Hydrogen Pipelines: Three Major Challenges & Solutions

Hydrogen may power the future, but transporting it safely is anything but simple. 

If you’re unfamiliar with hydrogen transportation and want to learn more, read on to learn three major challenges and some of the key strategies operators are using to tackle them: 

1. Hydrogen Embrittlement 
Hydrogen’s small size allows it to diffuse into metals, accelerating crack formation and increasing the risk of leaks. 

Solutions: 
• Use resistant materials (such as austenitic steel or other steel alloys) 
• Apply internal liners (such as PTFE or electroplating) 
• Perform frequent, high-resolution, and crack-focused inspections 

2. Explosive Potential 
Hydrogen has a low ignition energy, burns invisibly, and ignites with 0.2 mm gaps. 

Solutions: 
• Install hydrogen-specific leak detectors 
• Ensure proper ventilation and pressure control 
• Use inspection tools that can size extremely small cracks 

3. Permeation 
Hydrogen can pass through solid metals, even in the absence of cracks. 

Solutions: 
• Choose low-permeability materials (such as austenitic steel or nickel-based alloys) 
• Use high-grade gaskets and metal seals 
• Inspect joints and seals for early signs of wear (swelling, cracking, hardening) 

Hydrogen will shape the future of energy, but operators—along with their support teams—must get the infrastructure right.  

This starts with smart material choices, clear risk management, and the right inspection tools.