Re-purposing Existing Pipeline

for CO2 Transport

Sharing Ideas Prepared by:

Ir. M.A. Kariem, Ph.D, IPM

Rev. 01, 22-May-23

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 1. BACKGROUND

• Strong interest within the industry to explore the possibility for repurposing
of existing pipeline infrastructure for CO2 transport.
• This may seem attractive from a cost perspective; however, the technical,
safety and financial risks need to be acknowledged and addressed
accordingly.

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 2. APPLICABLE CODES, STANDARDS, RECOMMENDED PRACTICES
ASME B31.4 Chapter X (2019)
Carbon Dioxide Pipeline System

• DNV-RP-J201 (First Ed. 2010)

Qualification procedures for carbon dioxide capture technology
• DNV-RP-F104 (First Ed. 2010)
Design and operation of carbon dioxide pipelines
• DNV-RP-J203 (First Ed. 2017)
Geological storage of carbon dioxide

• ISO 27919-1 (First Ed. 2018)

Carbon dioxide capture – Performance evaluation methods for post-
combustion CO2 capture integrated with power plant
• ISO 27913 (First Ed. 2016)
Carbon dioxide capture, transportation and geological storage – Pipeline
transportation system
• ISO 27914 (First Ed. 2017)
Carbon dioxide capture, transportation and geological storage – Geological
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 3. KEY CONSIDERATION OF REPURPOSE A PIPELINE SYSTEM
FOR CO2 TRANSPORT
• Min 95% CO2 in composition, 5% hydrocarbons, nitrogen, and other non-
condensable and with trace of sulfur, oxygen, glycols and water.

1. Related to internal corrosion

• Corrosion rates and possibly the impact on fracture control evaluations
are strongly affected by the type of impurities, combination of
impurities and concentration of impurities.
• Risk of internal corrosion for C-Mn steel due to high corrosion rates
caused by CO2.
• O2 and H2S in the composition also need to be considered.

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 2. Related to material high toughness requirement
• Pipe could have sufficient toughness to arrest a running ductile
fracture when operated in dense phase, which is also affected b the
composition of CO2 and the material properties of the pipeline.
• CNV energy  300 J.
• Small leaks could lead to more severe cooling ➔ risk of brittle fracture.

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 4. HOW TO SAFELY REPURPOSE A PIPELINE SYSTEM FOR CO2
TRANSPORT?

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 5. REQUALIFICATION PROCESS
Re-qualification shall comply with the same
Initiate
requirements regarding safety and operation as for a
(1)
pipeline designed specifically for transportation of CO2.

Integrity Assessment Hydraulic analyses Safety Evaluation

(Diagnostic) and flow assurance (4)
(2) (3)

Define CO2 Transport

Premises
(5)

A
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 A

Reassessment Yes No STOP

Modifications
(Prognostic) CO2 Transport not
feasible?
(6) feasible

Integrity No Identify modifications

acceptable? (7)

Yes

Document Implement
(8) (9)

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 STEP 1 - INITIATION
Establishment of key information:
• Original design basis, Gap analysis
• any later modifications, CO2 Transport
• operation parameters, requirements
• operational history and
• Key elements within battery limits Base:
1. Capacity
• Material selections 2. Delivery pressure
• Pressure rating, etc. 3. CO2 state and compositions

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 STEP 2 – INTEGRITY ASSESSMENT
• The current integrity of the pipeline system shall be addressed through
assessment of the technical condition
• Historical operation information should be assessed
• Identification of material selections as well as the pressure rating shall be
screened for integrity assessment

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 STEP 3 – HYDRAULIC ANALYSIS AND FLOW ASSURANCE
Flow analysis should be
performed to identify feasibility
of transport capacity and
80 – 100 bara
(1160 – 1450 psia) corresponding pressure and
temperature distribution along
the route.
• Offshore pipeline: pressure
rating > 100 bar ➔ liquid
CO2
• Onshore pipeline: pressure
rating < 80 bar ➔ two-
phase flow ➔ hydraulic
analysis required.
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 • Flow assurance: one key concern is to ensure sufficient control on product
water content to prevent drop-out free water ➔ corrosion risk
• Water solubility varies significantly liquid and gas phase and may also be
affected by the presence of other impurities in the product.
• Thermo-hydraulic analysis ➔ temperature and pressure profiles along the
route.
• Simulations: design cases, normal operation, turn-down cases (s), line-
packing, shut-down and re-start.
• Pipeline depressurization (rate event) should also be simulation to
document that the pipeline can be safely depressurized within reasonable
time and within the specified design conditions such as minimum design
temperature.
• Any ‘one-way’ equipment or functions need to be identified and assessed.
• Booster or pressure reductions stations ➔ bypassed or reconfigured.
• Non-return valves ➔ removed or locked open.
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 STEP 4 – SAFETY EVALUATION
• Pipeline system should be evaluated toward the specific safety
requirement for CO2 pipeline.
• Need for modification should be identified and evaluated, e.g. additional
block valves, upgrade of leak detection system, etc.
• Valves and gaskets not suitable for CO2 should be evaluated and replaced.
• Attention to accidental release scenarios, and the effects on consequence
radius.

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 STEP 5 – DEFINE CO2 TRANSPORT PREMISES
Premises for CO2 transport should be defined incorporating the results from
the hydraulic analysis (3) as well as safety evaluation (4). This aspects will
define functional as well as system requirements, include stating
design/incidental pressure, receiving pressure, etc.

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 STEP 6 – REASSESSMENT
• Based on the input from the integrity assessment (2) and the CO2
transport premises (5), the integrity should be evaluated.
• Part of the system not to be compliant ➔ modifications.
• Assessment of additional failure mechanisms. Key areas to be
addressed:
o Compliance with existing material properties. Blow down & by-pass
(during extreme low temperature)
o Load conditions: compare original design code and with specific
requirements
o Change in the operational condition
• Risk register: appropriately addressed in relevant management and
replacement plans for the pipeline
• Gap-analysis: original vs new design standards.

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 Key material aspects for pipeline systems
Steel materials:
increase degradation due to:
• Internal corrosion in presence of water
• Embrittlement in case of CO2 composition with certain impurities, e.g. H2S
• Embrittlement in case of low steel temperatures in relation to small leaks.
Increase requirements to material properties (toughness) to arrest running
fracture.
Non-metallic materials:
Dense phase CO2 behaves as solvents to certain non-metallic materials such as
elastomer seals and gaskets. Swelling and explosive decompression damage
needs to be considered.
Potential low temperature condition
Risk of coating detachment for pipe with internal flow coating
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 Design aspects for pipeline systems
Internal corrosion:
Increase significantly due to present of free water (strict control and drying of the
flow is essential to prevent severe corrosion rate)

Fluid category and safety zones:

CO2 fluid category is same as natural gas.
Consequence zone larger for CO2 pipelines (CO2 spreading along ground) ➔
reduced design factor.

Running ductile fracture:

Higher fracture toughness and/or thicker wall thickness or having restrictions with
respect to CO2 composition and temperature to control the saturation pressure
which governs the driving force for running ductile fractures.
Install fracture arrestors (if required and possible)
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 Design aspects for pipeline systems

Brittle Fracture:
Small leaks ➔ low temperature ➔ brittle fracture.

Reversed flow direction:

May change from inlet to outlet (and vice versa). Expansion and contraction should
be evaluated and considered.

Effects of weight and mass of fluid:

Dense CO2 density: 10x natural gas ➔ free span, natural frequency.

Third party load:

Usually not change.

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 STEP 7 – MODIFICATION
• Modification alternative should be evaluated with respect to feasibility, safety
and integrity.
• Re-assessment of the modification alternative will be performed through
documenting the integrity status.
• This activity shall cover identification and description of possible mitigation or
modifications to ensure safe operation with CO2, considering acceptable
levels of impurities and operating envelop, other modifications/mitigation for
improving load condition for the pipeline, material testing to document
(original) material properties when information is lacking, etc.

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 STEP 8 – DOCUMENT
Documentation of the re-qualification process as well as update system
documentation, drawing, equipment lists, and operating procedures is
required to ensure that the re-purposed pipeline can be safely and
effectively operated.

STEP 9 – IMPLEMENT
Implementation of changes to the system should be performed prior to
transition of the system into the new operational made for CO2.

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 RISK OF COVERTING NATURAL GAS PIPELINES TO
CO2 SERVICE

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 Need for large-
Insufficient
scale repairs
Pipe
and
Strength
modifications

Insufficient
Engineering Insufficient
maintenance
records and & Safety Pipe Steel
Toughness
inspection history Concern

Risk to Incompatibility
adjacent CO2 with non-
communities metallic
components

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 ENGINEERING AND SAFETY CONCERN
1. Insufficient Pipe Strength Liquid CO2 pipelines must operate
above the “critical point” pressure of
1,070 psig, because if the pressure
falls below this point the CO2 will
80 – 100 bara change phase to a gas, which creates
(1160 – 1450 psia)
a pressure spike and may lead to a
rupture.
Required to check ANSI Class for
Pipe Component: valve, flange, etc.

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 ENGINEERING AND SAFETY CONCERN
2. Insufficient Pipe Steel Toughness

A Running Ductile Fracture (RDF) may happen

nearly instantly following an initial pipeline rupture,
as some of the CO2 will convert from a liquid to a
gas inside the pipeline and tear the pipe open next
to the rupture site, but then more liquid CO2 will
convert to a gas and more pipe will be torn open,
and this explosive process can continue for an
indeterminate distance along the pipe at more than
100 meters per second. Existing natural gas
pipelines may not have sufficiently tough steel to
stop running ductile fractures. (CVN energy > 300 J)

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 ENGINEERING AND SAFETY CONCERN
3. Incompatibility CO2 with non-metallic components
Liquid CO2 is an excellent solvent, to the point that it may
dissolve non-metallic pipeline components, such as seals,
gaskets, valves and lubricants. Existing natural gas pipelines
may include components that may be dissolved by CO2 and
result in leaks, ruptures, and damage to pipeline
equipment.

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 ENGINEERING AND SAFETY CONCERN
4. Risk to adjacent communities
CO2 pipelines are dangerous because the very
large volume of CO2 they may release can
asphyxiate and intoxicate people and animals,
and dangerous CO2 levels may spread more
than a mile from the rupture site.

It may not be appropriate to convert an

existing natural gas pipelines that passes
near sensitive locations, such as hospitals,
senior facilities, schools, etc.

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 ENGINEERING AND SAFETY CONCERN
5. Insufficient maintenance records and inspection history
Since CO2 pipelines usually require stronger
steel and operate under greater pressure, it is
vital that the weaknesses of used pipelines be
well understood before conversion to CO2
service. A full understanding of a natural gas
pipeline’s wear and tear is possible only if its
owner has kept adequate maintenance records
and inspection data. Not all natural gas pipeline
owner keep adequate records and data.

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 ENGINEERING AND SAFETY CONCERN
6. Need for large-scale repairs and modifications
It may need “crack arrestors” that can stop RDF to
be installed along the pipeline, replacement of parts
not compatible with liquid CO2, and/or repair of
weakened pipe segments and other components.
Such modifications and repairs may be expensive
and/or time consuming, yet a failure to undertake
such work without great care could result in a
catastrophic rupture.

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 In its three-volume treatise on carbon capture and sequestration (CCS), the
National Petroleum Council discusses the potential for repurposing natural gas
pipelines and finds that this is “not a practical option.” (National Petroleum
Council), Meeting the Dual Challenge, A Roadmap to At-Scale Deployment of
CCUS (Dec 2019; updated Mar 2021). In chapter 6 on pages 6-10 to 6-11 this report
states:
IS REPURPOSING NATURAL GAS PIPELINES AN OPTION?
The use of an existing natural gas pipeline is not a practical option for CO2 transport for large flow
rates of 1 BSCF/D (19 Mtpa) or more over long distances of hundreds of miles and more. Existing
natural gas pipelines have a maximum pressure rating of 1,480 psig, which are defined by the
American National Standards Institute (ANSI) as Class 600 pipelines. A pipeline built for CO2 service
is designed for 2,200 psig, which is an ANSI Class 900 pipeline. There are a few examples of an
existing pipeline that was converted to CO2 service for lower flow rates and/or shorter distances
(less than 100 miles). For longer distances, however, the lower rating of an existing gas pipeline
requires many more pump stations along the route compared with a pipeline built for CO2 service.
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 The life-cycle analysis showed that a repurposed pipeline was, at best, equal in
cost to a new pipeline and would more likely cost more than a new pipeline that
is designed for CO2 transport. The likelihood of identifying a viable existing
pipeline for a long transport route is low. Even if one was located, the large
number of pump stations required would not be operationally practical for a long-
distance pipeline.
If the goal is to transport large volumes of CO2 100 miles or more, then the lower
pressure rating of existing natural gas pipelines makes it impractical to repurpose
them for use with CO2. However, natural gas pipelines could be repurposed if the
diameters are large enough and throughput volumes are optimized for a tighter
operating range. Each pipeline’s potential should be studied based on the project-
specific conditions being evaluated and verified that the conversion of the line from
natural gas service to CO2 services complies with regulations.

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 SUMMARY
1. The feasibility of repurposing of a specific pipeline needs to be confirmed and documented
through a re-qualification process to ensure acceptable integrity, safety as well as transport
capacity. General codes and recommended practices that lay out requirements and
guidelines for design an operation of CO2 pipelines are already available and can be used as
basic for re-qualification of CO2 pipelines.
2. Impurities in captured CO2 affect critical pressure, critical temperature, and phase behavior,
which may affect pipeline materials and design parameters
3. Other challenges: lack of design and construction documentation, inspection history, local
rules and regulations.
4. Re-qualification of pipelines for CO2 transport in dense phase, is therefore not considered
trivial and requires a careful evaluation but is nevertheless considered as fully possible in
many cases

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 REFERENCES

1. https://www.pipeline-journal.net/ejournal/ptj-3-2022/#32
2. https://pipelinefighters.org/news/risks-of-converting-natural-gas-
pipelines-to-co2-service/

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 Thank You
Ir. M.A. Kariem, Ph.D, IPM
Fakultas Teknik Mesin dan Dirgantara
Institut Teknologi Bandung
Jl. Ganesa No.10,
Lb. Siliwangi, Kecamatan Coblong,
Kota Bandung, Jawa Barat 40132
Ph. 081910161318
Email: [email protected]
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