Analysis of Equipment Failures as a Contributor to Hydrogen Refuelling Stations Incidents

Hydrogen is a sustainable, clean source of energy and a viable alternative to carbon-based fossil fuels. To support the transport sector’s transition from fossil fuels to hydrogen, a hydrogen refuelling station network is being developed to refuel hydrogen-powered vehicles. However, hydrogen’s inherent properties present a significant safety challenge, and there have been several hydrogen incidents noted, with severe impacts to people and assets reported from operational hydrogen refuelling stations worldwide. This paper presents the outcome of an analysis of hydrogen incidents that occurred at hydrogen refuelling stations. For this purpose, the HIAD 2.1 and H2tool.org databases were used for the collection of hydrogen incidents. Forty-five incidents were reviewed and analysed to determine the frequent equipment failures in the hydrogen refuelling stations and the underlying causes. This study adopted a mixed research approach for the analysis of the incidents in the hydrogen refuelling stations. The analysis reveals that storage tank failures accounted for 40% of total reported incidents, hydrogen dispenser failures accounted for 33%, compressors accounted for 11%, valves accounted for 9%, and pipeline failures accounted for 7%. To enable the safe operation of hydrogen refuelling stations, hazards must be understood, effective barriers implemented, and learning from past incidents incorporated into safety protocols to prevent future incidents.