Abstract:
A long-distance hydrogen pipeline project in Hebei Province has completed government filing, featuring a pipe diameter, design pressure, and design throughput that rank highest among planned pure-hydrogen long-distance pipelines in China. Aiming at design challenges induced by hydrogen-specific properties, including susceptibility to hydrogen embrittlement, easy penetration of hydrogen atoms into metal lattices, wide explosion limit range, and high power consumption for compression, this study systematically analyzes similarities and differences between hydrogen and natural gas transmission pipelines, as well as the key technical points. Based on the project's feasibility study and design work, this analysis covers the full chain from strength design, material selection, equipment specification, and construction to approval and evaluation. The results indicate that hydrogen transmission pipelines can adopt strength design factors identical to those for natural gas pipelines once steel pipes pass hydrogen compatibility tests. With a performance-based wall thickness design method adopted and L415 (X60) longitudinal submerged arc welded (LSAW) pipes selected, the nominal wall thickness of the trunkline in Class 2 locations is reduced from 19.1 mm to 14.3 mm, saving approximately RMB 2.4 × 10
8 in steel pipe and construction investment. Furthermore, specialized hydrogen service requirements apply to valve stems, seats, sealing surfaces, and packing, while flow meters must be selected specifically for hydrogen service conditions. Hydrogen compatibility testing covering steel pipes, girth welds and valves, together with hydrogen industrial tests, serves as the core means to control the risk of hydrogen-induced material failure. This project's experience supports the development of standards such as GB/T 20801.5—2025 and SY/T 7820—2024, providing a valuable reference for future pure-hydrogen long-distance pipeline projects.