ReadHY

Development of an innovative testing method towards a better understanding of hydrogen[1]metal interactions to secure gaseous hydrogen transportation

Context : Renewable hydrogen is the key to securing a carbon-free energy supply by 2050.

National grid operators need support in the securing upgrade of existing facilities and in the development of new infrastructures to transport and store hydrogen-containing gases.

The development of new infrastructure or the repurpose / retrofitting of the existing gas transport network towards the transport of pressurized hydrogen requires an assessment of pipeline materials in terms of longevity in relation to exposure to hydrogen.

Unlike gas transport, hydrogen-metal interactions are expected in the case of hydrogen transport. Hydrogen can be absorbed by metals and even very small quantities of hydrogen (less than 1 to a few parts per million) can already lead to hydrogen embrittlement, characterized by a reduction of mechanical performance such as reduced ductility, delayed fracture, blistering, etc., which can lead to safety problems.

Project objective 

This project aims at designing a novel mechanical test in hydrogen-containing pressurized gases dedicated to industrial transportation pipe materials. The “Dynamic Tube Rupture Test”, as it will be named (and abbreviated DTRT), combines the specific features that need to be controlled to assess the ability of a pipe to be used for safe hydrogen transport. It will indeed enable to evaluate the resistance to crack propagation of industrial tubes (through the measurement of the crack growth rate) and the different zones of their welds containing defects and exposed to cyclic H2 pressures (in-situ testing).

The samples used for this assessment will have the same shape (tube) as the pipe but with a reduced diameter. Cracks will thus propagate in the same relative direction as in the real network which is not always feasible with CT specimens. This technique also exhibits the double benefit to answer an important industrial need, while allowing a fundamental investigation and understanding of hydrogen-metal interactions. The design of this novel technique will be challenging and will require a fine-tuned research to deliver a non-trivial testing method devoted to practical industrial issues.

Developed skills 

The ReadHY project aims at developing a technical support helpful for guaranteeing a safe transport of pressurized hydrogen within the Belgian transport infrastructure.

The project will contribute to the federal strategy :

• Expanding Belgian leadership in hydrogen technologies by developing competencies and tests directly useful to the market of the hydrogen economy.
• Establishing a robust hydrogen market by tackling the needs in the understanding the hydrogen interactions with real samples and to mimic the real industrial conditions to help in the development of efficient and safe processes in hydrogen transportation.
• Investing in cooperation between Wallon and Flemish universities and research centre for the benefit of industries associated to the gas infrastructure.

Funding framework : ETF Energy transition fund

Coordinator : Advanced Coatings & Construction Solutions

Partners :

Update June 2024

Renewable hydrogen constitutes a spearhead for guaranteeing zero carbon energy supply at 2050 skyline and enabling a successful energy shift. EU already exhibits a well-developed pipelines network for gas transportation. In order to retrofit / repurpose and complete this infrastructure, compatibility of materials with hydrogen has to be assessed (in terms of hydrogen embrittlement). In this framework, ReadHY project aims at studying the fatigue behaviour of materials in gas transport networks, which will be used for hydrogen transport. A new type of mechanical test, the Dynamic Tube Rupture Test (DTRT), will be developed to characterise hydrogen-material interactions at cracks and welds in order to assess the risk of pipe failure associated to material fatigue, reflecting variations in the pressure and flow rates of gas transport networks. The Dynamic Tube Rupture Test consists in exposing tubes to an internal cyclic pressure of gaseous hydrogen and in analyzing how this impacts crack propagation compared to a neutral gas pressure.

During 1st semester, work packages 1, 2 and 3 were started. Work was focused on materials selection, determination of specifications to be established for the DTRT, as well as on feasibility studies. Regarding material, X52 grade was chosen, for its good knowledge in literature, its use in gas transport applications and its availability in adequate formats. Material was obtained from a provider and disseminated between different partners. In terms of specifications of DTRT, many constraints were considered, going from dimension considerations of the tube to technologies for hydrogen cyclic compression, and including also safety, industrial representativity and budget considerations. To go further, the latter were also rapidly assessed through feasibility studies. More specifically, the different technologies of hydrogen compressors are analysed. Preliminary computations were performed to assess typical sizes of tubes and defects, the latter having to be consolidated by numerical means ulteriorly in the project. First proof-of-concepts trials are being elaborated (and will be performed and assessed during 2nd semester) to assess the feasibility of certain technical choices. Finally, an important feasibility study on the use of ultra-sound technique for crack growth propagation measurement was held. This study enabled to highlight that this technique is very promising, but that many artifacts can render the measurement very complicated and that an adequate measurement requires a very good knowledge of the tested material. In order to go further with this technique, real case studies will have to be performed to assess the global potential for measuring crack growth propagation, which will be done in the framework of the proof-of-concept trials foreseen.

During next semester, work packages 4 and 5 will start. WP4 will be focused on the characterization of material in presence of hydrogen in the presence of a controlled defect, while WP5 will go through the manufacturing of DTRT set-up and tubes.