Risk Management Approaches to the Japanese Regulations of Hydrogen Supply Stations

1. INTERNATIONAL CONFERENCE ON HYDROGEN SAFETY Second Plenary Risk Management Approaches to Hydrogen Safety, Regulations, Codes, and Standards (RCS) Risk Management Approaches to the Japanese Regulations of Hydrogen Supply Stations September 12, 2007 Japan Petroleum Energy Center (JPEC) Hydrogen Technology Group Shigeki Kikukawa

2. First Glance In this section: • Introduction • Risk Assessment Approaches to Hydrogen Supply Stations • Overview of the new combined gasoline/hydrogen supply station • Future issues • Summaries

3. 1. Introduction • Japanese government positively promotes widespread use of fuel cells. • They address a wide variety of technologies from the basic study about FC to the demonstrations of automotive FC and stationary FC system. Stationary FC System 206 million Euro Safety evaluation facilities for FCV

4. The society using hydrogen energy R&D of Hydrogen and FC Harmonize Codes & Standards Demonstration International C&S

5. Establishment of Codes & Standards for the society using hydrogen energy • Code & standard review projects in Japan • FCV Japan Automobile Research Institute • Stationary FC System Japan Gas Association • Hydrogen supply stations Japan Petroleum Energy Center • Aim: to collect data necessary to review the codes and standards, and to establish test methods. • Budget: 2.6 billion Yen (16 million euro) for 2007 from New Energy and Industrial Technology Development Organization (NEDO).

6. 2. Risk Assessment Approaches to Hydrogen Supply Stations

7. Hydrogen supply stations Reformer FCV Overview On-site type Dispenser Compressor Accumulator Trailer Off-site type LH2 dispenser Tanker truck LH2 tank, Evaporator Liquid hydrogen type FCV (LH2) IWATANI, JHFC HP

8. H2 8m 11.3m 17m To establish safety hydrogen stations in an urban area Key Issue: Setback Distance We had to review the High Pressure Gas Safety Law. Setback distance for general high pressured equipment 17m: Hospital, school, etc. 11.3m: Dwellings 8m: Fire sources Hydrogen stations must be FREE from DANGER! H2 6m

9. Review of the High Pressure Gas Safety Law • Traditional ways • Accumulation of safety related results • Negotiations with relevant authorities • Review of laws by empirical rules • In this case • Needs about review of laws are increased to spread hydrogen supply stations. • Data about safety of hydrogen supply stations is insufficient. • The risk is not zero (0). • Risk Assessment approach • Becoming popular and there is a lot of proof based on the past experiences • ISO/IEC Guide 51 • There have been no examples to review the law using the risk assessment. So it is epoch-making.

10. Tolerable Risk? Risk Assessment Approach START Experiments, Simulations,Surveys, etc. by Project Partners Definition of H2 station model Hazard Identification Risk Estimation Risk Reduction Risk Evaluation N Output of the study : Safety requirements for H2 stations Y END

11. Definition of the Hydrogen Station model • To undertake risk assessments, we designed a detailed model of the hydrogen station. • We decided on a design that could actually be built and that would be widely used in the future after several years. • On-site type Hydrogen station • H2 Demand : 300Nm3/hr (30Nm3/vehicle * 10vehicles/hr) • H2 Generation : 300Nm3/hr • Compressor : 300Nm3/hr, 40MPa • H2 Cylinders : 250L * 14 = 3500L (40MPa, 1400Nm3) • Dispenser : 35MPa (supply pressure)

12. Hazard Identification • Applied Methods : • HAZOP (Hazard and Operability Studies) • FMEA (Failure Mode and Effects Analysis) • 233 accident scenarios were identified for the on-site type H2 station model • Failure and deterioration • Human Error • Natural Disasters

13. Risk Matrix (Risk Acceptance Criteria) H (High):Risk is not acceptable. Remedial actions should be considered to reduce risk to an acceptable level. M (Medium):In principle, risk is not acceptable. It can be accepted only when risk reduction cannot be achieved by reasonably practical action L (Low):Acceptable. Further risk reduction is not necessarily required.

14. Likelihood Levels • Qualitative Evaluation • Based on engineering judgment • Not enough data available for quantitative evaluation Likelihood Estimation

15. Consequence Levels

16. Experiments, Simulations and Surveys • Basic data for likelihood and consequence estimation were provided by project partners. • Mitsubishi Heavy Industries Ltd. • Japan Steel Works • Tatsuno Corporation • Japan Industrial Gas Association

17. Large Scale Hydrogen Release Experiments （40MPa，φ10mm） Release point Hydrogen explosion experiment Hydrogen release experiment (in snow) 障壁なし 障壁あり Blow-out flame of Hydrogen with protection wall Blow-out flame of Hydrogen

18. Blow-out Flame of Hydrogen per hole diameter (40MPa) Hole diameter 0.32mmφ 0.53mmφ 1.17mmφ 2mmφ Note: The temperature region higher than 1,100℃ is made visible with an NaCl solution mist.

19. Dispenser • Durability Tests for • Filling hose & Joint • Hand valve • Breakaway device • Etc.

20. Compressor • Durability Tests • Hydrogen leakage • Noise Control • Vibration • Etc.

21. Metal Material (Stainless Steel and Chromium Molybdenum Steel) • Tests for Hydrogen Embrittlement • in a pressurized hydrogen environment are necessary. • Tensile test • Deep notch test • Fracture toughness test • Fatigue test • Etc. 45MPa hydrogen test unit

22. Reflection of risk assessment results on regulations and standards Points ・Social acceptability about safety ・Cost effectiveness about safety ・Public profits ・Consistency with conventional regulations Example Gasoline stationsCNG stations Other pressure vessels Risk Assessment Approach to Hydrogen supply stations 90 safety measures Regulation Exemplification Standard Voluntary Standard The High Pressure Gas Safety Institute of Japan (KHK) Government JPEC

23. 3. Overview of the new combined gasoline/hydrogen supply station P We proposed new regulations for hydrogen supply stations through the risk assessment. Then we installed a hydrogen supply station in conformity with the new regulations. This station is intended to verify the safety of overall hydrogen supply station. - Safety verification test - Investigation of extension of inspection frequency A D Continual improvement C

24. Site Ichihara city Chiba prefecture Space 726m2 Feedstock Kerosene Steam reforming with desulfurization of kerosene Process + PSA purification Production capacity 50Nm3/h More than 99.99% in volume Hydrogen purity ( CO less than 1ppm) Pressure : 25MPa(3,600psi) and 35MPa(5,000psi) Refueling capacity Capable of refueｌling 5 passenger vehicles continuously Overview of the Facility

25. Sequential flow of processes

26. Setback Distance can be shortened with appropriatefire protection wall Ａ Ｒ Ａ T C Ａ Ａ Ｐ Accumulator Compressor Tank Reformer PSA Office Gasoline Dispenser H2 Dispenser Wall h=2m Road Setback Distance 6 m Major Safety measures(High Pressure Gas Safety Law)

27. H2 leak detector Earthquake detector Flame detector Ａ Ｒ Ａ T C Ａ Ａ Ｐ Accumulator Compressor Tank Reformer PSA Office Gasoline Dispenser H2 Dispenser Road

28. Emergency isolation valve Excess flow valve Ａ Ｒ Ａ T C Ａ Ａ Ｐ Accumulator Compressor Tank Reformer PSA Office Gasoline Dispenser H2 Dispenser Road

29. Compressor • Compressor should be placed in an enclosure. • Ventilation with Interlock System H2 Leak Detector

30. H2 Leak Detector Water Sprinkler Flame Detector Accumulator Metal materials are limited to SUS316L or SCM435. Emergency Isolation Valve, Check Valve Pressure Indicator, Safety Valve Frame Structure

31. Excess flow valve Closed (Emergency) Open (Normal)

32. Dispenser Flame Detector Breakaway Device Emergency Stop Button Pressure release after refueling Piping in Trench Guardrail

33. 4. Future Issues • To widespread use of hydrogen supply stations • We need to research and develop metal materials having less hydrogen embrittlement. • We also need to reduce the costs of each unit, compressor, and accumulator used for hydrogen supply stations. • Additionally, we must promote development of new units in parallel to review of regulations and standards. • To extend the cruising range of FCV • We need to verify the safety of the hydrogen supply stations applicable to 70MPa-charging. • To achieve highly efficient hydrogen transportation and storage • We need to utilize liquid hydrogen. • We must research and develop utilization of metallic alloy for hydrogen storage or organic hydride.

34. 5. Summaries • We used the risk assessment approach to review the High Pressure Gas Safety Law so as to make proposal drafts. • Japanese government reviewed the regulations and standards based on our proposals. New regulations and standards have been in effect since March, 2005. • We installed a hydrogen supply station combined with the gasoline station that is in conformity with new regulations and standards. From this time onward, we will conduct the verification test of the safety. • Presently, we are investigating safety measures for hydrogen gas supply station applicable to 70MPa-charging.

35. Thank you for your attention. ACKNOWLEDGEMENT This study is a partial summary of results obtained by JPEC as part of a study into safety technology for a hydrogen supply infrastructure. The study was commissioned by the independent administrative organization New Energy and Industrial Technology Development Organization (NEDO) and conducted from 2003 to 2006.