Safety management strategies for the full lifecycle of green hydrogen based on renewable energy

Abstract

Green hydrogen, produced using renewable energy sources, is poised to play a pivotal role in global decarbonization efforts. However, hydrogen’s unique properties – including its wide flammability range, low ignition energy, buoyancy,and propensity for material embrittlement – pose significant safety challenges. This Master’s thesis presents a comprehensive safety management framework covering the full lifecycle of green hydrogen: Production, Storage, Transportation and Distribution, and End-Use. Through an extensive literature review and analysis of industry best practices, the thesis identifies key hazards at each phase and evaluates strategies such as advanced leak detection, ventilation systems, pressure relief devices, and robust materials to mitigate risks. The work also reviews relevant regulatory standards (ISO, NFPA, etc.) and economic considerations of safety investments. Four recent case studies – each corresponding to a lifecycle phase – are analyzed using root cause analysis methodologies. These include a hydrogen production facility explosion, a storage system failure, a distribution accident, and an end-use (fueling station) incident. The case studies reveal common causes like equipment failure, design shortcomings, and human error, echoing findings that equipment breakdowns account for over one-third of hydrogen incidents. Lessons learned emphasize the need for rigorous safety protocols, operator training, and ad herence to standards to prevent recurrences. The thesis concludes with a set of recommendations for industry and policymakers to strengthen hydrogen safety culture. Ensuring safety across the hydrogen value chain not only protects people and assets but also builds public confidence crucial for the widespread adoption of green hydrogen technologies.