Safety Issues Using Flexible Hoses
What are the safety issues when using flexible hoses that are continuously pressurized (but not cycled through pressures or moved very much) the way swap and drop tube trailer hoses would be?
Many methods are used to mitigate the risk of a tube trailer hose loss of containment incident. Examples that otherwise exceed code requirements are provided below. These have been deployed in various combinations depending on the risk analysis for a particular system:
- Installation of automatic shutoff valves on the tube trailer upstream of the hose to activate upon hose rupture. These can be operated in two modes:
- Always open and activated only with a manual and/or automatic emergency shutdown system or
- Always closed and only opened when in use, in addition to being closed via activation of an emergency shutdown system.
- Over-design of the hose with a higher factor of safety than the 3:1 otherwise required. Using a hose with a 4:1 factor, or even higher, is common.
- Implementation of hose replacement frequency as part of a mechanical integrity program. An interval of three years for a tube trailer hose is frequently used.
- Use of anti-whip restraints to anchor each end of the hose.
- Implementation of leak detection equipment, using either external gas detection or internal pressure monitoring systems.
- System design that prevents abrasion, kinking, or stretching of the hose when in service.
- Implementation of anti-pull-away systems for the trailer when connected to the station.
- Use of a self-sealing hose in the event of a hose rupture. 9. Use of a double-ended breakaway system similar to those used on fueling hoses.
Regulatory Requirements for Hydrogen Refueling Stations.
What are the regulatory requirements for “drop and swap” storage at hydrogen refueling stations? NFPA 2 is clear that no flexible hoses are allowed except the ones connecting to the vehicle being refueled. A drop and swap approach obviously needs to use flexible hoses to connect to the tube trailers.
A "drop and swap" delivery system using tube trailers is a common and accepted method of supply for both industrial and fueling station applications. While NFPA 2 - 2023, paragraph 10.6.3.5 states, "The use of hose in a hydrogen dispensing system shall be limited to vehicle fueling hose," this is intended for the dispenser itself, not the entire fueling station. This does not limit the use of a hose for other portions of the system where applicable. Examples where hoses are appropriate are tube trailer connections, compression equipment connections for vibration isolation, and purge connections.
This requirement is under review by the NFPA 2 Technical Committees for clarification.
Hydrogen Venting from Vaporizers
Vent loses are expensive, and some stations are venting from the vaporizers. Is this necessary for pressure release?
Gaseous hydrogen can be stored forever as long as the system integrity is maintained. However, liquid hydrogen is “use it or lose it” and will boil from system heat leak and build pressure unless it is used or vented. This is not usually an issue for continuous use or low-pressure applications which can use hydrogen gas pressure directly from the tank.
For intermittent or high-pressure applications such as vehicle fueling, this can be more challenging. If a gas compressor is used and if demand is regular enough, often the compressor can recover the boil-off gas. This is more difficult for a pump, but again, if usage is sufficient, then the liquid being removed from the tank can minimize or eliminate the need to vent.
Boil off Gas at Fuel Stations
What is the best approach to handling the boil-off gas from a liquefied hydrogen tank at a fueling station? What are the safety precautions?
If liquid hydrogen usage is sufficiently high at the fueling station, there may be no need to vent any boiloff generated from the LH2 storage tank. Boil-off gas should be minimized through system design, but where needed, the boil-off hydrogen along with any other hydrogen released must be vented through a local vent stack which is constructed to safely vent the hydrogen in accordance with CGA G5.5 and NFPA 2. These standards anticipate the possible ignition of hydrogen in a vent stack and have provisions for that to happen safely. If economical, the boil-off gas can also be captured by using a gas compressor to store the gas for dispensing into vehicles.
Dispensing at Fuel Stations
Is there a separate standard that governs dispensing of liquid hydrogen at a liquefied hydrogen fueling station?
In the U.S., liquid hydrogen fueling stations and dispensing equipment are addressed within NFPA 2, Chapter 11. Dispensing is covered within Section 11.3. When liquefied hydrogen is used as the supply for high pressure gaseous fueling, then Chapter 10 of NFPA 2 would apply.
ISO standards are also being developed for global LH2 fueling protocols.