Introduction to the Safe Design of LNG, CNG and Hydrogen Refueling Stations
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1 Introduction to the Safe Design of LNG, CNG and Hydrogen Refueling Stations Presentation to SFPE Northern California and Nevada Chapter March 16, 2007 by Jack Woycheese, PE, FSFPE
2 Background Existing LNG Import Terminals 5 in North America, 17 new plants approved, 25 proposed and submitted for approval, 17 more in planning Existing LNG/CNG Refueling Facilities Garden Grove, Anaheim, Irvine, Santa Monica Proposed LNG offloading in Long Beach 5 5 Hydrogen plants in SoCal
3 Alternative Fuels Demand driven by environmental goals Methanol Electrical (Batteries) Natural Gas CNG LNG Hydrogen
4 CRYOGENIC CHARACTERISTICS Cryogenic temperatures are defined as between -150ºF F and -460ºF F (absolute zero). At atmospheric pressure LNG boils at -259ºF. Hydrogen boils at -430ºF
5 FIRE HAZARD PROFILE - LNG Lower Explosion limit (% by vol.): 5.0 Upper explosion limit (% by vol.): 15.4 Auto ignition temperature: 537ºC Flammability classification Flammable Sensitivity to static discharge Ignitable by static electricity. Escaping gas may self ignite
6 FIRE HAZARD PROFILE- HYDROGEN Lower Explosion limit (% by vol.): 4.0 Upper explosion limit (% by vol.): Auto ignition temperature: 575ºC Flammability classification Flammable Sensitivity to static discharge Ignitable by static electricity. Escaping gas may self ignite because of friction.
7 Basic Design of CNG Station Dryer Compressor Natural Gas Inlet 35 or 160 psi Supply Compression skids Outlet Filter Buffer Priority/ Sequential Panel Storage Vessels FUEL DEPOT CNG FUELING Dispenser Card Reader CNG FUELING Dispensers CNG FUELING ISLAND-
8 Basic Design of L/CNG Station Vacuum-jacketed LNG storage tank LNG tank truck delivery fill port Sump-mounted centrifugal inducer pumps CNG dispensers on bus refueling islands High-pressure gas buffer storage vessel Forced-draft ambient-air vaporizer
9 LNG/CNG LNG Release Behavior (Cont d) As LNG vaporizes, water in air Condenses Forms visible cloud Initial release heavy, as it warms becomes light like CNG at -30 F
10 Methane Gas Supplies CNG LNG/CNG Pipeline to com- pressor to CNG storage Truck as CNG to CNG storage LNG Made on site Shipped in trucks to LNG storage
11 LNG/CNG Methane Gas Supplies (Cont d) L/CNG LNG/pump/vaporizer/ CNG storage LNG/vaporizer/ compressor/storage
12 Hazards of Natural Gas Fuel accumulation LNG/CNG Near ceiling In presence of potential ignition sources Fast releases Possible Considered improbable
13 Applicable Standards NFPA 52, 2006 edition NFPA edition NFPA 57 (Combined into NFPA 52) NFPA 59A, 2006 edition NFPA 88 Building Code Fire Code Pressure-vessel Code
14 Applicable Standards California Title 8: Pressure Vessel Code (Cont d) Incorporates NFPA 52/57/59A Approved in March, 2000 Methane Detection Addressed engineering approval of LNG Refueling
15 Spacing Site Considerations Site Equipment Drainage Away from buildings/equipment LNG vaporization rate LNG spill rate Environmental contamination Pressure Relief Discharge
16 Above-ground Tank, L/CNG Station Vertical tank Facilities Tank, pumps, vaporizer, containment, buffer Fueling island dispensers
17 Facilities Above-ground Vault, L/CNG Station Space constrained in residential area
18 Facilities LNG tanks & pumps in low-profile 87 x 38 vault High-expansion Foam System fills vault in ~2 minutes HAZOP - Process Safety Analysis Vault ½ above grade ½ below grade Walls Concrete Masonry Unit Ventilation System Blast-proof Doors Deflagration-relief relief Roof Panels
19 LNG Vessels Inside Vault Facilities
20 Facilities LNG TO CNG Pumps Inside Vault
21 Facilities Above-ground Vault Foam System Test
22 Below-ground Tanks Facilities
23 Facilities Temporary
24 Facilities Refueling Station
25 Facilities- Temporary
26 Pressure Letdown During Delivery
27 Sodium Bicarbonate Application
28 Sodium Bicarbonate Application
29 What is Hydrogen? Odorless Tasteless Nonirritating Nontoxic Colorless Flammable Rises and dissipates quickly No environmental impact
30 For Automotive Applications Where Does H2H Come From? Hydrogen is DERIVED from Hydrocarbon based fuels, steam methane (SMR) reforming - 80% today By-product of chemical processes, purification (20% today) Water, electrolysis (niche applications today)
31 Hydrogen Supply Modes
32 Hydrogen Supply Modes Liquid Hydrogen Delivery Delivered in Tankers Stored onsite as Cryogenic Liquid Vehicle Fueling Applications: Gas Onboard Liquid Onboard
33 Hydrogen Supply Modes Gaseous Tube Trailer Delivery Delivered in High Pressure Tubes
34 Basis for H2H Fuel Stations Hydrogen Supply Mode Onsite Production or hauled in Utilities Compression Required pressure, flow rates Maintenance program Gaseous Compression vs. Liquid Pump High Pressure Storage ASME Compliant Vessels for Stationary DOT Compliant for Mobile Storage
35 H2 Fuel Stations Dispensing Automatic vs. Manual Trained Operators Siting Issues/Permits/ Codes and Standards - NFPA, DOSH. Miscellaneous Personal Protective Equipment (PPE) Safety Reviews - FEMA, Hazop Develop site document
36 APCI Hydrogen Fuelers H2 Delivery for small fleets or spot jobs Various sizes and pressures
37 Hydrogen Supply Modes On-site Reforming Fossil Fuel Feed Stock Demonstration Project
38 Hydrogen Supply Modes On-site Electrolysis Water and Electricity Feed Stock Up to 100 kg/day Demonstration Projects Pathway to renewable fuel
39 Hydrogen Supply Modes Packaged Gases - Cylinder Supply Small volumes, spot requirements Portable Fueling Center/Cart
40 Hydrogen Fuel Stations University of California Davis
41 Hydrogen Fuel Stations University of California - Irvine, CA Ford Motor Co. - Dearborn, MI
42 Hydrogen Fuel Stations City of Las Vegas, NV
43 City of Las Vegas H2H Projects
44 Hydrogen Fuel Stations Chicago Transit Authority (CTA) Chicago, IL
45 Hydrogen Fuel Stations Cal. Fuel Cell Partnership West Sacramento
46
47
48 Finished Station
49 Ann Arbor, MI
50 Compressor
51 Compressed H2H Storage
52
53 Fuel Dispensers
54 Mobile Fueler
55 Tips for Successful Projects Process Safety Analysis Piping & Instrumentation Diagram Emergency Shut Down Site Plan/Spacing/Drainage
56 Tips for Successful Projects Deficiency Resolution Responsibility Equivalency Approvals Documentation Training
57 Tips for Successful Projects Process Safety Management API RP 750 AI ChemE/CCPS OSHA Don t t forget Fire Protection Considerations for Maintenance Garage!
58 Tips for Successful Projects In CA, all dispensing facilities Certified for Engineering integrity Safety and compliance By California Registered Engineer(s) competent in design, fabrication, construction of Cryongenic
59 Tips for Successful Projects Fire detection Fire protection equipment Methane or hydrogen gas detection Other components of the facility
60 General Requirements ESD Matrix Fixed and Portable Gas Detection Gas Alarms Transmit to FD Location of Safety Equipment
61 Initial Inspection Verify ESD Matrix Alarm Triggered by Gas Detection (10%LFL) Power and Fuel off (all required circuits) (50% LFL) Restart after Shutdown Electrical Area Classification
62 Follow-up Inspections Maintenance and Training Records Approved Drawings, PSA, etc. PRV s Gas Detection System Corrosion Protection Location of Safety Equipment Shields, Gloves, Aprons, etc. Portable Gas Detectors Retest ESD Matrix All Required Power Off Restart Non-suitable Electrical Equipment/Wiring
63
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