1 Risk Management Approaches to the Japanese Regulations of Hydrogen Supply Stations September 12, 2007 Japan Petroleum Energy Center (JPEC) Hydrogen Technology.

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Risk Management Approaches to the Japanese Regulations of Hydrogen Supply Stations

September 12, 2007

Japan Petroleum Energy Center (JPEC)Hydrogen Technology Group

Shigeki Kikukawa

INTERNATIONAL CONFERENCE ON HYDROGEN SAFETY

Second Plenary

Risk Management Approaches to Hydrogen Safety, Regulations, Codes, and Standards (RCS)

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First Glance

In this section:

1. Introduction

2. Risk Assessment Approaches to Hydrogen Supply Stations

3. Overview of the new combined gasoline/hydrogen supply station

4. Future issues

5. Summaries

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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.

METI's Total Budget for Fuel Cell and Hydrogen

0

5

10

15

20

25

30

35

40

2000 2001 2002 2003 2004 2005 2006 2007Fiscal Year

Bud

get

(Bill

ion

Yen

s)

Stationary FC System

Safety evaluation facilities for FCV

206 million Euro

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The society using hydrogen energyThe society using hydrogen energy

DemonstrationCodes & Standards

HarmoniHarmonizeze

International C&SInternational C&S

R&D of Hydrogen and FC

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Establishment of Codes & Standards Establishment of Codes & Standards for the society using hydrogen energyfor 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).

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2. Risk Assessment Approaches to Hydrogen Supply Stations

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Hydrogen supply stations

Reformer

Trailer

Compressor Accumulator Dispenser

On-site type

Off-site type

FCVOverview

IWATANI, JHFC HP

Liquid hydrogen type

FCV (LH2)

Tanker truck LH2 tank, Evaporator LH2 dispenser

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Key Issue: Setback Distance

H2

17m11.3m8m

17m: Hospital, school, etc.

11.3m: Dwellings

8m: Fire sources

Setback distance for general high pressured equipment

H2

We had to review the High Pressure Gas Safety Law.

Hydrogen stations must be FREE from DANGER!

To establish safety hydrogen stations in an urban area

6m

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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.

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Risk Assessment Approach

Definition of H2 station model

Hazard Identification

Risk Estimation

Risk EvaluationRisk Reduction

Tolerable Risk?N

Y

Output of the study : Safety requirements for H2 stations

Experiments, Simulations,Surveys, etc.

by Project Partners

END

START

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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)

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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

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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.

Likelihood

Consequence

severity

AImprobable

BRemote

COccasional

DProbable

1 Extremely Severe Damage H H H H

2 Severe Damage M H H H3 Damage M M H H4 Small Damage L L M H5 Minor Damage L L L M

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Likelihood Levels

Level Description DefinitionA Improbable Possible, but the probability is extremely low.

About once in several thousand years or less.

B Remote Unlikely to occur in the lifetime of one H2 station.

About once in several hundred years.

C Occasional Likely to occur once in the lifetime of one H2 station.

About once in several decades.

D Probable Likely to occur several times in the lifetime of one H2 station. About once in several years or more.

Likelihood Estimation Qualitative Evaluation

Based on engineering judgment Not enough data available for quantitative evaluation

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Consequence Levels

Level Description Material Damage Human Damage

1 Extremely Severe Damage

Collapse of nearby houses

One or more fatalities of pedestrians or residents

2 Severe Damage Major damage to nearby houses

One or more fatalities of customers or station workers

3 Damage Minor damage to nearby houses

Injury requiring hospitalization

4 Small Damage Windows broken Injury requiring medical treatment

5 Minor Damage No damage to nearby houses

Minor injury

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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

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Blow-out flame of Hydrogen 　 with protection wall

Large Scale Hydrogen Release Experiments Large Scale Hydrogen Release Experiments （（ 40MPa40MPa，， φ10mmφ10mm ））

Hydrogen release experiment (in snow) Hydrogen explosion experiment

障壁あり障壁なし

Blow-out flame of Hydrogen 　

Release point

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Note: The temperature region higher than 1,100 is made visible with an ℃NaCl solution mist.

0.32mmφ

0.53mmφ

1.17mmφ

2mmφ

Blow-out Flame of Hydrogen per hole diameter (40MPa)Blow-out Flame of Hydrogen per hole diameter (40MPa)

Hole diameter

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Dispenser

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

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Compressor

Durability Tests Hydrogen leakage Noise Control Vibration Etc.

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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

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Reflection of risk assessment results on regulations and standards

Risk Assessment Approach to Hydrogen supply stations

90 safety measures

Regulation Exemplification Standard

Voluntary Standard

Points

・ Social acceptability about safety

・ Cost effectiveness about safety

・ Public profits

・ Consistency with conventional regulations　 Example Gasoline stations CNG stations Other pressure vessels

Government The High Pressure Gas Safety Institute of Japan (KHK)

JPEC

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3. Overview of the new combined gasoline/hydrogen supply station

P

A

C

DContinual improvement

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

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Overview of the Facility

HydrogenProduction

UnitUtility

Accumulator

Road

GasolineStation area

HydrogenStation area

Office Compressor

Off-gasholder

H2-gasholder

Water Tank

Water Pump

Electric Supply Unit

H2 Dispenser

Canopy

Firewalls

Cable Pit

Barriers

HydrogenProduction

UnitUtility

Accumulator

Road

GasolineStation area

HydrogenStation area

Office Compressor

Off-gasholder

H2-gasholder

Water Tank

Water Pump

Electric Supply Unit

H2 Dispenser

Canopy

Firewalls

Cable Pit

Barriers

Site Ichihara city Chiba prefecture

Space 726m2

Feedstock Kerosene

Process Steam reforming with desulfurization of kerosene+ PSA purification

Production capacity50Nm3/h

Hydrogen purity More than 99.99% in volume( CO less than 1ppm)

Refueling capacityPressure : 25MPa(3,600psi) and 35MPa(5,000psi)Capable of refue ｌ ling 5 passenger vehicles continuously

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Sequential flow of processes

Reformer PSAGas

holderFeedKerosene

Desulfurizer

CO-remover

Hydrogen Production Unit

Compressor

Accumulator

DispenserFCV

Reformer PSAGas

holderFeedKerosene

Desulfurizer

CO-remover

Hydrogen Production Unit

Compressor

Accumulator

DispenserFCV

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Major Safety measures(High Pressure Gas Safety Law)

Road

H2 Dispenser

Office

CT

Compressor Accumulator

Gasoline Dispenser

Reformer

Ｒ

PSA

Ａ

Ａ

Ａ

ＡＰ

Tank

Setback Distance 6 mWall h=2m

Setback Distance can be shortened with appropriatefire protection wall

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Road

H2 Dispenser

Office

CT

Compressor Accumulator

Gasoline Dispenser

Reformer

Ｒ

PSA

Ａ

Ａ

Ａ

ＡＰ

Tank

H2 leak detector

Flame detector

Earthquake detector

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Road

H2 Dispenser

Office

CT

Compressor Accumulator

Gasoline Dispenser

Reformer

Ｒ

PSA

Ａ

Ａ

Ａ

ＡＰ

Tank

Emergency isolation valve

Excess flow valve

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•Compressor should be placed in an enclosure.•Ventilation with Interlock System

Compressor

H2 Leak Detector

30 Frame Structure

H2 Leak Detector

Emergency Isolation Valve,Check Valve

Water SprinklerFlame Detector

Accumulator

Pressure Indicator, Safety Valve

Metal materials are limited to SUS316L or SCM435.

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Excess flow valve

Closed (Emergency) Open (Normal)

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Breakaway Device

Guardrail Piping in Trench

Flame Detector

Emergency Stop Button

Pressure releaseafter refueling

Dispenser

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4. Future Issues

To widespread use of hydrogen supply stations We need to research and develop metal materials having les

s 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 p

arallel 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.

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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.

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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.