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FLOW & LEVEL CONTROL


CONVERTING SYSTEMS AND MINDS


Faris Churcher, principal applications engineer with Oxford Flow, explores how advances in regulator technology can leak-proof, and future-proof, the conversion of the gas network infrastructure to hydrogen-ready pipework and systems


2023 has focused minds on the practical implications. A significant contribution to the energy transition agenda, certainly, but addressing specific integrity and safety issues also needs to be part of the mix. Britain’s Hydrogen Blending Delivery Plan,


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published by the Energy Networks Association in January 2022, maps out how all five of the gas network companies will work towards the Government target. It also highlights how blending 20% hydrogen into the gas grid will reduce carbon emissions by up to six million tonnes every year – the equivalent of taking 2.5million cars off the road. However, the blending of hydrogen into


supplies does pose distinctive risks because of its more volatile nature and smaller molecular structure. Leaks from pipelines and associated assets would represent a new kind of safety challenge wherever they might occur. The ideal solution, of course, would be to


introduce new fit-for-purpose infrastructure designed, ultimately, to host 100% decarbonised gas. That, however, is simply impractical and would entail eye-watering levels of investment. So the focus is on converting the existing


network – all 284,000km of it – as part of a strategy to realise a zero carbon gas grid by 2050. A large number of studies, trials and projects are already under way and there is a general sense of confidence around the industry that the technical challenges can be fully and properly addressed. The results of large-scale pilot programmes


that focus on the blending of up to 100% hydrogen at transmission pressures – including National Grid’s FutureGrid project in Northern England – are likely to add new impetus to the conversion process. Some of the technical issues now under


close scrutiny relate to metallurgy: the nature of hydrogen molecules mean they can permeate into metal, in particular materials such as carbon steel. And when those molecules react with carbon elements and form methane within the pipe or casing material itself, they cause it to expand and crack, a process called embrittlement.


26 MAY 2022 | PROCESS & CONTROL


he Government target for Britain’s network of gas pipes to be ready to deliver 20% hydrogen nationwide from


The challenges also relate to the sizing, and


associated pressures, of networks. Much of the infrastructure has been designed and installed for the distribution of natural gas, but you need to burn much more hydrogen – up to three times more – to achieve the same results when it comes to heating a home or fuelling business operations. And of course, such large-scale networks


feature vast numbers of joints which individually represent potential leak points and therefore require careful monitoring, management and maintenance. Many of these issues coalesce around the


various valves and regulators that are maintained by specialist technicians in stations and similar facilities. Those stations are operated in line with robust safety protocols given the obvious risks already posed by leaks. The blending of hydrogen into supplies,


however, means there is a need for hydrogen- ready solutions to deliver on the 2023 deadline. It has certainly been a focus of attention,


and investment, at Oxford Flow. We’ve taken those challenges into careful account, for example, in the development of our IM series pilot-controlled gas regulators. They are compact in nature, can be retrofitted to systems and are machined and manufactured from 316 stainless steel, which is acknowledged to be less susceptible to the embrittlement process. Of equal significance, they do not feature


large elastomeric diaphragms which are used in many conventional solutions and which, research suggests, fare less well in trials of hydrogen transmission at various pressures. Instead, we have deployed profile fields of


hard materials as part of a hydrogen-ready product that requires less maintenance attention and is already in use in live operations. To cite one example of its alternative proposition, it directly addresses the issues around energy density. Many network stations are sized to deal with a one- in-twenty winter – a sort of worst-case scenario – and in that context it’s important to bear in mind that an eventual change to 100% hydrogen would effectively triple the flow to meet demand in such circumstances. So network operators will require regulators


that can cope with such flow increases. At the same time, we’re typically in situations where the system is perhaps only 5-10% open, and at the low end of flow capacity many standard regulators can experience instability. We invested hundreds of thousands of


simulation hours and completed a testing regime to demonstrate our IM series regulators can operate with stability at anything from zero to 100% of operating capacity. That helps to future-proof the system, because they protect from the implications of any scaling up of flow as the blend of hydrogen grows as a proportion of the overall flow and new demand emerges. We have now cumulatively reached the


equivalent of 10 years’ service across the regulators already installed, with no failures or unplanned maintenance. We like to think of it as an example of supply chain innovation that genuinely helps to deliver on the imperatives of our industry, and indeed of wider society. It’s always interesting, in our interactions with


clients, to show them the data generated by our regulators. It typically looks very similar to data they’ve seen before, and they ask: what’s so special about it? In truth, there’s nothing special about it, and nor should there be. We want operators to see the same quality of data they’ve always seen – data which provides assurance – albeit now being delivered by a new, more sustainable and reliable solution. It’s not just about converting the system, it’s


about converting the industry mindset to new ways of doing things – with the future in mind.


Oxford Flow www.oxford-flow.com


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