handbook for approval of hydrogen refuelling stations ... · pdf filehandbook for approval of...

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1st European Summer School on Hydrogen Safety, Belfast, 15 – 24 August 2006

HyApprovalHandbook for Approval of Hydrogen Refuelling Stations –

Safe and Harmonised Implementation of Hydrogen Refuelling Stations on a Global Scale(SES6 - 019813)

Reinhold Wurster (LBST)on behalf of the

HyApproval Consortium (www.HyApproval.org)

1st European Summer School on Hydrogen SafetyBelfast, 15 – 24 August 2006

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Definition: HRS = Hydrogen Refuelling Station

Prerequisites for a HRS

Prerequisites:

• Technical feasibility shown

• Acceptable investment costs achievable

• Clients on the road

• Demand/ supply for HRS infrastructure proven

• Permitting processes in place

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Technical Feasibility of an HRS

Total andAral/BPBerlin, Germany

Iwatani,Ariake Tokyo,Japan

ShellWashington, DC, USA

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Technical Feasibility of an HRS [TOTAL/ CEP] (1)

Source:Mullard, Schnell, EHEC2005

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Technical Feasibility of an HRS [TOTAL/ CEP] (2)

Source:Mullard, Schnell, EHEC2005

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Specific H2 Refueling Station Investment Costs

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

Low (CGH2) - manual High (LH2) - automatic

Type of Station

[M E

uro

]

Power SupplyRefueling Station Infrastructure

4 M€ averageH2 production +station infrastructure

Sources: TES/ LBST

Share of capital investment for energy generation

Capital investment in H2-equipment for filling station

1,3 M€ averagestation infrastructure

Estimated Investment Costs for a European H2-Supply and Refueling Infrastructure - 2010 / 2020

[50% from Natural Gas/ 50% from Renewable Electricity (Wind Power)]

Acceptable Investment Costs of a HRS

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Acceptable Investment Costs of HRS [2]

0100200300400500600700800900

2005

-20

15

2015

-20

25

2025

-20

35

Bill

ion

eu

ro

HydrogenstationaryHydrogenproductionFilling station

Pipeline & Trailer

Hydrogen vehiclepropulsion systemHydrogen vehiclewithout propulsion

(cumulative investments for a ten-year period, hydrogen high penetration scenario, HyWays Phase I results based on six HyWays countries D, F, I, GR, N, NL )

H2 Infrastructure Costs

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Clients = Vehicles on the Road (USA)

California - ZEV requirement:

2001 – 2008: 250 FCVs (1st ZEV Floor)2009 – 2011: 2,500 FCVs (2nd ZEV Floor)2012 – 2014: 25,000 FCVs (3rd ZEV Floor)2015 – 2017: 50,000 FCVs (4th ZEV Floor)

Applicable to all large volume manufacturers (i.e. > 60,000 LDVsper year): DC, Ford, GM, Honda, Nissan, Toyota (from 2010: BMW, from 2012+: VW)

[from 2011 on also obligatory for each other US ZEV state: MA, NY, VT, RI, CT, NJ, ME, OR, ML]

In the US Energy Policy Act of 2005 [PUBLIC LAW 109–58—AUG. 8, 2005],

In SEC. 811. REPORTS, sub-sec (a), indent (4), the US have formulated the goal to produce and deploy not less than:

(A)100,000 hydrogen-fueled vehicles in the United States by 2010

and

(B) 2,500,000 hydrogen-fueled vehicles in the United States by 2020

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Clients = Vehicles on the Road (Japan, EU)

Japan – FCVs Target Figures:

2010: 50,000 FCVs2020: 5,000,000 FCVs2030: 15,000,000 FCVs

[supplied by 500, 3,500 and 8,500 HRS in the respective years]

Europe:

HFP DS snapshot 2020: 0.4 – 1.8 m vehicles/ year sold

1 – 5 m vehicles on the road

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233 hydrogen fueling stations will cover all national highways in Japan.(Total 7,000km, 1 station every 30km)

Demand for HRS ProvenJapanese H2 Highway [by HESS]

Tokyo(Kasumigaseki, Senju, Ariake, Ohme)

Yokohama (Tsurumi, Daikoku, Asahi)

(Sagamihara, Hadano)

Kanagawa

Aichi (Tokai)+( EXPO×2)OsakaTakamatsu

Yakushima

Kawasaki

14 H2 stations +2 (under const.)

Hokkaido

Kyushu

Highways : Total 7,000km

Large number of vehicles are concentratedin metropolitan areas.

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Demand for HRS ProvenUSA Hydrogen Highway [by GM]

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Phase III:growth in population centres

extension to further populationcentres

Phase IV:HyNet roadmap analysis (not graphical)

Source: Wegener Falkplan BV

Phase IV - low

Up to 40% of the population (or ~170 million) in ~1,100 cities > 50,000 inhabitants could haveaccess to hydrogen as a fuel by building~5,000 hydrogen fuelling stations (~4,000 in cities and ~1,000 along motorways)

Phase IV - high

Up to 55% of the population (or ~250 million) in ~3,500 cities > 20,000 inhabitants could haveaccess to hydrogen as a fuel by building~10,000 hydrogen fuelling stations (~7,500 in cities and ~2,500 along motorways)

Demand for HRS ProvenHyNet - European Basic HRS Network

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Permitting Processes in Place ?

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For selected countries like Germany, based on CNG refuelling station permitting processes also HRS can be approved.

For other countries the process requires much higher efforts or is impossible at all.

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The HyApproval

Project

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HyApproval Partnership

Air Liquide S.A. (AL) Air Products PLC (APL)BP plcChinese Academy of Sciences, Technical Institute of Physics and Chemistry (CAS)Commissariat à l'Energie Atomique (CEA)Demokritos National Center for Scientific Research (NCSRD)Det Norske Veritas AS (DNV)EniTecnologie S.p.A. (ET)Engineering Advancement Association of Japan (ENAA)Federazione delle Associazioni Scientifichee Tecniche (FAST) in collaboration with H2ITForschungszentrum Karlsruhe GmbH (FZK)GM/Opel

Health and Safety Executive (HSE) Hydrogenics Europe N.V.Icelandic New Energy Ltd. (INE)Institut National de l’Environment Industriel et des Risques (INERIS)Instituto Nacional de Técnica Aeroespacial (INTA)Joint Research Centre of the European Commission (JRC)Linde AGNational Renewable Energy Laboratory (NREL)Norsk Hydro ASA (Hydro) Netherlands Organisation for Applied Scientific Research (TNO)Shell Hydrogen B.V.Total FranceLudwig-Bölkow-Systemtechnik GmbH (LBST)

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InvestigatedCountries

China, France, Germany, Italy, Japan,

Netherlands, Spain, USA

WP1HRS Definitions& Requirements

WP3Infrastructure& Deployment

ProjectWorkingGroups

Project Organisation HyApproval (24 months project)

WP6Vehicle

RequirementsWP5

DisseminationPA, CA

EC

Required Sectorial Competencies per Country Investigated:Infrastructure • Automotive • Safety • Approval Authorities

WP4Safety

WP2 Handbook

Compilation

Project Steering Group

AdministrativeProject

Management

WP0

Project Organigram

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• finalise the hydrogen refuelling station (HRS) draft guideline document started under EIHP2 (European Integrated Hydrogen Project) and to be pursued under ISO TC197, WG 11, addressing global recommendations to the technology providers, and representing the initial basis for developing a Handbook for the approval of HRS

• come up with a Handbook which assists all gas technology companies, fuel retailers/ HRS operators and the relevant approval authorities in laying out, installing, approving and operating HRS for CGH2 or LH2 on an EU-wide level, with the potential to also apply it to non-EU regions[An Approval in Principle contributes to reducing uncertainties and improving confidence for stakeholders, investors and funding bodies]

Main Project Goals

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Major Activities

• M0-3: Review and evaluation - Establishing safety matrix

• M3-4: Agreement on HRS concepts, safety documentation, modelling tools & techniques, target audience

• M5-8: Study phase

• M8-9: Agreement on HRS technical and on safety documentation, approval of EIHP2 draft, complete & agree matrix table of accident simulations & scenarios, risk assessment studies

• M9-12: Preparation of 1st Handbook draft and carry out risk assessments & accident simulations

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• M12-15: Dissemination models for different countries and several dissemination packages completed.

• M15-21: Deployment in several Member States (MS) and

support of WP3 “Infrastructure & Deployment”

• M21-23: Revision and adjustment phase for technical documentation, Handbook, EIHP2 draft, safety studies and sense check with MS and organisation of seminars in partner and non participating MS.A database of contacted agencies and officials on European and local level will be established.

• M23-24: Final partner agreement on Handbook

Major Activities (2)

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Main Safety Related TasksSafety-related tasks regarding HRS§ review and evaluate safety, codes & standards from existing

projects§ establish safety matrix (RCS, safety studies, risk assessment

criteria, etc.)§ establish best practices for safety§ develop realistic accident scenarios and their likelihood/ max.

credible total H2 leaks and leak rates§ agree on required modelling tools/ techniques for risk assessment

and simulations§ finalisation of HRS draft guideline started by EIHP2 (Ù WG11, ISO

TC 197)§ prepare safety documentation for Handbook

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Safety-related tasks regarding vehicle/HRS-interface§ general data interface description for LH2 and CGH2, according

to SAE J2601 draft, standard receptacle § data exchange between vehicle and HRS (one standard data

protocol)§ refuelling process, time, frequency, procedures, pressure

levels, etc.§ definition of a safe refuelling area and process, e.g. additional

grounding§ definition of best practices, usage of FMEA (Failure Mode &

Effect Analysis)à Only a technical report so far, not yet recommended practice

Main Safety Related Tasks (2)

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Pre-normative research task–Prioritisation and detailing for scenarios/ simulations of HRS

component failures:» CGH2 hose break/ nozzle/ dispenser failure at 35MPa and 70MPa» LH2 dispenser failure» CGH2 discharge hose break from tanker at 25 MPa and LH2

discharge hose break from tanker• at dedicated/ multi-fuel HRS• of 300kg/ 1,500kg/ 3,500kg onsite storage volume

investigated in CFD (Computational Fluid Dynamics) simulations, ifpossible, in 2 independent release and dispersion calculationsand 2 independent combustion calculations

Main Safety Related Tasks (3)

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Achievements in WP1 [¾ Y1] (1)

WP1 – HRS Definitions & Requirements:• ST1: Basic HRS technology completed• ST2: Safety Analysis of Equipment and Distances in progress• ST3: Integration of ST1 and ST2 into three “generic” HRS sizes

à Draft Design Paper established• ST4: RCS Review & Comparison in progress• ST5: LH2 Vehicle Refuelling Station Draft in progress

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Summary of respondents of the ST1 survey :London/ Berlin TOTAL/ Ariake, Japan/ Frankfurt (Infraserve Germany)/Berlin CEP/ Porto/ Bejing/ Madrid/ Stuttgart/ Hamburg/ Amsterdam/ Senjyu, Japan/ Seto-minami, Japan/ Barcelona/ Yokohama-Daikoku, Japan/ Seto-kita, Japan/ Yokohaam-Asahi, Japan/ Yokohama-Turumi, Japan/ Hadano, Japan/ Sagamihara, Japan/ Luxembourg/ Stockholm/ Kawasaki, Japan/ Mantova/ Ome Japan/ Kasumigaseki, Japan/

Storage < 300 kg

0

50

100

150

200

250

300

Stuttga

rt

Hambu

rg

Amsterda

m

Senjyu

, Jap

an

Seto-

minami, J

apan

Barcelo

na

Yoko

hama-D

aikok

u, Ja

pan

Seto-ki

ta, Ja

pan

Yokoh

aam-A

sahi,

Japa

n

Yoko

hama-T

urumi, J

apan

Hadan

o, Ja

pan

Sagam

ihara,

Japa

n

Luxe

mbourg

Stockh

olm

Kawas

aki, J

apan

Mantov

a

Ome Ja

pan

Kasum

igase

ki, Ja

pan

kg

Storage 300 - 3000 kg

0

500

1000

1500

2000

2500

3000

London Berlin TOTAL Ariake, Japan Frankfurt(InfraserveGermany)

Berlin CEP Porto Bejing Madrid

kg

On-site storage above 300 kg on current HRS in Europe, Beijing, Japan, light blue indicates stations with on-site liquefied hydrogen

On-site storage below 300 kg at current HRS in Europe and Japan

WP1 – basic HRS requirements [ ¾ Y1] (2)

ST1: Basic HRS requirements – basic HRS technologies

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WP1 – Safety Analysis [¾ Y1] (3)

CEP 1 Berlin

CEP Berlin new (Total)CUTE MadridECTOS ReykavikFrance TolouseShell WashingtonZero Regio FrankfurtZero Regio Mantova

Beijing

BP Hornchurch

ST2: Safety Analysis of Equipment and Distances for the following HRS:

• Safety Distances: methodology applied and challenges identified

• Shut Down: shut down philosophy; safety valves, ESDvalves and check valves

• Specific Safety Equipment: rupture disc, pressure relieve devices, security alarm button, fire detectors, gas detectors, gas analysers

• Physical Safety Features: dikes, crash bars, fence, locks, other physical barriers, explosion venting, emergency ventilation, fire extinguisher, deluge, emergency showers, other

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WP1 – RCS Review & Comparison [¾ Y1] (4)Document Country Definition Notes

ISO TR 15916 InternationalThe separation distance, or quantity-distance (Q-D), is a relationship between quantity of flammable or explosive material and distance separation from the exposed object(s) that provide(s) a defined type of protection.

EIGA IGC Doc 75/01 InternationalThe safety distance from a piece of equipment with inherent hazard is that minimum separation which will mitigate the effect of a likely foreseeable incident and prevent a minor incident escalating to a larger incident.

NSS 1740.16 USALocation and quantity distance (QD) requirements are based on the concept that the effects of fire, explosion, and detonation can be reduced to tolerable levels if the source of the hazard is kept far enough away from people and other fcilities

Seveso II Directive96/82/EC

EuropeIn order to provide greater protection for residential areas, areas of substantial public use and areas of particular natural interest or sensitivity, it is necessary for land-use and/or other relevant policies applied in the Member States to take account

Ministerial Decree 24/5/2002on fire prevention in NG RS

ItalyProtection distance: free area between the component and the fencing of the area in which it is located Internal safety distance: distance between the component and the other hazardous components or installations of the same plant External safety distance

High pressure gas safety law (Article 7.3 of general high pressure gas safety regulation)

Japan

Safety distance : Clearance distance between pressurized equipment and site borders, distance between dispenser and public thoroughfare, distance between pressurized equipment and flame handling facilities, distance between pressurized equipment and other

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WP1 – LH2 Vehicle RS - Draft [¾ Y1] (5)

Table of contents:

1. Introduction2. Scope3. References4. Terms and Definitions5. Properties of Hydrogen6. Design7. Safety distances and hazard zones8. Cryogenic Transfer Liquid Hydrogen Pump9. Filters10. Hydrogen vehicle refuelling stations11. Hydrogen Transfer12. Venting13. Dispensing Unit14. Electrical equipment and installations15. Fire protection16. Personnel protection and training17. Commissioning18. Maintenance and repairs19. APPENDIX A: Flow diagrams of typical liquid

hydrogen vehicle refuelling stations20. APPENDIX B: Emergency Notices21. APPENDIX C: Hazardous Area Diagrams

LIQUID HYDROGEN VEHICLE REFUELLING STATIONS (Draft)

by WP1 ST5: Development of LH2-Draft

ST5

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WP2 – HRS Handbook Compilation:Revised table of contents for Handbook established

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WP3 – Infrastructure & Deployment:• Interview protocols defined, questionnaires and information

package prepared, interview phase first interviews performed – questionnaire continuously improved

1. Identification Interviews2 Final Interview protocol

3 Performing interviews4. Reporting interviews5.Reporting draft HRS safety approach6. Presentation of draft HRS approach

7. Final report

juni juli aug

2006

april mei

2007

febsept okt nov dec jan mrt apr may jun

Planning / time schedule WP3

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Achievements in WP4 – Safety [¾ Y1] (1)

WP4 – Safety:• Safety matrix established• Identification of accident scenarios almost finalised• Agreement on safety documentation for Handbook in progress• Identification and critical review of reliability data from past

data collections and risk studies in progress

Risk Assessment• Consequence severity levels defined• Probability levels defined• Risk matrix and levels defined• Hole sizes (large/ medium/small/very small for vessels and pipes defined• Central events defined for:

reformer, electrolyser, compressor, CGH2 buffer storage, CGH2 dispenser, CGH2 and LH2trailer delivery, LH2 storage, LH2 transfer, LH2 vaporiser, LH2 dispenser, functional analysis for CGH2 and LH2, technical barriers, human barriers and open questions

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Risk matrix and risk levels

WP4 – Risk Assessment Methodology [¾ Y1] (2)

Source:Risk Assessment of hydrogen refuelling station concepts based on onsite production, S. Nilsen et al., EIHP2 project

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Proposed risk assessment table

WP4 – Risk Assessment Methodology [¾ Y1] (3)

Source:

Ref. Centralevent Causes Consequences Leak

class

Quantity ofcombustiblegas available

S P Remarks

Safety functions(limit, avoid,

control)

Technicalbarriers

Organisationalbarriers S P C Remarks Scenario to be

modelled

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WP4 – Accident Scenarios for HRS [¾ Y1] (4)

General mitigation factors applicable to all HRS:• All HRS’s are designed, constructed & operated to approved codes & standards• All HRS’s to have a prepared Emergency Response Procedure (ERP) plan• All HRS operator(s) shall be trained in ERP plans and operation of HRS as applicable.• All HRS’s to have an emergency shutdown (ESD) system or equal• Fire water supply & fire fighting equipment is available and appropriate to the size of the

HRS e.g. dry sprinkler, firewater monitor, fire extinguishers. Special attention must be paid at stations where liquid hydrogen is stored to prevent plugging vent outlets

• HRS’s comply with separation (or isolation) distances as per agreed codes & standards• HRS’s have a systematic preventative maintenance plan in place

Credible accident scenarios identified for HRS:• CGH2 dispenser @ 35 MPa• CGH2 dispenser failure at 70 MPa• LH2 dispenser failure at 3 – 8 Bar• CGH2 tanker discharge hose failure at 25 MPa• LH2 tanker discharge hose failure (11 bar max WP)• Underground line from CGH2 buffer storage or cascade priority panel to dispenser

HRS sizes (H2 onsite storage mass):• Small: < 350 kg H2• Medium: < 1,500 kg H2• Large: < 3,500 kg H2

3-4 min/ fill

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WP4 – Scenarios Selected for CFD Analysis [¾ Y1] (5)

Scenarios with relevance to customer safety (generally speaking scenarios with"low/ localised severity" in connection with dispenser):• Leakage at nozzle during refuelling (35 & 70 MPa)• Hole in dispensing line (35 & 70 MPa)• Leakage inside dispenser enclosure (CGH2)• Leakage at nozzle during refuelling (LH2 – 0.8 MPa)• Hole in dispensing line (LH2 – 0.8 MPa)

Scenarios with relevance to external safety (low probability, high severity):External safety scenarios will be studied with and without mitigation barriers in place in order to assess the risk reduction potential (and therefore the importance) of proposed safety barriers.

• Rupture of flexible dispensing hose (35 & 70 MPa)• Pupture of H2 buffer storage output line (35 & 70 MPa)• Burst of H2 storage tank (70 MPa)• Rupture of NG feed line inside production container• Trailer hose disconnection during refilling (25 MPa)• shear of hose line (LH2 – 0.8 MPa)• Tanker dispensing line disconnection during refuelling (LH2 – 1.1 MPa)• Below ground storage failure (LH2 – 0.8 MPa)

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It is realised that reliability and release data are lacking for hydrogen applications. Work is needed to close this knowledge gap. It is therefore suggested to initiate an initiative or project for this purpose in line with what has been done for non-hydrogen equipment and systems.This will enable better risk quantification and reliability analyses to be conducted also for hydrogen systems/applications like hydrogen refuelling stations. It is therefore highly recommended that initiatives are taken to plan for data collection of such data in line with what has been done throughout the years for other industries. Some work is already ongoing in this field both through the CUTE project and HySafe’s WP5 establishing HIAD, the Hydrogen Accident and Incident Database (even if HIAD is not initially intended to be a reliability type of database). It is recommended that the HyApproval, HySafe and CUTE projects that already work to assure a safe introduction of hydrogen in society cooperate and contribute with their specific competence and experiences, by joining forces in agreeing on a way forward utilising the partners’ experience in similar work and the successful database concepts that have been referred to in this document. It could be suggested to run a pilot project for hydrogen refuelling stations. In case successful, it will not be necessary in the future to use (adjusted) non-hydrogen data for release frequency estimations and reliability calculations for hydrogen applications.

WP4 – Reliability Database needed for H2 [¾ Y1] (6)

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experience as end user : ECTOS 2, Stockholm

experience as operator (e.g. bus driver, station operator) :

ECTOS, CUTE

experience from service operation

experience from official monitoring equiment/permits/

licence/The interviewees have own

experience of Hydrogen equipment

description of the sample / panel The interviewees have no

experience from Hydrogen equipment

The interviewers have supplied the information

about the hydrogen opportunities (known info

source) StorHy

The source of information is unspecified / education or mass media : ECTOS 1,

IPHE


WP5 – Dissemination, Public Awareness, Intl. Cluster Activities:• Matrix of acceptability and awareness levels of different

aspects of HRS finalised• Database of Fire Associations & First Responders established• Calendar of relevant hydrogen events established

Awareness Matrix (bifurcation):

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WP6 – Vehicle Requirements:• General interface description for 35 MPa CGH2 as J2600/

ISO 17268 finalised [recommended practice]• General interface description for 70 MPa CGH2 as draft close

to finalisation• General interface description for LH2 as draft SAE J2783 in

progress

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HyApproval is closely interlinked to the following projects:

» HySafe

» HyFleet:CUTE and ECTOS

» ZERO REGIO

» CEP

» open to further cooperation with similar upcoming EU projects

Cooperation with European Projects

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Main Dissemination Objectives

Next steps for taking forward the technicalachievements of the project

» HyApproval is the first EU project that aims at creating a universal handbook that collects the technical and regulatory requirementsbased on the expertise of all major companies and research institutes involved in the installation of the first HRS in Europe and abroad

» HyApproval therefore offers a unique first opportunity to disseminate its results to local authorities and inform them about the wealth of knowledge and experience already existing in Europe and the rest of the world on the use of hydrogen in transport applications and the requirements of installing the necessary elements of a hydrogen infrastructure

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Useful HyApproval References

l HyApproval [10/2005 - 09/2007] - www.hyapproval.org

l HySafe [03/2004 - 02/2009] - www.hysafe.net

l HarmonHy [05/2005 - 04/2006] - www.harmonhy.com

l European Integrated Hydrogen Project [1998-2000, 2001-2004] - www.eihp.org

l EU projects on H2/FC -http://europa.eu.int/comm/research/energy/pdf/h2fuell_cell_en.pdf

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Acknowledgement

This project is financed by the HyApproval partners and by funds from the European Commission under FP6 Priority [1.6] contract numberSES6 - 019813.

We would like to thank the EC that the European Hydrogen and Fuel Cell Platform provides the appropriate framework for the discussion process, and the HyApproval partners for their continuous support.

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