BARTEC - Your Trusted Partner across the entire Hydrogen Value Chain

The hydrogen value chain consists of:

• Hydrogen production, conversion and measurement
• Hydrogen storage and distribution 
• Hydrogen applications 

Each of these fields requires expert know-how to ensure safety in hazardous areas, decrease costs, and guarantee compliance with regulations, codes, and standards that hydrogen requires.

Hydrogen is rarely produced and consumed in one place. It travels through a complex chain of processes — starting with renewable power conversion through electrolysis or reforming, followed by compression, liquefaction or storage, transport through pipelines, trucks or ships, and ending in final use across mobility, power, or industry. Every stage of that value chain introduces unique hazards, where uncontrolled ignition could disrupt not just local operations, but entire communities and networks.

BARTEC’s portfolio is designed to safeguard this entire journey of hydrogen. In production facilities, our certified control cabinets, explosion-protected junction boxes, and analyzers enable safe operation of electrolyzers and reformers. Our solutions help operators monitor temperatures, control process parameters, and ensure the purity of hydrogen streams, reducing the risk of uncontrolled releases.

In transport and storage, BARTEC trace heating systems prevent line blockages and maintain safe flow conditions even in freezing climates, while our enclosures and control units protect critical monitoring electronics against ignition sources. We help prevent condensation and ice formation in cryogenic hydrogen systems, enabling secure transfer between production, storage, and final use.

Finally, at the point of use whether that is a hydrogen fueling station, industrial burner, or fuel cell application BARTEC provides intrinsically safe mobile devices and connectivity platforms, allowing operators to work efficiently and safely in hazardous zones. Our rugged devices support data collection, communication, and inspection even where explosive atmospheres are present, enabling digital transformation without compromising safety.

Bringing these systems together is what makes BARTEC unique. We combine reliable hardware, deep engineering expertise, and project support to offer an end-to-end approach to hydrogen safety. Whether you are developing a small pilot or a gigawatt-scale facility, you can trust BARTEC to secure your hydrogen investment and help you build a truly safe, resilient hydrogen value chain.

The mixture of hydrogen and oxygen is highly susceptible to ignition, capable of combusting from even minimal energy sources such as a spark, hot surface, or other ignition points. Owing to its high flammability, hydrogen is classified within Ignition Group IIC—reserved for the most easily ignitable gases. These characteristics necessitate exceptional safety measures and handling protocols. To ensure a controlled and safe environment, only equipment that poses no ignition risk or is certified with appropriate ATEX protection may be used within hazardous (Ex) zones in and around the facility.

Each step inside the hydrogen value chain has safety, environmental, and operational risks that need to be managed carefully.

1. Hydrogen raw material extraction – risk of explosions, environmental damage, and worker injuries (e.g., in mining or oil drilling).
2. Hydrogen transport and logistics – accidents, spills, or fires during movement of hazardous goods.
3. Hydrogen production and manufacturing – machinery accidents, exposure to toxic substances, or electrical hazards.
4. Hydrogen storage – fires, leaks, or contamination from improper handling of chemicals or flammables.
5. Hydrogen distribution – risk of product damage, theft, or delays affecting supply security.
6. Hydrogen applications - usage by end-users – Incorrect handling or installation causing malfunctions, fires, or safety breaches.
7. Disposal or recycling – exposure to hazardous waste, environmental pollution, or improper recycling practices.

For all these steps BARTEC provides specific solutions.

As renewable electricity is increasingly converted into hydrogen for decarbonization and seasonal storage, precise moisture monitoring is critical. The BARTEC HYGROPHIL F 5674 ensures compliance with strict moisture limits and supports safe, efficient hydrogen operations.

In hydrogen production via PEM or Alkaline Electrolysis, water is split into hydrogen and oxygen using electricity. The resulting hydrogen can be stored, transported through existing pipelines, and later used as fuel or re-electrified. At gas regulating and metering stations, hydrogen is analysed for oxygen, nitrogen, flow rate, heating value - and especially trace humidity. Excess moisture can cause condensation, corrosion, blockages, and safety risks, making adherence to feed-in limits (e.g. 50 mg/m³) essential.

The HYGROPHIL F 5674 is robust, resistant even to water slugs, and can be independently recalibrated. Designed for low-maintenance use in small or unmanned plants, its retraction armature allows fast, interruption-free servicing. At its core, the optical sensor uses a Fabry-Pérot Interferometer with porous silicon dioxide and zirconium dioxide layers, selectively detecting water vapour by measuring spectral shifts around 820 nm. A compact evaluation unit calculates dew point, vapour pressure, ppm, and mg/m³ values, with outputs via analogue signals, MODBUS, TCP/IP, and relays. Trusted worldwide, the HYGROPHIL F 5674 offers reliable, long-term operation - even offshore. It is certified for hazardous areas (ATEX, IECEx, CSA) and can be integrated with sample conditioning or in-line, emission-free installations.

These approvals cover both legal metrology regulations and explosion protection requirements. Our systems are deployed along the entire logistics chain. Within the hydrogen supply chain, we offer certified systems for both stationary trailer-filling stations and mobile high-pressure trailer systems. The latter are used for product monitoring throughout the entire transport route, as well as for legally approved quantity measurement during product discharge. The primary objectives of our systems are:

1. Establishing a reliable billing process between two parties
2. Achieving full transparency over all product movements
3. Maximizing safety

A core component of our legally approved system – in addition to the mass flow meter and the control unit – is at least one shut-off valve, which is controlled by intelligent system software. This ensures not only legally accurate measurement, but also continuous monitoring of the process for safety risks, with the ability to actively intervene when needed.

BARTEC’s H2 Trailer Logistics Solution entails HY LOG, HY COMP and HY TRACE solutions.

In the area of valve control, we possess over 30 years experience of in-house software development. While the hydrogen market is still in its early stages, our automation solutions are already well established in existing industries. Step by step, our software and Hardware are being expanded and functionalities are being adapted for the hydrogen sector to further enhance safety and transparency. As of today, both stationary and mobile trailer systems are already widely deployed in the market, with growing demand—driven especially by the increasing importance of safety.

Freezing liquids can cause major damage due to their expansion, causing pipes and vessels to burst and leak. Hydrogen transportation pipelines are typically operated at up to 100 bar (1450 psi) pressure and roughly 20 °C (68 °F). They need to be kept at this temperature even during the harsh winter to avoid ice build up and condensation, which can lead to damages in the pipework and thus leakage of the hydrogen, leading to an explosion hazard.

The distribution pipelines are operated at lower pressures and thus require lower temperatures, which need to specifically taken care of in order to avoid condensation of the surrounding humidity. The same holds true for hydrogen tanks on the road. Highly pressurized hydrogen can leak through the tiniest cracks, so a tank with good temperature control is required to prevent cracking through freezing or through stress in the tank due to temperature differences.

Hydrogen does not only need to be transported, but also stored. Many storage tanks are kept at lower temperatures well insulated on asphalt foundations. However, the foundations still need to be heated in order to avoid stress cracks within the material itself.

BARTEC trace heating systems will keep pipes and tanks operational, and foundations heated, preventing bursting and cracking via frost protection and tight temperature control. Thus, the risk damages and the resulting explosion hazard as well as financial loss can be mitigated.

BARTEC self-regulating heating cable PSB is well suited for pipelines, as the power output of the cable adjusts itself to compensate for the temperature change of the pipe, leading to lower energy cost at higher temperatures like during summer. PSB cables are easy to install and design for hazardous zones, as their temperature class is entirely dependent on the chosen cable itself.

For longer pipelines, the BARTEC series resistance cable EKL are a prime candidate. Cheap and easy to install with circuit lengths up to 500 m. The design of the circuits is more complex than with the self-regulating cables. However, BARTEC developed its own software HelocPro specifically for circuit design.

Our team of trace heating experts use their vast knowledge to provide the best service to our customers along all steps of trace heating projects: project management, customized designs, material procurement, installation, start-up, commissioning and maintenance.

In (new) energy and material applications, operators and component manufacturers need to be aware of the risks associated with high-pressure devices, the safe handling of hydrogen, and the conformity of parts, devices, and systems. For mobility applications, approval, global market access, and testing of components for hydrogen are crucial. BARTEC provides specific explosion-protected solutions fully customizable thanks to our in-house engineering capabilities and decades of experience in international projects. We deliver a full range of electrical safety systems and components which mainly include:

Operating & monitoring systems

Our reliable POLARIS HMI series ensures safe and intuitive asset control. With certified explosion protection and standard interface, it controls and operates at pressure or gas levels before flammable hydrogen mixtures form.

Automation interfaces

MODEX I/O modules provide safe signal transmission of standard bus systems in hazardous areas. Together with POLARIS HMIs, form the signal in.- and outputs to the control and visualization of the system, ensuring safety while maintaining seamless data flow across your hydrogen plant.

Control panel solutions with built-in electrical components for hazardous areas

Our explosion-protected solutions are designed to constrain internal faults and prevent hydrogen ignition. Each solution is custom-engineered to meet site-specific requirements, ensuring reliable power management, full regulatory compliance, and long-term durability. Especially in electrolyzer applications, our control panels can guarantee high levels of safety. They can be designed with various protection types, including Ex p, Ex d and Ex e, based on the specific needs of the application and the hazardous area classification. We provide a wide range of explosion-protected components and systems certified for hydrogen environments. These enable scalable, tailored integration into advanced hydrogen electrolyzer architectures, while meeting all applicable standards.

LED lighting

Our advanced LED fixtures minimize heat and eliminate the risk of electrical sparks, preventing ignition in hydrogen zones. They deliver strong illumination for safer work environments, while saving energy and reducing maintenance.

Working with hydrogen means operating in environments where safety, reliability, and efficiency are critical. BARTEC’s intrinsically safe mobile devices empower teams to work smarter and faster without compromising safety. From production plants and storage facilities to refuelling stations and industrial end-use sites, our technology keeps people connected, data flowing, and operations compliant.

Mobile Computers & Barcode Scanners

Purpose-built for harsh, industrial environments and co-developed with Zebra Technologies, our Zone 1/Div. 1 and Zone 2/Div. 2 rugged mobile computers and scanners streamline asset tracking, inventory management, and compliance tasks in hydrogen facilities.

• Applications include:  Production & storage: Scan cylinders, pallets, and equipment for inventory control.
• Compliance: Capture and log calibration dates, safety checks, and work permits. Key Advantages: − Ultra-rugged design tested for the toughest industrial conditions. − Best-in-class barcode scanning technology. − Loaded with Zebra Mobility DNA, the industry’s broadest suite of enterprise software.

Smartphones & Cameras

Our intrinsically safe smartphones and cameras combine advanced communication and imaging capabilities with the safety certifications needed for hydrogen’s hazardous zones. Applications include: − Remote support: Live video calls directly from hazardous areas for real-time troubleshooting. − Maintenance and inspections: record inspection data directly into maintenance and asset management systems. Capture high-resolution photos and videos for safety reporting and compliance records.

• Key Advantages: Lightweight, compact, yet rugged design —ideal for extended use in the field.
• High-performing platform with the latest wireless technology for ultra-fast connections on remote and complex sites.
• High-resolution cameras for crystal-clear imagery and 4K video capture.

Tablets

Our Zone 2/Div. 2 certified Android and Windows tablets deliver large-screen mobility for data-intensive tasks in the field.

• Applications include: Digital work orders: Review schematics, procedures, and checklists on site.
• Commissioning & testing: Record results during hydrogen refuelling station or pipeline startup.
• Training & safety: Access interactive training modules directly in hazardous zones.
• Key Advantages: 10-inch high-brightness display for clear viewing in direct sunlight. 
• Flexible configurations with optional premium features including integrated barcode scanners and cellular connectivity options.
• Modular design for forklift or vehicle mounting in industrial environments.

In today’s industrial landscape, seamless connectivity and accurate location tracking are essential for both efficiency and safety—especially in hazardous environments. BARTEC deliver trusted solutions that extend wireless networks into Ex zones connecting what matters to you. Our expertise in real-time visibility of people and assets brings a range of Real-Time-Location-System and RFID solutions that ensure you can locate your people and assets with confidence. Together, these innovations form the backbone of a safer, smarter, and more connected workplace.

Seamless Wireless Connectivity

In industrial environments with explosive atmospheres, BARTEC’s range of specialized wireless enclosure solutions offer purpose built products for housing radio devices with either integrated or externally mounted antennas. These enclosures provide the essential Ex certification required for safely mounting wireless communication devices in hazardous areas. Wireless radio hardware typically comes in two antenna configurations: integrated and externally mounted. These configurations significantly influence deployment strategies in hazardous areas. Extend your digital network into hazardous areas with compact, certified solutions from BARTEC:

•  EXgate™ – Next-generation Zone 1 enclosure for access points, gateways, and radios, with easy mounting and RF-transparent dome.
•  iWAP107 & iWAPXN3 – Universal wireless enclosures for Zone 1 and Zone 2, designed to host standard wireless devices from any vendor.
•  Xbeam™ Ex Antennas (0.5–6 GHz) – Ex antennas for Wi-Fi, LTE/5G, Zigbee, WirelessHART, and more.
•  iANT Antennas – Wide range of simple, safe antennas for hazardous area use.
•  iSOLATE501 – RF galvanic isolator enabling safe use of standard antennas in hazardous environments.

Real-Time Location Systems (RTLS)

By combining technologies like Wi-Fi, GPS, and Bluetooth Low Energy (BLE), hybrid RTLS solutions can deliver more accurate and comprehensive location data with reduced infrastructure. For companies operating in hazardous areas, a RTLS adds a critical layer of safety, security and productivity, enabling real-time tracking of personnel and assets. Locate your workforce and assets with accurate hybrid tracking:

• iTAG XB – A range of low cost Ex rated asset and personnel tags. Available in Quuppa or iBeacon/ Eddystone BLE options, or as a Wirepas RTLS solution.
• iTAG X-Range – Intrinsically safe, rugged hybrid location tehncology tags for worker safety and location tracking, leveraging Wi-Fi, BLE, GPS, location technologies. Available in Wi-Fi, LoRaWAN and Cellular connectivity options
• iTAG XM App – Turns any Ex-certified Android smartphone into a location tracking device for indoors and outdoors.
• Extronics Location Engine (ELE) – Software that delivers flexible, precise “dot-on-a-map” visualization with easy API integration into existing platforms.

As the explosion protection industry embraces the potential of hydrogen, careful consideration of safety measures, technological advancements, and collaborative efforts will be key to unlocking its full benefits. By navigating these challenges with diligence and innovation, we at BARTEC pave the way for a safer, more sustainable future where hydrogen plays a pivotal role in shaping the landscape of explosion protection.