Safety

The NREL Hydrogen Sensor Laboratory was commissioned in 2010 as a resource for the national and international hydrogen community to ensure the availability and proper use of hydrogen sensors. Since then the Sensor Laboratory has provided unbiased verification of hydrogen sensor performance for sensor developers end-users and regulatory agencies and has also provided active support for numerous code and standards development organizations. Although sensor performance assessment remains a core capability the mission of the NREL Sensor Laboratory has expanded toward a more holistic approach regarding the role of hydrogen detection and its implementation strategy for both assurance of facility safety and for process control applications. Active monitoring for detection of unintended releases has been identified as a viable approach for improving facility safety and lowering setbacks. The current research program for the Sensor Laboratory addresses both conventional and advanced developing detection strategies in response to the emerging large-scale hydrogen markets such as those envisioned by H2@Scale. These emerging hydrogen applications may require alternative detection strategies that supplement and may ultimately supplant the use of traditional sensors for monitoring hydrogen releases. Research focus areas for the NREL Sensor Laboratory now encompass the characterization of released hydrogen behavior to optimize detection strategies for both indoor and outdoor applications assess advanced methods of hydrogen leak detection such as hydrogen wide area monitoring for large scale applications implement active monitoring as a risk reduction strategy to improve safety at hydrogen facilities and to provide continuing support of hydrogen safety codes and standards. In addition to assurance of safety detection will be critical for process control applications such as hydrogen fuel quality verification for fuel cell vehicle applications and for monitoring and controlling of hydrogen-natural gas blend composition.

A series of more than 100 experiments with hydrogen-air mixtures at cryogenic temperatures have been performed in a shock tube in the frame of the PRESLHY project. A wide range of hydrogen concentrations from 8 to 60%H2 in the shock tube of the length of 5 m and 50 mm id was tested at cryogenic temperatures from 80 to 130K at ambient pressure. Flame propagation regimes were investigated for all hydrogen compositions in the shock tube at three different blockage ratios (BR) 0 0.3 and 0.6 as a function of initial temperature. Pressure sensors and InGaAs-photodiodes have been applied to monitor the flame and shock propagation velocity of the process. The experiments at ambient pressure and temperature were conducted as the reference data for cryogenic experiments. A critical expansion ratio for an effective flame acceleration to the speed of sound was experimentally found at cryogenic temperatures. The detonability criterion for smooth and obstructed channels was used to evaluate the detonation cell sizes at cryogenic temperatures as well. The main peculiarities of cryogenic combustion with respect to the safety assessment were that the maximum combustion pressure was several times higher compared to ambient temperature and the run-up-distance to detonation was several times shorter independent of lower chemical reactivity at cryogenic conditions.

This paper presents a series of experiments on the effectiveness of existing mechanical ventilation systems during accidental hydrogen releases in confined spaces like underground garages. The purpose was to find the mass flow rate limit hence the TPRD diameter limit that will not require a change in the ventilation system. The experiments were performed in a 40 ft ISO container in Norway and hydrogen gas was used in all experiments. The forced ventilation system was installed with a standard outlet 315 mm diameter. The ventilation parameters during the investigation were British Standard with 10 ACH and British Standard with 6 ACH. The hydrogen releases were obtained through 0.5 mm and 1 mm nozzle from different hydrogen reservoir pressures. Both types of mass flow: constant and blowdown were included in the experimental matrix. The analysis of hydrogen concentration of created hydrogen cloud in the container shows the influence of the forced ventilation on hydrogen releases together with TPRD diameter and reservoir pressure. The generated experimental data will be used to validate a CFD model in the next step.

Hydrogen is a renewable energy source with various features clean carbon-free high energy density which is being recognized internationally as a “future energy.” The US the EU Japan South Korea China and other countries or regions are gradually clarifying the development position of hydrogen. The rapid development of the hydrogen energy industry requires more hydrogenation infrastructure to meet the hydrogenation need of hydrogen fuel cell vehicles. Nevertheless due to the frequent occurrence of hydrogen infrastructure accidents their safety has become an obstacle to large-scale construction. This paper analyzed five sizes (diameters of 0.068 mm 0.215 mm 0.68 mm 2.15 mm and 6.8 mm) of hydrogen leakage in the hydrogen fueling station using Quantitative Risk Assessment (QRA) and HyRAM software. The results show that unignited leaks occur most frequently; leaks caused by flanges valves instruments compressors and filters occur more frequently; and the risk indicator of thermal radiation accident and structure collapse accident caused by over-pressure exceeds the Chinese individual acceptable risk standard and the risk indicator of a thermal radiation accident and head impact accident caused by overpressure is below the Chinese standard. On the other hand we simulated the consequences of hydrogen leak from the 45 MPa hydrogen storage vessels by the physic module of HyRAM and obtained the ranges of plume dispersion jet fire radiative heat flux and unconfined overpressure. We suggest targeted preventive measures and safety distance to provide references for hydrogen fueling stations’ safe construction and operation.

Efficient storage of hydrogen is crucial for the success of hydrogen energy markets. Hydrogen can be stored either as a compressed gas a refrigerated liquefied gas a cryo-compressed gas or in hydrides. This paper gives an overview of compressed hydrogen storage technologies focusing on high pressure storage tanks in metal and in composite materials. It details specific issues and constraints related to the materials and structure behavior in hydrogen and conditions representative of hydrogen energy uses. This paper is an update of the 2019 version that was presented in Australia. It especially covers recent progress made regarding regulations codes and standards for the design manufacturing periodic inspection and plastic materials’ evaluation of compressed hydrogen storage.

The use of hydrogen storage tanks at 100% of nominal working pressure NWP is expected only after refuelling. Driving between refuellings is characterised by the state of charge SoC<100%. There is experimental evidence that Type IV tanks tested in a fire at initial pressures below one-third of its NWP depending on a fire source were leaking without rupture. This paper aims at understanding this phenomenon and the development of a predictive model. The numerical research has demonstrated that the heat transfer from fire through the composite overwrap is sufficient to melt the polymer liner. This initiates hydrogen microleaks through the composite wall before it loses the load-bearing ability when the resin degrades deep enough to cause the tank to rupture. The dependence of tank fire-resistance rating (FRR) on the SoC is presented for tanks of volume in the range 36-244 L. The tank wall thickness non-uniformity i.e. thinner composite at the dome area is identified as a serious issue for tank’s fire resistance that must be addressed by tank manufacturers and OEMs. The effect of the burst pressure ratio on FRR is investigated. It is concluded that thermal parameters of the composite wall i.e. decomposition heat and temperatures play a vital role in simulations of tank failure and thus FRR.

This paper describes two models for analysing and simulating the physical effects of explosive phase transition of liquid hydrogen (LH2) also known as cold BLEVE. The present work is based on theoretical and experimental work for liquefied CO2. A Rankine Hugoniot analysis for evaporation waves that was previously developed for CO2 is now extended to LH2. A CFD-method for simulating two-phase flow with mass transfer between the phases is presented and compared with the Rankine Hugoniot analysis results. The Rankine Hugoniot method uses real fluid equations of state suited for LH2 while the CFD method uses linear equations of state suited for shock capturing methods. The results show that there will be a blast from a catastrophic rupture of an LH2 vessel and that the blast waves will experience a slow decay due to the large positive pressure phase.

Hydrogen which has a high energy density and does not emit pollutants is considered an alternative energy source to replace fossil fuels. Herein we report an experimental study on hydrogen leaks and ventilation methods for preventing damage caused by leaks from hydrogen fuel cell rooms in homes among various uses of hydrogen. This experiment was conducted in a temporary space with a volume of 11.484 m3 . The supplied pressure leak-hole size and leakage amount were adjusted as the experimental conditions. The resulting hydrogen concentrations which changed according to the operation of the ventilation openings ventilation fan and supplied shutoff valve were measured. The experimental results showed that the reductions in the hydrogen concentration due to the shutoff valve were the most significant. The maximum hydrogen concentration could be reduced by 80% or more if it is 100 times that of the leakage volume or higher. The shutoff valve ventilation fan and ventilation openings were required to reduce the concentrations of the fuel cell room hydrogen in a spatially uniform manner. Although the hydrogen concentration in a small hydrogen fuel cell room for home use can rapidly increase a rapid reduction in the concentration of hydrogen with an appropriate ventilation system has been experimentally proven.

On December 19 2017 a large balloon containing about 22 thousand cubic meters of hydrogen was deliberately torn open to initiate deflation at the completion of a filling test. An inadvertent ignition occurred after about two seconds and caused an explosion that produced extensive light damage to a large building near the balloon test pad. The analysis described here includes an estimate of the buoyancy induced mixing into the torn balloon and the blast wave produced by assumed constant flame speed combustion of the 55% to 65% hydrogen-in-air mixture. Comparisons of calculated blast wave pressures are consistent with estimates of the pressure needed to cause the observed building damage for flame speeds in the range 85 m/s to about 100 m/s.

Current safety codes and technical standards related to Japanese hydrogen refueling stations (HRSs) have been established based on qualitative risk assessment and quantitative effectiveness validation of safety measures for more than ten years. In the last decade there has been significant development in the technologies and significant increment in operational experience related to HRSs. We performed a quantitative risk assessment (QRA) of the HRS model representing Japanese HRSs with the latest information in the previous study. The QRA results were obtained by summing risk contours derived from each process unit. They showed that the risk contours of 10-3 and 10-4 per year were confined within the HRS boundaries whereas those of 10-5 and 10-6 per year are still present outside the HRS boundaries. Therefore we analyzed the summation of risk contours derived from each unit and identified the largest risk scenarios outside the station. The HRS model in the previous study did not consider fire and blast protection walls which could reduce the risks outside the station. Therefore we conducted a detailed risk analysis of the identified scenarios using 3D structure modeling. The heat radiation and temperature rise of jet fire scenarios that pose the greatest risk to the physical surroundings in the HRS model were estimated in detail based on computational fluid dynamics with 3D structures including fire protection walls. Results show that the risks spreading outside the north- west- and east-side station boundaries are expected to be acceptable by incorporating the fire protection wall into the Japanese HRS model.