Publications

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The use of risk information in establishing code and standard requirements enables: (1) An adequate and appropriate level of safety; and (2) Deployment of hydrogen facilities are as safe as gasoline facilities. This effort provides a template for clear and defensible regulations, codes, and standards that can enable international market transformation.

A series of experiments consisting of vessel-to-vessel transfers of pressurized gas using Transient PVT methodology have been conducted to provide a data set for optimizing heat transfer correlations in high pressure flow systems. In rapid expansions such as these, the heat transfer conditions are neither adiabatic nor isothermal. Compressible flow tools exist, such as NETFLOW that can accurately calculate the pressure and other dynamical mechanical properties of such a system as a function of time. However to properly evaluate the mass that has transferred as a function of time these computational tools rely on heat transfer correlations that must be confirmed experimentally. In this work new data sets using helium gas are used to evaluate the accuracy of these correlations for receiver vessel sizes ranging from 0.090 L to 13 L and initial supply pressures ranging from 2 MPa to 40 MPa. The comparisons show that the correlations developed in the 1980s from sparse data sets perform well for the supply vessels but are not accurate for the receivers, particularly at early time during the transfers. This report focuses on the experiments used to obtain high quality data sets that can be used to validate computational models. Part II of this report discusses how these data were used to gain insight into the physics of gas transfer and to improve vessel heat transfer correlations. Network flow modeling and CFD modeling is also discussed.

Part I of this report focused on the acquisition and presentation of transient PVT data sets that can be used to validate gas transfer models. Here in Part II we focus primarily on describing models and validating these models using the data sets. Our models are intended to describe the high speed transport of compressible gases in arbitrary arrangements of vessels, tubing, valving and flow branches. Our models fall into three categories: (1) network flow models in which flow paths are modeled as one-dimensional flow and vessels are modeled as single control volumes, (2) CFD (Computational Fluid Dynamics) models in which flow in and between vessels is modeled in three dimensions and (3) coupled network/CFD models in which vessels are modeled using CFD and flows between vessels are modeled using a network flow code. In our work we utilized NETFLOW as our network flow code and FUEGO for our CFD code. Since network flow models lack three-dimensional resolution, correlations for heat transfer and tube frictional pressure drop are required to resolve important physics not being captured by the model. Here we describe how vessel heat transfer correlations were improved using the data and present direct model-data comparisons for all tests documented in Part I. Our results show that our network flow models have been substantially improved. The CFD modeling presented here describes the complex nature of vessel heat transfer and for the first time demonstrates that flow and heat transfer in vessels can be modeled directly without the need for correlations.

A need exists for developing codes and standards to support the wide-spread delivery of liquid hydrogen bulk fuel and fueling station storage. To develop these codes and standards the consequences of planned and unplanned hydrogen releases must be understood. The systems under consideration are mainly those used in supplying hydrogen for transportation. These systems include production storage tanks, tanker trucks and tanks located at vehicle fueling stations. Typically these systems store hydrogen in the saturated state at approximately 11 atmospheres. Storage vessels are heavily insulated and sometimes actively cooled to minimize the rate of hydrogen boil-off (intended hydrogen release).

This report documents a series of models for describing intended and unintended discharges from liquid hydrogen storage systems. Typically these systems store hydrogen in the saturated state at approximately five to ten atmospheres. Some of models discussed here are equilibrium-based models that make use of the NIST thermodynamic models to specify the states of multiphase hydrogen and air-hydrogen mixtures. Two types of discharges are considered: slow leaks where hydrogen enters the ambient at atmospheric pressure and fast leaks where the hydrogen flow is usually choked and expands into the ambient through an underexpanded jet. In order to avoid the complexities of supersonic flow, a single Mach disk model is proposed for fast leaks that are choked. The velocity and state of hydrogen downstream of the Mach disk leads to a more tractable subsonic boundary condition. However, the hydrogen temperature exiting all leaks (fast or slow, from saturated liquid or saturated vapor) is approximately 20.4 K. At these temperatures, any entrained air would likely condense or even freeze leading to an air-hydrogen mixture that cannot be characterized by the REFPROP subroutines. For this reason a plug flow entrainment model is proposed to treat a short zone of initial entrainment and heating. The model predicts the quantity of entrained air required to bring the air-hydrogen mixture to a temperature of approximately 65 K at one atmosphere. At this temperature the mixture can be treated as a mixture of ideal gases and is much more amenable to modeling with Gaussian entrainment models and CFD codes. A Gaussian entrainment model is formulated to predict the trajectory and properties of a cold hydrogen jet leaking into ambient air. The model shows that similarity between two jets depends on the densimetric Froude number, density ratio and initial hydrogen concentration.

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This report documents activities performed in FY2006 under the ''Gas-Powder Two-Phase Flow Modeling Project'', ASC project AD2006-09. Sandia has a need to understand phenomena related to the transport of powders in systems. This report documents a modeling strategy inspired by powder transport experiments conducted at Sandia in 2002. A baseline gas-powder two-phase flow model, developed under a companion PEM project and implemented into the Sierra code FUEGO, is presented and discussed here. This report also documents a number of computational tests that were conducted to evaluate the accuracy and robustness of the new model. Although considerable progress was made in implementing the complex two-phase flow model, this project has identified two important areas that need further attention. These include the need to compute robust compressible flow solutions for Mach numbers exceeding 0.35 and the need to improve conservation of mass for the powder phase. Recommendations for future work in the area of gas-powder two-phase flow are provided.

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This report documents activities related to the ASCI AD Resistance Weld Process Modeling Project AD2003-15. Activities up to and including FY2004 are discussed. This was the third year for this multi year project, the objective of which is to position the SIERRA computational tools for the solution of resistance welding problems. The process of interest is a three-way coupled problem involving current flow, temperature buildup and large plastic deformation. The DSW application is the reclamation stem weld used in the manufacture of high pressure gas bottles. This is the first year the CALAGIO suite of codes (eCALORE, CALORE, and ADAGIO) was used to successfully solve a three-way coupled problem in SIERRA. This report discusses the application of CALAGIO to the tapered bar acceptance problem and a similar but independent tapered bar simulation of a companion C6 experiment. New additions to the EMMI constitutive model and issues related to CALAGIO performance are also discussed.