CFD simulation study to investigate the risk from hydrogen vehicles in tunnels

When introducing hydrogen-fuelled vehicles, an evaluation of the potential change in risk level should be performed. It is widely accepted that outdoor accidental releases of hydrogen from single vehicles will disperse quickly, and not lead to any significant explosion hazard. The situation may be different for more confined situations such as parking garages, workshops, or tunnels. Experiments and computer modelling are both important for understanding the situation better. This article reports a simulation study to examine what, if any, is the explosion risk associated with hydrogen vehicles in tunnels. Its aim was to further our understanding of the phenomena surrounding hydrogen releases and combustion inside road tunnels, and furthermore to demonstrate how a risk assessment methodology developed for the offshore industry could be applied to the current task. This work is contributing to the EU Sixth Framework (Network of Excellence) project HySafe, aiding the overall understanding that is also being collected from previous studies, new experiments and other modelling activities.     

Development of Korean hydrogen fueling station codes through risk analysis

When hydrogen fueling stations were constructed first time in Korea in 2006, there were no standards for hydrogen fueling stations. Hence the CNG (Compressed Natural Gas) station codes were temporarily adopted. In last three years, from 2006 to 2009, the studies for the development of hydrogen fueling station standards were carried out, with the support of the Korean government. In this study, three research groups cooperated to develop optimized hydrogen fueling station codes through risk analysis of hydrogen production and filling systems. Its results were integrated to develop the codes. In the first step to develop the codes, the standards for CNG stations and hydrogen fueling station were compared with each other and analyzed. By referring to foreign hydrogen fueling station standards, we investigated the potential problems in developing hydrogen fueling station codes based on the CNG station standards. In the second, the results of the high-pressure hydrogen leakage experiment were analyzed, and a numerical analysis was performed to establish the safety distance from the main facilities of a hydrogen fueling station to the protection facilities. In the third, HAZOP (Hazard and Operability) and FTA (Fault Tree Analysis) safety assessments were carried out for the on-site and off-site hydrogen fueling stations—currently being operated in Korea— to analyze the risks in existing hydrogen fueling stations. Based on the study results of the above three groups, we developed one codes for off-site type hydrogen fueling stations and another codes for on-site type hydrogen fueling stations. These were applied from September 2010.     

Simulation of high-pressure liquid hydrogen releases

Sandia National Laboratories is working with stakeholders to develop scientific data for use by standards development organizations to create hydrogen codes and standards for the safe use of liquid hydrogen. Knowledge of the concentration field and flammability envelope for high-pressure hydrogen leaks is an issue of importance for the safe use of liquid hydrogen. Sandia National Laboratories is engaged in an experimental and analytical program to characterize and predict the behavior of liquid hydrogen releases. This paper presents a model for computing hydrogen dilution distances for cold hydrogen releases. Model validation is presented for leaks of room temperature and 80 K high-pressure hydrogen gas. The model accounts for a series of transitions that occurs from a stagnate location in the tank to a point in the leak jet where the concentration of hydrogen in air at the jet centerline has dropped to 4% by volume. The leaking hydrogen is assumed to be a simple compressible substance with thermodynamic equilibrium between hydrogen vapor, hydrogen liquid and air. For the multi-phase portions of the jet near the leak location the REFPROP equation of state models developed by NIST are used to account for the thermodynamics. Further downstream, the jet develops into an atmospheric gas jet where the thermodynamics are described as a mixture of ideal gases (hydrogen–air mixture). Simulations are presented for dilution distances in under-expanded high-pressure leaks from the saturated vapor and saturated liquid portions of a liquid hydrogen storage tank at 10.34 barg (150 PSIG).     

Multidimensional risk assessment and categorization of hydrogen pipelines

The use of hydrogen has been shown to be an efficient form of producing energy and meeting society's demands for energy. In this perspective, pipelines are known as the safest and most economical transportation mode for hydrogen. However, accidents in this type of structure lead to multiple consequences of losses such as those related to people, the environment and properties. From this perspective, decision-makers are required to tackle the likelihood of these and to make suitable decisions that can prevent accidents from happening. Multicriteria methods have played an important role in addressing multiple risk problems when there is a need to assign priorities to risk-based decisions. This paper puts forward a multidimensional risk model to categorize hydrogen pipeline sections according to levels of risks based on Utility Theory and the ELECTRE TRI method. A probabilistic modeling is proposed so as to incorporate elements of risk analysis into the evaluation of situations such as accidental scenarios, their probabilities and consequences. An application of the model is presented for a hydrogen pipeline. The results demonstrate that measures to prevent and mitigate risks can be sharpened by taking into account the human, environmental and financial risks dimensions of impacts. Thus, the sections of the pipeline studied are sorted into categories of risks, where 4 out of 10 sections are assigned to the high-risk category, 1 to the medium-risk category, and 5 sections to the low-risk category. A local sensitivity analysis was conducted which varied the weights of the dimensions. Varying the weights by 20% showed that the risk of 3 sections increases to the medium-risk category and 1 section changes to the high-risk one. Moreover, this paper indicates visualization tools that are efficient at communicating information on the levels of risk and the categories of the sections, thus contributing to assessing models that categorize risk in hydrogen pipelines. By doing so this paper supports the process of prioritizing resources for pipeline sections, the aim being to minimize multiple losses.     

Quantitative risk assessment on 2010 Expo hydrogen station

This paper presents a QRA study on a gaseous hydrogen refueling station of 2010 World Expo. Risks to station personnel, to refueling customers and to third parties are evaluated respectively. Uncertainties that intervene in the risk analysis are also discussed. The results show that the leaks from compressors and dispensers are the main risk contributors to first party and second party risks of the Expo station, indicating that risk mitigation measures should in the first place be implemented on compressors and dispensers. For the sake of the safety of station personnel, customers, and people outside the Expo station, additional safety barrier systems must be implemented on compressors and dispensers to prevent continuous release of hydrogen from happening. With appropriate mitigation measures on compressors and dispensers, risks to all three parties of the Expo station can be reduced to the value lower than the risk acceptance criteria.     

Experimental evaluation of barrier walls for risk reduction of unintended hydrogen releases

Hydrogen-jet flames resulting from ignition of unintended releases can be extensive in length and pose hazards associated with radiation and impingement onto objects, combustible materials and people. Depending on the leak diameter and source pressure, the resulting consequence distances can be unacceptably large. One possible mitigation strategy to reduce exposure to jet flames is to incorporate barriers around hydrogen storage and delivery equipment. While reducing the extent of unacceptable consequences, the walls may introduce other hazards if not properly configured. An experimental program has been implemented to better characterize the effectiveness of barrier walls at risk mitigation. This paper describes the experiments and presents results obtained for various barrier configurations. The measurements include flame deflection using standard and infrared video, high-speed movies (500 fps) to study initial flame propagation from the ignition source, overpressure levels due to ignition, wall deflection, radiative heat flux, and gas and wall temperatures. The various barrier designs are evaluated in terms of their mitigation effectiveness for the associated hazards present. The results show that barrier walls are effective at deflecting flames in a desired direction. While barrier walls can result in increased overpressures and radiative heat flux in the vicinity of the wall, they can also attenuate the effects of these hazards in surrounding areas if properly implemented.     

Preliminary hazard identification for risk assessment on a complex system for hydrogen production

Renewable power generation facilities are constantly expanding due to the expected depletion of fossil fuels and the increasingly demanding policy of pollution control. Having said that, hydrogen is one of the promising energy sources. That said, hydrogen chain safety is an unescapable parameter that should continuously coexist with the development of hydrogen domain. In this context, this article presents a contribution to the risk analysis and evaluation of a complex hydrogen production system 'EGA-9000′ at CIEMAT (Centre for Research on Energy, Environment and Technology - Madrid, Spain). The methodology followed in this study revolves around the risk analysis process through a FAST (Functional Analysis System Technique) functional analysis method and a HAZOP (HAZard and Operability) dysfunctional analysis method. The evaluation of the thirty-three scenarios identified by the risk analysis shows that the studied system is insecure. Indeed, five scenarios at an unacceptable level of risk. And it is noted that the risk of fire and explosion is the major risk for all scenarios studied. To this end, safety measures (recommendation) have been proposed based on the weaknesses detected by the risk analysis carried out.     

Analysis of hydrogen incidents to support risk assessment

Hydrogen is an emerging alternative fuel, yet its properties like wide flammability range, extremely fast burning rate (order of magnitude larger compared to natural gas) and the considerably high amount of energy released when it burns or explodes render it as dangerous, if not handled with care. Hydrogen Incident Reporting Database (HIRD) is one of the various databases which have been generated to collect incident information in hydrogen industry. In this study, 32 chosen (from HIRD) hydrogen processing incidents have been analyzed to learn about their root causes. As a result of the study, statistical values about the effects, causes and consequences as well as a check-list for avoiding these incidents, have been developed. The support to risk assessment is mainly directed to the analysis of weak points and system optimization. For support of various aspects of risk analysis an extension of incident analysis and its documentation is recommended.     

Risk and sustainability analysis of complex hydrogen infrastructures

Building a network of hydrogen refuelling stations is essential to develop the hydrogen economy within transport. Additional, hydrogen is regarded a likely key component to store and convert back excess electrical power to secure future energy supply and to improve the quality of biomass-based fuels. Therefore, future hydrogen supply and distribution chains will have to address several objectives. Such a complexity is a challenge for risk assessment and risk management of these chains because of the increasing interactions. Improved methods are needed to assess the supply chain as a whole. The method of “Functional modelling” is discussed in this paper. It will be shown how it could be a basis for other decision support methods for comprehensive risk and sustainability assessments.     

Simulation on thermoelectric device with hydrogen catalytic combustion

The micro-thermoelectric-generator based on catalytic combustion of hydrogen and oxygen was designed. With the application of general finite reaction rate model in CFD software of FLUENT, the effect of inlet parameters on the highest temperature difference between the hot and cold plate of the generator was studied. Results showed that, the temperature in the heating and cooling channel of the micro-thermoelectric-generator was uniform; with the increasing of inlet reactant temperature, the highest temperature difference increased, but the total efficiency of the generator decreased. Results can be used to the further design and optimization of micro-thermoelectric-generator based on hydrogen catalytic combustion.     

Simulation of small-scale releases from liquid hydrogen storage systems

Knowledge of the concentration field and flammability envelope from small-scale leaks is important for the safe use of hydrogen. These small-scale leaks may occur from leaky fittings or o-ring seals on liquid hydrogen-based systems. The present study focuses on steady-state leaks with large amounts of pressure drop along the leak path such that hydrogen enters the atmosphere at near atmospheric pressure (i.e. Very low Mach number). A three-stage buoyant turbulent entrainment model is developed to predict the properties (trajectory, hydrogen concentration and temperature) of a jet emanating from the leak. Atmospheric hydrogen properties (temperature and quality) at the leak plane depend on the storage pressure and whether the leak occurs from the saturated vapor space or saturated liquid space. In the first stage of the entrainment model ambient temperature air (295 K) mixes with the leaking hydrogen (20-30 K) over a short distance creating an ideal gas mixture at low temperature (∼65 K). During this process states of hydrogen and air are determined from equilibrium thermodynamics using models developed by NIST. In the second stage of the model (also relatively short in distance) the radial distribution of hydrogen concentration and velocity in the jet develops into a Gaussian profile characteristic of free jets. The third and by far the longest stage is the part of the jet trajectory where flow is fully developed. Results show that flammability envelopes for cold hydrogen jets are generally larger than those of ambient temperature jets. While trajectories for ambient temperature jets depend solely on the leak densimetric Froude number, results from the present study show that cold jet trajectories depend on the Froude number and the initial jet density ratio. Furthermore, the flammability envelope is influenced by the hydrogen concentration in the jet at the beginning of fully developed flow.     

Hydrogen storage and delivery: Review of the state of the art technologies and risk and reliability analysis

Among all introduced green alternatives, hydrogen, due to its abundance and diverse production sources is becoming an increasingly viable clean and green option for transportation and energy storage. Governments are considerably funding relevant researches and the public is beginning to talk about hydrogen as a possible future fuel. Hydrogen production, storage, delivery, and utilization are the key parts of the Hydrogen Economy (HE). In this paper, hydrogen storage and delivery options are discussed thoroughly. Then, since safety and reliability of hydrogen infrastructure is a necessary enabling condition for public acceptance of these technologies and any major accident involving hydrogen can be difficult to neutralize, we review the main existing safety and reliability challenges in hydrogen systems. The current state of the art in safety and reliability analysis for hydrogen storage and delivery technologies is discussed, and recommendations are mentioned to help providing a foundation for future risk and reliability analysis to support safe, reliable operation.     

An index-based risk assessment model for hydrogen infrastructure

This study focuses on the development of a risk assessment model associated with the safety of a hydrogen infrastructure system. The safety of hydrogen infrastructure is one of the crucial pre-requisites for a sustainable economy and accordingly, its design should be made based upon the performance to investigate and evaluate the risks from or out of the required infrastructure. In order to support strategic decision-making for safe hydrogen infrastructure, this study proposes an appropriate index-based risk assessment model. The model evaluates the hydrogen infrastructure using the relative risk ranking of the hydrogen activities such as hydrogen production, storage and transportation, and the relative impact levels of regions. The relative risk rankings of the hydrogen activities are rated a quantitative risk analysis, whereas the relative impact level of regions is rated based on the regional characteristics such as population density. With consideration of regional characteristics, the proposed model makes it possible not only to assess the risks of processes and technologies associated with hydrogen but also to compare the relative safety levels of the hydrogen infrastructures made up with various hydrogen activities. In order to show the features and capabilities of the model, four future hydrogen infrastructure scenarios in Korea are examined in the study. The result shows that distributed production, and mass storage and transportation via liquefied hydrogen facility are relatively safer than centralized production, and compressed-gaseous hydrogen storage and transportation, respectively.     

Ignitability limits for combustion of unintended hydrogen releases: Experimental and theoretical results

The ignition limits of hydrogen/air mixtures in turbulent jets are necessary to establish safety distances based on ignitable hydrogen location for safety codes and standards development. Studies in turbulent natural gas jets have shown that the mean fuel concentration is insufficient to determine the flammable boundaries of the jet. Instead, integration of probability density functions of local fuel concentration within the quiescent flammability limits, termed the flammability factor, was shown to provide a better representation of ignition probability. Recent studies in turbulent hydrogen jets showed that the envelope of ignitable gas composition (based on the mean hydrogen concentration), did not correspond to the known flammability limits for quiescent hydrogen/air mixtures. The objective of this investigation is to validate the flammability factor approach to the prediction of ignition in hydrogen leak scenarios. The ignition probability within a turbulent hydrogen jet was determined using a pulsed Nd:YAG laser as the ignition source. Laser Rayleigh scattering was used to characterize the fuel concentration throughout the jet. Measurements in methane and hydrogen jets exhibit similar trends in the ignition contour, which broadens radially until an axial location is reached after which the contour moves inward to the centerline. Measurements of the mean and fluctuating hydrogen concentration are used to characterize the local composition statistics conditional on whether the laser spark results in a local ignition event or complete light-up of a stable jet flame. The flammability factor is obtained through direct integration of local probability density functions. A model was developed to predict the flammability factor using a presumed probability density function with parameters obtained from experimental data and computer simulations. Intermittency effects that are important in the shear layer are incorporated in a composite probability density function. By comparing the computed flammability factor with the measured ignition probability we have validated the flammability factor approach for application to ignition of hydrogen jets.     

Comparative risk study of hydrogen and gasoline dispensers for vehicles

This paper describes an investigation into the acceptability of installing hydrogen dispensers in public areas based on risk assessments. Because gasoline dispenser risks have been widely accepted for many years, they were used as a benchmark in this study to analyze the risks of hydrogen dispensers. More specifically, we performed risk assessments for both hydrogen and gasoline dispensers and then compared and analyzed the results. We began the process by creating models for both hydrogen and gasoline dispensers that represented their various specifications and elements. Next, potential accident scenarios for each dispenser model were identified by failure mode effect analysis (FMEA) and hazard and operability study (HAZOP). The risks of each scenario were then qualitatively evaluated and the results were organized into risk matrices. By comparing the results of both hydrogen and gasoline dispensers with and without existing safety measures, the appropriateness of their safety measures were validated. Furthermore, by comparing the results of hydrogen and gasoline dispenser safety measures, it was confirmed that the risk levels of the two types were practically equivalent. Therefore, we concluded that the risks involved with installing hydrogen dispensers in public areas can be considered acceptable.     

A quantitative risk assessment of hydrogen fuel cell forklifts

With the increasing deployment of hydrogen fuel cell forklifts, it is essential to understand the risks of incidents involving these systems. A quantitative risk assessment (QRA) study was conducted to determine the potential hydrogen release scenarios, probabilities, and consequences in fuel cell forklift operations. QRA modeling tools, such as fault tree analysis (FTA) and event sequence diagrams (ESD), were used together with hydrogen systems data. This work provides insights into the fatality risk from a hydrogen fuel cell forklift and the reliability of its design and components. The analysis shows that the expected fatal accident rate of a hydrogen forklift is considerably higher than current fatal injury rates observed by the Bureau of Labor Statistics for industrial truck operators and material handling occupations. Nevertheless, the average individual risk posed to forklift drivers was found to be likely tolerable based on current risks accepted by industrial truck operators. Jet fires are found to dominate the system's risk, however, the risk of explosions is also considerable. An importance measures analysis shows that these risks could be mitigated by improving the design and reliability of pressure relief devices, as well as other components prone to leak such as filters and check valves. We also identify sources of uncertainty and conservatisms in the QRA process that can guide future research in hydrogen systems. These results provide powerful insight into improvements in the design of fuel cell forklifts to reduce risk and enable the safe deployment of this key technology for a decarbonized future.     

Security risk analysis of a hydrogen fueling station with an on-site hydrogen production system involving methylcyclohexane

Although many studies have looked at safety issues relating to hydrogen fueling stations, few studies have analyzed the security risks, such as deliberate attack of the station by threats such as terrorists and disgruntled employees. The purpose of this study is to analyze security risks for a hydrogen fueling station with an on-site production of hydrogen from methylcyclohexane. We qualitatively conducted a security risk analysis using American Petroleum Institute Standard 780 as a reference for the analysis. The analysis identified 93 scenarios, including pool fires. We quantitatively simulated a pool fire scenario unique to the station to analyze attack consequences. Based on the analysis and the simulation, we recommend countermeasures to prevent and mitigate deliberate attacks.     

Simulation and risk assessment of hydrogen leakage in hydrogen production container

In this paper, the hydrogen leakage and diffusion characteristics analysis and risk assessment are carried out on the container where a 2 Nm³/h alkaline hydrogen production device is located. Firstly, the transient and steady process of hydrogen leakage from hydrogen production container is analyzed. Secondly, the dynamic balance of combustible hydrogen cloud is analyzed, the concept of critical ventilation flow is put forward. It was found that in order to reduce the flammable volume by 85%, the installed ventilation can only cover the leakage flow of 1.0 Nm³/min. Finally, TNT equivalent method is used to evaluate the hazard degree of hydrogen leakage. It is found that the existed hydrogen production container ventilation device can only exhaust the hydrogen-air cloud with small flow leakage, while the accumulation of gas cloud still exists in large flow leakage. Under the critical ventilation flow, the minor injury radius can be reduced from 4.8 m to 2.78 m. The effect of critical ventilation flow was verified.