Green hydrogen production

and storage – how to ensure

plant safety
—
Green hydrogen – hydrogen created without the use of fossil fuels – is today
often labeled as the fuel of the future. As large-scale power-to-x hydrogen
production increases, there is high need for risk evaluations and seamless
solutions to ensure plant safety – from the electrolysis process, compressor
facility and pipelines through to storage and distribution.
 D-36992-2021
Why green hydrogen?
Hydrogen is considered a valuable energy source because In recent years, blue hydrogen production has picked up
it burns clean and has extremely versatile use possibilities. pace. Here too, the hydrogen is produced from natural
Indeed, it is dubbed the “multitool of energy solutions” and gases, but the emissions are trapped using carbon capture
plays a growing role in many areas – such as developing and storage. Today, green hydrogen – produced through
low-carbon feedstock, as a low-carbon fuel, as an energy an electrolysis process that is powered by renewable elec-
carrier and as an energy source. tricity such as solar, wind and hydro power – is coming into
favor, thanks to its clean production process.
There are two main ways to produce hydrogen. The first
is through a process known as Steam Methane Reforming Companies are looking to reduce and even eliminate their
(SMR), where hydrogen is extracted from natural gas. And carbon footprint, thus putting green hydrogen in sharp fo-
the second by using electrolysis to produce hydrogen cus – as it is one of few sources of truly sustainable energy.
from water. Across the globe, many new hydrogen plants are being built
and major hydrogen production projects are being planned.
However, extracting hydrogen using the Steam Methane As these are successively realized over the next few years,
Reforming process can be extremely polluting to the growing safety challenges will need to be addressed:
environment. And as demand for hydrogen rises from year hydrogen is a highly-flammable gas and several risks are
to year, so too do CO2 emissions. Today, hydrogen pro- presented during production and storage phases.
duction through Steam Methane Reforming is responsible
for releasing approximately 830 million tonnes of carbon This will entail production plants taking an in-depth look
dioxide per year.¹ at the production chain in order to address safety needs at
every point.
Labeled as grey hydrogen, the SMR method of producing
hydrogen from natural gases and releasing emissions into
the air is still the cheapest form of hydrogen production.

2 | Green hydrogen production and storage

 D-3715-2024
Specific challenges during hydrogen
production
A higher demand for green hydrogen, and thus for elec- To start, there is an energy source – for example, wind
tricity as a power source, means that the number of wind, power. The currents can be converted to electricity which
solar and hydroelectric plants is also on the rise. Within can be used to produce hydrogen locally – for example,
the mix of these energy sources, solar plants play an offshore on a converter platform – or which can be sent
equally important role, however have less critical safety to an onshore hydrogen generation plant that consists
aspects attached. Therefore, wind and hydro power (water of an electrolyzer, a hydrogen compressor and, usually,
turbines) are of particular importance in regard to safety a hydrogen buffering or storage facility.
issues, the latter being developed more and more in the
Nordic countries. Using the power from these sources, Offshore converter platforms combine these components
hydrogen can be developed through electrolysis. This is in a closed-off building. Storage would occur elsewhere –
a relatively new area of production – and where there are for example in offshore subsea storage stations or in on-
new industry processes, new risks and challenges also shore storage tanks or buffers.
present themselves.
Although the safety challenges of hydrogen are the same,
In the following images, we take a closer look at the pro- the risks that come with it present themselves differently
cess and the plant elements for hydrogen production in and, as such, need to be handled differently depending on
which risks can occur. the unique setup of a facility.

Example: components of
a bigger plant.

Green hydrogen production and storage | 3

Risks and safety challenges of working Safety first: minimizing risk for plants
with hydrogen and workers
When handling hydrogen in the workplace, several safety When handling hydrogen in the workplace, several safety
challenges must be considered: challenges must be considered:

• High flammability: one of the major threats of hydrogen • Area monitoring is often necessary in larger outdoor
is an explosion as it requires very low energy to ignite installations where hydrogen is stored at pressure and
(0.02mJ). Hydrogen can auto-ignite just through the leaks can occur. This involves hazardous area protection
friction presented between the gas and a leak surface, and lower explosive limit (LEL) monitoring.
with a static shock that can be felt (1mJ). Spontaneous
ignition from the sudden release of compressed hydro- • Spot monitoring helps to detect leaks with fixed gas
gen into the atmosphere has occurred at pressure used detection solutions. This is useful for monitoring smaller
in current hydrogen storage systems – especially at the locations used for specific purposes – such as a critical
beginning of the production process, the gas is placed flange inside an airlet, where flammable gases may be
under extremely high pressure and thus is highly flam- sucked in.
mable. Hydrogen also has a very wide flammability range
(4%-77% volume in air), as compared to other fuels. At Based on regulatory safety management requirements,
the optimal combustion condition (29% hydrogen-to-air both inspections and manual leak detection must also be
volume ratio), the energy required to ignite hydrogen is conducted on a regular basis. This, as well as maintenance
lower than that of other common fuels. Equipment used work or inspection on critical parts, must be done with
must thus be suitable for use in hazardous areas. personnel. This often means working in hazardous areas
both in and outside of confined spaces. Consequently,
• Invisible flame: hydrogen flames are very pale or, in clearance measurements of confined spaces must also
daylight, even invi sible to the human eye. They emit a be taken into account. Workers must be equipped with
specific type of ultraviolet radiation. Therefore, dedicated rescue and escape equipment or, depending on the task,
flame detectors are required to reliably warn of fires. with personal protection equipment. Due to the high risk
of hydrogen explosion, the suitability of devices and
• Odorless: Hydrogen cannot be detected by smell. equipment for use in for use in hazardous areas is of
Natural gas and propane are also odourless gases, particular importance.
however a sulfurous odorant is added so that people can
detect them. There are currently no known odorants light
enough to move together with hydrogen at the same
dispersal rate. Odorants can also contaminate fuel cells.

• Permeation: Hydrogen molecules are tiny and can easily

penetrate materials. Appropriate selection, handling and
upkeep of all materials that come into contact with the
hydrogen is crucial.

• Gas pockets: Hydrogen has a lower density than air –

and even than hydrocarbons like methane. A very light
gas (57 times lighter than gasoline vapor and 14 times
lighter than air), it can be dispersed quickly, potentially
before gas detectors can even detect the leak. When
leaks occur, gas clouds can form on interior ceilings. Gas
detection technology therefore needs to be installed at
the top of a building.

• CO alarms: In some applications, carbon monoxide

(CO) also needs to be monitored. These carbon mono-
xide (CO) sensors are also sensitive to hydrogen, so false
D-36994-2021

alarms may occur – therefore, hydrogen-compensated

CO sensors are needed.

4 | Green hydrogen production and storage

Incidents and requirements for a solution
The root causes of incidents in a hydrogen installation
vary. They may occur due to inadequate joint and valve
seals, rupture of parts and even human error. Because of
the properties of hydrogen and the high pressure that it
is stored at, these issues may occur more often than with
other fuels – which can lead to severe consequences.
Requirements for a safety
In order to mitigate hydrogen hazards, a comprehensive system include:
plant safety system is required. Gas leaks must be detect-
• Quick, reliable and precise LEL monitoring
ed immediately in order to prevent catastrophic hydrogen
• Early and very fast detection, so that a potential
concentrations inside buildings, confined spaces and
hydrogen leak can be detected, and stopped
outdoor installations.
• Devices for outdoor installations that are not
sensitive to gas dilution or wind direction and
Several layers of detection methods can help to signifi-
that are not influenced by ambient conditions
cantly reduce escalations of hazard risk – which go from
(e.g. wind or rain)
leaks to gas dispersal and then from ignition to possible
• Measurement data that can be evaluated in
fire or explosion. This can, of course, result in severe
order to improve the efficiency of safety and
personal injury and property damage.
maintenance processes

An event tree for gas release explains how the deployment

of an early response system improves hazard management.

Event Tree for Gas Release

Gas Immediate Vapor Cloud Liquid Release & Explosion Toxic Outcome
Release Ignition Forms & Ignites Ignition Occures Chemical

Jet Fire
Yes
Yes Vapor Cloud
Explosion
Yes No
Flash Fire

No Yes
Pool Fire

Yes
Toxic Exposure
No
No
No Consequences

Ultrasonic Gas Flame Point Gas

Leak Detection Detection Detection

Green hydrogen production and storage | 5

 D-36991-2021
Combined fixed gas detection technologies
Left undetected, gas leaks can cause catastrophic fires • Selective point gas detection with electrochemical
and explosions. Since hydrogen is stored at extreme high sensors: These highly-sensitive devices detect ppm
pressure and leakages can occur relatively easily due to concentrations and are selective to hydrogen or other
hydrogen’s small molecule size, leaks must be detected gases – for example oxygen, which may also be present
extremely fast to ensure adequate safety response. in such processes.
Conventional gas detectors do not detect gas leaks until
a vapour cloud has formed and, after some time, reach • Hydrogen flame detection: Because hydrogen flames
the gas detector. Because hydrogen has such highly-flam- have unique characteristics, the most suitable sensor
mable properties, it can ignite even before a cloud forms. technology is one that can detect their radiation fre-
For this reason, it is essential to have a combination of quencies early and reliably. Flame detectors with triple
fixed gas detection technologies in place, as follows: IR sensors specially designed for hydrogen flames offer
very high immunity to false alarms caused by sources of
• Ultrasonic gas leak detection (UGLD): These early interference such as welding, hot CO2 emissions or other
warning area monitors detect high-pressure gas leaks fire sources. This is achieved by ensuring that only a
in outdoor industrial process environments. Thanks to unique relationship between the IR emissions picked up
an ultrasonic acoustic sensor, they respond earlier than by the three sensors triggers an alarm, making it more
conventional gas detectors because they register the effective and reliable than the typical UV/IR hydrogen
acoustic ultrasound of leaking gas instead of measuring flame detector, and offering greater detection range and
the concentration of accumulated gas clouds. As gas coverage.
escapes, leaks are immediately detected in the surrounding Ruggedness and resistance to all types of weather
area, regardless of wind direction. It is especially impor- conditions, such as ice fog or rain, are also critical.
tant for hydrogen outdoor installations, that devices are
not sensitive to gas dilution or wind direction, rain or Installation of these devices is often in remote areas that
other ambient conditions. In compressor stations, early can be difficult to access. It is therefore paramount that
leaks of compressed hydrogen and methane-hydrogen they are robust, fail-safe, need minimal maintenance, re-
mixes would also be detected by these devices. quire little power, have a long lifespan and a low lifecycle
cost. They should also be simple to operate and easy to
• Conventional catalytic point gas detectors: This tech- install and test. In some cases, where gasses other than
nology is used for lower explosive limit (LEL) monitoring. hydrogen (e.g. methane) needs to be detected, a wireless
Catalytic bead sensors can detect and measure com- gas detection solution could also be considered as a viable
bustible gases such as hydrogen within a few seconds. and effective solution.
These types of devices show long endurance under the
influence of poisonous substances, are approved for The starting point for any gas detection system installa-
temperatures of up to 302°F/150°C and can detect very tion should always be a risk assessment and solid project
low gas concentrations in a range of 0-10% LEL. planning, including fire and gas mapping. Experts review
existing designs to identify potential for improvement
and to establish sustainable safety. Tailored measures are
defined by safety consultants in conjunction with facility
managers and operators.

6 | Green hydrogen production and storage

 Dräger offers a full range of fixed gas detection technologies that are designed for
the specific and continuous monitoring and detection of highly-flammable gases
and vapors, such as hydrogen. Dräger solutions are specialized for the application
and situation on individual plants – resulting in greatly lowered risk and reliable
safety solutions for your workers and your property.

Fire and Gas Detection Systems

Hydrogen gas leaks can occur in various parts of a
hydrogen facility. Especially critical areas are hydrogen
compressors and storage tanks. Hydrogen compressors
have many moving mechanical parts which means flanges,
piping junctions and other openings from where the gas
has a chance to leak out. Hydrogen storage tanks are

D-5541-2018
under extreme pressure – and the higher the pressure that
the hydrogen is stored at, the higher the chance of hydro-
gen gas leaks. Electrolysers are a critical area due to the
Dräger Polytron® 8900 UGLD
pressure required in the electrolysis process.

In order to determine the optimal number and position of

gas and flame detectors, a thorough risk assessment and
properly managed gas mapping is necessary. Due to the
different properties and coverage which each technology
offers, an intelligent combination of gas detection devices
is key to a professional plant safety system.
D-9493-2022

Ultrasonic gas leak detectors have a rather large area of

coverage, combined with very fast detection of gas leaks
and they are not affected by wind direction. Therefore, they
Dräger Flame 1750 H₂
are generally installed in central places where they can
cover the whole area where potential leaks can occur. The
area they cover depends on the expected ultrasonic sound
level. Small leaks in pipelines with very high pressure, such
as in hydrogen plants, create high sonic speed. Depend-
ing on the plant layout, distances up to 20 meters can be
covered. In the case of interfering elements, such as tall
pillars, a higher number of ultrasonic gas leak detectors
D-797-2016

may be necessary.

Flame detectors identify and respond to the presence of

Dräger Polytron® 8200 CAT
flame by sensing radiation emissions. They can cover a
roughly 90° cone-shaped area of up to 40 meters distance.
They should have a clear view of all critical parts where hy-
drogen flames may occur. The number and positioning of
the flame detectors depends on the specific layout of the
facility. Ideally the whole plant area should be monitored,
making sure that blind spots are avoided.
D-2946-2018

Dräger Polytron® 8100 EC WL

Green hydrogen production and storage | 7

Point gas detectors measure the concentration of a gas Point gas detectors should be used to monitor dedicat-
at an LEL or ppm level. These devices tend to be rather ed areas where, after a thorough risk analysis and gas
sensitive to environmental conditions like wind or rain, mapping, the likelihood for hydrogen gas pockets is the
and so are mostly used indoor or in closed-off areas. As highest. In those areas, they should be installed high up. In
hydrogen is very light, dangerous concentrations can form cases where other gases are involved, such as hydrocar-
on ceilings. bons, these detectors should be installed below possible
hydrogen gas pockets.

Design model of a hydrogen electrolyzer

D-9493-2022

D-5541-2018
D-797-2016

Dräger Flame 1750 H₂ Dräger Polytron® 8200 CAT Dräger Polytron® 8900 UGLD
With its triple IR sensor the The Dräger Polytron® 8200 CAT The Dräger Polytron® 8900
Dräger Flame 1750 detects is an advanced explosion-proof UGLD transmitter is an early
hydrocarbon- and hydrogen- transmitter for the detection of warning area monitor for
based fires. flammable gases in the lower detecting high-pressure gas
explosion limit (LEL). leaks in outdoor industrial
process environments.

8 | Green hydrogen production and storage

Graphic simulation of a possible gas warning installation. Choice, real positioning and coverage of detectors
depends on individual plant set-up, environmental conditions and customer´s choice after risk assessment
and gas mapping.

Design model of a hydrogen compressor station

Design model of a hydrogen storage facility

Dräger Flame 1750 H₂ Dräger Polytron® 8200 CAT Dräger Polytron® 8900 UGLD

Green hydrogen production and storage | 9

Windmills are not directly involved in the hydrogen Mobile gas detection technologies
production cycle but they play an important role in the As with all regular plants, parts such as valves, flanges,
production chain. Especially in the case of a dedicated pipe and tank junctions must be regularly inspected, and
hydrogen windfarm, the converter platform for hydrogen maintenance work must be carried out. Hydrogen tanks,
is a facility where all the elements for production are com- whether indoor or outdoor, must adhere to certain
bined in one building. Windmills need regular maintenance regulations. For example, outdoor tanks must be at least
and have confined space in entryways where access is 1.5 metres away from all entryways of a building. They must
required. Windmills used for hydrogen production, as also be protected from vehicle collision if near a road.
compared to standard windmills, need specialised fixed Workers in the area must always be made aware of the
gas detection solutions. Both windmills and converter risks of flammable atmosphere and oxygen deficiency.
platforms have closed-off areas which require special
attention as hydrogen can collect in gas clouds in upper For inspection and maintenance work, mobile gas detection
areas, from where it cannot escape. technologies are highly recommended for personal air
monitoring, in order to ensure that any relevant hydrogen
leaks around personnel can be immediately detected.
Confined space entry work would require atmosphere test-
ing before entry and regular and repeated spot measure-
ments with portable gas detectors. These solutions would
apply across every area of the plant where inspection and
maintenance tasks come up and where gas hazards may
be present.

When hydrogen is present, maintenance tasks bring spe-

cial requirements with them – especially concerning the
equipment and technologies needed to keep workers safe.
Of particular importance, is the suitability of devices for
Ex-areas. Because hydrogen has a Lower Explosion Limit
(LEL) of only 4% by volume, gas detection equipment must
be approved at the highest level (explosion group IIC).
D-37001-2021

D-381-2018

10 | Green hydrogen production and storage

 As hydrogen itself is non-toxic to maintenance workers, it Maintenance and the need for PPE and emergency
is sufficient to protect them from explosions and concen- escape devices
trations which reach the LEL. For this reason, catalytic The regular inspection and maintenance of plants is critical
bead sensors which measure hydrogen in the LEL-range to the safety of the plant and its workers – and being
are a good choice – they give an A1 alarm when a concen- prepared for emergency incidents is always a necessary
tration of a predefined limit (e.g. 10% LEL) is reached. Here aspect of risk assessment. In areas where hydrogen gas is
it is important that the sensors are tested and calibrated stored and used, Ex-protection, Ex-approvals and antistatic
with H2; no alternative test gases are possible. properties require special focus and specific PPE and
Electrochemical sensors, which can take measurements emergency escape devices. Work done in confined spaces
in the parts per million (ppm) range, may be used to may also require independent air supply units. As hydro-
determine the exact concentration of hydrogen in order gen belongs to the highest gas explosion group IIC, it is
to detect any leaks. necessary to check whether all protective equipment is
suitable for use and to conform to, for example, ATEX type
When other gases, like oxygen or ammonia, must also be IIC. For offshore windfarms, a quick-response firefighting,
measured, multi-gas detectors are suitable. Depending rescue and safety protocol and related equipment should
on the exact requirements, they may be equipped with also be in place.
an electrochemical (EC) Sensor, a catalytic bead (CatEx)
sensor or even a combination of both. With Dräger, you stay prepared
As a specialist with decades-long experience in safety and
In the case of green hydrogen production, if no other gas detection, Dräger can bring you integrated solutions –
flammable gases are present, hydrogen-specific sensors from consultation through design, realization and imple-
may also be used. Easy handling and quick response mentation of fire and gas detection systems across your
times of devices may also play a role in device choice. plant to maintaining systems and ensuring compliance and
adequate safety measurements. Selecting the right detec-
Digital records: how smart data can play a vital role tion solutions, safeguards and best-practice approaches is
Today, with more compliance requirements in place, indus- the key to working with hydrogen smartly and safely.
trial plants must maintain detailed records of gas values
and alarms to prove that they adhere to safety standards. Dräger’s extensive experience in gas measurement tech-
To this end, they are turning to smart safety solutions to nology also extends to data analysis, risk management
improve efficiency and accuracy of such records, which and safety concepts – making Dräger a valuable partner
can be made available more quickly during audits. Data for industrial plants from planning through to installing
captured by gas detectors is automatically processed, and maintaining such systems.
making for easy record-keeping and the generation of data
patterns and valuable insights, which leads to improved When it comes to workplace safety and personal protec-
safety measures and reduced risk: potential failures can tion of your staff, Dräger offers the full range of respiratory
be prevented, and defects can be detected more quickly. protective devices and personal protection equipment
needed to keep every employee safe. Dräger also provides
i full-scale safety consultancy and outsourced services as
For more information on Dräger consulting services and part of a complete safety solution.
safety services, visit www.draeger.com/hydrogensafety

Green hydrogen production and storage | 11

Not all products, features, or services are for sale in all countries. Trademarks mentioned herein are the property of its respective owner.
Trademarks may be owned by Drägerwerk AG & Co. KGaA (Dräger) or its affiliates in certain countries and not necessarily in the country in which
this material is released. Visit www.draeger.com/trademarks for the current status of Dräger’s trademarks.

Corporate Headquarters Region Europe Region Asia Pacific

Drägerwerk AG & Co. KGaA Dräger Safety AG & Co. KGaA Draeger Singapore Pte. Ltd.
Moislinger Allee 53–55 Revalstraße 1 61 Science Park Road

DMC-107307 | 24.07-2 | HQ | PR | Subject to modifications | © 2024 Drägerwerk AG & Co. KGaA

23558 Lübeck, Germany 23560 Lübeck, Germany The Galen #04-01
+49 451 882 0 Singapore 117525
www.draeger.com +49 451 882 2080 +65 6872 9288
[email protected] +65 6259 0398

Region Middle East, Africa Region Central

Dräger Safety AG & Co. KGaA and South America
Branch Office Dräger Indústria e Comércio Ltda.
P.O. Box 505108 Al. Pucurui - 51 - Tamboré
Dubai, United Arab Emirates 06460-100 - Barueri - São Paulo
+971 4 4294 600 +55 (11) 4689-4900
+971 4 4294 699 [email protected]
[email protected]

Locate your Regional Sales

Representative at:
www.draeger.com/contact