DEVELOPMENT OF AN ENGINEERING-BASED HYDROGEN-ASSISTED FATIGUE CRACK GROWTH DESIGN METHODOLOGY FOR CODE IMPLEMENTATION

Introduction: As the demand for clean energy solutions rises, gaseous hydrogen emerges as a promising energy carrier. However, one of the primary challenges to its widespread adoption is the development of a reliable hydrogen-specific transportation network. Research conducted by the National Institute of Standards and Technology (NIST) in collaboration with the U.S. Department of Transportation and the ASME committee B31.12 (Hydrogen Piping and Pipelines) has resulted in a novel phenomenological model to predict hydrogen-assisted (HA) fatigue crack growth (FCG) in API pipeline steels subjected to cyclic loading in high-pressure hydrogen environments. This research aims to bridge the gap between theoretical modeling and practical engineering applications, ensuring safe and efficient hydrogen transport.

Key Findings on the Predictive Model and Simplified Iterations: The full model predicts HA fatigue crack growth as a function of applied load and hydrogen pressure, providing a comprehensive understanding of the material behavior under these conditions. To facilitate implementation, two simplified versions of the model were developed in collaboration with ASME B31.12 for practical engineering applications. These simplified engineering-based iterations streamline the predictive model, ensuring that it can be efficiently integrated into engineering codes and standards for hydrogen pipelines. A detailed case study demonstrates the application of both simplified models, highlighting their benefits in real-world scenarios and their ability to enhance predictive accuracy while maintaining usability.

Innovative Approach to Code Implementation: The research employs advanced CFD techniques, leveraging RANS simulations to create fully developed boundary layer flows. The procedure incorporates computational domains tailored to specific urban or topographic requirements, providing a scalable and robust framework for structural wind engineering applications. This method facilitates detailed investigations into wind loading and blockage effects, setting a new standard for CFD simulations.

Potential Impact on Hydrogen Pipeline Installations: The implementation of these engineering-based models has the potential to revolutionize hydrogen transportation systems. By incorporating HA fatigue crack growth predictions into design codes, future hydrogen pipelines can achieve enhanced safety through reduced risk of material failure under cyclic loads in high-pressure hydrogen environments. They also provide improved durability through accurate modeling of fatigue crack growth to ensure long-term pipeline reliability, while streamlined development is enabled by simplified code implementations for efficient design and construction of hydrogen-specific pipelines.

Conclusion: This research provides a critical step toward the realization of a hydrogen-specific transportation network. The study lays the foundation for safer and more efficient hydrogen pipelines by combining theoretical models with practical engineering applications. The successful collaboration between NIST, the U.S. Department of Transportation, and ASME highlights the importance of integrating research with industry standards for the advancement of clean energy infrastructure.

Join the Discussion: What are your thoughts on the potential for hydrogen pipelines to revolutionize energy transportation? Share your insights and engage in a discussion on the future of hydrogen as a sustainable energy carrier.

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Original Research - - The full research paper, titled "Development of an Engineering-Based Hydrogen-Assisted Fatigue Crack Growth Design Methodology for Code Implementation," can be found on NIST.Gov here.