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RCS Database

HRS Components

The entire HRS is subject to a complex approval process and bound by a wide range of RCS. Since an HRS consists of several components, it makes sense to assess the individual elements in relation to RCS. These components can generally be categorized as follows:

  • Storage (e.g. pressure tanks, cryogenic tanks)

  • Thermal and temperature systems (e.g. cooling, precooling, heat exchangers, liquefiers, evaporators)

  • Pressure Equipment (e.g. compressors, valves, pressure relief systems)

  • Transfer, filling and dispensing systems (dispensers, nozzles, pumps, pipelines, transfer lines)

  • Supply systems (cleaning systems, on-site electrolysers)

  • Transport vehicles

  • Safety systems (detectors/sensors, warning/alarm systems, vehicle communication)

Most components of an HRS require CE marking, which is issued by the component manufacturer. To obtain CE marking, the manufacturer must:

  • Comply with all applicable EU-wide requirements;

  • Depending on the requirements, either test the product themselves or involve a designated notified body;

  • Compile technical documentation demonstrating the product’s compliance;

  • Prepare and sign an EU Declaration of Conformity.

As a result, the manufacturer is responsible for verifying whether a majority of components (e.g. pressure vessels, heat exchangers, piping, flexible fuel lines, additional on-site storage units, liquefiers, electrolysers) comply with the PED (Pressure Equipment Directive). For all electrical equipment, the requirements of the BetrSichV (Ordinance on Industrial Safety and Health) and BImSchG (Federal Immission Control Act) apply

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Storage and Tanks

Thermal Systems

Pressure and Piping Equipment

Filling Systems

H2-Provision

Security Systems

Requirements for storage facilities for gaseous, cryocompressed and liquid hydrogen

Requirements for cooling, pre-cooling, heat exchangers, condensers and evaporators

Requirements for valves and compressors.

Requirements for dispensers and their components

Requirements for delivery by trailer and pipeline

Requirements for leak detection systems and cyber security

Storage and Tanks

The standard requirements for hydrogen storage vessels and tanks are application-specific and differentiated by physical state (gaseous, cryo-compressed, liquid), application type (mobile or stationary), container size, and insulation type (vacuum-insulated or non-vacuum-insulated).

General requirements for high-pressure hydrogen storage at HRS facilities are defined in ISO 19880-1. For stationary applications, the PED (Pressure Equipment Directive) / German Pressure Equipment Code (AD 2000) applies. For mobile applications, compliance with UN GTR 13 / UNECE R134 is required, while the ADR and TPED regulations govern the transport of hydrogen.

There is a particular need for European harmonization to enable the intermodal use of hydrogen containers across different regulatory domains. Currently, it is nearly impossible to use stationary (PED), mobile (UN GTR 13 / UNECE R134), and transport containers (ADR / TPED) in applications outside their original approval scope.

For Gas

DIN EN 13445 (Unfired Pressure Vessels)

DIN EN 13445 is a series of standards covering unfired pressure vessels. While the American ASME Code is widely used internationally, it does not comply with the European Pressure Equipment Directive (PED), unlike DIN EN 13445.
Part 1 (DIN EN 13445-1) provides general principles and serves as the foundation for the following parts. Parts 2 through 10 (DIN EN 13445-2 to DIN EN 13445-10) address topics such as materials, design, manufacturing, and testing of unfired pressure vessels.

EN 17533 – Gaseous Hydrogen – Cylinders and Large Cylinders for Stationary Storage

EN 17533 replaces ISO 19884. It defines requirements for cylinders and pressure vessels used for gaseous hydrogen with volumes up to 10,000 liters and a maximum operating pressure of 110 MPa. These are intended for stationary storage applications.
Accordingly, EN 17533 can be applied within HRS systems in the context of low-pressure storage vessels. The standard specifies, for example, requirements for design, construction, and testing of such cylinders and pressure vessels.

Cryo-Compressed/Liquid

The use of cryo-compressed and liquid hydrogen introduces new requirements for HRS components. As a result, a wide range of standards exists that are particularly relevant for cryogenic applications.

  • Stationary pressure equipment: EN 13458, ISO 21009, EN 14197 (non-vacuum insulated)
  • Mobile pressure equipment under 1000 L: EN 1251, ISO 21029
  • Mobile pressure equipment over 1000 L: EN 13530, ISO 20421, EN 14398 (non-vacuum insulated)

Other important standards include ISO 21028, which defines toughness requirements for cryogenic vessels, and ISO 23208, which specifies requirements for the cleanliness of internal vessel surfaces.

Thermal Systems

Thermal and temperature systems include components such as cooling units, pre-cooling systems, heat exchangers, liquefiers, and evaporators.
The installation and operation of heat exchangers must comply with the European Pressure Equipment Directive (PED), which corresponds at the national level to the German Pressure Equipment Ordinance (14th ProdSV).
The Ordinance on Industrial Safety and Health (BetrSichV) is also relevant in the context of thermal and temperature systems.

Pre-cooling of the dispenser is standardized in ISO 19880-2, while refrigeration systems and heat pumps are generally covered by the ISO 378 series.

Pressure Equipment

Pressure equipment includes, in addition to most storage vessels and tanks, components such as compressors, valves, and regulators.

At stationary HRS, pressure equipment such as compressors and valves are subject to the Pressure Equipment Directive (PED) and the corresponding 14th Product Safety Ordinance (14. ProdSV) in Germany. Mobile pressure equipment and vessels, on the other hand, fall under the Ordinance on Operational Safety (ODV).

General requirements for compressors are defined in ISO 19880-1, while ISO 19880-3 specifies requirements for valves. Seals used at hydrogen refueling stations, such as O-rings, are addressed in ISO 19880-7. These standards are specific to HRS applications. In contrast, DIN EN 764 (for pressure equipment) and ISO 4126 (for safety valves) apply more generally. Additionally, valves should be developed in accordance with ISO 15649.

Of particular note is TRBS 3151: “Prevention of fire, explosion, and pressure hazards at filling stations and gas filling facilities for refueling land vehicles”. This technical rule is of general relevance for HRS and holds particular importance in the context of pressure equipment.

Requirements for compressors are further detailed in ISO 19880-4, which also states that compressor protection should follow ISO/IEC 80079 and IEC 60079.

In cryogenic applications, ISO 21011 (for cryogenic valves) and ISO 21013 (for cryogenic pressure relief accessories) are of particular relevance.

Filling Systems

A dispenser is the unit at hydrogen refueling stations (HRS) that enables the transfer of hydrogen from the station’s storage system to the vehicle.
A general standard for dispensers is provided in ISO 19880-2, which outlines requirements for components such as filters, valves, pre-cooling systems, and others. Additional standards may apply to specific components individually.

The interface between the vehicle and the dispenser (nozzle and receptacle) is defined in ISO 17268.

According to ISO 19880-2, certain dispenser components—such as heat exchangers and hoses—must comply with ISO 15649, which covers piping systems.
Specific requirements for hoses and hose assemblies are detailed in ISO 19880-5, while ISO 21012 applies to cryogenic hose assemblies.

Seals used at refueling stations, such as O-rings, are addressed in ISO 19880-7.

Provisioning and on-site generation

For on-site hydrogen production, the general regulations governing hydrogen generation and electrolysis must be observed.

ISO 19880-1 includes requirements for on-site production, purification systems, and hydrogen supply via trailers or pipelines. It refers to ISO 22734 as the applicable standard for on-site hydrogen generation through electrolysis. Additionally, regional regulatory requirements must also be met.

The provision of trailers and storage vessels is likewise covered in ISO 19880-1.

Pipeline transport—particularly when using repurposed natural gas pipelines—can lead to contamination of the hydrogen. To meet the quality requirements defined in DIN EN 17124, the hydrogen must be purified before use at the refueling station.
For the interface between the pipeline and the HRS, the guidance provided in ISO 19880-1 and ISO 15649 should be followed.

Safety

Safety at hydrogen refueling stations (HRS) is supported by a safety-oriented design, which can be ensured through compliance with regulations such as the Pressure Equipment Ordinance, the Explosion Protection Ordinance, and the Ordinance on Industrial Safety and Health (BetrSichV).
Potentially hazardous situations can also be prevented through the use of safety and control systems.

To detect leaks in storage tanks or pipelines at an early stage, leak detection systems are used. These are addressed by the standards DIN EN 13160-1 through DIN EN 13160-7.
In addition, ISO 23551 is relevant, as it defines safety, control, and regulating devices for gas burners and gas appliances.
The emergency shutdown system is standardized in ISO 19880-2, while cybersecurity topics are addressed in DIN EN ISO/IEC 27000 and IEC 62443.

TRBS 1201 Part 3 regulates the repair and maintenance of devices, protective systems, and safety, control, and regulation equipment.

Refueling protocols also play a key role in ensuring the safety of HRS operations.

In cryogenic operations, DIN EN 13648 defines safety equipment for overpressure protection.

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