Three-Year Operational Failure Analysis and Reliability Assessment of an On-Site Hydrogen Refueling Station in Korea

Abstract

On-site hydrogen refueling stations (HRS) facilitate localized hydrogen production and supply, reducing dependence on external distribution networks. However, the limited deployment of on-site HRSs has hindered comprehensive analyses of their operational characteristics and equipment reliability due to a lack of long-term data and maintenance records. This study examines 3 years (2022–2024) of operational data from an on-site HRS, with a particular focus on 2023, to identify key failure modes, analyze downtime causes, and evaluate maintenance efficiency. Among the 74 recorded failures, the most frequent involved the degradation of the CO removal unit (PSA) in the reformer (23 cases, 31%), piston and gasket wear in the low-pressure compressor (13 cases, 18%), and refrigerant leakage in the chiller (5 cases, 7%). Reformer failures led to hydrogen purity issues, requiring an average maintenance time of 19.5 h, while compressor failures caused efficiency loss and gas leakage, necessitating 4.3 h of repair. Prolonged maintenance was primarily due to technological immaturity, including limitations in equipment performance and system reliability. Addressing these issues is essential to enhance the long-term reliability and operational efficiency of on-site HRSs, ensuring their viability for widespread adoption.