Pipeline transmission is expected to be the means by which hydrogen is delivered from future large-scale, centralized production plants and distributed to fueling stations. However, the existing hydrogen pipeline technology cannot be extrapolated to achieve the cost and performance goals required for successful implementation of this transmission and distribution network. Existing steel pipelines are subject to hydrogen embrittlement and are inadequate for widespread hydrogen distribution. Current joining technology (welding) for steel pipelines is major cost factor and can exacerbate the hydrogen embrittlement issues. New hydrogen pipelines will require large capital investments for materials, installation, and right-of-way costs. Hydrogen leakage and permeation pose significant challenges for designing pipeline equipment, materials, seals, valves and fittings. And the hydrogen delivery infrastructure is expected to rely heavily on sensors and robust designs and engineering.

Fiber-reinforced polymer (FRP) pipeline technology has the potential to overcome these barriers, enabling reductions in pipeline installation costs and providing safer, more reliable hydrogen delivery. An FRP pipeline is typically constructed as an inner non-permeable barrier tube that transports the fluid (pressurized gas or liquid), a protective layer over the barrier tube, an interface layer over the protective layer, multiple glass or carbon fiber composite layers, an outer pressure barrier layer, and an outer protective layer. FRP pipeline has improved burst and collapse pressure ratings, increased tensile strength, compression strength, and load carrying capacity, when compared to non-reinforced, non-metallic pipelines. The ability of FRP piping to withstand large strains allows it to be coiled so long lengths can be spooled onto a reel in an open bore configuration. The requirements for emplacement of FRP pipe are dramatically less than that for metal pipe; installation can be done in a narrow trench using light-duty, earth-moving equipment. This enables the pipe to be installed in areas where right-of-way restrictions are severe. In addition, FRP pipe can be manufactured with fiber optics, copper signal wires, power cables or capillary tubes installed directly into the structural wall of the piping. Sensors embedded in the pipe can be powered via copper wire from remote locations and real-time data from the sensors can be returned through fiber optics. This provides the advantage of lifetime performance monitoring of the pipe.

We will report on how FRP pipeline technology is being adapted for use with high-pressure hydrogen. We have assessed the capital cost for FRP hydrogen pipelines for delivery from production centers to population centers, and we project a cost that is near the DOE 2015 target for pipeline installation. We will report on our evaluation of life-cycle costs and failure modes, methods for qualifying materials and construction methods, the selection and integration of sensors, compliance with manufacturing codes and standards, and commercialization strategies.