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.

UPDATE DECEMBER 2024

By the end of 2024, the ReadHY project celebrated its first anniversary ! This is the opportunity to share progresses observed during 2nd semester of ReadHY project.

Indeed, different activities were performed. In terms of project management, two technical meetings were held, in July (Teams) and in October (in Gent). A first communication about the project was also presented by Gent University as a poster at European Conference on Fracture (ECF 2024) in Zagreb in August 2024. Regarding the design of the Dynamic Tube Rupture Test (DTRT) (WP2), the definition of the specifications, as well as the technological choices, were accompanied by the implementation of a first DTRT prototype working with inert gases (WP5). Indeed, some preliminary trials are required in order to make the adequate technological decisions, mainly for hydrogen compression according to our specifications. In parallel, investigations about different techniques to follow crack propagation had to be conducted and especially focused on ultrasounds and on a compliance method. Complementary trials of crack propagation were also prepared using a tensile-fatigue machine, requiring some further development. WP4, dedicated to the preliminary validation of defect localization, also started during this semester, through the characterization of studied materials. Furthermore, specific investigations on hydrogen charging (electrochemical and gaseous ways) were held and adequate procedures were proposed for the project as well as for round-robin tests between partners. Finally, as already mentioned, WP5 focusing on the manufacturing of the DTRT and its specimen, also started. A preliminary prototype was built for proof-of-concept trials using inert gases and will be updated to a final set-up progressively.

During next semester, the design of the DTRT and the technological choices will be finalized to start manufacturing the final DTRT prototype. In parallel, investigations about the introduction of welds in samples will start. A deeper analysis about samples and notch dimensions will also be initiated to confirm first-order estimations performed during 1st year. Finally, WP4 will also continue by developing adequate charging procedures and performing mechanical tests.