1. 1 Safety Study of Hydrogen Supply Stations for the Review of High Pressure Gas Safety Law in Japan International Conference on Hydrogen Safety September 10, 2005 Japan Petroleum Energy Center (JPEC) Hydrogen Technology Group Shigeki Kikukawa

2. 2 In Japan, regulations for gaseous hydrogen supply stations were revised in April 2005. We made drafts of the regulations.

3. 3 Topics Introduction Background of the project Safety Study Risk Assessment Basic Approach Risk Matrix Consequence Estimation and Likelihood Estimation Review of Regulations Safety Requirements for High Pressure Gas Safety Law Setback Distance and others

4. 4 Japan Petroleum Energy Center (JPEC) JPEC  Established in 1986  Affiliated with the Ministry of Economy, Trade and Industries of Japan (METI)  Carries out a range of activities, which are mainly related to petroleum industry.  http://www.pecj.or.jp/

5. 5 Governmental Leadership of FCV & H2 Infrastructure Japanese government is strongly promoting the wide spread of fuel cells. Anticipated market size Setting R&D Target Review of codes & Standards Financial help for R&D and Demonstration projects 201020202030 FCV (vehicles)50,0005M15M Hydrogen Fueling Station (stations)5003,5008,500 Driving Force

6. 6 Concerns with Regulation A task force formed by the government in Oct. 2002.  Released the Road Map.  Identified 28 concerns with regulation which should be reviewed for market introduction of Fuel Cells. 5 itemsTo be clarified before Dec. 2002 3 itemsFCV To be clarified before FY2005 4 itemsHigh Pressure H2 Tank of FCV 7 items Setback distance etc. H2 Infrastructure 5 itemsStationary FC

7. 7 Key Issue 2: Setback Distance H2 17m 11.3m 8m 17m : Hospital, school, etc. 11.3m : Dwellings 8m : Fire sources Setback distance for general high pressured equipment H2 We have to add some safety requirements to reduce the setback distance. High Pressure Gas Safety Law Hydrogen stations must FREE from DANGER!

8. 8 Key Issue 2 : Permission to set up H2 stations with Gasoline stations H2 Gas Separately Same area Gas H2 Fire Protection Law Key Issue 3 : Permission to build in an urban area Residential area H2 Commercial area H2 Industrial area H2 Residential area Commercial area Industrial area Building Standard Law

9. 9 Scope of JPEC’s project Mission: Developing drafts of revised safety C&S of H2 stations  Focused on H2 station  Pipelines, Transportation and FCV are out of scope  Relevant regulations High Pressure Gas Safety Law Fire Protection Law Building Standards Law Schedule  We should prepare drafts of review by Sep. 2004.  Government would review the regulations by the end of Mar. 2005. Funds  New Energy and Industrial Technology Development Organization (NEDO)

10. 10 Japan Steel Works Material Test (Stainless steels, Chromium Molybdenum steels ) Reliability of compressor Japan Steel Works Material Test (Stainless steels, Chromium Molybdenum steels ) Reliability of compressor Project Partners Japan Petroleum Energy Center (JPEC) General administration Risk assessment Japan Petroleum Energy Center (JPEC) General administration Risk assessment Mitsubishi Heavy Industries Ltd. (MHI) H2 Diffusion & Explosion Experiments/CFD Mitsubishi Heavy Industries Ltd. (MHI) H2 Diffusion & Explosion Experiments/CFD Tatsuno Corporation Reliability of H2 gas dispenser Tatsuno Corporation Reliability of H2 gas dispenser Japan Industrial Gas Association Reliability of piping materials, valves, etc. Japan Industrial Gas Association Reliability of piping materials, valves, etc. Iwatani International Corp. Reliability of liquid H2 system Iwatani International Corp. Reliability of liquid H2 system

11. 11 Safety Study Risk Assessment  Popular and highly experienced measure is used for our study.

12. 12 Basic Approach Definition of H2 station model Hazard Identification Risk Estimation Risk Evaluation Risk Reduction Tolerable Risk? N Y Output of the study : Safety requirements for H2 station Experiments, Simulations, Surveys, etc. By Project Partners END START

13. 13 Definition of H2 Station model The model should be concrete enough for risk assessment. The model should keep generality to be used for the review of C&S. On-site type H2 station  H2 Demand: 300Nm 3 /hr (30Nm 3 /vehicle * 10vehicles/hr)  H2 Generation : 300Nm 3 /hr  Compressor : 300Nm 3 /hr, 40MPa  H2 Cylinders : 250L * 14 = 3500L (40MPa, 1400Nm 3 )  Dispenser : 35MPa (supply pressure)

14. 14 Types of H2 Stations 1) On-site type 3) Liquid hydrogen type 2) Off-site type Material tank Reformer PSA Compressor Dispenser Heat Exchanger Gas Dispenser Liquid Dispenser Cylinders Liquid H2 storage Liquid H2 pump Study was finished Study is on progress

15. 15 Hazard Identification Applied Methods : HAZOP (Hazard and Operability Studies) FMEA (Failure Mode and Effect Analysis) 233 accident scenarios were identified for the on- site type H2 station model Failure and deterioration Human Error Natural Disasters

16. 16 Risk Matrix (Risk Acceptance Criteria) H (High):Risk cannot be acceptable. Remedial actions should be considered to reduce the risk to acceptable level. M (Medium):In principle, risk cannot be 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 A Improbable B Remote C Occasional D Probable 1 Extremely Severe Damage HHHH 2 Severe Damage MHHH 3 Damage MMHH 4 Small Damage LLMH 5 Minor Damage LLLM

17. 17 Examples of Risk Evaluation (1) Risk rank of no safety requirements 800Nm3 of hydrogen leakage from D=10mm, 40MPa Consequence Level 1: Extremely Severe Damage Likelihood Level C: Occasional Likelihood Consequence ABCD 1Extremely SevereHHHH 2Severe DamageMHHH 3DamageMMHH 4Small DamageLLMH 5Miner DamageLLLM Scenario : Rupture of pipe Earthquake – Fall of Cylinder Unit – Rupture of pipe – H2 leakage – Explosion or Jet Fire Earthquake – Fall of Cylinder Unit – Rupture of pipe – H2 leakage – Explosion or Jet Fire Can not be acceptable

18. 18 (2) Applied Safety Requirements + To Lower the Consequence + To Lower the Consequence - Install Earthquake detector and Emergency Isolation Valve with fail close type + To Lower the Likelihood + To Lower the Likelihood - Fix the cylinder unit on hard concrete base - Establish the Emergency Isolation Valve within the cylinder unit Acceptable! Likelihood Consequence ABCD 1Extremely SevereHHHH 2Severe DamageMHHH 3DamageMMHH 4Small DamageLLMH 5Miner DamageLLLM Examples of Risk Evaluation Cont. H2 STOP Cylinder Unit

19. 19 Consequence Estimation Basic data for consequence estimation was provided by Mitsubishi Heavy Industries, Ltd. MHI carried out Experiments and Computational Simulations of H2 Diffusion, Explosion, and Jet Fire.

20. 20 10mmΦ 40→1MPa Experiments of Jet Fire (video) Same as left, with wall (h=3m, w=6m)

21. 21 Likelihood Estimation Experiments & Surveys by our Project Partners Material: The Japan Steel Works Compressor: The Japan Steel Works Dispenser: Tatsuno Corporation General piping materials & instrument: Japan Industrial Gas Association

22. 22 Dispenser Durability Tests for Filling hose & Joint Hand valve Breakaway device Etc.

23. 23 Compressor Durability Tests Hydrogen leakage Noise Control Vibration Etc.

24. 24 Material (Stainless Steels and Chromium Molybdenum Steels) Tests for Hydrogen Embrittlement in pressurized hydrogen environment are necessary. Tensile test Deep notch test Fracture toughness test Fatigue test Etc.

25. 25 Review of Regulations The result of the study was reported to the competent authorities, then examined, and basically accepted by them. The competent authorities revised relevant regulations. The new regulations have been effective since April 2005. High Pressure Gas Safety Law Fire Protection Law Building Standard Law

26. 26 Safety Requirements for High Pressure Gas Safety Law Road H2 Dispenser Office C T Compressor Storage Gasoline Dispenser Reformer Ｒ PSA Ａ Ａ Ａ Ａ Ｐ Tank Setback Distance 6 m Wall h=2m Setback Distance can be shortened with appropriate fire protection wall

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

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

29. 29 Breakaway Device Guardrail Piping in Trench Flame Detector Emergency Stop Button Pressure release after refueling

30. 30 Frame Structure H2 Leak Detector Emergency Isolation Valve, Check Valve Water Sprinkler Flame Detector Fire Protection Wall Pressure Indicator, Safety Valve

31. 31 Compressor should be placed in an enclosure. Ventilation with Interlock System H2 Leak Detector

32. 32 Conclusions We made drafts of revised safety codes and standards of Hydrogen supply stations. Government reviewed the regulations based on our drafts and new regulations have been in force now.  High pressure gas safety law  Fire Protection Law  Building Standard Law It was permitted to build H2 supply station in an urban area and to install them in the premise of a gasoline station.

33. 33 END

34. 34 Likelihood Levels LevelDescriptionDefinition A ImprobablePossible, but the probability is extremely low. About once in several thousands years or less. B RemoteUnlikely to occur in lifetime of one H2 station. About once in several hundreds years. C OccasionalLikely to occur once in lifetime of one H2 station. About once in several decades. D ProbableLikely to occur several times in 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

35. 35 Consequence Levels LevelDescriptionMaterial DamageHuman Damage 1Extremely Severe Damage Collapse of nearby dwelling houses One or more fatalities of pedestrians or dwellers 2Severe DamageMajor damage of nearby dwelling houses One or more fatalities of customers or station workers 3DamageMinor damage of nearby dwelling houses Injury of hospitalization 4Small DamageWindows brokenInjury of medical treatment 5Minor DamageNo damage to nearby dwelling houses Minor injury