Inline Monitoring of Hydrogen Blends and Automated Pipe Leakage Detection
- Creare LLC
Need. Blending hydrogen into the existing natural gas infrastructure has national and regional benefits for energy storage, grid resiliency, and emissions reductions. However, the introduction of hydrogen as a consumer fuel has caused heightened concern over its safety. As hydrogen concentration in the pipeline increases, development of hydrogen monitoring, leak detection, and repair tools has become increasingly important. The sensor must operate in a hydrogen blended natural gas (0–20% hydrogen), in a 50–140°F environment, and over a broad pressure range (0.1–1,500 psi). Results. In the Phase I program, we focused on a multi-modal approach to detect hydrogen leaks from natural gas blended fuels. Our approach includes (1) a custom ultrasonic monitor that detects ultrasound waves produced by turbulent flow associated with gas leaks and (2) a high-accuracy hydrogen gas sensor that monitors concentration along the pipeline to assess whether hydrogen leakage is occurring. By combing two approaches, we effectively increase probability of detection. Leak detection was demonstrated in both air and helium gases (hydrogen surrogate) over a range of pressures and simulated defect sizes. Signal post-processing methodology was developed to maximize reliability of detecting the leak. We also outlined a Phase II approach that completes robot and sensor development into a prototype and characterizes performance at ULC’s laboratory. The robot will be designed to detect leaks in hydrogen-blended natural gas pipelines and conduct in-situ repairs. Accurate hydrogen concentration measurement was demonstrated for hydrogen-blended natural gas over a range of hydrogen concentrations (0–45%), pressures (0–400 psi), and temperatures (70–150°F). Sensitivity of hydrogen concentration measurement is roughly 0.25%. To enable concentration-based leak detection, we have outlined a Phase II approach to increase sensitivity down to the ppm level. Commercial Applications/Benefits. Our accurate and fieldable hydrogen concentration monitoring and leak detection sensors are being developed to assist with integrity management of the pipeline infrastructure for methane-hydrogen blended fuels. The goal is to prevent emissions that occur from leaks in gas transmission and distribution pipes while improving safety for people and property in the vicinity of these leaks. We are targeting two unique applications with our collaborators at ULC. The first application integrates hydrogen concentration monitoring and leak detection sensors onto ULC’s robotic platform. Once developed, ULC will offer a new service in the market to allow operators to quickly detect and repair leaks in their pipelines primarily in difficult-to-access locations such as at crossings (highways, bridges, railways, waterways). The service would be provided by ULC’s field services team who would transport the robot to the pipeline operator’s site and launch the robot into the live natural gas pipe for quick leak detection and repair. Operators such as National Grid will not allow field crew to access and repair pipes due to hazards associated with hydrogen. The proposed robotic system will become ever-increasingly important for performing leak detection, inspection, and repair tasks. The second application targets pipelines that are readily accessible by pipeline operators. Here, we are integrating the hydrogen concentration monitor into a nodal network, enabling dense, continuous monitoring of pipelines with LTE/satellite-based interconnectivity. Unlike competing technologies, this approach is truly viable; it is relatively low cost and does not require operator feedback. We estimate the cost of this sensing package at below $2,000 for low rate initial production, whereas competing technologies could approach $100,000. In addition to pipeline gas concentration monitoring, there are abundant commercial applications including industrial chemical processes, refineries, fuel cell reformers, fuel cell electric vehicles, and for measuring gas concentration in hydrogen-blended natural gas power plants.
- Research Organization:
- Creare LLC
- Sponsoring Organization:
- USDOE Office of Science (SC)
- DOE Contract Number:
- SC0021880
- OSTI ID:
- 1859705
- Type / Phase:
- STTR (Phase I)
- Report Number(s):
- TM-4857
- Country of Publication:
- United States
- Language:
- English
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