Germany

The current work is devoted to problems connected with application of CFD tools for safety analysis of large-scale industrial structures. With the aim to preserve conservatism of overall process of multistage procedure of such analysis special efforts are required. A strategy which has to lead to obtaining of reliable results in CFD analysis is discussed. Different aspects of proposed strategy including: adequate choice of physical and numerical models procedure of validation simulations and problem of ‘under-resolved’ simulations are considered. For physical phenomena which could cause significant uncertainties in the course of scenario simulation an approach which complements CFD simulations by application of auxiliary criteria is presented. Physical basis and applicability of strong flame acceleration and detonation-to-deflagration transition criteria are discussed. In concluding part two examples of application of presented approach for nuclear power plant and workshop cell for hydrogen driven vehicles are presented.

About 20 years ago Fraunhofer ICT has performed large scale experiments with premixed hydrogen air mixtures [1]. A special feature has been the investigation of the combustion of the mixture within a partial confinement simulating some sort of a “lane” which may exist in reality within a hydrogen production or storage plant for example. Essentially three different types of tests have been performed: combustion of quiescent mixtures combustion of mixtures with artificially generated turbulence by means of a fan and combustion of mixtures with high speed flame jet ignition. The observed phenomena will be discussed on the basis of measured turbulence levels flame speeds and overpressures. Conditions for DDT concerning critical turbulence levels and flame speeds as well as a scaling rule for DDT related to the detonation cell size of the mixture can be derived from the experiments for this special test setup. The relevance of the results with respect to safety aspects of future hydrogen technology is assessed. Combustion phenomena will be highlighted by the presentation of impressive high speed film videos.

To provide more practical data for safety assessments a systematic study of explosion and combustion processes which can take place in mixtures produced by jet releases in realistic environmental conditions is required. The presented work is aimed to make step forward in this direction binding three inter-connected tasks: (i) study of horizontal and vertical jets (ii) study of the burnable clouds formed by jets in different geometry configurations and (iii) examination of combustion and explosion processes initiated in such mixtures. Test matrix for the jet experiments included variation of the release pressure and nozzle diameter with the aim to study details of the resulting hydrogen concentration and velocity profiles depending on the release conditions. In this study the following parameters were varied: mass flow rate jet nozzle diameter (to alter gas speed) and geometry of the hood located on top of the jet. The carried out experiments provided data on detailed structure for under-expanded horizontal and buoyant vertical jets and data on pressure loads resulted from deflagration of various mixtures formed by jet releases. The data on pressures waves generated in the conditions under consideration provides conservative estimation of pressure loads for realistic leaks.

Metal hydrides are used for hydrogen storage. AlH3 shows a capacity to store about 10 wt% hydrogen. Its hydrogen is split-off in the temperature interval of 400–500 K. On dehydrogenation a nano-structured Al material emerges with specific surfaces up to 15–20 m2/g. The surface areas depend on the heating rate because of a temperature dependent crystallite growth. The resulting Al oxidizes up to 20–25% weight on air access forming an alumina passivation layer of 3–4 nm thickness on all exposed surfaces. The heat released from this Al oxidation induces a high risk to this type of hydrogen storage if the containment might be destroyed accidentally. The kinetics of the dehydrogenation and the subsequent oxidation is investigated by methods of thermal analysis. A reaction scheme is confirmed which consists of a starting Avrami-Erofeev mechanism followed by formal 1st order oxidation on unlimited air access. The kinetic parameters activation energies and pre-exponentials are evaluated and can be used to calculate the reaction progress. Together with the heat of the Al oxidation the overall heat release and the related rate can be estimated.

Precipitation hardenable (PH) nickel (Ni) alloys are often the most reliable engineering materials for demanding oilfield upstream and subsea applications especially in deep sour wells. Despite their superior corrosion resistance and mechanical properties over a broad range of temperatures the applicability of PH Ni alloys has been questioned due to their susceptibility to hydrogen embrittlement (HE) as confirmed in documented failures of components in upstream applications. While extensive work has been done in recent years to develop testing methodologies for benchmarking PH Ni alloys in terms of their HE susceptibility limited scientific research has been conducted to achieve improved foundational knowledge about the role of microstructural particularities in these alloys on their mechanical behaviour in environments promoting hydrogen uptake. Precipitates such as the γ′ γ′′ and δ-phase are well known for defining the mechanical and chemical properties of these alloys. To elucidate the effect of precipitates in the microstructure of the oil-patch PH Ni alloy 718 on its HE susceptibility slow strain rate tests under continuous hydrogen charging were conducted on material after several different age-hardening treatments. By correlating the obtained results with those from the microstructural and fractographic characterization it was concluded that HE susceptibility of oil-patch alloy 718 is strongly influenced by the amount and size of precipitates such as the γ′ and γ′′ as well as the δ-phase rather than by the strength level only. In addition several HE mechanisms including hydrogen-enhanced decohesion and hydrogen-enhanced local plasticity were observed taking place on oil-patch alloy 718 depending upon the characteristics of these phases when present in the microstructure.

Link to document download on Royal Society Website

"This paper summarises the modelling and experimental programme in the EC FP6 project HYPER. A number of key results are presented and the relevance of these findings to installation permitting guidelines (IPG) for small stationary hydrogen and fuel cell systems is discussed. A key aim of the activities was to generate new scientific data and knowledge in the field of hydrogen safety and where possible use this data as a basis to support the recommendations in the IPG. The structure of the paper mirrors that of the work programme within HYPER in that the work is described in terms of a number of relevant scenarios as follows: 1. high pressure releases 2. small foreseeable releases 3. catastrophic releases and 4. the effects of walls and barriers. Within each scenario the key objectives activities and results are discussed.<br/>The work on high pressure releases sought to provide information for informing safety distances for high-pressure components and associated fuel storage activities on both ignited and unignited jets are reported. A study on small foreseeable releases which could potentially be controlled through forced or natural ventilation is described. The aim of the study was to determine the ventilation requirements in enclosures containing fuel cells such that in the event of a foreseeable leak the concentration of hydrogen in air for zone 2 ATEX is not exceeded. The hazard potential of a possibly catastrophic hydrogen leakage inside a fuel cell cabinet was investigated using a generic fuel cell enclosure model. The rupture of the hydrogen feed line inside the enclosure was considered and both dispersion and combustion of the resulting hydrogen air mixture were examined for a range of leak rates and blockage ratios. Key findings of this study are presented. Finally the scenario on walls and barriers is discussed; a mitigation strategy to potentially reduce the exposure to jet flames is to incorporate barriers around hydrogen storage equipment. Conclusions of experimental and modelling work which aim to provide guidance on configuration and placement of these walls to minimise overall hazards is presented. "

The Hydrogen Incident and Accident Database (HIAD) is being developed as a repository of systematic data describing in detail hydrogen-related undesired events (incidents or accidents). It is an open web-based information system serving various purposes such as a data source for lessons learnt risk communication and partly risk assessment. The paper describes the features of the three HIAD modules – the Data Entry Module (DEM) the Data Retrieval Module (DRM) and the Data Analysis Module (DAM) – and the potential impact the database may have on hydrogen safety. The importance of data quality assurance process is also addressed.

Due to the nonideality of a high pressure hydrogen release the possibility of a two-phase flow and its effect on the dynamics of the discharge process was experimentally investigated. A small-scale facility was designed and constructed to simulate the transient blow-down of a cryogenic fluid through a small break. Gaseous and liquid nitrogen were planned to were used as a surrogate for GH2 and LH2. The results will complement the quasi-stationary safety regulation tests and will provide time-dependent data for verification of the theoretical models. Different orifice sizes (0.5 1 2 4 mm) and initial N2 pressures (30 – 200 bar) were used in the tests. The measured time-dependent data for vessel discharge pressure thrust discharge mass flow rate and gas temperatures were compared against a theoretical model for high pressure nitrogen release. This verification for nitrogen also assures the equation of state for hydrogen which is based on the same methodology.

Hydrogen Infrastructures are currently being built up to support the initial commercialization of the fuel cell vehicle by multiple automakers. Three primary markets are presently coordinating a large build up of hydrogen stations: Japan; USA; and Europe to support this. Hydrogen Fuelling Station General Safety and Performance Considerations are important to establish before a wide scale infrastructure is established.

This document introduces the ISO Technical Report 19880-1 and summarizes main elements of the proposed standard. Note: this ICHS paper is based on the draft TR 19880 and is subject to change when the document is published in 2015. International Standards Organisation (ISO) Technical Committee (TC) 197 Working Group (WG) 24 has been tasked with the preparation of the ISO standard 19880-1 to define the minimum requirements considered applicable worldwide for the hydrogen and electrical safety of hydrogen stations. This report includes safety considerations for hydrogen station equipment and components control systems and operation. The following systems are covered specifically in the document as shown in Figure 1:

• H2 production / supply delivery system
• Compression
• Gaseous hydrogen buffer storage;
• Pre-cooling device;
• Gaseous hydrogen dispensers.
• Hydrogen Fuelling Vehicle Interface

The draft TR 19880-1 (and current plan for the standard) also gives guidance for the fueling validation with safety considerations relevant to the interaction between the hydrogen station and hydrogen road vehicles (during fuelling).. Through a cross-industry risk assessment carried out between OEMs Hydrogen Suppliers and existing vehicle fuelling station providers & operators (e.g. oil and industrial gas companies) the hydrogen fueling protocol SAE J2601 and associated dispenser hardware was evaluated."

"The current practise of focusing the periodic retesting of composite cylinders primarily on the hydraulic pressure test has to be evaluated as critical - with regard to the damage of the specimen as well as in terms of their significance. This is justified by micro damages caused to the specimen by the test itself and by a lack of informative values. Thus BAM Federal Institute of Materials Research and Testing (Germany) uses a new approach of validation of composite for the determination of re-test periods. It enables the description of the state of a population of composite cylinders based on destructive tests parallel to operation.<br/>An essential aspect of this approach is the prediction of residual safe service life. In cases where it cannot be estimated by means of hydraulic load cycle tests as a replacement the creep or burst test remains. As a combination of these two test procedures BAM suggests the ""slow burst test SBT"". On this a variety of about 150 burst test results on three design types of cylinders with plastic liners are presented. For this purpose both the parameters of the test protocol as well as the nature and intensity of the pre-damage artificially aged test samples are analysed statistically. This leads first to an evaluation of the different types of artificial ageing but also to the clear recommendation that conventional burst tests be substituted totally if indented for assessment of composite pressure receptacles."