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Failure analysis of corroded hydrogen-blended natural gas pipelines based on finite element analysis and genetic algorithm-back propagation neural network

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  • Xie, Mingjiang
  • Wei, Ziqi
  • Zhao, Jianli
  • Chen, Yuejian

Abstract

Blending hydrogen into the existing natural gas pipelines is an effective way to reduce hydrogen transportation costs and facilitate the rapid adoption of hydrogen energy. However, the impact of hydrogen embrittlement on the burst pressure and remaining life of corroded pipelines is not well understood, which poses a significant challenge to pipeline integrity management. To overcome this challenge, this study examines the impact of hydrogen embrittlement on the mechanical properties of pipeline steel and utilizes finite element analysis to calculate the burst pressure of pipelines under varying corrosion geometrical parameters and hydrogen partial pressures. The results obtained are used to train a genetic algorithm-backpropagation (GA-BP) neural network model that predicts burst pressure for hydrogen-blended natural gas pipelines. Additionally, the corrosion maximum depth that can lead to pipeline failure is determined and the prediction of the remaining useful life is realized by integrating corrosion growth models. The findings indicate that the impact of hydrogen embrittlement on the burst pressure of corroded X52 pipelines is negligible. However, for corroded X80 pipelines, hydrogen embrittlement results in a reduction in the burst pressure of approximately 6 %, leading to a remaining useful life loss of around 0.24 years.

Suggested Citation

  • Xie, Mingjiang & Wei, Ziqi & Zhao, Jianli & Chen, Yuejian, 2025. "Failure analysis of corroded hydrogen-blended natural gas pipelines based on finite element analysis and genetic algorithm-back propagation neural network," Reliability Engineering and System Safety, Elsevier, vol. 262(C).
    • Handle: RePEc:eee:reensy:v:262:y:2025:i:c:s0951832025003758
    DOI: 10.1016/j.ress.2025.111174
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    1. Joshi, Anirudha & Sattari, Fereshteh & Lefsrud, Lianne & Khan, M.A. & Xue, Yuxuan, 2025. "Hydrogen Integration into Natural Gas Pipelines: Risk Analysis and Regulatory Recommendations," Reliability Engineering and System Safety, Elsevier, vol. 264(PB).
    2. Zhu, Xian-Kui & Herrington, Joshua, 2026. "Comments on “Failure analysis of corroded hydrogen-blended natural gas pipelines based on finite element analysis and genetic algorithm-back propagation neural network†[262 (2025) 111174]," Reliability Engineering and System Safety, Elsevier, vol. 269(C).
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