Standard
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AS 19880.1:2023
[Current]Gaseous hydrogen — Fuelling stations, Part 1: General requirements (ISO 19880-1:2020, MOD)
AS ISO 19880.1:2023 adopts and modifies ISO 19880-1:2020, which defines the minimum design, installation, commissioning, operation, inspection and maintenance requirements for the safety, and where appropriate, the performance of public and non-public fuelling stations that dispenses gaseous hydrogen to light duty road vehicles (e.g. fuel cell electric vehicles).
Published: 30/06/2023
Pages: 181
Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
Foreword
1 Scope
2 Normative references
3 Terms and definitions
4 Abbreviated terms
5 Risk management
5.1 Hydrogen fuelling station safety recommendations
5.2 Risk assessment
5.3 Mitigation measures to improve system safety
5.3.1 General
5.3.2 Mitigations which reduce the potential for the formation of a flammable mixture
5.3.2.1 General
5.3.2.2 Safety and emergency shut-off systems
5.3.2.3 Pressure relief devices for gaseous hydrogen systems
5.3.3 Mitigation for the formation of a flammable mixture in enclosures
5.3.4 Mitigation for the formation of a flammable mixture under a canopy
5.3.5 Mitigations which reduce the potential for ignition
5.3.5.1 General
5.3.5.2 Areas subject to restriction of activity
5.3.6 Mitigation of the escalation and/or impact of a fire or explosion originating from the fuelling installation
5.3.6.1 General
5.3.6.2 Flame or fire detection systems
5.3.6.3 Over-pressure protection of enclosures and buildings containing hydrogen systems
5.3.6.4 Emergency release of gas from hydrogen storage vessels under fire conditions
5.3.7 Mitigation of the effect of an external fire/events on the fuelling station installation
5.3.7.1 General
5.3.7.2 Layout
5.3.7.3 Fire barrier recommendations
5.3.7.4 Mitigating against vehicular impact
5.3.7.5 Firefighting systems
5.3.7.6 Emergency principles and operations
5.3.8 Mitigation of risk to the high pressure hydrogen storage system of the vehicle being fuelled
5.4 Safety distances
5.4.1 General
5.4.2 Safety distances relating to hydrogen vent stack outlets
5.5 Protection measures for non-hydrogen hazards
5.5.1 General
5.5.2 Protection measures for asphyxiation hazard in an enclosure (confined space)
5.5.3 Protection measures for emergency egress from enclosed spaces
5.5.4 Ingress protection measures
5.5.5 Protection measures for hose whip
5.5.6 Protection measures for noise
5.5.7 Protection against exposure to extremely cold or hot temperatures
6 Hydrogen supply safety and operation
6.1 On site generation
6.1.1 Hydrogen generators using water electrolysis
6.1.2 Hydrogen generators using fuel processing technologies
6.2 Hydrogen delivery
6.2.1 Gaseous hydrogen supply by tube trailers and multiple element gas containers (MEGC)
6.2.2 Liquid hydrogen supply by tanker
6.2.2.1 Liquid hydrogen storage layout and design features
6.2.2.2 Hydrogen and material compatibility at cryogenic temperatures
6.2.2.3 Liquid hydrogen transfer area
6.2.2.4 Tank foundation and supports
6.2.2.5 Liquid hydrogen delivery lines
6.2.2.6 Piping, fittings, valves, regulator for cryogenic service
6.2.2.7 Pressure relief devices
6.2.2.8 Cryogenic pumps
6.2.2.9 High pressure vaporizer
6.2.2.10 Venting from a liquid hydrogen system
6.2.2.11 Purging
6.3 Pipeline
7 Equipment and Components
7.1 General recommendations
7.1.1 Hydrogen materials
7.1.2 Material hydrogen compatibility
7.1.3 Other material recommendations
7.2 Piping carrying hydrogen
7.2.1 General
7.2.2 Pipe fittings, valves, hoses, for gaseous hydrogen
7.3 Hydrogen storage recommendations
7.3.1 General
7.3.2 Gaseous hydrogen storage vessels
7.3.3 Gaseous hydrogen storage siting recommendations
7.3.3.1 Ground storage
7.3.3.2 Buried underground storage
7.3.3.3 Below ground vaults
7.3.3.4 Roof top or canopy installation of gaseous hydrogen systems
7.3.3.4.1 General
7.3.3.4.2 Roof structural recommendations
7.3.3.4.3 Gaseous hydrogen storage mounting
7.3.3.4.4 Other hydrogen equipment mounting
7.3.3.4.5 Fire protection
7.4 Hazardous areas (with potentially flammable mixtures)
7.4.1 General
7.4.2 Equipment in hazardous areas
7.5 Hydrogen compressors
7.5.1 General
7.5.2 Vibration and movement
7.5.3 Control and monitoring
7.5.3.1 General
7.5.3.2 Inlet pressure
7.5.3.3 Discharge temperature
7.5.3.4 Discharge pressure
7.5.3.5 Cooling water alarm
7.5.3.6 Purge gas/pressurisation protection of electrical equipment
7.5.3.7 Purge gas/pressurisation protection of crankcases
7.6 Instruments for gaseous hydrogen systems
7.7 Filters for gaseous hydrogen
7.8 Gaseous hydrogen vent systems
7.8.1 General
7.8.2 Vent outlet
7.8.3 Vent sizing
7.8.4 Multiple relief devices
7.9 Pneumatics and hydraulics
7.10 Hydrogen purifier
7.11 Enclosures and buildings containing hydrogen equipment
7.11.1 General design
7.11.2 Maintenance access and possible occupancy
7.11.3 Ventilation of enclosures and buildings containing hydrogen equipment
7.11.4 Use of enclosures or compartments within enclosures to control hazards areas
7.11.5 Electrical and mechanical equipment within enclosures and buildings containing hydrogen equipment
7.11.6 Over-pressure protection of enclosures and buildings containing hydrogen equipment
8 Dispensing systems
8.1 General requirements
8.2 Hydrogen vehicle fuelling
8.2.1 Dispensing system process control
8.2.1.1 General requirements for the fuelling protocol
8.2.1.2 Fuelling protocol process limits for light duty vehicle dispensing systems
8.2.1.3 Fuelling protocol process limits for medium and heavy duty vehicle dispensing systems
8.2.1.4 Vehicle to station communications
8.2.1.5 Manual control of dispensing
8.2.1.6 Pressure integrity check (leak check)
8.2.1.7 Process flow measurement
8.2.1.8 Flow control and isolation
8.2.2 Dispensing system safety devices
8.2.2.1 General considerations
8.2.2.2 Dispensing system emergency shutdown
8.2.2.3 Dispensing system pressure control faults and over-pressure protection
8.2.2.4 Dispensing system temperature control faults
8.2.2.5 Shutdown in case of hose breakaway device activation
8.2.2.6 Limitation of hydrogen released in case of fuelling line break
8.2.2.7 Process control failure
8.2.2.8 Physical disturbance of the dispenser
8.3 Dispensing systems
8.3.1 General design and assembly
8.3.2 Dispensing system hydrogen components
8.3.2.1 General
8.3.2.2 Dispensing system hydrogen piping and fittings(s)
8.3.2.3 Dispensing system valves
8.3.2.3.1 General
8.3.2.3.2 Dispensing system hydrogen isolation valve(s)
8.3.2.3.3 Dispensing system hydrogen flow control valves
8.3.2.4 Dispensing system filters
8.3.2.5 Dispensing system temperature and pressure sensors
8.3.2.6 Metering
8.3.2.7 Dispenser vent system
8.3.3 Dispenser housings and cabinets
8.3.4 Dispenser fuelling assembly
8.4 Dispenser installation
8.4.1 General
8.4.2 Location and protection of dispensers
8.4.3 Fuelling pad
8.4.4 Hazardous area around the dispenser
8.4.5 Installation of the fuelling assembly to prevent damage in service
8.4.6 Electrical continuity for bonding and grounding
8.5 Operating considerations
8.6 Maintenance and inspection
9 Hydrogen quality
9.1 General
9.2 Dispensing system fuel filters
10 Electrical
10.1 General electrical
10.1.1 Components
10.1.2 Site (interconnections to and/or between equipment assemblies)
10.1.3 Electrical bonding and grounding
10.1.4 Lightning protection
10.2 Hazardous areas (potentially flammable mixtures)
10.2.1 General
10.2.2 Protection requirements for electrical equipment within hazardous areas
10.2.3 Protection from ignition due to accumulation of static charge
10.3 Electromagnetic compatibility and interference (EMC)
10.3.1 General
10.3.2 Industrial (EMC) Environments
10.3.3 Residential, Commercial, and Light-Industrial (EMC) Environments
11 Instrumentation and control system
11.1 General
11.2 Emergency shutdown functionality
11.2.1 General
11.2.2 Manually actuated emergency stop devices
11.2.3 Hydrogen detection systems
11.3 Remote system control
11.4 Modifications to control system
12 Station inspection and tests
12.1 General
12.2 Pressure test
12.3 Leak test
12.4 Electrical testing
12.5 Fuelling safety and performance functional testing
12.5.1 General
12.5.2 Fuelling protocol test
12.5.3 Test procedure
12.5.4 Site acceptance testing options
12.5.4.1 General
12.5.4.2 SAT overview — Option 1
12.5.4.3 SAT Overview — Option 2
12.5.5 Additional performance considerations for fuelling
12.6 Hydrogen quality testing
12.7 Station inspection and tests following modifications
13 Operation
13.1 General
13.2 Warning signs
13.3 Dispenser operational instructions
13.4 Functional identification
13.5 Marking of equipment (data plate)
13.6 Reference designations
13.7 Training
13.8 Emergency response plan
13.9 Emergency contact information
14 Technical documentation
14.1 General
14.2 Information to be provided
14.3 Recommendations applicable to all documentation
14.4 Installation documents
14.4.1 General
14.4.2 Installation documentation for hazardous areas
14.4.3 Venting documentation
14.4.4 Seismic documentation
14.4.5 Handling and lifting documentation
14.5 Overview diagrams and function diagrams
14.6 Circuit diagrams
14.7 Flow (P&ID) diagrams
14.8 Fuelling station operating manual
14.9 Maintenance and service manuals
14.10 Parts list
15 Inspection and maintenance
15.1 Inspection and maintenance program
15.2 Maintenance and testing frequency of gas detection
15.3 Maintenance and inspection frequency of filters
15.4 Maintenance of pressure relief devices
15.5 Hot work
15.6 Modifications to the hydrogen fuelling station and associated equipment
Annex A
A.1 General
A.2 Regional specific permitting guidance
A.2.1 Example of existing guidance
A.2.2 Example safety distances from each country/region
A.3 Methodology for semi-quantitative and quantitative risk assessment for assessing hydrogen installation safety
A.3.1 General
A.3.2 Summary of methodology
A.3.3 Analysis scoping
A.3.3.1 Target determination
A.3.3.2 Hazards
A.3.3.2.1 General
A.3.3.2.2 Hazard distance
A.3.3.3 Risk and harm criteria and tolerability limit selection
A.3.3.4 System description
A.3.3.5 Cause analysis
A.3.3.5.1 General
A.3.3.5.2 Exposure scenarios
A.3.3.5.3 Data for scenario quantification
A.3.3.6 Consequence analysis
A.3.3.6.1 General
A.3.3.6.2 Physical effects of the accidents
A.3.3.6.3 Hydrogen release characteristics
A.3.3.6.4 Ignition sources
A.3.3.6.5 Jet flame behaviour
A.3.3.6.6 Deflagration and detonation behaviour
A.3.3.7 Harm models
A.3.3.8 Risk calculation
A.3.3.9 Risk-informed mitigations
A.4 Quantitative risk assessment toolkits
A.4.1 General
A.4.2 Examples of toolkits/software tools
A.5 Safety distances definition
A.5.1 General
A.5.2 Types of safety distances
A.5.2.1 Restriction distances
A.5.2.2 Clearance distances
A.5.2.3 Installation layout distances
A.5.2.4 Protection distances
A.5.2.5 External risk zone
A.5.3 Examples of safety distances
A.6 Examples of safety distances derived from risk assessment
A.6.1 General
A.6.2 Description of scenarios for calculation of safety distances
A.6.3 Analyses performed
A.6.3.1 Risk and harm acceptance criteria used within.
A.6.3.2 Default parameters used in all cases
A.6.3.3 Case 1 analysis
A.6.3.4 Case 2 analysis
A.6.3.5 Case 3 analysis
Annex B
B.1 General
B.2 Hydrogen fuelling station safety recommendations for 5.1
B.3 Risk assessment guidance for 5.2
B.4 Guidance for 5.3
B.4.1 General
B.4.2 Mitigations which reduce the potential for the formation of a flammable mixture in 5.3.1
B.4.3 List of examples on how to prevent the formation of flammable mixtures in enclosures for 5.3.2
B.4.4 Mitigations to reduce the probability of ignition in 5.3.4
B.4.5 Mitigations to reduce the effects of flammable mixtures in 5.3.5
B.4.6 Mitigations against external fire or event in 5.3.6
B.4.6.1 General
B.4.6.2 Fire barrier recommendations for 5.3.6.2
B.5 Examples of non-hydrogen hazards for 5.5
Annex C
C.1 General description of dispensing
C.2 Description of SAE J2601
C.3 Use of vehicle-to-station communications
C.4 Description of SAE J2799
C.5 Validation of the fuelling protocol and vehicle-to-station communications
C.5.1 General
C.5.2 Acceptance criteria of testing (as per SAE J2601:2016)
C.5.3 FAT and SAT specification
C.5.3.1 FAT description
C.5.3.2 SAT description
C.6 Test descriptions and checklists — Additional fuelling tolerances
Annex D
Annex E
E.1 Explanation of pressure terminology
E.2 Guidance for defining verification tests of dispensing system components
E.3 Generalization of verification test requirements for hydrogen service
Annex F
F.1 General
F.2 “Lock Out” countermeasure examples
Annex G
G.1 General recommendations
G.2 Dispenser specific recommendations
Annex H
Annex I
Annex J
J.1 General
J.2 HSTA specification recommendations
J.2.1 HSTA hydrogen storage
J.2.2 HSTA system components
J.2.3 HSTA fuelling data collection
Annex K
K.1 Sampling hydrogen at fuelling stations for hydrogen fuel quality analysis
K.1.1 General
K.1.2 Sampling hydrogen at the dispenser for off-line hydrogen fuel quality
K.1.3 Matrix of factors impacting sample collection method selection
K.2 Safety for sampling hydrogen gas at the dispenser nozzle
K.2.1 General
K.2.2 Safety training
K.2.3 Operational safety during sample collection
K.2.4 Safe operation limits
K.2.5 Maintenance of the sample system
K.2.6 Consumables
K.3 Hydrogen gas sampling
K.3.1 General
K.3.2 Gas sample cylinders
K.4 Hydrogen gas sampling — Parallel method
K.4.1 General
K.4.2 Hydrogen gaseous sampling — Parallel instrumentation description
K.4.3 Operational hydrogen gas sampling procedure — Parallel method
K.4.4 Purging
K.5 Hydrogen gas sampling — Series method
K.5.1 General
K.5.2 Hydrogen gaseous sampling- series instrumentation description
K.5.3 Health and safety considerations
K.5.4 Operational hydrogen gas sampling procedure
K.6 Hydrogen gas sampling (direct method — with no vent)
K.6.1 General
K.6.2 Operational hydrogen gas sampling procedure — Direct method with no vent
K.7 Particulate sampling
K.7.1 Hydrogen particulate sampling using a CHSS
K.7.2 Particulate sampling instrumentation description
K.7.3 Particulate sampling health and safety considerations
K.7.4 Particulate sampling — Operational procedure
K.7.5 Particle sample adapter assembly and maintenance
K.8 Combining gas collection and particle collection with the same device
Bibliography
Appendix ZZ
ZZ.1 Scope
ZZ.2 Modifications
Cited references in this standard
SAE J2600: 2015-08
Compressed Hydrogen Surface Vehicle Fuelling Connection Devices
EN 13445-5
Unfired pressure vessels. Inspection and testing
[Current]
Fuel cell technologies - Part 3-100: Stationary fuel cell power systems - Safety
[Current]
Corrigendum 1 - Amendment 2 - Degrees of protection provided by enclosures (IP Code)
[Superseded]
Safety of machinery - Electrical equipment of machines - Part 1: General requirements
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