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Safe use of hydrogen cylinders in laboratories requires adherence to NFPA 2 and 45, focusing on handling, storage, and mitigation of release risks.

What are some of the safety considerations for use of hydrogen cylinders within a laboratory?

Cylinders used within a laboratory can be used safely by meeting the requirements prescribed in NFPA 2,
Hydrogen Technologies Code, and NFPA 45, Standard on Fire Protection for Laboratories Using Chemicals.
Special consideration should be given to both safe handling and storage of cylinders. Regarding lecture
size cylinders, their small size can make them susceptible to damage and mishandling. A release from an
open valve or relief device can be hazardous, particularly if the potential hazard is underestimated.

FAQ Category
FAQ Keyword
Submission Year
2023
Month
04

Storage of H2 gas cylinders and other gas cylinders

Do hydrogen gas cylinders need to be stored separately from other gas cylinders or can they be stored together?

Store flammable gas cylinders such as hydrogen, separated from oxidizing (e.g. oxygen), toxic, pyrophoric, corrosive, and reactive Class 2, 3, or 4 gases. Non-reactive gases, such as helium, may be co-located. See codes and standards such as NFPA 2 [7.2.1.1 Incompatible Materials] for further guidance.

FAQ Category
Submission Year
2023
Month
09

Best practices for storage and use of hydrogen cylinders inside the lab

What are the best practices for storage and use of hydrogen cylinders inside the lab?

In general, indoor storage should be limited and the use of hydrogen indoors should be the least necessary. Look to store flammable gases outdoors in dedicated protected area when practicable. Check to see what adopted building and fire codes in your jurisdiction say. NFPA 2, Hydrogen Technology Code, Sections 6.4.1 and 16.3 prescribe requirements to limit hydrogen storage and use in laboratories. NFPA also prescribes requirements for ventilation, gas cabinets, electrical classification, and fume hood operations. Consider outdoor or dedicated storage facilities if you need more than one standard-sized cylinder of hydrogen to support your work.

FAQ Category
Submission Year
2023
Month
09

H2 cylinders question about design (picture reference)

A picture of H2 cylinders showed vents. What makes this design poor?

I am not sure which picture you are referring to so I will attempt to answer.

If you are referring to the incident where a fire occurred and the vent system was damaged, then this may have been due to lack of proper supports and incomplete assembly of the test systems. In the past, vent systems were not pressure tested for strength but that is changing. 

If you are talking about small standard H2 cylinders (250 scf or less) then a review of the rupture disc operation is in order. Most individual cylinders have a lead-backed (referred to as fused) rupture disc (CGA type CG4 or CG5) that does not connect to a vent stack. Due to the required mobility of cylinders, a vent stack is not required. The rupture disc is not supposed to vent hydrogen unless the cylinder is engulfed in a fire both melting the lead back and then overpressuring the cylinder/ rupture disc. If engulfed in a fire, the rupture disc opening Is required to maintain cylinder integrity. Although adding hydrogen to a fire is not a perfect solution, it is better than a cylinder explosion and then still adding hydrogen to the fire. 

An interstage regulator relief device not connected to a vent stack. This design is poor and occurs more frequently than we would like. It is typical for a 2-stage regulator to have an interstage safety relief device that is not connected to a vent stack. If the 1st stage of the regulator fails open, the increased pressure can open the interstage relief device, If this is not connected to a vent system (which it normally is not), hydrogen will flow to wherever the relief device is pointed.

FAQ Category
FAQ Keyword
Submission Year
2024
Month
01

Ensuring Purity of Supplied Hydrogen

What is the recommended way to ensure that supplied hydrogen meets the specified 99.9995% ultra-pure requirement? The project in question receives gaseous hydrogen in K-size hydrogen cylinders and liquifies it for use in the lab. Over the last 8 years the project has had three safety related situations where the inlets to the liquid hydrogen tanks nearly froze shut due impurities in the incoming gas stream.

Cylinders are required to be tested periodically to verify structural integrity. The most common test method is hydrotesting, which means water is the most likely impurity that solidified in the inlets. Drying the tanks is normally a requirement after performing a hydrotest. In the USA, CFR 49 CFR § 180.209 applies: https://www.law.cornell.edu/cfr/text/49/180.209. Paragraph (b)(1)(v) requires that the “cylinder is dried immediately after hydrostatic testing to remove all traces of water.” This requirement is vague since there is no definition of “all traces” and might be interpreted to simply mean no visible water rather than a small enough quantity to meet the 99.9995% purity requirement. If the problem is caused by the gas supplier not meeting the specified purity requirements, there are some approaches that can be used for quality assurance of gas purity: 

  1. Discuss the issue with the supplier and put in contract language that a significant fraction or possibly all cylinders be tested and certified for purity. 
  2. Use non-steel cylinders since steel is usually the worst material for this issue. 
  3. Purchase gas from a supplier that verifies the moisture within cylinders after requalification. 
  4. Use a liquid nitrogen cold trap to remove water from the gaseous hydrogen flowing into the process.


It's important to note that over long periods of time, even the impurities within high purity systems can accumulate. It’s also important to understand that many suppliers will guarantee the total purity spec (i.e., percentage) based upon the measured impurities. Other impurities may exist, but not be included in the total purity, if not included on the list of impurities to be tested. In hydrogen, one of the most frequent impurities is helium since it is difficult to detect and it can pass through many hydrogen production and purification processes. However, it’s usually considered to be benign to nearly all processes. Helium would not have been the impurity for this application since it would not freeze at liquid hydrogen temperatures.
 

FAQ Category
Submission Year
2023
Month
07

Design, Installation, Testing

Has a fall test been done for a 6.8 ltr 30 MPa type IV tank from a 100 mtr/300 ft height in the past? What would be the standard for hydrogen fueling tanks installation in UAVs? How many g would be a good norm for the construction of the tank cradles? 35g has been mentioned for a space craft. A very old NASA standard is available but does not provide much information on the AIAA side. For IMO guidelines, the project in question uses 5g as the norm. For storing cargo in transport cargo planes per IATA, it is 2g. As not a lot of information is available, the decision has been made to pursue an independent fall test with a 6.8 ltr cylinder with regulator, filled with hydrogen. One member of the standard committee (NEN) will assist in the process. The setup will include a 500-fps fast camera and all fragment screens will be set. Any recommendations/ideas about the setup?

ASTM might be the best point of contact for crafting this test. The ASTM F38 Committee on Unmanned Aircraft Systems is probably the best source of information on drone airworthiness criteria. They have a subcommittee developing a standard on fuel cell drone safety. One Panel member has been involved in a test with an LD vehicle tank filled with hydrogen that was dropped 60m onto a concrete pad with no issues. Fortunately, the tank impacted in the horizontal position and bounced (fortunately because if the valve had struck the concrete first, it could have become a mini rocket if the valve was damaged. It is also important to thoroughly characterize the tank and appurtenances, including the specific qualification standards/testing for the tank, regulator, etc. 


Consider establishing ambient wind constraints as well, as the wind will influence the tumbling of the tank as well as the impact point. Also consider using a few blast wave transducers to record the blast pressures from some local component failure as well as the more catastrophic potential of tank rupture. The frame speed of the camera seems a little slow. Consider a higher speed camera (e.g., 3000 fps for cylinder drop/crush impact tests and 10,000 fps for bullet penetration tests; the actual speed depends on when and how the video recording will be initiated and the data storage limitations). Regarding the g values for cylinders, in automotive applications 20g has been used in the forward direction, and 8g in the other orthogonal directions per NFPA 52, which generally applies to aftermarket CNG vessels and their frames. 
 

FAQ Category
FAQ Keyword
Submission Year
2024
Month
05

Cylinder Connections

Are there generic best practices for connecting hydrogen cylinders to research equipment? The project in question uses single H2 cylinders outside of a gas cylinder cabinet. When and where should an excess flow control valve be installed? When and where should a flash arrestor be installed? Are there specific things to look out for when a hydrogen and oxygen or oxidizer cylinder (i.e., nitrous oxide) are on the same system? What kind of cross connections should be avoided? When and where should there be a check valve installed? Can quick connects be used on hydrogen tubing? Are there specific pressure regulators to select or avoid with hydrogen? When and where should purge valves be installed? What are the recommended valve and regulator components of a H2/O2 torch assembly?

It is difficult to provide trustworthy answers to these questions without understanding the design and configuration of the specific installation. It may be best to consult with a pressure systems expert to evaluate the specific installation and uses. The gas provider may also be a good resource for specifics on gas equipment use. Other beneficial resources include the HSP Best Practices online resource and the DOE Hydrogen Safety Training for Researchers, the AIChE Laboratory Safety Course.

NFPA 2, Hydrogen Technologies Code, and NFPA 45, Standard on Fire Protection for Laboratories Using Chemicals, may also be helpful in identifying requirements and best practices. In addition, the project designed should consult with the local authority having jurisdiction for safety guidance that is applicable to locally adopted codes.
 

FAQ Category
Submission Year
2024
Month
04

Cylinders-Tanks

Are GH2 cylinders/tanks pure H2? When the tank is emptied, is it a vacuum or is it displaced with air?

Hydrogen cylinders contain pure hydrogen unless they are specifically manufactured for and marked as a mixture. The purity grade is usually between 99.5% and 99.9999%. The balance is typically inert gases (such as nitrogen) with just ppm levels of other contaminants, but this can vary depending upon the production source. When emptied, the residual is still the same purity of hydrogen, just at lower pressure. If emptied to atmospheric pressure, there would still be one atmosphere of hydrogen within the container unless evacuated or purged to another gas. (See Properties section for related FAQs). Note that when a cylinder is reduced close to or at atmospheric pressure, it is very susceptible to air migration into the cylinder, especially if ambient temperature changes can create a slight negative pressure in the cylinder. Air should never be allowed into a hydrogen cylinder until it’s been properly purged with an inert gas such as nitrogen, helium or CO2.

FAQ Category
FAQ Keyword
Submission Year
2024
Month
04
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