FAQs about applications in the hydrogen industry

Hydrogen is highly flammable, has a wide ignition range (4-78% by volume) and a very low ignition energy (40 μJ).
Leakages, fire, explosions and frostbite due to cryogenic hydrogen are key sources of danger.

Hydrogen diffuses through the tiniest cracks in the material and rises quickly in enclosed spaces. Leakages are difficult to detect and pose a considerable risk of fire and explosion.

As hydrogen flames are almost invisible, UV/IR sensors or thermal gradient measurement are used. The latter enables reliable detection regardless of the fuel.

There are no specific hydrogen laws, but there are numerous guidelines such as:

• ATEX 2014/34/EU
• Pressure Equipment Directive 2014/68/EU
• Machinery Regulation 2023/1230 (applicable from 20/01/2027) 

VDMA standard sheets are also pioneering.

ISO 19880-1, EN 17127 and SAE J2601 define safety requirements, refuelling protocols and interoperability for H₂ refuelling stations.

ISO 22734 describes safety requirements for hydrogen generators using water electrolysis – including test methods for components and materials.

Further information:

ISO 22734-1: Important safety-related changes

Functional safety describes the reliable effect of safety-related control systems – from risk analysis and validation through to commissioning and maintenance.

Important standards are EN ISO 13849, EN IEC 62061, EN IEC 61508 and EN IEC 61511. They define requirements for safety functions, safety integrity levels (SIL/PL) and lifecycle considerations.  

Pressure transmitters and controllers such as PNOZmulti 2 or PSS 4000 record process values, compare them with limit values and trigger safety-related reactions in the event of discrepancies. 

Temperature monitoring is essential for refuelling in accordance with SAE J2601, for example. Failsafe analogue inputs and certified software modules guarantee compliance with safe temperature ranges.

Industrial Security protects automation and control systems from unauthorised access and manipulation. It is an integral part of functional safety

Various measures prevent unauthorised access to safety-related systems:

• Identification and Access Management (I.A.M.) with authentication systems for users 
• Entry and access management 
• Data and network security measures 
• Safe remote maintenance
• Segmented networks

RFID-based identification, sequence-controlled operator guidance and safe control ensure that only authorised persons carry out safety-compliant processes.

Voltage and current monitoring, gas and flame detection and emergency stop are essential to prevent the formation of oxyhydrogen gas and electrical hazards.

The standard ISO 16110-1 defines requirements such as EMC protection, pressure monitoring and explosion prevention. Burner management systems safely control the process heat.

Safety functions include pressure and temperature monitoring, leakage detection, flame detection and emergency stop. Refuelling is carried out in accordance with SAE J2601 under defined conditions.

IEC 62282-3-100 regulates the safety of stationary fuel cell systems – including pressure equipment, exhaust gas routing and electrical safety.

Through safe monitoring of the mix ratio, leakage detection and limitation of the hydrogen content to max. 40 % for example.