Is hydrogen safe? How to support safety & compliance across applications
Hydrogen is emerging as a cornerstone of the global transition to cleaner energy, offering a versatile, zero-emissions alternative to traditional fossil fuels. However, its potential to revolutionise industries—from transport to manufacturing—often raises one critical question: is it safe?
In short, yes. Hydrogen has been safely produced, stored, and transported around the world for decades. Like other fuels and resources, there are existing standards in place to ensure safety and compliance, with controls and protocols to facilitate its safe use. When handled correctly, hydrogen is as safe as any of its alternatives.
Understanding risks
As the lightest and most abundant element, hydrogen is non-toxic and burns cleanly, producing only water as a byproduct. Yet, it is also highly flammable and requires careful handling, particularly when stored under high pressure.
Compared to conventional fuels like petrol or diesel, its risks are different but not necessarily greater. For example, while hydrogen leaks dissipate quickly, minimising combustion risk, it is also odorless and invisible, necessitating advanced detection systems. Addressing these nuances is key to ensuring the safe use of hydrogen across diverse applications.
Ongoing work through hydrogen codes and standards, and delivering training for those involved in hydrogen applications is key to ensuring safety.
Installing safe hydrogen systems
When installing a hydrogen system for public or commercial use, the storage and generation of combustible fluids are subject to rigorous safety standards to mitigate potential risks and ensure ongoing safe operation of the system.
In Australia, Australian Standards have clear requirements on how systems must be designed, constructed, and validated to ensure the safety of personnel and the wider community. These requirements are subject to the system manufacturer and include, but are not limited to:
rigorous risk assessment and hazard minimisation during design
redundancy in safety equipment to prevent hazardous situations from arising
thorough system assessment and verification by a 3rd party accredited auditor prior to commencing operation.
By adhering to these standards, the safe operation of electrolysers, refilling, and refuelling systems can be ensured.
Did you know?
Endua is at the forefront of managing hydrogen safety. When the Queensland Government implemented the hydrogen safety code of practice in 2023, the Endua power bank was the first product to be compliant in this new code of practice!
The Standards describe the roles and responsibilities for owning and operating a hydrogen system. A strict maintenance programme must be adhered to, including regular external audits of critical equipment, as well as maintaining a hazardous area dossier, describing the system and any maintenance works that have been done.
Work must also be done between the manufacturer and customer to assess the proposed location for the system. When determining a suitable location, it’s critical to consider the interactions with other systems and hazardous areas in the vicinity. This is particularly important in commercial and industrial areas where other existing hazardous areas may be present.
This is typically undertaken through a HAZID and HAZOP study to identify any impacts and risks to existing operations caused by the addition of a new process and equipment. Location interactions between existing hazardous areas with the proposed system must also be considered as part of this analysis.
The strict legislative requirements for designing, installing, and maintaining a hydrogen system can make it challenging for businesses without specialised expertise to meet all necessary standards. Collaborating with qualified technical providers, such as Endua, is a reliable way to ensure compliance, while setting you up to operate the system safely and independently in the long-term.
Interested to learn more about how to establish and ensure safety and compliance for a hydrogen refuelling station? Read more in our 7-Step Guide to Transition to Hydrogen Vehicles.
Key applications and safety considerations
Hydrogen’s versatility makes it a valuable energy carrier and industrial feedstock, but each application comes with unique safety requirements. Let’s take a closer look at key use cases and the safety considerations they demand.
1. Hydrogen storage and refilling tanks
Hydrogen can be stored for use as a compressed gas or cryogenic liquid, both which require specialised equipment to ensure safety. Storage tanks must withstand high pressures, prevent leaks, and maintain structural integrity under varying temperatures. Automated systems for pressure monitoring and leak detection are essential to minimise risks during refilling operations, especially in industrial settings where large quantities of hydrogen are handled regularly.
2. Refuelling vehicles
Refuelling hydrogen-powered vehicles presents different safety requirements depending on vehicle type. Hydrogen road transport vehicles, for instance, cars, buses, and heavy trucks, are equipped with high-pressure dispensers and sensors to prevent overfilling. Provided users adhere to safety protocols, hydrogen refuelling is relatively straightforward, and swift refuelling times make it competitive with petrol and diesel.
Emerging technology vehicles, such as hydrogen-powered ships and aircraft, often rely on liquid hydrogen, which must be stored at cryogenic temperatures. Ensuring safe refuelling at ports and airports involves advanced insulation technology and robust ventilation systems to manage boil-off gas.
Boil-off gas (BOG) is the gas that results when liquid hydrogen (LH2) evaporates, primarily due to heat leaking into the tank.
3. Fuel cells and energy systems
In energy applications, hydrogen powers fuel cells that provide electricity and heat. Safety measures include designing systems to withstand environmental stresses, such as extreme temperatures, and incorporating emergency shutoff mechanisms. In residential or commercial settings, hydrogen fuel cell systems require routine maintenance to prevent leaks and ensure long-term reliability.
4. Industrial manufacturing
Hydrogen is used in a wide variety of industrial processes, such as ammonia synthesis for fertilisers and hydrogenation in food production. These applications involve high pressures and temperatures, requiring advanced safety systems to prevent incidents. Additionally, industries must comply with strict regulatory frameworks, from proper ventilation to regular inspections of equipment.
Supporting ongoing safety and compliance
Supporting hydrogen safety is achievable by adhering to regulations and standards. In summary, operators must take the following measures:
Ensure local compliance – refer to local government safety codes to ensure systems meet requirements for public and environmental safety.
Conduct appropriate risk analysis – such as HAZID/HAZOP studies to assess proposed location for systems
Obtain necessary certifications – such as Building Approval (BA) or Development Approval (DA).
Obtain a thorough system assessment and verification – by a 3rd party accredited auditor prior to commencing operation.
Utilise monitoring systems – such as real-time monitoring technology systems, equipped with sensors, to provide early warnings about potential issues, respond quickly, and minimise risks.
Perform regular inspections and maintenance – to further enhance safety, and check for signs of wear or corrosion.
Provide clear operational guidelines and adequate training – to establish consistency across hydrogen projects and educate staff on best practices and incidence response protocols.
By combining strict regulatory frameworks with proactive compliance efforts, hydrogen operators can maintain high safety standards across applications. Doing so not only provides the best operational benefits in mitigating risks – but builds public confidence in hydrogen to drive adoption on a wider scale.
Collaborating with qualified technical providers, such as Endua, is a reliable way to support compliance, while setting you up to operate the system safely and independently in the long term.
Ultimately, safety and sustainability go hand in hand. By integrating robust safety measures in every stage of a hydrogen project, industries can unlock its potential as a clean energy source while protecting people and the environment. With proper measures in place, hydrogen can be safely integrated across sectors, driving the global shift toward clean, renewable energy.
Interested to learn more about integrating a hydrogen solution in your operations? Access the Endua electrolyser data sheet or start a conversation with the Endua team.