AIChE’s Center for Hydrogen Safety (CHS) brings together a global community dedicated to advancing hydrogen safety and best practices worldwide.
A key part of that work is the Hydrogen Safety Panel, a group of experts who identify risks, share lessons learned, and provide guidance for safer hydrogen projects.
In this interview, Hydrogen Safety Panel member Tom Witte shares lessons from more than four decades designing and installing industrial gas systems. Witte has contributed to thousands of cryogenic and gaseous system installations, including hydrogen-fueling stations, and has helped develop hydrogen codes and standards for the National Fire Protection Association and the Compressed Gas Association. He explains which safety considerations should be addressed early, where projects commonly run into problems, and why hydrogen safety knowledge must extend beyond system operators.
Based on your experience designing and installing hydrogen systems, what safety considerations deserve more attention early in the design process?
The project scope often isn’t defined clearly enough. Without a well-developed scope, projects become vulnerable to safety concerns, delays, cost overruns, and rework.
Project teams should also identify the major equipment, its safety requirements, and how the equipment will interact within the complete system. Many projects rely on packaged or “black box” equipment purchased from vendors who may be reluctant to share detailed design information. Without that information, it’s difficult to understand how the equipment affects overall system safety.
Teams should perform a process hazard analysis (PHA), such as a hazard and operability study (HAZOP), when they have sufficient, current design information to support a meaningful and effective review. The scope, methodology, and timing should match the project’s design maturity, complexity, and risk profile. The process should also allow teams to incorporate findings into design and project decisions without compromising safety.
A HAZOP shouldn’t become a substitute for a complete design review. When schedule and budget take priority, equipment may be purchased or installed before the review is completed. At that stage, teams often resist implementing recommendations because of the additional time and expense. Addressing safety early gives teams greater flexibility to make necessary changes.
What are some of the most common mistakes you’ve seen when hydrogen systems move from design to installation and operation?
Improper commissioning is one of the most common problems. Commissioning requires significant time and effort, but some organizations don’t dedicate the resources needed to complete it thoroughly.
Training is also frequently treated as an afterthought. It should be developed and delivered before hydrogen arrives on site and reinforced regularly throughout the system’s operating life.
The level of training matters just as much. General hydrogen awareness is important, but it’s not enough for everyone. Operators and maintenance personnel need training tailored to their specific responsibilities and the equipment they’ll work with.
Operating and maintenance procedures require the same attention. Procedures should be written before startup and reviewed as part of commissioning. Waiting until a system is operating to develop training or procedures creates avoidable gaps in knowledge and preparedness.
Does hydrogen safety knowledge need to extend beyond those directly operating the equipment? If so, why?
Yes. Any company personnel who may be involved in an emergency or affected by it should be considered when developing safety and training plans.
First responders are often overlooked. They should be included in the facility’s training requirements, so they understand the system, its hazards, and the appropriate response before an incident occurs.
Hydrogen safety can’t stop with the people operating the equipment. It requires preparation across the facility and among those who may be called upon to respond.
Additionally, depending on the size and location of the facility and/or its operations, neighbors and neighboring communities may also need to be considered. Clear communication and appropriate community engagement help ensure that people surrounding a hydrogen facility understand how safety is being managed.
