Navigating the Gas Cylinder Amendment Rules 2025 to India: Focus on Hydrogen Safety and Compliance

Introduction

As India speeds up its shift to clean energy, gas cylinder safety rules have undergone a major transformation. The Gas Cylinder Amendment Rules, 2025, notified by the Ministry of Commerce and Industry on April 11, mark a turning point in how compressed gases—especially hydrogen—are handled, stored, and distributed. Notably, these changes raise safety standards while supporting the country’s hydrogen ambitions. In particular, the amendments define new terms, systems, and technical codes to modernize operations. From barcoding and cascade systems to electrolysers and composite cylinder testing, the rules provide a solid regulatory foundation. As a result, manufacturers, suppliers, testing stations, and vehicle fuel station operators must fully understand and adopt the new framework. This blog, therefore, breaks down each key update to support smooth and timely compliance.

Key Definitions Introduced in Gas Cylinder Amendment Rules 2025

To improve clarity, the amendment defines several key terms related to hydrogen infrastructure. For example, it codifies definitions for “Compressed Hydrogen Gas,” “Hydrogen Dispensing Stations,” and “Electrolyser.” In addition, it defines “Green Hydrogen” as hydrogen produced from renewable sources with emissions below specified limits. These updates, aligned with global standards like ISO 22734 and NFPA-2, help India stay consistent with international norms. More importantly, the new terms provide legal clarity for emerging hydrogen facilities and standardize safety compliance across the sector.

Barcoding and Cylinder Traceability Enhancements

One of the key updates in the 2025 rules is the mandatory use of barcodes on all gas cylinders and cryogenic containers. To begin with, the barcode must be tamper-proof, permanently attached, and both human- and machine-readable. Moreover, it must carry detailed traceability data, which must be available both digitally and physically upon request. As a result, these requirements improve transparency, prevent misuse, and boost accountability across the supply chain. Importantly, cylinders without valid barcodes will be denied refilling. Therefore, traceability now stands as a critical compliance requirement.

Hydrogen Storage and Dispensing Infrastructure Standards

The amendment outlines specific provisions for different hydrogen storage and dispensing systems including:

Bulk Hydrogen Systems with over 5000 SCF capacity
Non-bulk Systems for small-scale installations
Online Stations connected to pipelines or onsite generation
Daughter Booster Stations and Mobile Cascades

Each type must meet design, operation, and maintenance standards according to ISO 19880, IS 16061, and Chief Controller of Explosives (CCOE) guidelines. In particular, detailed layouts, emergency response plans, interlock systems, and gas detection mechanisms are now mandatory. These requirements are crucial as hydrogen is highly flammable, demanding precision safety controls.

Testing and Maintenance Requirements for Cylinders

The 2025 amendment significantly upgrades testing protocols for all cylinders, particularly for compressed hydrogen and CNG units. Notably:

Composite cylinders must be hydrostatically tested every three years.
ISO 11623 and ISO 19078 are applicable for hydrogen vehicle cylinders.
Visual inspections, ultrasonic tests, and non-destructive evaluations are prescribed.
End-of-life disposal procedures for composite cylinders have also been formalized.

Furthermore, all testing stations must now possess certified infrastructure, trained personnel, and digital systems for reporting. The rules also specify the role and qualifications of managers, supervisors, and operators to ensure uniformity and accountability during inspections.

Licensing, Documentation, and Online Processes

To enhance administrative efficiency, the amendments digitize various licensing and compliance processes. From April 2025, all license applications, test reports, and emergency plans must be submitted online. In addition:

CCOE approval is required for any hydrogen distribution station setup.
Detailed site layouts and hazard assessment reports must be prepared by certified agencies.
New fee payment mechanisms have been defined through the Bharat Kosh portal.
A new format “Form H” has been introduced specifically for hydrogen dispensing station licensing.

By shifting to digital systems, the government aims to reduce processing time and ensure real-time monitoring of high-risk installations.

Enhanced Safety Protocols for Electrical and Relief Systems

Hydrogen is highly explosive. Therefore, the rules now require all relevant facilities to use IEC/IS 60079-certified electrical fittings. Additionally, proper grounding and bonding are mandatory to prevent static discharge. Furthermore, facilities must install relief valves, vent stacks, gas detectors, and interlocking systems. To ensure integrity, regular calibration, CCTV surveillance, and backup systems are also required. As a result, these measures align Indian facilities with global best practices in fire prevention, emergency containment, and equipment resilience.

Conclusion: Gas Cylinder Amendment Rules

The Gas Cylinders Amendment Rules, 2025 mark a major shift in how India manages compressed gases, especially hydrogen. To begin with, the rules emphasize barcoding, traceability, advanced infrastructure, and digital compliance. As a result, they boost both safety and sustainability. Moreover, companies involved in manufacturing, testing, transport, or retail distribution must adapt quickly. In particular, the regulations set clear expectations for operational upgrades. Meanwhile, hydrogen continues to gain ground as a clean fuel option. Therefore, these rules help India lead in safety and innovation. In addition, they support energy security and environmental goals. Consequently, stakeholders must align their systems and processes without delay. Furthermore, the rules promote accountability at every stage. Ultimately, this regulatory update drives progress in a fast-evolving energy landscape.

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