Product Overview

Summary: This Safety Operating Procedure sets out the critical controls for producing hydrogen fuel safely in Australian workplaces, from plant start-up through to shutdown and maintenance. It provides a clear, step-by-step framework for managing flammable gas, high-pressure systems and process safety risks, helping duty holders demonstrate compliance with WHS laws and major hazard facility expectations.

Hydrogen fuel production introduces a unique combination of hazards: highly flammable gas, high-pressure systems, potential oxygen enrichment, and complex control systems that must operate flawlessly. In the Australian regulatory environment, organisations operating electrolysers, reformers or other hydrogen generation technologies must be able to demonstrate that they have robust, documented procedures to manage these risks. This Hydrogen Fuel Production Safety Safe Operating Procedure provides a structured, practical blueprint for safe operation across the full lifecycle of production activities.

The SOP breaks down hydrogen production into logical stages, including pre-start checks, system purging, start-up, normal operation, sampling, cylinder and storage handling, depressurisation, and shutdown. It defines clear roles, required competencies, and communication protocols between control room, field operators and contractors. The procedure embeds WHS risk management principles, lock-out/tag-out, hot work and confined space interfaces, and emergency response triggers specific to hydrogen behaviour (such as invisible flames and rapid dispersion). By implementing this SOP, businesses can reduce the likelihood of fires, explosions, gas releases and environmental incidents, while also providing workers with consistent, practical guidance that aligns with Australian standards, Safe Work Australia guidance and state-based dangerous goods requirements.

This document is particularly valuable for organisations scaling up new hydrogen projects, integrating hydrogen into existing industrial sites, or transitioning from pilot to commercial operations. It supports due diligence obligations for officers, underpins training and competency assessment, and provides a defensible framework for audits, incident investigations and regulatory inspections. The result is a safer, more controlled hydrogen production environment and a clear demonstration that the business is managing emerging energy technologies responsibly.

Key Benefits

• Ensure safe, consistent operation of hydrogen production systems from start-up to shutdown.
• Reduce the risk of fires, explosions and gas releases associated with hydrogen handling and storage.
• Demonstrate compliance with Australian WHS legislation, dangerous goods and major hazard facility requirements.
• Standardise training, competency assessment and contractor management across hydrogen operations.
• Support incident prevention, emergency preparedness and defensible responses to regulator audits and inspections.

Who is this for?

• Hydrogen Plant Managers
• Process Engineers
• WHS Managers and Advisors
• Operations Supervisors
• Control Room Operators
• Maintenance Technicians
• Electrical and Instrumentation Technicians
• HSE Compliance Officers
• Project Engineers (Hydrogen and Renewables)
• Contractor Coordinators and Permit Officers

Hazards Addressed

• Hydrogen gas leaks leading to fire or explosion
• High-pressure system failures, line bursts and equipment rupture
• Ignition from static electricity, hot surfaces or electrical equipment
• Oxygen enrichment and increased combustion risk around electrolysers
• Exposure to caustic or corrosive electrolytes and process chemicals
• Confined space hazards where hydrogen may accumulate
• Asphyxiation risks in enclosed or poorly ventilated areas
• Arc flash and electrical shock from high-voltage power supplies
• Manual handling injuries from gas cylinders and heavy components
• Process upsets leading to rapid pressure or temperature excursions

Included Sections

• 1.0 Purpose, Scope and Application
• 2.0 Definitions, Abbreviations and References
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Description of Hydrogen Production Process and Equipment
• 5.0 Hazard Identification and Risk Controls for Hydrogen Systems
• 6.0 Required Personal Protective Equipment (PPE) and Safety Devices
• 7.0 Pre-Start Safety Checks and System Isolation Requirements
• 8.0 Start-Up Procedure for Hydrogen Production Systems
• 9.0 Normal Operation, Monitoring and Process Control
• 10.0 Sampling, Testing and Quality Control of Hydrogen Product
• 11.0 Hydrogen Storage, Cylinder Handling and Transfer Procedures
• 12.0 Interaction with Other Permits (Hot Work, Confined Space, Electrical Isolation)
• 13.0 Abnormal Conditions, Alarms and Process Upset Management
• 14.0 Depressurisation, Purging and Shutdown Procedures
• 15.0 Maintenance, Lock-Out/Tag-Out and Verification of Isolation
• 16.0 Emergency Response, Evacuation and Incident Reporting
• 17.0 Inspection, Testing and Calibration of Safety-Critical Equipment
• 18.0 Training, Induction and Competency Assessment
• 19.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and state/territory equivalents)
• Work Health and Safety Regulation 2011 (Cth and state/territory equivalents)
• Safe Work Australia – Model Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Model Code of Practice: Managing the work environment and facilities
• Safe Work Australia – Model Code of Practice: Confined spaces
• AS/NZS 60079 series: Explosive atmospheres (electrical equipment for hazardous areas)
• AS/NZS ISO 31000: Risk management – Guidelines
• AS 1940: The storage and handling of flammable and combustible liquids (as applicable to associated fuels/solvents)
• AS 4289: Oxygen and oxygen-enriched atmospheres – Safe use and handling (relevant to electrolyser systems)
• AS 1894: The storage and handling of non-flammable cryogenic and refrigerated liquids (where liquid hydrogen or related cryogens are present)
• AS/NZS 3788: Pressure equipment – In-service inspection
• AS 61508 / AS IEC 61511: Functional safety of safety instrumented systems for the process industry (as guidance for interlocks and trips)
• State and territory Dangerous Goods and Major Hazard Facility regulations (where applicable)