The plan is for the German hydrogen backbone network to become part of the “European Hydrogen Backbone.” This network is expected to reach a length of approximately 50,000 kilometers by 2040. The idea behind this is clear: Hydrogen is expected to play an important role in industry, energy supply, and the transition of the energy system in the future.

How secure is the hydrogen network?

But before hydrogen can flow through existing and new pipelines, many questions must be answered. This is because a network designed for natural gas cannot automatically be used for hydrogen. The issues at hand include the suitability of existing materials, the behavior of pipelines under changed operating conditions, and the safety of the entire system.

This is precisely where the new “ModuH2Pipe” test platform from the H2Safety Hydrogen Competence Center at the Federal Institute for Materials Research and Testing comes in. This “real-world laboratory”—arguably the first of its kind in Europe—creates an environment in which pipelines and their components can be tested under realistic yet extreme conditions.

The platform makes it possible to replicate the stresses that may occur during subsequent operation. For example, it can simulate significant pressure fluctuations or high flow rates. Pipelines are repeatedly subjected to pressures ranging from 10 bar to 85 bar. In this way, the startup and shutdown of a system can be simulated—a scenario that is relevant to the practical operation of hydrogen networks.

Non-destructive testing methods under real-world conditions

The quality of the transported medium can also be examined. Contaminants can be specifically added to analyze potential aging and damage processes in materials. At the same time, tests are conducted to determine whether the components used function reliably even under these conditions.

The focus is not limited to the materials themselves. ModuH2Pipe will also be used to test and validate manufacturing, welding, and repair processes. After all, a safe infrastructure depends not only on the quality of individual components, but also on how they are manufactured, joined, maintained, and repaired.

Another focus is on monitoring the equipment. Non-destructive testing methods are tested and refined under real-world conditions to enable the early detection of potential damage. The findings from these investigations will be incorporated into digital diagnostic and decision-making tools. These tools can, for example, help calculate the remaining service life of components or optimize maintenance cycles in a more targeted manner.

Tests Under Extreme Conditions: Pushing the Limits

The test platform is also used to explore the limits of performance. Components such as pipes and valves can be tested under extremely high pressures of up to 900 bar—far beyond normal operating limits. If a failure occurs during testing, the consequences can be examined in detail. The results provide important insights for further developing protective measures and safety concepts and for preventing or reducing potential damage.

At the opening of the real-world laboratory, Dr. Kai Holtappels, spokesperson for the H2Safety@BAM Hydrogen Competence Center, emphasized the importance of the new testing environment for the development of the hydrogen economy: “The testing platform is intended to become a driver of innovation for the hydrogen economy: Here, companies, grid operators, and research institutions can test new materials, components, monitoring procedures, and maintenance and repair concepts under real-world conditions. Together, we want to build confidence in hydrogen technologies and advance their widespread adoption.”

The test platform received 3.8 million euros in funding from the Federal Ministry for Economic Affairs and Energy (BMWE) as part of the federal government’s economic stimulus and crisis management package.

Source:Federal Institute for Materials Research and Testing