Safety
Monte-Carlo-Analysis of Minimum Burst Requirements for Composite Cylinders for Hydrogen Service
Sep 2021
Publication
For achieving Net Zero-aims hydrogen is an indispensable component probably the main component. For the usage of hydrogen a wide acceptance is necessary which requires trust in hydrogen based on absence of major incidents resulting from a high safety level. Burst tests stand for a type of testing that is used in every test standard and regulation as one of the key issues for ensuring safety in use. The central role of burst and proof test is grown to historical reasons for steam engines and steel vessels but - with respect for composite pressure vessels (CPVs) - not due an extraordinary depth of outcomes. Its importance results from the relatively simple test process with relatively low costs and gets its importance by running of the different test variations in parallel. In relevant test und production standards (as e. g. ECE R134) the burst test is used in at least 4 different meanings. There is the burst test on a) new CPVs and some others b) for determining the residual strength subsequent to various simulations of ageing effects. Both are performed during the approval process on a pre-series. Then there is c) the batch testing during the CPVs production and finally d) the 100% proof testing which means to stop the burst test at a certain pressure level. These different aspects of burst tests are analysed and compared with respect to its importance for the resulting safety of the populations of CPVs in service based on experienced test results and Monte-Carlo simulations. As main criterial for this the expected failure rate in a probabilistic meaning is used. This finally ends up with recommendations for relevant RC&S especially with respect to GTR 13."
Hydrogen Inhibition as Explosion Prevention in Wet Metal Dust Removal Systems
Mar 2022
Publication
Hydrogen energy attracts an amount of attention as an environmentally friendly and sustainable energy source. However hydrogen is also flammable. Hydrogen fires and explosions might occur in wet-dust-removal systems if accumulated aluminum dust reacts with water. Hydrogen inhibition is a safe method to address these issues. For this purpose we used sodium citrate a renewable and nontoxic raw material to inhibit H2 formation. Specifically hydrogen inhibition experiments with sodium citrate were carried out using custom-built equipment developed by our research group. When the concentration of sodium citrate solution was in the range of 0.4–4.0 g/L a protective coating was formed on the surface of the Al particles which prevented them from contacting with water. The inhibitory effect was achieved when the concentration of sodium citrate was in a certain range and too much or too little addition may reduce the inhibitory effect. In this paper we also discuss the economic aspects of H2 inhibition with this method because it offers excellent safety advantages and could be incorporated on a large scale. Such an intrinsic safety design of H2 inhibition to control explosions in wet-dust-removal systems could be applied to ensure the safety of other systems such as nuclear reactors.
Safety Design and Engineering Solution of Fuel Cell Powered Ship in Inland Waterway of China
Oct 2021
Publication
From the perspective of risk control when hydrogen fuel and fuel cells are used on ships there is a possibility of low-flash fuel leakage leading to the risk of explosion. Since the fuel cell space (cabin for fuel cell installations) is an enclosed space any small amount of leakage must be handled properly. In ship design area classification is a method of analyzing and classifying the areas where explosive gas atmospheres may occur. If the fuel cell space is regarded as a hazardous area all the electrical devices inside it must be explosion-proof type which will make the ship’s design very difficult. This paper takes a Chinese fuel cell powered ship as an example to analyze its safety. Firstly the leakage rates of fuel cell modules valves and connectors are calculated. Secondly the IEC60079-10-1 algorithm is used to calculate the risk level of the fuel cell space. Finally the ship and fuel cells are optimized and redesigned and the risk level of the fuel cell space is recalculated and compared. The result shows that the optimized fuel space risk level could be reduced to the level of the non-hazardous zone.
Analysis of the Environmental Degradation Effects on the Cables of “La Arena” Bridge (Spain)
Sep 2017
Publication
After nearly 25 years of service some of the wires of the tendons of “La Arena” bridge (Spain) started to exhibit the effects of environmental degradation processes. “La Arena” is cable-stayed bridge with 6 towers and a reference span between towers of about 100 meters. After a maintenance inspection of the bridge evidences of corrosion were detected in some of the galvanized wires of the cables. A more in-deep analysis of these wires revealed that many of them exhibited loss of section due to the corrosion process. In order to clarify the causes of this degradation event and to suggest some remedial actions an experimental program was designed. This program consisted of tensile and fatigue tests on some strand samples of the bridge together with a fractographic analysis of the fracture surfaces of the wires its galvanized layer thickness and some hydrogen measurements (hydrogen embrittlement could be another effect of the environmental degradation process).Once the type and extension of the flaws in the wires was characterized a structural integrity assessment of the strands was performed with the aim of quantifying the margins until failure and establishing some maintenance recommendations.
Building Hydrogen Competence, a Technology Aligned Skills and Knowledge Approach
Sep 2021
Publication
There is a pressing need for a framework and strategic approach to be taken to workforce safety training requirements of new hydrogen projects. It is apparent that organisations embarking on projects utilizing or producing green hydrogen need to implement a program of training for their workforce in order to ensure that all personnel within their organisation understand not only the environmental benefits of green hydrogen but also the safety considerations that come with either producing or using hydrogen as a fuel. Energy Transition must be safe to be successful. If such an approach is taken by industry and stakeholders it is also possible to use the high level content as a vehicle and basis to offer public audiences which also require a basic level of understanding in order to fully accept the transition to using hydrogen more widely as a fuel. This will be crucial to the success of national hydrogen strategies. Coeus Energy has developed an innovative framework of training following engagement with operators keen to ensure their duty of care responsibilities have been met. Whilst having highly skilled personnel already employed within their organisations specific hydrogen content is still required for workforce competence. This is where the framework need arises as the knowledge is required at all levels of an organisation.
Development of Analysis Program for Direct Containment Heating
Feb 2022
Publication
Direct containment heating (DCH) is one of the potential factors leading to early containment failure. DCH is closely related to safety analysis and containment performance evaluation of nuclear power plants. In this study a DCH prediction program was developed to analyze the DCH loads of containment vessel. The phenomenological model of debris dispersal metal oxidation reaction debris-atmospheric heat transfer and hydrogen jet burn was established. Code assessment was performed by comparing with several separate effect tests and integral effect tests. The comparison between the predicted results and experimental data shows that the program can predict the key parameters such as peak pressure temperature and hydrogen production in containment well and for most comparisons the relative errors can be maintained within 20%. Among them the prediction uncertainty of hydrogen production is slightly larger. The analysis shows that the main sources of the error are the difference of time scale and the oxidation of cavity debris.
Simulation of Possible Fire and Explosion Hazards of Clean Fuel Vehicles in Garages
Nov 2021
Publication
Clean fuel is advocated to be used for sustainability. The number of liquefied petroleum gas (LPG) and hydrogen vehicles is increasing globally. Explosion hazard is a threat. On the other hand the use of hydrogen is under consideration in Hong Kong. Explosion hazards of these clean fuel (LPG and hydrogen) vehicles were studied and are compared in this paper. The computational fluid dynamics (CFD) software Flame Acceleration Simulator (FLACS) was used. A car garage with a rolling shutter as its entrance was selected for study. Dispersion of LPG from the leakage source with ignition at a higher position was studied. The same garage was used with a typical hydrogen vehicle leaking 3.4 pounds (1.5 kg) of hydrogen in 100 s the mass flow rate being equal to 0.015 kgs−1 . The hydrogen vehicle used in the simulation has two hydrogen tanks with a combined capacity of 5 kg. The entire tank would be completely vented out in about 333 s. Two scenarios of CFD simulation were carried out. In the first scenario the rolling shutter was completely closed and the leaked LPG or hydrogen was ignited at 300 s after leakage. The second scenario was conducted with a gap height of 0.3 m under the rolling shutter. Predicted results of explosion pressure and temperature show that appropriate active fire engineering systems are required when servicing these clean fuel vehicles in garages. An appropriate vent in an enclosed space such as the garage is important in reducing explosion hazards.
Overview on Hydrogen Risk Research and Development Activities: Methodology and Open Issues
Jan 2015
Publication
During the course of a severe accident in a light water nuclear reactor large amounts of hydrogen can be generated and released into the containment during reactor core degradation. Additional burnable gases [hydrogen (H2) and carbon monoxide (CO)] may be released into the containment in the corium/concrete interaction. This could subsequently raise a combustion hazard. As the Fukushima accidents revealed hydrogen combustion can cause high pressure spikes that could challenge the reactor buildings and lead to failure of the surrounding buildings. To prevent the gas explosion hazard most mitigation strategies adopted by European countries are based on the implementation of passive autocatalytic recombiners (PARs). Studies of representative accident sequences indicate that despite the installation of PARs it is difficult to prevent at all times and locations the formation of a combustible mixture that potentially leads to local flame acceleration. Complementary research and development (R&D) projects were recently launched to understand better the phenomena associated with the combustion hazard and to address the issues highlighted after the Fukushima Daiichi events such as explosion hazard in the venting system and the potential flammable mixture migration into spaces beyond the primary containment. The expected results will be used to improve the modeling tools and methodology for hydrogen risk assessment and severe accident management guidelines. The present paper aims to present the methodology adopted by Institut de Radioprotection et de Suˆ rete Nucleaire to assess hydrogen risk in nuclear power plants in particular French nuclear power plants the open issues and the ongoing R&D programs related to hydrogen distribution mitigation and combustion.
Condensed Phase Explosions Involving Liquid Hydrogen
Sep 2021
Publication
Liquid hydrogen may have an important role in the storage and transportation of hydrogen energy. It may also provide the best option for some users of hydrogen energy notably the aviation sector. In the 1960’s liquid hydrogen spillages in open uncongested conditions sometimes produced violent condensed phase explosions as well as the familiar gas phase flash and sustained pool fire. Testing showed that burning mixtures of LH2 and solid oxygen/nitrogen readily transitioned to detonation for oxygen concentrations in the solid phase at or above 50%. Such explosive events have been observed in more recent research work on LH2 spillage and the pressure effects could be significant in some accident scenarios. There is a need to understand how solids are produced following spillage and what factors determine the level of oxygen enrichment. This paper describes the physical processes involved in the accumulation of solids during a horizontal discharge at ground level based on observations made in a recent HSE test that led to a condensed phase explosion. Areas where solids accumulated but remained in intimate contact with LH2 are identified. The paper also includes a thermodynamic and fluid mechanical analysis of the condensation process that includes the calculation of densities of mixtures of LH2 and air in different proportions. When the difference in flow speed between air and underlying LH2 is low a stable condensation layer can develop above the liquid where the temperature is just under the initial condensation point of air allowing sustained oxygen enrichment of condensate.
Experimental Study on the Self-ignition of Pressurized Hydrogen Released into Three-way Tubes
Sep 2021
Publication
To explore the effect of bifurcation structures on the spontaneous ignition and shock wave result from the sudden release of pressurized hydrogen. Three-way tubes with different bifurcation angles (90° 120° 150°) were used in the experiments. They are two Y-shape tubes and one T-shape tube. The photoelectric and pressure signals in the tube were recorded by the sensor. The results show that the reflected shock wave will be formed at the bifurcation. In addition the intensity and velocity of the leading shock wave will attenuate sharply when it passes through the bifurcation.The smaller bifurcation angle of tubethe smaller overpressure decay rate of shock wave at bifurcation position.The smaller the bifurcation angle of tubes the weaker the reflected shock wave transmitted downstream and the greater attenuation of shock wave intensity. Experimental results have reference value for the safety of hydrogen storage at high-pressure and are helpful to understand the influence of different tube structures on spontaneous ignition when hydrogen is transported at high pressure.
Critical Morphological Phenomena During Ultra-lean Hydrogen-air Combustion in Closed Horizontal Hele-Shaw Cell
Sep 2021
Publication
Free quasi-two-dimensional outward propagation of the ultra-lean hydrogen-air flames was studied in a horizontal closed flat channel in order to minimize the influences of gravity and natural convection. Experiments were carried out with a sequential change of initial hydrogen concentration in the premixed gaseous hydrogen-air mixtures in the range from 3 to 12 vol. % H2 under normal pressure and temperature conditions. Two types of critical (in term of concentration threshold behavior) morphological phenomena were observed - formation of a pre-flame kernel and primary bifurcation of the pre-flame kernel and the higher order (secondary tertiary etc.) bifurcations of the individual locally spherical and restricted in space flame fronts. For the given initial ambient conditions (channel thickness initial gas mixture pressure and temperature) variation of initial mixture stoichiometry results in a few substantial changes in overall flame shape. These changes were recorded at the specific concentration limits which delineate three characteristic macroscopic morphological forms (morphotypes) of the ultra-lean hydrogen-air flame's ""trails"" - ""ray-like"" ""dendritic"" and ""quasi-uniform"". Transitions between the revealed basic flame morphotypes took place in different ways. The ""pre-flame kernel-to- rays"" and ""rays-to-dendrites"" transitions were abrupt and resembled the first order transitions in physics. -to-quasi-uniform morphology"" were significantly blurred and can be regarded as analogue to the second order transitions.
Fatigue Behavior of AA2198 in Liquid Hydrogen
Aug 2019
Publication
Tensile and fatigue tests were performed on an AA2198 aluminum alloy in the T851 condition in ambient air and liquid hydrogen (LH2). All fatigue tests were performed under load control at a frequency of 20 Hz and a stress ratio of R=0.1. The Gecks-Och-Function [1] was fitted on the measured cyclic lifetimes.<br/><br/>The tensile strength in LH2 was measured to be 46 % higher compared to the value determined at ambient conditions and the fatigue limit was increased by approximately 60 %. Both S-N curves show a distinct S-shape but also significant differences. Under LH2 environment the transition from LCF- to HCF-region as well as the transition to the fatigue limit is shifted to higher cyclic lifetimes compared to ambient test results. The investigation of the crack surfaces showed distinct differences between ambient and LH2 conditions. These observed differences are important factors in the fatigue behavior change.
Observation of the Hydrogen Dispersion by Using Raman Scattering Measurement and Increase of Measurable Distance
Sep 2017
Publication
Preparing for the arrival of the hydrogen society it is necessary to develop suitable sensors to use hydrogen safely. There are many methods to know the hydrogen concentration by using conventional sensors but it is difficult to know the behavior of hydrogen gas from long distance. This study measured hydrogen dispersion by using Raman scattering light. Generally some delays occur when using conventional sensors but there are almost no delays by using the new Raman sensor. In the experiments 6mm & 1mm diameter holes are used as a spout nozzle to change initial velocities. To ensure the result a special sheets are used which turns transparent when it detected hydrogen and visualized the hydrogen behaviour. As a result the behaviour of the hydrogen gas in the small container was observed. In addition measurable distance is increased by the improvement of the device.
Non-steady Characteristics of Dispersion and Ignitability for High-pressurized Hydrogen Jet Discharged From a Pinhole
Sep 2017
Publication
Hydrogen gas concentrations and jet velocities were measured downstream by a high response speed flame ionization detector and PIV (Particle Image Velocimetry) in order to investigate the characteristics of dispersion and ignitability for 40–82 MPa high-pressurized hydrogen jet discharged from a nozzle with 0.2 mm diameter. The light emitted from both OH radical and water vapor species yielded from hydrogen combustion ignited by an electric spark were recorded by two high speed cameras. From the results the empirical formula concerning the relationships for time-averaged concentrations concentration fluctuations and ignition probability were obtained to suggest that they would be independent of hydrogen discharge pressure.
Public Perception on Hydrogen Infrastructure in Japan
Oct 2015
Publication
A public survey was conducted in March 2015 in Japan asking public awareness knowledge perception and acceptance regarding hydrogen hydrogen infrastructure and fuel cell vehicle adopting the same key questions contained in the public surveys conducted six and seven years ago. Changes in answers between two different times of survey implementation were analyzed by comparing results of current survey to those of the previous surveys. Regression analyses were conducted and revealed influence of respondents’ awareness knowledge and perception about hydrogen hydrogen infrastructure and fuel cell vehicle on their acceptance on hydrogen station. We found a large increase in the awareness and relatively a small improvement on knowledge on hydrogen energy hydrogen infrastructure and fuel cell vehicle from the previous surveys. In contrast we did not find much changes in perception of risk and benefit perception on hydrogen society and hydrogen station and public acceptance of hydrogen infrastructure. Through the regression analyses we found large influences of negative risk perception of hydrogen itself and technology of hydrogen station and perception of necessity of hydrogen station on public acceptance of hydrogen station and the small influence of time background on the acceptance. Through the results of analyses implications to public communication in building public infrastructure are presented.
Hydrogen Fast Filling to a Type IV Tank Developed for Motorcycles
Oct 2015
Publication
If Hydrogen is expected to be highly valuable some improvements should be conducted mainly regarding the storage safety. To prevent from high pressure hydrogen composite tanks bursting the comprehension of the thermo-mechanics phenomena in the case of fire should be improved. To understand the kinetic of strength loss the heat flux produced by fire of various intensities should be assessed. This is the objective of this real scale experimental campaign which will allow studying in future works the strength loss of composite high-pressure vessels in similar fire conditions to the ones determined in this study. Fire calibration tests were performed on metallic cylinder vessels. These tests with metallic cylinders are critical in the characterization of the thermal load of various fire sources (pool fire propane gas fire hydrogen gas fire) so as to evaluate differences related to different thermal load. Radiant panels were also used as thermal source for reference of pure radiation heat transfer. The retained thermal load might be representative of accidental situations in worst case scenarios and relevant for a standardized testing protocol. The tests performed show that hydrogen gas fires and heptane pool fire allow reaching the target in terms of absorbed energy regarding the results of risk analysis performed previously. Other considerations can be taken into account that will led to retain an hydrogen gas fire for further works. Firstly hydrogen gas fire is the more realistic scenario: Hydrogen is the combustible that we every time find near an hydrogen storage. Secondly as one of the objectives of the project is to make recommendations for standardization issues it's important to note that gas fires are not too complex to calibrate control and reproduce. Finally due to previous considerations Hydrogen gas fire will be retained for thermal load of composite cylinders in future works.
Leakage-type-based Analysis of Accidents Involving Hydrogen Fueling Stations in Japan and USA
Aug 2016
Publication
To identify the safety issues associated with hydrogen fuelling stations incidents at such stations in Japan and the USA were analyzed considering the regulations in these countries. Leakage due to the damage and fracture of main bodies of apparatuses and pipes in Japan and the USA is mainly caused by design error that is poorly planned fatigue. Considering the present incidents in these countries adequate consideration of the usage environment in the design is very important. Leakage from flanges valves and seals in Japan is mainly caused by screw joints. If welded joints are to be used in hydrogen fuelling stations in Japan strength data for welded parts should be obtained and pipe thicknesses should be reduced. Leakage due to other factors e.g. external impact in Japan and the USA is mainly caused by human error. To realize self-serviced hydrogen fuelling stations safety measures should be developed to prevent human error by fuel cell vehicle users.
Validation and Recommendations for CFD and Engineering Modeling of Hydrogen Vented Explosions: Effects of Concentration, Stratification, Obstruction and Vent Area
Oct 2015
Publication
Explosion venting is commonly used in the process industry as a prevention solution to protect equipment or buildings against excessive internal pressure caused by an explosion. This article is dedicated to the validation of FLACS CFD code for the modelling of vented explosions. Analytical engineering models fail when complex cases are considered for instance in the presence of obstacles or H2 stratified mixtures. CFD is an alternative solution but has to be carefully validated. In this study FLACS simulations are compared to published experimental results and recommendations are suggested for their application.
Flame Acceleration and Deflagration-to-Detonation Transition in Hydrogen-Oxygen Mixture in a Channel with Triangular Obstacles
Sep 2021
Publication
Study of flame acceleration and deflagration-to-detonation transition (DDT) in obstructed channels is an important subject of research for hydrogen safety. Experiments and numerical simulations of DDT in channels equipped with triangular obstacles were conducted in this work. High-speed schlieren photography and pressure records were used to study the flame shape changes flame propagation and pressure build up in the experiments. In the simulations the fully compressible reactive Navier–Stokes equations coupled with a calibrated chemical-diffusion model for stoichiometric hydrogen-oxygen mixture were solved using a high-order numerical method. The simulations were in good agreement with the experiments. The results show that the triangular obstacles significantly promote the flame acceleration and provide conditions for the occurrence of DDT. In the early stages of flame acceleration vortices are generated in the gaps between adjacent obstacles which is the main cause for the flame roll-up and distortion. A positive feedback mechanism between the combustiongenerated flow and flame propagation results in the variations of the size and velocity of vortices. The flame-vortex interactions cause flame fragmentation and consequently rapid growth in flame surface area which further lead to flame acceleration. The initially laminar flame then develops into a turbulent flame with the creation of shocks shock-flame interactions and various flame instabilities. The continuously arranged obstacles interact with shocks and flames and help to create environments in which a detonation can develop. Both flame collision and flame-shock interaction can give rise to detonation in the channels with triangular obstacles.
Direct Numerical Simulation of Hydrogen Combustion at Auto-ignitive Conditions Ignition, Stability and Turbulent Reaction-front Velocity
Mar 2021
Publication
Direct Numerical Simulations (DNS) are performed to investigate the process of spontaneous ignition of hydrogen flames at laminar turbulent adiabatic and non-adiabatic conditions. Mixtures of hydrogen and vitiated air at temperatures representing gas-turbine reheat combustion are considered. Adiabatic spontaneous ignition processes are investigated first providing a quantitative characterization of stable and unstable flames. Results indicate that in hydrogen reheat combustion compressibility effects play a key role in flame stability and that unstable ignition and combustion are consistently encountered for reactant temperatures close to the mixture’s characteristic crossover temperature. Furthermore it is also found that the characterization of the adiabatic processes is also valid in the presence of non-adiabaticity due to wall heat-loss. Finally a quantitative characterization of the instantaneous fuel consumption rate within the reaction front is obtained and of its ability at auto-ignitive conditions to advance against the approaching turbulent flow of the reactants for a range of different turbulence intensities temperatures and pressure levels.
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