Hydrogen Testing

Facing challenges with hydrogen infrastructure? As hydrogen becomes crucial for clean energy, Element understand your material and system testing needs. From fuel cells to storage facilities and pipeline adaptation, cryogenic conditions to extreme pressures, and from fracture mechanics to permeation - our expertise ensures your hydrogen systems operate safely and efficiently. Element's technical guidance supports your evolving needs, whether you're developing new infrastructure or adapting existing systems for hydrogen-natural gas blending. We’ll help validate your components against hydrogen’s unique challenges.

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What is Hydrogen Testing at Element?

Hydrogen testing is critical for validating your infrastructure's safety and performance in today’s evolving energy landscape. Our comprehensive testing ensures your systems can handle hydrogen's unique properties – from its high permeability to its potential for material embrittlement. Following ASME B31.12 standards and leveraging our evolving research in materials science and electrochemistry, Element’s experts help you prevent failures, verify material compatibility, and ensure operational safety across production, storage, and distribution systems.

Materials testing scientist using microscope for quality analysis at Element laboratory

What can Element offer you for Hydrogen Infrastructure Testing?

Key tests offered

Element's comprehensive testing services focus on mechanical and fracture mechanics testing in hydrogen environments. We conduct permeation testing on elastomers and thermoplastics up to 100 bar, and cryogenic testing down to -268°C.

Including:

Mechanical testing in H2 environments
Fracture mechanics testing
Permeation testing on polymers
Cryogenic testing
Pressure testing
Material qualification testing
Non-destructive examinations
Leak detection
Visual inspections
Pipeline system testing

Components and materials we test

We specialize in testing materials and components critical to hydrogen infrastructure. Our expertise covers steel piping systems, elastomers, thermoplastic transmission lines, fuel tanks for aerospace and automotive, compressor seals, and carbon and low-alloy steels. Whether testing for green hydrogen produced from renewables or blue hydrogen with carbon capture requirements, we ensure materials perform under real-world conditions to prevent embrittlement and failure.

Methods and solutions offered

Building on decades of materials science expertise, we provide comprehensive mechanical testing and fracture mechanics-based design approaches for hydrogen containment and transport components. Our testing methods include constant displacement fracture mechanics testing per ASTM E1681 and ASME BPVC Sec VIII: Division 3- Article KD-1040, - a cost-effective, industry-preferred qualification method. We support both new infrastructure development and existing system adaptation, including the transition from natural gas or petroleum to hydrogen service.

This includes:

Fracture mechanics-based design approaches
Material characterization
Qualification processes
Pipeline conversion assessment

Testing covers materials and components in various conditions:

Cryogenic environments (down to -268°C)
High-pressure environments (up to 800 bar)
Hydrogen-containing environments
Mixed gas environments
Environmental testing conditions

Which labs offer this service

Our hydrogen experts in the UK, Texas and California support you from key energy hubs. Our unique facility for comprehensive gaseous and liquid hydrogen testing is the only one of its kind in the UK.

Standards we test to and materials we test

These are our most prevalent requests. Don't see what you're looking for? Contact us!

Piping system and pipeline testing

Element’s team of experts possesses extensive knowledge of the code content and demonstrated expertise in the field. With their profound understanding, they are adept at navigating through the requirements and conducting thorough assessments of Hydrogen Pipelines according to the ASME B31.12, ASME BPVC Sec VIII: Division 3- Article KD-1040, and ASTM E1681 standards.

Your Challenges, Our Solutions

Preventing Catastrophic Failures

Element's comprehensive testing helps prevent system failures through rigorous mechanical and fracture mechanics testing. Our expertise in hydrogen embrittlement mechanisms and material characterization, combined with our understanding of both CO2 and H2 behavior in blue hydrogen applications, ensures your infrastructure meets ASME B31.12 standards, protecting your assets and personnel.

Hydrogen Compatibility Challenges

Our specialized testing covers both metallic and polymeric materials under extreme conditions. We evaluate hydrogen permeation rates, comparing them to traditional gases like methane, and assess embrittlement resistance to ensure your components maintain integrity throughout their operational lifecycle.

Complex, Evolving Requirements

Our team of experts, with extensive knowledge of code development and implementation of ASME B31.12 and related standards, streamline your path to asset deployment. We provide complete testing documentation and qualification services, helping you achieve compliance efficiently while maintaining the highest safety standards.

Adapting Existing Systems

Whether converting natural gas pipelines for hydrogen service or developing new infrastructure for green hydrogen from renewable sources, our testing services support both new construction and system conversion projects. We help validate your infrastructure's hydrogen readiness through comprehensive material testing, permeation analysis, and detailed performance assessment under real-world conditions.

Element Experts at your service

Steve Summerhayes

Lead Engineer

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Why Choose Element

Element materials testing engineer operating precision measurement equipment for quality analysis

Decades of Materials Expertise

Our extensive track record in materials testing and qualification ensures deep understanding of hydrogen's unique challenges across multiple industries.

Complete Testing Range

From cryogenic (-268°C) to high-pressure testing capabilities, we offer comprehensive hydrogen testing under all critical conditions.

Fracture Mechanics Leadership

Active participation in ASME code development and research in fracture mechanics-based design approaches puts us at the forefront of hydrogen containment and transport solutions.

Standards Development Experience

We incorporate our team's profound understanding of and involvement in industry standards into your testing program.

-268°C
Lowest temperature capability

for cryogenic testing of materials.

100 bar
Testing pressure capability

for polymer and elastomer permeation.

30+
years experience

in materials testing and qualification across hydrogen applications

8,500
Expert engineers and technicians

across our global testing network.

Element materials scientist conducting precision testing with advanced laboratory instrumentation

But don't just take our word for it

See what others have to say about partnering with Element

Mastering Hydrogen's Motion: Simulating gust-induced sloshing in the fuel tank of a liquid hydrogen powered aircraft
Discover how Element Digital Engineering solved complex liquid hydrogen fuel sloshing challenges for the ATI FlyZero program through advanced CFD modeling, helping enable the future of zero-emission aviation.
Modeling Hydrogen Dispersion Mitigation in an Enclosed Space
Tom Elson
Principal Engineer
Element Digital Engineering utilized Computational Fluid Dynamics to assess and enhance hydrogen leak detection and mitigation systems in containerized workshop units, successfully preventing dangerous gas dispersion through optimized sensor placement.

Frequently asked questions

What is blue hydrogen and how does it affect material testing requirements?

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.

Why is hydrogen permeation testing important for polymeric materials?

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.

What specific pressures are required for automotive hydrogen storage testing?

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.

How does hydrogen pipeline testing differ from natural gas pipeline testing?

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.

What special considerations are needed for green hydrogen infrastructure?

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.

What is covered in the scope of ASME B31.12?

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.