Future Fuels and Service Conversion Consultancy

Converting existing networks to hydrogen, carbon dioxide or ammonia

The energy transition is accelerating. The future requirement to transport significant volumes of H2CO2 and NH3 is clearly recognized around the world and the use and transport of fossil fuels will have to decline. Pipelines have been the safest and most efficient method for transporting energy for decades. Building new pipelines is costly, the public often objects, and obtaining consent can be very difficult. Converting existing pipelines to transport these fluids is the obvious solution.

Your benefits of our future fuels and service conversion consultancy services

Icon: Documents in a row with lines as writing and graphs on the side.

Material testing to confirm performance

Icon: Document showing a process with three rectangles and arrows between them, next to it is a check mark in a round circle.

Proving conversion feasibility

Icon: Sign with right symbol in front of it.

Code and regulatory check

Many countries already have a future fuels strategy that involves the use of existing infrastructure, and others are bound to follow suit.

Pipeline network operators are looking to a future in which they will transport different fluids and will have to ask themselves:

  • Can I convert my existing pipeline?
  • How do I manage integrity?
  • Will it be profitable to operate?

Our experts in materials, inspection, integrity management, flow modeling, risk assessment, and system economics are world leaders in addressing the challenges of conversion and can answer all of these questions.

Our conversion roadmap provides a structured approach for pipeline re-purposing. Clear stage gates and decision points ensure cost effectiveness and aim to confirm the technical feasibility of a hydrogen conversion.

Graphic with several divisions and arrows representing the stages of a pipeline conversion.Conversion roadmap
Aerial view of several pipelines and their access points next to each other.

Filling the data gaps and defining the strategy for service conversion to determine conversion feasibility

The key requirements for conversion are to understand future operation, materials, and condition. The foundation is data. Future operation starts with a consideration of supply and demand, this defines the project terms of reference or boundaries.

A data gap analysis, integrity overview and data gap prioritization define a service conversion strategy, the cost and complexity of implementing this conversion strategy to make the pipeline ready for blended or 100 percent H2, CO2 or NH3 gives a clear indication of conversion feasibility.

Pipeline running through green landscape with trees, mountains in background.

Gap filling, risk check and inspection for conversion business risk assessment

Any final decision will be based on a comprehensive conversion business risk assessment. A baseline status must be established based on the understanding of the current pipeline condition (including existing records, risk assessments, inspection reports, ILI data, integrity assessments, and any specifically commissioned inspections and surveys).

The Material Property Data Review focuses on the investigation of available materials property data, including original material test certificates and construction records.

The next steps include an analysis of the pipeline route and associated location classes as well as an identification of gaps in existing data (Gap Analysis).

A practical conversion strategy is prepared including recommendations to fill any knowledge gaps, address any potential code non-conformities and finally make the pipeline hydrogen 'ready'.

Typical elements of a conversion strategy include a variety of in-line inspections, to gather any missing or outdated information relating to materials, loads, and existing damage. In addition, the in-line inspection will set a baseline for future monitoring. Post-ILI integrity assessments confirm the fitness-for-hydrogen-service of the pipeline in its current condition and highlight anomalies that may limit safe operation. Recommendations for further in-field investigations and repair are given here. Existing risk assessments and integrity management practices will also be updated. When this is completed the business risks associated with conversion can be defined.

Two employees in ROSEN's hydrogen lab work at a testing booth.

Final confirmation of conversion acceptability through testing, integrity assessment and consequence analysis

Our conversion preparation service provides final confirmation that pipeline integrity will be acceptable following Hconversion.

Key elements are:

  • A thorough code and regulatory check to ensure that any conversion will be compliant with relevant laws.
  • Effective material testing using a combination of ILI (RoMat) to identify populations of pipe and destructive laboratory tests in H2 to confirm performance.
  • Detailed integrity assessments assess existing pipeline anomalies taking into account the effects of hydrogen on ductility, toughness, and fatigue crack growth rate.
  • State-of-the-art consequence analysis shows what the effects of a loss containment would be when transporting H2.
Several employees in suits talking in a meeting in a conference room.

Guided framework for safe and efficient pipeline operation and condition assessment

Our Hydrogen Pipeline Integrity Management Plan provides a framework for future safe and efficient operation of the pipeline, with detailed risk-based schedules for condition assessment.