Virtual failure assessment diagrams for hydrogen transmission pipelines

TL;DR

This paper introduces a mechanistic approach combining advanced modelling techniques to predict failure states of hydrogen pipelines, producing virtual failure assessment diagrams that improve safety evaluations over traditional standards.

Contribution

It develops a novel integrated simulation framework for hydrogen pipeline failure prediction, incorporating residual stresses and weld microstructure effects.

Findings

Simulations accurately predict failure pressures under various conditions.

Mechanistic FADs are more conservative than standard approaches.

Residual stresses and weld microstructure significantly influence failure risk.

Abstract

We combine state-of-the-art thermo-metallurgical welding process modelling with coupled diffusion-elastic-plastic phase field fracture simulations to predict the failure states of hydrogen transport pipelines. This enables quantitatively resolving residual stress states and the role of brittle, hard regions of the weld such as the heat affected zone (HAZ). Failure pressures can be efficiently quantified as a function of asset state (existing defects), materials and weld procedures adopted, and hydrogen purity. Importantly, simulations spanning numerous relevant conditions (defect size and orientations) are used to build \emph{Virtual} Failure Assessment Diagrams (FADs), enabling a straightforward uptake of this mechanistic approach in fitness-for-service assessment. Model predictions are in very good agreement with FAD approaches from the standards but show that the latter are not conservative when resolving the heterogeneous nature of the weld microstructure. Appropriate, \emph{mechanistic} FAD safety factors are established that account for the role of residual stresses and hard, brittle weld regions.