Predictive maintenance and reinspection strategies for hydrogen refueling station pressure vessels: A case study in South Korea

Hydrogen refueling stations rely on pressure vessels capable of withstanding pressures up to 90 MPa while mitigating concerns related to hydrogen embrittlement. However, a gap exists in understanding the long-term fatigue behavior of these vessels under real operational conditions. This study focuses on evaluating the safety of SA372 pressure vessels using operational data from a hydrogen refueling station in Pyeongtaek, South Korea. A predictive reinspection methodology is proposed based on this evaluation. Parameters including hydrogen-induced stress intensity factor (KIH), IH ), initial crack size (a0, 0 , c0), 0 ), and pressure vessel specifications are considered to assess critical crack depth (ac), c ), critical usage cycles (Nc), c ), and allowable usage cycles (N allowed ). Leveraging operational data collected between August and November 2023, fatigue analysis and Rainflow counting inform reinspection schedules. Results indicate a need for mid-bank vessel reinspection within the second year, high-bank vessel reinspection every 20 years, and low-bank vessel reinspection every 143 years, in accordance with safety regulations. Additionally, a revised refueling logic is proposed to optimize vehicle charging methods and pressure ranges, enhancing operational safety. This study serves as a preliminary investigation, highlighting the need for broader data collection and analysis to generalize findings across multiple stations.