Hydrogen Safety and Permitting Hydrogen Fueling Stations

Jim OhiNational Renewable Energy Laboratory

International Conference on Hydrogen SafetySan Sebastian, Spain

September 13, 2007

• Insufficient technical data available to set requirements in standards, codes, and regulations– non-hydrogen or industrial codes often referenced– difficult to trace origins and scientific foundations of requirements

• Voluntary, consensus system of Codes and Standards development– many standards development organizations (SDOs) and model code

development organizations (CDOs)– harmonization of requirements between SDOs and CDOs, between

domestic and international standards • Approximately 44,000 governmental jurisdictions in U.S. with

authority to regulate hydrogen applications– most jurisdictions have limited hydrogen experience, training, funding– permitting process and requirements may vary from jurisdiction to

jurisdiction– permitting process can be time-consuming and expensive

Challenges and Barriers

DOE HydrogenSafety , Codes & Standards

Program

C/S R &D Plan

National Template C /S

Standards

Technical Requirements

Testing Protocols & Validation

R&DPriorities

R&DProjects

H2 C/S Coordinating Committee

C/S Tech Team DOE Safety PanelDOE Safety Guidelines

P . I. SOPs 1st Responder Training

IS 0, IEC Standards

GTR

Model Codes

Regulations

Hydrogen Behavior InterfaceVehicle Fuel

Infrastructure

DOE Program Structure: Focus of Talk

Technology Roadmap

• First Version: Completed 2004

• Living document, annual updates planned

• Tech Team Update in September 2006

• Details Needs and Gaps in each Target Area

Roadmap – Target Research Areas

1. Hydrogen Behavior (physical/chemical, combustion/flammability, materials properties, sensing/mitigation)

2. Vehicles(fuel storage system, components, sensors, whole vehicle, failure modes)

3. Infrastructure(production, terminals/distribution/delivery, refueling stations)

4. Interface(fuel quality, feedback strategies, refueling components)

Roadmap details Information Needs or Gaps for eachTarget Area to ensure RD&D efforts are properly directed

National Template: Vehicle Systems and Refueling Facilities

Fuel Specs: SAEASTM, APIWts/Measures: NIST,API, ASMEFueling: SAE, CSASensors/Detectors: UL,

NFPA, SAE, CSAConnectors: SAE, CSACommunications : SAE UL, CSA, API, IEEE

Controlling Authority: DOT/PHMSA (Over-road Transport, Pipeline Safety)

Standards Development:Composite Containers ASMECSA, CGA, NFPAPipelines ASME, API, CGA, AGAEquipment ASME, API, CGA, AGAFuel Transfer NFPA, API

Controlling Authority: State, Local Govt.Zoning, Building Permits

Standards Development: Storage Tanks: ASME, CSA, CGA, NFPA, APIPiping ASME, CSA, CGA, NFPADispensers CSA, UL, NFPA,On-site H2 Production: CSA, UL, CGA, APICodes for the Environment: ICC, NFPA

Controlling Authority: DOT/NHTSA (Crashworthiness)EPA (Emissions)

Standards Development: General FC Vehicle Safety: SAEFuel Cell Vehicle Systems: SAEFuel System Components: CSAContainers: SAEReformers: SAEEmissions: SAERecycling SAEService/Repair: SAE

Vehicles Fuel Delivery, Storage

Fueling, Service Parking Facility

Lead SDO underlined

Interface

Research Community

SAFETY

Industry

Public

Linking R&D and Codes and Standards Development

ConsumerEducation, Product Information

Risk Assessment, Risk Informed Standards, Risk

Management

Risk Information,Education and Training

Source: adapted from Thomas Jordan, HySafe

H2 BehaviorR&D

H2 FuelingStation Safety

SetbackDistances

Model Codes

Linking R&D and Codes and Standards Development

ConsumerEducation, Product Information

Risk Assessment, Risk Informed Standards, Risk

Management

Risk Information,Education and Training

Source: adapted from Thomas Jordan, HySafe

Linking R&D and Codes and Standards Development

Hydrogen Behavior/Separation Distances(from RD&D Roadmap)

• Properties• Flammable Vapor Cloud Formation• Flammability Limit• Hydrogen Jets and Flames• Liquid Hydrogen Releases• Materials Compatibility• Advanced Storage Materials, Behavior• Hydrogen Sensors

Source: Sandia National Laboratories

• Hydrogen Combustion & Release Scenarios

• Turbulent Non-Premixed Flame Length

• Experimental Heat Flux Measurement

• Thermal Radiation Models

• Flammability Limits for Hydrogen

• Jet Ignition Probability

• Flame Impingement on a Barrier Wall

• Preliminary Comparisons of Natural Gas and Hydrogen

• Overpressure Measurements

Linking R&D and Codes and Standards Development

Hydrogen Behavior/Separation Distances(Examples of Relevant R&D at Sandia National Laboratories)

• Clearly defined risk metrics are required for QRA implementation.

• Assume “no greater risk” principle where hydrogen fueling should be no riskier than other fueling alternatives.

Designarchitectures

Hydrogen behavior& Consequence

analysis

Lifecycle analysisof hydrogen economy

Risk benchmark and

Fuels comparison

Equipmentspacing &Mitigation

Fueling historyand

Lessons learned

H2 RA Considerations

High Risk

Acceptable Risk

Risk Reduction

No Harmful Effect

ALARP

Unacceptable

• Baseline “acceptable” risk might be defined as the risk of everyday life.

• Beyond baseline, reduce risk using ALARP– Consequences above the risk threshold require

mitigation strategies or engineering solutions to drive them below the acceptable level.

– Consequences below the threshold can still be driven downwards by reducing exposure.

Source: Sandia National Laboratories

Quantitative Risk Assessment Approach for Separation Distances

H2 BehaviorR&D

H2 FuelingStation Safety

SetbackDistances

Model Codes

Linking R&D and Codes and Standards Development

ConsumerEducation, Product Information

Risk Assessment, Risk Informed Standards, Risk

Management

Risk Information,Education and Training

Source: adapted from Thomas Jordan, HySafe

• Different timetables – R&D does not (cannot) follow a set timetable– Codes and standards development process has set timetables and deadlines

for public notice, public hearings/comment, publication• Different purposes and perspectives

– R&D addresses scientific problems, e.g., hydrogen behavior under given release, confinement, ignition conditions

– C&S development requires interpretation of scientific findings to help set requirements that improve safety of general class of applications, uses, situations

• Long-term interaction between researchers and C&S technical committee members essential– Cannot be limited to one-time presentations, “testimony”– Researchers must be integrated into technical committees– C&S technical committee members must become familiar with R&D objectives,

process, limitations (uncertainty, error bars)

Challenges and BarriersLinking R&D and Codes and Standards Development:

Linking R&D and Codes and Standards Development:

NFPA 2, Hydrogen Technologies

• Compilation of all NFPA hydrogen provisions into one model code – Scheduled publication date: July 2010– Technical Committee of stakeholder experts (ANSI consensus process) chaired by

Marty Gresho, Fire Marshall, Sandia National Laboratories, California– Task Groups formed to address specific key topics and augment Technical

Committee• Task Group 6: Separation Distances

– define approach to identify, assess, and select set of measures and criteria to specify separation distances for HRS based on foundation of scientific and technical data, analysis, modeling, QRA

– joint effort with NFPA technical committee to integrate effort with technical experts responsible for establishing separation distances for hydrogen storage

– storage pressure and leak size key factors to determining separation distances• separate tables for different pressure regimes• leak size defined in terms of the flow area as a percentage of the pipe diameter

– for given pressure and leak size, hazard distances considered for different exposure categories

• air intakes for HVAC systems, lot lines, openings in buildings, structures, equipment requiring protection from potential hazard scenarios

Linking R&D and Codes and Standards Development:

NFPA 2, Hydrogen Technologies

• Task Group 6: Separation Distances– hazard scenarios defined

• hydrogen gas release and subsequent entrainment or accumulation• fire spreading to or from adjacent equipment or structures• ignition of unignited release or venting of hydrogen

– exposures categories matched with hazard scenarios against which exposure must be protected

– consequence parameters identified for each exposure category and its accompanying hazard scenario or scenarios to provide measurable criteria for separation distances

• decay distance of an unignited plume of hydrogen to 4% volume fraction in air• radiative heat flux level of ignited hydrogen jet• flame length of ignited jet• parameters will vary with pressure, leak size, physical and environmental conditions at

site when event occurs

– example using radiative heat flux as consequence parameter• 1.6kW/m2 : “no-harm” level equivalent to exposure to the sun on a clear day• 4 to 5 kW/m2: second-degree burns within 20 sec. exposure• 25 kW/m2 : structural damage, significant injury within 10 sec., death within 60 sec.

Linking R&D and Codes and Standards Development:

NFPA 2, Hydrogen Technologies

• Task Group 6: Separation Distances

– if level of radiative heat flux is most appropriate consequence parameter to measure degree of protection provided by separation distance for given exposure category and hazard scenario, distance at which heat flux subsides to that level

will be equivalent to separation distance • at lot lines heat flux should not harm people and should be set no higher than 1.6 kW/m2

• for buildings and structures of noncombustible materials, heat flux as high as 25 kW/m2

could be allowed

– for exposure category of air intakes, decay distance of unignited hydrogen plume to 4% volume fraction is most appropriate consequence parameter

– separation distances for aboveground gaseous hydrogen systems based solely on consequence parameters can be reduced through mitigation measures

• barrier walls• noncombustible enclosures

– evaluate effects of mitigation measures through experiments, modeling, and analysis

– apply QRA techniques to define risk informed requirements• ensemble of events evaluated (LaChance, et al., paper)

Linking R&D and Codes and Standards Development:

NFPA 2, Hydrogen Technologies

• Conclusions– timeline to develop and publish NFPA 2 set from beginning to allow

sufficient time for supporting R&D, modeling, and analysis to be performed

• R&D and code development better synchronized than when R&D has to fit into code revision cycle already underway

– creation of task groups composed of technical committee members and outside experts to address key issues allows better interaction between researchers and code development experts

• Task Group 6 formed joint effort with NFPA 55technical committee members

– DOE supported critical R&D for safety codes and standards and work of key SDOs such as NFPA for many years

• support has fostered good working relationships at both institutional and

personal levels among researchers and codes and standards experts

H2 BehaviorR&D

H2 FuelingStation Safety

SetbackDistances

Model Codes

Linking R&D and Codes and Standards Development

ConsumerEducation, Product Information

Risk Assessment, Risk Informed Standards, Risk

Management

Risk Information,Education and Training

Source: adapted from Thomas Jordan, HySafe

• Create and maintain a comprehensive, user-friendly, one-stop information source for permitting HFS– Assist permitting officials to review HFS applications and take

informed and expeditious action– Facilitate interaction of permitting officials and HFS developers

• enable joint “navigation” of permitting process

– Post critical information• HFS technologies and associated safety considerations• pertinent sections of codes and standards

– Provide links to other sources of information

• Focal audiences: local permitting officials, HFS developers• Additional audiences: state and local officials, other

stakeholders

Permitting Hydrogen Fueling Stations: Objectives

Key Capability

• Users can obtain information on permitting procedures and requirements, hydrogen technologies, and pertinent standards and model code provisions

Auxiliary Information

• Case studies of HFS permitting and construction• Examples of best practices for permitting

advanced technologies • Fact sheets on HFS technologies• Network chart of code officials who have

addressed HFS permitting cases

• Three Interlinked Main Modules – HFS Permitting Process

• describes major steps in typical permitting process• highlights key information and issues involved with each step

– includes generic requirements for FMEA and QRA (with SNL)

– Retail Hydrogen Fueling Station Structure• fact sheets on and links to information on hydrogen production,

delivery, storage, and dispensing technologies• information on related safety issues and requirements in

pertinent codes and standards

– Codes and Standards Finder and Database• identifies and provides specific sections of standards and model

codes for permitting hydrogen fueling stations

Web Site Structure

HFS Web Site Concept

Permitting Process Retail Hydrogen Station

Codes and Standards

Addition to Existing Station Stand Alone Station

On-site Production H2 Delivery

Storage

Compression

Dispensing

LH2

CGH2

SMR ATR

GasolineDiesel

CNG H2

Application for Permit

Site Plan

Buildings

Equipment

Construction Inspection

Operation

Operation, Maintenance

Underground (LH2)At-gradeCanopy Top (CGH)

Process Flowchart

Case Studies

Fact Sheets

IFC 2209

NFPA 52

Level of Detail

Timetable

Etc.

Elect.

Pathway: Behind Fence to Retail

Best Practices

Hydrogen Safety and Permitting Hydrogen Fueling Stations:Summary

• Availability and consistent application of codes and standards whose requirements are founded on RD&D, modeling, and analysis are key barrier to widespread market entry of hydrogen and fuel cell technologies – DOE supports critical RD&D to help establish this foundation– DOE also supports key SDOs to help accelerate development of critical

codes and standards– DOE now addressing intersection of these two efforts in general and

permitting of HFS in particular• RD&D accommodated in organizational structure and timetable of

NFPA 2 code development cycle– potential to succeed and become template for integration of two distinct

but complementary elements of safe hydrogen use• DOE will facilitate permitting process for HFS to be less time

consuming and more efficient– work with HFS developers and fire and building code communities to

develop Web-based information repository– conduct workshops to review structure, content, and usefulness of

repository

Thank You!

DOE Hydrogen, Fuel Cells, and Infrastructure Technologies Program

www. hydrogen.energy.gov

National Renewable Energy Laboratorywww.nrel.gov