Finite Element Analysis of Local Hydrogen Concentration in Hydrogen Pipeline With Corrosion Defects

doi:10.11902/1005.4537.2024.161

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (2): 359-370 DOI: 10.11902/1005.4537.2024.161

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Finite Element Analysis of Local Hydrogen Concentration in Hydrogen Pipeline With Corrosion Defects

CUI Dechun¹^,², XIONG Liang¹, YU Bangting¹, WU Haozhi³, DONG Shaohua³, CHEN Lin³(

)

^1.New Energy Research Department, CNOOC Research Institute Co., Ltd., Beijing 100028, China
^2.Shanxi Research Institute of Huairou Laboratory, Taiyuan 030032, China
^3.College of Safety and Ocean Engineering, China University of Petroleum, Beijing 102249, China

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CUI Dechun, XIONG Liang, YU Bangting, WU Haozhi, DONG Shaohua, CHEN Lin. Finite Element Analysis of Local Hydrogen Concentration in Hydrogen Pipeline With Corrosion Defects. Journal of Chinese Society for Corrosion and protection, 2025, 45(2): 359-370.

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Abstract

Deep understanding on the interaction of hydrogen atoms with pipeline steel is crucial for the matter of the integrity and safety in-service of hydrogen pipeline infrastructure, especially for the case when the existing pipelines with corrosion defects were adopted as hydrogen transportation pipeline. Herein, a finite element (FE) model was developed by coupling mechanical- and diffusion-fields in COMSOL Multiphysics, so that the effect of internal pressure, defect location, defect length and depth on the hydrogen diffusion and distribution was assessed. Results demonstrated that internal pressure may induce local stress concentration and non-uniform hydrogen distribution at defect. Hydrogen concentration at defect increases with the internal pressure, but the threshold of hydrogen concentration at internal corrosion defects is lower than that at external corrosion defects, and the corresponding positions of the maximum hydrogen concentration are different for the two defects. Moreover, the defect length and depth also affect the hydrogen concentration threshold and where the hydrogen concentration maximum emerges, but such effects vary depending on whether the corrosion in question is internal or external.

Key words: corrosion defect finite element model hydrogen distribution X52 steel

Received: 22 May 2024 32134.14.1005.4537.2024.161

TG111.91

Corresponding Authors: CHEN Lin, E-mail: chenlin@cup.edu.cn

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	CUI Dechun
	XIONG Liang
	YU Bangting
	WU Haozhi
	DONG Shaohua
	CHEN Lin

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.161 OR https://www.jcscp.org/EN/Y2025/V45/I2/359

Fig.1 Schematic diagrams of a pipe segment under internal pressure (a), top and cross-sectional views of a corrosion defect present on the pipe (b), a quarter model used in numerical analysis (c), an internal corrosion defect and an external corrosion defect on the model (d), Schematic diagrams of the left and right edges of internal (e) and external (f) corrosion defect

Fig.2 Mesh of the model: (a) mesh of the whole model, (b) mesh of the region 1 and 2, (c) mesh of the corrosion defect

Fig.3 Maximum von Mises stress, hydrostatic stress and hydrogen concentration at the external corrosion defect and mesh sensitivity analysis

Fig.4 Distributions of von Mises stresses (MPa) at internal (a-c) and external (d-f) corrosion defects under an internal pressure of 6 MPa (a, d), 8 MPa (b, e) and 10 MPa (c, f)

Fig.5 Liner distributions of von Mises stresses along the left edge (a, c) and right edge (b, d) of the internal corrosion defect (a, b) and the external corrosion defect (c, d)

Fig.6 Distributions of hydrostatic stresses (MPa) at internal (a-c) and external (d-f) corrosion defects under an internal pressure of 6 MPa (a, d), 8 MPa (b, e) and 10 MPa (c, f)

Fig.7 Liner distributions of hydrostatic stresses along the left edge (a, c) and right edge (b, d) of the internal corrosion defect (a, b) and the external corrosion defect (c, d)

Fig.8 Hydrogen diffusion process at external corrosion defect at 10 MPa (Color legend: hydrogen concentration, mol/m³): (a) 1 × 10⁵ s, (b) 5 × 10⁵ s, (c) 1 × 10⁶ s, (d) 1.5 × 10⁶ s, (e) 2 × 10⁶ s, (f) 2.5 × 10⁶ s

Fig.9 Distributions of hydrogen concentrations (mol/m³) at internal (a-c) and external (d-f) corrosion defects under an internal pressure of 6 MPa (a, d), 8 MPa (b, e) and 10 MPa (c, f) at 5 × 10⁶ s

Fig.10 Liner distributions of hydrogen concentrations along the left edge (a, c) and right edge (b, d) of the internal corrosion defect (a, b) and the external corrosion defect (c, d)

Table 1 The maximum hydrogen concentrations under different internal pressures

Fig.11 Locations of the maximum hydrogen concentrations of internal corrosion defect (a) and external corrosion defect (b)

Fig.12 Hydrogen distribution at internal (a-d) and external (e-h) corrosion defects with different lengths under an internal pressure of 10 MPa at 5 × 10⁶ s (Color legend: hydrogen concentration, mol/m³): (a, e) 10 mm, (b, f) 12 mm, (c, g) 14 mm, (d, h) 16 mm

Table 2 The maximum hydrogen concentrations at different defect lengths

Fig.13 Hydrogen distribution at internal (a-d) and external (e-h) corrosion defects with different depths under an internal pressure of 10 MPa at 5 × 10⁶ s (Color legend: hydrogen concentration, mol/m³): (a, e) 1.91 mm, (b, f) 2.86 mm, (c, g) 3.81 mm, (d, h) 4.76 mm

Table 3 The maximum hydrogen concentrations at different defect depths

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