Hydrogen is central to the clean energy transition, but its safety challenges cannot be ignored. One of the most critical issues is hydrogen leak detection. Because hydrogen is colourless, odourless, and highly diffusive, undetected leaks can quickly create explosive conditions. Effective leak detection systems are therefore essential for ensuring the safety of industrial hydrogen systems, fuelling stations, and research environments.

In this blog, we explore the leading hydrogen gas sensor technologies, their applications and standards, and how smart hydrogen safety devices are transforming risk monitoring.

Hydrogen Leak Detection Methods

Electrochemical Sensors

These sensors detect hydrogen through oxidation reactions at an electrode surface. When hydrogen interacts with the electrode, it produces a current directly proportional to the gas concentration.

Catalytic Bead Sensors

Hydrogen is detected when it combusts on a heated catalyst-coated bead. The combustion changes the bead’s electrical resistance, which signals the presence of hydrogen.

Infrared (IR) Sensors

IR sensors measure hydrogen by analyzing how it absorbs infrared light as it passes through the gas. The degree of absorption is used to determine hydrogen concentration.

Ultrasonic Gas Leak Detectors

These detectors sense the ultrasonic sound waves generated when pressurized hydrogen escapes through leaks. The acoustic signal provides an immediate indication of gas release.

Sensor Placement and Response Time

Even the best sensors are only effective if correctly installed. Optimal placement is critical:

Place detectors above equipment and near potential leak sources (flanges, valves, joints)
In open environments, combine multiple sensor types for redundancy
Ensure sensors have fast response times (ideally within seconds) to allow early intervention

Real-World Incident: Hydrogen Leak at Kjørbo Fueling Station (Norway, June 2019)

Overview: On June 10, 2019, a hydrogen station at Kjørbo, Norway, suffered a high-pressure storage leak from a plug in a hydrogen tank. The leak ignited, causing an explosion and pressure wave, though the dispenser and electrolyzer were not affected, and no personnel were injured.

Root Cause: Investigations revealed the leak stemmed from an assembly error: inner bolts of the plug were not adequately torqued. This led to a hydrogen-air mixture that ignited. In response, inspection programs, stricter assembly protocols, and enhanced leak-detection measures were implemented.

Hydrogen Safety Standards

Effective leak detection is guided by global frameworks:

ISO 26142: Specifies requirements for stationary hydrogen detection apparatus.
IEC 60079: Explosive atmospheres, covering electrical equipment and gas detection.
ISO 19880-1: General requirements for hydrogen fueling stations, including monitoring systems.

Compliance with these standards ensures that hydrogen risk monitoring systems are not only effective but also globally recognized for safety assurance.

The Future: Smart Hydrogen Safety Devices

Traditional leak detection is evolving toward smart, wearable, and connected tools. These integrate IoT, data logging, and real-time alerts to make hydrogen monitoring more proactive and personalized.

At SAVEIONS LTD, we are advancing the field through the development of smart wearable hydrogen safety tools. These devices allow workers in hydrogen facilities to continuously monitor their environment, receive instant alerts, and integrate safety data into wider hydrogen risk management systems. By bridging standards-based engineering with digital innovation, SAVEIONS is helping industries move toward next-generation hydrogen safety.

With its expertise in hydrogen safety consulting, training, and smart wearable technologies, SAVEIONS LTD is committed to enabling industries and institutions to detect risks earlier, respond faster, and operate hydrogen systems with confidence.