Cascading Failure Analysis in Green Hydrogen Production

Cascading failure analysis of green hydrogen production in response to adverse events, i.e., component failures and degradation, was the focus of this master’s thesis. Safety and reliability are critical as the world transitions to hydrogen as a clean, sustainable energy carrier. The failure of one component in production plants increases the risk of system failure. This study aims to identify potential failure modes and causes of the domino effect in components, identify areas of limitations and gaps where these can have catastrophic consequences, and provide mitigation strategies on how to deal with them. Failure mode and effect analysis (FMEA) and event tree analysis (ETA) were used to identify potential failure modes in the PEM electrolyzer system, as well as the interdependence of its components. Fuzzy logic is incorporated into the ETA to address the inherent uncertainties associated with failure probabilities and provide a more realistic assessment. In addition, a fuzzy risk matrix was used with the MATLAB software to justify the risk picture. The cascading failure initiated by the water purification system and internal failures within the PEM electrolyzer stack, such as degradation of the membrane electrode assembly, were assessed using these methods. This study shows that in the green hydrogen production plant, the components are independent of one another. It focuses on major aspects directly affecting the reliability and safety of the electrolyzer. This thesis discusses the systematic process of identifying risks and analyzing the potential of green hydrogen cascade failure. The findings provide a systematic approach to risk identification and set effective mitigation measures to enhance the operational resilience and safety of next-generation green hydrogen plants for future sustainable energy growth.