CO2SafePipe - Phase 2: Advancing fracture control in CO₂ pipelines

The CO2SafePipe joint industry project (JIP), launched by DNV in 2023, is a key initiative to strengthen safety and enable scalable deployment of CO₂ pipeline infrastructure. The joint industry project quickly captured the industry’s attention. Starting with 15 forward-thinking participants, the project now boasts 38 engaged partners and stakeholders. This remarkable growth underlines the urgent demand for reliable, updated guidance within CO₂ pipelines.

The CO2SafePipe joint industry project builds on the proven foundations of DNV-RP-F104 Design and operation of CO₂ pipelines, as we integrate the latest research, field experience, and lessons from global collaborative projects. Our goal is to craft a project-specific guideline that not only informs the next revision of DNV-RP-F104 (due in 2026), but sets an updated new standard for the industry.

Challenge

Carbon capture and storage (CCS) may still be considered a young industry compared to oil and gas. Safe and cost-effective solutions for both new projects and existing assets are key for the development of a sustainable CCS value chain. As the sector is maturing and experiences are gained through R&D and projects, keeping the industry standards up to date and aligned with the latest knowledge is central to quickly tackle challenges as they arise.

Several operators are also evaluating repurposing existing pipeline infrastructure for CO₂ transport. In this context, ensuring e.g. reliable arrest of running ductile fracture can be more complex, and many practical cases still fall outside the current applicability range of existing standards such as DNV-RP-F104. 

There is therefore a clear need to:

• Reduce uncertainty in fracture predictions for dense phase CO₂
• Validate emerging models and assumptions
• Provide consistent, updated design guidance

Phase 2 focus: Validation through compact large-scale testing

With strong industry engagement and rapid growth in participation, CO2SafePipe is positioned to deliver the scientific basis and practical guidance needed to support the next revision of DNV-RP-F104 and future CCS projects worldwide. 

CO2SafePipe has led to two spin-off initiatives, namely the ongoing CO2SafePipe Polymers JIP and the upcoming CO2SpecChain JIP. Now, DNV is launching Phase 2 of the CO2SafePipe JIP to continue with the unsolved challenge of Running Ductile Fracture (RDF) and is calling for partners to join. 

Phase 2 centres on validating key findings from Phase 1 through targeted experimental testing and advanced simulations. By combining compact large-scale tests with numerical modelling, the project aims to establish an even more robust and reliable basis for fracture arrest in CO₂ pipelines.

Compact large-scale testing represents a step change in experimental validation of CO₂ pipeline behaviour, enabling efficient generation of high-quality data to support model development and design guidance.

The project has been awarded CLIMIT-Demo funding of up to 19.8 MNOK to support the experimental test programme.

Objective

Confidence through validation and testing

Phase 2 of CO2SafePipe is all about turning insight into impact. Our focus: validating key discoveries from Phase 1 with full-scale, physical testing in the challenging area of Running Ductile Fracture (RDF). By putting theory to the test, the objective is to provide:

• Rigorous validation through simplified models, simulations, and physical experiments
• Clear, actionable guidelines for ensuring fracture arrest across different pipeline types
• Comprehensive testing to address a wide range of operational scenarios and provide scientific evidence for new RDF models

Scope and test programme

A collaborative blueprint for success

The Phase 2 scope will combine experimental, numerical, and analytical work to address fracture behaviour under realistic conditions, supported by CLIMIT-Demo funding for the test programme. 

Our approach is structured, collaborative, and outcome driven. Phase 2 of CO2SafePipe’s work programme covers validation and execution of six compact large-scale tests supported by numerical simulations and development of a new RDF model. Our main work packages include:

• Model development: Creating next-generation RDF assessment tools
• Experimental validation: Performing unique compact large-scale tests for real-world assurance. Full-scale testing will be carried out at DNV’s Spadeadam Research & Development Facility in the UK, building on extensive experience from previous CO₂ pipeline test programmes
• Numerical evaluation: Harnessing digital tools to optimize crack arrestor design
• Water backfill assessment: Investigating new solutions for submerged pipeline safety
• Guideline development: Translating insights into practical standards and best practices

Benefit

The project will support the development of reliable and efficient CO₂ transport solutions by:

• Reducing design uncertainty and conservatism
• Enabling more cost-effective pipeline design (lower CAPEX)
• Supporting qualification of repurposed assets
• Providing access to shared data, test results, and validated methodologies

Ultimately, the project will contribute to accelerating CCS deployment and strengthening trust in CO₂ pipeline safety.

Project details

The JIP will be managed by DNV, and typical participants are operators, line pipe manufacturers, EPCI contractors, and authorities. Phase 2 is planned to be kicked off in Q2/Q3 2026, with an expected duration of approximately 24 months. 

The experimental test programme has been awarded CLIMIT-Demo funding of up to 19.8 MNOK, supporting the execution of compact large-scale testing. 

Full-scale testing will be carried out at DNV’s Spadeadam Research & Development Facility in the UK, building on extensive experience from previous CO₂ pipeline test programmes.

The project builds on strong engagement from Phase 1 and continues to invite partners to join and contribute to the development of future CO₂ pipeline standards. 

The results will form an important basis for the update of DNV-RP-F104.

Project status

The JIP proposal has been distributed to the industry and is open for participants to join. Information meetings will be arranged as needed.