Hydrogen Safety & Security
As hydrogen production, storage, and utilization expand across diverse sectors and geographies, the industry’s safety performance directly shapes its credibility with regulators, investors, and communities.
What Sets AcuTech Apart in Hydrogen Safety
With over 30 years of experience in process safety management (PSM), AcuTech has expanded its expertise to support clients managing the risks of hydrogen in chemical processing operations, refining operations, and gas production. These industries have produced and consumed hydrogen in a variety of reactions (e.g. reforming, hydrotreating, hydrocracking, hydrogenation, electrolysis) for nearly a century. As hydrogen has expanded from a process intermediate for critical reactions to new uses such as a fuel source, AcuTech has been at the center of the process safety initiative to effectively address the risks introduced with new uses of hydrogen.
AcuTech consultants bring hands-on experience supporting the safe use of hydrogen technologies and infrastructure, from research and development to deployment, and have provided input on codes, standards, and regulations, such as NFPA 2 and SAE J2601/3.
The Case for Process Safety Management in Hydrogen Operations
The hydrogen industry’s safety performance is paramount for ensuring its credibility across a wide range of applications. At AcuTech, we recognize PSM as the global standard for effectively managing catastrophic risks, particularly in chemical-related operations including those involving hydrogen. Our proposed approach to adopting PSM, irrespective of regulatory requirements, ensures benefits for all stakeholders. AcuTech is uniquely positioned to provide expert guidance on the safe production, storage, handling, and utilization of hydrogen as its prevalence continues to grow.
In particular, hydrogen fuel applications require substantial education efforts, and tailor-made PSM programs. AcuTech’s approach applies the knowledge from decades of existing hydrogen and chemical operations to new hydrogen and alternative fuel applications. This is where industry leadership, like AcuTech’s involvement with the Center for Hydrogen Safety (CHS), plays a pivotal role in advocating for the adaptation and implementation of PSM frameworks.
Learn more about AcuTech’s approach to process safety for hydrogen systems in our blog post.
Hydrogen PSM in Practice: AcuTech’s Experience & Expertise
AcuTech has experience developing hydrogen safety plans, facilitating HAZIDs and HAZOPs/LOPA, conducting risk assessments, and developing process safety management programs for large and small hydrogen organizations, from research laboratories to bulk scale chemical facilities.
To support organizations crossing the PSM threshold, AcuTech recently published a webinar on how organizations can leverage hydrogen safety plans to plan, organize, and support the development of PSM programs to comply with federal and state regulations and save time and cost downstream.
Presented by Aaron Harris, Group Leader.
AcuTech’s Contributions to Safety of the Hydrogen Industry
To ensure the most effective support for our clients, AcuTech has forged relationships with international organizations and academic centers to remain at the forefront of hydrogen risk assessment. In recent years, AcuTech has proactively been involved with industry consortia to help advance the safe and effective use of hydrogen as part of the energy transition.
As a member of the Center for Hydrogen Safety’s (CHS) Executive Committee, AcuTech’s consultants are up to date on global safety information and guidance.
AcuTech’s President & CEO, David Moore, and AcuTech’s Hydrogen Services Group Leader, Aaron Harris, were both selected for and currently serve on the U.S. Department of Energy’s Hydrogen Safety Panel (HSP).
AcuTech is also a member of the Fire and Blast Information Group (FABIG), which provides a platform for critical technical information sharing among operators and researchers on the latest experience and research on hydrogen risks.
Recent Hydrogen Projects
Process Safety Programs & Hazard Analysis
- Developing a process safety management system for the operating company of the world’s largest green hydrogen plant
- Developing a process safety management system for hydrogen forklifts at warehouse distribution centers
- Conducting HAZID, HAZOP, and LOPA of multiple hydrogen electrolyzer designs
- Conducting a HAZOP/LOPA of a hydrogen purification system for gas distribution
- Conducting a fire hazards analysis and a HAZID of a planned green hydrogen plant in Texas
- Conducting a comparative analysis of three PEM electrolyzers from a process safety perspective with a critique of inherent safety and operational safety barriers
Risk Assessment, Facility Siting & Consequence Modeling
- Conducting HAZID, HAZOP, and offsite consequence analysis for multiple heavy-duty hydrogen fueling stations
- Managing consequence modeling projects for H2 release analysis of various hydrogen production facilities
- Managing siting studies for facilities handling vapor and liquid hydrogen including risk studies for hydrogen fueling stations
Operations, Emergency Response & Security
- Conducting hydrogen emergency management training for fire responders for a new hydrogen manufacturing and distribution facility
- Conducting a root cause analysis of a hydrogen purification system fire incident
- Security risk assessment and critical infrastructure security design for a large-scale green hydrogen plant
Specialized Applications
- Serving as a member of the DOE Hydrogen Safety panel for advising on safety of novel technologies for hydrogen for multiple clients including:
- Conducting an analysis of a pink hydrogen application for a nuclear energy utility company
- Conducting an analysis of safe design and operation of a PEM membrane test laboratory
- Analyzing the risks of a novel subsea hydrogen power module for telecommunications
- Analyzing the risks of application use in road tunnels
Specialized Hydrogen Expertise
- Production pathways and facility support (electrolyzers, steam methane reforming, biohydrogen)
- Hydrogen storage systems (gaseous tanks, liquid tanks, hydride storage)
- Hydrogen transportation (trailers, pipelines, shipping, bunkering)
- Hydrogen utilization in stationary, mobile, and portable applications
- Safety and risk assessments for hydrogen operations
Regulatory Support & Compliance
- OSHA Process Safety Management (PSM) Program development, implementation, & management
- EPA Risk Management Program (RMP) development and compliance support
- State Regulations (such as California CalARP & CalOSHA PSM Program implementation)
- Hydrogen-specific facility design & siting requirements
- Pressure vessel code compliance (ASME BPVC)
- International hydrogen safety standards & directives
Risk Assessment & Analysis
- Process Hazard Analyses (HAZID, HAZOP, What-If/Checklist, LOPA, SIS, SIL)
- Failure Mode & Effects Analysis (FMEA), Safety Integrity Modeling (SIMOPs), & Fault Tree Analysis (FTA)
- Hydrogen dispersion modeling (PHAST, CFD) for vapor release scenarios
- Facility siting studies aligned with consequence modeling & hazard zones
- Electrolyzer installation risk analysis & design review
- Transportation route risk analysis & logistics studies
Safety Systems, Asset Integrity & Functional Safety
- Safety Instrumented Systems (SIS) design review & SIL verification/validation
- Mechanical integrity program implementation & optimization
- Inspection, testing, preventive maintenance, & critical-spares management
- Equipment reliability & lifecycle management
Emergency Response, Security & Incident Investigation
- Emergency Response Plan (ERP) development & tabletop exercises
- All-hazards emergency planning (ICS/NIMS aligned)
- Security Vulnerability Assessments (ANSI/API 780 methodology)
- Physical & cybersecurity planning for hydrogen facilities & operations
- Incident investigation, Root Cause Analysis (RCA), & Expert Witness services
- Critical infrastructure assessment & protection planning
Training: Hydrogen Safety & Design
- AcuTech offers advanced specialized training in process safety for hydrogen engineers, including:
- OSHA Process Safety Management (PSM) Overview
- EPA Risk Management Program (RMP) Overview
- Implementing California’s CalARP and CalOSHA PSM Program
- Best Practices in Process Safety and Risk Management
- Risk-Based Decision Making and Cost-Benefit Analysis
- Process Hazard Analysis (PHA) & Layer of Protection Analysis (LOPA) for Team Leaders/Members
- Human Factors and Procedure Analysis
- Incident Investigation & Root Cause Analysis
- Custom Hydrogen Safety Training
- We partner with organizations, from small-scale hydrogen laboratories to bulk-scale chemical plants, to strengthen their workforce and equip them with knowledge and skills to become process safety leaders.
AcuTech’s consultants are well versed in codes and standards and will refer to these as well as each client’s local jurisdiction codes and standards.
- NFPA 2: Hydrogen Technologies Code. Provides comprehensive requirements for the safe use of hydrogen in various applications, including stationary, mobile, and portable systems. It covers storage, handling, and utilization of hydrogen, aiming to mitigate potential hazards and ensure fire safety.
- NFPA 101: Life Safety Code. Sets standards for the design, construction, operation, and maintenance of buildings to ensure life safety. While not specific to hydrogen, it includes provisions relevant to the safe occupancy of buildings where hydrogen-related activities may occur, such as evacuation procedures and fire protection measures.
- NFPA 13: Standard for the Installation of Sprinkler Systems. Provides requirements for the design and installation of automatic fire sprinkler systems. While not hydrogen-specific, it may apply to facilities where hydrogen is stored or used, ensuring adequate fire protection measures are in place to mitigate fire risks.
- International Code Council (ICC) International Fire Code (IFC). Includes regulations related to hydrogen storage, handling, and use to ensure fire safety.
- American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC). Contains standards for the design, construction, and inspection of pressure vessels, including those used in hydrogen storage.
- International Organization for Standardization (ISO) 19880 Series. Provides guidelines for the safe storage and handling of hydrogen in stationary applications.
- European Union (EU) Directive 2014/68/EU. Sets requirements for the conformity assessment of pressure equipment, including hydrogen-related components.
- International Electrotechnical Commission (IEC) 62282 Series. Specifies safety requirements for fuel cell technologies, including those used in hydrogen-powered vehicles.
- Occupational Safety and Health Administration (OSHA) Regulations. Include general industry standards and guidelines applicable to workplaces handling hydrogen, ensuring worker safety.
- EPA Risk Management Program (RMP). Establishes requirements for facilities handling regulated hazardous chemicals above specific thresholds to develop and implement comprehensive risk management programs. While not hydrogen-specific, RMP may apply to hydrogen production, storage, and utilization facilities that store or use hydrogen in quantities exceeding regulatory thresholds. The program includes hazard assessment, prevention program development, incident investigation procedures, emergency response planning, and public notification to minimize the risk of accidental chemical releases and protect public health, property, and the environment.
- United States Department of Transportation (U.S. DOT) 49 CFR. Provides generalized guidance required to design, build, operate, and maintain equipment used for transportation of hazardous materials, including hydrogen.
- AcuTech’s President & CEO, David Moore, and AcuTech’s Hydrogen Services Group Leader, Aaron Harris, were both selected for and currently serve on the U.S. Department of Energy’s (DOE) Hydrogen Safety Panel (HSP).
- As members of the U.S. DOE HSP, AcuTech has contributed to authorship and revisions of multiple HSP technical documents, including recent white papers such as Hazard & Mitigations Associated with the Delayed Ignition of Hydrogen Releases, and Lessons Learned and Best Practices for Compressed Hydrogen Transport Trailers.
- AcuTech’s Hydrogen Services Group Leader, Aaron Harris is the current Chairman of the Managing Board of the CHS (2026-2027). President & CEO, David Moore, served as the Chairman of the Managing Board of the CHS in 2024-2025.
Learn the importance of global PSM application for hydrogen, including successful case studies, available frameworks, and potential safety enhancements.