The German Federal Institute for Materials Research and Testing (BAM) has opened a new living lab for hydrogen networks at its Test Site for Technical Safety near Baruth/Mark (Brandenburg). At its heart is the ModuH2Pipe modular test platform, the only one of its kind in Europe.
It enables the testing of materials, components, and operational processes for future hydrogen networks under realistic conditions. With this, BAM is laying an important foundation for the safe and cost-effective expansion of hydrogen infrastructure in Germany and Europe.
Germany plans to expand a hydrogen core network of more than 9000 km of pipelines by 2032. A large portion will be created by converting existing natural gas pipelines. This infrastructure is intended to become part of the European hydrogen network, the 'European Hydrogen Backbone,' which is expected to reach around 50 000 km by 2040. However, numerous technical and safety-related questions must be addressed to ensure safe operation – ranging from the suitability of existing materials to the behavior of pipelines under fluctuating operating conditions.
This is exactly where the test platform from the H2Safety@BAM Hydrogen Competence Center comes in. For the first time, ModuH2Pipe makes it possible to systematically test pipelines and their components under realistic and also extreme operating conditions.
This allows for the simulation of significant pressure fluctuations or high flow rates: Pipelines are repeatedly exposed to pressures ranging from 10 - 85 bar to simulate the start-up and shutdown of the system. Contaminants can also be specifically introduced to investigate potential aging and damage processes in materials as well as the functionality of components.
The focus is not only on the materials – manufacturing, welding, and repair processes will also be tested and validated. Non-destructive testing methods will be examined and further developed under real operating conditions to monitor pipelines and components. The insights gained will feed into the development of digital diagnostic and decision-making tools, such as those used to calculate remaining service life or optimize maintenance cycles.
In addition, ModuH2Pipe allows for the investigation of safety-critical issues: components such as pipelines or valves can be tested at extremely high pressures of up to 900 bar – far beyond normal operating limits. In the event of failure, the consequences can be analyzed in detail. On this basis, protective measures and safety concepts can be specifically improved and further developed to prevent or mitigate damage.
At the opening of the living lab, Dr. Kai Holtappels, spokesperson for the H2Safety@BAM Hydrogen Competence Centre, emphasised: “The test 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, as well as maintenance and repair concepts under real-world conditions. Together, we aim to strengthen confidence in hydrogen technologies and advance their widespread adoption.”
The test platform received €3.8 million in funding from the Federal Ministry for Economic Affairs and Energy (BMWE) as part of the German government’s economic stimulus and crisis management package.