HYDROGEN GAS SUPPLY & STORAGE SYSTEMS | VOGT CTE

Hydrogen is a versatile energy carrier, but it poses unique safety requirements during storage and use. Hydrogen is stored under high pressure in gas cylinders. At the same time, the gas is very light and can escape through the smallest leaks, forming a flammable mixture with air. Therefore, gas cylinders, pressure regulators, pipes, valves, and connections must always be viewed as a combined safety system.

Safe Installation and Storage of Gas Cylinders

Hydrogen cylinders must be protected against tipping over, mechanical damage, and unauthorized access. During transport, they must not be rolled, dragged, or dropped. Unconnected cylinders should be fitted with an appropriate protective cap.

Installation locations must be well-ventilated and chosen so that any escaping hydrogen cannot accumulate under ceilings or in closed areas. Ignition sources, such as open flames, sparks, or unsuitable electrical devices, must be kept at a safe distance.

Only Use Suitable Components

The safety does not end with the gas cylinder. Pressure regulators, pipes, seals, valves, and connections must be explicitly designed for hydrogen and the intended operating pressure.

Particularly important is the pressure regulator, as the high cylinder pressure must be controlled and reduced to the required operating pressure. Improvised adapters, unsuitable seals, or unspecified components are not acceptable in a hydrogen system.

Ensure Safe Execution of Pipes and Connections

Gas pipes should be laid as short, neat, and protected against mechanical stress as possible. Each connection and joint represents a potential leak point, so unnecessary connections should be avoided.

Vibrations, temperature changes, or movements of connected devices must also be considered in the planning. Pressure reliefs and safety valves must be designed so that any escaping hydrogen is safely directed to an appropriate location.

Regularly Check for Leaks

Before commissioning and after any work on the system, the tightness of pipes, connections, and fittings must be checked using a suitable method. An open flame must never be used to search for leaks.

Even during operation, gas pipes and connections must be regularly inspected. A small leak should not be underestimated with hydrogen, as it can quickly form a flammable mixture.

Commissioning and Cylinder Change

When connecting a gas cylinder, connections and sealing surfaces must be clean and undamaged. Valves are opened in a controlled manner to avoid sudden pressure load on the system.

Before changing cylinders, the cylinder valve is closed, and the system is put into a safe state according to the intended operating instructions. Even seemingly empty gas cylinders must continue to be treated as pressurized gas containers.

After work on pipes, air and hydrogen may be present in the same system. Therefore, commissioning and any purging processes must be carried out according to a defined and suitable procedure.

Operation Only by Trained Personnel

Hydrogen systems and gas cylinder systems may only be operated by properly trained and instructed personnel. Individuals must be familiar with the setup of the system, the components used, the intended operating procedures, and the correct behavior in case of an emergency.

Particularly, cylinder changes, commissioning, decommissioning, and work on pressure-carrying components must not be carried out improvised.

Regular Inspection and Audits

A safely built plant is not automatically safe over the long term. Seals age, connections may change, and mechanical or thermal stresses can affect components over time.

Therefore, the system should be regularly checked according to a defined maintenance and inspection plan. Additionally, periodic safety checks and audits by qualified personnel are advisable. This should involve not only individual components but also operational processes, documentation, training status, and emergency measures.

Safety Starts with Planning

An appropriate location, sufficient ventilation, correctly sized pipes, hydrogen-compatible materials, reliable pressure regulators, suitable safety devices, and trained personnel jointly form the foundation for a safe operation.

With hydrogen, the safety of the entire system is only as good as its weakest component and how it is handled.

Therefore, it is not the right place to cut costs on pressure regulators, pipes, fittings, seals, inspections, or personnel training at the expense of safety. A small savings is not worth the potential consequences of a leak or an unsuitable component.