Assess existing equipment for hydrogen compatibility across materials, seals and combustion components.
Engineering & Maintenance
Hydrogen-Ready Equipment Conversion and Maintenance Considerations
Prepares engineers and maintenance teams to assess and convert combustion and process equipment for hydrogen readiness, covering material compatibility, leak detection and safety zoning.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
Converting a burner, pipeline or compressor to run on hydrogen is not a simple fuel swap: hydrogen's small molecule size, wide flammability range and embrittlement effect on certain metals change what counts as safe and reliable equipment. This course prepares engineers and maintenance teams to assess and convert combustion and process equipment for hydrogen readiness, beginning with how hydrogen's physical properties affect burners, seals, valves and pipework differently from natural gas. Participants audit existing equipment for material compatibility, screening for hydrogen embrittlement risk and elastomer permeability, before planning burner conversion, seal replacement and pipeline upgrades. The course covers specifying hydrogen-appropriate leak detection and revising hazardous area zoning for converted plant, then adapts valve, compressor and pipeline maintenance practices to hydrogen service conditions. It closes with a commissioning sequence that verifies safety before hydrogen is introduced. Exercises include a compatibility audit exercise, a zoning review task and a commissioning checklist workshop grounded in realistic conversion scenarios.
Expected Learning Outcomes
Identify hydrogen embrittlement risk in metals and specify compatible alternatives.
Plan burner and combustion equipment conversion for hydrogen blending or full hydrogen firing.
Specify leak detection systems and response procedures suited to hydrogen's physical properties.
Apply hazardous area zoning principles to hydrogen-converted plant and equipment layouts.
Adapt valve, compressor and pipeline maintenance practices for hydrogen service conditions.
Plan commissioning and verification steps that confirm converted equipment is safe for hydrogen operation.
Who Should Attend
Maintenance and process engineers evaluating hydrogen conversion of existing plant.
Combustion engineers adapting burners for hydrogen blending or full conversion.
Process safety specialists assessing hazardous area classification for hydrogen.
Pipeline and compressor engineers preparing infrastructure for hydrogen service.
Energy transition project managers overseeing hydrogen-readiness programmes.
Asset integrity engineers assessing material compatibility risks.
Course Modules
Select any module to see its sessions and points.
01Assessing Hydrogen Compatibility of Existing Equipment
2 sessions · 8 points
Session 1Understanding Hydrogen's Properties and Equipment Impact
- Explain how hydrogen's low density, wide flammability range and small molecule size affect equipment design.
- Compare hydrogen combustion characteristics against natural gas to identify burner conversion implications.
- Assess flame speed and flashback risk differences that affect burner and ignition system selection.
- Identify equipment categories most affected by conversion, including burners, seals, valves and pipework.
Session 2Auditing Material and Component Compatibility
- Screen metallic components for susceptibility to hydrogen embrittlement based on material grade and stress state.
- Assess elastomer seals, gaskets and O-rings for permeability and swelling under hydrogen exposure.
- Review pipeline and vessel specifications against hydrogen service codes to identify upgrade needs.
- Compile an equipment compatibility register ranking items by conversion risk and replacement priority.
02Converting Combustion and Process Equipment
2 sessions · 8 points
Session 1Planning Burner and Combustion Conversion
- Assess burner tip design, air-fuel ratio control and flame monitoring changes needed for hydrogen blending.
- Plan phased blending trials that increase hydrogen content while monitoring combustion stability.
- Adjust flame safeguard and ignition system settings to account for hydrogen's faster flame speed.
- Coordinate combustion conversion with control system recalibration for changed fuel properties.
Session 2Adapting Seals, Gaskets and Piping for Hydrogen Service
- Specify hydrogen-compatible seal and gasket materials in place of components prone to permeation.
- Assess pipe joint design and flange gasket selection for hydrogen tightness requirements.
- Review pipeline wall thickness and fitting ratings against hydrogen embrittlement guidance.
- Plan a phased replacement schedule for incompatible components during planned shutdowns.
03Managing Leak Detection and Safety Zoning
2 sessions · 8 points
Session 1Specifying Leak Detection for Hydrogen Service
- Select hydrogen-specific gas detection technology suited to its low detection threshold and buoyancy.
- Position detectors accounting for hydrogen's tendency to rise and accumulate in high points.
- Set alarm thresholds and response procedures distinct from those used for natural gas systems.
- Test leak detection system response times as part of the hydrogen conversion commissioning plan.
Session 2Applying Hazardous Area Zoning to Converted Plant
- Reassess hazardous area classification for equipment converted to hydrogen or hydrogen-blended fuel.
- Review ventilation design in enclosed spaces where hydrogen accumulation risk increases.
- Specify equipment ratings appropriate to the revised zoning for instruments and electrical devices.
- Update area classification drawings and permit-to-work documentation following conversion.
04Maintaining and Commissioning Hydrogen-Ready Systems
2 sessions · 8 points
Session 1Adapting Maintenance for Valves, Compressors and Pipelines
- Adjust valve maintenance intervals and seat material selection for hydrogen service conditions.
- Review compressor seal and lubrication systems for compatibility with hydrogen's low viscosity behaviour.
- Set pipeline integrity monitoring intervals accounting for hydrogen embrittlement fatigue mechanisms.
- Update maintenance procedures and spare parts lists to reflect hydrogen-compatible replacement components.
Session 2Verifying Safety Through Commissioning
- Plan a commissioning sequence including pressure testing, purging and leak testing before hydrogen introduction.
- Verify control system logic and safety interlocks respond correctly under hydrogen operating conditions.
- Train operators and maintenance staff on revised procedures and hazard awareness before start-up.
- Document commissioning evidence to demonstrate the converted equipment meets applicable safety codes.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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