Risk Based Maintenance in hydrogen refuelling stations: Focus on Safety and Business Interruption risk
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Hydrogen FCVs (Fuel Cell Vehicles) could be one of the options to switch from fossil fuels to renewable sources with no greenhouse gas emissions. The potential future increase of FCVs will lead to the development of a network of new refuelling stations. However, related safety issues will have to be considered to avoid scenarios such as the accident recently occurred in Kjørbo (Norway). The objective of this study is to develop effective inspection and maintenance planning while guaranteeing the control of such safety issues. The consolidated RBI (Risk Based Inspections) methodology is integrated with detailed risk assessment and study of business interruption costs through the use of three different software solutions: Synergi RBI (to plan maintenance trough RBI), ExtendSim (to model the business) and Safeti (to analyse the risk towards humans). The methodology is applied to a refuelling station with hydrogen production by electrolysis on site, focusing on the storage unit that is composed by pressure storage vessels and PRDs (Pressure Relief Devices). For every selected Risk target, the RBI methodology provides a maintenance plan. By elaborating the LoFs (Likelihoods of Failure) of the vessel and the connected PRD (calculated through RBI methodology), it is possible to model potential accident scenarios using SAFETI and obtain a set of related risk metrics describing the safety level. The maintenance plan and the LoFs are in turn used as input to ExtendSim that models how the profit is influenced by maintenance and accidents shutdowns. The application of this approach to a case study and the results obtained show that there is the concrete possibility to support decision-making by: • Prioritizing maintenance for equipment with higher risk; • Assuring necessary safety levels; and • Considering related business interruption costs.