Lowering Costs Of Hydrogen Pipelines Through Use Of Fiber .

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Lowering Costs of Hydrogen Pipelines through Use of FiberReinforced Polymers and Modern SteelsGeorge Rawls1, Joe Ronevich2, Andrew Slifka31. Savannah River National Laboratory 2. Sandia National Laboratory 3. National Institute of Standards and TechnologyFuel Cell Technologies Office WebinarSeptember 27, 2017

Question and Answer Please type your questions to the chat box. Send to: (HOST)2U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE2

Codification of Fiber Reinforced Polymer (FRP) forHigh-Pressure H2 ServiceGeorge Rawls1, Barton Smith21Savannah River National Laboratory2 Oak Ridge National LaboratoryThis work was completed with funding from the U.S. Department of Energy’sOffice of Energy Efficiency and Renewable Energy’s (EERE’s)Fuel Cell Technologies Office (FCTO)

Fiber Reinforced Polymer Hydrogen PipelinesExisting Technology FRP is currently employed in the oil & gas industrySpoolable commercial products up to 8” diameter and 2,500psig rating.Site manufactured products are available up to 12” diameterand 1,000 psig rating.FRP Cross SectionImpact 0.5-mile lengths can be spooled for deliveryto installation sites, reducing installationcost by up to 25%Can be manufactured on-site in lengths of2-3 milesFRP is not susceptible to hydrogenembrittlement.FRP has superior chemical and corrosionresistance.Site Manufactured FRPSpooled FRP InstallationU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE4

Methodology to Enable Use of FRP for H2 Service Approach:– Critically evaluate available FRP product standards through independent testing.– Define necessary changes to FRP product standards to meet the ASME Code requirements.– Build a body of data to support codification in the ASME B31.12 Hydrogen Piping Code.ASME MethodologyDOER&D ProgramData Regression LineLong Term Hydrostatic Pressure95% LowerPredictionLower Prediction LimitService FactorNominal Pressure RatingHydrogen ServicePressureASME B31.12 Code Scope Materials Design Fabrication Examination Testing InspectionFRP Product Methodology5Maximum ServicePressure Hydrogen10,000 HoursDesign LifeU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICETime5

FRP Test Matrix in H2 Service Hydrogen exposure: 1 month and 1 year exposureso 1000 psig at 140F Samples of glass fiber, resin, and HDPE liners Control samples: Air environment 2 FRP Pipe Sections for Hydrostatic Burst 2 FRP Pipe Sections for Radius Bend TestORNL provided testing and evaluationof the exposed samples. The materialshowed no indication of degradationfrom the hydrogen exposure.4-Ft FRP SectionsU.S. DEPARTMENT OF ENERGYCompression TestTensile TestOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE6

Burst Tests of FRP in H2 Service40% ThroughWall FlawsBurst Testing Performedon SamplesWith Engineered Flaws1Burst Pressure le1. Flaws were through 40% of pipe wall thicknessFRP achieves a burst pressure of 4,000 psi (275 bar), even if flaws of detectablelengths are present.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE7

Fatigue Testing of FRP in H2 ServiceLegendR 0.1R 0.3R 0.5R ��𝑚𝑚𝑚𝑚𝑚𝑚Primary Design Fatigue Curve1101001,00010,000100,000Notes:1. Single cycle test represents burst test data2. 750 psig fatigue test was terminated at 54,160 cycles without a structural failure3. The fatigue tests for R 0.3 failed at 53020 cycles. The fatigue tests for R 0.5 failed at 100,000 cycles.Service pressure of FRP guides fatigue life.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE8

Design Life Assessment of FRP in H2 ServiceExpected Cycling Due toMaintenance in Pipeline SystemExperimentation on Glass Composite Rupture StressesYears of ServiceFatigue Cycles1112-2420240-48050600-1200Expected Cycling to SupplyHydrogen Fueling StationsCurrent data supports FRP design life of 50 years,with a 5% decrease in fiber stress and a limit onfatigue life of 28,500 cycles at an R ratio of 0.5.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYYears of ServiceFatigue Cycles21365 - 730207,300 - 14,6005018,250 - 36,5001. Assuming 1-2 cycles/month2. Assuming 1-2 cycles/dayFUEL CELL TECHNOLOGIES OFFICE9

FRP Connectors Connectors are metallic with elastomer O-ring seals: Internal diameter of polyethylene liner is machined to a specified diameter. Machined portion of liner is where O-rings in the metallic connector interface withcomposite piping to form fluid seal. Outer nut of the connector is tightened, mechanically compressing ferrules on thepiping, resulting in compression of the edPortionOf CouplingIllustration of O-Ring Extrusion Failures fromFatigue Extrusion failures were resolved by choosing O-rings with greater hardness level,approximately 75 durometer M. ASME pipeline operators expressed concern over the potential maintenance requirementsof mechanical joints.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE10

FRP for H2 Delivery- Code Case Approval ASME B31.12 Codification Approval ProcessB31.12 Code CommitteeB31 Standards CommitteeBoard on Pressure TechnologyB31 Case 200 ASME B31.12 Hydrogen PipingApproval Date: October 31, 2016Composite Piping for Hydrogen ServiceU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE11

For the first time, FRP can nowbe used in high-pressure H2service.“Spoolable FRP has been established as a proven, reliable, cost effective pipeline solution in theoil and gas industry and now with the research conducted through the Hydrogen Delivery Projectand subsequent codification by ASME, the benefits of the technology can be realized for highpressure Hydrogen applications. I'm excited to see acceptance of FRP technology expand as newresearch demonstrates the capabilities of these products. FRP technology offers corrosion freealternative with improved safety and ease of installation. Under the leadership of DOE andteamwork from project participants, I look forward to future research and the next newapplications for FRP technology."– Chris Makselon, Vice President of Sales, North America, NOV Completion & ProductionSolutionsU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE12

Assessment of Hydrogen Assisted Fatigue in SteelPipelinesJoe Ronevich1, Chris San Marchi1, Brian Somerday2, Andy Slifka3, Liz Drexler3,Robert Amaro4Sandia National Laboratories2 Southwest Research Institute (Somerday formerly at SNL)3 NIST4 University of Alabama1This work was completed with funding from the U.S. Department of Energy’sOffice of Energy Efficiency and Renewable Energy’s (EERE’s)Fuel Cell Technologies Office (FCTO)andthe U.S. Department of Transportation

Steel Hydrogen PipelinesExisting Technology 1,600 miles of steel H2 pipeline in service today, for petrochemical industryPipelines are most efficient method to deliver 1,000s of kilograms of H2 long term.H2 pipelines today are not commonly cycled in service (i.e. “fatigue”)Pipelines are designed per ASME B31.12 Code for Hydrogen Piping and Pipelines H2 embrittlement is seen as a risk to pipeline reliability. Pipelines are designed with thicker walls tomanage this risk.A. Elgowainy, ANLU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE14

Impact: Use of High-Strength Steels to Lower Pipeline CostsCost of Steel /08/f25/fcto myrdd delivery.pdf Higher strength pipes can enable both higher pressures and lower costs However, design codes (ASME B31.12) place penalties (increased thicknessrequirements) on use of higher strength pipes in H2, restricting cost savingsUsing X70 (instead of X52) can result in 31% cost reduction for 24”pipe operated at 103 bar (1500 psi)2.1.2.Based on 30 years of data on the costs of natural gas pipelines, excl. gj-data-to-developcost-equations.htmlFekete et al. 2015 (Int. J of Hydrogen Energy)U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE15

Background: Hydrogen Assisted Fatigueda/dN (crack growth rate) Fatigue: Loading of pipe caused by fluctuations in operatingpressurePH2PH2 K (stress intensity factor range)Crack growth under fatigue loading can be overan order of magnitude faster in H2 Service(i.e. hydrogen assisted fatigue crack growth;HA-FCG)HA-FCG does not preclude material from use but necessitatesproper design.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE16

Background: Current H2 Pipeline Design Codes ASME B31.8 Natural Gas pipeline thicknessF design factor 0.72 (Class 1) ASME B31.12 Hydrogen pipeline thickness Prescriptive Design MethodP design pressure 3ksi (21 MPa)S specified min yield stresst thicknessD outside diameter 24 in (610mm)E longitudinal joint factor 1T temp derating factor 1F design factor 0.5 (Class 1)HF Materials Performance FactorCurrent Design codes (ASME B31.12) apply thickness premiums tohigher strength H2 pipelines.Research Question: Is this premium necessary?U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE17

Background: Measurements of Fatigue InstrumentationASTM E647Compact Tension(C(T))ESE(T).loadH2H2 H2H2 H2H2HHHH2a.– Internal load cell in feedback loop– Crack-opening displacementmeasured internally using LVDT orclip gauge– Crack length calculated fromcompliance Mechanical loading– Triangular load-cycle waveform– Constant load amplitudefrequency 1Hz Environment– Supply gas: 99.9999% H2– Pressure 21 MPa (3 ksi)– Room temperatureU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE18

Results: Steels of Varying Strengths Tested in Fatigue in H2-2Fatigue crack growth rate (mm/cycle)10 -310Good agreement between SNLand NIST data All pipeline fatigue data fallwithin similar bandIn H2 gas -410X100BX70AX70BX52 VintageX52 NewX80X60X65 airX65X100AB31.12-510In Air @ 10 Hz-610Tests at 21 MPa or 34 MpaR 0.5 Freq 1 Hz-71056 7 8 91020 K (MPa m1/2)30Strengths of Steels Tested:358 to 689 MPa (SMYS1)NIST data2SNL data240 501.2.Specified Minimum Yield StrengthOnly represents small fraction ofpipeline data generatedFatigue performance does NOT appear to depend solely on strengthU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE19

Impact: ASME B31.12 Code Modified to Permit HigherStrength Steels Without Thickness PremiumUnder New Performance Based Design Method: In lieu of measuring FCGR, the following equation may be used for fatigueanalysis:Where: a1,b1 constantsB31.12 FCGR eqn Permits use of pipes up to SMYS of 70 ksi(e.g. X70) with no thickness penalty Reduces test burden Applicable for P 3000 psi (21 MPa)Additionally, higher strength pipes (X100) haverecently demonstrated similar behavior to B31.12FCGR curve Potential future inclusion in code.Modification enables reduction in cost of H2 steel pipe by up to 30% byreducing quantity of steel used, welding, and use of heavy machinery.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE20

Future Work: Greater cost savings across applications ofsteel in hydrogen service through fundamental R&DHow do we attain acceptance of novel steels? By characterizing behavior of pipes / weld /HAZX100 By decoupling residual stresseffects, particularly in weldsBy understanding relationships betweenmicrostructure and fatigue crack growth ratesFundamental understanding of strength, residual stress, and microstructure effectson FCGR improved predictive models of steel performanceU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE21

Physics-based Modeling of Pipeline SteelsJoe Ronevich1, Chris San Marchi1, Brian Somerday2, Andy Slifka3, Liz Drexler3,Robert Amaro4Sandia National Laboratories2 Southwest Research Institute (Somerday formerly at SNL)3 NIST4 University of Alabama1This work was completed with funding from the U.S. Department of Energy’sOffice of Energy Efficiency and Renewable Energy’s (EERE’s)Fuel Cell Technologies Office (FCTO) and the U.S. Department of Transportation

Background: H2 EmbrittlementMechanisms: Hydrogen induced decohesion: H2 inlattice and at internal interfaces lowerssteel cohesive strength Hydrogen-Enhanced Localized Plasticity(HELP): H2 affects plastic flow Hydride Formation– Highly brittle hydride precipitatesresults in a low energy fracture pathBrittle fracture associated withintergranular cracking [1][1] Novak, P., et al. "A statistical, physical-based, micro-mechanical model ofhydrogen-induced intergranular fracture in steel." Journal of the Mechanicsand Physics of Solids 58.2 (2010): 206-226.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE23

Background: HA-FCG Modeling Physics Hydrogen transport– Diffusion of lattice (HL) and trapped (HT)hydrogen- Focus on HL– Microstructural constituent specificdiffusion (DF, DP) Decohesion between grains HL– Hydrogen enhanced decohesion (D)Damage causing ductile crack growth– fun(D, HL, HT,DFHL𝜀𝜀 𝑃𝑃𝑃𝑃 ) Grain specific orientations andconstitutive models– Rotate constitutive tensor to be inlinewith grain crystal structure– Elastic-plastic model for eachmicrostructural constituent of interest.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYHLHTHLDPHTHTX52 simulation domainFUEL CELL TECHNOLOGIES OFFICE24

Models Developed to Couple Effects of Mechanical Loadingand Hydrogen Constitutive model– J2 Isotropic plasticity criterion used Hydrogen diffusion model– Implemented user defined material(UMAT) in ABAQUSJ2 plasticity Theoryda/dN (mm/cycle)0.1Abaqus model of H2concentration at crack tipU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY0.010.0010.00010.000016.89 MPaPrediction- 6.89 MPa0.000001550ΔK(MPa-m1/2)Models calibrated to X100 steelFUEL CELL TECHNOLOGIES OFFICE25

Model Extended to Real-World Steel GeometriesDepth of Initial Defect (% of wall thickness)Depthof Initial Defect (% of wall thickness) Calibrated to ExperimentalData from 4130 Alloy PressureVessels12020Predicted Cycles to Failure4130 T1 GeometryExperimental (Failed)15154130 T1 GeometryExperimental (Not Failed)Life Prediction Bound U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYSimulation of H2 concentrationaround a thumbnail crack in apressure vessel1. Data obtained from Sandia National LaboratoriesFUEL CELL TECHNOLOGIES OFFICE26

Finite Element Modeling of Deformation and H2 Diffusion Deformation and diffusion modelhas been implemented in ABAQUS– “Coarsely” calibrated using literaturedata– Being expanded to be capable ofsimulating effects of cyclic plasticity(shake-down, ratchetting,kinematic/isotropic hardening, etc.)– Applying effective diffusivity valuesfrom literature to inform predictions– Tessellating microstructure by use ofNEPER software to simulate grainswithin the materialU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYMicrostructural meshingFUEL CELL TECHNOLOGIES OFFICE27

Strain-Life Model Being Developed Creating a strain-life damage understanding in order toincorporate all sources of “damage energy,” (e.g. residualstresses, hydrogen-dislocation interactions). Focusing on X100 pipeline steel– Fully reversed strain-controlled teststo characterize: Stabilized hysteresis loop Stabilized stress-strain response– Strain-life characterized in air and H2– Separated effects of elastic andplastic strainshttp://wolfweb.unr.edu/homepage/yjiang/jixi zhang.htmlby gaseoushydrogen in metals." International Journal of Fatigue 68 (2014): 56-66.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE28

Damage Laws and Hydrogen Coverage Determine “Damage” laws toestimate:Cohesive law dependent onthe hydrogen coverage– Grain boundary decohesion– Lattice separation (crack growth)– Effects of hydrogen coverage Implement “Damage” laws inABAQUS through a cohesiveelements and a cohesive zone lawIncreasinghydrogencoverage θ[1] Moriconi, C., G. Hénaff, and D. Halm. "Cohesive zone modeling of fatigue crackpropagation assisted by gaseous hydrogen in metals." International Journal of Fatigue 68(2014): 56-66.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE29

ConclusionPhysics-based models of hydrogen embrittlement are in earlystages of development. These models will ultimately: Expedite the development of novel materials for hydrogenservice Expand the service conditions in which existing materialscan be used Lower costs and enhance reliability of hydrogen equipmentU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE30

Materials R&D funded by the U.S. Department of Energy’s FuelCell Technologies Office and the U.S. Department ofTransportation has:1. Enabled FRP to be used in high-pressure H2 service for thefirst time, lowering pipeline installation costs (materials andlabor) by 25%.2. Removed thickness premiums from steels used in highpressure H2 service, lowering steel pipeline installation costsby up to 30%.3. Initiated development of physics-based models of hydrogeneffects in steel.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE31

Question and Answer Please type your questions to the chat box. Send to: (HOST)32U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE32

Thank youNeha RustagiNeha.Rustagi@ee.doe.govEric lcells.energy.govU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYFUEL CELL TECHNOLOGIES OFFICE33

ASME B31.12 Codification Approval Process B31.12 Code Committee B31 Standards Committee . Board on Pressure Technology . B31 Case 200 ASME B31.12 Hydrogen Piping Approval Date:

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