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2025

How Pressure Regulators Improve Safety in Hydrogen Refuelling Stations

700 bar pump at a hydrogen refuelling station

31 July 2025

Hydrogen refuelling stations (HRS) are essential to supporting the transition to zero-emission transport. With hydrogen stored at pressures up to 700 bar, effective pressure regulation is critical to ensure safe and stable operation.

Let’s look at the role they play. Pressure regulators control the pressure of hydrogen from high-pressure storage to vehicle systems, maintaining consistent output pressure while protecting downstream components. The control element is critical because without it, there’s a risk of over-pressurisation, and even equipment failure.

At Pressure Tech, we have a range of regulators designed specifically for hydrogen service. Body and component material selection are of utmost importance to ensure strength, longevity, and resistance to hydrogen embrittlement. Hydrogen embrittlement is a form of material degradation where metals become brittle and crack due to the absorption and diffusion of hydrogen atoms into the metal—especially under stress.

Additional safety measures, such as integrated filters and optional venting, help prevent contamination damage and provide protection in overpressure scenarios. Positive Material Identification (PMI) testing and full material traceability further enhance quality assurance.

In line with the growing hydrogen infrastructure, the demand for robust, reliable pressure control is also increasing. Selecting the right pressure regulator doesn’t just optimise performance—it protects people, equipment, and long-term investment.

For OEMs and station developers, high-quality regulation is a fundamental part of building a safe and efficient hydrogen refuelling network.

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