Design and Footprint of LH2 Supplied Refueling

1. 1
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Hydrogen Fueling Infrastructure Research and Station Technology
Design and Footprint of Liquid Hydrogen-Supplied Refueling
Stationsfor Urban Sites
Brian Ehrhart
Sandia National Laboratories
Call with NREL and UMD
October 29,2019
SAND2019-XXXX
Sandia National Laboratories is a multi-mission laboratory managed and operated by National Technology and Engineering Solutions of
Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc.,for the U.S. Department of Energys National Nuclear Security
Administration under contract DE-NA0003525.
0Sandia National laboratories Hydrogen Fueling Infrastructure Research Station Technology
SAND2019-13054PE

2. Specified components needed for three methods of hydrogen
supply
Gas
Hydrogen
Compressed Hydrogen
L
Delivery Trucks Liquid Hydrogen
'
v.-
41)641j
Liquid
AC Power
• PEM
Water Electrolysis
On-site Hydrogen Production
LH2
Evaporator
Cascade Dispenser
Compressorl System
142F1RST
1. Fueling stationssupplied by LH2 may utilize
cryopumps in the long-term. Compressors were
assumedforsimplicity ofmodeling, as thefootprint
associated with a pump is likely to be comparable.
• Compressor • Cascade
— 25 kg/hrflow rate(constant600 kg/day)
— Outlet pressure of94.4 MPa(13,688 psi)
• Chillers
— 25.2 kW(7.2 tons)of refrigeration needed for
each chiller
— Aluminum cooling block of 1,330 kg(0.49 m3
)
needed for each
— 10cascade units,each containing 5(1:1:3)
pressure vessels
Outletflow rate 60 kg/hr to each dispenser
Dispensing
4fueling positions,70 MPa,-40°C
'mita National Laboratories 'Fr"ImREL Hydrogen Fueling Infrastructure Research Station Technology

3. Liquid storage P&ID
•
8 7 6 I 5 I 4 I 3 I 2 I 1
CONTROL AIR
PSV-101
PSV-100
10 bar
LIQUID STORAGE TAN K
HV-101
220-100
FV-1020
TO FIRE PANEL
RAH-100
IR FLAME DETECTOR
AIMED AT HYDROGEN STORAGE
HV- 00
CN L-100
CRVOGENIC PU MP
GH 100
AMBIENT AIR EVAPORATOR
TO COMPRESSOR
NOTE 1: APPLIES TO MODU LAR STATION ONLY. A BUILD-ON-SITE
STATION WILL NOT HAVE A SKID- OR CONTAINER-MOUNTED,PRE-
ASSEMBLED SYSTEM.
REFERENCE STATION:
LIQUID STORAGE
8 7 6 5 4 3 2 1
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Hydrogen Fueling Infrastructure Research Station Technology

4. H
G
F
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D
C
B
A
Compressor and Other EquipmentP&ID
8 7 6 5 4 3
(
4
H2 Z3r
I 2 I 1
GAS STORAGE
COMPRESSION SKID OR CONTAINER BOUNDARY.SEE NOTE 1 ♦
TO COMMON 136-VENT MAST
- LOCATED ON BACK OF GMP
10'ABOVE GRADE
TO GAS STORAGE
CONTROL AIR
TO FIRE PANEL
RAH-100
FSV-100
COH-100
AIR COMPRESSOR
PBAL 100
AF-1C0
FV-10:)
ee
HV-201
-0T0 I
I IfHV-202
ZVO-100
P CP< /'
ZVO-101
ZVO-400
AIR DRYER
AF-1O1
ZVO-401
IVO-402
C>
F
<I
ZVO-403
PLC/
Gas Control Cabinet
NOTE2
GW 800
OF-802
GW 801
C>4 C><C1
CW-800
ti
*V-204
HV-203
CNH 300
Motor - -
480 V,
60 kW - -
I
li ll
-
- '
14C-CHW-800-SCH40-F2
9/16"-H-15000PSI
COMPRESSOR,
MULTIP LE STAGES
-1643
1.17,
I HV-300
FXHV-300
A
Ul
FF 300
FV-101
CHILLERS 26.2-kW EACH
FSV-300 HV-301
HV-400 a FV-4(0
— I k_d
1-1-4 TO
DISPENSER
FROM
DISPENSER
TO CASCADE
TO CASCADE
CONTROL AIR
ZVO-046
IR FLAME DETECTOR
AIMED AT HYDROGEN
COMPRESSOR
NOTE 1:APPLIES TO MODULAR STATION ONLY. A BUILD-ON-SITE STATION
WILL NOT HAVE A SKID- OR CONTAINER-MOUNTED,PRE-ASSEMBLED SYSTEM.
NOTE 2:IN MANY MODULAR STATIONS THE HEAT EXCHANGE EQUIPMENT
WILL BE ROOF-MOUNTED
TO DISPENSER
CONTROL AIR
REFERENCE STATION:
COMPRESSION AND COOLING
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trAtOrfel E Hydrogen Fueling Infrastructure Research Stalion Technology

5. Cascade P&ID - Detail MIIMPIP'
8 7 6
4i42F1RST
RESTOF
CASCADE
CONTROL
AIR
A
AA
EU
, Ole
DTI3
HV-4X1
TO COM MON 2
-VENT MAST
LOCATED ON BACK OF GMP
10 ABOVE G RADE
9/16"-H-15000PSI
L><
ZVO-4X1
1>Y<I
ZVO-4X2
ZVO-4X3
-
41>F<
ZVO-4X4
[51
FV-4X1
11Aft
II
'="'
=7
EC,
r>a
-013-3
FP
HV-4X2
DTI
H2Storage PBNH-4X1
MAWP-13780PSIG
HV-4X01 HV-4XC2
FV-4X2
/IA
Tim, Tcry
.s• 481
Ole
HV-4X3
1>T<1
H2Storage PBNH-4X2
DTCI
MAWP-13780PSIG
HV-4X11 HV-4X12
ZVO-4X5
PLC/
Gas Control Cabinet
H2 Storage PBNH-4X3
MAWP-13780PSIG
FV-4X3 HV-4X21 HV-4X22
- 81
AlkAlk
t='ElOr
1-
4
HV-4X4
FV-4X4
A
Alk
-
7
=Tn:17
WIZ
•
FV-4X5
r>
T
1 H2Storage PBNH-4X4
•
c>
T
<3 H2 Storage PBNH-4X5
MAWP-13780PSIG
HV-4X31 HV-4X32
1>
T
1
MAWP-13780 PSIG
HV-4X41 -
1 HV-4X42
REFERENCE STATION:
CASCADE UNIT
8 7 6 5 4 3 1
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Hydrogen FuelIng Infrastructure Research Station Technology

6. H
G
F
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D
B
A
Cascade P&ID - Overview
8 7 6 5 4 3 2
4.41 11;r
1
MODULAR STORAGE SKID OR CONTAINER BOUNDARY.SEE NOTE 1
TO COMMON 2"VENT MAST
LOCATED ON BACK OFGMP
10ABOVEGRADE
SEE NOTE 2
—C
—C
—C
—C
(›
T
‹ sv-4
i
>
T
<
3 SV-3
E>
T
(
1 SV-2
cj
cz
i sv-1
• .e•
TO FIRE PANEL
7
-
1
RAH-400
IR FLAME DETECTOR
AIMED AT HYDROGEN STORAGE
FROM
COMPRESSOR
9/16
.
'-H-15000P51
CONTROL AIR
TO DISPENSER
NOTE 1: APPLIES TO MODU LAR STATION ONLY. A
BUILD-ON-SITE STATION WILL NOT HAVE A SKID- OR
CONTAIN ER-MOUNTED,PRE-ASSEMBLED SYSTEM.
NOTE 2: EACH SET OF 5 CYLINDERS SHOWN HERE IS
A REPRESENTATION OF THE CASCADE UNIT SHOWN
ON THE PREVIOUS SHEET
REFERENCE STATION:
CASCADE STORAGE
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7. Dispenser P&ID .1111
1111
.11111MPIIIIPilir
•
8 7
FROM CHILLER
-
/ 4
TO CHILLER
7o0 BAR
-N-OZZLE
9/16"-H-15000P5I
To EPO
circuit
FROM CASCADE
CONTROL AIR 2V0-900
r
. ER3
2V0-901
[2><Z1 r
ZVO-903
1:9<1
ZVO-902
HV-904
70MPa DISPENSER
WUN-900
FV/Controls Internal
120V,1p,15A
ON-900
H70-Cold
H70-740
HEAT
4— ](CHANGER
1330 kg
H70-Warm
T
di
HV-900
HEAT
EXCHANGER
1330 kg
PLC/Gas Control Cabinet
To EPO
circuit
--,•
CZ=1.
700 BAR NOZZLE
7OMPa DISPENSER
WUN-902
FV/Controls Internal
120V,lp,15A
DN-902
H7O-Co
HEAT
EXCHANGER
1330 kg
H70-1-40
H70-Warm
CI*
HV-902
70MPa DISPENSER
WUN-901
FV/Controls Internal
120V,lp,15A
ON-901
H70-CoW
H70-740
To EPO
cicuit
HV-901 H70-Warm
HEAT
EXCHANGER
1330 kg
70MPa DISPENSER
WUN-903
FV/Controls Internal
120V,1p,15A
DN-903
H70-Cold
H70-740
Jt
To EPO
circuit
-t
At
HV-903 H70-Warm
700 BAR NOZZLE
IR FLAME DETECTOR
AIMED AT DISP HOSES
TO FIRE PANEL
RAH-900
700 BAR NOZZLE
REFERENCE STATION:
DISPENSER SUB-SYSTEM
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Hydrogen Fueling Infrastructure Research Station Technology

8. Hydrogen System Layout
8
'
40'
_...„
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'mita National Laboratories rINREL Hydrogen Fueling !nfrastructure Research Station Technology

9. LH2 Base Case View
_____-------
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'mita National Laboratories veINREL Hydrogen Fueling !nfrastructure Research Station Technology

10. Base Case Liquid: Large footprintdue to delivery truck and
non-reducible 75ft. air intakes setback
78'
75'
170'
4k2F1RST
• Bulk liquid storage
— 800 kg, 11,299 L
(2,985 gal)
• Lot size: 170 x 125 ft
• Total Area: 21,250ft2
'mita National Laboratories NREL Hydrogen Fueling Infrastructure Research Station Technology

11. "
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7
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1
Identified challenges in interpretation and implementation of (
4H2F1RST
NFPA 2leading to code updates
Gaseoussetback distances
— Large system can have "bulk
storage" before and after
compressor
• Complexity ofsystem makes
selection of single pressure and
diameter challenging
Liquid setback distances
• Hybrid system (liquid-to-gas)analyzed as
all-liquid system
— Recently changedin 2020Ed.ofNFPA 55/2
• Setback distances are differentfor most
exposures,only a few able to be reduced
— Single system could take worst-case:
maximum pressure from one area
and maximum ID from other area
— Could also calculate setback
distances for each system section
and select largest
• In Appendix I, but nowhere else
Calculationsforlargersystem may lead to
unintendedsetback distances
anclia National Laboratories
Group Exposure Reducible Distance
1
1 Lotlines Yes 15 rn(50ft)
2 Air intakes 23 rn(75 ft)
3 Operable openings in buildings 23 rn(75 ft)
4Ignition sources 15 m(50ft)
2
5 Places ofpublic assembly 23 m(75 ft)
6Parked cars 1.7 m(25 ft)
3
7(a)(1)Sprinklered non-combustible building Yes 1.5 m(5 ft)
7(a)(2)(i)Unsprinklered, without fire-rated wall Yes 15 m(50ft)
7(a)(2)(ii)Unsprinklered, with fire-rated wall Yes 1.5 rn(5 ft)
7(b)(1)Sprinklered combustible building Yes 15 m(50ft)
7(b)(2)Unsprinklered combustible building Yes 23 m(75 ft)
8Flammable gas systems (other than H2) Yes 23 m(75 ft)
9Between stationary LH2containers 1.5 m(5 ft)
10 All classes offlammable and combustible liquids Yes 23 rn(75 ft)
11 Hazardous material storage including LO2 Yes 23 rn(75 ft)
12Heavy timber, coal Yes 23 rn(75 ft)
13 Wallopenings 15 m(50ft)
14 Inlet to underground sewers 1.5 m(5 ft)
15a Utilities overhead: public transit electric wire 15 m(50ft)
15b Utilities overhead: other overhead electric wire 7.5 m(25 ft)
15c Utilities overhead: hazardous material piping 4.6 m(15 ft)
16Flammable gas metering and regulating stations 4.6 m(15 ft)
-
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12. NFPA 2020 Requirements
Proposed Requirements
141' 91' 71'
-:7.
191'
1-41.5""-
0.1
Gas
Ga
G
Group 2
Group 1
Gas: Air In12ikas
75'
07'
sz Group 3
157'
Current Requirements
141' 91'
60'
71'
-4115"""
-
11-25'-1
"
-
80'
50'
130'
75'
180'
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191'
V
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13. New NFPA 2020 Liquid Station Layout
72"I
63'
-40
ol
72" 1'
44°1
151-
7
78'
75'
52'
55'
41'
-41-1°
- 71 2"
Comientence Store
eeeeeoeoee
156' •
30'
117'
12'
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'mita National Laboratories rINREL Hydrogen Fueling Infrastructure Research Station Technology

14. 1
1111.1.111Pmr—
Underground Direct Bury
22'
-410'
75'
8
'
37'
)(.
(
)
)
)
( )
( )
)
C )( )C
50'
ConvenienceStore
ag•
)
)
)
( )
)
)
145'
C )
)
5
'
30'
107'
12'
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andia National Laboratories -7-1NREL Hydrogen Fueling Infrastructure Research Station Technology

15. ---
'
11411111
Summary of lot sizesfor all cases
Total Lot Area (ft2
) Reduction from Base Case
Base Case Gas 17,640
New NFPA Separation Distances 17,640 0.00%
New Delivery Single Truck 14,391 18.42%
New Delivery Double Truck 15,875 10.01%
Gasoline Co-Location 21,980 -24.60% (Increase)
Underground Direct-Bury 16,060 8.96%
Underground Vault 13,720 22.22%
Rooftop Storage 15,400 12.70%
Base Case Liquid 21,250 0.00%
New NFPA Separation Distances 18,252 14.11%
New Liquid Delivery 19,080 10.21%
Gasoline Co-Location 25,330 -19.20% (Increase)
Underground Direct-Bury 15,515 26.99%
Rooftop Storage 19,840 6.63%
Base Case 14,756 0.00%
New NFPA Separation Distances 11,934 19.12%
Gasoline Co-Location 21,980 -48.96% (Increase)
Jnderground Direct-Bury 13,340 9.60%
Underqround Vault 16,240 -10.06% (Increase)
Roofto• Stora•e 11 466 2230%
F1RST

16. TECHNICAL BACK-UP SLIDES
41i
-i2F1RST 1
andia National Laboratories REL Hydrogen Fueling infrastructure Research Station Technology

17. Non-hydrogen station components have large impacton
footprint
Assumptions and considerations:
• Delivery truck path
— Trucks must be capable ofturning without reversing
— Corner lot not considered (entry and exit only on
single lot side)
Convenience store
— 50 x 30ft
• Parking/Traffic Flow
— Convenience store parking
— Fueling positions
— UT Parking Lot Design Manual
• Kept consistent between designs
• System was idealized for comparison
— Other location-specific factors will also have large
impact on footprint
-.m=51=
i2F1RST
WB-50 CIVB-15) DESIGN VEHICLE
RADIUS • 45 ft (13.72 mI
SCALE .1:20 (1:2001
Turning Template for Semi-Troiler with 50 ft (15.24 m1 Wneeloose
Texas DOT Road Design Manual
'mita National Laboratories
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1 .41 NREL Hydrogen Fueling !nfrastructure Research Station Technology