Gas warning systems for electrolyzers – safety in hydrogen production

Electrolysis is considered a key technology in the energy transition: It enables the climate-neutral production of green hydrogen from electricity and water. However, despite the ecological benefits, the production, handling and storage of hydrogen (H₂ ) poses considerable safety risks that need to be reliably controlled by gas warning systems.

How does an electrolyzer work?

– An electrolyser splits water (H₂O) into hydrogen (H₂) and oxygen (O₂) using electrical energy. This produces two highly reactive gases – both in pure form and often under pressure.

– Typical hazards during electrolysis:

– Hydrogen leaks: H₂ is colorless, odorless and tasteless – practically invisible without detection

– Explosion hazard: Even low H₂ concentrations (from 4% by volume) with air are flammable

– Accumulation in closed rooms: e.g. due to faulty ventilation, leaks or leaks

– Oxygen enrichment: also explosive if discharged improperly

Relevant areas for gas monitoring:

– Electrolysis module and stack area

– Hydrogen manifolds and storage systems

– Compressor stations and drying units

– Enclosures, containers, technical rooms, ventilation ducts

– Auxiliary rooms such as switch cabinets or operating buildings

Legal and normative requirements:

– ATEX zone classification for components carrying hydrogen (Zone 1 / Zone 2)

– TRGS 720-722, DIN EN 60079, BetrSichV, GefStoffV

– Recommendations according to IEC 60079-29-1 (gas detection with flammable gases)

– Why gas warning systems are indispensable for hydrogen electrolysis systems:

– Early leak detection below the explosion limit

– Explosion protection and fire prevention through automatic shutdown/ventilation

– Protection of personnel and systems in continuous operation and during maintenance

– Safe operation in sensitive application areas such as energy parks, industry or mobility

Our solution: gas warning technology for modern hydrogen systems

Our gas detection systems offer precise, standard-compliant detection of hydrogen – specially designed for the operation of

Electrolysis systems and H₂ infrastructure. Ideal for stationary systems, modular systems or mobile container solutions.

Your advantages:

– Sensitive H₂ sensors – also certified in Ex zones

– Fast alarm triggering & interfaces to shutdowns, ventilation, BMS

– Flexible placement: walls, ceilings, pipes, technical rooms

– Easy to maintain and can be integrated into a network (e.g. via Modbus, 4-20 mA, relay)

– Support with ATEX concepts, zoning and risk assessment

Green hydrogen needs safe processes.
With our gas warning systems, you create the basis for safe, standard-compliant and uninterrupted operation of your electrolysis system.

→ Contact us now – we will provide you with competent and solution-oriented advice.