Hydrogen-based mobility and other applications highly rely on the development of a robust hydrogen refueling infrastructure. However, some hazardous properties of hydrogen, including its wide flammability range, low ignition energy, and explosiveness, raise significant safety and reliability concerns for the deployment of refueling stations. This chapter reviews past accidents in hydrogen refueling stations (HRSs) and water electrolysis, using data from the Hydrogen Incident and Accident Database (HIAD) 2.1. Eighteen incidents were analyzed, with focus on their causes, consequences, injuries, fatalities, and lessons learned. It was found that major accidents, including explosions, were mostly due to corrosion, electrolyzer failures, and incompatible materials, while fires and hydrogen releases were linked to defective parts and leaks. Although HRS accidents were more frequent, water electrolysis plant incidents had more severe outcomes. The analysis identifies common failure modes and suggests preventive measures, emphasizing continuous monitoring, proper material testing, strict protocols, comprehensive risk assessments, and training programs.

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Historical Failure Analysis of Hydrogen Refueling Stations

  • Farhana Yasmine Tuhi,
  • Marta Bucelli,
  • Yiliu Liu

摘要

Hydrogen-based mobility and other applications highly rely on the development of a robust hydrogen refueling infrastructure. However, some hazardous properties of hydrogen, including its wide flammability range, low ignition energy, and explosiveness, raise significant safety and reliability concerns for the deployment of refueling stations. This chapter reviews past accidents in hydrogen refueling stations (HRSs) and water electrolysis, using data from the Hydrogen Incident and Accident Database (HIAD) 2.1. Eighteen incidents were analyzed, with focus on their causes, consequences, injuries, fatalities, and lessons learned. It was found that major accidents, including explosions, were mostly due to corrosion, electrolyzer failures, and incompatible materials, while fires and hydrogen releases were linked to defective parts and leaks. Although HRS accidents were more frequent, water electrolysis plant incidents had more severe outcomes. The analysis identifies common failure modes and suggests preventive measures, emphasizing continuous monitoring, proper material testing, strict protocols, comprehensive risk assessments, and training programs.