Hydrogen Storage Safety Standards

With the increasing adoption of hydrogen as a clean energy source, manufacturing and storage industries must prioritise the highest safety standards to manage risks effectively. Hydrogen, while promising as a fuel and industrial gas, presents unique challenges due to its flammability, diffusivity, and storage requirements.

This landing page offers an in-depth overview of the essential regulations, best practices, and insurance considerations for companies involved in hydrogen storage and equipment manufacturing. Our goal is to help you navigate the complex regulatory landscape and ensure your business meets all necessary compliance and safety obligations.

Why Safe Hydrogen Storage Matters

Hydrogen is the lightest and most abundant element, but it is highly flammable and can form explosive mixtures with air. Incorrect storage or handling can lead to leaks, fires, or catastrophic failures. Proper safety standards reduce the risk of incidents, protect workers and the public, and help maintain business continuity.

Beyond physical safety, compliance with safety standards is a prerequisite for insurance cover. Non-compliance can void insurance policies or result in increased premiums. Therefore, understanding and implementing hydrogen storage safety regulations is also a financial imperative.

Key Hydrogen Storage Safety Regulations in the UK

The United Kingdom has established several legal and regulatory frameworks governing the safe storage, handling, and manufacture of hydrogen. These include:

• The Control of Substances Hazardous to Health Regulations (COSHH) – Managing risks related to hazardous substances including hydrogen.
• The Pressure Systems Safety Regulations 2000 (PSSR) – Covering the safe design, examination, and maintenance of pressure systems used to store hydrogen.
• The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) – Controlling risks associated with hazardous atmospheres from hydrogen leaks or releases.
• The Health and Safety at Work Act 1974 – Broad legislation ensuring employers safeguard worker safety, encompassing hydrogen storage.
• British Standards and ISO Norms – Including BS EN ISO 19880-1 for gaseous hydrogen – General requirements for storage and handling.
• Building Regulations Approved Document B – For fire safety and safe construction of hydrogen storage facilities.

Industry Best Practices for Hydrogen Storage Safety

In addition to meeting legal requirements, implementing best practices builds a more robust safety culture and supports ongoing insurance eligibility. Some essential practices include:

• Use of Certified Equipment: Only hydrogen-specific tanks, cylinders, and pipes tested to appropriate standards should be used.
• Regular Inspection and Maintenance: Frequent checks for leaks, corrosion, and system integrity to prevent failures.
• Gas Detection Systems: Installation of hydrogen sensors and alarms to detect leaks promptly.
• Ventilation: Well-ventilated storage areas minimise accumulation of hydrogen and reduce ignition risks.
• Employee Training: Comprehensive safety and emergency response training for all personnel handling hydrogen.
• Explosion Protection Measures: Incorporation of intrinsically safe electrical systems, barriers, and explosion relief devices as per DSEAR.
• Emergency Procedures: Clear protocols including evacuation plans, fire-fighting measures, and incident reporting.
• Risk Assessment and Documentation: Ongoing risk assessments backed by accurate records and safety information.

Insurance Considerations for Hydrogen Equipment Manufacturers

With the particular risks associated with hydrogen, insurance policies for equipment manufacturers and storage operators must reflect the complexity of their exposure. Standard business insurance may be insufficient.

Relevant insurance coverages include:

• Public and Product Liability Insurance: Covers claims from third parties for injury or damage caused by hydrogen equipment or leaks.
• Property and Equipment Insurance: Protection for costly hydrogen storage tanks, compressors, and facility infrastructure.
• Environmental Liability: Coverage for pollution or contamination incidents related to hydrogen leaks or accidents.
• Business Interruption Insurance: Compensation for lost income due to delays caused by accidents, regulatory investigations, or shutdowns.
• Engineering and Machinery Breakdown Insurance: Coverage for accidental damage to equipment due to mechanical or electrical failures.
• Professional Indemnity: Protects against claims arising from design or manufacturing errors in hydrogen equipment.

Obtaining tailored insurance requires full transparency about your safety controls, compliance status, and risk management processes. Insurers will expect documented procedures aligned with current hydrogen storage standards.

Hydrogen Storage Safety Regulations: Detailed Insights and Guidance

Let’s explore in detail some of the most critical aspects of hydrogen storage safety regulations to help you ensure full compliance and operational excellence.

Pressure Systems Safety Regulations (PSSR 2000)

Under PSSR, any pressurised system used for hydrogen storage must be designed, installed, and maintained to stringent safety standards. Key requirements include:

• The system must be constructed to a recognised engineering standard or approved design codes.
• Regular examinations by competent persons must be scheduled to detect deterioration.
• Any defects or failures detected must be reported to enforcing authorities.
• Pressure relief devices and safe venting arrangements are mandatory.

Non-compliance with PSSR can expose companies to enforcement actions, severe penalties, and loss of insurance cover.

Dangerous Substances and Explosive Atmospheres Regulations (DSEAR)

DSEAR addresses risks where hydrogen gas may form explosive atmospheres. Important compliance actions include:

• Identify and assess risk areas where hydrogen can leak and mix with air.
• Classify hazardous zones according to the likelihood and duration of explosive atmospheres.
• Apply suitable electrical and mechanical equipment certified for use in hazardous zones.
• Keep ignition sources away and implement strict controls on hot work and static discharge.
• Prepare written emergency plans and train personnel effectively.

COSHH and Worker Protection

The Control of Substances Hazardous to Health Regulations enforce employer responsibility to protect workers’ health when exposed to hazardous substances like hydrogen. Measures generally include:

• Risk assessments to evaluate potential exposures and controls.
• Use of personal protective equipment (PPE) where necessary.
• Provision of health surveillance and medical checks for employees.
• Clear safety data sheets and hazard communication.

British and International Standards

The British Standards Institution and International Organisation for Standardisation set out detailed technical requirements for hydrogen storage systems:

• BS EN ISO 19880-1: Specifies general requirements for gaseous hydrogen storage and handling equipment, including design, safety devices, and performance testing.
• BS EN ISO 15916: Provides safety distances for hydrogen installations to minimise risks to people and property.
• BS EN ISO 14687: Defines quality standards for hydrogen fuel, impacting storage purity and safety.

Developing a Safety Culture in Hydrogen Storage Facilities

Legal compliance alone is not enough. A proactive safety culture involves everyone from management to frontline staff. Key culture elements include:

• Leadership Commitment: Management actively promotes safety as a core value and provides resources for compliance.
• Continuous Training: Employees receive ongoing education on hazards, safe procedures, and emergency preparedness.
• Reporting and Learning: Near misses and incidents are reported without blame and analysed to prevent recurrence.
• Regular Auditing: Structured audits identify gaps and foster a culture of continuous improvement.
• Engagement: Workers are involved in safety decisions and encouraged to provide feedback.

Common Challenges in Hydrogen Storage Safety Compliance

Many businesses face difficulties when implementing hydrogen safety standards. These challenges include:

• Complex Regulations: Overlapping safety laws and standards can cause confusion.
• Technical Expertise: Lack of specialised knowledge for hydrogen-specific safety design and maintenance.
• Cost Constraints: Safety upgrades and inspections may require capital investments some manufacturers hesitate to make.
• Changing Requirements: Hydrogen technology evolving fast, creating dynamic compliance challenges.
• Insurance Requirements: Insurers may demand documentation and compliance evidence, adding pressure.

How Insure24 Can Help with Hydrogen Storage Safety Insurance

Insure24 specialises in bespoke insurance solutions for hydrogen equipment manufacturers and storage operators. We work closely with insurers who understand the unique risks in this sector to deliver competitive and comprehensive policies tailored to your needs.

Our experienced advisors guide you through risk assessment, underwriting questions, and ensure your coverage aligns with your safety standards and business objectives.

Frequently Asked Questions