Measurement

solutions for
improving hydrogen
storage and
transport
Contents
Hydrogen provides a decarbonization opportunity 3

Maximizing the potential of hydrogen 4

Challenges of working with hydrogen 5

Hydrogen storage 6–7

Transporting hydrogen 8–9

Detecting hydrogen leaks 10 – 11

Custody transfer 12

Truck loading and unloading 13

Hydrogen pipelines 14 – 16

Measurements throughout the value chain 17

Hydrogen industry expertise 18

2
Hydrogen provides a
decarbonization opportunity
Hydrogen is ideally suited to support the decarbonization of hard to abate
sectors such as steel production, cement, power generation, heating and
heavy mobility. Already used extensively in the chemical and refining sectors,
hydrogen’s expanded use as a clean fuel is gaining momentum, with support
from governments and cross-industry consortia across the globe, driving
major investment and a strong project pipeline.

3
Maximizing the potential
of hydrogen
The need to understand exactly how hydrogen is being stored and
transported is becoming increasingly crucial for the global economy and
the future of our power systems. Historically, hydrogen has been produced
wherever it is needed, but as the way we use hydrogen changes and grows,
the methods of transporting hydrogen will also need to expand. Electrolyzer
technology provides a fantastic opportunity to produce hydrogen beyond the
traditional industrial plant and closer to its end use. Hydrogen hubs – clusters
of local hydrogen production, storage and demand – are being developed all
over the world, from Australia to the United States.
Expanded storage and transportation capability
As hydrogen production capability increases, transportation throughput and storage
capacity are becoming key to maximizing the potential of hydrogen and its derivatives.
There are many factors to consider when determining the best storage and transport
solution for each use case, such as safety and economics. A major challenge is the
extreme pressures and temperatures involved in storage and transportation. These
extreme process conditions cause difficulties, which we will address in this publication.
Measurement technology
Accurate and reliable measurement technologies will be central to the successful
development of hydrogen systems and to ensure proper custody transfer across
a wide range of emerging energy transport and storage systems. Safety will be
paramount for transport of this volatile fuel, so related measurement technologies such
as leak detection and gas analysis systems are fundamental to the nascent networks.
4
Challenges of working
with hydrogen
The handling of hydrogen presents some unique challenges that impact
operational safety, reliability, efficiency and profitability.

Detecting leaks and managing safety concerns

Safety must always be a priority, both in terms of protecting employees and
infrastructure. Although hydrogen is non-toxic, it is extremely flammable,
with a combustible range of between 4-74% in air compared with 5-20%
for natural gas. Hydrogen leak and flame detection solutions can ensure a
safe working environment for all employees while ensuring the integrity of
operational assets.

Minimize product loss

It is important to measure and verify the quantity of hydrogen which moves
through the value chain, including pipelines, loading and unloading sites,
and storage facilities. Custody transfer points are required for compliance
and accounting purposes, but accurate metering can also quickly identify
and alert you to leaks to prevent excessive product loss.

Ensure hydrogen purity

Hydrogen purity requirements are dependent on the end use of hydrogen,
as hydrogen quality for applications like heavy duty transit are different
than the requirements for blending into natural gas. It is important to
understand the purity of the hydrogen being produced, moved and utilized
to ensure safety and performance expectations are met. Gas analyzers can
provide these purity insights at every step in the hydrogen value chain.

5
Hydrogen storage
There are several storage mechanisms for hydrogen available, including
high-pressure gas cylinders and super-insulated low pressure liquid cryogenic
storage vessels. Naturally occurring or specially engineered geologic
(underground) bulk storage can also be leveraged where geology supports it.

6
Storage methods
Compressed gas
The most common way to store hydrogen today is as a high-pressure (250 to 700 bar) gas in
cylindrical pressure vessels. These can be used to provide on-site storage or to move the hydrogen
to its point of use. Compressed gas cylinders can be transported directly to end users by trucks,
known as tube trailers. Material selection and permeation are critical factors when dealing with
high-pressure hydrogen.

Liquefaction
An alternative to transporting hydrogen gas in compressed cylinders is to convert it into a liquid.
Cryogenic liquefaction involves bringing the hydrogen down to a temperature of -253 °C (-423 °F).
There is an energy cost to this conversion, but this enables greater quantities to be efficiently
transported over long distances – including via marine transport. To prevent boil-off and product
loss, the hydrogen is stored in insulated tanks and must be kept at temperatures of -253°C.

Underground caverns
Salt caverns offer a unique underground hydrogen storage solution that have been utilized in
the United States since the 1980s. While this storage methodology requires adequate geology,
it does pose a viable storage solution for hydrogen. The unique properties of salt (NaCl) help
to contain the hydrogen in the formation. Allocation measurements during hydrogen injection
are essential for maintaining an accurate inventory of stored quantities, and considerations
like safety during the loading/unloading process must also be considered.

Alternative molecules
Another method of storing hydrogen is converting it into ammonia, methanol or ethanol to
make use of existing storage systems. Unlike hydrogen, these energy carriers do not require
storage at high pressure or low temperatures. Liquid organic hydrogen carriers (LOHCs)
provide another effective storage and shipping method. LOHCs are compounds that can
absorb and release hydrogen through chemical reactions. LOHC technology has the potential
to offer great advantages such as high-density storage and enabling fuel cell electric vehicles
to be fueled easily, similar to conventional vehicles today.

7
Transporting hydrogen
If hydrogen is not being produced at its point of use, then there are several
transportation options which can be utilized to move the hydrogen to where it
is needed, including pipelines, trucks and marine vessels. Distance, geography,
cost, energy loss and end use are all key factors in determining which method
will be best suited.

Pipelines
Pipelines offer an established way to deliver large volumes of hydrogen.
These include dedicated hydrogen pipelines and those used to distribute
natural gas, with hydrogen blended in. Many countries around the world
have successfully trialed the blending of up to 20% hydrogen into the
natural gas line for use by residents. Studies show that you can still safely
use existing household appliances at these levels without retrofits. Accurate
metering is essential to ensure blends stay within safety limits and for
custody transfer of the hydrogen. New dedicated hydrogen pipeline
infrastructure projects connecting producers, distributors (i.e., fueling stations)
and consumers will help expand pure hydrogen usage.

Truck
Hydrogen can either be compressed and transported in high-pressure tube
trailers or liquefied using a cryogenic liquefaction process and transported in
hydrogen tankers. Transportation by truck is well established, allows for quick
deployment and provides endless flexibility.

Marine vessels
Transportation overseas is enabling large producers to be matched with
high consumers. Dedicated marine vessels that use hydrogen as a fuel and
transport it as cargo are now being built to ensure safe shipping. These
vessels resemble LNG tankers, but there are critical differences in terms
of construction materials and instrumentation that must be deployed for
process optimization and safety monitoring.

8
Alternative molecules
Similar to storing hydrogen as an alternative
molecule, hydrogen can be converted
into an alternative molecule or LOHC for
the purpose of transportation. Gases
like ammonia, methanol and ethanol
have well-established value streams and
safety systems in addition to the benefits
of not requiring high pressure or low
temperatures. LOHCs allow transportation
at ambient temperatures and pressures,
making it safer, more practical and cost
efficient using existing conventional fuel
networks. These alternative forms can be
used as-is or converted back into hydrogen
at the end destination for consumption.

Regardless of how hydrogen is handled, the

main challenges around operational safety,
reliability, efficiency and accountability
remain. Let us dive into how to manage
those challenges to ensure a safe and
profitable operation.

9
Detecting hydrogen leaks
Fast detection of leaks from pipelines and storage equipment is
needed to ensure safety, minimize product loss, and ensure regulatory
compliance. Hydrogen flames are invisible to the naked eye and
traditional methods of flame detection put employees at an elevated
risk. Being able to identify and locate a leak remotely improves the safety
of operators and provides early notification of product loss.

10
Leak detection
Not all leak detection devices are created equal. Lack of design durability and
diagnostics from detection devices can provide a false sense of security and
trigger unnecessary responses. Accurate, consistent monitoring utilizes a range
of Rosemount™ gas leak detection solutions from Emerson, to enable the early
detection of leaks. Rosemount Incus Ultrasonic Gas Leak Detectors use acoustic
sensors to identify fluctuations in noise that are imperceptible to the human ear.
Unlike traditional gas leak detectors that measure accumulated gas, ultrasonic
gas leak detectors “hear” the leak, triggering an early warning system. Ultrasonic
gas leak detectors are ideally suited for monitoring outdoor applications and are
unaffected by inclement weather, wind, leak direction or gas dilution.
FD
Rosemount 975HR
FD Multi-Spectrum Infrared
Hydrogen Flame Detector
Rosemount Incus
UGLD Ultrasonic Gas
Leak Detector
At storage facilities there is a need to protect both infrastructure and personnel by
implementing automated leak and flame detection solutions that quickly identify
the leak/ignition and raise an immediate alert, improving safety and corrective
action response time. The Rosemount 975HR Multi-Spectrum Infrared Hydrogen
Flame Detector is designed for tough environments and capable of detection at
long distances. These flame detectors provide a fast response with minimal false
alarms, allowing rapid corrective actions that lead to improved personnel safety
and productivity. Wherever hydrogen is produced, moved, stored or dispensed,
hydrogen leak detection will be an important consideration.
UGLD
FD
11
Custody transfer
Custody transfer takes place at multiple points throughout the value chain,
requiring accurate measurement during the loading and unloading of trucks
and marine vessels; at various points along pure hydrogen pipelines, where
hydrogen is injected into the natural gas infrastructure; and when hydrogen
moves in and out of storage vessels at tank farms and terminals. In addition to
pressure, temperature and flow measurements to account for the exact amount of
hydrogen that passes through transfer points, there is also a need to measure gas
purity to ensure hydrogen meets the required specification.
When hydrogen moves from one customer to another and across country borders,
it is essential to have a certified custody transfer solution that provides high fiscal
accuracy and accountability to ensure regulatory compliance and contractual
agreements are being met. It is also important to ensure your custody transfer
solution is able to deliver high metering accuracy across wide flow ranges and
requirements – especially if there is any variability in the hydrogen supply.
In addition to determining the total quantity of product, it is equally critical to ensure
the quality meets required specifications. If there is any variation in the hydrogen
supply, gas analysis technology can provide insights to the purity of hydrogen.
Metrology-certified metering solutions from Emerson combine Micro Motion™
Coriolis flow meters and Rosemount chromatographs to provide assured accuracy
and traceability. This gives buyers and sellers of hydrogen confidence and ensures
compliance with gas quality standards and contractual agreements. Real-time
measurement helps increase operational efficiency, while instrumentation reliability
maximizes availability and operational efficiency.
For tank farm and terminal operators, it is essential to accurately monitor all product
movements to support transactions between suppliers and customers, but also to
determine inventory to optimize operations and increase efficiency. Maintaining
inventory balances through the use of dynamic custody transfer measurements will
eliminate uncertainty and ensure fair exchanges.

AT Rosemount 700XA
Gas Chromatograph
FT PT
TT

FT Micro Motion
Coriolis Flow Meter

PT Rosemount Pressure
Transmitter

TT Rosemount X-well™
Technology with 3144P
Wired Temperature
Flow Computer
Transfer of Data Representative Emerson engineered solution for custody transfer.

12
Truck loading and unloading
Accurate measurement of transaction quantities, whether fiscal or otherwise,
is essential at tube trailer loading stations – but it is important that loading
and unloading efficiency is not sacrificed in the process. It is also important
that measurement equipment be extremely reliable. Any disruptions caused by
malfunctioning instrumentation have the capacity to affect the entire hydrogen
supply chain – as well as lead to potential safety issues. Micro Motion Coriolis flow
meters from Emerson are specifically designed for this type of application. Their
compact size makes them ideal for installation in the tight confines of a loading station,
with the ability to measure the flow of gas at pressures over 16,000 psi/1100 bar.

UGLD

FD UGLD

FT Micro Motion High-Pressure

Coriolis (HPC) Series Meter

FD
FT Micro Motion High-Pressure
Rosemount 975HR
Coriolis (HPC) Series Meter
FD Multi-Spectrum Infrared
Hydrogen Flame Detector
AT

Rosemount Incus Ultrasonic

Rosemount
UGLD 975HR
Gas Leak Detector
FD Multi-Spectrum Infrared
Hydrogen Flame Detector
AT

Rosemount Incus Ultrasonic

UGLD Gas Leak Detector

13
Pure hydrogen
pipelines
From short distances to a dispensing station or
storage cylinder, to longer distances between towns or
across countries, hydrogen pipelines are the backbone
of the hydrogen infrastructure. Extensive pipeline
systems totaling over 4,600 kilometers already exist
across North America, the Middle East and Europe,
with more networks in progress. These pipelines are
purpose-built, since the flow velocities associated with
pure hydrogen are considerably higher than traditional
natural gas, and therefore all components in the
system need to be designed accordingly.

Non-intrusive Flexim clamp-on ultrasonic flow meters

can be applied on the largest pipe diameters for
control and monitoring purposes. The installation does
not require any physical interruption of the pipeline
and is usually carried out during ongoing operation.
The measuring device is not subject to wear and tear,
and it does not pose any leakage risk.

For pure hydrogen, it can be easier to handle

quantities through a direct mass measurement,
since pressure and temperature can change volumes
dramatically. Micro Motion Coriolis meters are
approved by OIML R-137 for hydrogen measurement
and provide highly accurate direct mass measurement
of pure hydrogen.

14
Blended hydrogen
pipelines
Hydrogen can also be moved by injecting hydrogen directly into existing
natural gas pipelines, creating a hydrogen blended natural gas fuel that
can then be combusted similarly to natural gas.

When injecting hydrogen into the natural gas line, it is important

to know the exact amount of hydrogen injected to ensure end
use performance. Metrology-approved inline Rosemount gas
chromatographs and Micro Motion Coriolis flow meters ensure the
hydrogen component fraction is carefully measured to maintain
calorific value and Wobbe limits. Additionally, the Rosemount family of
Ultrasonic Flow Meters have been independently tested and certified
by DNV GL for use in custody transfer applications of blended natural
gas containing up to 30% hydrogen. Real-time gas analysis and mass
measurements increase transfer efficiency and provide a detailed
picture of current operations, tracking products and fluid composition
and optimizing capacity to ensure you hit contractual requirements.

When blending hydrogen into the gas network, it is essential to

continuously monitor and control the injection process to ensure the
gas mix meets the desired specification. The quantity of hydrogen
and other potential components entering the gas network, along with
the natural gas line upstream of the injection point, must be analyzed
to understand how much hydrogen can be injected. The final blend
downstream of the injection also needs to be measured to ensure the
blend specification is met. Depending on operating pressure, hydrogen
permeation and embrittlement can be a concern so it is important that
all instrumentation is suitable and has material compatibility for use
with hydrogen. Existing equipment may not be compatible and should
be upgraded to ensure reliability, performance, integrity and safety.

15
Disruption to the existing natural gas pipeline is not always possible. Leveraging
non-intrusive flow measurements with a Flexim Ultrasonic Meter enables flow
measurement independent of the transportation line size and pressure rating.
Flexim meters can also calculate the molecular mass of the blended natural gas,
providing redundancy to the gas chromatograph when needed.
If an integrated, engineered solution is needed, Emerson offers hydrogen blending
and pipeline injection systems that provide the necessary instrumentation and
control systems to ensure compliance with gas quality standards and contractual
agreements.

Rosemount 700XA FT2 FT1

AT Gas Chromatograph

95% Pure H2
Micro Motion
FT1 Coriolis Flow Meter

FT2 Flexim FLUXUS G831 Natural Gas Pipeline H2 Blended Natural Gas
<30% H2
or

Ultrasonic Gas Flow

Measurement

or FT2 FT2
AT
or or
Micro Motion
Coriolis Flow Meter

Transfer of Data or or

95% Pure H2

Natural Gas Pipeline

Flow Computer
H2 Blended Natural Gas <30% H2

16
Measurements throughout
the value chain
Operators are under increasing pressure to have visibility into all aspects of their operation
to handle increasing quantities of hydrogen safely, efficiently, and cost-effectively.
Emerson’s advanced measurement instrumentation simplifies the implementation of
reliable and accurate measurements and delivers actionable insight that allow you to meet
and exceed operational goals.

Process temperature measurement without a thermowell

Rosemount X-well™ Technology provides non-intrusive temperature measurement without
the need for a thermowell and is simple and quick to install. This innovative technology
provides accurate measurements without adding potential leak points or requiring a
shutdown of operations to install and is available with both the Rosemount 3144P Wired
and Rosemount 648 Wireless Temperature Transmitters.

Pressure measurement
Accurate pressure monitoring throughout the transportation process is important,
but a wide application range that requires multiple device types increases complexity.
Rosemount pressure transmitters not only help reduce installation time and costs, but are
suitable for a wide measurement range, enabling standardization on a single device type.
Gold plating provides protection against hydrogen permeation where necessary.

Level measurement
Flow rates are used to track hydrogen movement throughout the value chain, but in
cryogenic tanks a direct level measurement is important to track fill levels. Differential
pressure (DP) level devices, such as the Rosemount 3051SAL Level Transmitter, provide
reliable data to verify the volume of hydrogen stored in cryogenic tanks, either at on-site
storage or during transport. Rosemount differential pressure level devices are available with
gold plating to protect against hydrogen permeation, extending the life of instrumentation
and protecting your investment.

17
Hydrogen
industry
expertise
In this rapidly evolving industry, reliable experts
and partners are critical to success. Working with
a partner such as Emerson, that has supported
hydrogen production for decades – and has
established full capabilities across the hydrogen
value chain – strengthens your position and
provides a long-lasting competitive advantage.
Emerson’s comprehensive range of enhanced
automation solutions integrate seamlessly to
reduce project complexity and form plant-wide
ecosystems to manage hydrogen storage and
transportation effectively and efficiently.

This is backed by deep industry and application

expertise that helps to eliminate costs and
ensure regulatory compliance and reliable
project execution. Connect with an expert to
learn more about Emerson’s measurement
instrumentation and engineered solution
capabilities with hydrogen.

18
 Download other eBooks:

• Advanced measurement solutions enhance blue hydrogen production

• Measurement solutions enable transition to green hydrogen

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