Hydrogen Testing

Blue hydrogen is produced from natural gas with CO2 as waste product. When this CO2 is transported to underground storage sites for permanent carbon capture and storage (CCS), it creates unique testing challenges. Materials must withstand both CO2 and H2 at high pressures and temperatures, plus handle contamination from trace gases. Non-metallic seals and components must also be tested for rapid gas decompression (RGD) with CO2.  

 Due to hydrogen's small molecular size, it permeates through polymeric materials much faster than traditional gases like methane used in fossil fuels. Testing is essential to calculate potential losses through transmission line walls and seals. Element quantifies these rates at pressures up to 100 bar and compares these permeation rates with previously tested gases to provide accurate loss predictions.

 

Automotive hydrogen storage and fuel cell technologies require testing at particularly high pressures of 750-800 bar. These extreme conditions necessitate specialized testing protocols to ensure safety and reliability.

 

Hydrogen has different diffusivity and corrosivity properties compared to natural gas. This requires specific adaptations for production plants, transport infrastructure, and distribution systems, along with modified maintenance processes for hydrogen service.

Green hydrogen, produced using renewable electricity sources like wind or solar power, requires the same rigorous material testing as other hydrogen applications. However, the integration with renewable energy systems may introduce additional cycling requirements that need to be considered in material selection and testing protocols.

ASME B31.12 is the most comprehensive standard currently available for designing steel piping systems that carry gaseous hydrogen.

The code comprises several sections, including General Requirements and Industrial Piping, as well as Pipelines, which encompass distribution systems. These sections are tailored to address the unique considerations associated with hydrogen systems.

Notably, the code incorporates fracture mechanics testing and material performance factors that account for the potential detrimental impact of hydrogen gas on the mechanical properties of carbon and low-alloy steels operating within the hydrogen embrittlement range. 

ASME B31.12 mandates that the pipe and its associated weld material must demonstrate sufficient resistance to fracture when exposed to hydrogen gas. The qualification process involves following the test method specified in ASME BPVC Sec VIII: Division 3- Article KD-1040, which in turn refers to ASTM E1681. This standard recommends the use of a constant displacement fracture mechanics test method, which is a cost-effective and relatively straightforward option for qualifying hydrogen transportation pipelines.

As a result, it has become a preferred choice in the industry for qualification testing purposes. Additionally, the Code introduces rules for the conversion or retrofitting of existing pipeline and distribution systems, allowing for the transition from natural gas or petroleum to hydrogen service.