Risk assessment of refuelling Fuel Cell Electric Vehicles

The growing utilization of hydrogen as an energy carrier raises significant safety concerns, particularly at hydrogen refuelling stations and the surrounding areas for refuelling. This paper evaluates the relevant risks, highlighting the possible dangers from hydrogen leakages, high-pressure storage, and cryogenic temperatures. This study utilized an Operational Risk Management framework to investigate hazard identification, analyse risks under critical conditions, and develop measures for risk mitigation actions. These analyses were guided by stakeholder feedback from industry, academia, government, and societal sectors. Accordingly, variations in risk perception among the different stakeholder groups are brought out, demonstrating the requirement for holistic risk management practices. The key conclusions of the research are that risks of hydrogen, especially the potential for explosions due to ruptures in fuel tanks with risk grade 2.18–2.45 and the absence of proper safety procedures with risk grade 2.19, call for the institution of rigorous safety procedures. The outcomes of this investigation will assist in formulating detailed safety guidelines and best practices for facilitating the safe installation of future hydrogen refuelling systems. • Stakeholder-driven risk assessment identified critical safety concerns for fueling stations. • Leakage from storage tank or trailer, vessel overheating and poor safety identified as the most critical. • ORM was applied to evaluate hydrogen-related hazards and inform mitigation strategies. • Technical experts focus on engineering risks. • Policymakers and societal groups emphasize natural and human-made hazards.