Introduction to the Introduction to the Safe Design of LNG, CNG and Safe Design of LNG, CNG and Hydrogen Refueling StationsHydrogen Refueling Stations
Presentation to Presentation to SFPE SFPE
Northern California and Nevada ChapterNorthern California and Nevada Chapter
March 16, 2007March 16, 2007byby
Jack Woycheese, PE, FSFPEJack Woycheese, PE, FSFPE
BackgroundBackground
Existing LNG Import TerminalsExisting LNG Import Terminals 5 in North America, 17 new plants approved, 25 proposed 5 in North America, 17 new plants approved, 25 proposed
and submitted for approval, 17 more in planningand submitted for approval, 17 more in planning
Existing LNG/CNG Refueling FacilitiesExisting LNG/CNG Refueling Facilities Garden Grove, Anaheim, Irvine, Santa MonicaGarden Grove, Anaheim, Irvine, Santa Monica
ProposedProposedLNG offloading in Long BeachLNG offloading in Long Beach
5 Hydrogen plants in SoCal5 Hydrogen plants in SoCal
Alternative FuelsAlternative Fuels
Demand driven by environmental goalsDemand driven by environmental goals
MethanolMethanol
Electrical (Batteries)Electrical (Batteries)
Natural GasNatural Gas CNGCNG
LNGLNG
HydrogenHydrogen
CRYOGENIC CHARACTERISTICSCRYOGENIC CHARACTERISTICS
Cryogenic temperatures are defined as Cryogenic temperatures are defined as between between --150150ººF and F and --460460ººF (absolute zero). F (absolute zero). At atmospheric pressure LNG boils at At atmospheric pressure LNG boils at --259259ººF.F.
Hydrogen boils at Hydrogen boils at --430430ººF F
FIRE HAZARD PROFILE FIRE HAZARD PROFILE -- LNGLNG
Lower Explosion limit (% by vol.):Lower Explosion limit (% by vol.): 5.05.0
Upper explosion limit (% by vol.):Upper explosion limit (% by vol.): 15.415.4
Auto ignition temperature:Auto ignition temperature: 537537ººCC
Flammability classification Flammability classification Flammable Flammable
Sensitivity to static discharge Sensitivity to static discharge Ignitable byIgnitable by static static electricity. Escaping electricity. Escaping gas may self ignite gas may self ignite
FIRE HAZARD PROFILEFIRE HAZARD PROFILE-- HYDROGENHYDROGEN
Lower Explosion limit (% by vol.):Lower Explosion limit (% by vol.): 4.04.0
Upper explosion limit (% by vol.):Upper explosion limit (% by vol.): 75.0075.00
Auto ignition temperature:Auto ignition temperature: 575575ººC C
Flammability classification Flammability classification Flammable Flammable
Sensitivity to static discharge Sensitivity to static discharge Ignitable byIgnitable by static static electricity. Escaping electricity. Escaping gas may self ignite gas may self ignite because of friction.because of friction.
Basic Design of CNG StationBasic Design of CNG Station
Priority/Sequential
Panel
Dispenser
NaturalGasInlet
Dryer Compressor
Storage VesselsFilter
Outlet
CNG FUELING ISLAND-
CNG FUELING
CNG FUELING
35 or 160 psi Supply
Dispensers
Compression skids
Buffer
FUEL DEPOT
Card Reader
CNG dispensers onbus refueling islands
High-pressure gasbuffer storage vessel
Vacuum-jacketed LNG storage tank
LNG tanktruck deliveryfill port
Basic Design of L/CNG Station
Sump-mounted centrifugalinducer pumps
Forced-draftambient-air vaporizer
LNG/CNGLNG/CNG
LNG Release Behavior (ContLNG Release Behavior (Cont��d)d)
As LNG vaporizes, water in air As LNG vaporizes, water in air CondensesCondenses
Forms visible cloudForms visible cloud
Initial release heavy, as it warms Initial release heavy, as it warms becomes light like CNG at becomes light like CNG at --3030°°FF
LNG/CNGLNG/CNG
Methane Gas Supplies Methane Gas Supplies
CNGCNG Pipeline to comPipeline to com--
pressor to CNG storagepressor to CNG storage
Truck as CNG to CNG storageTruck as CNG to CNG storage
LNGLNG Made on siteMade on site
Shipped in trucks to LNG storageShipped in trucks to LNG storage
LNG/CNG LNG/CNG
Methane Gas Supplies (ContMethane Gas Supplies (Cont��d)d)
L/CNGL/CNG LNG/pump/vaporizer/LNG/pump/vaporizer/
CNG storageCNG storage
LNG/vaporizer/LNG/vaporizer/compressor/storagecompressor/storage
LNG/CNGLNG/CNG
Hazards of Natural Gas Hazards of Natural Gas
Fuel accumulation Fuel accumulation Near ceiling Near ceiling
In presence of potential ignition sourcesIn presence of potential ignition sources
Fast releasesFast releases PossiblePossible
Considered improbableConsidered improbable
Applicable StandardsApplicable Standards
NFPA 52, 2006 editionNFPA 52, 2006 edition
NFPA 55 2005 editionNFPA 55 2005 edition
NFPA 57 (Combined into NFPA 52)NFPA 57 (Combined into NFPA 52)
NFPA 59A, 2006 editionNFPA 59A, 2006 edition
NFPA 88NFPA 88
Building CodeBuilding Code
Fire CodeFire Code
PressurePressure--vessel Codevessel Code
Applicable StandardsApplicable Standards
California Title 8: Pressure Vessel Code California Title 8: Pressure Vessel Code (Cont(Cont��d)d)
Incorporates NFPA 52/57/59AIncorporates NFPA 52/57/59A
Approved in March, 2000 Methane Approved in March, 2000 Methane DetectionDetection
Addressed engineering approval of LNG Addressed engineering approval of LNG RefuelingRefueling
Site ConsiderationsSite Considerations
SpacingSpacing SiteSite EquipmentEquipment
Drainage Drainage Away from buildings/equipmentAway from buildings/equipment LNG vaporization rate LNG vaporization rate LNG spill rateLNG spill rate Environmental contaminationEnvironmental contamination
Pressure Relief DischargePressure Relief Discharge
Above-ground Tank,
L/CNG Station
Tank, pumps, vaporizer, containment, buffer
Fueling islanddispensers
FacilitiesFacilities
Vertical tank
Space constrained in residential area
FacilitiesFacilities
Above-ground Vault, L/CNG Station
FacilitiesFacilities
LNG tanks & pumps in LNG tanks & pumps in lowlow--profile 87profile 87�� x 38x 38��vaultvault
HighHigh--expansion Foam expansion Foam System fills vault in ~2 System fills vault in ~2 minutesminutes
HAZOP HAZOP -- Process Process Safety AnalysisSafety Analysis
Vault Vault ½½ above grade above grade ½½ below gradebelow grade Walls Concrete Masonry Walls Concrete Masonry
Unit Unit Ventilation System Ventilation System BlastBlast--proof Doorsproof Doors DeflagrationDeflagration--relief Roof relief Roof
PanelsPanels
LNG Vessels Inside Vault
FacilitiesFacilities
LNG TO CNG
Pumps Inside Vault
FacilitiesFacilities
Above-ground Vault Foam System Test
FacilitiesFacilities
FacilitiesFacilities
Below-ground Tanks
FacilitiesFacilities
TemporaryTemporary
Facilities Facilities �� Refueling StationRefueling Station
FacilitiesFacilities-- TemporaryTemporary
Pressure Letdown During DeliveryPressure Letdown During Delivery
Sodium Bicarbonate Sodium Bicarbonate ApplicationApplication
Sodium Bicarbonate Sodium Bicarbonate ApplicationApplication
What is Hydrogen?What is Hydrogen?
OdorlessOdorless TastelessTasteless NonirritatingNonirritating NontoxicNontoxic ColorlessColorless FlammableFlammable Rises and dissipates Rises and dissipates
quicklyquickly No environmental No environmental
impactimpact
For Automotive ApplicationsFor Automotive ApplicationsWhere Does HWhere Does H22 Come From?Come From?
Hydrogen is DERIVED from Hydrogen is DERIVED from
Hydrocarbon based fuels, steam methane (SMR) Hydrocarbon based fuels, steam methane (SMR) reforming reforming -- 80% today80% today
ByBy--product of chemical processes, purification (20% product of chemical processes, purification (20% today)today)
Water, electrolysis (niche applications today)Water, electrolysis (niche applications today)
Hydrogen Supply ModesHydrogen Supply Modes
Hydrogen Supply ModesHydrogen Supply Modes
Liquid Hydrogen Delivery Delivered in TankersDelivered in Tankers Stored onsite as Cryogenic Stored onsite as Cryogenic
LiquidLiquid Vehicle Fueling Applications:Vehicle Fueling Applications:
Gas OnboardGas Onboard Liquid OnboardLiquid Onboard
Hydrogen Supply ModesHydrogen Supply Modes
Gaseous Gaseous ��Tube TrailerTube Trailer�� DeliveryDeliveryDelivered in High Pressure TubesDelivered in High Pressure Tubes
Basis for HBasis for H22 Fuel StationsFuel Stations
Hydrogen Supply ModeHydrogen Supply Mode Onsite Production or hauled inOnsite Production or hauled in UtilitiesUtilities
CompressionCompression Required pressure, flow ratesRequired pressure, flow rates Maintenance programMaintenance program Gaseous Compression vs. Liquid PumpGaseous Compression vs. Liquid Pump
High Pressure StorageHigh Pressure Storage ASME Compliant Vessels for StationaryASME Compliant Vessels for Stationary DOT Compliant for Mobile StorageDOT Compliant for Mobile Storage
HH22 Fuel StationsFuel Stations DispensingDispensing
Automatic vs. ManualAutomatic vs. Manual Trained OperatorsTrained Operators
SitingSiting Issues/Permits/Issues/Permits/Codes and Standards Codes and Standards --NFPA, DOSH.NFPA, DOSH.
MiscellaneousMiscellaneous Personal Protective Equipment Personal Protective Equipment
(PPE)(PPE) Safety Reviews Safety Reviews -- FEMA, FEMA, HazopHazop Develop site documentDevelop site document
APCI Hydrogen APCI Hydrogen FuelersFuelers H2 Delivery for small fleets or spot jobsH2 Delivery for small fleets or spot jobs
Various sizes and pressuresVarious sizes and pressures
Hydrogen Supply ModesHydrogen Supply Modes
OnOn--site Reformingsite Reforming
Fossil Fuel Feed StockFossil Fuel Feed Stock
Demonstration ProjectDemonstration Project
Hydrogen Supply ModesHydrogen Supply Modes
OnOn--site Electrolysissite ElectrolysisWater and Electricity Feed Water and Electricity Feed
StockStock
Up to 100 kg/dayUp to 100 kg/day
Demonstration ProjectsDemonstration Projects
Pathway to renewable fuelPathway to renewable fuel
Hydrogen Supply ModesHydrogen Supply Modes
Packaged Gases Packaged Gases -- Cylinder SupplyCylinder Supply Small volumes, spot requirementsSmall volumes, spot requirements Portable Fueling Center/CartPortable Fueling Center/Cart
Hydrogen Fuel Stations Hydrogen Fuel Stations University of California DavisUniversity of California Davis
Hydrogen Fuel StationsHydrogen Fuel Stations
University of California University of California -- Irvine, CAIrvine, CA
Ford Motor Co. Ford Motor Co. -- Dearborn, MIDearborn, MI
Hydrogen Fuel StationsHydrogen Fuel Stations
City of Las Vegas, NV
City of Las Vegas HCity of Las Vegas H22 ProjectsProjects
Hydrogen Fuel StationsHydrogen Fuel StationsChicago Transit Authority (CTA) Chicago, ILChicago Transit Authority (CTA) Chicago, IL
Hydrogen Fuel StationsHydrogen Fuel Stations
Cal. Fuel Cell PartnershipWest Sacramento
Finished StationFinished Station
Ann Arbor, MIAnn Arbor, MI
CompressorCompressor
Compressed HCompressed H22 StorageStorage
Fuel DispensersFuel Dispensers
Mobile Mobile FuelerFueler
Tips for Successful ProjectsTips for Successful Projects
Process Safety Analysis Process Safety Analysis
Piping & Instrumentation DiagramPiping & Instrumentation Diagram
Emergency Shut DownEmergency Shut Down
Site Plan/Spacing/DrainageSite Plan/Spacing/Drainage
Tips for Successful ProjectsTips for Successful Projects
Deficiency ResolutionDeficiency ResolutionResponsibilityResponsibility
Equivalency ApprovalsEquivalency Approvals
DocumentationDocumentation
TrainingTraining
Tips for Successful ProjectsTips for Successful Projects
Process Safety ManagementProcess Safety ManagementAPI RP 750API RP 750
AI ChemE/CCPSAI ChemE/CCPS
OSHAOSHA
DonDon��t forget Fire Protection t forget Fire Protection Considerations Considerations
for Maintenance Garage!for Maintenance Garage!
Tips for Successful ProjectsTips for Successful Projects
In CA, all dispensing In CA, all dispensing facilitiesfacilities
Certified for Certified for Engineering integrityEngineering integrity
Safety and Safety and compliance compliance
By California By California Registered Registered Engineer(s) Engineer(s) competent in competent in design, fabrication, design, fabrication, construction of construction of CryongenicCryongenic
Tips for Successful ProjectsTips for Successful Projects
Fire detectionFire detectionFire protection equipmentFire protection equipmentMethane or hydrogen gas detectionMethane or hydrogen gas detectionOther components of the facilityOther components of the facility
General RequirementsGeneral Requirements
ESD MatrixESD Matrix
Fixed and Portable Gas DetectionFixed and Portable Gas Detection
Gas Alarms Transmit to FDGas Alarms Transmit to FD
Location of Safety EquipmentLocation of Safety Equipment
Initial InspectionInitial Inspection
Verify ESD MatrixVerify ESD MatrixAlarm Triggered by Gas Detection Alarm Triggered by Gas Detection
(10%LFL)(10%LFL)
Power and Fuel off (all required circuits) Power and Fuel off (all required circuits) (50% LFL) (50% LFL)
Restart after ShutdownRestart after Shutdown
Electrical Area ClassificationElectrical Area Classification
FollowFollow--up Inspectionsup Inspections
Maintenance and Training RecordsMaintenance and Training Records Approved Drawings, PSA, etc.Approved Drawings, PSA, etc. PRVPRV��s s Gas Detection SystemGas Detection System Corrosion ProtectionCorrosion Protection
Location of Safety EquipmentLocation of Safety Equipment Shields, Gloves, Aprons, etc.Shields, Gloves, Aprons, etc. Portable Gas DetectorsPortable Gas Detectors
Retest ESD MatrixRetest ESD Matrix All Required Power OffAll Required Power Off RestartRestart
NonNon--suitable Electrical Equipment/Wiringsuitable Electrical Equipment/Wiring