Hydrogen Newsletter Summer 1997: Hydrogen Codes and Standards

Drafting of Manual of Recommended Practices for Hydrogen Systems to Begin

by William Hoagland, President, and Susan Leach, Project Manager, W. Hoagland & Associates, Inc.

A number of hydrogen projects—demonstrations, integrated experiments, field tests, scaleups, and proofs of concept—are now in progress or are contemplated, but the lack of formal codes and standards is a major barrier to their success. Obtaining required permits and approvals for new technologies for which there are neither formal standards or extensive operating experience can be difficult.

Codes and standards are typically created for commercial products and processes, and normally take five to eight years. Because this process is so lengthy, and it is difficult to develop standards for systems that are not well-established, a compendium of general guidelines and recommended practices would fill this early need.

For these reasons, W. Hoagland & Associates, Inc., and the Hydrogen Research Institute at the University of Québec [Canada], with support from the U.S. Department of Energy and Natural Resources Canada, are developing a Manual of Recommended Practices for Hydrogen Energy Systems to document current knowledge and experience and provide guidelines for the design and operation of hydrogen systems. The Manual will serve in the interim while a more formal standards process progresses. When more experience is gained, and new technologies become established, hydrogen-specific codes and standards will be published, lessening the need for the Manual.

The Manual will be applicable in both the U.S. and Canada. Its development will involve several engineering disciplines and standards organizations, such as the American Society of Mechanical Engineers (ASME), American National Standards Institute (ANSI), the Compressed Gas Association (CGA), and the International Standards Organization (ISO), as well as their counterparts in Canada.

Two Workshops Held

Two workshops were conducted earlier this year [1997]: March 11th in conjunction with the NHA’s annual meeting and May 30th as a concurrent session at the 8th Canadian Hydrogen Workshop. The purpose was to identify the need for and benefits of a Manual, as well as its organization and content. Presentations and discussions on the experiences of three current hydrogen demonstrations highlighted several important issues and the need for a Manual. Design guideline considerations for each of the hydrogen systems to be included also were discussed. The second workshop focused on the difficulty of obtaining needed permits, approvals, and certifications, and the importance of getting approval authorities on-board in advance.

There was general agreement on the outline of the Manual (see Table 1, below). Due to funding limitations, it was decided that design guidelines be developed last, when all of the DOE funding becomes available. The Manual also will identify sources of technical assistance that developers and approval authorities can call upon to answer any questions or concerns not covered in the Manual. Workshop participants also recommended that the insurance and auto industries be involved.

NHA members that are also members of the Compressed Gas Association have expressed interest in providing an expert to ensure that the Manual is compatible with current practice in the gas industry. This was raised to the NHA Board at its June meeting.

Recent Hydrogen Demonstrations Highlight Recurring Needs

Tn addition to helping shape the Manual, workshop presenters echoed similar experiences and lessons learned from recent hydrogen demonstrations:

Need for Hydrogen-Specific Codes and Standards. While many existing codes and standards have applicability to new hydrogen energy systems, there is a definite need for hydrogen-specific codes and standards to facilitate project approval.
Need for Early Communication with Local Officials. Prior to installation, detailed operating and safety procedures should be reviewed with officials to gain familiarity with local regulations and concerns. Codes and standards applicable to the installation site may differ from those used by equipment manufacturers. If identified early, exemptions or special permits to implement new technologies may be obtained if they are demonstrably better.
Need for Hydrogen-Certified Components. Finding equipment suitable for hydrogen applications is difficult, and modifications made to equipment designed for other fuels can be expensive. For some projects, components had to be custom-designed and specifications had to be written where none existed.
Need for Success Stories. An important value of hydrogen demonstrations is to counteract the myth that hydrogen cannot be safe. It is critical that there be no public failures.
Need for Rigorous Safety Reviews. Safety reviews should be performed early, and the review document should guide the design and construction.
Need for Schedule Flexibility. Projects usually take longer than planned, and projects should not be rushed at the expense of the best possible result.
Need to Improve Insurability of Hydrogen Projects. [See Survey.]
Need for Design Guidelines. Design guidelines that reduce or minimize hazardous situations are needed for vehicle systems, on-board storage systems, stationary storage systems, on-site production, hydrogen detection and safety, and dispensing stations. Because there is limited system experience with evolving hydrogen technologies, design guidelines must be flexible to allow for innovation.
Need for Safety at a Reasonable Cost. Safety is an important consideration in developing codes and standards, but so is cost. At present, cost is a primary market barrier. New systems must be designed and demonstrated to be both safe and economical.

All agreed that, if properly done, the Manual could become a focal point for current practice and experience, serving the function of published codes and standards in smoothing the project approval process. It will serve as evidence of past experience and review, and will help ease concerns over the safety of hydrogen systems. It should be technically grounded while providing guidelines for people who are not experts on hydrogen. In addition, it can be used to assist developers of hydrogen technology in training personnel, and will provide a sample emergency response plan that could be tailored for a particular project or site.

A Manual of Recommended Practices for Hydrogen Energy Systems will not obviate the need for codes and standards, but will be a valuable step toward the commercial reality of hydrogen energy technologies.

Participation Sought

We intend to develop a comprehensive draft by January 1998. To accomplish this, input and guidance from technology developers, industry, government, and regulatory organizations is being sought to gather needed information and obtain review and comment. We also will develop recommendations for the publication, distribution, and updating of the Manual. A number of organizations, including the NHA, will be considered.

Anyone interested in participating as a reviewer or provider of information should contact Bill Hoagland at +1.303.530.1140, or Tapan Bose, Director of the Hydrogen Research Institute [Québec, Canada], at +1.819.376.5139.

TABLE 1
Outline for the Manual of Recommended Practices
For Hydrogen Energy Systems

1.0 General Information About Hydrogen

General Characteristics of Hydrogen Gases and Liquids
Use in Industry, Historical and Current
General Properties of Hydrogen Relative to Other Fuels
Benefits of Widespread Hydrogen Usage
Components of Typical Hydrogen Systems

2.0 Design Guidelines for Hydrogen Systems

General Design Considerations
Hydrogen Transportation Systems

Hydrogen Vehicles

On-Board Hydrogen Storage
Hydrogen Fuel Cell Electric Vehicles
Hydrogen Hybrid Electric Vehicles
Hydrogen-Containing Fuels for Internal Combustion Engines

Hydrogen Storage and Dispensing Stations

Bulk Storage Systems
Dispensing Stations (connectors, valving, materials, etc.)

On-Site Hydrogen Production

Electrolysis Systems
Methane Reformers

Hydrogen Safety Systems

Hydrogen Detection
Fire Protection

3.0 Safe Operating Practices

Discussion of Risks and Hazards
General Practices
Personnel/Operator Training
Loss Prevention
Emergency Response

4.0 Case Studies

Description of Current and Past Hydrogen Projects
Lessons Learned

Appendices

A Sources of Information and Technical Assistance

B Equipment Vendors and Suppliers

C Bibliography of Related Information

D Descriptive Bibliography of Related Codes and Standards

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