Hydrogen Fuel Supply Safety System

Company: VSK Test Solutions
Author(s): Mr. Parth Joshhi, Miss Sabrine Charkaui, Miss Sirine Charkaui
Product(s) Used: Siemens PLC, Siemens SM1223, Siemens SM1234, Siemens SIMATIC HMI, neoxid Hydrogen Sensors, Hydrotechnik Pressure Sensors, OMEGA Pressure Sensor, Burkert Solenoids, Thermal Fuse
Software(s) Used: TIA Portal V17 (STEP 7)
Industry: Automotive

The Challenge

The design and development of a system to monitor and control the flow of hydrogen within a hydrogen-pumped engine to ensure stability and enable a shutdown sequence if any fault is detected.

The Solution

Used a Siemens PLC with Siemens TIA Portal V17 (Step 7) to monitor the hydrogen fuel supply to an engine with hydrogen sensors, pressure sensors, and a flame sensor, while controlling the flow through solenoids. These values would be displayed through a Siemens HMI with UI shutdown buttons for additional safety.

Hydrogen Supply Safety System Diagram Black and White


VSK Test Solutions was established in 2015 in order to provide consultancy services for test development in various domains like telecommunication, green energy, aerospace, and smart metering.

The Hydrogen Fuel Supply Safety System consists of sensors, solenoids, and an emergency stop button. For sensors, we have pressure, hydrogen, and optical.

Application Description

If any of these situations occur it indicates there is a fault and the shutdown procedure will start:

  • Pressure sensors are not giving the same value
  • Hydrogen sensors are reading abnormal values
  • Optical sensor detects a fire
  • Manual button is pressed

The software solution provided by VSK Test Solutions was divided into the following sections:

  • Startup
  • Initial Checks
  • Direct Injection
  • PFI Injection
  • Shutdown
  • Stop PLC
Breakout Box
Hydrogen Supply Safety System HMI


VSK Test Solutions has provided the client with a successful and stable safety system with accurate ongoing results.


The solution was successfully delivered to the client to be used as research at a learning centre to help with their studies on alternative automotive engines.

Author Contact Details

VSK Test Solutions

Unit 16 & 20 Space Business Centre
Smeaton Close, Aylesbury
Buckinghamshire HP19 8FJ

Phone: +44 (0) 1296695548