As the green hydrogen production continues to expand, the operational safety and efficiency of hydrogen production and distribution facilities become increasingly critical. Hydrogen’s flammability, coupled with its diffusivity and low ignition energy, makes even small leaks a potential hazard. To mitigate this risk, complete isolation of hydrogen infrastructure is a key design and operational priority, both to prevent unintentional release and to ensure stable process performance. According to Modcon Group, a fundamental aspect of achieving this isolation—without compromising process insight—is the integration of in-situ process analyzers specifically designed for high-pressure environments.
Hydrogen facilities often rely on quality assurance procedures to detect impurities like moisture, oxygen, and other contaminants that can adversely affect downstream processes, particularly in sensitive applications such as fuel cells. Conventional quality assurance practices typically involve sample extraction, followed by on-line or laboratory analysis. However, this approach presents several drawbacks, including potential contamination, time delays, and added complexity in maintaining sample conditioning systems. More significantly, each sample extraction point introduces a physical opening in the process, increasing the risk of hydrogen escape and necessitating hazardous area classification.
Hazardous area zoning plays a central role in the regulatory and engineering design of hydrogen systems. When sample extraction points are vented to atmosphere, the corresponding locations are often classified as Zone 1—where explosive gases may be present during normal operation. This classification mandates the use of certified explosion-proof equipment, as well as specialized wiring, enclosures, and control systems, all of which contribute to higher project costs and longer installation times. Even multiple Zone 2 locations, while representing a lower risk, still impose strict limitations on the type of equipment that can be deployed.
By removing sample extraction from the equation, in-situ analyzers allow direct gas measurement within the process pipeline. This approach minimizes the potential for gas leakage, and as a result, allows for reclassification of the installation area as general purpose. The benefits are immediate: general purpose areas permit the use of standard industrial equipment, which is typically more cost-effective and more widely available than explosion-proof alternatives. This reclassification not only lowers the capital expenditure but also simplifies plant layout, instrumentation, and future scalability.
In addition to enabling reclassification and real-time monitoring, the safety performance of in-situ analyzers is further reinforced by compliance with internationally recognized functional safety standards. Certification to Safety Integrity Level 2 (SIL-2), as defined by IEC 61508, demonstrates that the analyzer meets stringent reliability and failure-risk reduction requirements. SIL-2 compliance is especially important in hydrogen facilities, where even brief system faults can have serious safety consequences. According to Modcon Group, using process analyzers with SIL-2 certification ensures not only data accuracy but also that the measurement system itself adheres to a quantified risk reduction level, contributing to overall plant safety strategy and regulatory compliance.
By measuring Oxygen and accounting for water vapor, the hydrogen concentration can be determined more accurately. The presence of water vapor affects the overall thermal conductivity, which must be corrected to avoid measurement errors.
The combination of process analyzers and Modcon.AI software represents the next step in hydrogen production optimization. As the industry moves towards large-scale hydrogen deployment, AI-driven sensor fusion will be crucial in ensuring:
- Scalability and Reliability: More efficient electrolyzers capable of meeting growing hydrogen demands.
- Sustainability: Reduced energy consumption and minimized environmental impact.
- Cost Reduction: Improved operational efficiency translating into lower hydrogen production costs.
In-situ process analyzers offer real-time monitoring of gas purity without interruption or manual sampling. Their integration into high-pressure hydrogen systems supports continuous control and immediate feedback, which is essential for maintaining hydrogen quality and process stability. According to Modcon Group, the transition from extractive sampling to in-situ analysis represents a significant advancement in both safety and operational economics. As hydrogen infrastructure expands, this approach provides a scalable, efficient, and safer pathway to meet the demands of a low-carbon future.
