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White Paper Repurposing Pipelines Hydrogen
White Paper Repurposing Pipelines Hydrogen
FOR HYDROGEN:
Guiding operators through the
re-evaluation process
AUTHORS:
Victoria Monsma, Tim Illson, Ramgopal Thodla, Afzal Hussain
CONTRIBUTORS:
JØrg Aarnes, Shane Finneran
WHI T E PA P ER
Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
CONTENTS
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
1. REPURPOSING PIPELINES IS
ESSENTIAL TO SCALING HYDROGEN
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
1. REPURPOSING PIPELINES IS
ESSENTIAL TO SCALING HYDROGEN
The energy transition and climate targets have created a pressing need to scale technologies to
decarbonize hard-to-abate sectors, many of which require low-carbon gases as well as greater
electrification.
European Union Agency for the Cooperation of Energy Regulators (2021) Transporting Pure Hydrogen by Repurposing Existing Gas Infrastructure.
1
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
2. OVERVIEW OF STANDARDS
AND R&D
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
Industrial users, such as producers of ammonia, have 2.1 Current standards focused on natural gas and
transported hydrogen in pipelines for decades, but in limited new-build hydrogen pipelines
use cases. Standards are not yet fully developed for the
transportation of hydrogen more widely in gas infrastructure Existing pipeline infrastructure has been designed for
and in repurposed pipelines. transporting natural gas. Various industry standards govern
the construction and operation of natural gas pipelines, as
This is where R&D and joint industry projects play an essential seen in Table 1, along with local regulations. However, the
role to close knowledge gaps to develop standards and codes that are currently in place provide limited guidance
recommended practices needed for safe and efficient on the design and use of hydrogen in existing pipelines.
repurposing of pipelines for hydrogen as an essential enabler The commonly cited design practice for hydrogen pipelines
of a hydrogen economy. is based on the ASME B31.12 standard.
ASME B31.12 Hydrogen piping and United States Yes, 10-100% hydrogen Yes
pipelines
ISO 13623 Petroleum and natural gas International Organization for Yes No
industries - pipeline transportation systems Standardization
AS/NZS 2885.1 Pipelines gas and liquid Australia and New Zealand No No
petroleum, Part 1: Design and construction
Table 1 - Existing standards related to gas pipelines RED: no requirements and hydrogen is not allowed
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
2.2 Understanding the application standards 2.3 Key considerations when repurposing pipelines
for hydrogen
Many existing international pipeline standards include
hydrogen in their scope but provide no specific integrity or Transport of hydrogen in pipelines poses a wide range of
materials requirements for hydrogen. As a result, the ASME challenges, which include safety and financial risks for both
B31.12 standard is often used as the template for feasibility new and repurposed pipelines. The demand for hydrogen
assessments. However, some ASME requirements are likely from end users is likely to place constraints on the quality and
to be conservative as they are based on sour (infrastructure quantity of hydrogen transported in pipelines, and it may also
containing hydrogen sulfide (H2S) or sulfuric acid (H2SO4)) place operating restrictions and challenges on pipelines.
service design guidance. These requirements are then
challenging to achieve for existing natural gas transmission
pipelines. Some of the requirements, such as weld hardness,
are even more conservative than those found in sour service
guidelines such as NACE MR0175/ ISO 15156. ENVIRONMENT OPERATIONS
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
Pressure
Low amplitude load
One of the major gaps in the ASME B31.12 is that it does High amplitude load
not consider the probability of hydrogen embrittlement
mechanisms: it always assumes that hydrogen has entered Time
the steel and caused degradation of properties, but this
assumption is conservative. For hydrogen embrittlement or
other hydrogen-related degradation mechanisms to occur, Figure 2 - Typical operating conditions of a gas pipeline
atomic hydrogen (H+) must enter the metal matrix. Molecular
hydrogen, H2, does not directly cause material issues; it must
dissociate to H first to cause issues. This dissociation can be Another gap is knowledge on different blends of hydrogen.
promoted by high temperatures, arcs, or other high-energy The blend of hydrogen versus natural gas will affect the gas
phenomena, which are rarely encountered in transmission properties in many aspects. The ASME B31.12 standard
pipelines. is applicable for ≥10% hydrogen. However, some of the
requirements such as impact radius and arrested crack length
However, atomic hydrogen can also be generated at an are based on the 100% hydrogen case and do not account for
actively growing fatigue crack, where the fresh metal surfaces the different properties of blends – especially in cases where
catalyse the dissociation mechanism. In addition to H2 most of the blend is natural gas. There is a need for guidelines
interacting with surface-breaking flaws, one often-raised related to the assessment of the integrity and safety of natural
consideration is whether H+ can enter the pipeline steel gas grids for natural gas/hydrogen mixtures with different
under typical operating conditions and interact with mid-wall hydrogen concentrations.
or external defects associated with the pipeline. The entry of
atomic hydrogen, under the typical operating temperatures of The above discussion highlights a few important aspects that
a pipeline, through the oxide films of steel is kinetically limited, operators need to consider when qualifying the integrity of
according to the latest industry understanding. However, both new hydrogen pipelines and natural gas pipelines that
limited work has been performed to ascertain whether H2 will be repurposed for hydrogen service.
dissociation and entry can occur over the lifetime of the pipe.
It is important to determine with sufficient confidence whether Many of the existing pipeline codes are under revision.
H2 dissociation and entry can occur, as this will have significant Alongside this, the requirements for an engineering
implications for structural analysis of mid-wall and outer assessment are evolving as project experience and research
diameter flaws. develops best practice guidance. Pipeline operators and the
wider energy industry are participating in several ongoing
Furthermore, the standard provides guidance on fatigue efforts aimed at addressing the critical questions needed to
behaviour but does not account for the low amplitude safely transport hydrogen via pipelines, and to improve the
behaviour in hydrogen service. The fracture toughness existing repurposing guidelines and requirements (see
recommendations in ASME B31.12 are based on constant Section 2.5).
displacement methods that are applicable for pressure
vessel design, but do not provide representative toughness
behaviour for pipeline operations.
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
2.5 Developing standards and recommended practices — ongoing joint industry projects
HYREADY — Preparing networks and end users for the H2Pipe — Developing standards for offshore hydrogen
addition of hydrogen to natural gas pipelines
Within the HYREADY Joint Industry Project (JIP)2, With the rapidly growing interest for hydrogen
partners have prepared guidelines for the injection of transportation in offshore pipelines, either in new
hydrogen into natural gas systems. The HYREADY project pipelines or in conversion of existing natural gas pipelines,
gathers and evaluates existing information about the the industry needs guidance on how to do this safely
impact of hydrogen on natural gas systems for 2, 5, 10, and effectively. DNV launched a JIP in 2021 to develop a
20 and 30% blends added to natural gas, and 100% of recommended practice for offshore hydrogen pipelines3.
hydrogen. The guidelines developed as part of the The objective of the JIP is for this Recommended Practice
project will provide support in the decision-making to supplement the existing offshore pipeline standard,
process in which a balance needs to be found between DNV-ST-F101. This would take a similar approach to the
the aimed maximum hydrogen percentage and the cost development of DNV-RP-F104 for CO2 pipelines.
of the needed counter measures to overcome
unacceptable consequences from the addition of
hydrogen. These guidelines are intended to be converted
further into DNV Recommended Practices.
2
HYREADY, Joint Industry Project, DNV: https://www.dnv.com/article/hyready-219355
3
H2Pipe, Joint Industry Project, DNV: https://www.dnv.com/article/transportation-of-hydrogen-gas-in-offshore-pipelines-h2pipe-213006
4
In-service welding of methane/hydrogen mixture pipelines, Joint Industry Project,
DNV: https://www.dnv.com/article/in-service-welding-of-methane-hydrogen-mixture-pipelines-219708
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
4. A HARMONIZED, RIGOROUS
EVALUATION PROCESS
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
4. A HARMONIZED, RIGOROUS
EVALUATION PROCESS
Before a natural gas pipeline is filled with hydrogen, operators need to understand and account for
the challenges and impact of hydrogen. Hydrogen use in long-distance pipelines, for example, has
been relatively limited to date, and such new uses could lead to new and unknown failure modes.
A harmonized process is needed to align operators on DNV has developed a process to guide operators in
their repurposing projects, to ensure safety, as significantly evaluating their pipelines for hydrogen. This process, set
greater amounts of hydrogen are transported, by a growing out in the following sections, considers the current state of
network of repurposed pipelines, over longer distances and infrastructure, the anticipated operating conditions, and the
across borders. Beyond a harmonized process, operators various damage mechanisms involved. It includes examples
also need to perform a rigorous evaluation of the specific of some of the variables that may influence the evaluation.
pipeline system before converting a pipeline for transporting
hydrogen.
Initiation
Revisit step 2
INTEGRITY ACCEPTABLE? OR
consider new pipeline
Hydraulic assessment
Document
Implement
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
The following describes some of the key steps of the process, Assessing safety
providing current knowledge to guide operators in applying it Operators should perform a safety evaluation of the system,
in their own pipeline re-evaluation initiatives. addressing the implications of the change from natural gas
to hydrogen. The system should be evaluated based on the
specific safety requirements for hydrogen pipelines.
Defining the requirements and parameters for
operations As part of the safety evaluation, operators should identify and
evaluate the requirement for modifications of the pipeline
To properly assess whether a pipeline system can be system, such as additional block valves, leak detection
repurposed, operators need to define the content of upgrades, and updating ATEX zones. This should include an
hydrogen in the blend and the requirements for the evaluation of the suitability of components, and a change-out
pipeline material and compare this with existing natural gas of valves and gaskets not suitable for hydrogen transport.
code requirements. ASME B31.12 offers two options for Operators should pay particular attention to analysing the
determining design pressure: a prescriptive option (A) and consequence of accidental releases, caused by the change in
a performance-based option (B). Each option has different characteristics from natural gas to hydrogen.
material requirements as shown in Table 2.
The most important differences between natural gas and
When designing a new pipeline, the pipeline material can hydrogen to consider in terms of accidental releases are:
be specified for hydrogen service to meet the ASME B31.12
requirements. For existing natural gas pipelines that have • Hydrogen’s larger flammability range, which means that
been in operation for years, it will be a challenge to meet all a larger part of the gas can be ignited when mixed with air
requirements, especially for the performance-based option • Hydrogen’s lower ignition energy (for the high
(option B). Typically, mid-strength steel such as X42 to X65 is concentrations)
used for natural gas transport for pipelines with a diameter of • Shorter burning distances needed to initiate deflagration
16-36 inches and pressures of 40-66 bar. Higher steel grades to detonation transition (DDT)
are used for large-scale transport at 66-94 bar, and it is these • Higher explosion pressures in a hydrogen explosion.
pipelines that are intended for dedicated hydrogen transport.
Charpy base metal absorbed energy CVN = 0.008 · (R · T)0.39 · σhoop2 Same as option A
Fracture shear % At least 80% (average) for full size Charpy Same as option A
At least 40% (average) for drop weight
teat test (DWTT)
Ultimate tensile strength (UTS) Max. 689 N/mm2 Max. 758 N/mm2
Thickness Not addressed Repair and other activities may not reduce wall
thickness to less than 87.5%
Design pressure limits Not addressed P≤85% of mill test pressure or field hydrotest
pressure. Cold worked pipe P≤75% of the design
pressure.
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
Regarding failure causes, a switch to hydrogen can increase Option A limits the pressure up to 50% of that possible for
the potential for embrittlement of materials. Other failure natural gas, depending on the steel grade, which is not
causes such as third-party damage, corrosion, and ground economically feasible in most cases. For this reason, gas
movement, can be assumed to be the same as for natural gas operators are more interested in Option B, which allows them
transmission pipelines. A switch to hydrogen may reduce the to keep a higher maximum operating pressure (MAOP).
pipeline resistant capacity related to third-party damage, and
reduce the pipeline’s post-incident performance, and this must When determining the MAOP, operators should consider the
be considered during the integrity assessment. pipeline condition. For old pipelines with defects, it is currently
uncertain how operators should assess the remaining strength
capacity. The remaining strength of corroded pipelines for
Assessing integrity oil and gas operations have traditionally been assessed
using methods defined in standards such as ASME B31G or
Integrity assessments can be performed based on material DNV-RP-F101. The question is whether these methods are
properties, historical operating condition, and state of the applicable to assess pipelines under high-pressure hydrogen
infrastructure. The results of the assessments can be used to environments without modifications or calibration. This is
determine the new operating conditions, which could include an area of current research both in DNV and international
one or a combination of the following: research institutes (The European Gas Research Group,
European Pipeline Research Group).
6
R. Dinata, S. Finneran, N. G. Thompson; EPRI Report 300202505: Transitioning Line Pipe to Hydrogen Service – Integrity Management;
Report #: 3002025050, Oct 31, 2022
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
The transport capacity of a transmission system will change if When considering the conversion of an existing pipeline to
the gas composition is changed. The energy content of 1m3 hydrogen service, operators need to consider the business
of hydrogen at pressures relevant for pipeline transportation case justifying the conversion. This includes factors such
is roughly one third of the energy content of 1m3 natural gas as the demand for energy capacity from end users, supply
at equivalent pressure. This implies that to transport an equal availability, determination of an acceptable conversion cost
amount of energy, the velocity of pure hydrogen would need compared to a new-build option (or alternative transportation
to be three times that of natural gas. method), the consequences for end users, the required
pipeline life, and the availability of state support or funding.
When converting an existing natural gas system to hydrogen,
there are typically three scenarios:
Confirming operating conditions
• Equal maximum velocity – most conservative option
sticking to maximum design velocities Based on the MAOP calculations and capacity assessment,
• Equal pipeline capacity or equal pressure loss operators should define optimal operating conditions,
• Equal energy flow – the velocity of pure hydrogen considering the pipeline condition and operating scenario
would need to be three times that of natural gas. — see three scenarios set out in the section above. Operators
should then compare the pipeline capacity with the
Operators need to calculate and evaluate these scenarios to requirements of the business case, to determine if conversion
determine the most optimum one – considering all pipeline is economically viable or if a modified strategy is needed.
limitations. Figure 6 depicts the pipeline capacity for these
three main scenarios.
Identifying gaps
Percentage of hydrogen
PERCENTAGE OF HYDROGEN
Eqenergy
Eqenergy Eqcapacity
Eqcapacity Eqvelocity
Eqvelocity
Determining pipeline feasibility and recommended
mitigation actions
Source: Hydrogen Network Readiness, DNV, Pipeline Technology Conference (PTC) 20217
7
Hydrogen Network Readiness, Pipeline Technology Conference (PTC) 2021, DNV, V Monsma, H. Riezebos
https://www.pipeline-conference.com/abstracts/hydrogen-network-readiness
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
Here we present five projects in which DNV is supporting network operators to assess the suitability of their infrastructure
for hydrogen – readying operators to keep pace with the energy transition and accelerate the supply of low-carbon gas
to their customers.
As a Central European gas transmission system operator, NET4GAS is an important player in the European
gas market and is one of the sponsors of the “European Hydrogen Backbone” initiative. As part of the
initiative, NET4GAS is mapping its existing infrastructure and its preparedness for the transmission of pure
hydrogen and various hydrogen blends with natural gas.
NET4GAS contracted DNV to evaluate the hydrogen suitability of an existing DN 1400 pressure natural gas transmission pipeline and
related stations8, 9 – drawing on DNV’s technical knowledge and gas network understanding to provide a tailor-made solution.
DNV is investigating different scenarios for mixtures of hydrogen and natural gas, from 2% up to 100% hydrogen. The assessment includes
integrity aspects as well as safety, metering, operation, and maintenance topics.
Pipeline Infrastructure Limited (PIL) operates a 1,375 km long natural gas transmission pipeline in India,
connecting major domestic supply hubs in India’s east to key demand centers in the west.
The operator is assessing the readiness of its infrastructure to incorporate hydrogen – driven by the ambitions of
India’s National Hydrogen Mission to produce five million tonnes of hydrogen production a year by 203010.
DNV is providing technical advice and support to the operator on the integration of blended hydrogen into their gas
trunkline assets – including transmission pipelines, interconnects and spur lines, compressor, valve, and metering stations
and equipment11.
This includes assessing the technical impacts on gas pipelines of using hydrogen at different blending ratios (5%, 10%, 15%, 50%
and 100%). The assessment covers pipeline integrity and safety, and network operations.
8
DNV to evaluate hydrogen suitability of Czech Republic natural gas pipeline:
https://www.dnv.com/news/dnv-to-evaluate-hydrogen-suitability-of-czech-republic-natural-gas-pipeline-224937
9
V. Monsma, DNV Challenges of converting existing natural gas pipelines to hydrogen service, including high-grade steels. PTC2022
10
National Green Hydrogen Mission, Ministry of New and Renewable Energy, India: https://mnre.gov.in/hydrogen_energy_government_of_india
11
DNV and Pipeline Infrastructure Limited (PIL) collaborate to integrate hydrogen into PIL gas network assets in India:
https://www.dnv.com/news/dnv-and-pipeline-infrastructure-limited-pil-collaborate-to-integrate-hydrogen-into-pil-gas-network-assets-in-india-227964
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Repurposing pipelines for hydrogen: Guiding operators through the re-evaluation process
Technical advisory and testing the suitability of hydrogen blending, for South Korea’s gas network
Korea Gas Corporation (KOGAS) is the world’s largest importer of liquefied natural gas (LNG) and transports the
regasified fuel nationwide through its extensive high-pressure gas pipeline network. The operator has an ambitious
strategy to build hydrogen production capacity and related infrastructure.
DNV is assessing the scope for blending hydrogen with natural gas in KOGAS’ 5,000-kilometre-long domestic
transmission network12.
Assessing the suitability of the Danish gas network for PtX (Power to X) opportunities in line with the EU Green Deal
Energinet is Denmark’s national transmission system operator for electricity and gas. The operator is assessing
its infrastructure in the context of the European Green Deal strategy for decarbonization. The operator is eyeing
significant upside for Denmark’s PtX producers and clusters of off-takers, if large parts of the gas network can
be repurposed and possibly extended with new infrastructure to the likes of hydrogen.
DNV is supporting Energinet using its Repurposing Pipelines for Hydrogen process13. This includes assessing and
advising on pipeline re-qualification, especially in identifying the major risks for project feasibility – as any weaknesses
found could significantly increase the cost of conversion.
Previously, DNV has advised Energinet as part of a conversion study for its Frøslev to Egtved pipeline route, which is part of the Danish
Hydrogen Backbone to set up a connection to Germany for hydrogen export.
FGSZ operates the Hungarian high-pressure natural gas transmission pipeline system, servicing gas distribution
companies, power plants, and large industrial consumers. In the context of the European Green Deal, FGSZ is
examining the possibility to transport hydrogen and hydrogen mixtures in the Hungarian natural gas system.
Towards this aim, DNV is assessing the suitability for FGSZ’s 72 km DN600 high-pressure natural gas pipeline for
transport of hydrogen and hydrogen blends14. This includes different scenarios to assess the implications of exchanging natural gas
with up to 100% gaseous hydrogen.
12
DNV to assess the viability of blending hydrogen into South Korea’s gas transmission network,
https://www.dnv.com/news/dnv-to-assess-the-viability-of-blending-hydrogen-into-south-korea-s-gas-transmission-network-238562
13
DNV will aid Energinet TSO with critical knowledge on PtX (Power to X) and Denmark’s progression with EU’s green deal strategy:
https://www.dnv.com/news/dnv-will-aid-energinet-tso-with-critical-knowledge-on-ptx-power-to-x-and-denmark-s-progression-with-eu-s-green-deal-strategy-227843
14
DNV assesses hydrogen readiness of Hungarian gas pipeline,
https://www.dnv.com/news/dnv-assesses-hydrogen-readiness-of-hungarian-gas-pipeline-216291
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