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1、Hydrogen Technologies in Refueling Station FacilitiesExecutive summaryUL.com/services/hydrogen-integrated-system-servicesWHITE PAPER2Because of emissions from burning fossil fuels there is an increase in carbon dioxide and global warming.We are moving to greener solutions in different areas and that
2、 directly impacts the worldwide transportation system.Globally,1.4 billion vehicles were produced until 2021 and by 2035 this number is expected grow up to 1.8 billion.Companies and consumers are looking for green solutions.Hydrogen use as a fuel for vehicles is already a reality in 2022.But there a
3、re many other aspects to be considered in determining how green of a fuel it is.The cost of production is the first thing that comes to mind but the type of source is an important topic to consider as well.Production of hydrogen is classified with many different colors:for example Grey,Blue,Turquois
4、e and Green.What basically differs between them is the process and the source,which will be detailed on this document.Governments around the globe will need to commit to the zero emission vehicles transition where not only hydrogen but also electrical cars will become more popular.After the COP26(UN
5、 Climate Change Conference in Glasgow)that happened in UK in November 2021,several governments agreed to pursue the zero emission vehicle transition.As an example the US government signed the Infrastructure Law to help move the country into a clean energy transmission.UL.com/services/hydrogen-integr
6、ated-system-servicesWHITE PAPER3Hydrogen Source TypesHydrogen can be produced from a variety of sources.The most common form still comes from fossil fuels.As countries move to a renewable source they can take advantage of the benefits of producing green hydrogen.Below are listed examples of the diff
7、erent colors of hydrogen which are directly connected to the sources.Grey HydrogenProcess:SMR(Steam Methane Reforming)or gasificationSource:Methane or coalBlue HydrogenProcess:SMR or gasification with carbon capture(8595%)Source:Methane or coalTurquoise HydrogenProcess:PyrolysisSource:MethaneGreen H
8、ydrogenProcess:ElectrolysisSource:Renewable electricity(*)(*)There are other green hydrogen production methods which may include:hydrogen extraction from reformed biogas and hydrogen extraction from waste.nt.Low pressure storageCompressorH2 coolerH2 dispenserCooling systemto get H2 to-40FCEVHeat exc
9、hangerDry cooler4 way valve4 way valveDelivery storage high pressureSUPPLY SOURCECOMPRESSIONDELIVERY STORAGEPRE COOLINGHIGH PRESSURE PIPINGVEHICLE DELIVERYHydrogen Refueling Fuel Cell Electric vehicles(FCEV)UL.com/services/hydrogen-integrated-system-servicesWHITE PAPER4Hydrogen Station Delivery to F
10、ueling Process FlowA typical hydrogen station contains multiple components including:low pressure storage,compressor,heat exchanger,dry cooler,low,medium and high pressure,4 way valve,hydrogen cooler(down to-40)and a hydrogen dispenser.The below picture illustrates this typical hydrogen fueling syst
11、em:What are the hazards associated with hydrogen refueling?Hydrogen specificsImproper refueling,embrittlement of metallic parts,high pressure,low temperature,hose rupture,breakaway operationHazardous LocationsExplosion of a gas cloud,spark ignition,thermal ignition,area classificationFunctional Safe
12、tyUnintended operation of a critical safety function,leak detection,e-stop,process flowOther hazardsRisk of Fire,Electric Shock and CasualtyUL.com/services/hydrogen-integrated-system-servicesWHITE PAPER5United States MarketsHydrogen specific ANSI/CSA HGV Series SAE J2600,“Compressed Hydrogen Surface
13、 Vehicle Fueling Connection Devices”SAE J2601,“Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles”UL 2249,“Outline of Investigation for Hydrogen Fuel Dispensing Systems”SAE J2799,70MPa Compressed Hydrogen Surface Vehicle Refueling Connection Device and Optional Vehicle to Station Com
14、munication USA National Institute of Standards and Technology(NIST)Office of Weights and Measures,Hydrogen Gas-Measuring DevicesHazardous Locations UL 60079 Series UL 1203 UL 121201 UL 913 NFPA 497Functional Safety UL 1998 UL 991 IEC 61508 Series IEC 61511-1,“Functional Safety-Safety Instrumented Sy
15、stems for the Process Industry Sector-Part 1:Framework,Definitions,System,Hardware and Application Programming Requirements”Ordinary Locations Fire,Shock and Casualty:UL 50E,“Enclosures for Electrical Equipment,Environmental Considerations”Part I of UL 508,“Industrial Control Equipment”UL 508A,“Indu
16、strial Control Panels”UL 1238,“Control Equipment for Use with Flammable Liquid Dispensing Devices”UL 1995,“Heating and Cooling Equipment”UL 61800-5-1,“Adjustable Speed Electrical Power Drive Systems-Part 5-1:Safety Requirements-Electrical,Thermal and Energy”ANSI/UL508C,“Power Conversion Equipment”UL
17、991,“Test for Safety-Related Controls Employing Solid-State Devices”United States Standards and Codes addressing the hazardsFor the United States market the standards addressing the different hazards cover the following areas:hydrogen,hazardous locations,functional safety and ordinary locations fire
18、,shock and casualty.The table below demonstrates the various standards and its markets.UL.com/services/hydrogen-integrated-system-servicesWHITE PAPER6International MarketsHydrogen specific ISO TS 20100,Gaseous Hydrogen-Service Stations ISO 17268 Gaseous Hydrogen Land Vehicle Refueling Connection Dev
19、ices ISO 19880-1-Gaseous hydrogen Fuelling stations Part 1:General requirements ISO 19880-2 Gaseous Hydrogen Fueling Station Dispensers ISO 19880-3 Gaseous hydrogen Fuelling stations Part 3:Valves ISO 19880-5-Gaseous hydrogen Fuelling stations Part 5:Dispenser hoses and hose assemblies-First edition
20、 ISO 19880-6 Gaseous Hydrogen Fueling Station-Fittings ISO 19880-8 Gaseous Hydrogen Fueling Station-Part 8:Hydrogen Quality ControlHazardous Locations IEC 60079 Series IEC 60079-10-1,“Classification of Areas-Explosive Gas Atmospheres”Functional Safety IEC 61508 Series IEC 61511-1,“Functional Safety-
21、Safety Instrumented Systems for the Process Industry Sector-Part 1:Framework,Definitions,System,Hardware and Application Programming Requirements”IECEx System Proposed H2 Dispenser program based on IEC60079-46 and references to ISO 19880 standard series CoPC Ex011 for Hydrogen Safety A hydrogen disp
22、ensing system may be constructed with the following USA standards:Dispenser:HGV 4.1 Hose:HGV 4.2 Hydrogen fueling parameter evaluation:HGV 4-3 Gaseous hydrogen Fuelling stations Valves:HGV 4.4 Compressor guidelines:HGV 4-8 Hydrogen fuelling stations:HGV 4.9 Fittings:HGV 4.10 Compressed hydrogen surf
23、ace vehicle connection devices:SAE J2600 Breakaway:HGV 4.4,Manual valves:HGV 4.6 and Automatic valves:HGV 4.7 were incorporated into Gaseous hydrogen Fuelling stations Valves:HGV 4.4.International Standards addressing the hazardousFor International market the standards addressing the different hazar
24、ds cover the following areas:hydrogen,hazardous locations,functional safety and ordinary locations fire,shock and casualty.The table below demonstrates the various standards and its markets.UL.com/services/hydrogen-integrated-system-servicesWHITE PAPER7What are the safety certifications available an
25、d how UL can support?The certification solutions can be summarized in two levels:Component level certification System level certificationUL offers the following types of certifications:CertificateThird party attestation related to products,processes,systems or persons.This is a broad term that cover
26、s various service offerings that are provided by NRTLs.ListedDefined in the codes as“Equipment,materials,or services included in a list published by an organization that is acceptable to the authority having jurisdiction and concerned with evaluation of products or services,that maintains periodic i
27、nspection of production of listed equipment or materials or periodic evaluation of services,and whose listing states that either the equipment,material,or service meets appropriate designated standards or has been tested and found suitable for a specified purpose.”Recognition or Recognized Component
28、 Components or materials that are evaluated and intended for use in a complete product or system,because incomplete in construction features or testing.These components are intended only for end-use products that may be eligible for certification.Limited Production CertificationA process where a sin
29、gle unit or a limited quantity of production undergoes the full construction review,testing evaluation,and then a certification decision is made.This results in the witnessing the application of a Certification Mark after the inspection of each piece of equipment.For component or system level certif
30、ication,UL has a solution to address different demand and customer needs.Field EvaluationAssistance for an Authority Having Jurisdiction(AHJ)in the process of determining“acceptance”of a product leading to“approval”of the installation.Limited to the jobsite installation.The evaluation process consis
31、ts of documentation review,limited testing,and inspection of the equipment.UL.com/services/hydrogen-integrated-system-servicesWHITE PAPER8Hydrogen Fuel Dispensing System CertificationAccording to CSA/ANSI HGV 4.1 Standard for hydrogen-dispensing systems-5.12.2 Risk assessment the manufacturer of the
32、 HFS shall conduct a safety review that shall include the review of the safety analyses of supplied systems and equipment.The safety analyses may include a Hazardous Operations Review(HAZOP),or an FMEA,or equivalent risk assessment intended to identify failures that have significant consequences aff
33、ecting the fueling station operation.Risk assessments are also required in NFPA 2,Hydrogen Technologies Code,and HGV 4.9,Hydrogen Fueling Stations.The system certification plan will depend on a review of the risk assessments in these standards.UL 2249 standard was developed by UL experts to cover si
34、te-assembled and modular gaseous hydrogen fueling stations(HFS)intended to dispense hydrogen to hydrogen fuel vehicles for automotive applications.The systems may include electronic controls and software to compress,store,cool and transfer the hydrogen from the station storage and/or compressor syst
35、ems to the vehicle fuel tank.The system may include modular delivery,compression,storage and dispensing equipment that is intended to operate in conjunction as a system.UL.com/services/hydrogen-integrated-system-servicesWHITE PAPER9Other Hydrogen Related Service OfferingsFuel Cell Module Certificati
36、on Offerings UL 2262 Outline for Fuel Cell Modules for Use in Portable and Stationary Equipment IEC 62282-2-100 Fuel cell technologies Part 2-100:Fuel cell modules Safety(Cert)Industrial Truck Fuel Cell Certifications UL 2267 Fuel Cell Power Systems for Installation in Industrial Electric Trucks IEC
37、 62282-4-101 Fuel cell technologies Part 4-101:Fuel cell power systems for propulsion other than road vehicles and auxiliary power units(APU)Safety of electrically powered industrial trucksStationary Fuel Cell Certification Offerings ANSI CSA FC1-Fuel Cell Technologies-Part 3-100:Stationary Fuel Cel
38、l Power Systems IEC 62282-3-100-Fuel Cell Technologies-Part 3-100:Stationary Fuel Cell Power SystemsHydrogen Generators UL 2264A Outline for Water Electrolysis Type Hydrogen Generators UL 2264B Outline for Hydrogen Generators Using Water Reaction UL 2264D Outline for Portable Water Electrolysis Type
39、 Hydrogen Generators UL/CSA FC4(Under development)Engine Generators Fueled by Hydrogen and Hydrogen Blends UL 2200(CRD)Stationary Engine Generator Assemblies ANSI/CSA America FC 3-Portable Fuel Cell Power Systems Energy Storage Systems and Equipment UL 9540 Energy Storage Systems and EquipmentOther
40、Hydrogen Component Standards UL 147 Hand-Held Torches For Fuel Gases UL 252 Compressed Gas Regulators UL 252A Compressed Gas Regulator Accessories UL 404 Gauges,Indicating Pressure,for Compressed Gas Service UL 429 Electrically Operated Valves Currently allows some leakage.UL 1357 Outline for Oxygen
41、-Fuel Gas Combination Flash Arrester and Backpressure Check Valves UL 1358 Outline for Compressed Gas Check Valves and Hose Couplers UL 1477 Outline for Compressed Gas Shutoff ValvesUL.com/services/hydrogen-integrated-system-services10WHITE PAPERLearn more at UL.com/services/solutions/hazardous-loca
42、tions.Regulatory Assessment Services for Industrial Systems|UL SolutionsA curated regulatory mapping The Regulatory Assessment Service for Industrial Hydrogen Systems collects publicly available and authoritative information about technical regulations that impact safety,health and the environment,r
43、esulting in the creation of Technical Regulations and Standards(TRS)reports specific to the clients system and destination markets.This report also identifies the mandatory requirements to those critical parts of the product and system.The TRS report allows clients to develop a regulatory strategy f
44、or timely and cost-efficient market entry,including requirements for sustaining the regulatory compliance into operations and product and system retirement.EIA22CS606290UL.com/Solutions 2022 UL LLC.All rights reserved.This white paper may not be copied or distributed without permission.It is provided for general information purposes only and is not intended to convey legal or other professional advice.