Hydrogen is an important resource for many different industries throughout the world, including refining, manufacturing, and as a direct energy source. Hydrogen production, through methods such as steam methane reforming, has been developed over several decades. There is a large global demand for hydrogen from these industries and safe production and distribution are paramount for hydrogen systems. Codes and standards have been developed to reduce the risk associated with hydrogen accidents to the public. These codes and standards are similar to those in other industries in which there is inherent risk to the public, such as gasoline and natural gas production and distribution. Although there will always be a risk to the public in these types of fuels, the codes and standards are developed to reduce the likelihood of an accident occurring and reduce the severity of impact, should one occur. This report reviews the current state of hydrogen in the United States and outlines the codes and standards that ensure safe operation of hydrogen systems. The total hydrogen demand and use in different industries is identified. Additionally, the current landscape of hydrogen production and fueling stations in the United States is outlined. The safety of hydrogen systems is discussed through an overview of the purpose, methods, and content included in codes and standards. As outlined in this safety overview, the risk to the public in operation of hydrogen generation facilities and fueling stations is reduced through implementation of appropriate measures. Codes, such as NFPA 2, ensure that the risk associated with a hydrogen system is no greater than the risk presented by gasoline refueling stations.
LaFleur, Chris B.; Taylor, Gabriel T.; Putorti, Anthony P.; Salley, Mark H.
This report documents an experimental program designed to investigate High Energy Arcing Fault (HEAF) phenomena for low-voltage metal enclosed switchgear containing aluminum conductors. This report covers full-scale laboratory experiments using representative nuclear power plant (NPP) three-phase electrical equipment. Electrical, thermal, and pressure data were recorded for each experiment and documented in this report. This report covers experiments performed on two low-voltage switchgear units with each unit consisting of two vertical sections. The data collected supports characterization of the low-voltage HEAF hazard and these results will be used to support potential improvements in fire probabilistic risk assessment (PRA) methods. The experiments were performed at KEMA Labs located in Chalfont, Pennsylvania. The experimental design, setup, and execution were completed by staff from the NRC, the National Institute of Standards and Technology (NIST), Sandia National Laboratories (SNL) and KEMA. In addition, representatives from the Electric Power Research Institute (EPRI) observed some of the experimental setup and execution. The HEAF experiments were performed between August 26 and Augsut 29, 2019 on nearidentical Westinghouse Type DS low-voltage metal-enclosed indoor switchgear. The threephase arcing fault was initiated on the aluminum main bus or in select cases on the copper bus stabs near the breaker. These experiments used either nominal 480 volts AC or 600 volts AC. Durations of the experiments ranged from approximately 0.4 s to 8.3 s with fault currents ranging from approximately 9.2 kA to 19.3 kA. Real-time electrical operating conditions, including voltage, current and frequency, were measured during the experiments. Heat fluxes and incident energies were measured with plate thermometers, radiometers, and slug calorimeters at various locations around the electrical enclosures. Environmental measurements of breakdown, conductivity and electromagnetics were also taken. The experiments were documented with normal and high-speed videography, infrared imaging and photography. The results, while limited, indicated the difficulty in maintaining and sustaining low-voltage arcs on aluminum components of sufficient duration and at a single point as observed operating experience.
This report documents an experimental program designed to investigate High Energy Arcing Fault (HEAF) phenomena. The experiments focus on providing data to better characterize the arc to improve the prediction of arc energy emitted during a HEAF event. An open box experiment allow for direct observation of the arc, which allows diagnostic instrumentation to record the phenomenological data needed for better characterization of the arc energy source term. The data collected supports characterization of the arc and arc jet, enclosure breach, material loss, and electrical properties. These results will be used to better characterizing the hazard for improvements in fire probabilistic risk assessment (PRA) realism. The experiments were performed at KEMA Labs located in Chalfont, Pennsylvania. The experimental design, setup, and execution were completed by staff from the NRC, the National Institute of Standards and Technology (NIST), Sandia National Laboratories (SNL) and KEMA Labs. In addition, representatives from the Electric Power Research Institute (EPRI) observed some of the experimental setup and execution. The HEAF experiments were performed between August 22, 2020 and September 18, 2020 on near-identical 51 cm (20 in) cube metal boxes suspended from a Unistrut support structure. The three-phase arcing fault was initiated at the ends of the conductors oriented vertically and located at the center of the box. Either aluminum or copper conductors were used for the conductors. The low-voltage experiments used 1 000 volts AC, while the medium-voltage experiments used 6 900 volts AC consistent with other recently completed experiments. Durations of the experiment ranged from 1 s to 5 s with fault currents ranging from 1 kA to 30 kA. Real-time electrical operating conditions, including voltage, current and frequency, were measured during the experiments. Heat fluxes and incident energies were measured with plate thermometers, radiometers, and slug calorimeters at various locations around the electrical enclosures. The experiments were documented with normal and high-speed videography, infrared imaging and photography.
This white paper describes the work performed by Sandia National Laboratories in the New Mexico Small Business Agreement with BayoTech. BayoTech is a hydrogen generation and distribution company that is located in Albuquerque, NM. Their goal is to distribute hydrogen via their hydrogen systems which utilize the core design that was developed by Sandia. However, because the hydrogen economy is in its nascency, the safety and operation of the generating systems require independent validation. Additionally, in their pursuit of permitting at various locations around the nation, they require fire protection engineering support in discussions with local fire marshals and neighboring industrial entities. Sandia National Laboratories has subject matter expertise in hydrogen risk modeling of consequence (overpressure and dispersion) as well as fire protection engineering. Throughout this project, Sandia has worked with BayoTech to provide our expertise in these subject areas to facilitate the market entry of their hydrogen generation project to address the dire need for decarbonization due to climate change. The general approach of the support by Sandia is outlined in the main body, while the location specific evaluation for the Port of Stockton is contained in Appendix A.
In order to establish a zone of influence (ZOI) due to a high energy arcing fault (HEAF) environment, the fragility of the targets must be determined. The high heat flux/short duration exposure of a HEAF is considerably different than that of a traditional hydrocarbon fire, which previous research has addressed. The previous failure metrics (e.g., internal jacket temperature of a cable exposed to a fire) were based on low heat flux/long duration exposures. Because of this, evaluation of different physics and failure modes was considered to evaluate the fragility of cables exposed to a HEAF. Tests on cable targets were performed at high heat flux/short duration exposures to gain insight on the relevant physics and failure modes. These tests yielded data on several relevant failure modes, including electrical failure and sustained ignition. Additionally, the results indicated a relationship between the total energy of exposure and the damage state of the cable target. This data can be used to inform the fragility of the targets.
The application of hydrogen as an energy carrier has been expanding into industrial and transportation sectors enabling sustainable energy resources and providing a zero-emission energy infrastructure. The hydrogen supply infrastructure includes processes from production and storage, to transportation and distribution, to end use. Each portion of the hydrogen supply infrastructure is regulated by international, federal, state, and local entities. Regulations are enforced by entities which provide guidance and updates as necessary. While energy sources such as natural gas are currently regulated via the Code of Federal Regulations and United States Code, there might be some ambiguity as to which regulations are applicable to hydrogen and where regulatory gaps may exist. This report contains an overview of the regulations that apply to hydrogen, and those that may indirectly cover hydrogen as an energy carrier participating in a sustainable zero emission global energy system. As part of this effort, the infrastructure of hydrogen systems and regulation enforcement entities are defined, and a visual map and reference table are developed. This regulatory map and table can be used to identify the boundaries of federal oversight for each component of the hydrogen supply value chain which includes production, storage, distribution, and use.
The need to understand the risks and implications of traffic incidents involving hydrogen fuel cell electric vehicles in tunnels is increasing in importance with higher numbers of these vehicles being deployed. A risk analysis was performed to capture potential scenarios that could occur in the event of a crash and provide a quantitative calculation for the probability of each scenario occurring, with a qualitative categorization of possible consequences. The risk analysis was structured using an event sequence diagram with probability distributions on each event in the tree and random sampling was used to estimate resulting probability distributions for each end-state scenario. The most likely consequence of a crash is no additional hazard from the hydrogen fuel (98.1–99.9% probability) beyond the existing hazards in a vehicle crash, although some factors need additional data and study to validate. These scenarios include minor crashes with no release or ignition of hydrogen. When the hydrogen does ignite, it is most likely a jet flame from the pressure relief device release due to a hydrocarbon fire (0.03–1.8% probability). This work represents a detailed assessment of the state-of-knowledge of the likelihood associated with various vehicle crash scenarios. This is used in an event sequence framework with uncertainty propagation to estimate uncertainty around the probability of each scenario occurring.
DOE has identified consistent safety, codes, and standards as a critical need for the deployment of hydrogen technologies, with key barriers related to the availability and implementation of technical information in the development of regulations, codes, and standards. Advances in codes and standards have been enabled by risk-informed approaches to create and implement revisions to codes, such as National Fire Protection Association (NFPA) 2, NFPA 55, and International Organization for Standardization (ISO) Technical Specification (TS)-19880-1. This project provides the technical basis for these revisions, enabling the assessment of the safety of hydrogen fuel cell systems and infrastructure using QRA and physics-based models of hydrogen behavior. The risk and behavior tools that are developed in this project are motivated by, shared directly with, and used by the committees revising relevant codes and standards, thus forming the scientific basis to ensure that code requirements are consistent, logical, and defensible.
Safety standards development for maintenance facilities of liquid and compressed natural gas fueled vehicles is required to ensure proper facility design and operating procedures. Standard development organizations are utilizing risk-informed concepts to develop natural gas vehicle (NGV) codes and standards so that maintenance facilities meet acceptable risk levels. The present report summarizes Phase II work for existing NGV repair facility code requirements and highlights inconsistencies that need quantitative analysis into their effectiveness. A Hazardous and Operability study was performed to identify key scenarios of interest using risk ranking. Detailed simulations and modeling were performed to estimate the location and behavior of natural gas releases based on these scenarios. Specific code conflicts were identified, and ineffective code requirements were highlighted and resolutions proposed. These include ventilation rate basis on area or volume, as well as a ceiling offset which seems ineffective at protecting against flammable gas concentrations. ACKNOWLEDGEMENTS The authors gratefully acknowledge Bill Houf (SNL -- Retired) for his assistance with the set-up and post-processing of the numerical simulations. The authors also acknowledge Doug Horne (retired) for his helpful discussions. We would also like to acknowledge the support from the Clean Cities program of DOE's Vehicle Technology Office.
This report presents the results of instrumentation cable tests sponsored by the US Nuclear Regulatory Commission (NRC) Office of Nuclear Regulatory Research and performed at Sandia National Laboratories (SNL). The goal of the tests was to assess thermal and electrical response behavior under fire-exposure conditions for instrumentation cables and circuits. The test objective was to assess how severe radiant heating conditions surrounding an instrumentation cable affect current or voltage signals in an instrumentation circuit. A total of thirty-nine small-scale tests were conducted. Ten different instrumentation cables were tested, ranging from one conductor to eight-twisted pairs. Because the focus of the tests was thermoset (TS) cables, only two of the ten cables had thermoplastic (TP) insulation and jacket material and the remaining eight cables were one of three different TS insulation and jacket material. Two instrumentation cables from previous cable fire testing were included, one TS and one TP. Three test circuits were used to simulate instrumentation circuits present in nuclear power plants: a 4–20 mA current loop, a 10–50 mA current loop and a 1–5 VDC voltage loop. A regression analysis was conducted to determine key variables affecting signal leakage time.
The objective of this research is to better understand the fire-induced failure modes of instrumentation cables and evaluate the potential effect those failure modes could have on plant instrumentation circuits (i.e., circuit, component, and/or system response). In particular, this research is intended to better quantify the signal leakage that may occur before catastrophic failure in instrumentation circuits.
This paper presents a risk assessment of a Liquefied Natural Gas (LNG)/diesel hybrid locomotive to identify and rank failures that could result in the release of LNG or Gaseous Natural Gas (GNG) to the surrounding environment. The Federal Railroad Administration (FRA) will analyze industry safety assessments of the proposed rail vehicles and the goal of this risk analysis is to identify and prioritize hazard scenarios so the FRA can ensure that they are properly addressed. For operational activities, a Failure Modes and Effects Analysis (FMEA) was performed to identify high risk failure modes. A modified hazard and operability study (HAZOP) methodology was used to analyze hazard scenarios for the maintenance activities for the LNG and Compressed Natural Gas (CNG) dual-fuel locomotives and the LNG tender car. Because refueling operations are highly dependent on human interactions, a human factors assessment was also performed on a sample refueling procedure to identify areas of improvement and identify best practices for analyzing future procedures. The FMEA resulted in the identification of 87 total failure modes for the operational phase, three of which were deemed to have a High risk priority, all involving the cryogenic storage tank. The HAZOP for the LNG tender resulted in the identification of eight credible hazard scenarios and the HAZOP for the locomotive in the maintenance mode identified 27 credible hazard scenarios. The high and medium risk failure modes and hazard scenarios should be prioritized for further analysis.
A fire at a nuclear power plant (NPP) has the potential to damage structures, systems, and components important to safety, if not promptly detected and suppressed. At Browns Ferry Nuclear Power Plant on March 22, 1975, a fire in the reactor building damaged electrical power and control systems. Damage to instrumentation cables impeded the function of both normal and standby reactor coolant systems, and degraded the operators’ plant monitoring capability. This event resulted in additional NRC involvement with utilities to ensure that NPPs are properly protected from fire as intended by the NRC principle design criteria (i.e., general design criteria 3, Fire Protection). Current guidance and methods for both deterministic and performance based approaches typically make conservative (bounding) assumptions regarding the fire-induced failure modes of instrumentation cables and those failure modes effects on component and system response. Numerous fire testing programs have been conducted in the past to evaluate the failure modes and effects of electrical cables exposed to severe thermal conditions. However, that testing has primarily focused on control circuits with only a limited number of tests performed on instrumentation circuits. In 2001, the Nuclear Energy Institute (NEI) and the Electric Power Research Institute (EPRI) conducted a series of cable fire tests designed to address specific aspects of the cable failure and circuit fault issues of concern1. The NRC was invited to observe and participate in that program. The NRC sponsored Sandia National Laboratories to support this participation, whom among other things, added a 4-20 mA instrumentation circuit and instrumentation cabling to six of the tests. Although limited, one insight drawn from those instrumentation circuits tests was that the failure characteristics appeared to depend on the cable insulation material. The results showed that for thermoset insulated cables, the instrument reading tended to drift and fluctuate, while the thermoplastic insulated cables, the instrument reading fell off-scale rapidly. From an operational point of view, the latter failure characteristics would likely be identified as a failure from the effects of fire, while the former may result in inaccurate readings.
The objective of this project was to devolop a plan for modifying the Turbulent Combustion Laboratory (TCL) with the necessary infrastructure to produce a cold (near liquid temperature) hydrogen jet. The necessary infrastructure has been specified and laboratory modifications are currently underway. Once complete, experiments from this platform will be used to develop and validate models that inform codes and standards which specify protection criteria for unintended releases from liquid hydrogen storage, transport, and delivery infrastructure.
A cooperative research and development agreement was made between Linde, LLC and Sandia to develop a plan for modifying the Turbulent Combustion Laboratory (TCL) with the necessary infrastructure to produce a cold (near liquid temperature) hydrogen jet. A three-stage heat exchanger will be used to cool gaseous hydrogen using liquid nitrogen, gaseous helium, and liquid helium. A cryogenic line from the heat exchanger into the lab will allow high-fidelity diagnostics already in place in the lab to be applied to cold hydrogen jets. Data from these experiments will be used to develop and validate models that inform codes and standards which specify protection criteria for unintended releases from liquid hydrogen storage, transport, and delivery infrastructure.
This project addresses the following technical barriers from the Safety, Codes and Standards section of the 2012 Fuel Cell Technologies Office Multi-Year Research, Development and Demonstration Plan (section 3.8): (A) Safety data and information: limited access and availability (F) Enabling national and international markets requires consistent RCS (G) Insufficient technical data to revise standards.
Building a hydrogen infrastructure system is critical to supporting the development of alternate- fuel vehicles. This report provides a methodology for implementing a performance-based design of an outdoor hydrogen refueling station that does not meet specific prescriptive requirements in NFPA 2, The Hydrogen Technologies Code . Performance-based designs are a code-compliant alternative to meeting prescriptive requirements. Compliance is demonstrated by comparing a prescriptive-based fueling station design with a performance-based design approach using Quantitative Risk Assessment (QRA) methods and hydrogen risk assessment tools. This template utilizes the Sandia-developed QRA tool, Hydrogen Risk Analysis Models (HyRAM), which combines reduced-order deterministic models that characterize hydrogen release and flame behavior with probabilistic risk models to quantify risk values. Each project is unique and this template is not intended to account for site-specific characteristics. Instead, example content and a methodology are provided for a representative hydrogen refueling site which can be built upon for new hydrogen applications.
Sandia National Laboratories evaluated published safety assessment methods across a variety of industries including Liquefied Natural Gas (LNG), hydrogen, land and marine transportation, as well as the US Department of Defense (DOD). All the methods were evaluated for their potential applicability for use in the LNG railroad application. After reviewing the documents included in this report, as well as others not included because of repetition, the Department of Energy (DOE) Hydrogen Safety Plan Checklist is most suitable to be adapted to the LNG railroad application. This report was developed to survey industries related to rail transportation for methodologies and tools that can be used by the FRA to review and evaluate safety assessments submitted by the railroad industry as a part of their implementation plans for liquefied or compressed natural gas storage ( on-board or tender) and engine fueling delivery systems. The main sections of this report provide an overview of various methods found during this survey. In most cases, the reference document is quoted directly. The final section provides discussion and a recommendation for the most appropriate methodology that will allow efficient and consistent evaluations to be made. The DOE Hydrogen Safety Plan Checklist was then revised to adapt it as a methodology for the Federal Railroad Administration’s use in evaluating safety plans submitted by the railroad industry.
Automakers and fuel providers have made public commitments to commercialize light duty fuel cell electric vehicles and fueling infrastructure in select US regions beginning in 2014. The development, implementation, and advancement of meaningful codes and standards is critical to enable the effective deployment of clean and efficient fuel cell and hydrogen solutions in the energy technology marketplace. Metrics pertaining to the development and implementation of safety knowledge, codes, and standards are important to communicate progress and inform future R&D investments. This document describes the development and benchmarking of metrics specific to the development of hydrogen specific codes relevant for hydrogen refueling stations. These metrics will be most useful as the hydrogen fuel market transitions from pre-commercial to early-commercial phases. The target regions in California will serve as benchmarking case studies to quantify the success of past investments in research and development supporting safety codes and standards R&D.
Safety standards development for maintenance facilities of liquid and compressed gas fueled large-scale vehicles is required to ensure proper facility design and operation envelopes. Standard development organizations are utilizing risk-informed concepts to develop natural gas vehicle (NGV) codes and standards so that maintenance facilities meet acceptable risk levels. The present report summarizes Phase I work for existing NGV repair facility code requirements and highlights inconsistencies that need quantitative analysis into their effectiveness. A Hazardous and Operability study was performed to identify key scenarios of interest. Finally, scenario analyses were performed using detailed simulations and modeling to estimate the overpressure hazards from HAZOP defined scenarios. The results from Phase I will be used to identify significant risk contributors at NGV maintenance facilities, and are expected to form the basis for follow-on quantitative risk analysis work to address specific code requirements and identify effective accident prevention and mitigation strategies.