WIKA – Hydrogen Handbook

WIKA HYDROGEN HANDBOOK_1.0.docx

1 General Information ....................................................................................................................... 3

1.1 Hydrogen Usage ...................................................................................................................... 3
1.2 Storage types of hydrogen ...................................................................................................... 4
1.3 Colors of Hydrogen ................................................................................................................. 5
2 Making the right Choice .................................................................................................................. 6
2.1 Choice of material ................................................................................................................... 6
2.2 Products – choice for hydrogen applications.......................................................................... 7
2.2.1 Mechanical pressure gauges ........................................................................................... 7
2.2.2 Differential pressure gauges ........................................................................................... 7
2.2.3 Electronic pressure sensor .............................................................................................. 9
2.2.4 Diaphragm seals ............................................................................................................ 10
2.2.5 Electrical temperature sensor ....................................................................................... 10
2.2.6 Valves ............................................................................................................................ 10
2.2.7 Mechanical pressure and temperature switches.......................................................... 11
2.2.8 Flow products................................................................................................................ 14
2.2.9 Sealing materials ........................................................................................................... 14
3 Change Log .................................................................................................................................... 15

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1 General Information

1.1 Hydrogen Usage

Hydrogen is the most common element in the universe, although not the most common element on
earth. It is the smallest and most simple atom in the periodic table.

On the way towards a CO2-neutral economy Hydrogen is gaining a more and more important role
across various industries. Typical and for WIKA interesting areas of usage are for example (no claim
that this list is complete):

 Hydrogen production (grey, blue, green)

 Ammonia / fertilizer production
 Methanol production
 E-fuel production
 Steel industry
 Conditioning, transport / distribution and storage
 Mobility, incl. fuel stations
 Power supply in buildings

The usage of Hydrogen is by no means a new technology. Already in the 18. Century hydrogen was
found to be a source of energy and is used since decades in aerospace as energy source for
propulsion and also in many other industries.

The strong push towards environmental friendly sources of energy revived the work on further
developing the potential of hydrogen.

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1.2 Storage types of hydrogen

CGH2 – Compressed Gaseous Hydrogen

- Gaseous hydrogen is stored at ambient temperatures

- Storage in solid steel or steel composite vessels
- Pressure ranges between 20 and 1000 bar
- Typical pressure levels in vehicles: 350 or 700 bar
- Industrial storage in salt caverns, exhausted oil and gas fields possible to store big amounts
of hydrogen

Liquefied Hydrogen (LH2)

- Hydrogen liquefies at -253°C

- Insulated tanks necessary
- Still evaporation will happen over time
- A boil-off system has to be implemented to release the small amounts of gaseous hydrogen
over time
- LH2 has almost double the energy density of CGH2 @ 700 bar
- Energy required to liquefy the hydrogen

Cold- and cryo-compressed hydrogen (CcH2)

- Combination of low temperatures and increased pressure

- Higher energy density than LH2
- Again more energy required to compress and cool the hydrogen

Materials-Based H2 storage

- Generally in development stage, examples:

o Hydride storage systems: hydrogen is stored inside the metallic lattice
o Liquid organic hydrogen carriers (LOHC): chemical compounds that bind hydrogen
- In both cases heat is required to release the hydrogen again from the storage system

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1.3 Colors of Hydrogen

GREY hydrogen:

- Most important production processes are:

o Natural gas is used in Steam Methane Reforming (SMR) to produce Hydrogen
o Oil or coal is used in the Partial Oxidation (POX) method
- Both processes produce CO2 in large scales releasing it to the environment
- 1 ton hydrogen generates approx. 10 tons of CO2
- most of the hydrogen today (2021) is produced by these methods

BLUE hydrogen:

- Production methods same as the ones for grey hydrogen

- CO2 is captured and permanently stored or used for other processes
(CCS = carbon capture storage)

GREEN hydrogen:

- Hydrogen is generated through water electrolysis

- The electrical power used for the electrolysis is generated solely through renewable energy
(solar, wind, water)
- No CO2 is produced

Turquoise hydrogen

- Turquoise hydrogen is created when natural gas is broken down with the help of methane
pyrolysis into hydrogen and solid carbon
- Solid carbon can be used in other applications, e.g. in the car tire industry
- If renewable energy is used to power the process it can be considered carbon-neutral
- Process is still in development phase. Pilot plants are being built.

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2 Making the right Choice

2.1 Choice of material

One of the challenges to handle is the so-called “hydrogen embrittlement”:

Hydrogen can permeate material structures leading to hydrogen embrittlement, i.e. weakening the
material. To encounter this effect the right material in direct contact with hydrogen has to be
chosen.
This relates to pressure port, sensing element, gauge movement, sealing: in general all materials in
direct contact with hydrogen.

In the following typical materials used at WIKA are shown that may or may not be used in direct
contact with Hydrogen:

The following materials can be used when measuring hydrogen:

- Austenitic steels:
o 1.4404, ,1.4435 / 316L
o 1.4571 / 316Ti
o 1.4307

- Specific Alloys:
o 2.4819 / Hastelloy C-276
o 2.4610 / Hastelloy C-4
o 2.4711 / Elgiloy
o 2.4668 / Inconel 718

Regarding the usage of brass in hydrogen applications please consult the Technical
Support Team as the overall application conditions need to be considered.
The material brass itself can be used in contact with hydrogen. Mainly the tightness of
the connection (usually soldering) has to be considered case by case.

The following materials MUST NOT be used in contact with hydrogen:

- martensitic steels, like
o 1.4534
o 1.4542
- Titanium
- Zircon
- Ferritic Steels
- Super Duplex (if mandatory requested by the customer; contact Technical Support)

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2.2 Products – choice for hydrogen applications

2.2.1 Mechanical pressure gauges

- Standard stainless steel pressure gauges can be used in hydrogen
applications, typical choice type 232.xx
- An oil-filling of the gauge is permitted 1)
- Material choice: 316L = standard material for type 232.xx up to 1.600 bar
- Standard limitations as shown on the datasheets apply (temperature range,
accuracy etc)

The gauge must be located in a vented area to avoid creating an explosive

atmosphere due to hydrogen permeation.

1)
Remark regarding oil-filling: even if hydrogen permeates through the bourdon tube it will
further permeate through sealings and will not influence the gauge measurement

2.2.2 Differential pressure gauges

732.51, 732.31, DPGS43, DPGT43 : can be used with hydrogen because

- all materials in contact with hydrogen are suitable
- measuring system fully welded
- no elastomeres used as sealing
- no oil-filling as pressure transmission fluid

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732.15, 712.15 „Cryo Gauge“

- - the gauge is not in contact with liquid hydrogen (-253°C), but only with
hydrogen in gas phase (> -40°C)
- Membrane material is NBR and can be used with hydrogen
- All gauges are helium tested in production
- The gauge can be used in hydrogen applications (e.g. hydrogen tank level
monitoring) provided that it is located open to the environment to avoid
creating an explosive atmosphere . A limited diffusion of hydrogen to the
atmosphere has to be considered by customer during the risk assessment
of the application.

732.14: must not be used with hydrogen applications

- the measuring chamber is filled with a transmission fluid
- hydrogen could permeate the diaphragm an create a “hydrogen bubble”
inside the transmission fluid which would offset the measurement system

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2.2.3 Electronic pressure sensor

For electronic pressure sensors both pressure range and temperature have
to be considered.

Due to hydrogen permeation into the sensor structures or the oil filling,
signal drift can occur over time. The time until the occurrence of a relevant
signal drift and the extent of the signal drift depends mainly on factors such
as the temperature of the hydrogen, hydrogen content in the medium and
the diaphragm thickness of the pressure sensor used. The diaphragm
thickness depends on the nominal pressure. It is recommended that users
test the selected product version in their specific application environment for
suitability.

Pressure range >20 bar </= 20 bar

Permanent
-40…+30°C > +30°C…+125°C (150°C) -40…+125°C (150°C)
Temperature
Technical Standard pressure port Front Flush pressure port
solution out of 316L or 316Ti out of 316L, Hastelloy

Sensor: 2.4711 Gold Plating (~20-25 µm)

A temporary short increase of Max. 600 bar available
Remarks
temperature is acceptable! Above +125°C: add cooling fins
Standard limitations as shown on the datasheets and certifications apply
(e.g. temperature range according Ex-certificates, accuracy etc)

Typical products:

- IS-3 / E-10/11: where ATEX is required, e.g. hydrogen filling stations, compressors
- MH-3-HY: mobile hydrogen applications, e.g. trucks, busses, fork-lifts
- S-20: stationary applications without ATEX requirement, e.g. testing facilities
- WU, iWU, WUx: Production in semiconductor business

ATTENTION: Pressure transmitters with an Explosion-proof approval must not be mechanically

modified outside the datasheet specifications. A permanent connection for example of a
pressure port adapter, e.g. by welding, is not allowed!!

SIL: As of today only the CPT-2x can be used with hydrogen providing a SIL specification.
The SIL rating of IPT-2x and IS-3 is not valid in connection with hydrogen.

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2.2.4 Diaphragm seals

With a diaphragm seal always a gold plating is required as hydrogen
barrier.
- Only diaphragm seals with front flush membrane can be gold-
plated  no internal diaphragm can be used
- Diaphragm seals typically used and available for gold plating are:
o 990.40
o 990.41
o 990.27
o 990.29

- Material guidelines as shown on page 6 have to be followed

- Gold plating can be provided with thickness of 6, 25 or 40 µm

2.2.5 Electrical temperature sensor

Under consideration of the “choice of material”, page 6, all electrical
temperature sensors can be used in hydrogen applications.
316L is the recommended choice
Remark on liquid hydrogen (LH2):
For liquid hydrogen (temperature = -253°C) measurement solutions are
under investigation. Resistance thermometers are specified only to -
200°C.
Thermoelements, recommendation is type E, have to be used when
measuring -253°C theoretically. The practical definition and validation is
ongoing (as of July 2021). Please contact Technical Support for latest
information updates.

2.2.6 Valves
Under consideration of the “choice of material” as shown on page 6 all
valves can be used in hydrogen applications.
Standard limitations as shown on the datasheets and certifications apply
A fugitive emission certificate can be provided on request, with applicable
temperature -29...+180°C and medium Helium.
The Instrumentation needle valves can be used down to -196°C for
cryogenic applications. Refer datasheets for further reference.

A usage in direct contact with liquid hydrogen (-253°C) is not possible!

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2.2.7 Mechanical pressure and temperature switches

Mechanical switches (WIKA Instruments Italia, former “Cella”-products)
can be used with hydrogen considering:
- The right Choice of material, page 6.
- Select the right approvals: both Ex ia or Ex d are available
- Direct mounting on process (use diaphragm seal for very high
pressure range)

Pressure Switches, e.g. in steam methane reforming (“grey” hydrogen

production), cryogenic tank applications (not in direct contact with liquid
hydrogen)

Pressure switches
Typical products - Specific characteristics of Pressure Switch for hydrogen:

Mod. PCA (Ex d) and PCS (Ex ia):

Sensor Element only use Type “M” (diaphragm in Inconel®)
Pressure ranges from 0,5/2,5 bar to 20/100 bar; see datasheet
electrical contacts all SPDT and DPDT available
Gaskets ok for hydrogen
Special features ambient temperature -60°C available
Note: for high pressure ranges up to 1.000 bar we have to investigate
the use of “piston” sensor type “P” in combination with H2; alternative is
the mount on diaphragm seal

Mod. MA / MAB (Ex d) and MW / MWB (Ex ia):

Sensor Element Type “XX” (diaphragm) - materials in AISI 304 /
316 / Inconel® ; refer to pressure range in
datasheet
Pressure ranges from vacuum, 0/16 mbar up to 0/40 bar;
Mod. MA (Ex d) overpressure available
electrical contacts all SPDT and DPDT available
Gaskets ok for hydrogen
Diaphragm welded also available with the diaphragm welded to
process connection
Special features ambient temperature -60°C available
Mod. MW (Ex ia)

Mod. PXA (Ex d) and PXS (Ex ia):

Sensor Element only use Type “M” (diaphragm in Hastelloy®)
Pressure ranges from vacuum, 1/2,5 bar up to 6/25 bar
electrical contacts all SPDT and DPDT available
Gaskets ok for hydrogen
Gaskets or welded diaphragm; see datasheet; it
depends on pressure ranges and overpressure

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Mod. BA/BAX (Ex d) and BWX (Ex ia):

Sensor Element Bourdon tube in AISI 316L  can be used with
hydrogen
Pressure ranges from vacuum up to 0/600 bar
electrical contacts all SPDT and DPDT available
Mod. BA (Ex d) Special features ambient temperature -60°C available
Note: material for 1.000 bar version is 1.4542 for the bourdon tube 
MUST NOT be used with hydrogen
Note: for higher pressure ranges, we have to the mount on diaphragm
seal
Mod. BWX (Ex ia)
SIL certification
The SIL rating of mechanical pressure switches is valid for hydrogen applications, too!

Differential pressure switches

Typical products - Specific characteristics of DPS for hydrogen:
Mod. DCE (Ex d) and DCC (Ex ia):
Sensor Element Based on ONE diaphragm for measuring the
delta pressure
Diaphragm material in Inconel®
DP Pressure ranges from 0/160 mbar up to 0/6 bar; static pressure
25 bar
electrical contacts all SPDT and DPDT available
Note: Process connection in Aluminum, which complies H2
SIL certification
The SIL rating of Differential mechanical pressure switches is valid for hydrogen applications, too!

Temperature switches
Typical products - Specific characteristics of TS for hydrogen:
It is recommended to use a thermowell in connection with the temperature switches, under
consideration of the right Choice of material, page 6.
Because of thermowell separation, all TS in catalogue comply to hydrogen
There is no limitation in the selection of TS
SIL certification
The SIL rating of temperature switches is valid for hydrogen applications, too!
Mod. TCA (Ex d) TCS (Ex ia) Mod. TAG (Ex d) TWG (Ex ia) Mod. TXA (Ex d) TXS (Ex ia)

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Level products (applicable only for liquid hydrogen)

A tank level measurement filled with liquid hydrogen can be done

using the CryoGauge, model 732.15.160 or 892.44 with transmitter.
The measurement instrument is not in contact with liquid hydrogen
at -253°C, but only with the gas phase of the hydrogen (> -40°C)
See also the explanation for Differential Pressure Gauges.

Float based solutions cannot be used with hydrogen, because:

- Gaseous media cannot be measured with a float
- Liquid Hydrogen has a density too small to create a float that
stays on top of the liquid phase

But: Float based level products can be used at electrolysers to control

the level of water necessary for the electrolysis.

As level switch for liquid hydrogen the OLS is available.

The ATEX approval has to be renewed. For the time being the OLS is
available without explosion proof approval.

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2.2.8 Flow products

Under consideration of the “choice of material” as shown on page 6 all
primary flow elements can be used in hydrogen applications.
316L is the recommended choice of material for hydrogen
applications.

A mass flow calculation of hydrogen is not available with WIKA

products today.

2.2.9 Sealing materials

Metal Seals:

First choice in hydrogen applications are fully metallic seals,

either by sealing cone or CrNi-Sealing.

Copper can be used with H2 in applications up to 300°C

Above 300°C the detailed copper material has to be evaluated (should
be oxygen-free copper!)

Elastomer sealing:
!!When using an elastomer sealing the environment of the
measurement device must be vented to avoid creating an explosive
atmosphere!!

In any case the environmental conditions, like temperature range, of

the sealing according to its datasheet must be considered.
Recommended material choice:
- EPDM (-40…+150°C) - For pure hydrogen gas and hydrogen
with water particles
- In case of oil residues in the hydrogen gas: FKM (-10…+200°C)
or NBR (-30…+100°C)

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3 Change Log

Version Description of change Date Author

1.0 Initial Release 24.09.2021 C. Wirl

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Author:

Christian Wirl

Technical Input:

Material properties - Alexandra Ziegler, Rüdiger Völker

Electrical Temperature – Uli Staab, Martin Kullmann

Diaphragm Seals – Iris Benkstein

Mechanical Switches - Mario Tanzilli

Flow – Federica Tonti, Michael Lutz

Gauges – Andreas Müller

PI Pressure - Thomas Simon, Christian Preising

Valves – Daniele Maniero, Pratik Vishwakarma

Level products – Dieter Hägele, Andreas Krüger

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