wHydrogen: Codes avalanche for having a hydrogen fuel station.

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goptyresxI support hydrogen fuel cell development and deployment. I think it is the most important development for assuring the mobility of the masses. I find it superior to traditional EV’s and think it can go toe to toe with LNG/CNG commercial grade vehicles as well.

The following is a list of the codes that dictate the construction layout of a hydrogen fuel station. Although many of the line items are part of a bigger package and visually the layout of a station seems fairly easy I was still set aback by the list.

Setback distances are indicated by colored regions and are summarized in a setback table titled “2010 National Fire Protection Association (NFPA) Setbacks”:

  • NFPA 55, Table 11.3.2.2 – Minimum distance from liquefied hydrogen systems to exposures:
    • Walls adjacent to system constructed of combustible material (1,500 liter liquid hydrogen storage tank) – 50-foot setback
  • NFPA 55, Table 11.3.2.2.1(a) – Minimum distance from outdoor gaseous hydrogen systems to exposures:
    • Air intake openings – 30-foot setback
    • Wall openings – 30-foot setback
    • Lot line – 30-foot setback
    • Parked vehicles – 15-foot setback
    • Building (with combustible walls) – 10-foot setback
  • NFPA 52, Table 9.3.1.4 – Separation distances for outdoor gaseous hydrogen dispensing systems:
    • Building, line of adjoining property that can be built on, any source of ignition (only pertains to dispersing equipment) – 10-foot setback
    • Nearest public street or public sidewalk (only pertains to dispersing equipment) – 10-foot setback
    • Storage containers (only pertains to dispersing equipment) – 3-foot setback

Setbacks are applicable to a 7,000 psi hydrogen system.

Construction Approval Codes

ASME B31.3, Process Piping (American Society of Mechanical Engineers, 2006)

  • F323.4(5) Specific Material Considerations-Metals
  • IX K305 Pipe
  • IX K306 Fittings, Bends, and Branch Connections
  • IX K307 Valves and Specialty Components

CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations (Compressed Gas Association, 2005)

  • 3.0 Piping System Criteria
  • 3.1 General
  • 3.2 Piping Materials
  • 3.3.2 Isolation Valves
  • 3.3.3 Emergency Isolation Valves
  • 3.3.4 Excess Flow Valves
  • 3.3.5 Check Valves
  • 3.3.7 Gasket and Sealing Materials
  • 3.3.8 Additional Requirements
  • 5.0 Installation
  • 5.1 Installation General
  • 5.1 Piping Installation General
  • 5.2 Piping Installation Above Ground Installation
  • 5.3 Piping Installation Underground Installation

CGA G-5.5, Hydrogen Vent Systems (Compressed Gas Association, 2004)

  • 6.0 Vent System
  • 6.2 Sizing
  • 6.3 Design
  • 6.4 Materials
  • 6.5 Components
  • 7 Installation
  • 9 Maintenance

CGA P-1, Safe Handling of Compressed Gases in Containers (Compressed Gas Association, 2006)

  • 4.1 Transportation Regulating Authorities
  • 4.2 Container Regulations
  • 4.3 Container Filling Regulations
  • 4.4 Regulating Authorities of Employee Safety and Health
  • 6.2 Flammable Gases

CGA PS-20, Direct Burial of Gaseous Hydrogen Storage Tanks (Compressed Gas Association, 2006)

CGA PS-21, Adjacent Storage of Compressed Hydrogen and Other Flammable Gases (Compressed Gas Association, 2005)

CGA S-1.3, PRD Standards Part 3 – Stationary Storage Containers for Compressed Gases (Compressed Gas Association, 2005)

  • 5.3.2 Nonliquid Compressed Gases
  • International Fire Code (International Code Council, 2009)
  • 404 Fire Safety and Evacuation Plan
  • 406 Employee Training and Response Procedures
  • 407 Hazard Communication
  • 906 Portable Fire Extinguishers
  • 907 Fire Alarm and Detection Systems
  • 911 Explosion Control
  • 2201 Scope
  • 2201.1 Scope
  • 2201.5 Electrical
  • 2204 Dispensing Operations
  • 2204.3.5 Emergency Procedures
  • 2205.4 Sources of Ignition
  • 2209.2 Equipment
  • 2209.2.1 Approved Equipment
  • 2209.2.3 Electrical Equipment
  • 2209.3 Location on Property
  • 2209.3.1 Separation from Outdoor Exposure Hazards
  • 2209.3.2.3 Indoors
  • 2209.3.2.6 Canopy Tops
  • 2209.3.3 Canopies
  • 2209.4 Dispensing into Motor Vehicles at Self-Service Hydrogen Motor Fuel-Dispensing Facilities
  • 2209.5 Safety Precautions
  • 2209.5.2 Emergency Shutoff Valves
  • 2209.5.2.1 Identification
  • 2209.5.3.1 System Requirements
  • 2209.5.4 Venting of Hydrogen Systems
  • 2209.5.4.2 Pressure Relief Devices
  • 2209.5.4.2.1 Minimum Rate of Discharge
  • 2211.3.1 Equipment
  • 2211.7 Repair Garages for Vehicles Fueled by Lighter-than-Air Fuels
  • 2211.8 Defueling of Hydrogen from Motor Vehicle Fuel Storage Containers
  • 2211.8.1.2 Atmospheric Venting of Hydrogen from Motor Vehicle Fuel Storage Containers
  • 2211.8.1.2.4 Grounding and bonding
  • 2703.2.1 Design and Construction of Containers, Cylinders, and Tanks
  • 2703.2.2 Piping, Tubing, Valves, and Fittings
  • 2703.9.3 Protection from Vehicles
  • 2703.9.4 Electrical Wiring and Equipment
  • 2703.10.1 Valve Protection
  • 2705 Use, Dispensing, and Handling
  • 2705.1.10 Liquid Transfer
  • 3003 General Requirements
  • 3003.2 Design and Construction
  • 3003.3 Pressure Relief Devices
  • 3003.6 Valve Protection
  • 3003.8 Wiring and Equipment
  • 3003.16.8 Connections
  • 3003.16.14 Classified Areas
  • 3005.3 Piping Systems
  • 3005.4 Valves
  • 3005.5 Venting
  • 3005.7 Transfer
  • 3203.1.3 Foundations and Supports
  • 3203.2 Pressure Relief Devices
  • 3203.2.2 Vessels or Equipment Other than Containers
  • 3203.2.6 Shutoffs Between Pressure Relief Devices and Containers
  • 3203.3 Pressure Relief Vent Piping
  • 3203.5.3 Securing of Vaporizers
  • 3203.5.4 Physical Protection
  • 3203.7 Electrical Wiring and Equipment
  • 3203.8 Service and Repair
  • 3204.4.5 Venting of Underground Tanks
  • 3205.1.2 Piping Systems
  • 3205.1.2.3.2 Shutoff Valves on Piping
  • 3205.3.2 Emergency Shutoff Valves
  • 3501.1 Scope
  • 3503 General Requirements
  • 3503.1.2 Storage Containers
  • 3503.1.3 Emergency Shutoff
  • 3503.1.5.1 Bonding of Electrically Conductive Materials and Equipment
  • 3504 Storage
  • 3505 Use

International Fuel Gas Code (International Code Council, 2009)

  • 101.2.1 Gaseous Hydrogen Systems
  • 703.3 Pressure Relief Devices
  • 703.4 Venting
  • 704 Piping, Use, and Handling
  • 705 Testing of Hydrogen Piping Systems
  • 706.3 Outdoor Gaseous Hydrogen Systems
  • 708 Design of Liquefied Hydrogen Systems Associated with Hydrogen Vaporization Operations

NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages (National Fire Protection Association, 2003)

  • 6.7 Emergency Electrical Disconnects
  • 8 Electrical Installations
  • 9.2.2 Tank Filling and Bulk Delivery
  • 9.4 Operating Requirements for Attended Self-Service Motor Fuel Dispensing Facilities
  • 9.5 Operating Requirements for Unattended Self-Service Motor Fuel Dispensing Facilities

NFPA 52, Vehicular Fuel Systems Code (National Fire Protection Association, 2010)

  • 5.3 Design and Construction of Containers, Cylinders, and Tanks
  • 5.4 Pressure Relief Devices
  • 5.5 Vent Pipe Termination
  • 5.6 Pressure Gauges
  • 5.7 Pressure Regulators
  • 5.8 Fuel Lines
  • 5.9 Valves
  • 5.10 Hose and Hose Connections
  • 5.11 Vehicle Fueling Connection
  • 9.2 General System Requirements
  • 9.2.3 Equipment Security and Vehicle Protection
  • 9.2.4 Out of Service Bulk Storage
  • 9.2.5 Equipment Security and Vehicle Protection
  • 9.2.6 Cargo Transport Unloading
  • 9.2.7 Control Device Icing
  • 9.2.8 Vehicle Ignition Classification
  • 9.2.9 Fueling Connection Leak Prevention
  • 9.2.10 Compression and Processing Equipment
  • 9.2.11 Reference to NFPA 37 for Compressor Installations
  • 9.2.12 Electrical Classification for Compressors
  • 9.2.13 Liquid Carryover Prevention
  • 9.2.14 Detection for Dispensing Equipment
  • 9.2.15 General System Requirements
  • 9.2.16 General System Requirements
  • 9.3 System Siting
  • 9.3.1 General
  • 9.3.1.3 General
  • 9.3.2.3 Outdoors
  • 9.3.3 Indoors
  • 9.3.3.12 Warning Signs
  • 9.3.3.3 Indoors
  • 9.6 Installation of PRDs on Fueling Systems
  • 9.7 Installation of Pressure Gauges
  • 9.9 Installation of Piping and Hoses
  • 9.11 Installation of Emergency Shutdown Equipment
  • 9.12 Installation of Electrical Equipment
  • 9.13 Stray or Impressed Currents and Bonding
  • 9.14 System Operation
  • 9.15 Fire Protection
  • 14.2.4 Indoor Fueling
  • 14.4.3 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.8 Pressure Relief Devices

NFPA 55, Compressed Gases and Cryogenic Fluids Code (National Fire Protection Association, 2010)

  • 4 General Requirements
  • 6.12 Hazard Identification Signs
  • 7.1.2.5 Pressure-Relief Devices
  • 7.1.4 Security
  • 7.1.6 Separation from Hazardous Conditions
  • 7.3.1.10 Use and Handling
  • 10.2.1 Pressure-Relief Devices
  • 10.2.2 Pressure-Relief Devices
  • 10.2.4 Marking
  • 10.3.2 Specific Requirements
  • 10.3.2.1 Specific Requirements
  • 10.3.2.2 Minimum Distance
  • 11.2.3 Piping, Tubing, and Fittings
  • 11.2.5 Liquefied Hydrogen Vaporizers
  • 11.3.1.4 General

SAE J2600, Compressed Hydrogen Surface Vehicle Refueling Connection Devices (Society of Automotive Engineers, 2002)

Operation Approval Codes

CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations (Compressed Gas Association, 2005)

  • 7.0 Maintenance and Repair

CGA G-5.5, Hydrogen Vent Systems (Compressed Gas Association, 2004)

  • 9 Maintenance

International Fire Code (International Code Council, 2009)

  • 105.6.8 Compressed Gases
  • 105.6.10 Cryogenic Fluids
  • 105.6.39 Repair Garages and Motor Fuel-Dispensing Facilities
  • 404 Fire Safety and Evacuation Plan
  • 404.3.2 Fire Safety Plans
  • 406 Employee Training and Response Procedures
  • 406.2 Frequency
  • 407 Hazard Communication
  • 901.6.2 Records
  • 906 Portable Fire Extinguishers
  • 907 Fire Alarm and Detection Systems
  • 907.2 Inspection, Testing, and Maintenance
  • 2204 Dispensing Operations
  • 2204.2 Attended Self-Service Motor Fuel-Dispensing Facilities
  • 2204.3 Unattended Self-Service Motor Fuel-Dispensing Facilities
  • 2204.3.5 Emergency Procedures
  • 2205.1 Tank Filling Operation for Class I, II, or IIIA Liquids
  • 2206.2.1.1 Inventory Control for Underground Tanks
  • 2209.3.2.3.2 Smoking
  • 2209.3.2.3.3 Ignition Source Control
  • 2209.3.2.6.2 Fire-Extinguishing Systems
  • 2209.3.2.6.3 Signage
  • 2209.4 Dispensing into Motor Vehicles at Self-Service Hydrogen Motor Fuel-Dispensing Facilities
  • 2209.5.1 Protection from Vehicles
  • 2209.5.2 Emergency Shutoff Valves
  • 2209.5.2.1 Identification
  • 2209.5.3 Emergency Shutdown Controls
  • 2209.5.4 Venting of Hydrogen Systems
  • 3204.5.2 Corrosion Protection
  • 3205.4 Filling and Dispensing
  • 3503.1.4 Ignition Source Control

NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages (National Fire Protection Association, 2003)

  • 6.2 General Requirements
  • 6.3 Requirements for Dispensing Devices
  • 6.3.7 Requirements for Dispensing Devices
  • 7.3.5 Fixed Fire Protection
  • 9.2.2 Tank Filling and Bulk Delivery
  • 9.4 Operating Requirements for Attended Self-Service Motor Fuel Dispensing Facilities
  • 9.5 Operating Requirements for Unattended Self-Service Motor Fuel Dispensing Facilities

NFPA 52, Vehicular Gaseous Fuel Systems Code (National Fire Protection Association, 2010)

  • 9.2.3 Equipment Security and Vehicle Protection
  • 9.2.15 General System Requirements
  • 9.2.16 General System Requirements
  • 9.3.3.12 Warning Signs
  • 9.10.5 Installation of Emergency Shutdown Equipment
  • 9.13 System Operation
  • 9.14 Fire Protection
  • 9.15 Maintenance System
  • 14.2.1.6 General
  • 14.4.1 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.2 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.3 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.5 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.11 Liquid Hydrogen Vehicle Dispensing Systems

NFPA 55, Compressed Gases and Cryogenic Fluids Code (National Fire Protection Association, 2010)

  • 4.1 Permits
  • 4.2 Emergency Plan
  • 4.6 Personnel Training
  • 4.7 Fire Department Liaison
  • 4.8 Ignition Source Controls
  • 4.9 Signs
  • 6.12 Hazard Identification Signs
  • 7.1.6 Separation from Hazardous Conditions
  • 7.6.3 Ignition Source Control
  • 10.2.4 Marking
  • 10.3 Location of Gaseous Hydrogen Systems
  • 11.3.1.4 General
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