99.996%) |
| Other Investigator | Project Contact , Cadent Eastern (0.001%) Project Contact , Cadent North London (0.001%) Project Contact , Cadent North West (0.001%) Project Contact , Cadent West Midlands (0.001%) |
|
| Industrial Collaborator | Project Contact , Cadent Gas (0.000%) |
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| Web Site | https://smarter.energynetworks.org/projects/NIA_CAD0103 |
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| Objectives | This project is being delivered by DNV, with laboratory testing being carried out in Columbus, Ohio and Engineering Critical Assessment support being provided by the UK team in Loughborough and Aberdeen. The Cadent team will manage the delivery of the project.In order to progress with a high stress design approach, a fracture mechanics based qualification plan has been developed. The qualification includes the testing of pipe, seam weld and production girth weld samples in a hydrogen environment. The girth welds have been produced using the automated Cold Metal Transfer (CMT) and twin head pulsed GMAW technique, with a narrow gap for main lining, and a manual Surface Tension Transfer (STT) with mechanised flux core for tie-ins. The testing approach takes place in two phases.Phase 1 focuses on the identification of a realistic worst case hydrogen environment for the testing. As hydrogen production may include "blue" hydrogen, which is reformed from methane, there are certain components that may be contained within the hydrogen that are detrimental to fracture performance.Phase 2 will focus on the qualification tests for pipe and girth welds to demonstrate the required properties of a high stress design approach.The testing includes:ASTM E384 Standard Test Method for Micro-indentation Hardness of Materials,ASTM E92 Standard Test Method for Vickers Hardness of Metallic Materials,ASTM E399 Standard Test Method for Plane-Strain Fracture Toughness of Metallic Materials,Rising displacement fracture toughness testing: ASTM E1820-20b,Standard Test Method for Measurement of Fracture Toughness,Fatigue crack growth rate testing: ASTM E647-15, Standard Test Method for Measurement of Fatigue Crack Growth Rate.Fracture toughness and fatigue crack growth testing will be carried out on pipe body, seam weld centreline, seam weld heat-affected zone, girth weld centreline and girth weld heat-affected zone.Two pipe materials are being tested; X65 grade seam welded thermomechanical rolled representative of pipe used in main lines and seamless quench and tempered representative of pipe used in spur lines. Both line pipe materials have a chemistry compliant with Annex H of API 5L and ferritic / bainitic microstructure.Automated girth welding processes will be tested using procedures for mainlining and tie-ins.The results from the fracture and fatigue testing will be implemented into an Engineering Critical Assessment for a transmission pipeline network to justify the use of the high stress design option. This ensures that the network can operate for a minimum of 40 years. In order to address the problem outlined in Section 2.1, the following scope is being delivered. The scope is split into two phases of work.The aims of the scope are to support with line pipe specification and pipeline design requirements and confirm that material performance for the pipe, seam weld and girth welds meets the requirements of pipeline operation in a transmission network. The ultimate aim is to give confidence that the material used in the pipeline can operate safely for its design life. Phase 1 relates to hydrogen environments, testing pipe body and longitudinal seam weld and Phase 2 relates to testing of girth welds. Testing of grade two X65 line pipe materials is being carried out, with different heat treatment conditions. The pipes are representative of ones that will be used in new build hydrogen pipeline networks.Phase 1 will identify the realistic worst case environmentthat can be seen in a hydrogen network. The environments will range from dry 100% H2 to moist H2 with H2S and CO2. Control tests in air will also be carried out.Phase 2 will take the worst case environment from Phase 1 and carry out testing on girth welds to demonstrate fracture and fatigue performance.The results from testing will be used to confirm that the materials can perform to the requirements calculated in an Engineering Critical Assessment for a high stress hydrogen pipeline network operating for a minimum of 40 years.The benefits of this project support the efficient construction of new build hydrogen transmission pipelines with steel, welding consumable and carbon savings compared to using a low-stress design approach and standard welding practices. The objectives of the project lead to achieving the aim set out in Section 2.3. The objectives are broken down as follows:· Development of a test matrix for Phase 1 and Phase 2· Production of detailed testing procedures· Inspection of as-received pipe and welds· Preparation of samples for testing· Determination of Phase 1 testing environments· Control of testing environments during tests· Carrying out testing inc. crack growth measurement· Analysis and reporting of testing results· Detailed interpretation of testing resultsReview of Engineering Critical Assessment based on testing results. | |
| Abstract | Hydrogen pipeline design codes currently offer two design options low stress and high stress. Adopting a high stress design approach can offer significant advantages. However, requires more detailed qualification based on fracture mechanics.This project will determine the identification of a realistic worst case hydrogen environment for the testing and will focus on the qualification tests for pipe and welds to demonstrate the required properties of a high stress design approach to achieve a minimum of 40 years operational life based on Engineering Critical Assessment.This supports the efficient construction of major capital hydrogen pipeline projects. Girth welds will be made using modern welding techniques on high-strength steel line pipe with two different heat treatment conditions. | |
| Data | No related datasets |
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| Projects | No related projects |
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| Publications | No related publications |
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| Added to Database | 02/10/24 | |
