Safety

Air pollution and traffic congestion are two of the major issues affecting public authorities policy makers and citizens not only in Italy and European Union but worldwide; this is nowadays witnessed by always more frequent limitations to the traffic in most of Italian cities for instance. Hydrogen use in automotive appears to offer a viable solution in medium-long term; this new perspective involves the need to carry out adequate infrastructures for distribution and refuelling and consequently the need to improve knowledge on hydrogen technologies from a safety point of view. In the present work possible different configurations for gaseous hydrogen refuelling station has been compared: “stand-alone” and “multi-fuel”. These two alternative scenarios has been taken into consideration each of one with specific hypotheses: “stand-alone” configuration based on the hypothesis of a potential model consisting of a hydrogen refuelling station composed by on-site hydrogen production via electrolysis a trailer of compressed gas for back-up compressor unit intermediate storage unit and dispenser. In this model it is assumed that no other refuelling equipment and/or dispenser of traditional fuel is present in the same site. “multi-fuel” configuration where it is assumed that the same components for hydrogen refuelling station are placed in the same site beside one or more refuelling equipment and/or dispenser of traditional fuel. Comparisons have been carried out from the point of view of specific risk assessment which have been conducted on both the two alternative scenarios.

To provide more practical data for safety assessments a systematic study of explosion and combustion processes which can take place in mixtures produced by jet releases in realistic environmental conditions is required. The presented work is aimed to make step forward in this direction binding three inter-connected tasks: (i) study of horizontal and vertical jets (ii) study of the burnable clouds formed by jets in different geometry configurations and (iii) examination of combustion and explosion processes initiated in such mixtures. Test matrix for the jet experiments included variation of the release pressure and nozzle diameter with the aim to study details of the resulting hydrogen concentration and velocity profiles depending on the release conditions. In this study the following parameters were varied: mass flow rate jet nozzle diameter (to alter gas speed) and geometry of the hood located on top of the jet. The carried out experiments provided data on detailed structure for under-expanded horizontal and buoyant vertical jets and data on pressure loads resulted from deflagration of various mixtures formed by jet releases. The data on pressures waves generated in the conditions under consideration provides conservative estimation of pressure loads for realistic leaks.

Several today’s and future applications in energy technology bear the risk of the formation of flammable hydrogen/air mixtures either due to the direct use of hydrogen or due to hydrogen appearing as a by-product. If there’s the possibility of hydrogen being released accidentally into closed areas countermeasures have to be implemented in order to mitigate the threat of an explosion. In the field of nuclear safety passive auto-catalytic recombiners (PAR) are well-known devices for reducing the risk of a hydrogen detonation in a nuclear power plant in the course of a severe accident. Hydrogen and oxygen react on catalyst materials like platinum or palladium already far below conventional flammability limits. The most important concern with regard to the utilization of hydrogen  recombiners is the adequate removal of the reaction heat. Already low hydrogen concentrations may increase the system temperature beyond the self-ignition limit of hydrogen/air mixtures and may lead to an unintended ignition on hot parts of the PAR.<br/>Starting from the nuclear application since several years IEF-6 and LRST perform joint research in the field of passive auto-catalytic recombiners including experimental studies modelling and development of new design concepts. Recently approaches on specifically designed catalysts and on passive cooling devices have been successfully tested. In a design study both approaches are combined in order to provide means for efficient and safe removal of hydrogen. The paper summarizes results achieved so far and possible designs for future applications.

To make “Hydrogen vehicles and refuelling station systems” fit for public use research on hydrogen safety and designing mitigative measures are significant. For compact storage it is planned to store under high pressure (40MPa) at the refuelling stations so that the safety for the handling of high-pressurized hydrogen is essential. This paper describes the experimental investigation on the hypothetical dispersion and explosion of high-pressurized hydrogen gas which leaks through a large scale break in piping and blows down to atmosphere. At first we investigated time history of distribution of gas concentration in order to comprehend the behaviour of the dispersion of high-pressurized hydrogen gas before explosion experiments. The explosion experiments were carried out with changing the time of ignition after the start of dispersion. Hydrogen gas with the initial pressure of 40MPa was released through a nozzle of 10mm diameter. Through these experiments it was clarified that the explosion power depends not only on the concentration and volume of hydrogen/air pre-mixture but also on the turbulence characteristics before ignition. To clarify the explosion mechanism the numerical computer simulation about the same experimental conditions was performed. The initial conditions such as hydrogen distribution and turbulent characteristics were given by the results of the atmospheric diffusion simulation. By the verification of these experiments the results of CFD were fully improved.

In the frame of a sustainable development investigations dealing with massive Hydrogen production by means of nuclear heating are carried out at CEA. For nuclear safety thermodynamic efficiency and waste minimization purposes the technological solution privileged is the coupling of a gas cooled Very High Temperature Reactor (VHTR) with a plant producing Hydrogen from an Iodine/Sulfur (I/S) thermochemical cycle. Each of the aforementioned facilities presents different risks resulting from the operation of a nuclear reactor (VHTR) and from a chemical plant including Hydrogen other flammable and/or explosible substances as well as toxic ones. Due to these various risks the safety approach is an important concern. Therefore this paper deals with the preliminary CEA investigations on the safety issues devoted to the whole plant focusing on the safety questions related to the coupling between the nuclear reactor and the Hydrogen production facility. Actually the H2 production process and the energy distribution network between the plants are currently at a preliminary design stage. A general safety approach is proposed based on a Defence In Depth (DID) principle permitting to analyze all the system configurations successively in normal incidental and accidental expected operating conditions. More precisely the dynamic answer of an installation to a perturbation affecting the other one during the previous conditions as well as the potential aggressions of the chemical plant towards the nuclear reactor have to be considered. The methodology presented in this paper is intended to help the designer to take into account the coupling safety constraints and to provide some recommendations on the global architecture of both plants especially on their coupling system. As a result the design of a VHTR combined to a H2 production process will require an iterative process between design and safety requirements.

Hydrogen energy is very promising as it ensures a high efficiency and ecological cleanliness of energy conversion. The goal of the present work is to provide the analysis of hydrogen safety aspects and to prescribe methods of safety operation with hydrogen. The authors conducted a hazard analysis of hydrogen operation and storage in comparison with other fuels. Good ventilation is the main hydrogen operation requirement. Besides an effective way of protection against propagation of hazards (for instance leaks) is neutralization of dangerous hydrogen-air mixtures by a method of controlled catalytic combustion inside special devices so-called recombiners [1-3]. The basis of these devices is a high porosity cell material (HPCM) activated by platinum deposition. Apart from recombiners HPCM was also applied for development of hydrogen detectors intended for measurement and analysis of hydrogen concentration for hydrogen-driven transport and objects of hydrogen infrastructure (including vapor-air media at high pressure and  temperatures). A system of hydrogen safety based on hydrogen detectors and hydrogen catalytic recombiners was developed. Experimental and theoretical studies of hydrogen combustion processes heat- and mass transfer and also gas flows in catalytic-activated HPCM allowed for a design optimization of recombiners and their location. Pilot hydrogen detectors and hydrogen catalytic recombiners were fabricated and their laboratory tests were successfully performed. Thus it was indicated that on condition of following the  appropriate passive and active safety measures hydrogen is just as safe as the other fuels. This conclusion represents another incentive for a transition to the hydrogen energy.

For decades risk assessment has been an important tool in risk management of activities in several industries world wide. It provides among others authorities and stakeholders with a sound basis for creating awareness about existing and potential hazards and risks and making decisions related to how they can prioritise and plan expenditures on risk reduction. The overall goal of the ongoing HySafe project is to contribute to the safe transition to a more sustainable development in Europe by facilitating the safe introduction of hydrogen technologies and applications. An essential element in this is the demonstration of safety: that all safety aspects related to production transportation and public use are controlled to avoid that introducing hydrogen as energy carrier should pose unacceptable risk to the society.<br/>History has proven that introducing risk analysis to new industries is beneficial e.g. in transportation and power production and distribution. However this will require existing methods and standards to be adapted to the specific applications. Furthermore when trying to quantify risk it is of utmost importance to have access to relevant accident and incident information. Such data may in many cases not be readily available and the utilisation of them will then require specific and long lasting data collection initiatives.<br/>In this paper we will present the work that has been undertaken in the HySafe project in developing methodologies and collecting data for risk management of hydrogen infrastructure. Focus is laid on the development of risk acceptance criteria and on the demonstration of safety and benefits to the public. A trustworthy demonstration of safety will have to be based on facts especially on facts widely known and emphasis will thus be put on the efforts taken to establish and operate a database containing hydrogen accident and incident information which can be utilised in risk assessment of hydrogen applications. A demonstration of safety will also have to include a demonstration of risk control measures and the paper will also present work carried out on safety distances and ignition source control.

​This paper discusses the results of validation of Computational Fluid Dynamics (CFD) modelling of hydrogen releases and dispersion inside a metal container imitating a single car garage based on experimental results. The said experiments and modelling were conducted as part of activities to predict fuel cell vehicles discharge flammability and potential build-up of hydrogen for the development of test procedures for the Recommended Practice for General Fuel Cell Vehicle Safety SAE J2578. The experimental setup included 9 hydrogen detectors located in each corner and in the middle of the roof of the container and a fan to ensure uniform mixing of the released hydrogen. The PHOENICS CFD software package was used to solve the continuity momentum and concentration equations with the appropriate boundary conditions buoyancy effect and turbulence models. Obtained modelling results matched experimental data of a high-rate injection of hydrogen with fan-forced dispersion used to create near-uniform mixtures with a high degree of accuracy. This supports the conclusion that CFD modelling will be able to predict potential accumulation of hydrogen beyond the experimental conditions. CFD modelling of hydrogen concentrations has proven to be reliable effective and relatively inexpensive tool to evaluate the effects of hydrogen discharge from hydrogen powered vehicles or other hydrogen containing equipment.​

In October 2004 the International Energy Agency Hydrogen Implementing Agreement (www.ieahia.org) approved the initiation of a collaborative task on hydrogen safety. During the past twelve months a work plan has been established and several member countries have committed to participate. Because of the nature of the International Energy Agency which is an international agreement between governments it is hoped that such collaboration will complement other cooperative efforts to help build the technology base around which codes and standards can be developed. In this way the new task on hydrogen safety will further the IEA Hydrogen Agreement in fulfilling its mission to accelerate the commercial introduction of hydrogen energy. This paper describes the specific scope and work plan for the collaboration that has been developed to date.

The detection of hydrogen after its accidental release is not only important for research purposes but will be much more important under safety aspects for future applications when hydrogen should be a standard energy resource. At Fraunhofer ICT two principally different approaches were made: first the new optical background-oriented schlieren method (BOS) is used for the visualization of hydrogen distribution and mixing processes at a rate of up to 1000 frames per second. The results from experiments with small scale injection of hydrogen/air–mixtures into air flows and free jets of hydrogen and hydrogen/air–mixtures emerging from 1” hoses simulating exhaust pipes will be discussed and interpreted with support from selected high speed videos. Finally mixing zones and safety distances can be determined by this powerful method.

Introduction and commercialisation of hydrogen as an energy carrier of the future make great demands on all aspects of safety. Safety is a critical issue for innovations as it influences the economic attractiveness and public acceptance of any new idea or product. However research and safety expertise related to hydrogen is quite fragmented in Europe. The vision of a significant increased use of hydrogen as an energy carrier in Europe could not go ahead without strengthening and merging this expertise. This was the reason for the European Commission to support the launch on the first of March 2004 of a so-called Network of Excellence (NoE) on hydrogen safety: HySafe.

In this document after a review of the accidents/incidents are described the different interactions between hydrogen gas and the most commonly used materials including the influence of "internal" and "external" hydrogen the phenomena occurring in all ranges of temperatures and pressures and Hydrogen Embrittlement (HE) created by gaseous hydrogen. The principle of all the test methods used to investigate this phenomenon are presented and discussed. The advantages and disadvantages of each method will be explained. The document also covers the influence of all the parameters related to HE including the ones related to the material itself the ones related to the design and manufacture of the equipment and the ones related to the hydrogen itself (pressure temperature purity etc). Finally recommendations to avoid repetition of accidents/incidents mentioned before are proposed.

The following paper describes researches to evaluate the behaviour under various accidental conditions of systems of transport compressed hydrogen. Particularly have been considered gaseous tube trailer and the packages cylinders employed for the road transport which have an internal gas pressures up to 200 barg.<br/>Further to a verification of the actual safety conditions this analysis intends to propose a theme that in the next future if confirmed projects around the employment of hydrogen as possible source energetic alternative could become quite important. The general increase of the consumptions of hydrogen and the consequently probable increase of the transports of gaseous hydrogen in pressure they will make the problem of the safety of the gaseous tube trail particularly important. Gaseous tube trailers will also use as components of plant. for versatility easy availability' and inexpensiveness.<br/>The first part of the memory is related to the analysis of the accidents happened in the last year in Italy with compressed hydrogen transports and particularly an accurate study has been made on the behaviour of a gaseous tube trailer involved in fire following a motorway accident in March 2003. In the central part of the job has been done a safety analysis of the described events trying to make to also emerge the most critical elements towards the activities developed by the teams of help intervened.<br/>Finally in the last part you are been listed on the base of the picked data a series of proposals and indications of the possible structural and procedural changes that could be suggested with the purpose to guarantee more elevated safety levels.

This paper presents the current results of the theoretical and experimental activity carried out by the Italian Working Group on the fire prevention safety issues in the field of the hydrogen transport in pipelines. From the theoretical point of view a draft document has been produced beginning from the regulations in force on the natural gas pipelines; these have been reviewed corrected and integrated with the instructions suitable to the use with hydrogen gas. From the experimental point of view a suitable apparatus has been designed and installed at the University of Pisa; this apparatus will allow the simulation of hydrogen releases from a pipeline with or without ignition of the hydrogen-air mixture. The experimental data will help the completion of the above-mentioned draft document with the instructions about the safety distances. However in the opinion of the Group the work on the text contents is concluded and the document is ready to be discussed with the Italian stakeholders involved in the hydrogen applications.

We performed a hydrogen combustion analysis in the Advanced Power Reactor 1400 MWe (APR1400) containment during a severe accident initiated by a small break loss of coolant accident (SBLOCA) which occurred at a lower part of the cold leg using a multi-dimensional hydrogen analysis system (MHAS) to confirm the integrity of the APR1400 containment. The MHAS was developed by combining MAAP GASFLOW and COM3D to simulate hydrogen release distribution and combustion in the containment of a nuclear power plant during the severe accidents in the containment of a nuclear power reactor. The calculated peak pressure due to the flame acceleration by the COM3D using the GASFLOW results as an initial condition of the hydrogen distribution was approximately 555 kPa which is lower than the fracture pressure 1223 kPa of the APR1400 containment. To induce a higher peak pressure resulted from a strong flame acceleration in the containment we intentionally assumed several things in developing an accident scenario of the SBLOCA. Therefore we may judge that the integrity of the APR1400 containment can be maintained even though the hydrogen combustion occurs during the severe accident initiated by the SBLOCA.

The paper presents CFD simulations of high pressure hydrogen release and dispersion inside the storage room of realistic hydrogen refuelling station and comparison to experimental data. The experiments were those reported by Tanaka et al. (2005) carried out inside an enclosure 5 m wide 6 m long and 4 m high having 1 m high ventilation opening on all sidewalls (half or fully open) containing an array of 35 x 250 L cylinders. The scenarios investigated were 40 MPa storage pressure horizontal releases from the center of the room from one cylinder with orifices of diameters 0.8 1.6 and 8 mm. The release calculations were performed using GAJET integral code. The CFD dispersion simulations were performed using the ADREA-HF CFD code. The structure of the flow and the mixing patterns were also investigated by presenting the predicted hydrogen concentration field. Finally the effects of release parameters natural ventilation and wind conditions were analyzed too.

Interest in the future is not new. Economic constraints and acceptability considerations of today compel decision-makers from industry and authorities to speculate on possible safety risks originating from a hydrogen economy developed in the future. Tools that support thinking about the long-term consequences of today's actions and resulting technical systems are usually prognostic based on data from past performance of past or current systems. It has become convention to assume that the performance of future systems in future environments can be accommodated in the uncertainties of such prognostic models resulting from sensitivity studies. This paper presents an alternative approach to modelling future systems based on narratives about the future. Such narratives based on the actions and interactions of individual "agents" are powerful means for addressing anxiety about engaging the imagination in order to prepare for events that are likely to occur detect critical conditions and to thus achieve desirable outcomes. This is the methodological base of Agent-Based Models (ABM) and this paper will present the approach discuss its strengths and weaknesses and present a preliminary application to modelling safety risks related to energy scenarios in a possible future hydrogen economy.

Safety-barrier diagrams have proven to be a useful tool in documenting the safety measures taken to prevent incidents and accidents in process industry. In Denmark they are used to inform the authorities and the nonexperts on safety relevant issues as safety-barrier diagrams are less complex compared to fault trees and are easy to understand. Internationally there is a growing interest in this concept with the use of so-called “bowtie” diagrams which are a special case of safety-barrier diagrams. Especially during the on-going introduction of new hydrogen technologies or applications as e.g. hydrogen refueling stations this technique is considered a valuable tool to support the communication with authorities and other stakeholders during the permitting process. Another advantage of safety-barrier diagrams is that there is a direct focus on those system elements that need to be subject to safety management in terms of design and installation operational use inspection and monitoring and maintenance. Safety-barrier diagrams support both quantitative and qualitative or deterministic approaches. The paper will describe the background and syntax of the methodology and thereafter the use of such diagrams for hydrogen technologies are demonstrated.

In close cooperation with their Canadian counterparts United States public safety authorities are taking the first steps towards creating a proper infrastructure to ensure the safe use of the new hydrogen fuel cells now being introduced commercially. Currently public safety officials are being asked to permit hydrogen fuel cells for stationary power and as emergency power backups for the telecommunications towers that exist everywhere. Consistent application of the safety codes is difficult – in part because it is new – yet it is far more complex to train emergency responders to deal safely with the inevitable hydrogen incidents. The US and Canadian building and fire codes and standards are similar but not identical. The US and Canadian rules are unlikely to be useful to other nations without modification to suit different regulatory systems. However emergency responder safety training is potentially more universal. The risks strategies and tactics are unlikely to differ much by region. The Hydrogen Executive Leadership Panel (HELP) made emergency responder safety training its first priority because the transition to hydrogen depends on keeping incidents small and inoffensive and the public and responders safe from harm. One might think that advising 1.2 million firefighters and 800000 law enforcement officers about hydrogen risks is no more complicated than adding guidance to a website. One would be wrong. The term “training” has specific legal implications which may vary by state. For hazardous materials federal requirements apply. Insurance companies place training requirements on the policies they sell to fire departments including the thousands of small all-volunteer departments which may operate as private corporations. Union contracts may define training and promotions may be based on satisfactorily completed certain levels of training. Emergency responders could no sooner learn how to extinguish a<br/>hydrogen fire by reading a webpage than a person could learn to ride a bicycle by reading a book. Procedures must be learned by listening reading and then doing. Regular practice is necessary. As new hydrogen applications are commercialized additional responder training may be necessary. This highlights another obstacle emergency responders’ ability to travel distances and take the time to undergo training. Historically fire academies established adjunct instructor programs and satellite academies to bring the training to firefighters. The large well-equipped academies are typically used for specialized training. States rarely have enough instructors and instructors often must take the time to create a course outline research each point and produce a program that is informative useful and holds the attention of responders. The challenge of training emergency responders seems next to impossible but public safety authorities are asked to tackle the impossible every day and a model exists to move forward in the U.S. Over the past few years the National Association of State Fire Marshals and U.S. Department of Transportation enlisted the help of emergency responders and industry to create a standardized approach to train emergency responders to deal with pipeline incidents. A curriculum and training materials were created and more than 26000 sets have been distributed for free to public safety agencies nationwide. More than 8000 instructors have been trained to use these materials that are now part of the regular training in 23 states. Using this model HELP intends to ensure that all emergency responders are trained to address hydrogen risks. The model and the rigorous scenario analysis and review used to developing the operational and technical training is addressed in this paper.

The permitting process for hydrogen fueling stations varies from country to country. However a common step in the permitting process is the demonstration that the proposed fueling station meets certain safety requirements. Currently many permitting authorities rely on compliance with well known codes and standards as a means to permit a facility. Current codes and standards for hydrogen facilities require certain safety features specify equipment made of material suitable for hydrogen environment and include separation or safety distances. Thus compliance with the code and standard requirements is widely accepted as evidence of a safe design. However to ensure that a hydrogen facility is indeed safe the code and standard requirements should be identified using a risk-informed process that utilizes an acceptable level of risk. When compliance with one or more code or standard requirements is not possible an evaluation of the risk associated with the exemptions to the requirements should be understood and conveyed to the Authority Having Jurisdiction (AHJ). Establishment of a consistent risk assessment toolset and associated data is essential to performing these risk evaluations. This paper describes an approach for risk-informing the permitting process for hydrogen fueling stations that relies primarily on the establishment of risk-informed codes and standards. The proposed risk-informed process begins with the establishment of acceptable risk criteria associated with the operation of hydrogen fueling stations. Using accepted Quantitative Risk Assessment (QRA) techniques and the established risk criteria the minimum code and standard requirements necessary to ensure the safe operation of hydrogen facilities can be identified. Risk informed permitting processes exist in some countries and are being developed in others. To facilitate consistent risk-informed approaches the participants in the International Energy Agency (IEA) Task 19 on hydrogen safety are working to identify acceptable risk criteria QRA models and supporting data.

The paper presented experimental studies of the liftoff and blowout stability of pure hydrogen hydrogen/propane and hydrogen/methane jet flam es using a 2 mm burner. Carbon dioxide and Argon gas were also used in the study for the comparison with hydrocarbon fuel. Comparisons of the stability of H 2/C3H8 H 2/CH4 H 2/Ar and H 2/CO2 flames showed that H 2/C3H8 produced the highest liftoff height and H 2/CH4 required highest liftoff and blowoff velocities. The non-dimensional analysis of liftoff height approach was used to correlate liftoff data of H 2 H2-C3H8 H 2-CO2 C 3H8 and H2-Ar jet flames tested in the 2 mm burner. The suitability of extending the empirical correlations based on hydrocarbon flames to both hydrogen and hydrogen/ hydrocarbon flames was examined.

The rapid evolution of information related to hydrogen safety is multidimensional ranging from developing codes and standards to CFD simulations and experimental studies of hydrogen releases to a variety of risk assessment approaches. This information needs to be transformed into system design risk decision-making and first responder tools for use by hydrogen community stakeholders. The Canadian Transportation Fuel Cell Alliance (CTFCA) has developed HySTARtm an interactive Hydrogen Safety Training And Risk System. The HySTARtm user interacts with a Web-based 3-D graphical user interface to input hydrogen system configurations. The system includes a Codes and Standards Expert System that identifies the applicable codes and standards in a number of national jurisdictions that apply to the facility and its components. A Siting Compliance and Planning Expert System assesses compliance with clearance distance requirements in these jurisdictions. Incorporating the results of other CTFCA projects HySTARtm identifies stand-out hydrogen release scenarios and their corresponding release condition that serves as input to built-in consequence and risk assessment programs that output a variety of risk assessment metrics. The latter include on- and off-site individual risk probability of loss of life and expected number of fatalities. These results are displayed on the graphical user interface used to set up the facility. These content and graphical tools are also used to educate regulatory approval and permitting officials and build a first-responder training guide.

This paper presents results from laboratory experiments with hydrogen dispersions and explosions in a 3 m long channel. Our objective is to get a better understanding of the phenomena and to develop tools that can analyse hydrogen dispersions and explosions. A total of 5 test series were performed with flow rates of hydrogen from 1.8 dm³/min to 75 dm³/min. The propagation of the combustible hydrogen-air cloud in the channel was observed from high-speed video recordings. The hydrogen-air cloud in the channel behaves as a gravity current and the flow appears to be well described by Froude scaling with a length scale corresponding to the height of a layer of 100 % hydrogen. The Froude numbers observed in the experiments are in good agreement with the theory of "light-fluid intrusion" for gravity currents found in the literature. Numerical simulations with the Flacs code correlate well with the experimental results. The flame propagation indicated that approximately half the height of the channel was filled with combustible mixture. We believe that this Froude scaling can be useful as a tool to analyse the consequences of hydrogen release in buildings channels and tunnels.

Hydrogen stations and supply systems for public transport have been demonstrated in a number of European cities during the last four years. The first refuelling facility was put into operation in Reykjavik in April 2003. Experience from the four years of operation shows that safety related incidents are more frequent in the user interface than in the other parts of the hydrogen refuelling station (HRS). This might be expected taking into account the fact that the refuelling is manually operated and that according to industrial statistics human failures normally stand for more than 80% of all safety related incidents. On the other hand the HRS experience needs special attention since the refuelling at the existing stations is carried out by well trained personnel and that procedures and systems are followed closely. So far the quality and safety approach to hydrogen refuelling stations has been based on industrial experience. This paper addresses the challenge related to the development of safe robust and easy to operate refuelling systems. Such systems require well adapted components and system solutions as well as user procedures. The challenge to adapt the industrial based quality and safety philosophy and methodologies to new hydrogen applications and customers in the public sector is addressed. Risk based safety management and risk acceptance criteria relevant to users and third party are discussed in this context. Human factors and the use of incident reporting as a tool for continuous improvement are also addressed. The paper is based on internal development programmes for hydrogen refuelling stations in Hydro and on participation in international EU and IPHE projects such as CUTE HyFLEET:CUTE HySafe and HyApproval.

In the last years different Italian hydrogen projects provided for gaseous hydrogen motor vehicles refuelling stations. Motivated by the lack of suitable set of rules in the year 2002 Italian National Firecorps (Institute under the Italian Ministry of the Interior) formed an Ad Hoc Working Group asked to regulate the above-said stations as regards fire prevention and protection safety. This Working Group consists of members coming from both Firecorps and academic world (Pisa University). Throughout his work this Group produced a technical rule covering the fire prevention requirements for design construction and operation of gaseous hydrogen refuelling stations. This document has been approved by the Ministry’s Technical Scientific Central Committee for fire prevention (C.C.T.S.) and now it has to carry out the “Community procedure for the provision of information”. This paper describes the main safety contents of the technical rule.