{"id":4015,"date":"2025-08-12T14:07:17","date_gmt":"2025-08-12T14:07:17","guid":{"rendered":"https:\/\/projectzero.network\/it\/?p=4015"},"modified":"2025-08-22T11:52:56","modified_gmt":"2025-08-22T11:52:56","slug":"hydrogen-pipeline-safety-projectzero-2025","status":"publish","type":"post","link":"https:\/\/projectzero.network\/it\/hydrogen-pipeline-safety-projectzero-2025\/","title":{"rendered":"Il tuo gasdotto per idrogeno rischia di fallire le norme ISO 2025"},"content":{"rendered":"\n
\"\"<\/figure>\n\n\n\n

Here’s How to Stay Safe and On Track<\/strong><\/h2>\n\n\n\n

Hydrogen is a key enabler of the energy transition, but it brings unique technical challenges: it\u2019s ultra-light, highly diffusive, and can weaken materials over time. That\u2019s why the International Organization for Standardization (ISO) has released a major update to ISO 19880-1<\/strong>, coming into effect in 2025.<\/p>\n\n\n\n

Two new requirements in particular will impact design, procurement, and commissioning right away:<\/p>\n\n\n\n

    \n
  • Valves rated above 100 bar<\/strong> must now meet a minimum strength factor of 1.35<\/strong><\/li>\n\n\n\n
  • Gaskets exposed to open air<\/strong> must achieve Leak Tightness Class A+<\/strong><\/li>\n<\/ul>\n\n\n\n

    At first glance, these may seem like minor technical changes. In reality, they affect lead times, costs, and safety margins. The good news? ProjectZero<\/strong> already supports oil & gas and hydrogen pilot projects with audits, training, and digital tools\u2014so you can act now without scrambling later.<\/p>\n\n\n\n

    Why the Strength Factor Increases from 1.25 to 1.35<\/h3>\n\n\n\n

    Lab tests in 2023 showed that valves originally certified for methane failed prematurely when exposed to high-pressure hydrogen.
    The solution involves using thicker walls or stronger alloys\u2014but this shifts many valves (such as DN50 Class 600) from catalogue items to special orders, often doubling delivery times<\/strong>.<\/p>\n\n\n\n

    Why Gaskets Must Comply with Class A+<\/h3>\n\n\n\n

    Unlike methane, hydrogen can escape as an invisible gas cloud.
    For this reason, the new standard limits leakage to 10\u207b\u2074 mbar\u00b7L\/s<\/strong> for exposed gaskets.
    Above 50 bar, metal-to-metal seals<\/strong> and spring-energized rings<\/strong> become the new baseline\u2014already widely used in high-integrity environments.<\/p>\n\n\n\n

    Retrofit or Rebuild? Assessing Existing Lines<\/h3>\n\n\n\n

    Many legacy pipelines built for natural gas now face a fork in the road:<\/p>\n\n\n\n

      \n
    • Lines older than 20 years and operating above 100 bar<\/strong> often require full replacement<\/strong><\/li>\n\n\n\n
    • Mid-pressure lines<\/strong> with strong hydrotest records may only need upgrades to gaskets and soft parts<\/strong><\/li>\n<\/ul>\n\n\n\n

      Every case requires a tailored assessment\u2014but acting before the 2025 deadline is key.<\/p>\n\n\n\n

      How to Run a Gap Analysis Without Drowning in Excel<\/h3>\n\n\n\n

      A practical first step is to update your valve inventory<\/strong> by adding four new columns:<\/p>\n\n\n\n

        \n
      • Design pressure<\/li>\n\n\n\n
      • Current strength factor<\/li>\n\n\n\n
      • Current leak class<\/li>\n\n\n\n
      • ISO 2025 compliant?<\/li>\n<\/ul>\n\n\n\n

        This simple addition allows you to quickly pinpoint critical issues and prioritize upgrades.<\/p>\n\n\n\n

        Testing and Commissioning: What Changes in Practice<\/h3>\n\n\n\n

        Testing requirements are getting tighter. New standards call for helium sniffers<\/strong> sensitive to 1 \u00d7 10\u207b\u2076 atm-cc\/s<\/strong>.
        High-pressure skids may also require a second round of testing<\/strong>.
        Technicians must calibrate the equipment, document results, and upload everything to the cloud dashboard<\/strong> already in use by ProjectZero\u2019s digital transformation programs.
        The result: real-time traceability<\/strong>, ready for inspections.<\/p>\n\n\n\n

        Budget and Timeline Considerations<\/h3>\n\n\n\n

        Upgrading to meet the new standards carries a cost\u2014but it\u2019s manageable:<\/p>\n\n\n\n

          \n
        • CAPEX<\/strong> for high-pressure sections may increase by 5\u20137%<\/strong>, mainly due to upgraded valves and seals<\/li>\n\n\n\n
        • Lead times<\/strong> may extend by about four weeks<\/strong>, but active expediting<\/strong> helps anticipate and prevent delays<\/li>\n<\/ul>\n\n\n\n

          Early pilot plants are already seeing benefits: 40% fewer unplanned hydrogen leaks<\/strong>, with ROI in around two years<\/strong>.<\/p>\n\n\n\n

          What Comes After 2025?<\/h3>\n\n\n\n

          ISO has already hinted at new 2027 updates, including:<\/p>\n\n\n\n

            \n
          • In-line hydrogen purity sensors<\/strong><\/li>\n\n\n\n
          • Modular, swappable filter pods<\/strong><\/li>\n<\/ul>\n\n\n\n

            Firms that invest today in digital project data management<\/strong> (such as digital twins) will be ready to implement future changes with just a click\u2014instead of rushing to adapt under pressure.<\/p>\n\n\n\n

            In Summary: What You Should Do Now<\/h3>\n\n\n\n
              \n
            • Upgrade valve strength<\/strong> to meet the 1.35 factor<\/li>\n\n\n\n
            • Use Class A+ gaskets<\/strong> for all exposed connections<\/li>\n\n\n\n
            • Map compliance<\/strong> with a simple updated spreadsheet<\/li>\n\n\n\n
            • Train technicians<\/strong> for the new testing protocols<\/li>\n\n\n\n
            • Track everything<\/strong> with cloud-based tools<\/li>\n<\/ul>\n\n\n\n

              By acting now, the 2025 ISO 19880-1 revision becomes a manageable improvement\u2014not a costly last-minute scramble.<\/p>\n","protected":false},"excerpt":{"rendered":"

              Here’s How to Stay Safe and On Track Hydrogen is a key enabler of the energy transition, but it brings …<\/p>\n","protected":false},"author":4,"featured_media":3995,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[1],"tags":[],"class_list":["post-4015","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"acf":[],"_links":{"self":[{"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/posts\/4015","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/users\/4"}],"replies":[{"embeddable":true,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/comments?post=4015"}],"version-history":[{"count":10,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/posts\/4015\/revisions"}],"predecessor-version":[{"id":4031,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/posts\/4015\/revisions\/4031"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/media\/3995"}],"wp:attachment":[{"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/media?parent=4015"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/categories?post=4015"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/projectzero.network\/it\/wp-json\/wp\/v2\/tags?post=4015"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}