HYDROGEN TRANSPORTATION PIPELINES

1 HYDROGEN TRANSPORTATION PIPELINES IGC Doc 121/04/E GLOBALLY HARMONISED DOCUMENT EUROPEAN INDUSTRIAL GASES ASSOCIATION AVENUE DES ARTS 3-5 B 1210 BRUSSELS Tel : +32 2 217 70 98 Fax : +32 2 219 85 14 E-mail : Internet : EIGA 2004 - EIGA grants permission to reproduce this publication provided the Association is acknowledged as the source EUROPEAN INDUSTRIAL GASES ASSOCIATION Avenue des Arts 3-5 B 1210 Brussels Tel +32 2 217 70 98 Fax +32 2 219 85 14 E-mail: Internet: IGC Doc 121/04 HYDROGEN TRANSPORTATION PIPELINES KEYWORDS CORROSION CLEANING CONTRACTOR ENVIRONMENT FIRE HAZARD HYDROGEN INSPECTION LEGISLATION METERING PIPING SYSTEM PREVENTION SAFETY TRANSPORTATION VALVE WELDING WORK PERMIT PIPELINE Disclaimer All technical publications of EIGA or under EIGA's name, including Codes of practice, Safety procedures and any other technical information contained in such publications were obtained from sources believed to be reliable and are based on technical information and experience currently available from members of EIGA and others at the date of their issuance.

2 While EIGA recommends reference to or use of its publications by its members, such reference to or use of EIGA's publications by its members or third parties are purely voluntary and not binding. Therefore, EIGA or its members make no guarantee of the results and assume no liability or responsibility in connection with the reference to or use of information or suggestions contained in EIGA's publications. EIGA has no control whatsoever as regards, performance or non performance, misinterpretation, proper or improper use of any information or suggestions contained in EIGA's publications by any person or entity (including EIGA members) and EIGA expressly disclaims any liability in connection thereto. EIGA's publications are subject to periodic review and users are cautioned to obtain the latest edition. IGC DOC 121/04 Table of Contents 1 Introduction.

3 1 2 Scope and 1 3 Definitions .. 2 4 Design 5 General criteria .. 5 Properties of 6 Flammability .. 6 Brittle fracture and environmental damage mechanisms .. 6 Metallic Materials .. 7 Generalities .. 7 Carbon 8 Microalloyed Steels .. 9 Carbon-Molybdenum (C-Mo) and Carbon-Molybdenum-Chrome (C-Mo-Cr) Low Alloy 11 Stainless Steels ..11 Nickel Alloys .. 11 Copper and Cobalt 12 Compatibility with Non Metallic Materials .. 12 Plastics .. 12 12 Piping Systems .. 13 Underground piping 13 Above-ground piping systems .. 14 Pipeline 14 Corrosion protection .. 14 Leakage 16 Hazard analysis and risk assessment .. 16 16 Identification of the hazards .. 16 Mitigating measures .. 16 Typical event scenarii .. 17 Consequences of these events .. 17 Selection of a model to simulate the impact of an 17 Criteria for the feared 17 Definition of the zone to be studied around the 18 Risk 18 Siting.

4 18 5 Piping, valves and equipment .. 18 General criteria .. 18 Material selection criteria .. 18 Electrical hazardous area requirements .. 19 Piping .. 19 Venting .. 19 Flanges and 20 Threaded connections .. 20 Instrument 21 Valves .. 21 21 Valve functions ..21 Valve type 23 Miscellaneous valve issues .. 24 Other 24 Strainers and filters .. 24 IGC DOC 121/04 Flow measuring 24 Rupture Insulating 25 Flexible connections (hose, expansion joint, etc.).. 25 Miscellaneous equipment items .. 25 6 Cleaning .. 25 General requirements .. 25 Cleaning strategy .. 25 Standard of cleanliness .. 26 Cleaning methods .. 26 Pipeline components .. 26 27 Pressure Installation of pipeline equipment .. 27 Post-installation cleaning.

5 27 27 Propelling 28 Typical cleaning sequence .. 28 Maintaining cleanliness .. 29 Inspection .. 29 Acceptance criteria .. 30 Sealing, inerting, leak testing and monitoring .. 30 7 Construction .. 30 General Criteria .. 30 Specification and manufacture of line pipe 31 General 31 Codes and standards .. 31 Manufacturing process .. 31 Heat Hydrostatic test of line pipe .. 31 Construction 31 Pipe fabrication and 31 Qualifications .. 32 Backing rings ..32 Preparation for welding .. 32 Welding requirements for 32 Assembly and installation ..32 32 Flanged joints ..32 Insulating 33 Threaded 33 33 Supports, guides and 34 Inspection and examination .. 34 Non-destructive testing .. 34 Pressure Non destructive examination .. 35 36 8 Design and construction of 36 Function.

6 36 Design 36 Excess flow valves .. 37 Isolation valves ..37 Filters and strainers .. 37 Flow meters ..37 IGC DOC 121/04 Flow and pressure control .. 37 Gas storage ..37 Pressure relief ..37 38 Electrical .. 38 Standards and Design 38 Materials and fabrication .. 38 Access limitation .. 38 Location .. 38 Grounding .. 39 39 Pressure and leak testing ..39 39 Safety .. 40 Pre-commissioning 40 40 Pre-commissioning checks of the whole pipeline system .. 40 Operation .. 40 Filters / screens ..41 9 Operation and monitoring .. 41 Operation and maintenance manual .. 41 Management Systems .. 41 General Safety Requirements .. 41 Personnel for operation and maintenance .. 42 Welding and cutting .. 42 In service welding and cutting.

7 42 Out of Service welding and 42 Shut down, repair and start up of PIPELINES .. 42 Hot-Tapping HYDROGEN 43 43 43 Hot-Tap Procedure 43 Venting and pressure Venting: .. 44 Purging and 44 Commissioning PIPELINES and stations .. 45 Operation and monitoring .. 45 Information to third parties, work adjacent to PIPELINES and update of 45 45 Flow of information .. 46 Summary of work .. 46 Records .. 46 Updating of pipeline drawings .. 46 Specialised Damage to the pipeline 46 46 Other defects ..47 Detection of Defects .. 47 47 10 General protective measures ..47 Emergency response plan .. 47 Liaison with Public Authorities and other Consultees .. 47 Description of Pipeline 47 Control Centers .. 47 Notification of an Incident .. 48 Alerting 48 Shutting Down a Pipeline.

8 48 Emergency Equipment .. 48 IGC DOC 121/04 Remedial Action .. 48 PIPELINES with cathodic protection .. 48 Incident Report Form .. 48 Emergency drills .. 49 Accident and damage 49 Safety Management 49 Notification to Authorities and Consultation on Routing .. 49 Design and 49 Shutdown 49 Operations .. 49 Control of third party 50 Maintenance and Inspection .. 50 Major Accident Prevention Policies and Safety Management 50 Emergency Planning .. 50 Information to the Public and Interested Parties .. 50 Land Use 51 Accident Reporting .. 51 Appendix A: Typical arrangements for PIPELINES systems .. 52 Appendix B: Embrittlement And Environmental Damage Mechanisms Involving HYDROGEN And Applicable Test 53 Appendix C: Table of Nominal Alloy Compositions & 58 Appendix D: Metallurgical factors Affecting H2 Toughness and Brittle Fracture Mechanisms.

9 61 Appendix E: Table of Typical Safety Distances for HYDROGEN Control and Isolating / Metering 65 APPENDIX F: Example of Preventive Maintenance Program for HYDROGEN PIPELINES .. 66 APPENDIX G: Composition criteria for H2 and 67 Appendix H: Requalification of existing PIPELINES for HYDROGEN service .. 68 Appendix I: Ultra High Purity (UHP) HYDROGEN PIPELINES .. 72 Appendix J: Examples of risk criteria applicable in The Nederlands and in the United Kingdom .. 73 Appendix K: References .. 74 IGC DOC 121/04 11 Introduction This publication has been prepared by a group of specialists in pipeline systems, representing major industrial gases producers in various countries of Western Europe and North America and is based on the technical information and experience currently available to the authors.

10 The industrial gases companies have engaged, through CGA and EIGA, in a process of developing harmonized safety practices and this publication is one of them. It must be recognized, however, that pipeline systems, developed over 40 years in the various countries of Western Europe and North America have shown good and comparable safety records, although national practices show many differences in design and operations. Some national authorities have also introduced legislation, which is mandatory for the operators in those countries. Thus, the information contained in this document applies only to future installations and not to existing installations or those in the project phase, as of the date of this publication. Furthermore, to the extent that they exist, national laws supersede the suggested practices listed in this publication.