Reliability, Maintenance, and Safety of Power-to-Hydrogen: Lessons Learned from an Industrial Demonstrator

Power-to-Gas is the process by which electrical energy is converted into chemical energy in gaseous form. It conventionally involves an electrolysis stage, producing hydrogen (Power-to-Hydrogen) from electricity and water. Because it relies on emerging technologies, the management of reliability, maintenance, and safety of these systems must address specific issues that are not yet well documented. Jupiter 1000 is an industrial demonstrator of Power-to-Gas, commissioned in 2019 by GRTgaz, which became NaTran in 2025. One of the objectives of the project is to demonstrate the feasibility of this type of process and to share initial feedback to support the development of the industrial Power-to-Gas sector. This paper presents the main lessons learned and results from Jupiter 1000 on reliability, maintenance, and safety for Power-to-Hydrogen installations. The experience gained from this demonstrator revealed that reliability is mainly affected by failures in systems such as compression, storage, and auxiliaries rather than in the electrolysers. Maintenance is challenged by limited availability of hydrogen-adapted equipment and skilled personnel, which can result in extended downtimes. Safety requires advanced leak detection, adapted materials, and comprehensive risk analyses, especially for hydrogen-specific hazards. These findings highlight five priorities for the sector: strengthening the industrial supply chain, improving equipment reliability, developing specialized risk management expertise, advancing safety solutions, and continuing R&D on hazardous phenomena and monitoring.