A Methodology for Quantitative Risk Assessment of a High-capacity Hydrogen Fueling Station with Liquid Hydrogen Storage

Hydrogen fueling stations are critical infrastructure for deploying zero emission hydrogen fuel cell electric vehicles (FCEV). Stations with greater dispensing capacities and higher energy efficiency are needed, and cryogenic liquid hydrogen (LH2) has the potential to meet these needs. It is necessary to ensure that hazards and risks are appropriately identified and managed. This paper presents a Quantitative Risk Assessment (QRA) methodology for high-capacity (dispensing >1000 kg/day) hydrogen fueling stations with liquid hydrogen storage, and presents the application of that methodology by presenting a Failure Mode and Effect Analysis (FMEA) and data curation for the design developed for this study. This methodology offers a basis for risk and reliability evaluation of these systems as their designs evolve and as operational data becomes available. We developed a generic station design and process flow diagram for a high-capacity hydrogen fueling station with LH2 storage. Following the system description is hazard identification done from FMEA to identify the causes of hydrogen releases and the critical components causing the releases. Finally, data collection and curation is discussed, including challenges stemming from the limited public availability of reliability data on components used in liquid hydrogen systems. This paper acts as an introduction to the full QRA presented in its companion paper, Schaad et al. [1].