Investigating the Integrity Impacts of Hydrogen Gas on Composite/Multi-Layered Pipe

Overview

Main Objective

The objective of this project is to investigate the impact to the integrity of composite pipe when used to transport pressurized hydrogen gas. EWI will identify and address safety hazards to the pipeline facilities, people, and the surrounding environment. EWI will identify required design, material and construction specifications, maintenance procedures, and a roadmap for using alternative-steel and non-steel composite systems for composite pipelines.

Public Abstract

Non-metallic composite pipe (CP) is increasingly being used or considered as an alternative or replacement for metallic pipe in numerous conventional and low carbon oil and gas applications. Use of CP can be in dedicated, stand-alone pipelines or as an internal liner to retrofit existing steel pipeline networks. The growth in the use of CP in recent years is being driven by lower material and installation cost as compared to conventional welded steel pipelines, reduced corrosion concerns, and higher operational performance metrics. These features can significantly reduce material and transport cost, labor and numerous logistics concerns related to pipe procurement and pipeline construction. While interest in using and deploying CP is growing, there are many unknowns in its long-term durability, inspection and condition monitoring methods, and safety when used in higher pressure and temperature applications and to transport different fluids, including hydrogen.

The outcome of this investigation will enable development of enhanced guidelines for CP pipe manufacture, installation, operation, repair, and rehab for future hydrogen pipeline systems utilizing CP materials, both for stand-alone and internal liner applications. EWI's current PHMSA-funded project under Agreement No.: 693JK32110010POTA to investigate NDE methods for assessing damage in composite pipe systems will supplement the work and outcomes of this proposed program. This current PHMSA-funded research at EWI has provided valuable insights into the various manufacturing methods used in the CP industry and understanding various damage mechanisms that can occur in CP pipeline systems. The outcomes of both programs will be used to enhance actionable guidance to CP manufacturers and CP pipeline operators with specific consideration for hydrogen gas service.

Potential Impact on Safety: The proposed investigation on integrity impacts to composite pipes and their connectors will help ensure that long-term material properties are well understood before commissioning. This includes the transitions where composite pipe meets conventional steel pipeline systems. The deliverables of this project will set forth processes to understanding composite pipeline degradation mechanisms, potential damage tolerance limits, and their corresponding kinetics for manufactures, operators, and regulators.

Summary and Conclusions

Polymer-based composite pipes are gaining traction as a promising alternative to traditional steel pipelines in both conventional and low-carbon energy applications, including hydrogen transmission. Their appeal lies in reduced corrosion risk, lower material and installation costs, and ease of transport and installation—thanks to the ability to manufacture them in long, spoolable lengths. As the energy sector explores the transition to hydrogen, this report examines the potential and limitations of using composite pipes in high-pressure hydrogen systems, especially with regard to safety, durability, and monitoring.

The report outlines key materials and design differences among pipe types, identifies hydrogen-specific safety hazards, and evaluates current codes and standards, including gaps that need to be addressed. It draws from a wide body of research and industry insights to highlight ongoing demonstration projects, structural monitoring technologies, and the impact of hydrogen contaminants on pipe performance. As composite pipes move closer to widespread use in hydrogen infrastructure, the findings underscore the need for updated regulations, tailored testing standards, and continuous innovation in monitoring and safety technologies.

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