Forecasting and monitoring hydrogen storage systems
The Challenge
A hydrogen distribution operator, experiencing rapid growth in demand across its H₂-fuelling network, began facing mounting pressure on system availability and reliability. As more fleets and heavy-duty vehicles transitioned to hydrogen, station downtime and equipment failures became frequent, resulting in:
- Hydrogen losses: discrepancies between hydrogen distributed and delivered pointed to possible losses - both in fuel and financial terms.
- High default rates: increased strain on compressors, dispensers, and storage systems led to equipment failure and system unreliability.
- Limited operational visibility: without real-time monitoring, issue detection was reactive and inefficient, delaying resolution and exacerbating downtime.
The Solution
To address both strategic and technical needs, the operator tested Hyggle’s SCADA Hypervision, a cloud-based Sofware-as-a-Service solution designed for real-time monitoring, performance analysis, live alerting across hydrogen refuelling stations. Key elements of the deployed solution include:
1. Dedicated analysis of hydrogen flows. The innovation continuously monitors the flow of hydrogen through critical subsystems, including:
- Compressors, storage units, and dispensers, ensuring that hydrogen supply meets demand.
- Pressure and temperature conditions, detecting inefficiencies that could impact performance or safety.
- Energy consumption per subsystem, identifying areas where operational costs can be optimised.
2. Anomaly detection and automated alerts. The system:
- Detects abnormal pressure drops, compressor failures, or unexpected energy spikes before they impact operations.
- Provides automated alarms with escalation, ensuring that critical issues are addressed immediately.
- Reduces unplanned maintenance and extends equipment lifespan through predictive maintenance.
This ensures proactive management of hydrogen stations, increasing reliability and reducing operational disruptions.
Making an impact
By integrating SCADA Hypervision, the hydrogen operator now benefits from:
- Improved availability: real-time monitoring reduced station downtime by 5% and improved reliability for the HRS operator.
- Operational efficiency: energy consumption was optimised at each subsystem level, minimising operational costs by 10%.
- Hydrogen loss mitigation: enhanced visibility enabled more precise reconciliation of hydrogen flow, reducing financial loss risks.
Hyggle’s SCADA Hypervision transforms complex hydrogen refuelling infrastructure into an intelligent, automated system that ensures maximum uptime, efficiency, and cost control. The operator now has the tools to restore operational excellence, scale confidently, and maintain leadership in the hydrogen transition.
Lessons learnt
The project revealed two critical enablers required for Hyggle’s SCADA / Hypervision system to deliver its full value:
- Open data access from equipment suppliers:
To fully leverage SCADA and Hypervision capabilities, it is essential that HRS (Hydrogen Refuelling Station) equipment suppliers provide transparent and unrestricted access to operational data. The current practice of restricting data exchange limits the ability of operators to monitor performance, detect inefficiencies, and optimise station operations. - Cybersecurity readiness and awareness:
The deployment highlighted gaps in cybersecurity awareness, where certain integration practices introduced vulnerabilities within the data ecosystem. These weak points can act as potential entry paths - akin to “Trojan horses” - compromising the security posture of the Hyggle platform. Ensuring all stakeholders adhere to best practices in cybersecurity is vital for a secure and robust system.
