Failure analysis and maintenance of hydrogen refueling stations

An analysis of various system configurations of hydrogen refueling stations and the types of failures that can occur in these stations is presented herein. Although the major components (compressor, storage tank, dispenser and chiller) are the same across various configurations, the numbers of compressors and storage tanks, as well as the system layouts, are different. Because compressors are operated at high pressure, leakage from valves and malfunctioning of lubricant oil pumps occur frequently (−50 % of all failures). Moreover, because hydrogen gas at −40 °C flows through the dispenser, the receptacle at the inlet of the storage cylinder can freeze, and leakage of cold refrigerant from the chiller system occurs frequently (both account for −20 % of all failures). Periodic maintenance of pipes and valves, compressor, and dispenser should be performed to pre-vent leakages and compressor malfunction. The outcomes of this study can help improve the economic feasibility of hydrogen refueling stations.