Research for Hydrogen Safety, Codes & Standards

1. 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

2. ADVANCED ENERGY INITIATIVE(February 2006) • 22% increase in funding for clean energy research. • Accelerates R&D of near-term transportation options—biofuels and plug-in hybrids, as well as technologies for electricity generation. • Reinforces Hydrogen Fuel Initiative. • “20-in-10” INITIATIVE (January 2007) • Accelerates R&D to produce 35 billion gallons of renewable and alternative fuels by 2017, and increases fuel economy standards, to displace 20% of annual gasoline use in 2017. • Expands scope of Renewable Fuel Standard (RFS) to “Alternative Fuel Standard,” including corn and cellulosic ethanol, biodiesel, methanol, butanol, hydrogen, and other alternative fuels. 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

3. E E R E 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.

4. HYDROGEN FUEL INITIATIVE: TOTAL FUNDING • President Bush committed $1.2 billion over 5 years (FY04 – FY08) to accelerate R&D to enable technology readiness in 2015. • President’s 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

5. DOE HYDROGEN PROGRAM BUDGET by Office Does not include Department of Transportation

6. HYDROGEN PROGRAM MISSION:Reduce 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

7. National Labs 35% Large 16% Industry Developers 35% Small 9% Universities & Institutes 20% Energy Companies 2% Auto Companies 8% Other 10% HYDROGEN PROGRAM SPENDING: A balanced, diverse portfolio

8. Basic Research & Applied R&D DELIVERY TECHNOLOGY VALIDATION PRODUCTION FUEL CELLS STORAGE 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 R&D 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

9. 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.

10. SAFETY, CODES & STANDARDS BUDGET Fiscal Year 2007 Total $13.8 million

11. 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 C&S Organizations Lack of harmonization of domestic and international standards Limited government influence on C&S process Limited DOE role in international C&S development process Challenges

12. RESEARCH NEEDS ARE IDENTIFIED IN COOPERATION WITH INDUSTRY Roadmap detailing information gaps for the following target areas ensures RD&D 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)

13. 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 PH2>100 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

14. 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

15. HYDROGEN JET AND FLAME BEHAVIOR:H2 jets and flames are similar to other flammable gases • Fraction of chemical energy converted to thermal radiation • Radiation heat flux distribution • Jet length

16. Unignited H2 Jets (a) H2 Mixing (b) (c) Deflagration to detonation Over-pressure from ignition of premixed hydrogen / air Pressure Axial Distance 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-pressurecharacterization • 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

17. Stabilized flame H2 Jet Flames (a) H2 (b) (c) Radiometers 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)

18. Alternative Mitigation: Wall Jet release in any direction Distance if large diameter leak, high pressure H2 Distance if small diameter leak, high pressure H2 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.

19. 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

20. Cumulative frequency of accidents resulting in consequences that requires this separation distance 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

21. 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

22. 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

23. FUEL QUALITY: Relative Tradeoffs Identified • To date, the North American industry-government team has identified the following as critical constituents around which near-term R&D and testing should be focused: • CO • S compounds • He • CH4 and inerts • NH3 • Particulate Matter (<10µ diameter) • This list may change and other critical constituents may be identified as R&D 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

24. 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 R&D/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

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

26. DEVELOPMENT OF CODES, STANDARDS, AND REGULATIONS 2015 2004 2010 Research R&D Roadmap Domestic Codes & Standards Standards National Template Codes Global Technical Regulations (GTR) IEC, ISO GRPE International Coordination GTR

27. 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 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 Regulators Guide to Permitting Hydrogen Technologies Objective Help code officials sort through applicable codes and standards when permitting hydrogen facilities. 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/permitting_guides.html

28. 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 www.fuelcellstandards.com

29. 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, C&S permitting process, information tools Workshops in key regions locations where industry will focus H2 infrastructure development and vehicle deployment Permitting HFS: DOE Initiative

34. 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 R&D 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

35. ONLINE INFORMATION TOOLS BIBLIOGRAPHIC DATABASE • Contains ~400 documents related to hydrogen safety • Will contain 650 by end of FY 2007 H2 INCIDENTS DATABASE • Information on hydrogen incidents and lessons learned • Over 100 incidents documented www.hydrogen.energy.gov www.h2incidents.org Hydrogen Safety Best Practices Manual Under Development – Dec. 2007

36. FOR MORE INFORMATION www.hydrogen.energy.gov Antonio Ruiz antonio.ruiz@ee.doe.gov +1 202-586-0729

37. THANK YOU ESKERRIK ASKO GRACIAS СПАСИБО MERCI GRÀCIES 감사합니다 謝謝 OBRIGADO DANKE ΕΥΧΑΡΙΣΤΏ ありがとうございました GRAZIE