Hydrogen  

and  Fuel  Cells  

are  Coming…
Are  You  Ready?
Nick  Barilo
PNNL  Hydrogen  Safety  Program  Manager
IAFC/USFA   Webinar  -­ September   15,  2015

PNNL-­‐SA-­‐112620 September  1 7,  2 015 / 1

PNNL  Hydrogen  Safety  Program

Hydrogen   Safety  Panel

• Identify  Safety-­‐Related  Technical  Data  Gaps
• Review  Safety  Plans  and  Project  Designs
• Perform  Safety  Evaluation  Site  Visits
• Provide  Technical  Oversight  for  Other  Program  Areas

Safety  Knowledge   Tools   and  Dissemination

• Hydrogen  Lessons  Learned
• Hydrogen  Best  Practices
• Hydrogen  Tools  (iPad/iPhone   mobile  application)
• Hydrogen  Tools  Portal  (http://h2tools.org)

Hydrogen   Safety  First  Responder  Training

• Online  Awareness  Training
• Operations-­‐level  Classroom/Hands-­‐on   Training
• National   Hydrogen  and  Fuel  Cell  Emergency  Response  Training  Resource

September  1 7,  2 015 / 2
Outline  for  Today’s  Presentation

• Fuel  Cell  Basics  and  Applications

• Properties  of  Hydrogen
• Primary  Codes  and  Standards
• Fundamental  Safety  Considerations
• Hydrogen  Safety  Resources
• First  Responder  Training  Resources
• Concluding  Thoughts

September  1 7,  2 015 / 3
Fuel  Cell  Basics  and  
Applications

September  1 7,  
2015 / 4
Why  Hydrogen?

• Excellent  energy  carrier

• Nonpolluting

• Economically  competitive

• As  safe  as  gasoline  

• Used  safely  for  over  50  years

• Produced  from  a  variety  of  sources

Photo  courtesy  of  the   California   Fuel   Cell   Partnership

September  1 7,  2 015 / 5
Where  Do  We  Get  Hydrogen?

Renewable  Sources Traditional  Sources

Solar,  wind,  geothermal,   Natural  gas,  gasoline,  

hydro,  biomass,  algae nuclear,  coal

September  1 7,  2 015 / 6
Hydrogen  Uses

The  use  of  hydrogen  is  not  new;;  private  industry  has  used  it  safely  for  many  
decades.  Nine  million  tons  of  hydrogen  are  safely  produced  and  used  in  the  
United  States  every  year.  56  billion  kg/yr  are  produced  globally.  For  example,  H2
is  used  for:

• Petroleum   refining • Petrochemical  

manufacturing
• Glass  purification
• Semiconductor   industry
• Aerospace  applications
• Hydrogenation   of  
• Fertilizers   unsaturated   fatty  acids  in  
vegetable   oil
• Annealing   and  heat  
treating  metals The  Air  P roducts  and  Chemicals  h ydrogen  production  facilities  in  
Port  Arthur,  Texas,  is  funded  b y  the  Energy  Department  through   • Welding
the  2 009  Recovery  Act.  |  Photo  credit  Air  P roducts  and  Chemicals  
hydrogen  p roduction  facilities.
• Pharmaceutical   products • Coolant   in  power  
generators                                              

September  1 7,  2 015 / 7
How  a  Fuel  Cell  Works

September  1 7,  2 015 / 8
 Fuel  Cell  Applications

Fuel  cells  have  a  broad  range  of  applications:

• Transportation
§ Light  and  medium   duty
§ Heavy  duty  and   transit
§ Auxiliary  power   for  refrigeration   trailers  and  trucks
§ Forklifts
§ Maritime
Photo:  Nuvera

• Stationary  power
§ Backup  power  for  cell  tower  sites
§ Combined   heat  and  power
§ Data  centers,  etc.

• Portable  power
Toyota’s  stationary  power  supply  in  Torrance,  CA

September  1 7,  2 015 / 9
Fuel  Cells
Where  are  We  Today?

Fuel  Cells  for  Stationary  Power,  Auxiliary  

Power,  and  Specialty  Vehicles
The  largest  markets  for  fuel  cells  today  are  in  stationary  power,  
portable  power,  auxiliary  power  units,  and  forklifts

More  than  35,000  fuel  cells  shipped  in  2013  

(~a  consistent  30%  annual  growth  since  2010)

Fuel  cells  can  be  a  cost-­competitive  option  for  critical-­load  

facilities,  backup  power,  and  forklifts

September  1 7,  2 015 / 10
Industrial  Trucks

Forklift  Equipped  with  Fuel  Cells

Typical  Hydrogen  Fueling  Infrastructure  ( Courtesy  of  
Air  Products  and  Chemicals,  Inc.)

• Forklifts  are  equipped   with  fuel  

cells  as  a  replacement   for  
traditional  battery  packs.    
• A  typical  project  consists  of  a  
refueling  system  (tank,  
compressor,  piping,  etc.)  
providing  hydrogen   to  a  
dispenser  located  inside  a  
warehouse.    

September  1 7,  2 015 / 11
 Fuel  Cell  Cars  are  Here!
FCEVs  on  display  at North  American  auto  shows.  

Honda   Fuel  Cell  Electric   Vehicle

Hyundai’s   first  mass-­‐produced  

Tucson   Fuel  Cell  SUVs  arrived   in  
Southern   California  
May  20,  2014
Lease   includes   free  H2 and  
maintenance.  
Toyota   Mirai  Fuel  Cell  Electric  Vehicle

/ 12
 / 132 015
September  1 7,  
 FCEV  System  Layout

High  
Voltage  
Electric   Power   Fuel  Cell Hydrogen   Battery
Cooling   Motor Electronics Tanks
Electrical   Electrical  
System Electrical Electrical   component;;   Compressed,   component;;  
Typically,  s lightly   component;;  drives   component;;   generates   gaseous  fuel;;   captures  regen  
larger  radiators   vehicle  by   distributes   electricity  from   vehicle  fueled  with   braking,  s upports  
than  c onventional electricity electricity hydrogen hydrogen acceleration
Source:  California  Fuel  Cell  P artnership

September  1 7,  2 015 / 14
Hydrogen  Fueling  Stations

September  1 7,  2 015 / 15
H2 Infrastructure  Development  and  Status

NE  states,  California   and   Hawaii   have  H2

infrastructure  efforts  underway September  1 7,  2 015 / 16
Typical  Station  Configurations

• Hydrogen  can  be  delivered  or  made  on  site

• Liquid  delivered  → gaseous  H2

• Gaseous  delivered  or  piped  → booster  

compressed  gaseous  H2

• Natural  gas  → gaseous  H2

• Water  +  electricity  → gaseous  H2

September  1 7,  2 015 / 17
Hydrogen  Fueling  Stations
Gaseous  Hydrogen  Storage  

Gaseous  hydrogen  is:

Hydrogen  
Compressor
• Delivered  to  fueling  
station  by  tube  trailer
Gaseous  Hydrogen  
• Compressed  and  stored   Delivery  by  Tube  Trailer

onsite  in  cylinders

• Piped  to  dispenser  for   Hydrogen  Storage  
fueling  vehicles Cylinders

Hydrogen  
Dispenser

Graphic:  P acific  Northwest  National  L aboratory

September  1 7,  2 015 / 18
 Hydrogen  Fueling  Stations
Liquid  Hydrogen  Delivery
Liquid  hydrogen  can  be  delivered  to  the  fueling  station  by  tanker  truck,  as  
is  shown  for  this  hydrogen  and  gasoline  station

Compressed   gas  storage

IC  90  Compressor LH2   tank

Fueling   dispenser   &  canopy

Photos:  California  Fuel  Cell  P artnership  a nd  L inde.

September  1 7,  2 015 / 19
Hydrogen  Fueling  Stations
Liquid  Hydrogen  Storage

Liquid  hydrogen  is:

• Delivered  to  fueling  station  by  tanker  truck
• Stored  underground  as  a  liquid     Hydrogen  
Hydrogen   Dispenser
• Vaporized  in  above-­ground   vessel
Storage  
• Compressed  and  stored  onsite   Cylinders
in  cylinders
• Piped  to  dispenser  for  fueling  vehicles

Liquid  Hydrogen Vaporizer Hydrogen  

Liquid  Hydrogen  Delivery   Storage  Tank Compressor
by  Tanker  Truck (underground)

September  1 7,  2 015 / 20
Properties  of  Hydrogen

September  1 7,  2 015 / 21
Hydrogen  Properties  and  Behavior

• A  gas  at  ambient  conditions

• Hydrogen   is  a  cryogen:  exists  as  a  liquid  at  

-­423°F  (-­253°C).
§ Compressing  the  gas  does  not  liquefy  it
§ No  liquid   phase  in  a  compressed  gaseous  hydrogen   storage  
tanks

• LH2  storage  at  relatively  low  pressure  (50  psi)

• Double   walled,  vacuum  insulated   tanks  with  burst  disks,  

vents,  and  PRDs  

• Volumetric  ratio  of  liquid  to  gas  is  1:848

Molecular   Hydrogen
§ Compare   water  to  steam  (1:1700)

• Energy  content  of  1kg  of  H2 is  approximately  equal   to  1  

gal  of  gasoline  (in  BTUs)

Codes  and   Standards:    IFGC  Chapter  7,  ASME   B31.12,  CGA  G5.5
September  1 7,  2 015 / 22
Gaseous  Hydrogen

Gaseous  hydrogen:
• has  a  flammable  range  of  4-­
75%  in  air
• will  typically  rise  and  disperse  
rapidly  (14x  lighter  than  air)
• diffuses  through  materials  not  
normally  considered  porous
• requires  only  a  small  amount  
of  energy  for  ignition  (0.02  mJ)
• burns  with  a  pale  blue,  almost  
invisible  flame
• can  embrittle  some  metals

September  1 7,  2 015 / 23
Hydrogen  Properties:  A  Comparison

Hydrogen Natural  Gas Gasoline

Color No No Yes

Toxicity None Some High

Odor Odorless Mercaptan Yes

Buoyancy 14X 2X 3.75X

Relative  to  Air Lighter Lighter Heavier

Energy 2.8X ~1.2X

43 MJ/kg
by  Weight >  Gasoline >  Gasoline

Energy 4X 1.5X
120 MJ/Gallon
by  Volume <  Gasoline <  Gasoline

Source:   California   Fuel   Cell   Partnership

September  1 7,  2 015 / 24
Comparing  Hydrogen  and  Propane  Flames

September  1 7,  2 015 / 25
Primary  Codes  and  Standards

September  1 7,  2 015 / 26
Design  Consideration:  Codes  &  Standards
There  are  many  organizations  working  on  codes,  
standards  and  guides.  https://h2tools.org/fuelcellstandards-­
view is  currently  tracking  the  world-­wide  development  of  
over  300  hydrogen  and  fuel cell  standards  and  related  
documents.    Let’s  focus  on  the  critical  infrastructure  
documents.
• International  Fire  Code  (IFC)  -­ addresses  
hydrogen  applications
• International  Building  Code  (IBC)  -­ general  
construction  requirements
• International  Fuel  Gas  Code  (IFGC)
• NFPA  1  Fire  Code
• NFPA  2  Hydrogen  Technologies   Code
• NFPA  55  Compressed  Gases  and  Cryogenic  
Fluids  Code
• NFPA  70  National  Electrical  Code
• ASME  B31.12  Hydrogen  Pipelines  and  Piping  
Code  -­ hydrogen  piping  design

September  1 7,  2 015 / 27
Important  ICC  2015  Code  References

• IFC  Section  2309  – Hydrogen  Motor  Fuel-­

Dispensing  and  Generation  Facilities
• IFC  Chapter  50  – Hazardous  Materials  -­ General  
Provisions
• IFC  Chapter  53  – Compressed  Gases
• IFC  Chapter  58  – Flammable  Gases  and  
Flammable  Cryogenic  Fluids
• International  Fuel  Gas  Code  (IFGC)  Chapter  7  
– Gaseous  Hydrogen  Systems

Significant  changes   in  the  2015   IFC

“Compressed  hydrogen   (CH2)  for  use  as  a  vehicular  fuel  shall  also  comply  with  
Chapters  23  and  58  of  this  code,  the  International   Fuel  Gas  Code   and  NFPA  2.”  
(IFC  5301.1)
”Hydrogen   motor  fuel-­dispensing   stations  and  repair  garages  and  their  associated  
above-­ground   hydrogen   storage  systems  shall  also  be  designed,  constructed  and  
maintained   in  accordance   with  Chapter  23  and  NFPA   2.”    (IFC  5801.1)

September  1 7,  2 015 / 28
The  Need  for  a  National  Hydrogen  Code

With  the  increased  interest  in  hydrogen  being  used  as  a  fuel  source,  the  National  
Fire  Protection  Association  was  petitioned  to  develop  an  all-­encompassing  
document  that  establishes  the  necessary  requirements  for  hydrogen  technologies.

• Origin  and  development  of  the  NFPA  2,  Hydrogen  Technologies  Code
– Technical  committee  formed  in  2006
– Focus  is  to  address  all  aspects  of  hydrogen  storage,  use,  and  handling
– Draws  from  existing  NFPA  codes  and  standards  (extracts  from  NFPA  52,  
55  and  853)  (NFPA  52  hydrogen  requirements  removed  and  transferred  to  
NFPA  2)
– Identifies  and  fills  technical  gaps  for  a  complete  functional  set  of  
requirements
– Developed  for  code  users  and  enforcers
– Structured  so  that  it  works  seamlessly  with  building  and  fire  codes

In  the  course  of  this  presentation,  any  c omment  as  to  the  “ meaning” of  any  part  of  any  NFPA  code  or  standard  is  
only  the  opinion  of  the  presenter  and  is  NOT  to  be  relied  upon  as  either  accurate  or  official.    Only  the  NFPA  may  
issue  a  formal  interpretation  of  its  c odes  and  s tandards.

September  1 7,  2 015 / 29
Contents  of  NFPA  2,  2016  Edition
Document  Title,  Hydrogen  Technologies  Code
Chapter  1 ,  Administration
Chapter  2 ,  Referenced  Publications
Chapter  3 ,  Definitions
Chapter  4 ,  General  Fire  Safety  Requirements
Fundamental  
Chapter  5 ,  Performance-­‐Based  Option
Chapters
Chapter  6 ,  General  Hydrogen  Requirements
Chapter  7 ,  Gaseous  Hydrogen
Chapter  8 ,  Liquefied  Hydrogen
Chapter  9 ,  Explosion  Protection Reserved
2016
Chapter  1 0,  GH2  Vehicle Fueling  Facilities
Chapter  1 1,  LH2  Fueling  Facilities
Chapter  1 2,  Hydrogen  Fuel  Cell  Power  Systems
Chapter  1 3,  Hydrogen  Generation  Systems
Use  Specific   Chapter  1 4,  Combustion  Applications
Chapters Chapter  1 5,  Special  Atmosphere  Applications
Chapter  1 6,  Laboratory  Operations
Chapter  1 7,  Parking  Garages
Chapter  1 8,  Road  Tunnels
Chapter  1 9,  Repair Garages
Annex  A
Annexes  B-­‐M

September  1 7,  2 015 / 30
Fundamental  Safety  
Considerations

September  1 7,  2 015 / 31
The  Basics…

Hydrogen  safety,  much  like  all  flammable  gas  safety,  relies  on  five  
key  considerations:

▶ Recognize  hazards  and  define  mitigation  measures

▶ Ensure  system  integrity

▶ Provide  proper  ventilation  to  prevent  accumulation  (manage  

discharges)

▶ Ensure  that  leaks  are  detected  and  isolated

▶ Train  personnel

September  1 7,  2 015 / 32
General  Considerations
Hydrogen  cylinders  and  storage  tanks  should  be  stored  outside  at  a  safe  distance  from  
structures,  ventilation  intakes,  and  vehicle  routes.  This  applies  even  while  in  use.  Best  
practices  call  for  compressed  hydrogen  bottles  supplying  a  manifold  to  be  located  
outside,  with  welded  lines  to  connect  to  indoor  equipment.   Safety  considerations   for  
indoor  storage  or  use  of  bulk  gaseous  hydrogen  include:

▶ Buildings  should  be  constructed  of  noncombustible   materials.  

▶ Mechanical  ventilation  systems  s hould   have  inlets  low  to  the  ground   and  exhausts  at  the  
highest  point  of  the  room  in  the  exterior  wall  or  roof.  Consideration   should  be  given  to  
providing  venting  for  both  normal  conditions  and  emergency  situations.  
▶ Hydrogen   sensors  should  be  installed  at  the  exhaust  within  the  enclosure.

▶ Automatic  shutoff  that  activates  if  a  leak  or  fire  is  detected   in  the  facility  that  is  being  
supplied  with  hydrogen.
▶ Ignition  sources  should  in  storage  areas  should  be  avoided.

▶ Classified  electrical  equipment   should  be  used  in  close  proximity  to  storage  systems.

▶ Gaseous  hydrogen   system  c omponents   should  be  electrically  bonded   and  grounded.

Code  and   Standards:    IFC,  IBC,   IFGC,  NFPA  2,  NFPA   70

September  1 7,  2 015 / 33
Electrical  Equipment
Specific  considerations:
Electrical  Equipment   Requirements   for  Bulk  Systems
• Fans  for  active  ventilation  
Location Classification* Distance
systems  should  be   Area  containing  gaseous  hydrogen   Class  1,  Division  2 Up  to  15  ft  from  storage/equipment  
provided  with  a  rotating   storage,  compression  or  ancillary  
equipment
element  of  nonferrous  or   Area  containing  liquefied   Class  1,  Division  2 Up  to  25  ft from  the  storage  equipment,  
hydrogen  storage excluding  the  piping  system,  
spark-­resistant   downstream  of  the  source  v alve  
construction.
Class  1,  Division  1 Within  3  ft from  points  w here  
• Equipment  or  devices   connections  are  r egularly  made  and  
disconnected
should  be  designed  for  use   Interior  of  dispensing  equipment Class  1,  Division  2 Up  to  the  support  mechanism  (anchoring  
the  dispenser)  or  connection  to  the  
in  hydrogen  service.   ground  level
Exterior  of  outdoor  dispensing   Class  1,  Division  2 Up  to  5  ft  from  dispenser  
• The  gaseous  hydrogen   equipment
Exterior  of  indoor  dispensing   Class  1,  Division  2 Up  to  15  ft  from  the  point  of  transfer  
system  should  be   equipment from  floor  to  ceiling
electrically  bonded  and   Outdoor  discharge  from  r elief   Class  1,  Division  1 Up  to  5  ft  from  the  source
vents
grounded.   Class  1,  Division  2 5-­‐‑15  ft  from  the  source
Discharge  from  r elief  v ents  w ithin   Class  1,  Division  1 Within  15  ft from  source
• Equipment  not  conforming   15  degrees  of  the  line  of  discharge
to  NEC  requirements  must   *  All  equipment  shall  b e  rated  f or  Group  B  applications  ( NFPA  70-­‐‑500.6).
be  located  outside  the  area  
classified  as  hazardous.  

Code  and   Standards:    IFC   2309.2.3,  NFPA  2-­‐10.3.1.16

September  1 7,  2 015 / 34
Outdoor  Separation  Distances

• Hydrogen  cylinders  and  storage  tanks  

should  be  stored  outside  at  a  safe  
distance  from  structures,  ventilation  
intakes,  and  vehicle  routes.  
• A  bulk  hydrogen  compressed  gas  
system  is  an  assembly  of  equipment  that  
consists  of,  but  is  not  limited  to,  storage  
containers,  pressure  regulators,  pressure  
relief  devices,  compressors,  manifolds,  
and  piping,  with  a  storage  capacity  of  
more  than  5,000  scf  (141.6  Nm3)  of  
compressed  hydrogen  gas  and  that  
terminates  at  the  source  valve.   Photo:  h2tools.org

Code  and   Standards:    NFPA   2-­‐7.3.2.3

September  1 7,  2 015 / 35
Outdoor  Separation  Distances  for  Bulk  Hydrogen  Systems

Pressure  (psig) >  1 5  t o >  2 50  t o   >  3 000  t o   >  7 500  t o  

≤  2 50 ≤  3 000 ≤  7 500 ≤  1 5000
Pipe Internal  Diameter  (in.) 2.07 0.75 0.29 0.28
Exposure  Group  1
a) Lot  lines
b) Air  intakes  ( HVAC,  compressors,  Other) 40  ft 46  ft 29  ft 34  ft
c) Operable  openings  in  buildings  and  S tructures
d) Ignition  sources  such  as  open  flames  and  w elding  

Exposure  Group 2
a) Exposed  persons  other  than  those  servicing  the  system 20  ft 24  ft 13  ft 16  ft
b) parked  cars  
Exposure  Group 3
a) Buildings  of  non-­‐combustible  non-­‐fire-­‐rated  construction  
b) Buildings  of  combustible  construction
c) Flammable  gas  storage  systems  above  or  below  ground
d) Hazardous  m aterials  storage  systems  above  or  below  ground
e) Heavy  timber,  coal,  or  other  slow-­‐burning  combustible  solids
f) Ordinary  combustibles,  including  fast-­‐burning  solids  such  as   17  ft 19  ft 12  ft 14  ft
ordinary  lumber,  excelsior,  paper,  or  combustible  w aste  and  
vegetation  other  than  that  found  in  m aintained  landscaped  
areas  
g) Unopenable  openings  in  building  and  structures  
h) Utilities  overhead  including  electric  power,  building  services  or  
hazardous  m aterials  piping  systems  
Source:   NFPA  55,  2013  Edition

Code  and   Standards:    NFPA   55-­‐10.3.2

September  1 7,  2 015 / 36
Selection  of  Materials
• Materials  of  construction,  including  materials  
used  in  piping,  valves  and  seals,  must  be   Preferred
carefully  selected  to  account  for  their   • Generally  acceptable  
deterioration   when  exposed   to  hydrogen   at  the  
materials  include  austenitic  
intended   operating   conditions.  
stainless  steels,  aluminum  
• The  mechanical  properties  of  metals,  including   alloys,  copper,  and  copper  
steels,  aluminum   and  aluminum   alloys,  titanium   alloys.
and  titanium  alloys,  and  nickel  and  nickel  alloys  
are  detrimentally  affected  by  hydrogen.
Avoid
• Exposure   of  metals  to  hydrogen   can   lead  to   • Nickel  and  most  nickel  alloys  
embrittlement,  cracking   and/or  significant   should  not  be  used  since  they  
losses   in  tensile  strength,  ductility,  and   are  subject  to  severe  
fracture  toughness.   This  can  result  in   hydrogen   embrittlement.
premature  failure  in  load-­carrying  
components.  
• Gray,  ductile,  and   malleable  
• Additionally,  hydrogen   diffuses  through   many   cast  irons  should  generally  not  
materials,  particularly  nonmetals,   due  to  its   be  used  for  hydrogen   service.  
small  molecular  size.  

See  http://www.h2tools.org/tech-­ref/technical-­reference-­for-­hydrogen-­compatibility-­of-­materials
for  additional   guidance.

Codes  and   Standards:    IFGC  5003.2.2.1,  IFGC  704.1.2.3,  NFPA  2-­‐10.3.1.3

September  1 7,  2 015 / 37
A  Lesson  Learned  on  Material  Selection

A  pressure  relief  device  (PRD)  valve  failed  on  a  high-­pressure   storage  tube   at  a  hydrogen  
fueling  station,  causing  the  release  of  approximately   300  kilograms  of  hydrogen   gas.  The  
gas  ignited  at  the  exit  of  the  vent  pipe  and   burned   for  2-­1/2  hours  until  technicians  were  
permitted  by  the  local  fire  department   to  enter  the  station  and   stop  the  flow  of  gas.

• The  root  cause  of  the  incident  

was  a  failed  pressure  relief  
valve…
• An  extensive  metallurgical  
analysis  of  the  failed  valve  
concluded   that  improper  
material  selection   and  
deviations   from  valve  
production   processes   led  
to  the  valve   failure.

The  good   news…    There   were  no  injuries  and  very  little  property  damage.   The  corrugated  
roof  on  an  adjacent  canopy  over  a  fueling  dispenser  was  slightly  singed  by  the  escaping  
hydrogen   flame,  causing  less  than  $300   in  damage.
Source:  http://www.h2tools.org/lessons

September  1 7,  2 015 / 38
Checking  for  Leaks

Hydrogen  burns  with  a  pale  blue  flame  that  is  nearly  

invisible  in  daylight.  Hydrogen  flames  also  emit  low  
radiant  heat,  so  a  person  may  not  feel  heat  until  they  
are  very  close  to  the  flame.  Best practices  include  
the  following:  
• A  portable   flame  detector  (e.g.,  thermal  imaging  
camera)  should  be  used  if  possible.  
• Otherwise,  listen  for  venting  hydrogen   and  watch  for  
thermal  waves  that  signal  the  presence   of  a  flame.
• Use  a  combustible  probe   (e.g.,  broom)
• Always  allow  enough   time  for  
troubleshooting/debugging   a  monitoring   system   Hydrogen  and  Propane  Flames  in  Daylight
before  it's  used. (Photo  courtesy  of  HAMMER)

• Where  multiple  gases  are  co-­located,  always  respond  

in  a  manner   to  investigate/  mitigate  the  most  
hazardous   gas.

September  1 7,  2 015 / 39
A  Lesson  Learned  on  Hydrogen  Leaks

Hydrogen   Explosion   and  Iron  Dust  Flash   Fires  in  Powdered   Metals  Plant
• Operators  in  a  powdered  metals  production  facility  heard  a  hissing  noise  near  one  of  the  plant  furnaces  and  
determined  that  it  was  a  gas  leak  in  the  trench  below  the  furnaces.  T he  trench  carried  hydrogen,  nitrogen,  
and  cooling  water  runoff  pipes  as  well  as  a  vent  pipe  for  the  furnaces.  
• Maintenance  p ersonnel  p resumed  that  the  leak  was  n onflammable  n itrogen  b ecause  there  h ad  
recently  b een  a  n itrogen  p iping  leak  elsewhere  in  the  p lant.  Using  the  plant's  overhead  crane,  they  
removed  some  of  the  heavy  trench  covers.  T hey  determined  that  the  leak  was  in  an  area  that  the  crane  
could  not  reach,  so  they  brought  in  a  forklift  with  a  chain  to  remove  the  trench  covers  in  that  area.
• Eyewitnesses  stated  that  as  the  first  trench  cover  was  wrenched  from  its  position  by  the  forklift,  friction  
created  sparks  followed  immediately  by  a  powerful  explosion.  Several  days  after  the  explosion,  Chemical  
Safety  Board  (CSB)  investigators  observed  a  large  hole  (~3x7  inches)  in  a  corroded  section  of  hydrogen  
vent  piping  inside  the  trench.
• As  the  hydrogen-­air  mixture  in  the  partially  open  trench  exploded,  the  resulting  overpressure  dispersed  
large  quantities  of  iron  dust  from  the  rafters  and  other  surfaces  in  the  plant,  and  some  of  this  dust  
subsequently  ignited.  Eyewitnesses  reported  that  embers  were  raining  down  and  igniting  iron  dust  flash  
fires  in  the  area.  Visibility  was  so  poor  due  to  dust  and  smoke  that  even  with  a  flashlight,  it  was  impossible  
to  see  more  than  3  or  4  feet.  T hree  plant  employees  eventually  died  from  burn  injuries  despite  wearing  
supposedly  flash-­fire-­resistant  garments.  Two  others  suffered  smoke-­inhalation  injuries.  Due  to  the  
extensive  nature  of  the  injuries,  and  the  abundance  of  both  hydrogen  and  combustible  dust  present  at  the  
time  of  the  incident,  it  is  difficult  to  specifically  determine  which  fuel,  if  not  both,  caused  the  fatal  injuries  to  
the  victims.
source:  http://www.h2tools.org/lessons

September  1 7,  2 015 / 40
Hydrogen  Safety  Resources

September  1 7,  2 015 / 41
 Hydrogen  Safety  Panel

The  Hydrogen  Safety  Panel  is  a  team  of  highly  experienced  individuals  
created  to  address  concerns  about  hydrogen  as  a  safe  and sustainable  
energy  carrier.

Principal  Objective:    Promote  the  safe  operation,  handling, and  use  of  
hydrogen  and  hydrogen  systems  across  all  installations  and  applications  
by:

• identifying  and  addressing  safety-­related  technical  data  gaps

• making  design,  construction,  and  operations  personnel  aware  of  
relevant  issues  and  best  practices  that  affect  safe  operation  and  
handling  of  hydrogen  and  related  systems
• convincing  design,  construction,  and  operations  personnel  to  give  
sufficient  priority  to  safety  in  their  daily,  ongoing  work.

September  1 7,  2 015 / 42
Hydrogen  Safety  Panel  Activities

The  Hydrogen  Safety  Panel  contributes  to  its  objective  by:

▶ participating  in  safety  reviews

▶ providing  safety  planning
guidance
▶ reviewing  project  designs
and  safety  plans
▶ sharing  safety  knowledge
and  best  practices
▶ presenting  and  recognizing Hydrogen  Safety  Panel  members  at  the  California  Fuel  Cell  
Partnership  in  West  Sacramento,  CA,  for  the  2 1st  meeting
safety  as  a  priority
▶ participating  in  incident  investigations.

September  1 7,  2 015 / 43
 Hydrogen  Safety  Panel  Accomplishments
• Reviewed   over  270  projectss covering  
Current  Hydrogen  Safety  Panel  Members
vehicle  fueling  stations,  auxiliary  power,  
backup  power,  combined   heat  and  power,   Name Affiliation
industrial  truck  fueling,  portable   power  and   Nick  Barilo,  Manager Pacific  Northwest  National  Laboratory
R&D  activities. Richard  Kallman,  Chair City  of  Santa  Fe  Springs,  CA
David  Farese Air  Products  and  Chemicals
• White  papers  with  recommendations  
Larry  Fluer Fluer,  Inc.  
recently  include:
• Secondary  Protection  for  70MPa   Fueling Bill  Fort Consultant
• Safety  of  Hydrogen  Systems  Installed   in   Donald  Frikken Becht  Engineering
Outdoor  Enclosures Aaron  Harris Air Liquide
• Supported   development/updating   of  safety   Chris  LaFleur Sandia  National  Laboratories
knowledge   tools:  Lessons  Learned   and   Miguel  Maes NASA-­‐JSC  W hite  Sands  Test  Facility
Best  Safety  Practices  on  the  Hydrogen   Steve  Mathison Honda  Motor  Company
Tools  Portal  (h2tools.org). Larry Moulthrop Proton OnSite
Glenn  Scheffler GWS  Solutions  of  Tolland
• Conducted   21  Hydrogen   Safety  Panel  
Steven  W einer Excelsior  Design,  Inc.
meetings  since  2003.    Panel   meetings  
Robert  Zalosh Firexplo
currently  engage   a  broad  cross-­section  of  
the  hydrogen   and  fuel  cell  community.

September  1 7,  2 015 / 44
New  Requirements  for  NFPA  2-­2016

NFPA  2,  2016  Edition  has  prescriptive   requirements   for  Hydrogen  Equipment  
Enclosures1,   including:
• Ventilation
• Isolation  (gas  and  fire  barrier)
• Electrical   requirements
• Bonding/grounding
• Explosion   control
• Detection
1 A  prefabricated   area   confined  by  at   least   three   walls  and   a  roof,  not  routinely   occupied   or  used   in  a  

laboratory,  with   a  total  area  less   than  450  ft2 designed  to  protect  hydrogen.

Code  and   Standards:    NFPA   2-­‐7.1.23  (2016  Edition)

September  1 7,  2 015 / 45
The  Certification  Challenge
The  scarcity  of  listed  hydrogen  equipment  places  an  extraordinary  burden  on  code  
officials  to  ensure  (approve)  that  products  include  the  appropriate  inherent  or  automatic  
safety  measures.  

Certification  presents  significant  challenges.

§ Few  systems  or  equipment  that  are  listed,  labeled  
or  certified
§ Significant  costs  since  the  technology  and  
products  are  still  rapidly  changing  and  each  new  
iteration  would  require  recertification
Development  of  a  Certification  Guide
The  Hydrogen  Safety  Panel  is  developing  a  guide  to
assist  code  officials,  designers,  owners,  evaluators
and  others  with    the  application  of  requirements  
pertinent  to  the  design  and/or  installation  of  hydrogen  
equipment  as  regulated  by  the  model  codes.    The  
scope  of  the  Guideline  will  be  limited  to  those  
requirements  where  the  terms  approved,  certified,  
listed and/or  labeled are  used.

Code  and   Standards:    IFC   2309.2.2,  NFPA  2-­‐7.1.3

September  1 7,  2 015 / 46
Supporting  State  Efforts
The  Panel  is   a   unique   resource  and   can  be   a   valuable   asset  for  supporting   the   safe  
commercial   rollout  of  fuel   cell  vehicles,  stationary  applications   and  the  supporting  
infrastructure.
Can   provide   support  to:
▶ Other   federal   agencies
▶ State   agencies,   code  officials  and
permitting   authorities
▶ Private   industry   and   commercial
installers
Types  of  Activities:
▶ Design  and   document  reviews
▶ Participation   in   or  review   of  risk   assessments
▶ Site   reviews

Safety  is  paramount  -­‐ its  the   first  question  we   get  asked   in  California  when  we   go  into  local  communities.  If  
anything,  we  need   to  figure   out  how  to  expand  the   Safety  Panel's  reach.   The   reviews   from  the   Panel  have   already  
shown  benefit  to   the  state  -­‐ its  a  crucial,  trusted   3rd  party   resource. – 2015  DOE  AMR  Reviewer   Comment

More  information  is  available   at  http://www.h2tools.org/hsp

September  1 7,  2 015 / 47
 Hydrogen  Tools
A  Transformative  Step  Towards  Hydrogen  Adoption

/
48
 Opportunities  for  Information/Knowledge  Dissemination

Phase  1 Share  your  

User  Groups
Spring  2015 tools!
• AHJ/code  officials
Potential • First  responders
Future  Tools Training  for  First   • Investors
Responders,   User  Group • Insurers  and  risk  managers
Code  O fficials   Networking
and  Researchers
• Operations  and  maintenance
Codes • Public
Compatibility  of   and • Project  proponents
Materials Standards • Research  and  development
Tools

Properties,  
Calculators  & QRA
Bibliographic Tools
Database

Lessons  Learned  
and  Best  Safety  
H2Tools   Other
relevant
Practices
Portal information
sources

September  1 7,  2 015 / 49
H2tools.org/bestpractices
…sharing  experience,  applying  best  practices
• Introduction  to  Hydrogen
– So  you  want  to  know  something   about  
hydrogen?
• Hydrogen   Properties
– Hydrogen  compared  with  other  fuels
• Safety  Practices
– Safety  culture
– Safety  planning
– Incident  procedures
– Communications
• Design  and  Operations
– Facility  design  considerations
– Storage  and  piping
– Operating   procedures
– Equipment   maintenance
– Laboratory  safety
Safety  events  from  “ H2incidents.org” illustrate  
– Indoor  refueling   of  forklifts what  can  go  wrong  if  best  practices  are  not  
http://h2tools.org/bestpractices followed.

September  1 7,  2 015 / 50
H2tools.org/lessons
…capturing  the  event,  focusing  on  lessons  learned

Each  safety  event  record  contains

– Description
– Severity  (Was  hydrogen   released?
Was  there  ignition?)
– Setting
– Equipment
– Characteristics  (High  pressure?  Low  
temperature?)
– Damage   and   Injuries
– Probable   Cause(s)
– Contributing   Factors
– Lessons  Learned/Suggestions   for  
Avoidance/Mitigation   Steps  Taken

http://h2tools.org/lessons Tube  Trailer  Rollover

September  1 7,  2 015 / 51
 Quantitative  Risk  Assessment

• Developed   toolkit  to  enable   integrated  

probabilistic  and  deterministic  modeling  
– Relevant  H2  hazards  (thermal,  
mechanical)
– Probabilistic   models  (traditional   QRA  
models)  &  H2-­specific  component   data
– H2 phenomena   (gas  release,  heat  flux,  
overpressure)

• Variable  Users
– High  level,  generic  insights  (e.g.,  for  
C&S  developers,  regulators)
– Detailed,   site-­specific  insights  (e.g.,  for  
AHJs,  s tation  designers)

• Currently,  two  interfaces  (views):   First-­‐of-­‐its-­‐kind   software   tool  for  integrating  

– “QRA  mode”  and  “Physics  mode” H2  consequence   models   w/  QRA   models
– Planned   “performance-­based   design”   Includes  behavior  models  &   data   developed  
mode  for  targeted   analyses through   FY12

September  1 7,  2 015 / 52
Introduction  to  Hydrogen  for  Code  Officials

Provides  an  overview  of  hydrogen  and  fuel  cell  technologies,  discusses  
how  these  technologies  are  used  in  real-­world  applications  and  
discusses  the  codes  and  standards  required  for  permitting  them.

• Hydrogen  and  fuel  cell  basics

• Hydrogen  and  fuel  cell  
applications
• Hydrogen  fueling  stations
• Fuel  cell  facilities

Developed  by  the   National  Renewable  

Energy   Laboratory

http://h2tools.org/content/training-­materials

September  1 7,  2 015 / 53
 Technical  Reference  for
Hydrogen  Compatibility  of  Materials
Consists  of  material  specific  chapters  (as  individual  PDF  files)  
summarizing  mechanical-­property  data  from  journal  publications  and  
technical  reports

• Plain  Carbon  Ferritic Steels

• Low-­Alloy  Ferritic Steels
• High-­Alloy  Ferritic Steels
• Austenitic  Steels
• Aluminum  Alloys
• Copper  Alloys
• Nickel  Alloys
• Nonmetals
http://h2tools.org/tech-­ref/technical-­reference-­for-­
hydrogen-­compatibility-­of-­materials

September  1 7,  2 015 / 54
 H2USA  Public-­Private  Partnership
to  address  H2  Infrastructure  Challenges http://h2usa.org

The  mission   of  H2USA   is  to  promote  the  commercial   introduction   and  widespread  
adoption   of  FCEVs   across  America  through   creation  of  a  public-­private   collaboration   to  
overcome   the  hurdle  of  establishing   hydrogen   infrastructure.

September  1 7,  2 015 / 55
Key  Early  Market  Challenges  Addressed  by  H2USA

Ø Station  Cost  Reduction

-­ Fueling  resources  &  delivery
-­ State  and  local  regulations
Ø Station  Locations
-­ Identify  and  prioritize  markets
-­ Regulatory  barriers  (zoning)
-­ Station  rollout  timing
Ø Investment  and  Finance
-­ Private  sector  financing
-­ Government  support
Ø Market  Support   and  Acceleration
-­ Product  launch  and  timeline
-­ Codes  and  standards  (non-­vehicle  
related)
-­ Public  education

September  1 7,  2 015 / 56
First  Responder   Training  
Resources

September  1 7,  2 015 / 57
Working  with  First  Responders
Preplanning
• Facility  owners  and  first  responders  should  work  
together   to  perform  preplanning   activities.    This  
should  include  a  tour  of  the  hydrogen   facilities  with  
focused  attention  on  safety  features  and  emergency  
shutoffs.

Training
• Training   of  emergency  response  personnel   should  
be  a  high  priority  to  ensure  that  these  personnel  
understand   how  to  properly  respond   to  a  hydrogen  
incident.
• A  variety  of  resources  are  available  to  assist  with  
this  training  (see  the  resource  lists  at  the  end   of  this  
presentation).
Photo:  V olpentest  HAMMER  Federal  Training  Center
Equipment
• A  hydrogen   fire  is  often  difficult  to  detect  without  a  
thermal  imaging  camera  or  flame  detector.    First  
responders  have  one  available   for  their  use.

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First  Responder  Hydrogen  Safety  Training

▶ National  Goal
– Support  the  successful  implementation  of  hydrogen  and  
fuel  cell  technologies  by  providing  technically  accurate  
hydrogen  safety  and  emergency  response  information  to  
first  responders
▶ Integrated  Activities
– Online,  awareness-­level  training
(http://hydrogen.pnl.gov/FirstResponders/)
– Classroom  and  hands-­on  operations-­level  training
– National  training  resource  (enabling  trainers)
(http://h2tools.org/fr/nt)    

A  properly   trained  first   responder  community   is   critical  to  the   successful   introduction
of   hydrogen   fuel   cell  applications   and   their  transformation   in  how   we  use   energy.

September  1 7,  2 015 / 59
 Training  Resources  Timeline  and  Accomplishments

2009
2002 DOE  makes   Accomplishments
CaFCP operations   Future
developed  an   level  class  and   Enhancements • Online  training  –
ER  education   props   to  the  training   over  32,000   visits
program available resources
• Operations-­level  (in-­
person)  training  has  
been   attended   by  
1,030   firefighters  
2007 2014 • CaFCP training  has  
DOE  r eleases   DOE/CaFCP reached   over  7,000  
online   release  the  
awareness   National   first  responders
level  training Hydrogen  and  
Fuel  Cells  ER  
Training  
Resource

September  1 7,  2 015 / 60
Online  Awareness-­level  Training

• 100  from  hydrogen  and  emergency  response

community  conduct  broad  review  (Summer  2006) http://hydrogen.pnl.gov/FirstResponders/
• On-­‐line  training  launched  January  27,  2007
• 200-­‐300  unique  visits  monthly;  >30,000  total.

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Classroom  and  Hands-­on  Training

▶ Classroom  Content
– Hydrogen  and  Fuel  Cell  Basics
– Hydrogen  Vehicles
– Stationary  Facilities
– Emergency  Response
– Incident  Scenarios Multiple  i nstructors  for  classroom  training

▶ Demonstrations/Hands-­on  
Exercise  with  FCEV  Prop
– Demonstration  of  Hydrogen  
Flame  Characteristics
– Student  Participation  in  
Rescue  Evolutions
A  “ rescue”  at  Sunnyvale  (CA)    
Department  of  Public  Safety  

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National  First  Responder  Training  Resource

Can  be  downloaded   at  http://h2tools.org/fr/nt

September  1 7,  2 015 / 63
National  Training  Resource  Downloads

Since  October   2014

• 278  downloads

• in  6  Continents

• and  35  of  50  

states

• translated   into
Japanese   in  
support
of  Japan   fuel  cell
activities

September  1 7,  2 015 / 64
Concluding  thoughts

▶ Safe  practices  in  the  production,  storage,  distribution  and  use  of  hydrogen  
are  essential  for  deployment  of  hydrogen  and  fuel  cell  technologies. A  
significant  incident  involving  a  hydrogen  project  could  negatively  
impact  the  public's  perception  of  hydrogen  systems  as  viable,  safe,  and  
clean  alternatives  to  conventional  energy  systems.

▶ Hydrogen  CAN  be  used  safely.    However,  because  hydrogen’s  use  as  a  fuel  
is  still  a  relatively  new  endeavor,  the  proper  methods  of  handling,  storage,  
transport  and  use  are  often  not  well  understood  across  the  various  
communities  either  participating  in  or  impacted  by  its  demonstration  and  
deployment.  Those  working  with  hydrogen  and  fuel  cell  technologies  should  
utilize  the  online  resources  discussed  in  this  presentation  to  become  familiar  
with  the  technology.

▶ The  IFC,  IFCG  and  NFPA  2  provide  fundamental  requirements  for  the  use  of  
hydrogen  and  fuel  cell  technologies.     Online  resources  are  available  to  help  
code  officials  and  project  proponents  better  understand  and  apply  the  
necessary  safe  practices  for  the  successful  deployment  of  this  technology.

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Thank  You  for  Your  Attention!

The  author  wishes  to  thank  the  U.S.  Department  of  Energy’s  Fuel  Cell  
Technologies  Office  (Sunita  Satyapal,  Director  and  Charles  James,  
Safety,  Codes  and  Standards  Lead),  Dave  Conover  from  the  Pacific  
Northwest  National  Laboratory  and  the  California  Fuel  Cell  Partnership  for  
their  support  of  this  work.  

My  Contact  Information:

Nick  Barilo,  P.E.

Hydrogen   Safety  Program   Manager
Pacific  Northwest  National  Laboratory
P.O.  Box  999,  MSIN  K7-­76
Richland,  WA 99352   USA
Tel:  509-­371-­7894
[email protected]

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