The growing adoption of hydrogen as a clean energy carrier, particularly in fuel cell vehicle infrastructure, has increased the need for accurate mass flow measurement under high-pressure conditions. Coriolis flowmeters are widely used in these applications due to their direct mass flow measurement capabilities. However, challenges arise when calibrating these meters for hydrogen service, owing to hydrogen’s low density, high compressibility, and operational conditions that differ significantly from standard calibration environments.

This study analyzes the limitations of traditional calibration methods—including water and low-pressure air—against the requirements of hydrogen service at pressures up to 875 bar and temperatures down to -40 °C. Using five years of calibration data from the ISO 17025 accredited TrigasFI GmbH flow calibration lab, the performance of Coriolis meters calibrated with pressurized air at matched hydrogen densities was evaluated and compared with manufacturer-supplied water calibration data. The findings confirm that density-matched air calibration significantly reduces tolerance-induced errors, achieving total uncertainties as low as 0.7–1.1%, compared to >2% for water and up to 1.7% for low-pressure air calibrations.

Additionally, the study investigates drift over time, manufacturing tolerances, and dynamic response errors that impact performance under hydrogen-like conditions. Recommendations are provided for optimal calibration procedures and recalibration intervals to ensure reliable custody transfer measurements in hydrogen distribution networks. The results support matched-density air calibration as a practical and accurate surrogate to gravimetric hydrogen calibration, offering a cost-effective approach without compromising metrological integrity.