Under Pressure Welding and Preheat Temperature Decay Times on Carbon Dioxide Pipelines

2014 ◽  
Author(s):  
Simon Slater ◽  
Robert Andrews ◽  
Peter Boothby ◽  
Julian Barnett ◽  
Keith Armstrong
Keyword(s):  
Heat Transfer ◽  
Carbon Dioxide ◽  
Natural Gas ◽  
Cooling Rate ◽  
Gaseous Phase ◽  
Transfer Model ◽  
Dense Phase ◽  
Pressure Welding ◽  
One Dimensional ◽  
Decay Times

Whilst there is extensive industry experience of under pressure welding onto live natural gas and liquid pipelines, there is limited experience for Carbon Dioxide (CO2) pipelines, either in the gaseous or dense phases. National Grid has performed a detailed research programme to investigate if existing natural gas industry under pressure welding procedures are applicable to CO2 pipelines, or if new specific guidance is required. This paper reports the results from one part of a comprehensive trial programme, with the aim of determining the preheat decay times, defined by the cooling time from 250 °C to 150 °C (T250–150), in CO2 pipelines and comparing them to the decay times in natural gas pipelines. Although new build CO2 pipelines are likely to operate in the dense phase, if an existing natural gas pipeline is converted to transport CO2 it may operate in the gaseous phase and so both cases were considered. The aims of the work presented were to: • Determine the correlations between the operating parameters of the pipeline, i.e. flow velocity, pressure etc. and the cooling rate after removal of the preheat, characterised by the (T250–150) cooling time. • Compare the experimentally determined T250–150 cooling times with the values determined using a simple one dimensional heat transfer model. • Define the implications of heat decay for practical under pressure welding on CO2 pipelines. Small-scale trials were performed on a 150 mm (6″) diameter pressurised flow loop at Spadeadam in the UK. The trial matrix was determined using a one dimensional heat transfer model. Welding was performed on a carbon manganese (C-Mn) pipe that was machined to give three sections of 9.9 mm, 19.0 mm and 26.9 mm wall thickness. Trials were performed using natural gas, gaseous phase CO2 and dense phase CO2; across a range of flow velocities from 0.3 m/s to 1.4 m/s. There was relatively good agreement between the T250–150 cooling times predicted by the thermal model and the measured T250–150 times. For the same pipe wall thickness, flow velocity and pressure level, the preheat decay cooling times are longest for gaseous phase CO2, with the fastest cooling rate recorded for dense phase CO2. Due to the fast cooling rate observed on dense phase CO2, the T250–150 times drop below the 40 second minimum requirement in the National Grid specification for under pressure welding, even at relatively low flow velocities. The practical limitation for under pressure welding of pipelines containing dense phase CO2 will be maintaining sufficient preheating during welding. The results from this stage of the technical programme were used to develop the welding trials and qualification of a full encirclement split sleeve assembly discussed in an accompanying paper (1).

Under Pressure Operations on Dense Phase CO2 Pipelines: Issues for the Operator

2014 ◽  
Author(s):  
Julian Barnett ◽  
Richard Wilkinson ◽  
Alan Kirkham ◽  
Keith Armstrong
Keyword(s):  
Natural Gas ◽  
Flow Velocity ◽  
Wall Thickness ◽  
Gaseous Phase ◽  
Operating Conditions ◽  
Cooling Time ◽  
Phase Behaviour ◽  
Pipeline System ◽  
Dense Phase ◽  
Pressure Welding

National Grid, in the United Kingdom (UK), has extensive experience in the management and execution of under pressure operations on its natural gas pipelines. These under pressure operations include welding, ‘hot tap’ and ‘stopple’ operations, and the installation of sleeve repairs. National Grid Carbon is pursuing plans to develop a pipeline network in the Humber and North Yorkshire areas of the UK to transport dense phase Carbon Dioxide (CO2) from major industrial emitters in the area to saline aquifers off the Yorkshire coast. One of the issues that needed to be resolved is the requirement to modify and/or repair dense phase CO2 pipeline system. Existing under pressure experience and procedures for natural gas systems have been proven to be applicable for gaseous phase CO2 pipelines; however, dense phase CO2 pipeline systems require further consideration due to their higher pressures and different phase behaviour. Consequently, there is a need to develop procedures and define requirements for dense phase CO2 pipelines. This development required an experimental programme of under pressure welding trials using a flow loop to simulate real dense phase CO2 pipeline operating conditions. This paper describes the experiments which involved: • Heat decay trials which demonstrated that the practical limitation for under pressure welding on dense phase CO2 systems will be maintaining a sufficient level of heat to achieve the cooling time from 250 °C to 150 °C (T250–150) above the generally accepted 40 second limit. • A successful welding qualification trial with a welded full encirclement split sleeve arrangement. The work found that for the same pipe wall thickness, flow velocity and pressure, dense phase CO2 has the fastest cooling time when compared with gaseous phase CO2 and natural gas. The major practical conclusion of the study is that for dense phase CO2 pipelines with a wall thickness of 19.0 mm or above, safe and practical under pressure welding is possible in accordance with the existing National Grid specification (i.e. T/SP/P/9) up to a flow velocity of around 0.9 m/s. The paper also outlines the work conducted into the use of the Manual Phased Array (MPA) inspection technique on under pressure welding applications. Finally, the paper identifies and considers the additional development work needed to ensure that a comprehensive suite of under pressure operations and procedures are available for the pipeline operator.

Under Pressure Welding on CO2 Pipelines: The Effect of Thermal Decay on Mechanical Properties

2016 ◽  
Author(s):  
Simon Slater ◽  
Julian Barnett ◽  
Peter Boothby ◽  
Robert Andrews
Keyword(s):  
Mechanical Properties ◽  
Natural Gas ◽  
Carbon Capture And Storage ◽  
Cooling Time ◽  
Welding Parameters ◽  
Significant Finding ◽  
Low Carbon ◽  
Dense Phase ◽  
Pressure Welding ◽  
Decay Times

Whilst there is extensive industry experience of under pressure welding onto operational natural gas and liquid pipelines, there is limited experience for Carbon Dioxide (CO2) pipelines, either in the gaseous or dense phase. National Grid has performed a detailed research program to investigate if existing natural gas industry under pressure welding procedures are applicable to CO2 pipelines, or if new specific guidance is required. At IPC 2014 a paper was presented (IPC2014-33223) that dealt with the results from one part of a comprehensive trial program, which defined the cooling time from 250 °C to 150 °C (T250-150) in CO2 pipelines and compared them to the typical decay times for natural gas pipelines. The results from this part of the work identified that maintaining the pre-heat using the established guidance in T/SP/P/9 during under pressure welding on dense phase CO2 pipelines would be very difficult, leading to potential operational issues. The previous paper gave a brief summary of the effect that cooling time had on the mechanical properties. The aim of this paper is to present the findings of the T800-500 weld decay trials in more detail including the full testing programme, detailing the affect that variables such as CO2 phase, CO2 flow velocity and the welding parameters had on the weld and heat affected zone (HAZ) hardness. The main finding is that although there is an indication that a higher cooling rate measured in the weld pool (characterized by the cooling time from 800 °C to 500 °C) leads to increased hardness in the HAZ region, there are no clear correlations. No hardness values were recorded that were considered unacceptable, even for the dense phase CO2 case which delivered the fastest cooling time. A significant finding was the requirement for controlling the buttering run procedure. A discussion of the critical aspects, including the link between weld cooling time and hardness, is presented with guidance on how this essential variables need to be controlled. The paper is aimed at technical, safety and operational staff with CO2 pipeline operators. Read in conjunction, this paper and the previous IPC paper form a comprehensive review of this critical work that is contributing to the development of dense phase CO2 transportation pipelines and will facilitate the implementation of Carbon Capture and Storage (CCS)1 projects which is a critical part of the transition to a low carbon economy.

The Decompression Behaviour of Carbon Dioxide in the Dense Phase

2012 ◽  
Author(s):  
Andrew Cosham ◽  
David G. Jones ◽  
Keith Armstrong ◽  
Daniel Allason ◽  
Julian Barnett
Keyword(s):  
Carbon Dioxide ◽  
Natural Gas ◽  
Shock Tube ◽  
Gaseous Phase ◽  
Initial Pressure ◽  
Successful Implementation ◽  
Dense Phase ◽  
Test Programme ◽  
Rich Mixtures ◽  
Arrest Toughness

Pipelines can be expected to play a significant role in the transportation infrastructure required for the successful implementation of carbon capture and storage (CCS). National Grid is undertaking a research and development programme to support the development of a safety justification for the transportation of carbon dioxide (CO2) by pipeline in the United Kingdom. The ‘typical’ CO2 pipeline is designed to operate at high pressure in the ‘dense’ phase. Shock tube tests were conducted in the early 1980s to investigate the decompression behaviour of pure CO2, but, until recently, there have been no tests with CO2-rich mixtures. National Grid have undertaken a programme of shock tube tests on CO2 and CO2-rich mixtures in order to understand the decompression behaviour in the gaseous phase and the liquid (or dense) phase. An understanding of the decompression behaviour is required in order to predict the toughness required to arrest a running ductile fracture. The test programme consisted of three (3) commissioning tests, three (3) test with natural gas, fourteen (14) tests with CO2 and CO2-rich mixtures in the gaseous phase, and fourteen (14) tests with CO2 and CO2-rich mixtures in the liquid (or dense) phase. The shock tube tests in the liquid (dense) phase are the subject under consideration here. Firstly, the design of the shock tube test rig is summarised. Then the test programme is described. Finally, the results of the dense phase tests are presented, and the observed decompression behaviour is compared with that predicted using a simple (isentropic) decompression model. Reference is also made to the more complicated (non-isentropic) decompression models. The differences between decompression through the gaseous and liquid phases are highlighted. It is shown that there is reasonable agreement between the observed and predicted decompression curves. The decompression behaviour of CO2 and CO2-rich mixtures in the liquid (dense) phase is very different to that of lean or rich natural gas, or CO2 in the gaseous phase. The plateau in the decompression curve is long. The following trends (which are the opposite of those observed in the gaseous phase) can be identified in experiment and theory: • Increasing the initial temperature will increase the arrest toughness. • Decreasing the initial pressure will increase the arrest toughness. • The addition of other components such as hydrogen, oxygen, nitrogen or methane will increase the arrest toughness.

Predicting the Decompression Characteristics of Carbon Dioxide Using Computational Fluid Dynamics

2012 ◽  
Author(s):  
H. E. Jie ◽  
B. P. Xu ◽  
J. X. Wen ◽  
R. Cooper ◽  
J. Barnett
Keyword(s):  
Heat Transfer ◽  
Fluid Dynamics ◽  
Carbon Dioxide ◽  
Computational Fluid Dynamics ◽  
Shock Tube ◽  
Pipe Wall ◽  
Numerical Study ◽  
Wall Friction ◽  
Transfer Model ◽  
Dense Phase

In a previous paper, we reported the development of CFD-DECOM, a Computational Fluid Dynamics (CFD) model based on the Arbitrary Lagrangian Eulerian (ALE) approach and the Homogeneous Equilibrium Method (HEM) for simulating multi-phase flows, to predict the transient flow following the rupture of pipelines conveying rich gas or pure carbon dioxide (CO2). The use of CFD allows the effect of pipe wall heat transfer and friction to be quantified. Here, the former is considered through the implementation of a conjugate heat transfer model while the two-phase pipe wall friction is computed using established correlations. The model was previously validated for rich gas and to a limited extent dense phase CO2 decompression against the available shock tube test data. This paper describes the extension of the model to the decompression of both gaseous and dense phase CO2 with impurities. The Peng-Robinson-Stryjek-Vera Equation Of State (EOS), which is capable of predicting the real gas thermodynamic behaviour of CO2 with impurities, has been implemented in addition to the Peng-Robinson and Span and Wagner EOSs. The liquid-vapour phase equilibrium of a multi-component fluid is determined by flash calculations. The predictions are compared with the measurements of some of the recent gaseous and dense phase CO2 shock tube tests commissioned by National Grid. The detailed comparison is presented showing reasonably good agreement with the experimental data. Further numerical study has also been carried out to investigate the effects of wall friction and heat transfer, different EOSs and impurities on the decompression behaviour.

Structure Evolution of Fe-7.5at.%Ni Alloy Thin Strips under Near-Rapid Solidification Conditions

2011 ◽  
Vol 391-392 ◽  
pp. 793-797 ◽  
Author(s):  
Yuan Yi Guo ◽  
Liang Zhu ◽  
Ke Xie ◽  
Ke Feng Li ◽  
Chang Jiang Song ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Cooling Rate ◽  
Rapid Solidification ◽  
Strip Thickness ◽  
Experimental Results ◽  
Structure Evolution ◽  
Transfer Model ◽  
One Dimensional ◽  
Ni Alloy ◽  
Equiaxed Grains

In this paper, the structure evolution of Fe-7.5at.%Ni thin strips under near-rapid solidification conditions was investigated. One-dimensional (1D) heat transfer model was used to calculate the cooling rate of thin strips. The calculated results showed that the decrease of distance from the surface, made the effective heat transfer increase sharply, which led to a higher cooling rate. Moreover, the experimental results showed that the size of the columnar crystals increased clearly by the increase of the distance from the surface, and equiaxed grains appeared when the distance was above 0.75mm. In addition, it is indicated that even the strip thickness changed from 1.0mm to 2.0mm, the size of columnar crystals didn’t change much in regions which have the same distance from the surface.

Transient Behavior of Glow Plugs in Direct-Injection Natural Gas Engines

2012 ◽  
Vol 134 (9) ◽  
Author(s):  
Stewart Xu Cheng ◽  
James S. Wallace
Keyword(s):  
Heat Transfer ◽  
Natural Gas ◽  
Direct Injection ◽  
High Surface ◽  
Cold Start ◽  
Transfer Model ◽  
Ignition Process ◽  
Computational Domain ◽  
Glow Plug ◽  
Natural Gas Engines

Glow plugs are a possible ignition source for direct injected natural gas engines. This ignition assistance application is much different than the cold start assist function for which most glow plugs have been designed. In the cold start application, the glow plug is simply heating the air in the cylinder. In the cycle-by-cycle ignition assist application, the glow plug needs to achieve high surface temperatures at specific times in the engine cycle to provide a localized source of ignition. Whereas a simple lumped heat capacitance model is a satisfactory representation of the glow plug for the air heating situation, a much more complex situation exists for hot surface ignition. Simple measurements and theoretical analysis show that the thickness of the heat penetration layer is small within the time scale of the ignition preparation period (1–2 ms). The experiments and analysis were used to develop a discretized representation of the glow plug domain. A simplified heat transfer model, incorporating both convection and radiation losses, was developed for the discretized representation to compute heat transfer to and from the surrounding gas. A scheme for coupling the glow plug model to the surrounding gas computational domain in the KIVA-3V engine simulation code was also developed. The glow plug model successfully simulates the natural gas ignition process for a direct-injection natural gas engine. As well, it can provide detailed information on the local glow plug surface temperature distribution, which can aid in the design of more reliable glow plugs.

Modelling of Thermal Quantities for Quick Process Assessment and Process Capability Space Refinement at an Early Design Phase During Laser Welding

2021 ◽  
Author(s):  
Anand Mohan ◽  
Dariusz Ceglarek ◽  
Michael Auinger
Keyword(s):  
Heat Transfer ◽  
Laser Welding ◽  
Cooling Rate ◽  
Process Parameters ◽  
Thermal Cycle ◽  
Welding Process ◽  
Process Capability ◽  
Peak Temperature ◽  
Transfer Model ◽  
Process Assessment

Abstract This research aims at understanding the impact of welding process parameters and beam oscillation on the weld thermal cycle during laser welding. A three-dimensional heat transfer model is developed to simulate the welding process, based on the finite element (FE) method. The calculated thermal cycle and weld morphology are in good agreement with experimental results from literature. By utilizing the developed heat transfer model, the effect of welding process parameters such as heat source power, welding speed, radius of oscillation, and frequency of oscillation on the intermediate performance indicators (IPIs) such as peak temperature, heat-affected zone volume (HAZ), and cooling rate is quantified. Parametric contour maps for peak temperature, HAZ volume, and cooling rate are developed for the estimation of the process capability space. An integrated approach for rapid process assessment, process capability space refinement, based on IPIs is proposed. The process capability space will guide the identification of the initial welding process parameters window and help in reducing the number of experiments required by refining the feasible region of process parameters based on the interactions with the IPIs. Here, the peak temperature indicates the mode of welding performed while the HAZ volume and cooling rate are weld quality indicators. The regression relationship between the welding process parameters and the IPIs is established for quick estimation of IPIs to replace time-consuming numerical simulations. The proposed approach provides a unique ability to simulate the laser welding process and provides a robust range of process parameters.

One-Dimensional Zonal Model for the Unsteady Heat Transfer Analysis in an Open Volumetric Air Receiver

2020 ◽  
Vol 13 (1) ◽  
Author(s):  
Gurveer Singh ◽  
Vishwa Deepak Kumar ◽  
Laltu Chandra ◽  
R. Shekhar ◽  
P. S. Ghoshdastidar
Keyword(s):  
Heat Transfer ◽  
High Heat ◽  
Operating Conditions ◽  
Heat Transfer Analysis ◽  
Transfer Model ◽  
High Heat Flux ◽  
Unsteady Heat Transfer ◽  
Volumetric Heating ◽  
One Dimensional ◽  
Zonal Model

Abstract The open volumetric air receiver (OVAR)-based central solar thermal systems provide air at a temperature > 1000 K. Such a receiver is comprised of porous absorbers, which are exposed to a high heat-flux > 800 Suns (1 Sun = 1 kW/m2). A reliable assessment of heat transfer in an OVAR is necessary to operate such a receiver under transient conditions. Based on a literature review, the need for developing a comprehensive, unsteady, heat transfer model is realized. In this paper, a seven-equations based, one-dimensional, zonal model is deduced. This includes heat transfer in porous absorber, primary-air, return-air, receiver casing, and their detailed interaction. The zonal model is validated with an inhouse experiment showing its predictive capability, for unsteady and steady conditions, within the reported uncertainty of ±7%. The validated model is used for investigating the effect of operating conditions and absorber geometry on the thermal performance of an absorber. Some of the salient observations are (a) the maximum absorber porosity of 70–90% may be preferred for non-volumetric and volumetric-heating conditions, (b) the minimum air-return ratio should be 0.7, and (c) the smallest gap to absorber-length ratio of 0.2 should suffice. Finally, suggestions are provided for extending the model.

Thermal Accumulation in Metal Micro-Parts Fabricated by Micro Droplet Deposition Manufacturing Technique

2014 ◽  
Vol 941-944 ◽  
pp. 2154-2157
Author(s):  
Han Song Zuo ◽  
He Jun Li ◽  
Le Hua Qi ◽  
Jun Luo ◽  
Song Yi Zhong
Keyword(s):  
Heat Transfer ◽  
Processing Parameters ◽  
Transfer Model ◽  
Droplet Deposition ◽  
One Dimensional ◽  
Input And Output ◽  
Deposit Surface ◽  
Micro Parts ◽  
Thin Walled ◽  
Deposit Height

Thermal accumulation in micro droplet deposition manufacturing (MDDM) has a significant influence on geometric profile and microstructure of the fabricated metal micro-parts. In this paper, thermal behavior of a new aluminum droplet on the deposit surface was investigated using one-dimensional heat transfer model. Then several thin-walled aluminum cubic pipes were fabricated by MDDM to verify the numerical analysis result. The result shows that the thermal accumulation would increase gradually with the increase of the deposit height. It associated with thermal input and output on the top surface of the deposit, which could be controlled or eliminated by optimizing processing parameters such as deposition frequency.

scholarly journals A one-dimensional modeling study on the effect of advanced insulation coatings on internal combustion engine efficiency

2020 ◽  
pp. 146808742092158
Author(s):  
Alberto Broatch ◽  
Pablo Olmeda ◽  
Xandra Margot ◽  
Josep Gomez-Soriano
Keyword(s):  
Heat Transfer ◽  
Combustion Engine ◽  
Heat Transfer Model ◽  
Transfer Model ◽  
Insulation Material ◽  
One Dimensional ◽  
Engine Efficiency ◽  
Dimensional Modeling ◽  
The One ◽  
The Impact

This article presents a study of the impact on engine efficiency of the heat loss reduction due to in-cylinder coating insulation. A numerical methodology based on one-dimensional heat transfer model is developed. Since there is no analytic solution for engines, the one-dimensional model was validated with the results of a simple “equivalent” problem, and then applied to different engine boundary conditions. Later on, the analysis of the effect of different coating properties on the heat transfer using the simplified one-dimensional heat transfer model is performed. After that, the model is coupled with a complete virtual engine that includes both thermodynamic and thermal modeling. Next, the thermal flows across the cylinder parts coated with the insulation material (piston and cylinder head) are predicted and the effect of the coating on engine indicated efficiency is analyzed in detail. The results show the gain limits, in terms of engine efficiency, that may be obtained with advanced coating solutions.

Sign in / Sign up

Export Citation Format

Share Document