Differentiating Hydrogen-driven Hazards from Conventional Failure Modes in Hydrogen Infrastructure

Hydrogen is a promising carbon-free energy carrier for large-scale applications, yet its adoption faces unique safety challenges. Microscopic physicochemical properties, such as high diffusivity, low ignition energy, and distinct chemical pathways, alter the safety of hydrogen systems. Analyzing the HIAD 2.0 incident database, an occurrence-based review of past hydrogen incidents shows that 59% arise from general industrial failures common to other hydrocarbon carrier systems. Of the remaining 41%, only 15% are unequivocally linked to the fuel’s unique properties. This study systematically isolates hazards driven by hydrogen’s intrinsic properties by filtering out confounding factors, and provides an original clear characterization of the different failure mechanisms of hydrogen systems. These hydrogen-specific cases are often poorly described, limiting their contribution to safety strategies and regulations improvement. A case study on pipeline failures illustrates how distinguishing hydrogen-specific hazards supports targeted risk mitigation. The findings highlight the need for evidence-based regulation over broadly precautionary approaches.