LDAR and Hydrogen Integration: Protecting Safety While Cutting Methane Emissions
H. VENNERBERG, INFICON, Linköping, Sweden
As the global energy sector intensifies its efforts to tackle climate change, methane emissions have emerged as a critical focus. Methane, the main component of natural gas, has more than 80 times the global warming potential of carbon dioxide over a 20-yr period. Unintentional leaks from pipelines, wellheads, compressors, valves and processing facilities are not only a major environmental concern but also pose serious safety and operational risks.
To address this, many companies have implemented leak detection and repair (LDAR) programs. These programs aim to identify and fix fugitive emissions before they escalate into larger hazards. LDAR has long been championed for its safety benefits, but as regulation, technology and infrastructure evolve, there is a growing need to emphasize environmental aspects with equal weight — without losing the safety aspect.
This is particularly urgent as the industry begins integrating hydrogen (H₂) into gas systems.
The energy landscape is undergoing rapid transformation. Digital tools, remote sensing and advanced analytics are revolutionizing LDAR capabilities. Technologies once seen as futuristic — like drone-mounted sensors or satellite-based methane monitoring — are now part of operational toolkits. Yet, while these innovations improve detection and efficiency, they also introduce new challenges. Chief among them is ensuring that the equipment used in hazardous environments meets stringent safety standards.
Ensuring Safety
Methane leaks often occur at small, localized components that require technicians to physically enter hazardous areas. This direct interaction means handheld tools must be intrinsically safe. H₂’s introduction into the grid complicates the matter further; unlike methane, H₂ has a lower ignition energy and a wider flammability range. It also diffuses more easily, making it harder to contain and more likely to form explosive mixtures in confined spaces, for instance.
Currently, three major systems govern explosion protection ratings worldwide: Atmospheric Explosives (ATEX), used in the EU; International Electrochemical Commission System (IECEx), internationally recognized; and the North American Class/Division system. These frameworks classify hazardous areas and define what equipment can be used safely within them. For H₂-rich environments, the requirements are more rigorous.
Equipment must be certified for Gas Group IIC under ATEX/IECEx or Group A under the North American system — the highest level of explosion protection.
Another key consideration is the Zone or Division classification. Instruments used in areas where explosive gases are frequently or continuously present during normal conditions need Zone 0 or Zone 1 (ATEX/IECEx) or Class I, Division 1 (North America) ratings. Many modern LDAR instruments, especially high-tech or remote models, are not certified for these high-risk zones.
Temperature class is equally critical. H₂ ignites at around 560°C, so equipment must have surface temperatures well below this threshold. T3-rated equipment (with a maximum surface temperature of 200°C) is generally considered safe and provides a conservative safety margin for H₂ applications.
LDAR Integration
What also complicates matters is the longevity of LDAR instruments. Most devices are expected to remain in use for 8 yrs–10 yrs. That means the purchasing decisions made today will shape operational safety well into the next decade. Even if a company only handles methane, its grid could be H₂-blended in the near future. Equipment that is not certified for H₂ may soon become obsolete, requiring premature replacement or — worse — presenting safety liabilities if misused.
Investing in H₂-safe tools is not just about regulatory compliance — it is a strategic decision that safeguards operational continuity. Instruments with forward-compatible certifications offer flexibility, reduce future capital expenditure and enable seamless adaptation as the gas landscape evolves.
Moreover, while remote sensing and predictive maintenance tools are reshaping how we think about leak detection, they do not eliminate the need for ground-level confirmation. A drone may spot an anomaly or a sensor may flag a concentration spike, but human technicians still need to approach the leak site to verify and repair the issue. At that moment, the equipment safety rating becomes crucial.
If a device is not certified for the specific explosive atmosphere, it cannot legally or safely be used, and the entire LDAR workflow breaks down. This is not merely a technical oversight; it has real-world consequences. Using non-certified equipment in explosive atmospheres — especially those involving H₂ — can invalidate insurance, breach safety protocols and, in the worst-case scenario, trigger a catastrophic event.
The shift toward H₂ is not hypothetical. Globally, countries are advancing H₂ production, infrastructure and regulatory frameworks. Blending H₂ into existing gas networks is already underway in many regions, and dedicated H₂ pipelines are on the horizon. This evolution calls for a reassessment of equipment standards across the board.
Takeaway
LDAR programs remain a critical component of emissions reduction and operational safety as hydrogen integration accelerates. They must integrate safety as a core pillar, alongside emissions reduction and digital innovation. Safety certifications should be a top priority during procurement, not an afterthought. Teams must be trained to understand gas group classifications, zone requirements and intrinsic safety standards. Perhaps most importantly, organizations need to future-proof their technology stack to accommodate the inevitability of H₂.
Forward-thinking companies will not only reduce methane emissions but will do so with equipment that is as safe as it is smart. Because in the race to reduce emissions, safety is not a secondary concern — it is the foundation of success.
HENRIK VENNERBERG is Market Segment Manager Energy in the leak detection division of INFICON. He has more than 20 yrs of experience in product development, manufacturing and application support towards the energy and automotive industry, with special focus in natural gas and H₂ leak detection.