Active Research & Development Projects

The overarching goal of this project is to develop the knowledge basis for updating the existing operating and maintenance procedures to prevent and mitigate the risks of pipeline Stress Corrosion Cracking (SCC). The main objectives are to (1) understand the causes of pipeline SCC by evaluating the effects of multiple causal factors, including pressure cycling, temperature cycling, soil condition, metallurgy, and welding methods, on the initiation and growth of pipeline SCC, with the consideration of both individual and combined effects; (2) develop and test an innovative technique for monitoring the initiation and growth of multi-scale pipeline SCC; (3) provide recommendations to enhance preventive measures, repair criteria, and safe operating parameters for at-risk pipeline segments to improve pipeline safety; and (4) train undergraduate and graduate students via the proposed research activities for workforce development.

The objective of the proposed study is to comprehensively characterize the expected compositional ranges and product quality specifications for upper and lower bound ranges for CO2 product streams derived from diverse sources, including ethanol production, cement manufacturing, power generation facilities, steel manufacturing, and direct air capture (DAC), with an emphasis on near-term emitters.

The main objective is to develop an integrated framework for creating a dynamic, risk-model-compatible pipeline data repository. The developed methodology will be validated through field testing on selected pipeline sections, incorporating feedback from subject matter experts and users to ensure alignment with industry best practices and standards. The outcome will be an integral and reliable tool for pipeline risk assessment, improving data management, mitigating risks, and enhancing the integrity and safety of pipeline systems.

The objective of this research project is to develop new monitoring technology for the presence and effectiveness of VCI installed in aboveground storage tank floors.

Develop and validate a comprehensive risk assessment model, incorporating CFD and advanced machine learning techniques, to accurately predict the Potential Impact Radius (PIR) for hydrogen and hydrogen-natural gas blends in pipelines. Utilize controlled field trials, detailed literature reviews, and robust data analysis to inform and enhance pipeline safety regulations, ensuring a safe transition to cleaner energy sources within the existing infrastructure.

The proposed project goal is to develop and test an above-ground, self-contained measurement system to detect steel anomalies on transmission pipelines. The proposed work capitalizes on years of NYSEARCH-funded work and picks up the development and testing stages before the prototype field tests. The objectives of the proposed work are to complete the advancement of the source signal electronics and enhance the measurement precision to prepare the system for a fully automated system to switch between the optimal source-coil modes and to develop a data retrieval computer and a GPS-positioning system to fully prepare the system for realistic condition field testing. The final deliverable of the project will be a pre-commercial product to field test in the next phase of the project.

The proposal will address concerns associated with repair of steel and plastic pipelines that will transport H2 or H2-NG blends. Addressing these concerns will increase the industry's confidence in using conventional pipeline repair methods to ensure the integrity of the H2 or H2-NG blended pipeline systems.

The study team will partner with leak detection and quantification (LDAQ) solution developers to catalyze development of advanced leak detection for pipelines by (a) supporting enhanced solution testing in a pseudo-realistic environment, (b) documenting deployment protocols, and (c) providing an annual showcase event to demonstrate solutions to operators, regulators and other stakeholders.

Create a real-time leak detection system for compressible hydrocarbon products, validated with real-world data. This system will be integrated into a commercial Leak Detection System (LDS) to enhance pipeline safety, environmental protection, regulatory compliance, and operational efficiency. Our objective is to deliver a reliable and effective solution that addresses the critical need for improved leak detection in the pipeline industry.

A joint team from Colorado State University (CSU) and Southern Methodist University (SMU) proposes to develop practical, deployable protocols and supporting software / field tools for gas pipeline leak detection (and secondarily, quantification) that can be used by all major pipeline operational sectors. The proposed work will level up existing protocols to well defined and readily implemented methods that will find gas leaks at a reduced cost per surveyed mile.

The project will develop a comprehensive database of mechanical characteristics of close to one hundred pipelines steels available to the project. The data will include instrumented Charpy v-notch dynamic toughness test data for the steels where the full S-curve will be developed for steels conditioned in air, methane, and methane/hydrogen blends. This database will be made available to the providers of non-destructive evaluation testing and is based toughness predictions to refine the prediction models.

The objective is to evaluate the consequences due to failure of low- and high-pressure LNG storage tanks. Modern LNG tanks have a long history of successful operation, but it is critical for the first responders and local authorities to better understand the potential impacts of catastrophic LNG tank failure, which have the potential to generate several types of hazards, including fire, explosion, rapid cooldown due to exposure to cryogenic liquid, and toxic plume. This will help develop emergency evacuation plans for a range of LNG storage facilities.

The purpose of this project is to 1) conduct a thorough gap analysis of LDAR federal and state regulations to identify regulatory gaps and duplications, 2) identify industry standards and best practices, LNG facilities safety, environmental and reporting requirements and the thresholds, methods, frequency, exceptions, and components/equipment and 3) assess feasibility of public portal to disseminate findings of leak and emission data from LNG facilities. The efforts of this project will support an effective LDAR program that drives down CH4 emissions, retains product, and thereby support U.S DOT PHMSA's mission to protect people and the environment by advancing the safe transportation of energy.

The project will produce a validated and complete instrument specification capable of delivering accurate and reliable fracture toughness data when deployed commercially by performing finite element simulations, field trials, and third-party validation tests. These specifications will include hardware and software, testing procedures, and the requirements for the training and certification program of end users. This project will also increase the accuracy and reduce the material removal associated with the field procedure.

This first phase of this project will develop a systematic process, agnostic of product, for operators to follow to identify risks that can be applied to any repurposing effort. For this scope, repurposing a pipeline refers to a change in product (i.e. crude to refined product), a change in flow direction, and/or a conversion of service (i.e. hazardous liquid to natural gas). In the second phase of the project, the systematic process developed in Phase 1 will be used to identify specific integrity threats specific to conversion between liquids, natural gas, carbon dioxide (CO2), hydrogen (H2)/hydrogen-natural gas (H2-NG) blends, renewable natural gas (RNG), and sustainable aviation fuel (SAF). With this approach, it is DNV's intent to create a legacy systematic process to identify and reduce risk for any system, while consolidating the specific changes in risk with products under consideration in today's world.

Project Description The objective of this project is to create a mechanism for Team Training, Hazardous Condition Response and Emergency Response that is as real world as possible, creates an emotional experience that anchors learnings, and streamlines the effort required to perform training and exercises.

Project Description: RapiCure's motivation for pursuing this project is to bring together the necessary entities to generate a high-performing, cost-effective, and rapid curing solution for internal pipe repair. With over 80 million homes and 250 million gas-powered vehicles in the US alone, the transition to clean energy will take time. As such, we must protect our aging critical infrastructure. This project will develop a resin system that exhibits 3X the fracture toughness of standard epoxies, exhibits nearly 95% the strength of steel, and cures quickly and easily with simple initiation with light or heat, for internal pipeline repair applications.

Developing a non-contact Magnetic Barkhausen Noise (MBN) technique for measuring stress in pipelines. MBN is the result of discrete jumps in magnetization of the material as domains align, and in Phase II, we demonstrated these jumps are strongly correlated to the stress state of a pipe. Our approach focuses on refining the sensor first for in-the-ditch measurement prior to development of an inline inspection tool. Our Phase IIB aims to address the technical and commercial challenges associated with developing, implementing, and commercializing pipeline inspection hardware.

This SBIR Phase IIb project seeks to build on Phase I and Phase II results by building a field-ready tool to calculate fracture toughness values of pipeline steel by measuring coercivity of the steel in-ditch. The project will additionally test the tool on samples of known fracture toughness to create calibration curves.

The objective of this project is to develop experimental data to validate the appropriateness and effectiveness of passive fire mitigation systems subject to fire impingement. Additionally, the project will develop criteria for hazard modeling of these passive fire mitigation systems, and define criteria for the onset of structural failure of structural steel or pressure vessels exposed to fire. The project deliverables will support PHMSA in its ongoing efforts to improve LNG fire safety.

The main objective of this project is to provide an inclusive source of knowledge about the formation, diagnostics, and mitigation methods of microannulli as potential leak paths in gas storage wells experiencing cyclic injections and depletions, through a comprehensive literature review and knowledge gathering. The project aims to develop improved guidelines and techniques for identifying, characterizing, and effectively sealing leak paths by evaluating current practices, barrier materials, and testing methods and introducing new lab tests and modeling tools. The anticipated results will include a comprehensive guidebook of diagnostic methods, a list of effective sealing materials and their application methods, as well as a decision tree for material selection and testing. These outcomes are ultimately contributing to enhanced safety and integrity in underground natural gas storage operations to curtail greenhouse gas emissions.

The project objectives are to (1) analyze failure mechanisms related to hydrogen and hydrogen/natural gas blends, (2) develop knowledge regarding critical flaw sizes and availability and accuracy of ILI tools, and (3) recommend changes to practices for determining reinspection intervals.

The project objectives are: 1) Leveraging the power of knowledge graphs and web and cloud technologies to develop a comprehensive knowledge graph framework that offers seamless access to multiple geohazard monitoring data repositories and provides efficient search, processing, visualization and analytical capabilities to end users; 2) extracting meaningful insights and relationships from the integrated datasets by leveraging the semantic capabilities of knowledge graphs to reduce the risks and uncertainties related to geohazards management in natural gas and hazardous materials pipelines; and 3) empowering stakeholders to make informed decisions regarding hazard assessment, early warning systems, and disaster response planning by providing a unified view of the data and developing methodologies to capture the essential decision-related information.

This project is expected to achieve the following objectives:

• Establish a comprehensive understanding of the applicability of various FO techniques for monitoring UGS wells in both salt caverns and depleted reservoirs;

• Develop guidelines and best practices for implementing the FO technology in UGS well monitoring; and

• Establish a cost structure to provide UGS operators with a reference to conduct technoeconomic assessment for implementing the FO technology.

The goal of this project is to develop a reliable solution of using FO technology as an alternative well integrity monitoring method that allows extension of MITs or traditional well inspection intervals specified by regulators.

The PHMSA stated objective is to develop methods and standards to qualify (VCIs), establish performance metrics, and develop monitoring best practices for their use in breakout tank corrosion control. This project is focused on establishing methods and standards for qualifying VCIs as an alternative to CP systems, identifying performance and monitoring metrics, and establishing best practices for VCIs in breakout tank service. As per PHMSA, the project scope must:

1. Perform a literature review of relevant research from private or public research efforts,
2. Consider methods of VCI application under primary tank bottoms, between bottoms in tanks with multiple bottoms, and under original tank bottoms,
3. Establish a method to evaluate the performance of VCIs compared to a functioning CP system and qualify their effectiveness for use in breakout tank applications,
4. Establish best practices for VCI application and monitoring in breakout tank application, and
5. Deliver reported results in 24 months.

Deliver well-documented data, information, and model fusion architectures that can be implemented on many commercially available platforms.

The objective of this project is to evaluate various tank configurations including foundation designs, bottom designs, and corrosion control equipment to develop methods and best practices for monitoring for corrosion, improving corrosion control, detecting leaks, and mitigating potential damage caused by leaks. These efforts are intended to improve public and environmental safety associated with breakout and other ASTs built with different foundation designs and equipment.

The scope for this project includes new and existing ASTs with a focus on those in breakout service. Additional tank records that may be sought and reviewed include non-breakout tanks if they are built or have been modified to non-traditional designs or materials and will further the goals of this research. Records targeted include those pertaining to a tank's foundation and floor including construction, construction inspection, as-builts, routine inspection such as out-of-service inspection floor scans, floor repair history associated with bottom side corrosion, CP inspection records, and any other tank modification documents that are associated with the objectives and scope of this project.

The main objective is to develop an innovative method for assessing the effectiveness and protection level of CP systems through the integration of remote inspection, advanced simulation, and data analytics.

The main objective is to determine whether rhamnolipids can be used as a corrosion inhibitor and sulfate-reducing bacteria (SRB) biocide for crude oil pipelines.

The main objectives are to develop a novel green inhibitor synthesis method, optimize its implementation in gas pipeline environments, and evaluate the inhibitor's effectiveness and compatibility using laboratory testing and nondestructive evaluation (NDE) measurements.

The main objective is to evaluate cathodic protection (CP) effectiveness using a novel reliability-based approach.

The main objective is to investigate genetically engineered peptides, which are a type of biopolymer derived from biomass, for mitigating corrosion of metal pipelines.

The main objective is to provide a framework to identify, characterize, and assess CP systems on remote and difficult-to-access buried pipelines.

This project will deliver a ready-to-commercial product and the associated software package which can be applied to transfer a cleaning pig into a dual-purpose pig for simultaneous cleaning and pipeline internal integrity assessment.

To address the challenge of providing nondestructive fracture toughness measurements on API 5L pipeline steels in a field environment, Guidedwave proposed a nonlinear ultrasonic surface wave measurement solution for this SBIR project. This technology utilizes a specially designed electronics system and a pair of transducers to transmit a Rayleigh surface wave through the material under test and analyzes linear and nonlinear signal parameters of this data using custom-developed software and algorithms.

During Phase IIB, the effort will be focused on achieving technology transfer and developing a commercial solution ready for field testing with commercial partners. Specifically, the technical objectives of Phase IIB will include:

• Conducting a new round of machine learning model training and validation on a variety of real-world pipeline specimens with verified fracture toughness properties, which will be provided by a strategic partner company specializing in structural integrity evaluation and nondestructive testing in the oil and gas and nuclear industries.
• Improving and revising the machine learning model to improve the performance of the nonlinear measurements based on the data collected as part of the validation study.
• Refining the design of the nonlinear testing probe to improve usability and performance. This will also include manufacturing and assembly considerations.
• Improving the laboratory-grade data collection and analysis software into a commercially viable format and incorporating the revised model results.
• Partnering with a strategic partner company to spearhead the use of this technology for field applications.

This Small Business Innovation Research Phase II project proposes an innovative approach for leak identification and mitigation for underground natural gas storage reservoir by providing an Anthronoetic artificial intelligence and high-fidelity physics simulation tool for pre-identifying potential leak pathways and an advanced neutrally buoyant particle (NBP) based solution for dynamically plugging leaks. It will also model and test the ability of forming plugs in small and complex gaps found in geologic and physical systems through the release of micro-particles. The Phase II goal is to demonstrate product maturity by conducting testing in representative geometries, pressures and flow conditions consistent with industrial application, and to begin design of commercial product to meet application specifications.

This Small Business Innovation Research Phase II project will continue development a new Fiber-Optic Excavation Monitoring Sensor (FOCOS) system, based on phase-sensitive optical time-domain reflectometry (φ-OTDR), machine learning (ML) algorithms, and Internet of Things (IoT) communication. Specifically, the innovative implementation of φ-OTDR in fiber-optics for excavation detection together with ML algorithms, based on convolution neural network (CNN) for data interpolation, provides vibration detection with high spatial resolution, long sensing distance, threat localization/classification, low false alarms, and strong EMI immunity.

The project will evaluate and document chemo-mechanical, morphological, and microstructural changes as well as the degradation and mechanical response of various liner materials under hydrocarbon and pressurized environments. Additionally, the researcher will develop models for liner materials that consider pipeline operational, chemical, and loading conditions. Furthermore, the project will analyze the structural integrity of liner-rehabilitated cast-iron and steel pipelines, as well as develop guidelines for structural liner material selection.

The objectives of this work are:

1. Identify and understand existing PHMSA regulatory functions and needs as they relate to characterizing, permitting, and assessing underground natural gas storage (UGS) operations within the subsurface in order to define appropriate metrics relevant to UHS;
2. Quantify the suitability of existing UGS facilities (which includes the well and subsurface geologic system) for storing pure and blended hydrogen;
3. Characterize operational expectations with emphasis on quantifying risk for H2 resource loss processes, UGS asset degradation, and estimating transient behavior based on geologic and operational conditions.

The project will develop a model for use by operators to investigate coating disbondment from vintage pipelines under cathodic protection (CP). The researcher will use the experimental testing, numerical analysis, and the resulting coating performance data to develop a probabilistic degradation model that operators can use to determine pipeline sections in need of coating remediation and recoating times.

The project will determine practical methods for optimizing or repurposing existing pipeline networks for the safe transport of pure hydrogen or hydrogen blends. Additionally, the project will provide insight into which existing gas transmission pipeline components and associated facilities may need modifications to safely introduce hydrogen gas or natural gas/hydrogen blends.

The project will investigate the: 1) impact of hydrogen injection on leakage dynamics, and 2) effect of hydrogen on existing leak detection equipment. The resulting analysis will inform new approaches for hydrogen sensing and integration into next-generation leak detection equipment.

The project will evaluate the following:

• Threats to aged cast iron and bare steel gas distribution pipes by establishing a risk-based approach to 1) provide acceptable pipe deformations, and 2) recommend actions for pipe rehabilitation.
• Segments suitable for rehabilitation or trenchless repair based on attributes, site conditions, and installation cost. A web-based tool will provide risk levels in a Geographic Information System (GIS) platform.

The project will develop a next-generation UV-cured adhesive and curing method that yields a faster cure, adheres to the host gas main, and facilitates a more precise and repeatable installation process.

The resulting commercialized product will enable a 1-day return to service and be suitable for gas mains up to 48 inches in diameter. Additionally, a well-designed and optimized UV-cured adhesive will reduce working time, reduce construction footprint, eliminate resin pot life obstacles, and enable a fully monitored curing process from within the pipe.

The project will develop a web-based, GIS-enabled recommendation tool for identifying and assessing the impact of geohazards in cast iron and non-cast iron oil and gas pipelines. The tool will—

• Follow industry standards and best practices.
• Incorporate satellite-based radar geohazard detection and monitoring technology.
• Be cloud-based to enable efficient scaling to pipeline systems of any size.

The project will use data analytics-based modeling techniques to create a comprehensive compatibility assessment model. This model will be utilized to determine the capability of existing pipelines to transport blended and pure hydrogen gas, while accounting for hydrogen caused embrittlement. The researcher will also develop a publicly available software tool that operators can use to determine which existing pipelines are suitable for pure hydrogen or blended gas. Also, the software will identify what modifications would be needed to make a pipeline suitable for hydrogen transportation.

The project will research and identify technologies that can detect and quantify the interaction between Vapor Corrosion Inhibitors (VCI)- and Cathodic Protection (CP)-associated components. Additionally, the project will provide an in-depth understanding of the VCI technology's operating parameters—including delivery methods, coverage, dosages, monitoring, reinjection, and interaction with CP and associated components such as anodes.

The project will develop the following:

• Improved algorithms to better estimate pipeline inventories short of full pipeline transient modeling applications.
• A new algorithm for enhanced zone balancing calculations.
• Recommended practices to troubleshoot facilities with high error probabilities.
• Pattern identification methods that identify how corrected zone balances shift based on changes in system flow. These methods, in turn, will be used to identify issues that are most likely attributing to measurement flow errors.

The main objective of the project will be to develop and test the feasibility of an all-in-one, multifunctional, high-performance cured-in-place pipe (CIPP) structural liner that is self-healing and self-sensing. Upon validation, the CIPP structural liner can be partially or fully implemented with commercially available solutions that enhance CIPP technology sustainability and reliability to better mitigate risks from CIPP-repaired cast iron pipelines.

The project will develop and implement a holistic framework for an AI-powered, platform-forward software tool that will accelerate the transition of existing gas pipelines for hydrogen transport. Additionally, the researcher will develop decision support tools using AI interfacing with goal-oriented optimization and a context-driven platform to recommend potential pipeline risk mitigation measures.

The main objective of this project will be to establish a computational fluid dynamics (CFD) model to simulate the release and dispersion of supercritical CO2 from full pipeline ruptures, then use the simulation results to construct a database comprising CO2 dispersion data under different scenarios. The researcher will use the resulting scenario data in a machine learning analysis for predicting dispersion ranges and health consequences. Using the analysis results and existing literature, the researcher will develop a rapid, universally applicable tool to assess the consequences of accidental CO2 dispersion from high-pressure pipelines.

This project is expected to achieve the following objectives:

• Provide an in-depth understanding of the capability and limitations of through-tubing casing corrosion logging technology and vendor tools;

• Assist commercial through-tubing logging vendors to improve their technology though a collaborative experimental research that includes an iterative fit-for-purpose lab test program;

• Develop a reliability-based assessment framework to inform decision making as it pertains to the deployment of through-tubing casing logs in casing corrosion management; and

• Perform a field trial to demonstrate 1) the performance of selected through-tubing casing logging tools and 2) the newly developed methodology to implement the through-tubing logs in casing corrosion management.

The objective of the program is to quantify the ability of several NDE methods for detection, sizing and characterizing defects, damage and anomalies that may occur in non-metallic pipe (NMP), and to characterize the erosion performance of the inner liners and the potential to detect liner erosion wall loss externally. This program will develop critically important guidance on methods to quantify the condition of NMP for use as a manufacturing plant QC tool and field inspection.

The research objective is to develop Artificial Intelligence (AI) - enabled tools to improve accuracy of probabilistic performance modeling and support decision making of inspection and repair actions in pipeline risk management. The educational objective is to engage, inspire, and train undergraduate and graduate students through research and prepare them for future career in pipeline industry.

Investigate the feasibility of using DAS to detect and locate pipeline integrity risks based on vibration, and the effectiveness and robustness of risk assessment using different cable deployment methods, especially easy deployed cables inside the pipeline.

This Small Business Innovative Research Program Phase II project will develop and test materials and techniques for cost-effective, secure, and permanent attachment of sensors to pipelines. The researcher will work with domestic fiber-optic cable companies to manufacture a tightly-coupled fiber-optic cable with a predicted lifetime over 30 years that accurately measures strain, temperature, and acoustics on pipelines.