Table of Content

IPHE: Hydrogen is Not a Greenhouse Gas and Will Not be Included in The ISO International Standards

By Mhamed Samet, FCHEA

In an article by Rachel Parkes published in Hydrogen Insight, the International Partnership for Hydrogen and Fuel Cells in the Economy (IPHE) executive director, Laurent Antoni, was quoted at the World Hydrogen Summit in Rotterdam, stating that 'Hydrogen is not a greenhouse gas and will not be counted as one in our ISO international standards'. According to the same article, he also added that in the context of hydrogen, only methane emissions should be factored, and fugitive methane emissions have already been woven into the methodology for the draft international standard (ISO 19870-1). 

To access the Hydrogen Insight article, click here. A subscription is needed to access the article.

ANSI Unmanned Aircraft Systems Standardization Collaborative (UASSC) Releases May 2025 Gaps Progress Report

By Mhamed Samet, FCHEA

The American National Standards Institute (ANSI) announced on May 19, 2025, the availability of the May 2025 Gaps Progress Report. ANSI states that this is a vital document capturing key standardization progress and opportunities for the rapidly evolving unmanned aircraft systems (UAS) industry. According to ANSI, the report was compiled by ANSI staff based on inputs from standards developing organizations (SDOs), subject matter experts, and independent research. It lists newly published standards and new standards projects, alongside suggestions for future roadmap modifications. The report is not a consensus document but rather is intended to serve as an interim “living document” that will be maintained and periodically re-published until such time as the UASSC develops a next version of the standardization roadmap.

To access the full ANSI May 2025 Gaps Progress Report, click here.

Failure Analysis of Stainless-Steel Pipe in Hydrogen Service, a Case Study Improving Our Knowledge of Hydrogen Safety in Pipes

By Mhamed Samet, FCHEA

Sudhakar Mahajanam, Materials and Corrosion Engineer at Mistras Group, provided a presentation during the Hydrogen Technology Expo North America in Houston on June 26, 2025, titled " Failure Analysis of Stainless-Steel Pipe in Hydrogen Service”. A summary of this presentation is included below:

The failure analysis of a stainless-steel pipe in hydrogen service revealed external chloride-induced stress corrosion cracking. The pipe underwent alternating heating and cooling cycles, potentially introducing moisture. Two primary cracks were found on either side of the weld, with trans granular fracture morphology and multiple branching. Metallographic examination showed typical austenitic stainless-steel microstructures with residual ferrite. Microhardness measurements ranged from 82 to 92 HV, higher than expected for 316L stainless steel. Chemical analysis confirmed the material met 316L specifications. The failure was attributed to corrosion under insulation, emphasizing the need for proper insulation and maintenance to prevent such issues.

Detailed information from the presentation can be found below. 

Failure Analysis:

Mr. Mahajanam explained the process involves alternating heating and cooling cycles, with temperatures ranging from 160 degrees centigrade to 210 degrees centigrade, followed by cooling to 25 degrees centigrade. The process stream is hydrogen with traces of chlorosilane, and there is a possibility of moisture presence, which reacts with chlorosilane to form hydrochloric acid, causing corrosion. Upon receiving the pipe section, two distinct cracks were found on either side of the weld and on the intrados side, with additional pits on the other side of the weld. Fractography and metallographic examination were conducted using stereo microscopy, scanning electron microscopy, and energy dispersive excess spectroscopy to analyze the fracture surface and corrosion products.

Fractography and Metallographic Examination:

The speaker described the use of lab overload techniques to open the cracks and the subsequent fractography and metallographic examination. Stereo micrographs showed the fracture surface on the pipe side, with a predominantly trans granular fracture morphology. Energy dispersive excess spectroscopy revealed the presence of iron, oxygen, chromium, chloride, sulfur, nickel, and silicon on the fracture surface. Metallographic examination revealed multiple branching trans granular cracks originating from the outside surface of the component, with typical austenitic stainless-steel microstructures and residual ferrite bands.

Microhardness Measurements and Chemical Analysis:

Microhardness measurements were taken using a microhardness indenter, with the pipe side showing the highest hardness, the weld side the softest, and the elbow side in between. Optical emission spectroscopy confirmed that the pipe and elbow materials met the 316 austenitic stainless-steel specifications, with nickel levels slightly below the 10% minimum. The analysis concluded that the cracks were due to external chloride-induced stress corrosion cracking, initiated by moisture leaching through breaks in the weather barrier during alternating heating and cooling cycles. Mr. Mahajanam concluded the presentation emphasizing the importance of proper insulation and maintenance to prevent corrosion under insulation, which can be mitigated by using coatings, inhibitors, and low-chloride insulation materials.

Hydrogen Blending into Natural Gas Pipelines - Safety and Operational Best Practices

By Mhamed Samet, FCHEA

Wakelin Fulford, Professional Engineer and Solutions Specialist at Lakeside Process Controls, provided a presentation during the Hydrogen Technology Expo North America in Houston on June 26, 2025, titled "Hydrogen Blending into Natural Gas Pipelines”. A summary of this presentation is included below:

The discussion focused on hydrogen blending into natural gas pipelines, highlighting the need for accurate metering using Coriolis technology, the importance of safety measures like fire detection and environmental monitoring, and the necessity of (Computational Fluid Dynamics) CFD analysis to ensure proper gas mixing. The speaker emphasized the need for specialized technology and safety standards. The presentation also covered the importance of accurate gas analysis for financial reasons and the potential use of different technologies for rapid data transfer.

Given that pipeline companies are checking if their infrastructure can handle hydrogen blends, Mr. Fulford focused on the technical considerations for hydrogen blending. He started by explaining the importance of 100% uptime for gas utilities. Hydrogen blends need to be managed to avoid shutting down the pipeline. Slipstreams and shutdown valves are recommended to handle overshoots in the blend. Coriolis metering was suggested by the speaker for accurate hydrogen measurement.

Safety and Environmental Considerations:

The speaker also emphasized the importance of fire and leak detection due to the different burning characteristics of hydrogen and hydrocarbons. Environmental monitoring and personal gas monitoring are necessary for hydrogen leaks. Safety standards may need to be updated for hydrogen injection projects. Hydrogen diffuses and mixes differently in pipelines, requiring CFD analysis to ensure proper mixing.

Gas Analysis and Technology:

Mr. Fulford discussed the use of Gas Chromatography Mass Spectrometry GC-MS for full gas analysis but notes their slow response time. Accumulation chambers or fast-response technologies like catalytic or Infrared (IR) technology are recommended for verifying blends. Different gas analysis technologies have varying maintenance requirements and response times. Specialized technicians and (Standard Operating Procedures) SOPs may be needed for hydrogen blend stations.

Engineering and Management Considerations:

The expert highlighted the importance of material science to avoid embrittlement and pipe structuring. Management of change is crucial, with proper reviews required for any changes. Management of change is crucial, with proper reviews required for any changes. Hydrogen blend skids can be more complex than natural gas skids, requiring more technology and safety considerations. The presentation concluded by Mr. Fulford emphasizing the importance of safety and accuracy in hydrogen blend projects.

CGA H-7, Standard Procedures for Hydrogen Supply Systems - Training Now available

By Mhamed Samet, FCHEA

CGA announced the release of a set of resources relating to an important standard: CGA H-7, Standard Procedures for Hydrogen Supply Systems. This standard provides comprehensive best practices for working with both gaseous and cryogenic liquid hydrogen systems, including:

·       Key hydrogen properties and hazard awareness

·       General safety principles for hydrogen supply systems

·       Step-by-step procedures for commissioning and decommissioning systems

Explore more by visiting CGA's hydrogen safety initiative, safehydrogenproject.org, or click here to contact CGA.

Report on Safety Considerations for Green Hydrogen Production

By Aidan Dennehy, FCHEA

The Institute for Sustainable Process Technology (ISPT), a non-profit organization working towards a climate-neutral process industry, released a report titled “Enabling Safe Green Hydrogen Production on Industrial Scale”. The study examined process safety based on generify hazard scenarios for Alkaline (AEM) electrolyzers and Proton Exchange Membrane (PEM) electrolyzers. The report was managed and produced by the ISPT in collaboration with hydrogen safety experts at a variety of organizations, such as Shell, Ørsted, and Plug Power.

Threats identified

The report identified two primary ‘top event’ scenarios with unique threats: in-equipment hydrogen and oxygen mixing, leading to explosion or fire, and a loss of containment, leading to unintended hydrogen release.

In-equipment mixing:

One of the principal safety concerns in green hydrogen production via electrolysis is the unwanted mixing of hydrogen and oxygen within equipment. The design of systems, degradation of cell stacks/components, membrane maintenance, and process control all minimize threats which can lead to in-equipment mixing. Design-related issues to avoid include inadequately defined low-load operating conditions and non-uniformities in flow, temperature, or current distribution within the stacks. Proper inspection and maintenance is key to monitor equipment degradation over time, caused by factors such as pressure fluctuations, particle intrusion, or membrane wear, compromises the integrity of cell components and increases the risk of gas crossover. Manufacturing or maintenance errors, such as improper assembly or overtightening of membranes, could also pose a risk. In addition, process control failures, including inadequate monitoring or regulation of key parameters like pressure, temperature, flow, and current, can allow hazardous conditions to develop undetected.

Loss of containment:

The second major safety scenario addressed in this study is the loss of containment of hydrogen or oxygen, which can lead to dangerous leaks into the surrounding environment. This scenario can be mitigated by proper design, maintenance/manufacturing procedures, and process control. When a system’s design properly accounts for environmental conditions and the properties of hydrogen, loss of containment is made less likely. Design considerations include material compatibility to avoid weaknesses such as hydrogen embrittlement, corrosion from alkaline substances, and equipment fatigue due to improper material selection or system stress. Manufacturing and maintenance activities, especially those involving external mechanical interactions, should avoid errors during repair, which could lead to unintentional breaches in containment. Lastly, process control failures, particularly those involving pressure and temperature regulation, must be avoided, as these can result in dangerous pressure levels or mechanical stress that compromises containment.

Recommendations

Technical recommendations

·       Install gas analyzers and detectors near stacks and gas/liquid separators

·       Install Safety Instrumented Systems (SIS) which trigger automatic safety measures when a certain amount of gas is detected

·       Utilize Cell Voltage Monitoring (CVM) and trend analysis to identify early signs of membrane degradation

·       Define minimum safe load thresholds based on the specific technology and operating conditions of each electrolyzer plant

·       Separate hydrogen and oxygen streams in the plant

·       Minimize the number of flanges

·       Design for the end-of-life conditions of electrolyzer components, such as thinner membranes with increased gas crossover

Organizational recommendations

·       Creating an evolving Process Management System (PSM) which covers specifies responsibilities, identifies hazards, establishes emergency plans, and plans for performance monitoring and inspections

·       Selecting unmanned or remote options

·       Minimizing the use of local instruments which need frequent inspections or calibration

·       Specifying the maximum number of staff and maximum hours per day if operations require regular manual assistance

AEM and PEM specific recommendations

PEM electrolyzers often feature a pressure difference between the anode and cathode sides which limits the speed at which a detector can identify a flammable atmosphere. This report recommends considering an explosion-proof design for the anode side of the plant.

To read the full report from the ISPT, click here. To view the ISPT’s webinar presentation of the report, click here.

Cornell, Air Liquide and Other Universities, Non-profits, and Industry Members Launch Joint Study to Estimate Real-world Hydrogen Emissions Across Global Infrastructure

By Aidan Dennehy, FCHEA

A consortium of academics, non-profits, and members of the hydrogen industries have launched a joint study with the aim of estimating the hydrogen emissions from existing infrastructure in Europe and North America. The study will quantify hydrogen emissions rates from steam methane reformers, pipelines and compressors, liquefication facilities, and fuelling stations. Detecting and estimating hydrogen emissions has important safety and environmental implications which all participants are interested in.

Researchers will use one of the first commercially available highly precise and fast hydrogen analyzers and mobile/portable sensing platforms to detect site and component level hydrogen emissions. Field work began in March 2025 and is planned to finish in early 2026. The four industry partners enabled the study by providing researchers access to their facilities. After the data is aggregated and anonymized, researchers hope to analyze and publish it in peer-reviewed journals.

“As hydrogen becomes an increasingly important part of the energy system, developing a robust, data-driven understanding of its emissions is essential to supporting informed decisions,” said Steven Hamburg, chief scientist and senior vice president at the Environmental Defense Fund. The research findings will help inform the policies, practices, and standards for preventing leaks from existing and emerging hydrogen technologies.

The consortium is made up of the following organizations:

  • Cornell University

  • Utrecht University

  • University of Rhode Island

  • West Virginia University

  • Air Products

  • Air Liquide

  • Shell

  • TotalEnergies

  • Aerodyne Research

  • TNO

  • Transport Energy Strategies

  • Environmental Defense Fund (EDF)

To read the press release from Cornell, click here.