2024年氢能行业的功能安全工业信息安全和防爆保护白皮书-皮尔磁Pilz

Functionalsafety,IndustrialSecurityandexplosionprotectionforthe

hydrogenindustry

Whitepaper

Status:July2024

WhitepaperFunctionalsafety,IndustrialSecurityandexplosionprotectionforthehydrogenindustry

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WhitepaperFunctionalsafety,IndustrialSecurityandexplosionprotectionforthehydrogenindustry

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Ataglance

InordertoreachnetzeroCO2emissionsby2050,globaleffortsareconcentratedon

decarbonisationoftheenergysupply.CO2-neutralhydrogenplaysakeyroleinthisgoal.

Forallthoseinvolvedinthehydrogenvaluechainsectors–manufacturers,operators,users,notifiedbodiesandinsurers–theprimaryobjectiveistokeeptheriskofanaccidentbelowasociallyacceptableresidualrisk.Thisappliesnotonlyduringdesignandengineering,butalsoforoperationandmaintenance–particularlyrelevantintheenergysupplysector–andalsotoguaranteebusinesscontinuity.

Pilzsupportsthechallengesofstakeholderswithitsmanyyearsofexperienceintheglobalautomationindustry.

Inthiswhitepaperwefocusonthedifferentelementsoftheoverallhydrogenchainandprovideashortdescriptionofthekeysafety-relatedrequirements.

Inviewofalltheopportunitiesthatarisefromtheimpressivepropertiesofhydrogen,itisworthemphasisingthatbroadsocialacceptanceoftheuseofnewtechnologiesdevelopswhen

thinkingextendsbeyondmerecompliancewithlegalrequirements,industrialregulationsortechnicalstandards.

Eachsafety-relatedincidentdelaystheintroductionofnewtechnologies.

However,weareconvincedthatwhenprovensolutionsareused,thenumberofsafety-relatedincidentswillinnowaydevelopinparalleltothespreadofhydrogentechnology.

Nonetheless,itisimportanttobeaware:eveninthefuture,badnewswillcontinuetosellbetterthangoodnews.

Theansweristogetitrightfromthestart!

Toachievelasting,reliablesafety,itisessentialtouseprovenproceduresandtoolsfortheriskanalysis,riskevaluation,andwhendevelopingplantandmachinery.

Innumerousdiscussionswithmanufacturers,users,organisationsandassociationswesee

uncertaintywhendealingwiththesafetyrequirements.That’swhyinthisdocumentwelookinmoredetailatthedifferenthydrogenapplicationsandtheirspecificstandardsandrequirements.

Ifyouwouldliketogetintouchwithus,you

canusethecontactoptionsat/hydrogen!

Welookforwardtohearingfromyou!

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Contents

1.Introduction 5

1.1.ProcessindustryandMachinerySafety–Similaritiesanddifferences 6

1.2.Whataretheriskswhenusinghydrogen? 6

1.3.Basicexplanation–Theterm“functionalsafety” 7

1.4.Explosionprotection 11

2.Legalframeworkforhydrogen 12

3.IndustrialSecurityforthehydrogenindustry 14

3.1.1.Foreseeablemisuse,faultyoperation 15

3.1.2.Simplificationoforganisationalmeasures 17

4.Generalsafetyaspects 18

4.1.Sensorsfordetectingleaks,gasconcentrationsandflames 19

4.2.Monitoringofprocessvalues 19

4.2.1.Safepressuremonitoring 22

4.2.2.Safetemperaturemonitoring 22

5.Applicationexamples 22

5.1.Hydrogenproduction 25

5.2.Electrolyser 25

5.3.Steamreforming 26

5.4.Hydrogenrefuellingstations 26

5.5.Hydrogenconsumers 27

5.5.1.Fuelcell 27

5.5.2.Burner 27

5.5.3.Combustionengine 29

6.Conclusion 30

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1.Introduction

Hydrogenhasincrediblepotentialwhenitcomestoaddressingthekeyquestionsoffutureenergysupply.

Atthesametime,questionsregardingacceptancealwaysarisewhennewtechnologiesareintroduced.Theaimistoimproveallaspectsoftechnical,commercial,environmentaland

globalstrategiccriteria.Usuallythistaskcanonlybetackledstepbystep,andprovideseverclearerandmoreplausibleanswersinaretrospectiveviewthaniseverpossiblebylookingahead.

However,itisimportanttotakeaccountofempiricalvaluesfromother,comparableapplicationsandbringaboutbetter,safersolutions–includingbyanalogy.Thisrequirescloseinteraction

andcross-sectorexchange.

Themarketramp-upoftheentirehydrogenvaluechainisakeytaskforallconcerned.Theuseandtransferofindustrially-provenprinciplesrequiresopenco-operation.

Theindustrialproductionanduseofhydrogenisnotanewtechnology–buttheapplicationsandapplicationareashaveundergoneconsiderablechanges.Inadditiontoupscalingtolargermassflows,completelynewapplicationareaswillalsoemerge.

Today,experienceinhandlinghydrogenexistsprimarilyinlarge-scaleprocessingplants–

whereasdirectcontactwithconsumerswasratherararityinthepast.Decentralisationoftheenergysupplyisaclearlystatedgoal–wherebytheusergroupalsochanges–andthereforerequiresspecialconsideration.

Inadditiontoglobalstrategicandeconomicconsiderations,increasingmarketshareisalsofundamentallydependentonsocialacceptance.Andtheabilitytohandletechnologysafely

playsakeyrole.Thetaskistoguaranteesafetyforallapplicationsandallpotentiallevelsofqualification–fromaqualified,trainedprofessionaltoanuntrainedconsumerattherefuellingstation.

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1.1.ProcessindustryandMachinerySafety–Similaritiesanddifferences

Therearesomesimilarities-butalsodifferences–inthesafetyphilosophyoftheprocessindustryandMachinerySafety.

Inparticular,itisworthconsideringthetargetgroupforwhichthesafetymeasuresareprimarilydesigned–andwhichqualificationsmayberequiredthere.

Themarketramp-upandincreasedmarketsharemeanthatlarge-scaleindustrialusersarenottheonlyonescomingintocontactwithpotentiallydangerousmaterialsandsubstances–sotooareuntrainedtechnicallaypeople.

Thebasicphilosophyofindustrialsafetytechnologyisthathumansmustalwaysbeprotectedfromhazardsandrisksmustbeaverted.Asafety-relatedworst-caseassessmentmustalwaysbedesignedtoconsidertheweakestlinkinachain–andthisisgenerallythehuman.

Processindustry

MachinerySafety

Safety-relatedanalyses

、LOPA,HAZOP,PHA

、Hazardandriskanalysisforeachhazard

Hazarddueto

、Harmfulsubstances

、Heat,steam,radiation,leakage,electricity,butmainlyduetofailureofthecontrolsystem

、Movingmachineparts(shearing,crushing...)

、Hazardsarisingfromthe(manufacturing)process

Safereactionthroughmonitoring

、Typicallyalarm,followed

byoperatorintervention、Differentlevelsof

protection

、Processcontrolsafety

device

、Stoppingofhazardousprocesses(e.g.

machinemovement)

、Automatic,direct,safeinterventioninthe

controlsequence

Reactiontime

、Adjustedtotheprocessreaction(seconds...

hours)

、Immediate

(milliseconds)

Environment

、Plantanditsenvironment

、Limitedlocallytotheplant/machine

Organisationalmeasuresfor

、Experts(monitored

workflows,checklists,comprehensive

documentation)

、Machineoperator,trainedforthe

productionorder

、Protectionagainstmanipulation

Safetyphilosophy

、Safetydesignforhighlyqualifiedandtrained

professionals

、Safetydesignforall,occasionally

beginners,whohavenothaddetailed

training

Table:ComparisonofsafetymeasuresintheprocessindustryandinMachinerySafety

1.2.Whataretheriskswhenusinghydrogen?

Hydrogeninconjunctionwithoxygenisahighlyexplosivegasmixture;itisoftenunderhigh

pressureandisextremelycoldinitsliquidstate.Thisrequiresextensiveprotectivemeasures

duringmanufacture,transportandprocessing.Hydrogenandoxygenhaveanextremelywideflammabilityrangeof4to78percentbyvolume,atwhichignitionoranexplosioncanoccur.At

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thesametime,hydrogenrequiresamuchlowerignitionenergythanpetrolornaturalgas,forexample,asaresultofwhichitcanignitemuchmoreeasily.

Forthisreason,whendesigninghydrogendevicesandcontainersitisvitallyimportantthat

adequateventilationand/orleakdetectionisavailable.Becausehydrogenburnswithaflame

thatisalmostinvisible,specialflamesensorsarealsorequired.Theselectionofappropriate

materialsisalsoimportantfordesigningdurable,robusthydrogencontainers.Metalscan

becomebrittlewhenexposedtohydrogen.Givenitssmallmoleculesize,itcanleakthroughthesmallestoftearsormaterialtransitions.

Therearealargenumberofrisksconnectedtothemanufacture,processingandstorageof

hydrogen,whichmustbeconsidered.Fire,explosionandasphyxiationarethemost

importantsafetyaspectsthatmustbeconsideredwhenhandlinghydrogen.Particularlyinthecontextofthewideflammabilityrangeof4%to78%oftheH2volumeinair.

、Leakage:Duetoitssmallmoleculesize,lowmolecularweight,high

diffusivityandlowviscosity,hydrogenisverydifficulttocontainandcaneasilyleak.Hydrogenleaksposeaseriousriskoffireorexplosion.

Itisgenerallyassumedthatinenclosedspacesitwillrisetotheceiling,displacingtheoxygen.Consequentlyitisverydifficulttodetectinspaceswhereaccumulationscanoccur.

Pressurisedhydrogenleakscanbeevenhardertodetectasthedirectionofthegasjetasitescapesfromapipeorcontainercanbeunpredictable.Thismakesitmoredifficulttopositionanappropriatesensor.

、Fire/ignition:Hydrogenishighlyflammableandnaturallyexplosive.Itignitesandburnsmuchmoreeasilythanotherfuels,andasoneofthelightestelementsonearth,itspreadsupwardsveryquickly.Hydrogenflamesareinvisible,whichmakesitdifficulttolocalisethefiresource.Whenmixedwithair,hydrogenishighlycombustible.However,apurehydrogenflameisverypaleandalmostinvisibleindaylight.

、Contactinjury:Becausehydrogenisnormallystoredandtransportedinliquidstateinpressurisedhydrogentanks,itisextremelycold.Ifhydrogenescapesinthisstateandcomesintocontactwiththeskinoriftheicy

vapouroftheliquidhydrogenisinhaled,thiscanleadtoburns,frostbite,hypothermiaandlungdamage.

Safetyprecautionsareessentialtoensuresafeapplication.Detectiontechnologiescombinedwithsafecontroltechnologyplayakeyroleinsafeuseandalsoinavoidingdamageand

accidents.

1.3.Basicexplanation–Theterm“functionalsafety”

Standardsandregulationsguaranteethatindustrialplantandmachineryissafetouse.Theycoverawiderangeofmachineryandequipment,focusingonessentialhealthandsafety

requirements.Whetherit’sanassemblylineorasinglemachine,compliancewiththeseregulationsiscrucialforprotectingemployeesandpreventingaccidents.

Also,riskassessmentsareessentialtoensurethatmachineryisdesignedandconstructedtominimiserisksduringoperationandintheeventofforeseeablemisuse.

“Functionalsafety”isthetermusedwhensafetydependsonthecorrectfunctionofacontrolsystem.However,functionalsafetydoesnotonlyconsiderthecurrentstateofaplantormachine–considerationsoverthewholelifecyclealsoplayaroleintheassessment.The

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standardsforfunctionalsafetyincluderiskanalysis,specificationofrequirements,validation,regularfunctiontestsandcommissioning.

Riskassessmentplaysacentralrolewithregardtofunctionalsafetyrequirements.ThestepsyouneedtoconsiderwhenassessingandreducingriskonmachinerycomefromthestandardENISO12100:Generalprinciplesfordesign—Riskassessmentandriskreduction.TheevaluationandverificationofsafetyfunctionsaretheprevailofthestandardsENISO13849:

Safety-relatedpartsofcontrolsystemsandENIEC62061:Safetyintegritylevels(SIL),

providedtherequiredsafeguardingisdependentonacontrolsystem.Thesafetyintegrityrequirements(PL,SIL)arederivedfromtheriskestimation.

AccordingtoENIEC61508:Functionalsafetyofelectrical,electronicandprogrammableelectronicsafety-relatedsystems,safetyintegrityreferstotheeffectivenessofthesafetyfunctionsofasafety-relatedsystem.

Whenlookingtodeterminetheeffectiveness,thewholechainofalltheelementsinvolvedinthesafetyfunctionarealwaysconsidered,i.e.

、Appropriatesensortosafelyrecordsafety-relatedprocessvariables、Appropriatecontrollertosafelyevaluateprocessstates

、Appropriateactuatortosafelyinfluenceprocessvariables(control,regulation)

Withthecomplexityofthesystemsandsafety-relatedrequirements,electronicsystemsare

increasinglybeingused,especiallyprogrammablecontrollers.Theseareused,forexample,tomonitorthepressure,temperature,speed,flowrateandlevelsinsafety-relatedapplications.

ThestandardseriesENIEC61511:Functionalsafetycoverssafetyissuesonplantsand

systemsintheprocessindustry.AsasectorstandardofEN61508,theENIEC61511seriesisasisterstandardofENIEC62061.Thisisreflectedinthesimilarobservationsand

mathematicalprinciplescontainedinthethreestandards.However,animportantdifferenceformostendusersandcomponentmanufacturersisthedistinctionbetweenoperatingmodeswithloworhighdemandrate.Intheprocessindustry,plantsaregenerallydesignedinsuchawaythatasafetyfunctionisprocessedwithalowdemandrate.

AccordingtoENIEC61511-1,afailureistheterminationoftheabilityofanitemtoperformarequiredfunction.

Infunctionalsafety,adistinctionismadebetweenrandomandsystematicerrors.、Randomhardwarefailuresarehardwarefailuresthatoccurstatisticallyandwitha

reproducibleprobabilityonelectroniccomponents.Thefailureratesdeterminedinfunctionalsafetycanthereforeonlyrefertorandomfailures.Thefailureratesdeterminedforrandomfaultsarebasedonoperationunderthepermittedoperatingconditions,suchasambient

temperature,radiation,andthepermittedlifetimeofadevice.

、Systematicfailuresarenotstatisticallyquantifiable,sofailureratescannotbespecified.

Systematicfailurescanbetracedbacktospecificcausesthatcanonlybeinfluencedby

modificationofthedesign,manufacturingprocess,operation,bymediainfluences,

corrosionorwear.Systematicerrorsalsooccuronmechanicalcomponentsinthesafetysystem.Theseare,forexample,theconnectionsoftheelectronicsensorstotheoperatingmediaaswellasthemechanicalcomponentsoftheactuators.

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Example:Safety-relatedsystem(SRS)andSafety-relatedfunction(SRF)

Thediagramaboveshowsanexampleoftheconsiderationandevaluationmethodofsafety-relatedfunctions,aslistedindividuallyforeachdefinedsafetyfunctioninthetablebelow.

Safety-relatedassessment,processvalue

Inputvariablefromtheprocess

Monitoring

Output(processreaction)

Pressureinthepipe

、Safepressuremeasurementinthepipe

、Safetransmissionofthemeasuredcurrentvaluetotheevaluationdevice

、Safemonitoringofthepressurevalue

、Computationalcomparisonwithafixed/variablelimit

value

、Safereaction

、Endingoftherefuellingprocess,closingofthesafetyvalve

、Monitoringofthesafetyvalve

Increaseinpressure

、Safepressuremeasurementinthetank

、Safetransmissionofthemeasuredcurrentvaluetotheevaluationdevice

、Gradientmeasurement、Storageofcurrentvalues、Safeevaluation:Rising-

constantlyhigh-falling-constantlylow

、Basicfunctions:safe

storage,safetimebase,safelimitvalue

comparison,safecalculation,etc.

、Safereaction

、Endingoftherefuellingprocess,closingofthesafetyvalve

、Monitoringofthesafetyvalve

Temperatureinthetank

、Safetemperature

measurementinthetank

、Safetransmissionofthemeasuredcurrentvaluetotheevaluationdevice

、Safemonitoringofthetemperaturevalue

、Computationalcomparisonwithafixed/variablelimit

value

、Safestorageoflimitvalues

、Safereaction

、Endingoftherefuellingprocess,closingofthesafetyvalve

、Monitoringofthesafetyvalve

Hydrogendetection

、Leakdetection

、Measurementofhydrogenconcentrationinthe

surroundingair

、Flamedetection

、Controlofventilationandfreshairvolume

、BypassmanagementmustalsobemonitoredbytheSIS

、Startingupforcedventilation

、Ventopening

Table:Considerationandevaluationmethodofsafety-relatedfunctions

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1.4.Explosionprotection

Thethirdpillarofsafetywhenhandlinghydrogen,alongsidefunctionalsafetyandIndustrialSecurity,isexplosionprotection.

Operatorsofplantsthatprocesshydrogenmustcarryoutahazardassessment.Thiswill

examinetheexplosionhazardsthatcanariseduetotheoccurrenceofexplosivemixtures.

Theseincludehydrogen/oxygenmixtures.TheserequirementsservetoprotectemployeesandotherpersonsinthedangerzoneandarederivedfromtheChemicalAgentsDirective

1998/24/ECandtheATEX137Directive1999/92/EC.TheChemicalAgentsDirective

1998/24/ECregulatesgeneralexplosionprotectionrequirements,whileDirective1999/92/ECregulatestheexplosionprotectionrequirementsunderatmosphericconditions.Theexplosionprotectionconceptandclassificationoftheplantintoexplosionprotectionzones(Exzones)shouldbedescribedintheso-calledexplosionprotectiondocument.

IftheresultfromthehazardanalysisisadefiniteExzone,thenthemanufacturers’componentsthatareusedtheremustbequalifiedforuseinthiszone.

Thedifferentzones(0/20,1/21,2/22)representtheprobabilityofanexplosiveatmosphereoccurringatthespecificlocation.Zone0/20representsthehighestprobabilityandzone2/22

thelowest.

Duetotheprotectiontype,theignitionprotectiontypesvarygreatlyintheirtechnical

implementation.Forexample,Pilzsensorsarelistedintheignitionprotectiontype

“Encapsulation”ExmCand“Protectionthroughhousing”Extc.Foracomponentinstalledinacontrolcabinet,suchasacontroller,theignitionprotectiontype“Increasedsafety”Execcanbe

considered.Inadditiontothequalificationforaspecificzone,importantfeaturesarethe

temperatureclassT1..T6andthedevicegroup/ignitionenergyI,IIA,BorCthatisachievedbythecomponent.

Hydrogenhasaratherhighignitiontemperatureof400°Candaverylowignitionenergyof

40mJ.

ThenormativerequirementsforthedevelopmentofacomponentforexplosionprotectionaredescribedinthestandardseriesENIEC60079-*.

Amanufacturer’sQMsystemshouldreflecttherequirementsofISO80079-34.

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2.Legalframeworkforhydrogen

TheEUdoesnothaveaspecificlawexclusivelydedicatedtohydrogentechnologiesand

systems.Instead,thesetechnologiesmustcomplywithvariousdirectivesandregulations.

Notably,theseincluderegulationsgoverninghazardsassociatedwithpotentialexplosive

atmospheresandthetransportandstorageofflammablegasesusingpressuriseddevices.Asaresultoftheselegislativeefforts,aclusterofharmonisedEuropeanstandardshasemerged.

Thesestandardsspecifydesignaspects,technicalsolutions,andtestingandcertificationprocedures.

IntheEuropeancontext,theEuropeanregulatoryframeworkforhydrogentechnologieshas

beenthoroughlyreviewed,includingaspectsrelatedtosafety.TheEU-fundedcoordinationandsupportactionprojectcalledHyLAWwasinitiatedtoaddressthelegalbarriersandchallengeshinderingthedeploymentofhydrogentechnologies.Thisprojectsystematicallyidentifiesand

describesthelegal-administrativeprocessesapplicabletohydrogentechnologiesacross18nationallegalsystemswithintheEU.Italsoassessesandquantifiestheimpactsofthese

processesintermsoftimeandresources,identifyinganylegalbarrierstodeployment.

Additionally,HyLAWcomparespracticesacrosscountriestoidentifybestpracticesandto

advocatefortargetedimprovements.Theprojectaimstoraiseawarenesswherelegalbarriersexistandtomakeitsfindingswidelyaccessiblethroughanonlinedatabase,policypapers,andworkshops.

Insummary,whiletheEUlacksadedicatedlawforhydrogentechnologies,effortsarebeing

madetoharmonisestandardsandaddresslegalobstaclestotheirdeployment.Theseinitiativesaimtoensurethesafedesign,testing,construction,andoperationofhydrogensystems,whilepreventingdamagefromtheunintendedreleaseofflammablegases

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Thesestandardscontainrequirementsfortheinherentlysafedesignofhydrogeninstallationsandcomponents.Residualrisksmustbereducedbymechanicalsystems(suchasblow-offvalves)orelectrical,electronicorprogrammableelectronicsystems.ThestandardIECEN

61508orIECEN61511mustbeappliedforelectrical,electronicorprogrammableelectronicsystems.Toperformariskassessment,IEC61882canbeusedasanapplicationguideforhazardandoperabilitystudies(HAZOPstudies).

Thediagrambelowillustratesanexampleofappropriatedirectives,standardsandguidelinesthatmightapplytodifferentapplications.

Figure:Europeanregulatoryframeworkwithregulations,directives,standardsandguidelines

Localregulationsmustalsobetakenintoaccount.Forexample,hydrogenrefuellingstationsrequireadditionallocallaws,whicharenotharmonised.IntheFrenchregulatoryframework:

https://www.legifrance.gouv.fr/loda/id/JORFTEXT000037519292,Articles2.7.2and2.8settheminimumsafetyfeaturesthatmustbepresentonahydrogenrefuellingstation.

IncontrasttotheEU,theUnitedStateshasitsownregulatoryframework,codes,andstandardsforhydrogentechnologies.IntheUSA,theregulatorylandscapeforhydrogentechnologiesis

shapedbyvariousmodelcodeorganisations,includingtheInternationalCodeCouncil(ICC)

andtheNationalFireProtectionAgency(NFPA).Theseorganisationsdevelopfireandbuildingcodes,whichguidesafetypractices.Anexampleofthesestandards:

、NFPA2Codeforhydrogentechnologies:NFPA2isahigh-levelstandard,

specificallyfocusedonhydrogen.Itcontainsrequirementsforhydrogen-relatedaspectssuchasbuildings,outdoorstorage,dispensing,electrolysersandrepairgarages.MostrefuellingstationsintheUSAarebasedontherequirementsofNFPA2.

、NFPA55Codeforcompressedgasesandcryogenicfluids:WhileNFPA2focusesongaseousandliquidhydrogen(LH2),NFPA55complementsthecodebyaddressingothergasesandcryogenicfluids.

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3.IndustrialSecurityforthehydrogenindustry

IndustrialSecuritydescribestheprotectionofproductionandindustrialplantsfromintentionalorunintentionalmanipulation.

Previously,securitymeasuresweresolelyataskforinformationtechnology(IT),intheformofITsecurity.Today,productionandindustrialproductionplantsarealsohighlyinterconnected

usingIT.Duetothelargenumberofinterfacesandthehighdegreeofnetworking,itiseasier

forattackerstopenetrateautomationandcontrolsystems,manipulatethemandevenendangerfunctionalsafety(MachinerySafety).ThismeansthatevenstaffwhoarenotITexpertshavetodealwithpotentialhazards.IndustrialSecuritydealsw