Hydrogen infrastructure components such as valves, pipelines, and storage tanks are critical to the safe and efficient operation of hydrogen systems. Failure Mode and Effects Analysis (FMEA) is a systematic, structured approach to identifying potential failure modes, their causes, and their effects on system performance. This method is particularly valuable in hydrogen applications due to the material compatibility challenges, high-pressure conditions, and flammability risks associated with hydrogen.

FMEA follows a step-by-step process to evaluate risks and prioritize mitigation efforts. The first step involves defining the scope of the analysis, such as a specific component within a hydrogen refueling station or an electrolyzer system. For example, a high-pressure storage tank in a refueling station may be analyzed for potential failure modes like cracks due to hydrogen embrittlement or seal degradation.

The next step is identifying potential failure modes. Each component is examined for ways it could fail, such as leaks in pipelines, valve malfunctions, or tank ruptures. For each failure mode, the effects are documented. A leaking valve in a hydrogen pipeline could lead to gas accumulation, creating an explosion hazard. Similarly, a failed compressor in an electrolyzer system might disrupt hydrogen production.

Once failure modes and effects are listed, the analysis proceeds to assess severity (S), occurrence (O), and detection (D) ratings. Severity measures the impact of the failure, typically on a scale from 1 (minor) to 10 (catastrophic). A hydrogen pipeline rupture would score high in severity due to the potential for explosions and fatalities. Occurrence rates the likelihood of the failure happening, from 1 (unlikely) to 10 (inevitable). Hydrogen embrittlement in high-strength steel components might have a moderate occurrence rating if material selection is not optimized. Detection evaluates the ability to identify the failure before it causes harm, with 1 being certain detection and 10 meaning undetectable. Advanced leak detection systems in refueling stations could lower detection ratings for hydrogen leaks.

The product of these three ratings gives the Risk Priority Number (RPN): RPN = S × O × D. High RPN values indicate critical risks requiring immediate action. For instance, a hydrogen storage tank with an RPN of 300 (S=10, O=3, D=10) due to undetected cracks would demand design improvements or enhanced inspection protocols.

Mitigation strategies are then developed to reduce RPN values. This could involve material upgrades, such as using hydrogen-resistant alloys for valves, or process changes like increasing inspection frequency for pipelines. In hydrogen refueling stations, redundant safety systems—such as double-walled storage tanks and automated shutdown mechanisms—are common solutions derived from FMEA.

FMEA is often compared to other risk assessment tools like Hazard and Operability Study (HAZOP) and Fault Tree Analysis (FTA). While HAZOP focuses on deviations from intended operations using guide words, FMEA is more component-centric, making it better suited for hardware-focused assessments. FTA, on the other hand, is a top-down approach that starts with a system-level failure and traces back root causes, whereas FMEA builds up from individual component failures. FMEA’s granularity makes it ideal for hydrogen infrastructure, where material and mechanical failures are primary concerns.

Industry applications demonstrate FMEA’s effectiveness. In electrolyzer systems, FMEA has been used to evaluate membrane degradation in PEM electrolyzers, leading to improved catalyst coatings and membrane materials. For hydrogen refueling stations, FMEA has identified high-risk areas such as compressor failures and dispenser leaks, prompting the adoption of real-time monitoring systems.

The automotive sector provides another example, where FMEA has been applied to onboard hydrogen storage tanks in fuel cell vehicles. By analyzing failure modes like composite layer delamination or valve seal wear, manufacturers have enhanced tank durability and safety. Similarly, in pipeline networks transporting hydrogen, FMEA has guided the selection of welding techniques and inspection intervals to prevent failures.

FMEA is an iterative process, requiring updates as new data becomes available or system modifications are made. For hydrogen infrastructure, continuous improvement is essential due to evolving materials and operating conditions. By systematically addressing failure modes, FMEA helps ensure the reliability and safety of hydrogen systems, supporting the broader adoption of hydrogen as a clean energy carrier.

In summary, FMEA provides a rigorous framework for assessing risks in hydrogen infrastructure. Its structured approach to evaluating severity, occurrence, and detection enables targeted mitigation strategies, reducing the likelihood of catastrophic failures. While other risk assessment tools offer complementary insights, FMEA’s component-level focus makes it indispensable for hydrogen applications, from refueling stations to electrolyzers and beyond. Industry practices underscore its value in enhancing safety and performance across the hydrogen value chain.