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Safety Study of Hydrogen Supply Stations for the
Review of High Pressure Gas Safety Law in Japan
International Conference on Hydrogen SafetySeptember 10, 2005
Japan Petroleum Energy Center (JPEC)Hydrogen Technology Group
Shigeki Kikukawa
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In Japan, regulations for gaseous hydrogen
supply stations were revised in April 2005.
We made drafts of the regulations.
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Topics
Introduction Background of the project
Safety Study Risk Assessment Basic Approach Risk Matrix Consequence Estimation and Likelihood Estimation Review of Regulations
Safety Requirements for High Pressure Gas Safety Law Setback Distance and others
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Japan Petroleum Energy Center (JPEC)
JPECEstablished in 1986Affiliated with the Ministry of Economy, Trade and
Industries of Japan (METI) Carries out a range of activities, which are mainly
related to petroleum industry.http://www.pecj.or.jp/
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Governmental Leadership of FCV & H2 Infrastructure Japanese government is strongly promoting the wide spread
of fuel cells. Anticipated market size
Setting R&D Target Review of codes & Standards Financial help for R&D and Demonstration projects
2010 2020 2030
FCV (vehicles) 50,000 5M 15M
Hydrogen Fueling Station (stations) 500 3,500 8,500
Driving Force
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Concerns with Regulation
A task force formed by the government in Oct. 2002. Released the Road Map. Identified 28 concerns with regulation which should be
reviewed for market introduction of Fuel Cells.
5 items To be clarified before Dec. 2002
3 items FCV
To be clarified before FY2005
4 items High Pressure H2 Tank of FCV
7 items
Setback distance etc.
H2 Infrastructure
5 items Stationary FC
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Key Issue 2: Setback Distance
H2
17m11.3m8m
17m : Hospital, school, etc.
11.3m : Dwellings
8m : Fire sources
Setback distance for general high pressured equipment
H2
We have to add some safety requirements to reduce the setback distance.
High Pressure Gas Safety Law
Hydrogen stations must FREE from DANGER!
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Key Issue 2 : Permission to set up H2 stations with Gasoline stations
H2Gas
Separately
Same areaGas
H2
Fire Protection Law
Key Issue 3 : Permission to build in an urban area
Residential area
H2
Commercialarea
H2 H2
Industrialarea
H2Residential areaCommercial area
Industrial area
Building Standard Law
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Scope of JPEC’s project Mission: Developing drafts of revised safety C&S of H2 stations
Focused on H2 station Pipelines, Transportation and FCV are out of scope Relevant regulations
High Pressure Gas Safety Law Fire Protection Law Building Standards Law
Schedule We should prepare drafts of review by Sep. 2004. Government would review the regulations by the end of Mar. 2005.
Funds New Energy and Industrial Technology Development Organization (NEDO)
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Japan Steel WorksMaterial Test (Stainless steels, Chromium Molybdenum steels )Reliability of compressor
Japan Steel WorksMaterial Test (Stainless steels, Chromium Molybdenum steels )Reliability of compressor
Project Partners
Japan Petroleum Energy Center (JPEC)General administrationRisk assessment
Japan Petroleum Energy Center (JPEC)General administrationRisk assessment
Mitsubishi Heavy Industries Ltd. (MHI)H2 Diffusion & Explosion Experiments/CFD
Mitsubishi Heavy Industries Ltd. (MHI)H2 Diffusion & Explosion Experiments/CFD
Tatsuno CorporationReliability of H2 gas dispenser
Tatsuno CorporationReliability of H2 gas dispenser
Japan Industrial Gas Association Reliability of piping materials, valves, etc.
Japan Industrial Gas Association Reliability of piping materials, valves, etc.
Iwatani International Corp.Reliability of liquid H2 system
Iwatani International Corp.Reliability of liquid H2 system
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Safety Study
Risk AssessmentPopular and highly experienced measure is used
for our study.
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Basic Approach
Definition of H2 station model
Hazard Identification
Risk Estimation
Risk EvaluationRisk Reduction
Tolerable Risk?N
Y
Output of the study : Safety requirements for H2 station
Experiments, Simulations,Surveys, etc.
By Project Partners
END
START
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Definition of H2 Station model
The model should be concrete enough for risk assessment.
The model should keep generality to be used for the review of C&S.
On-site type H2 station H2 Demand : 300Nm3/hr (30Nm3/vehicle * 10vehicles/hr) H2 Generation : 300Nm3/hr Compressor : 300Nm3/hr, 40MPa H2 Cylinders : 250L * 14 = 3500L (40MPa, 1400Nm3) Dispenser : 35MPa (supply pressure)
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Types of H2 Stations
1) On-site type
3) Liquid hydrogen type
2) Off-site type
Material tank
Reformer
PSA
CompressorDispenser
Heat Exchanger
Gas Dispenser
Liquid Dispenser
Cylinders
Liquid H2 storage
Liquid H2 pump
Study was finished
Study is on progress
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Hazard Identification
Applied Methods : HAZOP (Hazard and Operability Studies) FMEA (Failure Mode and Effect Analysis)
233 accident scenarios were identified for the on-site type H2 station model Failure and deterioration Human Error Natural Disasters
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Risk Matrix (Risk Acceptance Criteria)
H (High):Risk cannot be acceptable. Remedial actions should be considered to reduce the risk to acceptable level.
M (Medium):In principle, risk cannot be acceptable. It can be accepted only when risk reduction cannot be achieved by reasonably practical action
L (Low):Acceptable. Further risk reduction is not necessarily required.
Likelihood
Consequence
severity
AImprobable
BRemote
COccasional
DProbable
1 Extremely Severe Damage H H H H
2 Severe Damage M H H H3 Damage M M H H4 Small Damage L L M H5 Minor Damage L L L M
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Examples of Risk Evaluation
(1) Risk rank of no safety requirements
800Nm3 of hydrogen leakage from D=10mm, 40MPa
Consequence Level 1: Extremely Severe Damage
Likelihood Level C: Occasional
Likelihood
Consequence
A B C D
1 Extremely Severe H H H H
2 Severe Damage M H H H
3 Damage M M H H
4 Small Damage L L M H
5 Miner Damage L L L M
Scenario : Rupture of pipeScenario : Rupture of pipe
Earthquake – Fall of Cylinder Unit – Rupture of pipe – H2 Earthquake – Fall of Cylinder Unit – Rupture of pipe – H2 leakage – Explosion or Jet Fireleakage – Explosion or Jet Fire
Can not be acceptable
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(2) Applied Safety Requirements(2) Applied Safety Requirements + To Lower the Consequence+ To Lower the Consequence
- Install Earthquake detector and Emergency Isolation Valve with fail close type- Install Earthquake detector and Emergency Isolation Valve with fail close type + To Lower the Likelihood+ To Lower the Likelihood
- Fix the cylinder unit on hard concrete base - Fix the cylinder unit on hard concrete base - Establish the Emergency Isolation Valve within the cylinder unit
Acceptable!
Likelihood
Consequence
A B C D
1 Extremely Severe H H H H
2 Severe Damage M H H H
3 Damage M M H H
4 Small Damage L L M H
5 Miner Damage L L L M
Examples of Risk Evaluation Cont.
H2
STOP
Cylinder Unit
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Consequence Estimation
Basic data for consequence estimation was provided by Mitsubishi Heavy Industries, Ltd.
MHI carried out Experiments and Computational Simulations of H2 Diffusion, Explosion, and Jet Fire.
20 10mmΦ 40→1MPa
Experiments of Jet Fire (video)
Same as left, with wall (h=3m, w=6m)
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Likelihood Estimation
Experiments & Surveys by our Project Partners Material : The Japan Steel Works Compressor : The Japan Steel Works Dispenser : Tatsuno Corporation General piping materials & instrument:
Japan Industrial Gas Association
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Dispenser
Durability Tests for Filling hose & Joint Hand valve Breakaway device Etc.
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Compressor
Durability Tests Hydrogen leakage Noise Control Vibration Etc.
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Material (Stainless Steels and Chromium Molybdenum Steels)
Tests for Hydrogen Embrittlement in pressurized hydrogen environment are necessary.
Tensile test Deep notch test Fracture toughness test Fatigue test Etc.
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Review of Regulations
The result of the study was reported to the competent authorities, then examined, and basically accepted by them.
The competent authorities revised relevant regulations.
The new regulations have been effective since April 2005. High Pressure Gas Safety Law Fire Protection Law Building Standard Law
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Safety Requirementsfor High Pressure Gas Safety Law
Road
H2 Dispenser
Office
CT
Compressor Storage
Gasoline Dispenser
Reformer
R
PSA
A
A
A
AP
Tank
Setback Distance 6 mWall h=2m
Setback Distance can be shortened with appropriatefire protection wall
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Road
H2 Dispenser
Office
CT
Compressor Storage
Gasoline Dispenser
Reformer
R
PSA
A
A
A
AP
Tank
H2 leak detector
Flame detector
Earthquake detector
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Road
H2 Dispenser
Office
CT
Compressor Storage
Gasoline Dispenser
Reformer
R
PSA
A
A
A
AP
Tank
Emergency isolation valve
Excess flow valve
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Breakaway Device
Guardrail Piping in Trench
Flame Detector
Emergency Stop Button
Pressure releaseafter refueling
30 Frame Structure
H2 Leak Detector
Emergency Isolation Valve,Check Valve
Water SprinklerFlame Detector
Fire Protection Wall
Pressure Indicator, Safety Valve
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•Compressor should be placed in an enclosure.•Ventilation with Interlock System
H2 Leak Detector
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Conclusions We made drafts of revised safety codes and standards
of Hydrogen supply stations. Government reviewed the regulations based on our
drafts and new regulations have been in force now. High pressure gas safety law Fire Protection Law Building Standard Law
It was permitted to build H2 supply station in an urban area and to install them in the premise of a gasoline station.
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END
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Likelihood LevelsLevel Description Definition
A Improbable Possible, but the probability is extremely low.
About once in several thousands years or less.
B Remote Unlikely to occur in lifetime of one H2 station.
About once in several hundreds years.
C Occasional Likely to occur once in lifetime of one H2 station.
About once in several decades.
D Probable Likely to occur several times in lifetime of one H2 station. About once in several years or more.
Likelihood Estimation Qualitative Evaluation
Based on engineering judgment Not enough data available for quantitative evaluation
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Consequence LevelsLevel Description Material Damage Human Damage
1 Extremely Severe Damage
Collapse of nearby dwelling houses
One or more fatalities of pedestrians or dwellers
2 Severe Damage Major damage of nearby dwelling houses
One or more fatalities of customers or station workers
3 Damage Minor damage of nearby dwelling houses
Injury of hospitalization
4 Small Damage Windows broken Injury of medical treatment
5 Minor Damage No damage to nearby dwelling houses
Minor injury