www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2025 31 operators the insight needed to manage complex storage systems. Automation and hydrogen mobility Hydrogen is set to transform transportation and mobility. Heavy-duty vehicles, trains and even aircraft are turning to hydrogen to cut carbon emissions. However, hydrogen fuelling presents challenges distinct from traditional petrol or diesel. Fuel must be dispensed at pressures up to 1000 bar. Every step of the dispensing process must be monitored for safety, efficiency and reliability. Automation must not only offer realtime control, but also seamless integration with Internet of Things (IoT) platforms. Operational data is captured and transmitted securely to cloud-based systems, enabling remote monitoring and optimisation of maintenance schedules. A good example of what this looks like in practice is provided by Nel Hydrogen, a leading developer of hydrogen fuelling stations. Its stations are capable of serving dozens of vehicles daily and rely on fast, reliable control systems to manage the entire fuelling process - from monitoring tank pressure and temperature to detecting leaks and ensuring safe refuelling. Real-time data from sensors is analysed instantly to control fuelling precisely, while simultaneously being transmitted to remote monitoring platforms. This approach ensure safety and efficiency of individual stations as well as providing fleet-wide insights that support wider system optimisation and predictive maintenance. Open, scalable platforms are key to these developments. An open architecture facilitates seamless communication between diverse sensors, actuators and cloud services, regardless of manufacturer. It also ensures futureproofing, allowing operators to upgrade or expand their systems easily as technology requirements evolve. Resilience and safety Safety is paramount at every stage of the hydrogen value chain. Explosion risks must be mitigated not only in high-risk zones but throughout entire facilities. Automation platforms must therefore offer integrated functional safety, with the ability to process safety-relevant signals alongside regular process data. In hazardous areas, equipment must be certified for explosion protection. Intrinsically safe input and output modules that are capable of operating directly within explosion zones, can dramatically simplify system design and reduce installation costs. They also allow for more flexible system layouts, essential for sprawling hydrogen production plans or refuelling sites. Ensuring resilience against system failures is also crucial. Redundancy in communication networks, controllers and data storage projects against downtime supports continuous operation. Whether monitoring hydrogen pipelines that stretch for kilometres or managing distributed storage units, a robust, failsafe approach is vital. The rapid rise in hydrogen projects shows that momentum is building at an unprecedented rate. Automation technology is keeping pace, evolving to deliver the flexibility, safety and intelligence this sector demands. By embedding smart control across the entire hydrogen value chain, the industry can fulfil the enormous potential forecast by the International Energy Agency, driving forward a cleaner, greener energy future. For further information please visit: https://www.beckhoff.co.uk/ Claim your FREE monthly digital subscription For the latest news and techology visit our website www.hpmag.co.uk www.hpmag.co.uk March 2024 HYDRAULICS & PNEUMATICS VOL 29N 2 p22 p16 Retrofitting pumps for a new role Seven reasons to monitor hydraulic flow on mobile machines The shifting vision of a smart factory p40 Harnessing the power of pneumatic control THE JOURNAL OF FLUID POWER AND SYSTEMS
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