Hydrogen:

How to meet the safety challenges

Production, storage and transport of hydrogen bears special safety risks. ​
To handle them needs expert knowledge in all phases of the process.​
 02 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | MEETING SAFETY CHALLENGES IN THE EMERGING HYDROGEN ECONOMY

Meeting safety challenges in the

emerging hydrogen economy
From transportation to heating, hydrogen is set to play
a major role in the energy mix as countries move to
decarbonise their economies. But with organisations in both
the public and private sectors taking their first steps into the
emerging hydrogen economy (be it with marine shipping,
or trams and buses in cities), safety awareness could be
due an update – both to reduce risk exposure through good
preparation and safeguards, and to build confidence in the
new technology as an energy source for the future. What
are the key safety challenges with hydrogen? What solutions
to handle them are available? Dräger, a leading safety
technology and gas detection expert, introduces the key
points in this guide.
03 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | HYDROGEN IS KEY TO GLOBAL CLEAN ENERGY INITIATIVES

Hydrogen is key to global

clean energy initiatives
HYDROGEN: FUEL OF THE FUTURE
As countries move ahead on climate pledges
undertaken in the Conference of the Parties (COP21) Targets / Forecast by 2050:
Paris agreement,¹ initiatives are underway worldwide
to commercialise hydrogen energy. Government EUROPE
investments in Europe and Asia already top US$ 2 25% of energy demand covered
billion,² with much more planned. In its bid to be the
2,250 terawatt hours (TWh) produced
first climate-neutral continent by 2050, Europe plans to
5.4 million jobs
meet 25 % of its future energy needs with hydrogen.³
The resulting 2,250 terawatt hours (TWh) would ~EUR 820 bn annual revenue
replace fossil fuels now used for heating, transport,
USA
power generation and buffering, and industry, and
would eliminate 560 Mt of CO2 emissions.⁴ Japan, 14% of energy demand covered from green hydrogen
which recently adopted a net-zero-emissions target by 100% domestically produced
2050, aims by then to increase hydrogen production to
20 million metric tons (which would be equivalent to the JAPAN
power output of over 30 nuclear reactors).⁵ And in the 20 million tonnes of hydrogen produced
USA, analysts already forecast that by 2050 the country
Equivalent to over 30 nuclear reactors
could meet around 14 % of its energy needs using
“green” hydrogen from low-carbon sources.

These national-level goals are increasingly driving

adoption of hydrogen technologies across the public
and private sector.

¹ United Nations Climate Change, Conference of the Parties 21

https://unfccc.int/process-and-meetings/conferences/past-conferences/paris-climate-change-conference-november-2015/cop-21
² Roadmap to a US Hydrogen Economy 2020
https://static1.squarespace.com/static/53ab1feee4b0bef0179a1563/t/5e7ca9d6c8fb3629d399fe0c/1585228263363/
Road+Map+to+a+US+Hydrogen+Economy+Full+Report.pdf
³ Hydrogen Roadmap Europe 2019
https://www.fch.europa.eu/sites/default/files/Hydrogen%20Roadmap%20Europe_Report.pdf
⁴ Hydrogen Roadmap Europe 2019
https://www.fch.europa.eu/sites/default/files/Hydrogen%20Roadmap%20Europe_Report.pdf
⁵ Strategic Roadmap for Hydrogen and Fuel Cells, Japan Ministry of Economy, Trade and Industry, 2019
https://www.meti.go.jp/english/press/2019/pdf/0312_002a.pdf
 04 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | THE MULTITOOL OF ENERGY SOLUTIONS

The multitool of energy solutions

It is no surprise that hydrogen features so prominently Public transport providers looking for ways to reduce
in emissions reduction plans. Dubbed the “multitool their carbon footprint might turn to green hydrogen to
of energy solutions”, hydrogen is a versatile, clean power trams, trains and buses. Logistics companies
vector in the bid to achieve net-zero carbon. Apart from see new opportunities with hydrogen as a fuel for
reducing carbon emissions in traditionally difficult to fork-lift trucks on the shop floor. Others use it for
decarbonize industries such as cement manufacture, it emergency power generation, as a backup power
can be used in fuel cells to produce electricity and heat, supply. Renewable power generation companies might
be blended with natural gas or synthetized to kerosine. consider producing and storing hydrogen on site, close
ENERGY
to energy sources. Hydrogen is also playing a growing STORAGE
Hydrogen is the only at-scale technology that can be role as a fuel in marine shipping.
used to store, transport and distribute energy over large
geographies and between sectors (known as “sector
coupling”). “Green” hydrogen – produced from wind or
solar power and considered to be the only sustainable
hydrogen solution in the long term – can be produced
where energy is generated and be distributed to top up DECARBONISATION
energy supplies. Hydrogen can also be used as a base
ENERGY
substance in the production of ammonia and fertilizer SOURCE
(to date met by hydrogen from fossil fuels).

Hydrogen use is already being ramped up at all levels.

Within the next ten years, hydrogen-powered transport,
blended hydrogen heating, industry heat and feedstock,
and power generation with hydrogen are expected to SECTOR COUPLING
have a significant mass-market impact.

BASE
H2 SUBSTANCE

⁶ Roadmap to a US Hydrogen Economy 2020

https://static1.squarespace.com/static/53ab1feee4b0bef0179a1563/t/5e7ca9d6c8fb3629d399fe0c/1585228263363/
Road+Map+to+a+US+Hydrogen+Economy+Full+Report.pdf
 05 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | HEAVYWEIGHT SAFETY FOR A LIGHTWEIGHT GAS

Heavyweight safety
for a lightweight gas
Hydrogen is increasingly used by organisations to
replace other fuels. Many of these new hydrogen
users, although otherwise safety-aware in their
systems and procedures, may be unfamiliar with the
special challenges, safeguards and infrastructure
required with hydrogen. Some may have knowledge
of working with LPG as a fuel, for instance, but
this has only limited applicability for working with
hydrogen. As Dräger has experienced in numerous
projects with customers, covering everything from
advice on basic risk and safety considerations
to safe practice in system maintenance, there
is considerable demand for guidance on the
practicalities of working with hydrogen.

The broader the rollout, the greater the need to raise

awareness of the safety challenges – and how best
to address them.

HYDROGEN PROFILE

ODOURLESS COLOURLESS

PALE FLAME EXPLOSIVE

 06 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | APLICATIONS AND SAFETY CONSIDERATIONS

Applications and safety considerations

Hydrogen production
(Power to X, which can be liquid or gas)
Although hydrogen is today produced chiefly from fossil fuels, carbon neutrality initiatives worldwide are
expected to make far greater use of “green” hydrogen, generated from renewable sources, as well as
“blue” hydrogen, which uses carbon capture and storage to avoid carbon emissions. Wind and solar farm
operators could choose to produce green hydrogen via electrolysis on site for onward transport. This
presents safety challenges which may be new to operators. Especially at the start of production, hydrogen
is under extremely high pressure and is highly flammable. The flame itself is virtually invisible, which
means plants require excellent safeguards against explosions.

Hydrogen storage and distribution

The midstream link in the value chain is about getting hydrogen from the point of production to the point of
consumption. In many cases, hydrogen can be shipped to markets using existing infrastructure. Europe, for
example, has well distributed and maintained gas networks and pipelines that can be used for hydrogen,
although this requires monitoring and maintenance to be adapted. In shipping, dedicated bunkering stations
serve to supply hydrogen as fuel to ships (e.g. truck to ship or shore to ship). In this sector, one common
risk is of leaks at connector points along extensive pipeline networks.

Most facilities, including tanks and valves, are safe, but the probability of safety incidents increases when
people are involved. When heavy machines such as trucks are moved around, even minor bumps need to
be taken seriously as they increase the risk of leakage.
 07 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | APLICATIONS AND SAFETY CONSIDERATIONS

Hydrogen fuel consumption

Hydrogen is increasingly emerging as a power source for applications that would previously have depended on fossil fuels. One key sector is mobility, at present one of the world’s most fossil
fuel-dependent sectors. (In the EU, for example, analysts have calculated that a 90 % reduction in emissions in this sector will be needed by 2050 to achieve net zero emissions.⁷) Fuel cell
electric vehicles (FCEVs) are an obvious solution because they produce no tailpipe emissions. Hydrogen is used where electricity is not directly feasible, for long-distance transport for example
(buses, trains, trucks and maritime transport).

An entire value chain has emerged around the hydrogen consumption sector, comprising activities such as fuel cell production, the associated service infrastructure such as fuel stations
or repair shops, as well as facilities for garaging vehicles. In these areas, it is often the case that organisations extend their core business to embrace hydrogen, meaning that the requisite
hydrogen safety experience must be built up.

⁷ European Environment Agency 2020

https://www.eea.europa.eu/themes/transport/term/increasing-oil-consumption-and-ghg
 08 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | THE SPECIAL SAFETY CHALLENGES OF HYDROGEN

The special safety challenges

of hydrogen EXPLOSION
Hydrogen is not an explosive and cannot explode in its pure or highly diluted form. Only when hydrogen and oxygen,
Hydrogen does not impose major new risks for example from the air, come together can the mixture react explosively in conjunction with an ignition source.
For hydrogen to cause an explosion, oxygen needs to be present, and its volumetric concentration needs to be
compared to other fuels, and the actual hydrogen between 4 % and 77 % by volume in air, the Lower and Upper Explosion Levels (LEL and UEL). But if hydrogen is
allowed to escape, even a static spark from clothing would be enough to set off an explosion.
fuel cell is a very safe unit. The trouble spots
occur where people are involved in tasks along INVISIBLE FLAME
Hydrogen burns with a very bright flame that is almost invisible in daylight. In addition, it emits very little radiant heat,
the hydrogen value chain, from production to which is why people perceive the great heat of the flame only at a very short distance. Hydrogen flames however, emit
electromagnetic radiation in a specific wavelength range between 2 and 4 μm. To detect them, special flame detectors
use – refilling tanks, for example, transport and that can measure them are particularly suitable for rapid warning.

maintenance. Even though specific challenges

LEAKS
differ between applications, plant safety is common Owing to its small molecules and low viscosity, hydrogen can leak from pipelines and other structures more easily
than gases with a higher density, such as methane or natural gas. As well as pipelines engineered to hydrogen-ready
to all – and this involves all the measures to ensure specifications, regular inspection is imperative to detect leaks, especially at joints along the pipelines. Fixed leak
detectors add another layer of safety.
safe installation, maintenance and operation of plant
and equipment. Here are some of the risk factors PERMEATION
Hydrogen can easily permeate materials and in some cases embrittle them. For this reason, stainless steel and
which Dräger explores in projects with customers: composite materials are typically used for storage tanks.

CO ALARMS
Carbon monoxide (CO) sensors are cross-sensitive to hydrogen. If used near possible hydrogen exposure, CO
sensors should be compensated for hydrogen so that cross-sensitivity and false alarms are reduced to a minimum.

GAS POCKETS
Like ammonia and methane, hydrogen is less dense than air and forms gas pockets below indoor ceilings when leaking.
The presence of hydrogen will not be perceived at ground level, even when dangerous amounts are accumulating
beneath the ceiling. When hydrogen and methane are mixed, hydrogen can form gas pockets above methane.
Hydrogen detectors are therefore typically placed at the top, with methane detectors below that level.

ODOURLESS AND COLOURLESS

Hydrogen has no smell and no colour, so is undetectable for humans. With methane, this issue is mitigated by adding
odorants, and research is in progress to determine whether this will also be possible with hydrogen. Gas and leak
 9| HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | ASSESING THE RISKS - PLANNING FOR SAFETY

Assessing the risks – planning for safety

The landscape of risks, although broad, should not stand in the way of widespread companies running hydrogen-powered trams or buses need to observe rules for
ramp-up of hydrogen as a source of power. All these risks can be mitigated. Therefore, garaging their vehicles. Hydrogen sensors are mandatory to check for gas in hollow
before joining the hydrogen economy, organisations need to conduct an individual spaces such as wheel cavities. Tanks must be emptied outside. To prevent static
risk assessment. This enables plant and operations managers to plan for safety and discharge, precautions must be taken to ground components, for example by ensuring
establish best practice as they introduce hydrogen use. There is no standard risk the ground in working areas is conductive. Large refineries and chemical plants
profile, and the risks manifest differently depending on the infrastructure. When that regularly handle flammable gases or chemicals will be familiar with the risks of
Dräger conducts a risk assessment with stakeholders, the objective is to help improper grounding, but the same cannot be said for new users. In-depth knowledge
organisations to understand on a fundamental level what it means to use hydrogen, to of explosion protection requirements and standards is essential for selecting the
identify their specific safety challenges, define safety metrics, quantify risk and reduce right protections such as gas detection systems. Dräger’s expert local contacts are
it to an acceptable level. Gas measuring and warning systems are one key element familiar with international safety standards as well as national authority and production
of risk control which organisations need to engage with in accordance with legal and technology standards. There are also health and safety rules to consider, and HSE
regulatory requirements and their own circumstances. Only after thorough analysis managers have a key responsibility for the safety of the employees. With its decades
can the project proceed to designing and installing gas detection infrastructure, of experience in gas detection and personal protection, Dräger frequently helps
and training staff. Dräger is able to channel decades of expertise in gas detection customers steer a path through the plethora of HSE and plant safety regulations and
technology into ensuring organisations gain the insights (and confidence) to work advises on measures to take.
safely with hydrogen.

If hydrogen is to be stored, for instance, the assessment will explore planned storage
locations; in alignment with the identified risk, Dräger experts will propose the
specific type and placement of detectors. One key consideration is working out where
the gas will go if it escapes: will hydrogen bubbles, for example, form undetected
beneath ceilings? Efficient incident prevention also means integrating gas detectors
into an internal alarm management system. Is an effective ventilation system in place
which can be activated by an alarm? Advanced technology, such as flame and gas
mapping, help to develop suitable solutions for specific organisational needs. It is also
important to plan a rescue concept to flank preventive measures. This includes rescue
and emergency training, with clear plans on the course of action, such as first aid,
treatment and recovery. The number of users is also assessed (together with the type
of staff training required).

REGULATORY FRAMEWORKS
Regulatory frameworks for working with hydrogen are especially strict, and companies
also need to consider their compliance. In Germany , any company working with
FCEVs, for example, is subject to rules for fuel cell storage and refills. Transport
 10 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | SAFETY SOLUTIONS WITH DRÄGER

Safety solutions with Dräger

Detection technology
Gas detection systems are only as effective as Hydrogen detecting sensors – from ultrasonic leak
the planning which goes in to them. Therefore, detectors to flame detectors with infrared sensors CATALYTIC BEAD SENSOR (CATEX)

after the risk assessment comes the planning – provide instant alerts if anything goes wrong. CatEx sensors detect flammable gases and vapours such as hydrogen
and project engineering stage. The projects that A professional combination of the different below their lower explosive limit (100% LEL). They have good long-term
work best are those which can call on expert technologies offers the highest possible safety stability and a fast response time. They are mainly used for continuous
guidance throughout. This is why Dräger has level. area monitoring of the ambient air.
established a global network of system centres
with teams of specialists in planning, assembly and FLAME DETECTORS

commissioning. From advising on and planning In order to detect hydrogen-based fires, which are barely visible to the
the gas detection systems, to installation and human eye, flame detectors are required whose sensor technology and
operational maintenance, Dräger provides end-to- programming are specially designed for hydrogen or its combustion
end service, also integrating third-party products product (H2O). This specialisation ensures rapid detection of the
(such as horns) or existing solutions to create a dangerous flames and, at the same time, very high immunity to false
seamless safety infrastructure. Through on-site alarms, which, for example, multifunction devices cannot cannot provide
assessments, customers know, for instance, exactly to the same extent.
where to place sensors, how sensitive they have to
be, and what happens in the event of an alarm. ULTRASONIC GAS LEAK DETECTION
Dräger PointGard 2200 Dräger Flame 1750 H2 Ultrasonic detectors “listen” to high-pressure leaks, and can detect even
Flammable Gas Detector Flame Detector (IR3)
All these details are difficult for organisations to small leaks very fast. They serve as early warning area monitors: they
(available from 2023)
resolve on their own, and doing so involves huge respond earlier than conventional gas detectors because they register
investment of time and effort. Having identified the the sound of leaking gas instead of measuring the concentration of
specific challenges and risks, we accompany our accumulated gas clouds.
customers on the rest of the project, with order
management and project documentation as well as ELECTROCHEMICAL SENSOR (EC)

commissioning of the equipment and training of staff. EC sensors are a good choice when selective measurements of hydrogen
This ensures organisations receive solutions and on ppm concentration level are required. They offer advantages such as
installations that are an excellent fit for their situation. fast response, high accuracy, great stability and a long service life. This
technology is useful for point leak detection and personal air monitoring.
EXPLOSION PROTECTION
Due to the properties of hydrogen, explosion Dräger Polytron® 8900 UGLD Dräger X-am® 8000
protection by early leak detection is key to ensuring Ultrasonic Leak Detector Multi Gas Detector
plant and personal safety. Gas detection is regarded
as the primary way to protect against explosion by
preventing explosive atmospheres from building in
the first place. Different detection technologies come
into practice to build efficient protection layers.
 11 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | DOCUMENTATION REQUIREMENTS AND SMART DATA ANALYTICS

Documentation requirements
and smart data analytics
As compliance requirements become stricter,
organisations are required to maintain detailed
records – for example of measured gas values
or alarms – to demonstrate adherence to safety
standards. Paper-based documentation and
reporting are neither efficient nor often secure
enough to demonstrate compliance.

In a bid to raise efficiency of documentation

tasks and make use of the large amount of data
generated, organisations are turning to solutions
Dräger: trusted advisor for safety and gas detection
with smart data analytics. Data captured by gas
detectors are processed in a single, automated
workflow that takes care of record keeping, and
Dräger’s experience in gas measurement technology, risk
turns raw data into valuable insights for operational management and plant safety concepts takes organisations
safety. The digital records are more accurate
and can be made available faster during audits.
through the entire project – from greenfield planning through to
Predictions and improvements can also be derived installing and maintaining systems.
from data patterns. Impending failures can be
prevented before they occur, for example, and leaks
and defects can be detected before they lead to
serious damage.
 12 | HYDROGEN: HOW TO MEET THE SAFETY CHALLENGES | OUTLOOK

Outlook

Hydrogen, being versatile and abundant (it is the most abundant element in the
universe), definitely has a role to play in initiatives to reduce carbon emissions. At
present, organisations are keen to move forward at pace with their projects, but the big
concern is that safety challenges may be underestimated, or that the connection between
specific risk factors and the resulting operational hazards may not be fully appreciated.
As a specialist with decades-long experience in safety and gas detection, Dräger can
help would-be users move forward, with insights on general hydrogen safety, advice on
managing challenges for gas detection, and the selection of the right detection solutions
to keep installations consistently secure. With good awareness of safeguards, smart,
future-driven technologies and best-practice approaches to working with hydrogen, this
clean energy source will become routine – just as much a part of everyday life as diesel
and petrol are today.

Find out more

If you want to be part of the journey into a future with
hydrogen, explore how to make it safe and reliable with Dräger.

Visit Dräger at www.draeger.com

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