Transportation and Shipment of Hydrogen in Metal Hydride Assemblies
Robert Wichert, U.S. Fuel Cell Council

As was reported previously in the Hydrogen Safety Report in October of 2007, prior to 2005 hydrogen stored in metal hydride assemblies could not be properly shipped or transported in normal commerce at all.  Although hydrogen could be shipped in compressed form, and metal hydride material could be shipped alone, the shipment of hydrogen stored in metal hydride assemblies was not covered by theUnited Nations Recommendations on the Transport of Dangerous Goods, Model Regulations.  Without such coverage, the various modes of transport and the nations that routinely adopt this document as the basis of their national regulations were not able to permit transportation of hydrogen stored in metal hydrides without special permissions that could be costly and time consuming.  This may have contributed to storage of hydrogen in metal hydrides not reaching its full potential as a safe and convenient method of hydrogen storage.  In an effort to correct this inadequacy, a Working Group under the auspices of the International Standards Organization Technical Committee 197 (ISO TC 197) wrote an international standard that forms the basis for international approval of hydrogen stored in metal hydride assemblies and their shipment.  This effort was led by Ned Stetson, then employed by Energy Conversion Devices (ECD).  Ned has subsequently been made an employee of the US Department of Energy in this same area of expertise.  The hydrogen community owes Mr. Ned Stetson a large debt of gratitude for his stalwart efforts to publish ISO 16111: 2008 Transportable gas storage devices -- Hydrogen absorbed in reversible metal hydride.

Regulatory harmonization
In an effort to harmonize the regulations for the transport of hydrogen in metal hydride storage systems, the US Fuel Cell Council petitioned the UN Sub-Committee of Experts on the Transport of Dangerous Goods, asking them to revise the United Nations Recommendations on the Transport of Dangerous Goods, Model Regulations.  The US Fuel Cell Council proposal can be found here:http://www.unece.org/trans/doc/2008/ac10c3/
ST-SG-AC10-C3-2008-74e.pdf

The US Fuel Cell Council proposed using ISO 16111: 2008Transportable gas storage devices - Hydrogen absorbed in reversible metal hydrideas the basic requirement for shipment of hydrogen stored in metal hydride assemblies.  If this proposal were adopted, shipment of hydrogen storage assemblies meeting ISO 16111 could become routine instead of requiring a special permit on a case-by-case basis.  During their consideration of the US Fuel Cell Council proposal, the United Nations Sub-Committee of Experts on the Transport of Dangerous Goods provided further clarification of the requirements that hydrogen stored in metal hydride assemblies must meet.  The US Fuel Cell Council proposal was finally accepted after much debate and revision.  The report on the meeting that accepted this proposal can be found here:
http://www.unece.org/trans/doc/2009/ac10/ST-SG-AC10-36a1e.pdf

The following is a summary of the requirements that will take effect with the publication of the 16th Edition of the United Nations Recommendations on the Transport of Dangerous Goods, Model Regulations in January of 2010.

  1. Metal hydride storage systems are formally defined as a pressure receptacle by the United Nations Recommendations on the Transport of Dangerous Goods, Model Regulations (UN Model Regulations).

  2. The specific definition of a metal hydride storage system is given in the UN Model Regulations as "Metal hydride storage system means a single complete hydrogen storage system, including a receptacle, metal hydride, pressure relief device, shut-off valve, service equipment and internal components used for the transport of hydrogen only."

  3. Metal hydride storage systems are limited to a water capacity (overall container volume) of 150 litres.

  4. Metal hydride storage systems are limited to a maximum developed pressure in use of 25 MPa.

  5. Steel components in contact with hydrogen must be suitable for hydrogen service, as designated by the “H” mark, properly applied in accordance with the UN Model Regulations.

  6. Metal hydride storage systems must meet the service conditions, design criteria, rated capacity, type tests, batch tests, routine tests, periodic tests, test pressure, rated charging pressure and provisions for pressure relief devices for transportable metal hydride storage systems specified in ISO 16111:2008.

  7. The hydrogen filling pressure of the metal hydride storage system must not exceed the rated charging pressure for the metal hydride storage system as specified in ISO 16111:2008 and as properly marked on the system.

  8. The periodic test interval for the metal hydride storage system must not exceed five years.

  9. The valve protection requirements of ISO 16111: 2008 must also be met.

  10. Specific requirements for the periodic batch testing of the pressure receptacles used, as well as the metal hydride assemblies, are given in a new paragraph of Part 6 of the UN Model Regulations.  New paragraph 6.2.1.5.3 additionally requires that these inspections and tests be performed on an adequate sample of the receptacles used in the construction of the metal hydride storage system.
    1. Testing of the mechanical characteristics of the material of construction;
    2. Verification of the minimum wall thickness;
    3. Verification of the homogeneity of the material for each manufacturing batch;
    4. Inspection of the external and internal conditions of the pressure receptacles;
    5. Inspection of the neck threads;
    6. Verification of the conformance with the design standard;
  11. A hydraulic pressure test is required for each and every pressure receptacle used in the construction of metal hydride storage systems. Pressure receptacles shall withstand the test pressure without expansion greater than that allowed in the design specification;

    NOTE: With the agreement of the competent authority, the hydraulic pressure test may be replaced by a test using a gas, where such an operation does not entail any danger.

  12. Every pressure receptacle that includes manufacturing defects must have an inspection and assessment of manufacturing defects and appropriate documentation of either repairing them or rendering the pressure receptacles unserviceable. In the case of welded pressure receptacles, particular attention shall be paid to the quality of the welds;

  13. An inspection of the markings on each pressure receptacle.

  14. New paragraph 6.2.1.5.3 additionally requires that these additional inspections and tests be performed on an adequate sample of the metal hydride storage systems.
    1. Verification of the homogeneity of the material for each manufacturing batch.
    2. Inspection of the neck threads, if applicable.
    3. Verification of the conformance with the design standard.
  15. Every metal hydride storage system that includes manufacturing defects must have an inspection and assessment of manufacturing defects and appropriate documentation of either repairing them or rendering the system unserviceable.

  16. An inspection of the external conditions of, and the markings on, the metal hydride storage system is required on each and every one.

  17. Every metal hydride storage system must successfully pass a leak tightness test as well as a functional test for satisfactory operation of the service equipment, such as valves.

  18. The following markings are required on the metal hydride storage system:
    1. The United Nations packaging symbol 
    2. "ISO 16111" (the technical standard used for design, manufacture and testing);
    3. The character(s) identifying the country of approval as indicated by the distinguishing signs of motor vehicles in international traffic;
    4. The identity mark or stamp of the inspection body that is registered with the competent authority of the country authorizing the marking;
    5. The date of the initial inspection, the year (four digits) followed by the month (two digits) separated by a slash (i.e. "/");
    6. The test pressure of the receptacle in bar, preceded by the letters "PH" and followed by the letters "BAR";
    7. The rated charging pressure of the metal hydride storage system in bar, preceded by the letters "RCP" and followed by the letters "BAR";
    8. The manufacturer's mark registered by the competent authority. When the country of manufacture is not the same as the country of approval, then the manufacturer's mark shall be preceded by the character(s) identifying the country of manufacture as indicated by the distinguishing signs of motor vehicles in international traffic. The country mark and the manufacturer’s mark shall be separated by a space or slash;
    9. The serial number assigned by the manufacturer;
    10. In the case of steel receptacles and composite receptacles with steel liner, the letter "H" showing compatibility of the steel (see 1SO 11114-1:1997); and,
    11. In the case of metal hydride storage systems having limited life, the date of expiry, denoted by the letters "FINAL" followed by the year (four digits) followed by the month (two digits) separated by a slash (i.e. "/").

Vehicle systems
Irrespective of the guidance above, metal hydride storage systems intended for use in conveyances such as passenger vehicles or buses must also have the special approval of the authority having such jurisdiction in the country of shipment and receipt prior to shipment.

Next steps
Now that the UN Model Regulations provide coverage for hydrogen stored in metal hydride storage systems that conform to ISO 16111: 2008 and the requirements above, the various transportation modes (air, sea, road and rail) will be asked to adopt these same requirements as a matter of course.  It is expected that this will eventually result in harmonized regulations worldwide.

For more information, please contact the US Fuel Cell Council Technical Director, Robert Wichert, at Wichert@usfcc.com.

 

NFPA Update
Paul May, National Fire Protection Association

NFPA 2
The NFPA Hydrogen Technologies Technical Committee has voted to release the document for public review. NFPA 2, Hydrogen Technologies Code, is currently available for public comment. The document can be downloaded for review on the NFPA website, at:http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=2.

The document is also available on the Proposed Documents page at:http://www.nfpa.org/itemDetail.asp?categoryID=163&itemID=19006

NFPA 2 is primarily an extract document, meaning that most NFPA 2 text is extracted from other NFPA documents. The intent is to create a single document for fire prevention matters related to hydrogen for use by designers, permitting authorities and regulators. This draft of NFPA 2 is intended to give public reviewers a good indication of the current content and breadth of NFPA 2. The Technical Committee has prepared a 90% draft of the document for this release; however, it is in the process of detailed technical review for coordination and consistency. The committee has decided to issue this 90%-complete draft for public review while continuing to improve the document—with the express point being made that this is not intended to unintentionally place excessive editorial burden on the public review process. It is anticipated that the coordinated revised draft will be reviewed and acted on during the Report on Proposals (ROP) meeting of the committee, which is expected to take place in August 2009.

Public proposals are due by May 29, 2009. Information on the proposal process and forms can be found at www.nfpa.org.

NFPA 55 and NFPA 52
The NHA reported in the December Hydrogen & Fuel Cell Safety Report that numerous Notices to Make a Motion (NITMAMs) were received for NFPA 52 and one was received for NFPA 55. 
NFPA 55, Standard for the Storage, Use, and Handling of Compressed Gases and Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks, with proposed modifications for the 2009 edition, was submitted for public comment and one NITMAM (Notice of Intent To Make A Motion) was Certified by the NFPA Standards Council. The NITMAM was for the return of the Entire Report to the Committee. This Certified Amending Motion has been withdrawn by the originating submitter. Withdrawal of the motion removes NFPA 55 from consideration at the 2009 NFPA Association Technical Meeting, and NFPA 55 will be submitted to the Council for recommendation on issuance. 

NFPA 52, Vehicular Fuel Systems Code, with proposed modifications for the 2009 edition, received eleven Certified Motions, involving Chapters 9 and 14. Ten of the eleven Certified Amending Motions have been withdrawn by the originating submitter.

There is still one remaining Certified Amending Motion on NFPA 52, which will be considered during the NFPA Annual Meeting of June 10-11, 2009. The remaining motion relates to replacing the separation distance table 9.3.1.3 in the NFPA 52 Report on Comments with the version that is adopted in NFPA 55, as the scope of NFPA 55 includes the purview for requirements from the system installation up to the source valve.

If, during the June 2009 meeting, the Association recommends that a portion of a Report be returned to the Technical Committee, any existing text to which the returned portion pertains shall remain standing. 

ISO TC197 Update
Karen Hall, National Hydrogen Association

WG6:

ISO/TS 15869:2009, Gaseous hydrogen and hydrogen blends—Land vehicle fuel tanks has been published. Although failing at its third attempt at a draft International Standard (DIS), voting members indicated strong support for the document to become a Technical Specification until consensus could be agreed on the outstanding technical issues. Without changes, the failed third DIS has been published as a Technical Specification.

SCOPE: ISO/TS 15869:2009 specifies the requirements for lightweight refillable fuel tanks intended for the on-board storage of high-pressure compressed gaseous hydrogen or hydrogen blends on land vehicles.

It is not intended as a specification for fuel tanks used for solid, liquid hydrogen or hybrid cryogenic high-pressure hydrogen storage applications. 

ISO/TS 15869:2009 is applicable for fuel tanks of steel, stainless steel, aluminium or non-metallic construction material, using any design or method of manufacture suitable for its specified service conditions. 

ISO/TS 15869:2009 applies to the following types of fuel tank designs:
  1. Type 1: metal fuel tanks;
  2. Type 2: hoop-wrapped composite fuel tanks with a metal liner;
  3. Type 3: fully wrapped composite fuel tanks with a metal liner;
  4. Type 4: fully wrapped composite fuel tanks with no metal liner.

WG 11:

ISO/TC 197 WG 11 Task Group 1 (Separation Distances), met in Paris, France on March 3 and 4. This task group is evaluating a variety of approaches for determining separation distances in support of the developing International Standard 20012: Gaseous Hydrogen - Fuelling Stations. ISO 20012 specifies the characteristics of outdoor commercial fuelling stations that dispense gaseous hydrogen used as fuel onboard land vehicles of all types. It covers, as applicable; the system that produces gaseous hydrogen on-site, the system that stores and dispenses gaseous hydrogen from the point of supply at the fuelling station property to the filling connector installed onboard the land vehicle.

The document was recently published as a Technical Specification while the Working Group continues development of an International Standard.

WG12:

ISO/TC 197 WG 12 met in Grenoble, France on February 2 and 3 to continue work on the draft of CD 14687-2, Hydrogen fuel — Product Specification — Part 2: Proton exchange membrane (PEM) fuel cell applications for road vehicles. Most of the meeting was spent with presentations from participants describing the fuel cell testing they have performed. WG 12 needs to gather as much test data as possible in order to make proper determinations on the tolerance of fuel cells to impurities. Therefore much time was spent understanding testing that has already been done by participating presenters, and planning for a future workshop to provide additional information. The proposal for a workshop was requested by ISO/TC 197 Chair, Randy Dey, with a view of an ISO/TC 197 workshop to gain support for the document. Following the meeting, a draft announcement was sent by E-mail to Mr. Dey for approval. WG12 plans to use the workshop to gain the technical data required to complete the work.

WG13:

ISO/DIS 26142, Hydrogen Detection Apparatus (renamed fromHydrogen Detectors), recently completed a period of comment and voting. The draft received unanimous approval.

It could have proceeded directly to publication, but the Chair, in consultation with the WG convener and the Secretariat, has recommended that the comments be addressed. The comments received are therefore returned to ISO/TC 197 WG 13 for consideration. A revised text will be submitted to the ISO Central Secretariat for the approval procedure (FDIS vote) after the comments have been addressed by the working group.

This working group met in Berlin on March 11 and 12 to address the comments.

Interactive Website for European Installation Guidance
Karen Hall, National Hydrogen Association

The Installation Permitting Guidance (IPG) for hydrogen and fuel cells stationary systems was created in response to the growing need for guidance to facilitate small hydrogen and fuel cell stationary installations in Europe, and is now available on an interactive website. This document is not a standard, but is a compendium of useful information for a variety of users with a role in installing these systems.

The IPG site provides users interactive guidance through the document as well as an on-going ability to provide comments and suggestions to its content. In this way, the IPG will remain a living document. The website can be found through the HYPER project website (http://www.hyperproject.eu/) or directly athttp://epshypp.web.its.manchester.ac.uk/.

HySafe: International Association for Hydrogen Safety Founded

The International Association for Hydrogen Safety was founded on February 26 in Brussels. 21 members from research and industry from 11 European countries plus Canada agreed to set up an association under Belgian law. The mission of HySafe is to facilitate the international coordination, development and dissemination of hydrogen safety knowledge by being the focal point for hydrogen safety research, education and training. 

The association is the sustainable continuation of some of the work of the EU supported network of excellence under the same name. This project in the 6th research framework program aimed at integrating the interested and competent parties in Europe and their global partners.

One of the main activities of the association will be to support the continuation of the "International Conference for Hydrogen Safety" (ICHS). This meeting was held twice in 2005 (Pisa) and 2007 (San Sebastián), and the next will take place from September 16 to 18 in Ajaccio (Corse, France). 

Another will be the maintenance of a database on hydrogen accidents and incidents which will accessible to scientifically qualified parties from all over the world.

The association will also promote high level education on hydrogen safety by supporting universities in the organisation of summer schools and post-graduate education.

Finally the association will act as center of competence to support research projects or political decisions whenever necessary and desired. 

The association will be officially recognized as an international non-profit association under Belgian law.

Membership is open for any interested legal party or person from all over the world, not restricted to Europe.

More information is available on http://www.hysafe.net/IAHySafe.

Contact: Manfred Wilms (m.wilms@fz-juelich.de)