Purpose: Disseminate Proposed SG270 Fuel Cell Interim Guidance Hazard Assessment Process Provide updates since guidance was published ~FY13 Goal: Solicit feedback from Stakeholders Comments, Questions Possible revisions to process Develop approval process so early designs can be influenced to increase chance of approval Sg270 fc brief_17_nov2016_01b_public_release

1. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Interim Guidance for Adopting Fuel Cell
Technology into the Navy Fleet
SG270 Fuel Cell Working Group
POC: Christian Schumacher
Naval Under Sea Warfare Center (NUWC)
17 NOV 2016

2. NUWC Newport

7. Example Mission:
Bottom Survey
Constant Power Run Profile
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8. Monterey Bay Aquarium Research
Institute (MBARI)- AUV “D. Allan B.”
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9. AUV “D. Allan B.” Configuration
Example
9

10. Interior of AUV “D. Allan B.”
10

11. Bottom Mapping Survey
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12. 12
Navy Unmanned Undersea
Vehicles (UUVs)

20. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
SG270-BV-SAF-010
High Energy Systems Safety Manual
Interim Guidance for Fuel Cell Technology
SG270 Fuel Cell Working Group
POC: Christian Schumacher
Naval Under Sea Warfare Center (NUWC)
17 NOV 2016

21. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
BLUF: SG270 Interim Guidance for Fuel Cells
• Purpose: Disseminate Proposed SG270 Fuel Cell
Interim Guidance
– Hazard Assessment Process
– Provide updates since guidance was published ~FY13
• Goal: Solicit feedback from Stakeholders
– Comments, Questions
– Possible revisions to process
21
• Develop approval process so early designs can
be influenced to increase chance of approval

22. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Introduction
• SG270 defines process to characterize:
– Hazards associated with Lithium High Energy Systems
– Ensures hazard mitigation strategies implemented
– Provides “Maximum Reasonable Assurance” against harm
to NAVY platforms & personnel
• Purpose of this Effort:
– Broaden scope of SG270 to include the current ONR, PMS
406 and 408 High Energy System programs of interest
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23. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Scope: Navy’s Near Term Focus
UUV Energy Sections
PEM & SOFC:
1.Oxidants
1.GO2 <5000, 10000 psig
2.LO2
3.H2O2 , <70 wt%
4.O2 Storage Materials
1.LiClO4, etc.
2.Fuels
1.GH2 <5000, 10000 psig
2.LH2
3.Logistic Fuels (JP-5/8/10)
4.H2 Storage Materials
1.LOHC, Chemical Hydrides, etc.
• Platforms Considered:
– Test Facility
– Pier-to-Pier
– White Hull
– Grey Hull
– Submarine
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Ultimate Goal: Expand
Process for All Platforms

24. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Fuel Cell System
Risk Characterization
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25. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
System of Systems
Proposed fuel cell systems at the core level are
assembly of components used in other
approved Navy shipboard applications
• Compressed gas (NSTM Ch. 550)
• Cryogenic O2 (NSTM Ch. 550)
• Logistic fuels (NSTM Ch. 542)
• Regulators, Blowers, Piping, etc. (NSTM Ch. 505)
• Valving, Materials, Procedures, etc.
• Handling, Storage, Standards, etc.
25Many FC Subcomponents are used throughout Navy

26. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
High Energy System Hazards
• Greatest Hazard: Inadvertent mixing of reactants
can result in Explosion, Fragmentation, and Fire
– Battery: Reactants in a single package
– Fuel Cell: Reactants can be isolated
• System engineering is required to address the
hazards associated with locating components in
close proximity
– Beyond a breach of reactant storage vessel …
– Multi-point failure mechanism is required to cause a
catastrophic release of energy
26Proper System Design can Mitigate Hazards

27. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Relevant Operational Cycle of
Energy Section Defined
1. Storage
2. Loading
3. Platform Transport
4. Pre-Deployment Operations
5. Deployment
6. Operations
7. Recovery
8. Post-Deployment Operations
9. Return Transport
10.Off Loading
Fueling/
De-Fueling
Fueled
Un-Fueled
27To Minimize Hazards: Do Not Fuel until Absolutely Necessary

28. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Initial Approach
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29. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
SG270 Need: Hazard Metric
• Metric that Non-Fuel Cell people can use to
understand the Relative Hazard without an
intimate understanding of the chemistry or
the system
• Provide clear process:
– To define when this metric is relevant
– To challenge this metric through testing
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30. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Precedent: Reactants
DoD 6055.9 “DoD Ammunition and Explosives Safety Standards”
Liquid Propellant:
• Energetic liquids used for propulsion or operating
power for missiles, rockets, Ammunition &
Explosives (AE) and other related devices
Energetic Liquid:
• A liquid, slurry, or gel, consisting of, or containing
an explosive, oxidizer, fuel, or combination of the
above, that may undergo, contribute to, or cause
rapid exothermic decomposition, deflagration or
detonation.
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31. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Energetic Liquid Examples
(DoD 6055.9)
• H2O2, >60 wt%
• Liquid Oxygen
• RP-1 (Refined Kerosene)
• JP-10
• Liquid Hydrogen
• Hydrazine, >64 wt%
• Ethylene Oxide
• Propylene Oxide
• Otto Fuel II
• Liquid Fluorine
• IRFNA (Inhibited Red Fuming Nitric
Acid)
• Nitrogen Tetraoxide/ MON
• Aerozine 50 (50%N2H4/50% UDMH)
• Methylhydrazine
• UDMH
• Nitromethane
• Hydroxylammonium Nitrate (HAN)
• Halogen Fluorides (ClF3/ClF5)
• Nitrogen Trifluoride
• Nitrate esters (e.g. NG, TMETN,
DEGDN, TEGDN, BTTN)
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32. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Hazard Classification of Energetic Liquids
• Class 1: Explosives.
• Class 2: Compressed or liquefied gases.
• Class 3: Flammable liquids.
• Class 4: Flammable solids and self-reactive
materials.
• Class 5: Oxidizers.
• Class 6: Toxic/infectious substances.
• Class 8: Corrosive.
• Class 9: Miscellaneous.
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33. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Determine Hazard Classification
(DoD 6055.9)
33
Defining Fuel Cell Reactants as Energetic Liquids
provides handling & storage guidance both
Afloat (OP4) & Ashore (OP5)

34. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Explosive Equivalency
(DoD 6055.9)
Net Explosive Weight (NEW):
• TNT equivalent weight of energetic materials
• Used in determination of explosive limits and
explosive quantity distance arcs
34
Defining Fuel Cell Reactants as Energetic Liquids
provides handling & storage guidance both
Afloat (OP4) & Ashore (OP5)

35. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Overview of
Risk Approval Process
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36. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Process Stages Intent
1. Risk Determination (Minimize & Assign NEW)
– Most useful reactant combinations have a NEW
– Focus Developer on system level safety design to
remove NEW
– Focus Operator on safe procedures
2. Risk Concurrence (Risk Validation)
– Provides path to challenge NEW rating
3. Risk Acceptance (Check & Balance)
– Proceeds along MIL-STD-882 lines
• Probability and Severity
• Failure mode and effects analysis (FMEA) 36

37. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Design Mitigation Strategies I
(DoD 6055.9)
37
1 System level approach taken to prevent the undesired mixing
and appropriate venting of incompatible energetic liquids
upon failure.
2 All tanks are American Society of Mechanical Engineers
(ASME) certified and maintained per ASME Code, section VIII,
Division 1, 2, or 3 or ASME Section X, as applicable.
3 All cryogenic tanks are constructed with double wall jacketing
certified and maintained per ASME Code, section VIII, X
Division 1, 2, or 3 as applicable.
4 Run tankage to shut-off valve is protected from fragments
produced by malfunction in any of the other subsystems.
5 Both the fuel and oxidizer lines contain two (redundant),
remotely operated valves to shut off flow in the event of a
malfunction.

38. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Design Mitigation Strategies II
38
6. Reactant Tank relief valves are ASME certified.
7. At the system level there is a method to assure a non-
hazardous atmosphere exists in all enclosed spaces.
8. At the system level, there is a capability of detecting, or
sequestering, both reactants prior to reaching a hazardous
condition.
9. Interlock systems will need to be monitored by the Vehicle
Controller so that the appropriate action (shutdown, return
to surface, vent, etc.) can be performed
10. Burst Discs/ Pressure Relief Valves only functional near
platform or personnel

39. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
System Design Standards
Navy Standards
– S9086-SN-STM-010 NSTM Ch. 541
“Ship Fuel And Fuel Systems”
– S9086-SP-STM-010 NSTM Ch. 542
“Gasoline and JP-5 Fuel Systems”
– S9086-SX-STM-010 NSTM Ch. 550
“Industrial Gases-Generating,
Handling and Storage”
– S9086-KC-STM-010 NSTM Ch. 300
“Electric Plant – General”
– MIL-STD-1330D (SH) “Precision
Cleaning And Testing Of Shipboard
Oxygen, Helium, Helium-oxygen,
Nitrogen, and Hydrogen Systems “
Industrial Standards
– ANSI/CSA America FC 1-2004 “Stationary Fuel Cell
Power Systems”
– ANSI/CSA America FC 3 - 2004 “Portable Fuel Cell
Power Systems”
– ANSI/ AIAA G-095-2004 “Standard Guide to Safety
of Hydrogen and Hydrogen Systems”
– NASA WSTF-IR-1117-001-08 “Hydrogen Hazards
Assessment Protocol for Components and Systems”
– ASTM Manual 36 (MNL 36) “Safe Use of Oxygen
and Oxygen Systems: Handbook for Design,
Operation, and Maintenance”
– NASA TM-2007-213740 “Guide for Oxygen
Compatibility Assessments on Oxygen Components
and Systems”
– ASME “Boiler & Pressure Vessel Code (BPVC),
Section VIII – “Pressure Vessels”, Section X – “Fiber-
Reinforced Plastic Pressure Vessels”
– ASME /ANSI “Piping Code” : B-31.1 “Power Piping”,
B-31.3 “Process Piping”, B-31-12 “Hydrogen Piping”39
Best Engineering Practices

40. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Updates since SG270 Interim
Guidance was released ~FY13
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41. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
FY13 Interim Guidance Deviations
• Approval process relied heavily on NOSSA
involvement and use of existing safety
manuals by drawing analogy to rocket/ missile
community which uses similar reactants.
– Based on Energetic liquid classification, DOD
6055.9 scope would need to be changed to
include UUVs, undersea systems, etc.
– Transportation of systems unfueled removed need
for hazard classification
– NOSSA has little experience in fuel cell systems,
would be new area
41
NOSSA may NOT be the best place for SG270 system approval

42. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
SG270 Approval Authority
• NAVSEA 05Z recognizes requirement for
advanced energy system safety approval and
technical oversight
– This aligns with current structure and scope of
SG270
– Majority of advanced energy systems will contain
lithium batteries, which already fall under the
purview of NAVSEA 05Z
42
SEA 05Z may be a better place for SG270 approval

43. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Way Forward
• Staying abreast of relevant Fuel Cell related
technologies (DOD, DOE, NASA, Commercial,
etc.)
• Monitoring ONR BAA funded Fuel Cell Projects
• Guiding ONR performers to safe, transitional,
Navy certified systems
• Leveraging most relevant standards and
specifications to incorporate into future Navy
guidance
43
Continuous improvement of High Energy Systems Guidance & Systems

44. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
H2 Safety Panel Guidance
• Near Term: Test Facility Pier-to-Pier (TRL 6)
– Valves, regulators, PV , SRV, PRV, etc.
– Stack leakage H2 Sensors, catalysts,
– Controls, interlocks, etc.
• Mid Term: Commercial Ships (White Hulls)
– May overlap with Maritime focus
• Long Term: Navy Surface Ships (Grey Hulls)
– Mil Shock & Vibration, sympathetic Detonation, etc.
• Very Long Term: Submarines (Black Hulls)
44

45. DISTRIBUTION STATEMENT A.: Approved for public release; distribution is unlimited
Questions?
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