Beyond Hazop: Modelling of Hilp (high Intensity Low Probability) Scenarios in Hydrogen Production and Storage Plants

Hydrogen, as a versatile and sustainable energy carrier, plays a pivotal role in the global transition towards a low-carbon economy. However, the safe and efficient operation of hydrogen production plants is paramount to exploiting the full potential of this clean energy source. This scientific article investigates typical HILP (High Intensity Low Probability) scenarios that can occur in hydrogen production plants and storage. The assessment is based on a HazOp (Hazard and Operability) study on a representative electrolysis unit. The study has been conducted through a multidisciplinary approach, integrating knowledge from chemical engineering, process safety and risk analysis, focusing on consequence modelling, to understand root causes, potential impacts and mitigation strategies. Through the analysis of plant design and operation parameters, the article identifies common vulnerabilities in hydrogen production processes. The main accident scenarios explored include equipment failures and leaks, each with the potential to compromise plant safety and disrupt production. Furthermore, the article analyses the dynamic interaction between technological progress and safety protocols in shaping the risk landscape of hydrogen production and storage facilities. The insights from this analysis help to propose possible risk management strategies, emphasising the importance of proactive safety measures, early detection systems and effective emergency response plans. By elucidating the typical incident scenarios in hydrogen production plants, this article seeks to enhance industry awareness, facilitate knowledge sharing, and drive continuous improvement in the design, operation, and maintenance of hydrogen facilities. The findings presented herein offer valuable insights for engineers, researchers, and policymakers working towards the widespread adoption of hydrogen as a clean and sustainable energy solution.