Safety in Hydrogen Applications -An article series, Vol 7 of 7. Integrated Safety

Safety Across the Hydrogen Value Chain

The hydrogen value chain has four critical phases: generation, transformation, transportation, and consumption. Given the inherent risks associated with hydrogen, ensuring safety across these phases is paramount. Comprehensive safety systems must integrate safety measures for hydrogen processes and fire safety for the entire facility. Solutions from Autronica and Det-Tronics address the safety needs of the entire hydrogen value chain, meeting international safety standards and providing reliable protection at an economical cost.

Hydrogen Generation and Transformation

Hydrogen is generated through various methods, including water electrolysis (using alkaline or proton exchange methods) and natural gas reforming. It is then transformed into methanol and ammonia for use as synthetic fuels or in industrial processes. Ammonia, for instance, is extensively used in fertilizer production worldwide.

Hydrogen Transportation and Consumption

Hydrogen is transported from production sites to consumption points either in compressed form (CH2) or as liquid hydrogen (LH2). Its consumption spans diverse applications, such as green steel production, cement industries for limestone processing, chemical processes in refineries, power plants, rocket fuel, and as a fuel in mobility. This diversity in applications necessitates adaptable and scalable safety systems, provided by integrated solutions from Autronica and Det-Tronics.

Designing Safety Systems for Hydrogen Applications

The design of safety systems for hydrogen applications is divided into two components:

1. Process Safety: This component addresses fire and explosion hazards from hydrogen as the main process. Safety systems must detect and respond promptly to potential fire and explosion hazards caused by hydrogen leaks. Det-Tronics provides solutions such as the CGS gas detector, FlexSonic acoustic leak detector, X3302 multispectrum IR flame detector, and GT3000 oxygen leak detector for generation sites.
2. Area Safety: This component involves fire detection systems for supporting infrastructure, such as utility rooms, machinery areas, and office spaces. It is crucial to prevent fires originating from electrical, electronic, or machinery systems from escalating to the main process areas. Autronica’s AutroSafe system, combined with AutroGuard protector, X3301 flame detectors, manual call points, alarming devices, and beacons, offers a comprehensive and integrated solution.

Integrated Safety Solutions

AutroGuard protector integrates multiple detection features into a single unit, including heat detection, smoke detection, sounder, visual alarm devices, carbon monoxide detector, and loudspeaker. It is resistant to salt, vibration, oil mist, weather, and pollution, with a life expectancy of over 20 years for connectors and electronics in normal environments. The Self-Verify functionality detects 100% of errors in the signal path and 99% of all components, ensuring high sensitivity suitable for hydrogen applications. These integrated solutions comply with major safety standards such as EN54, FM, and NFPA72, and are SIL2 certified for enhanced safety and availability.

Scalability and Reliability

The AutroSafe fire alarm control panel supports up to 15,000 loop units and 64 systems, available in both single and redundant configurations. Its scalability makes it suitable for small electrolyzer or filling stations to large-scale industrial hydrogen facilities. Enhanced safety is provided by built-in fault monitoring, which automatically identifies failed detection units, and SelfVerify? functionality, which provides daily checks of all detectors, interfaces, connections, and cables, ensuring system reliability and sensitivity. Major protocols such as AutroCom, Modbus, ESPA 4.4.4, and NMEA 0183 are supported to ensure seamless integration.

Conclusion

The integration of specialized safety systems for hydrogen applications is crucial to mitigate the risks associated with hydrogen’s flammability and explosive potential. The AutroSafe system, with its comprehensive features and compliance with international standards, offers a reliable solution for ensuring safety across the hydrogen value chain. By addressing both process and non-process areas, the system effectively prevents the potential escalation of incidents, safeguarding both personnel and infrastructure.