Sandia National Labs Research on Effects of Hydrogen in Pipelines

Sandia National Laboratories ItFCHydrogen andFuelCellsProgram
Hydrogen Effects on Pipeline Steels and
Blending into Natural Gas
Joe Ronevich and Chris San Marchi
Sandia National Laboratories, Livermore, CA
American Gas Association
Sustainable Growth Committee
November691,2019
1
Sandia National Laboratories is a multimission laboratory managed and operated by National Technology and Engineering Solutions
ofSandia,LLC.,a wholly owned subsidiary of Honeywell International, Inc.,for the U.S. Departmentof Energy's National Nuclear
Security Administration under contract DE-NA-0003525
SAND2019-12737PE

Hydrogen embrittlement occurs in materials under the
influence ofstress in hydrogen environments
Environment
Materials
Stress/
Mechanics
H
Hydrogen
embrittlement
also called
hydrogen-assisted *s
ilt
fatigue and fracture '
t
Bulk
interactions
40
0
Surface

interactions

H
/ NA H
H
i
I
4
,
Hydrogen-assisted
fracture
AZ`
•2
4
Hy
Hydrogen dissociates on metal surfaces,dissolves into the metal
lattice, and changes the mechanical response ofthe metal

Sandia National Laboratories ri1
2
1
-111-
Hydrogen Embrittlement=
Hydrogen Accelerated Fatigue Crack Growth(HA-FCG)
Pressure fluctuations can result in fatigue loading ofthe pipe
kA`.
73°°
0 pJR
-0
-
0 AK(stress intensityfactor range)
Fatigue crack growth rates can
increase by over an order of
magnitude in pipeline steels
HA-FCG does not preclude material from usage but
necessitates proper design

W'
Fracture mechanics-based assessment of
fatigue and fracture of pipelines
A
/
Rupture
determined by
fracture
resistance
i _____
Evolution of
flaw size
. determined by
Number of pressure cycles, N Nc fatigue crack
growth
ASME B31.12 describes rules for hydrogen pipelines with
reference to ASME BPVC Section VIII, Division 3,Article KD-10

Various pipeline steels tend to show very similar
fatigue crack growth rates in gaseous hydrogen
10-1(
5 6 7 8 910 20 30 40 50
AK(MPa m112
)
X1OM
tA4)
AER
ale
111
R = 0.5
r•
1
6
9
.
:
dri#
•
o
•••
0
1.
• X100A(21 MPa)
• ](100A(air)
• X65(alr)
• X65(21MPa)
D X80(21MPa)
x X60(21MPa)
+ X10013(21MPa)
▪ X70A(34MPa)
•X70B(34MPa)
•X52Vintage(34MPa)
▪ X52Modern(34MPa)
• A wide variety of
pipeline steels display
nominally the same
fatigue response in
high-pressure gaseous
hydrogen
• The effect of pressure
on fatigue crack growth
rates is modestfor high-
pressure hydrogen
•2`
HH y
S
0
H 54,
HH
HH HH
HH

Welds in pipelines tend to show similarfatigue crack
growth rates as the base metals in hydrogen
Crack
growth
rate,
da/dN
(mm/cycle)
10-2
1o3
1o4
1o5
10-6
X65 GMAW X52 Vintage
- GW(34 MPa)
0,
lao
Pipeline Steels
21 MPa H2
f = 1 Hz -
R = 0.5
295 K
5 6 7 8 910 20 30 40 50
AK(MPa m112)
From: Ronevich et al, Int J. ofHydrogen Energy,2017
To first order,welds
behave similarly in
gaseous hydrogen as
the base metals
Similar trends have been
observed for a variety of
weld processes
R
L
/*.
Heat Affected Zone
(HAZ)
Base Metal
(BM)
Weld Fusion Zone
(WFZ)
— Weld Passes
10 mm

Sandia National Laboratories ItFCHydrogenandFuelCellsProgram
imik
TYlpeline steels have relatively high fracture
resistance in gaseous hydrogen
120
100
a_
2
z
0 60
(7)
2 40I-
cy
C.)
El 20
u_
80
0
0
—A— X60
X80-B
—
0
— X80-E
X80-F
Grade B(as rolled)
Grade B(normalized)
20
I I
40 60
Minimum fracture
resistance per
ASME B31.12
80 100
Hydrogen test pressure (MPa)
Data sets that evaluate
effect of pressure on
fracture are relatively
limited
4 Available data suggest
fracture depends on
pressure
Fracture resistance
(even at low pressure)
is significantly lower
than in air
From: San Marchi et al,ASME PVP-2011 conf.

Growing interest in using hydrogen blends in natural gas
to reduce carbon emissions
4 Power-to-gas(P2G)using excess renewable
electricity to produce hydrogen and inject into
pipeline
H20
Renewable
Electricity
(4)
EU Hydrogen Limits for Injection into the HP Gas Grid
Covered by a range of local Iaws and EU Directives
E.:A)urn
UK +
1
Switzerla
Austfla
III Fr2nc?
d
lirnitfalls to2% ifthere is a
CNG station dovmstrearn
Germany
0% 1% 2% 3% 4% 6% 6h 7% 8% 9% 10% 11%
Hollard
Volume/Molar
12%
Percent
1 1 1
0% 02% 04% 06% 08%3 1 0% 1 2% 1 4% 1 6% 1 8%
Zero emission
h dro en
Electrolyzer
No harmonization of
allowable hydrogen
concentration in natural
gas
MassPercert
1%
Ref: George Minter, SoCal Gas
"New Natural Gas Pathwaysfor
California: Decarbonizing the
Pipeline" Presentation 2014.
Ref:SoCal Gas,"Hydrogen:
Market Fundamentals,Trends
and Opportunities",California
Hydrogen Business Council,
December 11,2018.

Many demonstration projects are being performed around the world
France — Dunkirk6% up to 20% H2 into buses and 200 residential homes
Italy — Snam 5% H2 into gas transmission network
UK — H21 Leeds CityGate Project — converting existing NG network to 100% H2
UK — HyDeploy at Keele University(up to 20% H2 blend)
US — SoCalGas/ UC Irvine — blending H2 from excess renewable electricity to campus pipeline
Germany — Trial of 170 customers supplied with up to 10% H2 blend by E.ON Technologies
Netherlands — up to 20% H2 blend injected in Amerland
Many references point to results from
NaturalHy report,2010
9
SES6/CT/2004/502661
NATURALHY
•-Prepanng for the hydrogen economy by hung the extstmg natutal gas system as a catalyst..
Integrated Protect
6.I.ii Call I Sustainable Energy Systems
https://www.engie.com/en/businesses/gas/hydrogen/power-to-gas/the-grhyd-
demonstration-project/
https://www.azernews.az/region/148145.html
https://www.northerngasnetworks.co.uk/wp-content/uploads/2017/04/H21-Report-Interactive-PDF-July-2016.compressed.pdf
https://www.elp.com/articles/2016/12/socalgas-uc-irvine-test-hydrogen-energy-technology-to-store-renewable-energy.html

So how much hydrogen is allowed in natural gas?
A)2%?
B)5%?
C)10%?
D)It depends on your operating conditions and
your definition ofthe word "allowed".
Often times these values(2,5,10% H2
)are based on
performance of burners, not measurements of
material compatibility with hydrogen

Sandia National Laboratories iSFL
Relative
fracture
resistance
Low pressure H2 has substantial effect on
fracture resistance of pipeline steels
1.2
1
0.8
0.6
0.4
0.2
0
cI
z
I I I
X70 -
(12.3 psi)
PH2 = 0.85 bar (123 psi)
(1,232 psi)
PH2 = 8.5 bar
PH2 = 85 bar _
C C
0 o
Measurements of
fracture resistance in
gaseous mixtures of
H2 and N2show
substantial effects of H2
1% H2 is only modestly
different than 100% H2
<1 bar of H2 reduces
fracture resistance
From: Briottet et al,ASME PVP-2018 conf.
0

da/(1
/
mm/cycle
Low pressure H2 has sub;tantial effect on fatigue
crack growth of pipeline steels
0.1
0.01
1E-3
1 E-4
1E-5
30
: 12 MPa total pressure
F te*
40.4.
4
:
:AZ
.
:
A AA4
X80
R = 0.1
- 1 Hz
A
AA AAA AA
N2 5vol%H2
• 10vol% H2 * 20vol% H,
• 50vol% H,
40 50
AK TNIPa rn"
From: Meng et al, IJ Hydrogen Energy42
(2017)7404.
60 70 80
Measurements in gaseous
mixtures of H2 and N2
show acceleration of
fatigue crack growth rate
with 5% H2
But little additional
acceleration with higher
H2 content
Small amounts of hydrogen
can have substantial effect
on fatigue and fracture

13
In lower AK range,lower pressures still exhibit
sizeable increases in FCGR
, 1
: C-Mn Steels
- R=0.5
o
X100
SA516 Gr.70
0 105 MPa
o 21 MPa
O 5.5 MPa
• Air
o 2.8 MPa(R=0.2) -
• 2.8 MPa(R*=0.5)
5 6 7 8 910 20
AK(MPa m112
)
30 40 50
SNL data(taken from
various published and
unpublished sources)
Pressures ranging from 15,000 psi to 400 psi H2 still
exhibit accelerated fatigue crack growth rates

Impurities can influence measurements, but can also
provide pathways to mitigate the effects of H2
10-2 =
X52 Base Metal
21 MPa H2
f=10 Hz
R=0.1
295 K
-,
- air
R=0.1 and 0.5
f=10 Hz
From:Somerday et al, Acta
Mater61 (2013)6153.
o -1 ppm 0
2
o 10 ppm 02
El 100 ppm 02
A 1000 ppm 0
2
5
1
10 20
Stress intensity factor range, AK (MPa m1/2)
50
Oxygen mitigates H2-
accelerated fatigue
crack growth rates at
low AK
Attributed to oxygen
diffusion to new
crack surfaces
Natural gas may have
sufficient0
2to
mitigate hydrogen
(0.1% = 1000 ppm 0
2
)
Impurity content in H2can have substantial effects
on both measurements and in-service performance

--P—
The role of mixed hydrogen gas environments
and impurities should be considered carefully
Small partial pressure of gaseous H2 can have substantial
effects on fracture and fatigue ofsteels
Oxygen can mitigate effects of H2 in ferritic steels
Sensitive to mechanical and environmental variables
Other passivating species can have similar effects
Structural integrity of pipelines carrying mixed gases will
depend sensitively on the details
NG has many impurities, which can mitigate H2 effects
Pure methane is inert and even small additions of H2 can be
significant
Materials compatibility for hydrogen containment structures
depends on the application and the design

Lre
jSandia National Laboratories ItFCHydrogen andFuelCellsProgram
OIL
—
Summary
w
What is hydrogen embrittlement and when is it important?
_
Hydrogen degrades mechanicalproperties ofmost metals
How does gaseous hydrogen affectfatigue and fracture of
pipeline steels?
Fatigue is accelerated by >30x and fracture resistance is
reduced by >50%
Is there a threshold below which hydrogen effects can be
ignored?
NO,even smallamounts ofhydrogen have large effects
Can the effects of hydrogen be masked by other physics?
Oxygen can mitigate the effects ofhydrogen in some cases,
which perhaps can be exploited

Sandia National Laboratories tFCHydrogen andFuelCellsProgram
Back up Slides

Sandia National Laboratories
The effects of H2 on fatigue crack growth in steels
can be captured with "master" design curve
10-2 •
R=0.5
- f =1 Hz
AA 21 MPa H
A.•
t#
A
'
-
'AA
A
A
A
HH
HH HH
• X52
• X60
• X65
• X80-B
• X100A
A X100B
10-6
5 6 7 8 9 10 20 30 40 50
AK(MPa m112
)
• Tested steels represent:
Wide range ofstrength
Wide range of
microstructure
• A relatively simple master
curve has been developed
(dashed line) that bounds
fatigue crack growth
performance in gaseous
hydrogen
da [1 + C2Ri mon f
=
dN 1 1 — R Vo)
1/2

Sandia National Laboratories
Consider a typical "high-pressure" pipeline
Material:X70
TS= 586 MPa
YS=500 MPa
a/t=crack depth
a/2c= depth to length ratio
natural crack shape:a/2c= 1/2
ASME crack shape:a/2c= 1/3
OD = 762 mm
t= 15.9 mm
Pmax = 7 MPa.
Pmin =4 MPa
Semi-elliptical crack
thickness(t)
2c =3a
inside surface
A
a
semi-elliptical
19

Stress intensity associated with semi-
elliptical crack in "high-pressure" pipeline
50
,,,-, 40
E
co 30
o_
2
'ctl 20
E
10
0
Minimum KIH -_
(per ASME B31.12)
0 0.2 0.4 0.6 0.8
Crack Depth,a/t
1
Hoop stress atP,,,,,„= 162 MPa
stress ratio: hoop/TS=28%
Driving force on semi-elliptical
crack:
Kir
.<40 MPa n11/2
1)
Typical pipeline material fracture
resistance:
KJH> 75 MPa n11/2
o
Fracture resistance of pipeline
steels in H2 is greater than driving
force on semi-elliptical cracks

Predicted lifetime of pipeline witrgrowing
fatigue cracks in hydrogen
0.8
0.6
cp_
sa)
0 0.4
0
0.2
Time(years)— 2cycles/day
8 16 24 32 40 48 56 64
a/2c =1/3
a/2c =1/2 -
a/2c =1/2
a/2c =1/3
16 1 '
,000 1 ' 1
20,000 30,000 ' 1
46,0'
00 50,000
Number of cycles
Assuming
• Pressure cycles between
4 & 7 MPa
• Constant crack shape(a/2c)
• Large initial defects
• Fatigue crack growth rates in
pure H2(at higher pressure)
Using: a=a,
a=a,+(dcy
dN
) N
• 10,000s of cycles are needed to
extend the crack significantly
• At 2cycles per day,decades are
needed to advance the crack

Residual stresses impactfatigue crack growth
rates in hydrogen as in ambient environments
21 MPa H2]
f= 1 Hz ::
R = 0.5 -
295 K
A Kapp(MPa m112
)
10-2
6 8 10
Alcorr(APa m"
2
)
21 MPa H2 -
R=0.5 E.
Freq = 1 Hz:
30 50
• Residual stresses should be considered for design
• Base metal properties generally represent weld metal
22 From: Ronevich et al, Eng Fract Mech 194

Sandia National Labs Research on Effects of Hydrogen in Pipelines

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