Research for Hydrogen Safety,

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Research for Hydrogen Safety, Codes Standards
Research for Hydrogen Safety, Codes Standards
An Integrated Approach
Antonio Ruiz U.S. Department of Energy Hydrogen
Program
International Conference on Hydrogen Safety San
Sebastián, Spain September 2007
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POLICY CONTEXT Presidential Energy Initiatives
Addressing Challenges through Technology
Development

• HYDROGEN FUEL INITIATIVE (January 2003)
• 1.2 billion over five years
• Establishes partnerships with private sector
• Develops hydrogen, fuel cell and infrastructure
  technologies
• Goal to make fuel cell vehicles practical and
  cost-effective by 2020

H F I

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DOE HYDROGEN PROGRAM PARTICIPANTS
Office of Energy Efficiency Renewable
Energy Research, develop, and validate fuel cell
and H2 production, delivery, and storage
technologies for transportation and stationary
applications. Office of Fossil Energy Continue
studies for scaling up hydrogen membrane reactors
and CO2/H2 separation technologies for coal-based
hydrogen systems. Office of Nuclear
Energy Operate sulfur-iodine thermochemical and
high-temperature electrolysis experiments to
gather data on operability and reaction
rates. Office of Science Expand basic research
on nano-materials for storage, catalysis for fuel
cells, and bio-inspired and solar H2 production.
Increase emphasis on nano-structured design,
novel synthesis, and theory and modeling of the
physical and chemical interactions of hydrogen
with materials.
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HYDROGEN FUEL INITIATIVE TOTAL FUNDING

• President Bush committed 1.2 billion over 5
  years (FY04 FY08) to accelerate RD to enable
  technology readiness in 2015.

• Presidents cumulative request of 1.267 B (for
  FY04 FY08) has been consistent with the
  original commitment of 1.2 B.

• Congress has been supportive Appropriations of
  885M for FY04 FY07.

1 Includes EERE, FE, NE, SC and Department of
Transportation
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DOE HYDROGEN PROGRAM BUDGET by Office
Does not include Department of Transportation
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HYDROGEN PROGRAM MISSIONReduce Oil Consumption
and GHG Emissions
The Hydrogen Program mission is to research,
develop, and validate hydrogen production,
storage, and fuel cell technologies to reduce
dependence on oil in the transportation sector,
and to enable clean, reliable energy for
stationary and portable power generation.
U.S. Greenhouse Gas Emissions
U.S. Oil Consumption
GOAL
GOAL
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HYDROGEN PROGRAM SPENDING A balanced, diverse
portfolio
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HYDROGEN PROGRAM STRUCTURE
Research is at the core of the DOE H2 Program
Funds basic research, applied research and
development, and learning demonstrations to
advance and validate hydrogen and fuel cell
technologies.
TECHNOLOGY RD and VALIDATION
Ensures safe practices within the Program and
disseminates safety information to the industry.
Safety
Works with established national organizations to
lay the groundwork for technically sound codes
standards.
Codes Standards
Enables understanding and assessment of
technology needs and progress supports program
decision-making, planning, and budgeting.
Sytems Integration/Analysis
Overcomes knowledge barriers, by conducting
outreach and providing information for training
programs.
Education
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SAFETY, CODES STANDARDS PROGRAM GOALS

• To develop and implement practices and procedures
  that will ensure safety in the operation,
  handling, and use of hydrogen and hydrogen
  systems for all DOE funded projects.
• To perform the underlying research to enable
  codes and standards to be developed for the safe
  use of hydrogen in all applications.
• And to facilitate the development and
  harmonization of domestic and international codes
  and standards.

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SAFETY, CODES STANDARDS BUDGET Fiscal Year 2007
Total 13.8 million
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Challenges

• Limited historical data / insufficient technical
  and performance data to develop and revise
  standards
• Large number of Authorities Having Jurisdiction
• Lack of uniform training of officials
• Lack of standard practices for safety assessments
• Lack of integrated, coordinated approach among
  CS Organizations
• Lack of harmonization of domestic and
  international standards
• Limited government influence on CS process
• Limited DOE role in international CS development
  process

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RESEARCH NEEDS ARE IDENTIFIED IN COOPERATION WITH
INDUSTRY
Roadmap detailing information gaps for the
following target areas ensures RDD efforts are
properly directed.

• Hydrogen Behavior (physical/chemical,
  combustion/flammability, materials properties,
  sensing/mitigation)
• Vehicles(fuel storage system, components,
  sensors, whole vehicle, failure modes)
• Infrastructure(production, terminals/distribution
  /delivery, refueling stations)
• Interface(fuel quality, feedback strategies,
  refueling components)

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MATERIALS COMPATIBILITY TESTING

• TWO OBJECTIVES
• Generate benchmark H2 cracking thresholds for
  low-alloy steels currently in codes for seamless
  pressure vessels
• Establish best procedures for testing in H2

Version 1.0 of Technical Reference for H2
Compatibility of Materials Complete www.ca.sandia.
gov/matlsTechRef

• Increased material strength lowers threshold for
  H2-assisted crack growth
• Increased H2 gas pressure lowers threshold for
  H2-assisted crack growth

first data points in 30 years at PH2gt100 MPa
H2 compatibility of 316 stainless steel can be
optimized by controlling composition,
particularly nickel content. Carbon content seems
to be less important
ASME SA-372 Grade J steel is relatively resistant
to hydrogen-assisted fracture at high-pressure
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HYDROGEN BEHAVIOR
Flame Characterization
Experimentally Measure Heat Flux
Impinging jet, 10 ft impingement diameter
Thermal Radiation Models
C(x/L) 4 p R 2 qrad(x/L) / Srad
Flammability Limits and Ignition Probabilities
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HYDROGEN JET AND FLAME BEHAVIORH2 jets and
flames are similar to other flammable gases

• Fraction of chemical energy converted to thermal
  radiation
• Radiation heat flux distribution
• Jet length

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BARRIER WALLS AS A MITIGATION STRATEGY

• Goal determine if barriers are an effective jet
  mitigation technique since mixtures of H2 and air
  can ignite and potentially generate large
  overpressures.
• Contributing member of the HYPER project in
  Europe.

Over-pressure characterization

• Characterize H2 transport and mixing near barrier
  walls through combined experiment and modeling
• Identify conditions leading to deflagration or
  detonation
• residence time and ignition timing
• magnitude of over-pressure and duration
• Develop correlations for wall heights dependency
  and wall-standoff distances

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H2 JET BEHAVIOR NEAR BARRIER WALLS

• Characterize stabilization of H2 jet flame on and
  behind barrier
• Characterize thermal/structural integrity of
  barriers
• Use CFD modeling and validation for H2 jet flames
  to minimize the number of tests
• Develop correlations for wall height dependencies
  and wall stand-off distances
• Combine data and analysis with quantitative risk
  assessment for barrier configuration guidance

Barlow flame A (ref. Combustion and Flame, v.
117, pp. 4-31, 1999)
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QUANTITATIVE RISK ASSESSMENT A Traceable
Technical Basis for Code Development
Sample architecture from NREL H2 Station Simulator

• Quantitative risk assessment (QRA) provides a
  framework for making risk-informed decisions.
• We are applying QRA to help define refueling
  setbacks.
• Likelihood of events is estimated from component
  reliability and architecture-based FMEA studies.
• Event consequences are quantified using
  engineering models from the research program and
  published data.
• Consequences are integrated and evaluated
  relative to acceptable risk metrics.
• Site-specific mitigation strategies should be
  identified where appropriate.

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USING QRA TO CONSIDER SEPARATION DISTANCES FOR H2
FACILITIES

• Current code separation distances are not
  reflective of future fueling station operations
  (e.g., 70 MPa)
• Facility parameters (e.g., operating pressure and
  volume) should be used to delineate separation
  distances
• Consequence-based separation distances (i.e.,
  single event) can be large depending on pressure,
  leak size, and consequence parameter
• QRA insights are being considered by NFPA-2 to
  help establish meaningful separation distances
  and other code requirements

Leak Diameter (mm)
Consequence Parameter
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QRA Towards a Risk-informed Code Development
Framework

• Quantitative Risk Assessment (QRA) provides code
  developers with risk insights to help define
  codes and standards requirements
• requires quantification of consequences from of
  all possible accidents
• requires definition of event frequencies
• requires definition of acceptable risk levels and
  metrics
• Accounts for parameter and modeling uncertainty
  present in analysis evaluates importance of risk
  assumptions through sensitivity analysis

example
Risk Frequency x Consequence
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HIGH-PRESSURE (70MPa) REFUELING

• 25 Fueling Trials at Powertech with 4 individual
  tanks (not system type 3 and type 4 tanks used
  ranging from 34 to 130 L)
• Evaluated SAE J2601 targets regarding fill
  density/time changes between different fueling
  methods w/ and w/out pre-cooling communications
• Preliminary Results Precooling is needed to
  achieve fueling in a short amount of time, in
  some cases also communications
• Results were used to formulate the follow-on work

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HIGH-PRESSURE REFUELING AT THE SYSTEM LEVEL
2007 Government/Industry 70MPa Multi-Client Study

• Purpose accelerate progress of informed
  standards for hydrogen vehicle fueling utilizing
  real vehicle and station hardware
• Why? Not enough information currently available
  for standards organizations on fueling protocol
  and station hardware
• OEMs to bring their onboard storage systems to
  third party organizations (Powertech JARI) also
  as in-kind contribution to the project
• Participants DCX, Ford, GM, Honda, Nissan,
  Toyota
• Funding Energy Companies Government
• Air Liquide, BP, Linde, Nippon Oil, Sandia (DOE),
  Shell
• Modeling effort at Sandia for on-board storage
  and hydrogen station dispensing

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FUEL QUALITY Relative Tradeoffs Identified

• To date, the North American industry-government
  team has identified the following as critical
  constituents around which near-term RD and
  testing should be focused
• CO
• S compounds
• He
• CH4 and inerts
• NH3
• Particulate Matter (lt10µ
• diameter)
• This list may change and other critical
  constituents may be identified as RD and testing
  proceed

CRITICAL CONSTITUENTS
SPECIFICATION TRADEOFFS
Sulfur species
Ammonia
Carbon Monoxide
Aromatic Aliphatic HCs
Low High
Impact on Fuel Cell
Oxygen
Methane
Carbon Dioxide
Nitrogen
Helium
Low High
Difficulty to Attain and Verify Level
Source Shell Hydrogen
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SUMMARY OF FUEL QUALITY PROGRESS

• Consensus national and international fuel quality
  guidelines available
• ISO Technical Specification (TS 14687-2) approved
  and in press
• ISO TS and SAE J2719 are nearly identical
• Significant progress on RD/testing to obtain
  data needed to convert guidelines into standards
• Test protocol, test matrix, data reporting format
  adopted
• Testing underway at LANL, HNEI
• FQ solicitation winners integrated into overall
  effort
• International collaboration underway
• Modeling subgroup formed
• International and national standards under
  preparation
• Committee draft for ISO standard
• Updating of SAE J2719

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OBSTACLES TO LINKING RD AND CODES STANDARDS
DEVELOPMENT

• Different timetables
• Codes and standards development process has set
  timetables and deadlines for public notice,
  public hearings/comment, publication
• RD does not (cannot) follow a set timetable
• Different purposes and perspectives
• RD addresses scientific problems, e.g., hydrogen
  behavior under given release, confinement,
  ignition conditions
• CS 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 CS
  technical committee members essential
• Cannot be limited to one-time presentations,
  testimony
• Researchers must be integrated into technical
  committees
• CS technical committee members must become
  familiar with RD objectives, process,
  limitations (uncertainty, error bars)

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DEVELOPMENT OF CODES, STANDARDS, AND REGULATIONS
2015
2004
2010
Research
RD Roadmap
Domestic Codes Standards
Standards
National Template
Codes
Global Technical Regulations (GTR)
IEC, ISO
GRPE
International Coordination
GTR
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Regulators Guide to Permitting Hydrogen
Technologies
Objective Help code officials sort through
applicable codes and standards when permitting
hydrogen facilities.

• Content Covers stationary fuel cells for
• commercial buildings and hydrogen motor
• fuel dispensing facilities and includes
• Hydrogen's use as a fuel
• The regulatory process
• Relevant codes and standards
• Partners
• National Fire Protection Association
• International Code Council
• Pacific Northwest National Laboratory
• National Renewable Energy Laboratory

• 1 Foundation and Protection
• 2 Fire Protection Systems
• 3 Piping Components and Connections
• 4 Ventilation, Exhaust, and Makeup Air
• 5 Siting, Installation, and Protection
• 6 Fuel Supply and Storage
• 7 Interconnections

Typical installation requirements for a fuel cell
in a commercial building
Module 1 - Permitting Stationary Fuel Cell
Installations Module 2 - Permitting Hydrogen
Motor Fuel Dispensing Facilities
www.eere.energy.gov/hydrogenandfuelcells/codes/per
mitting_guides.html
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www.fuelcellstandards.com

• Web site maintains
• The status of all fuel cell codes and standards
  activities
• Calendar of meetings and other significant dates
• Bulletin board for posting questions and answers

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Permitting HFS DOE Initiative

• Information Toolkit
• Fact sheet(s)
• basic information on HFS (examples,
  codes/standards typically used, information
  sources)
• Network chart
• contact list of code officials whose
  jurisdictions have issued permits for HFS
• Flowchart of permitting requirements
• web-based map to navigate requirements with
  database of key standards and codes
• HFS Permitting Compendium
• web-based notebook and database
• Education-outreach workshops for code officials
• National workshops with NASFM, NCSBCS
• vet case studies, CS permitting process,
  information tools
• Workshops in key regions
• locations where industry will focus H2
  infrastructure development and vehicle deployment

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Remaining Challenges

• Open Issues/Remaining Barriers
• Difficult permitting process for retail hydrogen
  facilities
• Delayed adoption of approved codes and standards
• Synchronizing codes and standards development and
  adoption with technology commercialization needs
• Future Research Direction
• QRA Identify necessary event frequency, define
  maintenance protocols, secure frequency data
• Fuel Quality Continue collaborative
  international RD testing effort.
• 70MPa Complete expanded cross-industry test
  program, demonstration project data needed
• Materials Compatibility Expand on the completed
  initial materials set -initiate investigation of
  composite and other materials
• Provide technical support/ guidance to local code
  officials to facilitate permitting of retail
  hydrogen facilities

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ONLINE INFORMATION TOOLS

• H2 INCIDENTS DATABASE
• Information on hydrogen incidents and lessons
  learned
• Over 100 incidents documented

• BIBLIOGRAPHIC DATABASE
• Contains 400 documents related to hydrogen
  safety
• Will contain 650 by end of FY 2007

www.h2incidents.org
www.hydrogen.energy.gov
Hydrogen Safety Best Practices Manual Under
Development Dec. 2007
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FOR MORE INFORMATION
www.hydrogen.energy.gov
Antonio Ruiz antonio.ruiz_at_ee.doe.gov 1
202-586-0729
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ESKERRIK ASKO
THANK YOU
GRACIAS
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MERCI
GRÀCIES
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OBRIGADO
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DANKE
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GRAZIE