Introduction to the Safe Design of LNG, CNG and Hydrogen ... · PDF fileIntroduction to the Safe Design of LNG, CNG and Hydrogen Refueling Stations ... NFPA 59A, 2006 edition NFPA

Introduction to the Introduction to the Safe Design of LNG, CNG and Safe Design of LNG, CNG and Hydrogen Refueling StationsHydrogen Refueling Stations

Presentation to Presentation to SFPE SFPE

Northern California and Nevada ChapterNorthern California and Nevada Chapter

March 16, 2007March 16, 2007byby

Jack Woycheese, PE, FSFPEJack Woycheese, PE, FSFPE

BackgroundBackground

Existing LNG Import TerminalsExisting LNG Import Terminals 5 in North America, 17 new plants approved, 25 proposed 5 in North America, 17 new plants approved, 25 proposed

and submitted for approval, 17 more in planningand submitted for approval, 17 more in planning

Existing LNG/CNG Refueling FacilitiesExisting LNG/CNG Refueling Facilities Garden Grove, Anaheim, Irvine, Santa MonicaGarden Grove, Anaheim, Irvine, Santa Monica

ProposedProposedLNG offloading in Long BeachLNG offloading in Long Beach

5 Hydrogen plants in SoCal5 Hydrogen plants in SoCal

Alternative FuelsAlternative Fuels

Demand driven by environmental goalsDemand driven by environmental goals

MethanolMethanol

Electrical (Batteries)Electrical (Batteries)

Natural GasNatural Gas CNGCNG

LNGLNG

HydrogenHydrogen

CRYOGENIC CHARACTERISTICSCRYOGENIC CHARACTERISTICS

Cryogenic temperatures are defined as Cryogenic temperatures are defined as between between --150150ººF and F and --460460ººF (absolute zero). F (absolute zero). At atmospheric pressure LNG boils at At atmospheric pressure LNG boils at --259259ººF.F.

Hydrogen boils at Hydrogen boils at --430430ººF F

FIRE HAZARD PROFILE FIRE HAZARD PROFILE -- LNGLNG

Lower Explosion limit (% by vol.):Lower Explosion limit (% by vol.): 5.05.0

Upper explosion limit (% by vol.):Upper explosion limit (% by vol.): 15.415.4

Auto ignition temperature:Auto ignition temperature: 537537ººCC

Flammability classification Flammability classification Flammable Flammable

Sensitivity to static discharge Sensitivity to static discharge Ignitable byIgnitable by static static electricity. Escaping electricity. Escaping gas may self ignite gas may self ignite

FIRE HAZARD PROFILEFIRE HAZARD PROFILE-- HYDROGENHYDROGEN

Lower Explosion limit (% by vol.):Lower Explosion limit (% by vol.): 4.04.0

Upper explosion limit (% by vol.):Upper explosion limit (% by vol.): 75.0075.00

Auto ignition temperature:Auto ignition temperature: 575575ººC C

Flammability classification Flammability classification Flammable Flammable

Sensitivity to static discharge Sensitivity to static discharge Ignitable byIgnitable by static static electricity. Escaping electricity. Escaping gas may self ignite gas may self ignite because of friction.because of friction.

Basic Design of CNG StationBasic Design of CNG Station

Priority/Sequential

Panel

Dispenser

NaturalGasInlet

Dryer Compressor

Storage VesselsFilter

Outlet

CNG FUELING ISLAND-

CNG FUELING

CNG FUELING

35 or 160 psi Supply

Dispensers

Compression skids

Buffer

FUEL DEPOT

Card Reader

CNG dispensers onbus refueling islands

High-pressure gasbuffer storage vessel

Vacuum-jacketed LNG storage tank

LNG tanktruck deliveryfill port

Basic Design of L/CNG Station

Sump-mounted centrifugalinducer pumps

Forced-draftambient-air vaporizer

LNG/CNGLNG/CNG

LNG Release Behavior (ContLNG Release Behavior (Cont��d)d)

As LNG vaporizes, water in air As LNG vaporizes, water in air CondensesCondenses

Forms visible cloudForms visible cloud

Initial release heavy, as it warms Initial release heavy, as it warms becomes light like CNG at becomes light like CNG at --3030°°FF

LNG/CNGLNG/CNG

Methane Gas Supplies Methane Gas Supplies

CNGCNG Pipeline to comPipeline to com--

pressor to CNG storagepressor to CNG storage

Truck as CNG to CNG storageTruck as CNG to CNG storage

LNGLNG Made on siteMade on site

Shipped in trucks to LNG storageShipped in trucks to LNG storage

LNG/CNG LNG/CNG

Methane Gas Supplies (ContMethane Gas Supplies (Cont��d)d)

L/CNGL/CNG LNG/pump/vaporizer/LNG/pump/vaporizer/

CNG storageCNG storage

LNG/vaporizer/LNG/vaporizer/compressor/storagecompressor/storage

LNG/CNGLNG/CNG

Hazards of Natural Gas Hazards of Natural Gas

Fuel accumulation Fuel accumulation Near ceiling Near ceiling

In presence of potential ignition sourcesIn presence of potential ignition sources

Fast releasesFast releases PossiblePossible

Considered improbableConsidered improbable

Applicable StandardsApplicable Standards

NFPA 52, 2006 editionNFPA 52, 2006 edition

NFPA 55 2005 editionNFPA 55 2005 edition

NFPA 57 (Combined into NFPA 52)NFPA 57 (Combined into NFPA 52)

NFPA 59A, 2006 editionNFPA 59A, 2006 edition

NFPA 88NFPA 88

Building CodeBuilding Code

Fire CodeFire Code

PressurePressure--vessel Codevessel Code

Applicable StandardsApplicable Standards

California Title 8: Pressure Vessel Code California Title 8: Pressure Vessel Code (Cont(Cont��d)d)

Incorporates NFPA 52/57/59AIncorporates NFPA 52/57/59A

Approved in March, 2000 Methane Approved in March, 2000 Methane DetectionDetection

Addressed engineering approval of LNG Addressed engineering approval of LNG RefuelingRefueling

Site ConsiderationsSite Considerations

SpacingSpacing SiteSite EquipmentEquipment

Drainage Drainage Away from buildings/equipmentAway from buildings/equipment LNG vaporization rate LNG vaporization rate LNG spill rateLNG spill rate Environmental contaminationEnvironmental contamination

Pressure Relief DischargePressure Relief Discharge

Above-ground Tank,

L/CNG Station

Tank, pumps, vaporizer, containment, buffer

Fueling islanddispensers

FacilitiesFacilities

Vertical tank

Space constrained in residential area

FacilitiesFacilities

Above-ground Vault, L/CNG Station

FacilitiesFacilities

LNG tanks & pumps in LNG tanks & pumps in lowlow--profile 87profile 87�� x 38x 38��vaultvault

HighHigh--expansion Foam expansion Foam System fills vault in ~2 System fills vault in ~2 minutesminutes

HAZOP HAZOP -- Process Process Safety AnalysisSafety Analysis

Vault Vault ½½ above grade above grade ½½ below gradebelow grade Walls Concrete Masonry Walls Concrete Masonry

Unit Unit Ventilation System Ventilation System BlastBlast--proof Doorsproof Doors DeflagrationDeflagration--relief Roof relief Roof

PanelsPanels

LNG Vessels Inside Vault

FacilitiesFacilities

LNG TO CNG

Pumps Inside Vault

FacilitiesFacilities

Above-ground Vault Foam System Test

FacilitiesFacilities

FacilitiesFacilities

Below-ground Tanks

FacilitiesFacilities

TemporaryTemporary

Facilities Facilities �� Refueling StationRefueling Station

FacilitiesFacilities-- TemporaryTemporary

Pressure Letdown During DeliveryPressure Letdown During Delivery

Sodium Bicarbonate Sodium Bicarbonate ApplicationApplication

Sodium Bicarbonate Sodium Bicarbonate ApplicationApplication

What is Hydrogen?What is Hydrogen?

OdorlessOdorless TastelessTasteless NonirritatingNonirritating NontoxicNontoxic ColorlessColorless FlammableFlammable Rises and dissipates Rises and dissipates

quicklyquickly No environmental No environmental

impactimpact

For Automotive ApplicationsFor Automotive ApplicationsWhere Does HWhere Does H22 Come From?Come From?

Hydrogen is DERIVED from Hydrogen is DERIVED from

Hydrocarbon based fuels, steam methane (SMR) Hydrocarbon based fuels, steam methane (SMR) reforming reforming -- 80% today80% today

ByBy--product of chemical processes, purification (20% product of chemical processes, purification (20% today)today)

Water, electrolysis (niche applications today)Water, electrolysis (niche applications today)

Hydrogen Supply ModesHydrogen Supply Modes

Hydrogen Supply ModesHydrogen Supply Modes

Liquid Hydrogen Delivery Delivered in TankersDelivered in Tankers Stored onsite as Cryogenic Stored onsite as Cryogenic

LiquidLiquid Vehicle Fueling Applications:Vehicle Fueling Applications:

Gas OnboardGas Onboard Liquid OnboardLiquid Onboard

Hydrogen Supply ModesHydrogen Supply Modes

Gaseous Gaseous ��Tube TrailerTube Trailer�� DeliveryDeliveryDelivered in High Pressure TubesDelivered in High Pressure Tubes

Basis for HBasis for H22 Fuel StationsFuel Stations

Hydrogen Supply ModeHydrogen Supply Mode Onsite Production or hauled inOnsite Production or hauled in UtilitiesUtilities

CompressionCompression Required pressure, flow ratesRequired pressure, flow rates Maintenance programMaintenance program Gaseous Compression vs. Liquid PumpGaseous Compression vs. Liquid Pump

High Pressure StorageHigh Pressure Storage ASME Compliant Vessels for StationaryASME Compliant Vessels for Stationary DOT Compliant for Mobile StorageDOT Compliant for Mobile Storage

HH22 Fuel StationsFuel Stations DispensingDispensing

Automatic vs. ManualAutomatic vs. Manual Trained OperatorsTrained Operators

SitingSiting Issues/Permits/Issues/Permits/Codes and Standards Codes and Standards --NFPA, DOSH.NFPA, DOSH.

MiscellaneousMiscellaneous Personal Protective Equipment Personal Protective Equipment

(PPE)(PPE) Safety Reviews Safety Reviews -- FEMA, FEMA, HazopHazop Develop site documentDevelop site document

APCI Hydrogen APCI Hydrogen FuelersFuelers H2 Delivery for small fleets or spot jobsH2 Delivery for small fleets or spot jobs

Various sizes and pressuresVarious sizes and pressures

Hydrogen Supply ModesHydrogen Supply Modes

OnOn--site Reformingsite Reforming

Fossil Fuel Feed StockFossil Fuel Feed Stock

Demonstration ProjectDemonstration Project

Hydrogen Supply ModesHydrogen Supply Modes

OnOn--site Electrolysissite ElectrolysisWater and Electricity Feed Water and Electricity Feed

StockStock

Up to 100 kg/dayUp to 100 kg/day

Demonstration ProjectsDemonstration Projects

Pathway to renewable fuelPathway to renewable fuel

Hydrogen Supply ModesHydrogen Supply Modes

Packaged Gases Packaged Gases -- Cylinder SupplyCylinder Supply Small volumes, spot requirementsSmall volumes, spot requirements Portable Fueling Center/CartPortable Fueling Center/Cart

Hydrogen Fuel Stations Hydrogen Fuel Stations University of California DavisUniversity of California Davis

Hydrogen Fuel StationsHydrogen Fuel Stations

University of California University of California -- Irvine, CAIrvine, CA

Ford Motor Co. Ford Motor Co. -- Dearborn, MIDearborn, MI

Hydrogen Fuel StationsHydrogen Fuel Stations

City of Las Vegas, NV

City of Las Vegas HCity of Las Vegas H22 ProjectsProjects

Hydrogen Fuel StationsHydrogen Fuel StationsChicago Transit Authority (CTA) Chicago, ILChicago Transit Authority (CTA) Chicago, IL

Hydrogen Fuel StationsHydrogen Fuel Stations

Cal. Fuel Cell PartnershipWest Sacramento

Finished StationFinished Station

Ann Arbor, MIAnn Arbor, MI

CompressorCompressor

Compressed HCompressed H22 StorageStorage

Fuel DispensersFuel Dispensers

Mobile Mobile FuelerFueler

Tips for Successful ProjectsTips for Successful Projects

Process Safety Analysis Process Safety Analysis

Piping & Instrumentation DiagramPiping & Instrumentation Diagram

Emergency Shut DownEmergency Shut Down

Site Plan/Spacing/DrainageSite Plan/Spacing/Drainage

Tips for Successful ProjectsTips for Successful Projects

Deficiency ResolutionDeficiency ResolutionResponsibilityResponsibility

Equivalency ApprovalsEquivalency Approvals

DocumentationDocumentation

TrainingTraining

Tips for Successful ProjectsTips for Successful Projects

Process Safety ManagementProcess Safety ManagementAPI RP 750API RP 750

AI ChemE/CCPSAI ChemE/CCPS

OSHAOSHA

DonDon��t forget Fire Protection t forget Fire Protection Considerations Considerations

for Maintenance Garage!for Maintenance Garage!

Tips for Successful ProjectsTips for Successful Projects

In CA, all dispensing In CA, all dispensing facilitiesfacilities

Certified for Certified for Engineering integrityEngineering integrity

Safety and Safety and compliance compliance

By California By California Registered Registered Engineer(s) Engineer(s) competent in competent in design, fabrication, design, fabrication, construction of construction of CryongenicCryongenic

Tips for Successful ProjectsTips for Successful Projects

Fire detectionFire detectionFire protection equipmentFire protection equipmentMethane or hydrogen gas detectionMethane or hydrogen gas detectionOther components of the facilityOther components of the facility

General RequirementsGeneral Requirements

ESD MatrixESD Matrix

Fixed and Portable Gas DetectionFixed and Portable Gas Detection

Gas Alarms Transmit to FDGas Alarms Transmit to FD

Location of Safety EquipmentLocation of Safety Equipment

Initial InspectionInitial Inspection

Verify ESD MatrixVerify ESD MatrixAlarm Triggered by Gas Detection Alarm Triggered by Gas Detection

(10%LFL)(10%LFL)

Power and Fuel off (all required circuits) Power and Fuel off (all required circuits) (50% LFL) (50% LFL)

Restart after ShutdownRestart after Shutdown

Electrical Area ClassificationElectrical Area Classification

FollowFollow--up Inspectionsup Inspections

Maintenance and Training RecordsMaintenance and Training Records Approved Drawings, PSA, etc.Approved Drawings, PSA, etc. PRVPRV��s s Gas Detection SystemGas Detection System Corrosion ProtectionCorrosion Protection

Location of Safety EquipmentLocation of Safety Equipment Shields, Gloves, Aprons, etc.Shields, Gloves, Aprons, etc. Portable Gas DetectorsPortable Gas Detectors

Retest ESD MatrixRetest ESD Matrix All Required Power OffAll Required Power Off RestartRestart

NonNon--suitable Electrical Equipment/Wiringsuitable Electrical Equipment/Wiring