CONFIDENTIAL AND PROPRIETARY
Date: November 20, 2015
H2 Dispenser 1 Prototype Safety and Transfer
Purpose: This document is to ensure that the operational safety requirements and ecommendations of the H2Dl prototype are clearly documented and provided for CHEM personnel and for those intended to use the H2Dl. The operational comments, safety requirements and recommendations contained
herein are the most complete known as of the date of this document.
General Prototype Operating Precautions and guidelines:
1. This unit is a prototype. It is intended for test and demonstration by trained operators. It is not intended for commercial or unrestricted operation. While a number of safety features have been included in this prototype system, it does not meet UL, CE, orTUV safety standards.
2. Safe operation of this unit requires continuous, technically trained operators. Failure to adequately train the operator of the unit, or failure of the operator's continuous on site monitoring of the unit could result in unsafe conditions, severe personnel injury, and/or property damage.
3. The unit must be operated in an outdoor environment with significant ventilation. This unit emits significant amounts of Carbon Monoxide exhaust which can be harmful or fatal if inhaled.
4. Personnel must avoid standing directly over or in the vicinity of the exhaust to avoid inhalation of carbon monoxide.
5. The exhaust surfaces (top) of the unit and the exhaust itself are extremely hot. Do not touch the top I exhaust surfaces or allow any person within [3] feet of the exhaust, except for occasional operation of the touch control panel. Touching the hot surfaces, or coming in contact with the exhaust will result in serious burns.
6. The unit is not waterproof. System and all electrical wiring must be protected from direct exposure to water.
7. H2Dl system, local electrical supply and vehicle under treatment are equipotential before, during and after treatment or while H2 buffer is pressurized. Vehicle grounding connection must be the first action in setting up for operation. Vehicle grounding disconnection must be the last action performed for all vehicle treatments.
8. No smoking or open flames are allowed within 10 meters of the vehicle being treated or the H2Dl in operation.
9. Electrical supply (208 or 240 AC) should conform to national safety standards.
10. Remote• Emergency Shutdown: The unit is equipped with a manual emergency shutdown switch (EMO) on the exterior, front of the enclosure. There is no remote emergency. In order to remotely shutdown the unit, the AC power must be cut. Operator should be familiar with breaker location or other means to cut the AC power to the unit in case a remote shutdown is required.
11. An emergency off switch, EMO, is provided for rapidly stopping hydrogen production. The EMO switch de-activates the fuel processor power including all valves and heaters. If the switch is activated during hydrogen production, the hydrogen buffer tank will remain pressurized. The process control computer, hydrogen flow controller and safety loops remain powered under the EMO condition. The unit can only be re-started by pressing the start button.
12. A hydrogen sensor is provided within the cabinet enclosure. Its purpose is to shut down the hydrogen production should the alarm be activated. A hydrogen alarm has the same effect on the system as depressing the EMO.
13. A thermal protection device is provided on the exhaust flue. Its purpose is to stop the fuel processor if it senses high temperatures which could indicate a fire or similar malfunction. A high temperature alarm has the same effect on the system as depressing the EMO.
14. The cabinet is ventilated by fans and under a positive pressure during all conditions; however, the ventilation fans are not monitored for proper operation and will not cause an alarm if there is a malfunction. This unit relies on the hydrogen sensor to detect an unsafe hydrogen condition and trigger an alarm I shutdown.
15. For electrical hazards, such as electrical shock from the AC supply line, the EMO switch will have no effect. For this case, the power must be removed at the source breaker panel.
Vehicle and system setup Precautions:
1. All connections to vehicle are secured in a safe manner clear of all hazards including but not limited to hot surfaces and rotating machinery and in a way to prevent damage to the hydrogen supply lines and the unexpected release of hydrogen to the surrounding area.
2. Hydrogen supply lines used for injecting hydrogen from the H2Dl must be protected from damage and inspected for damage or wear on a regular basis.
3. The unit will not detect a broken or leaking hydrogen supply line. Therefore, to avoid uncontrolled release of hydrogen into the area, the operator must be alert to any situation in which the hydrogen supply line may be broken or disconnected from the car.
4. Hydrogen supply lines used for Injecting hydrogen from the H2Dl must be protected from damage and inspected for damage or wear on a regular basis.
5. All connections, hoses, cables between the H2D1 and vehicle must be protected from trip hazards and routed away from the vehicle to prevent unintentional vehicle roll over while vehicle under treatment, or other vehicles enter or exit treatment area.
6. Vehicle under treatment is placed in park or neutral, parking brake set, engine hood up and wheel chocks in place during vehicle treatment.
Other Precautions
1. The exhaust pressure based flame-out detector system verifies that the vehicle's engine is operating. Should this detector fail to detect a non-operating engine the hydrogen may continue to flow creating a fire or explosion hazard. This sensor will not verify that the hydrogen supply line is properly connected to the vehicle. It is possible for the flame-out detector to show the engine is running without ever connecting the supply line to the vehicle creating a hazardous condition. Therefore, operator must verify that the hydrogen supply line is connected at all times during the procedure.
2. Over supply of hydrogen can cause the vehicle engine to stall or significantly alter the engine RPM (up or down). Either case may vent hydrogen to the local atmosphere possibly creating a fire or explosion hazard. Should the engine RPM be low while the exhaust pressure flame-out indicates positive engine operation, a hydrogen over supply condition might occur causing a hazardous condition.
3. Each vehicle must be understood for methods of air intake and vacuum generation prior to vehicle treatment. Vacuum supplied to the brake booster may not be supplied by the fuel intake system, in some cases the vacuum may be generated by a camshaft or crankshaft based supply, in these cases the hydrogen may not enter the combustion chamber. Turbo charged engines and possibly others may divert air intake during certain operating conditions such that for each engine model the methods used for injecting the hydrogen must be fully understood prior to treatment in order to avoid potential release of hydrogen and/or damage to vehicle.
4. Hydrogen injected into the air intake filter system combines with air possibly creating hazardous mixture levels. There may exist equipment in this air stream that could reach auto ignition temperatures for the hydrogen rich air stream, such as hot-wire air flow sensors, turbo charges or other unanticipated devices.
Fuel precautions: The fuel used by the H2Dl is a methanol and water mixture. It is toxic and must be handled with appropriate care. Additionally, maintaining fuel purity is essential, or equipment damage can result. Ensure all precautions and requirements of the ME2 methanol fuel cell system are understood and followed.
The CHEM and H2PT development team acknowledge and understand the above safety requirements and approve the H2Dl prototype units for transfer to CHEM for test and demonstration use with customers under these requirements.