The core challenge of process reliability and what is overlooked by many

Hydrogen is highly reactive and is often handled under enormous pressure, whether during the electrolysis of water, compression in high-pressure tanks or distribution in mobile trailers or filling stations. The molecule is also very small, which makes it more susceptible to leakage. Reliability is the top priority for all applications in the hydrogen value chain. Because in an emergency, people, systems and budgets can be jeopardised. This means that processes are sensitive at every stage of the value chain. It is important to keep these aspects in mind:

• Functional safety according to the SIL (safety integrity level) protects against uncontrolled states in the event of malfunction.
• IECEx regulations and regional standards guarantee explosion prevention and protection during the production, transport and storage of hydrogen.
• The permanent and automated monitoring of systems is not a luxury, but a basic requirement for safe operation.

If you cut corners here or consider requirements too late, you not only run the risk of facing delays but also expensive retrofits. Find out in our blog post on functional safety using the example of hydrogen production how you can minimise risks right from the start by using a reliable safety concept.

What if the tried and tested approach is not the best decision?

Traditional installations in the chemical and process industry often rely on individual valves mounted directly on the actuator. With numerous valves, sensors and controllers, the density of interfaces is high. Modern hydrogen systems often rely on modular units. While this facilitates integration into the overall system, this approach also increases the complexity of the individual modules. Without a consistent system architecture, this often leads to:

• Compatibility problems that delay commissioning
• Higher costs due to more time-consuming troubleshooting and
• More maintenance work than necessary

This can be prevented with a sophisticated architecture and the right products. This is where compact valve terminals are a real game changer: their installation and maintenance costs are lower, they have centralised diagnostic options and are extremely modular for adaptations and expansions at a later stage.

Example: compact, modular valve terminal solutions such as VTUG or CPX-MPA combine controller, valves and monitoring in a single system. Depending on the application, they fulfil SIL requirements, are particularly suitable for harsh environments and can be used not only in stationary but also in mobile applications.

There is no energy transition without sophisticated automation

The challenges in the automation of hydrogen processes are real but can be solved. Choosing the right partners and concepts from the outset reduces risks, accelerates projects and creates the basis for long-term success.

What needs to be taken into account:

• A comprehensive view of your application, from safety to integration to servicing.
• A well-thought-out automation concept that enables scalability and conforms to standards.
• Technologies and components that are suitable for the special requirements of hydrogen.
• An automation solution that is cost-effective despite high production costs.