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Deliverable - 2 - 1 - Specification Report
Deliverable - 2 - 1 - Specification Report
Deliverable - 2 - 1 - Specification Report
1 MARANDA - Grant
agreement no: 735717
Confidentiality: Public
Submission date: 30.6.2017
Revision: 0.1
MARANDA - Grant agreement no:
735717 D2.1 Specification report
1 (15)
Report’s title
Specification report
Customer, contact person, address Order reference
Lionel Boillot, FCH JU Grant agreement no:
735717
Project name Project number/Short name
Marine application of a new fuel cell powertrain validated in MARANDA
demanding arctic conditions
Author(s) Pages
16 + 5
VTT: Pohjoranta A., Ihonen J., Nissilä M.
ABB: Kajava M.
SH: Hannesen U., Haimad N.
OMB: Franzoni M., Coombs G.
SYKE: Pajala J.
Summary
This report sets the basis for the coordinated design of the MARANDA fuel cell power plant
and its H2 storage system and, in particular, provides a common reference point for the
discussion between the project consortium and the related authorities, DNV-GL (class
authority) and TraFi (Finnish flag state authority), and the shipyard (Rauma Marine
Constructions).
The report summarizes the main technical characteristics of the MARANDA FC+H2 system
and reviews its safety approaches. The report describes the baseline system which is submit
to changes based on comments and requirements from the authorities and the capacities of
the manufacturing consortium.
The report consists of a main descriptive part and three technical annexes:
1) The fuel cell power plant overview diagram
2) The H2 storage diagram
3) The fuel cell power module diagram
Confidentiality Public
MARANDA - Grant agreement no:
735717 D2.1 Specification report
2 (15)
Contents
1.1 The MARANDA project and the working group ........................................................ 3
2 Glossary .......................................................................................................................... 5
3 General structure and safety approach of the fuel cell and hydrogen system .................. 6
4 Fuel cell plant general description ................................................................................... 7
4.1 Fuel cell and electronics system/container .............................................................. 9
4.2 H2 storage module ................................................................................................ 10
4.3 Interfacing ............................................................................................................. 10
4.4 Containerization .................................................................................................... 11
4.4.1 Container fire and H2 safety equipment ..................................................... 11
4.4.2 Filtering of container intake air ................................................................... 11
5 Fuel cell power module .................................................................................................. 12
5.1 Cooling of fuel cell power module .......................................................................... 12
6 H2 storage system......................................................................................................... 12
7 Power electronics .......................................................................................................... 13
8 System operation and control ........................................................................................ 14
9 Annexes ........................................................................................................................ 15
9.1 Annex 1: The fuel cell power plant and H2 storage system overview diagram ....... 15
9.2 Annex 2: The H2 storage system description ........................................................ 15
9.3 Annex 3: The fuel cell power module diagram ....................................................... 15
Both of the subsystems - the PEMFC system and the H2 storage - are installed in 10-foot
sea containers, attached on the deck of Aranda. In particular, the H2 storage system is
made so that it can be detached from the fuel cell system as well as the ship, and lifted
to/from shore by using Aranda’s own lift crane. The purpose is to enable re-filling the H2
storage in a maximal variety of locations and in particular, at standard automotive hydrogen
refueling stations (HRS).
As Aranda is an ice-going vessel, the ship and the fuel cell plant on-board it will be subject to
the harshest marine and winter conditions during its operation. Whatever the conditions, the
safety of the equipment and especially the personnel (and other people) on-board must be
guaranteed at all times. To this end, dedicated safety considerations, abiding to the normal
sea-going vessel design and classification processes shall be undertaken. Furthermore, as
part of the classification process of the Aranda ship, also the fuel cell plant shall be put into
class by the class authority DNV-GL.
Because the MARANDA fuel cell plant is not a critical/single power source of the Aranda
vessel, the requirements operative reliability - typically a substantial part of marine power
system safety - may be relaxed. Nevertheless, as the fuel cell system and the hydrogen fuel
storage are both systems containing highly flammable hydrogen gas, particular safety
procedures must be followed in the design and construction of these systems.
The purpose of this draft specification document is to support the concise design and
implementation process of a safe, sea-capable hydrogen-fueled PEMFC power plant and the
class acceptance thereof. This document is not intended to be the final system specification.
Instead, it will be completed based on the discussion with and comments from the class
authority DNV-GL and with detailed technical data/information from the subsystem providers,
according to the requirements of the class authority.
Table 1 - MARANDA partners and their roles in the Aranda vessel FC & H2 plant isntallation.
The general safety philosophy of the FC system as well as the H2 storage follows that of the
ESD (emergency shutdown) approach, meaning the system is fully powered off if hydrogen
is detected elsewhere than where it is supposed to be. This is considered feasible, because
the FC plant is not an operationally critical power source of the Aranda vessel.
During its operation, the fuel cell system is ventilated to ensure hydrogen concentration
remains within safe limits even in case of leakage. Furthermore, the ventilation air hydrogen
concentration is continuously monitored. When not in operation, the fuel cell system is
always purged of hydrogen gas. Therefore, the fuel cell system is considered a safe zone
when not in operation (hazardous zone 1 when in operation).
The hydrogen storage system is always considered hazardous zone 1 and continuous,
ATEX-rated, redundant ventilation and hydrogen monitoring is therefore applied to this part.
In addition, explosion relief hatches for controlled impact direction in case of pressure build-
up or even explosion are installed to the hydrogen storage module container.
On behalf of fire safety, A60 level fire insulation is included in the hydrogen storage parts.
Furthermore, thermally activated pressure relief devices (TPRDs) are included in the
hydrogen storage system to assure hydrogen release in case of long-enduring fire. For the
case of fire inside systems, smoke detectors, fire dampers at ventilation air inlets and a fire
extinction system is included in both the fuel cell system as well as the hydrogen storage
system.
The fuel cell plant is installed in two containers on the Aranda deck, as illustrated in Figure 2.
The fuel cells are integrated into fuel cell power modules and two modules are installed in
total. Each power module has a dedicated power electronics train up to the DC/AC inverter.
In addition to the fuel cell stack, the fuel cell power module includes the fuel cell air feed
blower, the hydrogen (secondary) pressure regulator, the hydrogen recycling system and the
necessary instrumentation and automation to control the process in the module.
Data transfer / communication between the different parts of the fuel cell power system and
the power electronics takes place over a CAN bus. The physical layer is a enforced, shielded
twisted pair cable and two different CAN standards (CAN 2.0 and CAN Open) are used, as
illustrated in Figure 3.
In Figure 2, a 2 x 15 kVA power intake to the system is denoted. This depicts the maximum
momentary power intake possibly needed by the system and is therefore given as the power
inlet connection rating.
The hydrogen storage system is installed in a container and can be detached from the FC
system container as a whole. When detached, the H2 storage system can be hoisted off
from the vessel and transported with a truck for refueling. For this purpose, also on-road
safety regulations and standards, in particular the TPED (Transportable Pressure Equipment
Directive), are applied to the H2 storage system.
On behalf of marine approval and safety of the H2 storage system, it is proposed that the
most relevant rules and standards to be followed are listed as follows:
DNV, Standard for certification No. 2.7-1, Offshore containers, Apr. 2006
DNV-GL-OS-D301, Offshore standard, Fire protection, Jul. 2015
International Maritime Dangerous Goods Code (IMDG code), Ch. 6.7 (Introduction
and 6.7.5), Requirements for the design, construction, inspection and testing of
portable tanks and UN multiple element gas containers (MEGCs), 2014
4.3 Interfacing
To facilitate refueling, the H2 storage system is detachable from the Aranda vessel and
therefore the H2 gas connection between the H2 storage container and the fuel cell system
container is not solid. A 18-mm Swagelok screw-joint (with flexible hose on FC system side)
is used as connector between the H2 system and FC system H2 line.
The Aranda ship deck structure is designed to hold the standard container weight and
suitable attachments with the dimensions are installed on the deck.
For the purpose of the MARANDA project, the FC and H2 system containers will be modified
accordingly. In particular:
- Fire and hydrogen safety mechanisms are integrated into the containers (see
following section)
- Air inlet and outlet ports for the FC system and container ventilation are made
- Fire-insulated through-holes for hydrogen and data signal passage between the
containers are made
- Necessary utility power inlet ports are included in both containers
The H2 storage container walls, roof and floor, are enforced with A60 level fire insulation.
Fire dampers - i.e. flaps which close automatically in case of fire - are installed on the
container ventilation air inlet and outlet ports.
A fire extinction system based on either N2 choking or a commercial fire extinction fluid (e.g.
Novec™ 1230) is installed in both containers. (When the H2 container is taken to land, the
fire extinction system will remain in both containers.)
ATEX-rated, fully redundant ventilation blowers are installed in the H2 storage system
containers. A single, regular ventilation air blower is installed in the fuel cell system
container. Sufficient safety distances between the containers’ ventilation air inlets and outlets
are arranged for. In terms power and control, the containers’ ventilation air systems are fully
independent of each other.
A nitrogen gas purge system is installed in the fuel cell system container so to enable
purging of H2 gas from the container (i.e. the FC system within it) when the FC system is not
in use. To this purpose a flow of 3-5 Nl/s per system is required over 10 to 30s for one
purge. As an example, a normal 50-litre bottle at 200 bar fill pressure will enable at least 70
purge cycles.
The container intake air is used for two purposes: (i) the container ventilation required for
safe operation with H2 gas and (ii) the fuel cell feed air (in the fuel cell module when fuel
cells are in operation). To preserve both the components hosted by the containers, and in
particular the fuel cell stacks, the intake air must be filtered from particles, Sulphur-
containing chemicals as well as salinity. To this end particular sea-capable intake air filters
are installed, such as Camfil Cam GT-E12 or Premaberg Type B two-stage separator.
A similar fuel cell power module has been used in the fuel cell system deployed on-sea in
the “Race for Water” vessel and is therefore considered suitable to be used in the
MARANDA FC system. Furthermore, this type of FC system has also been inspected and
approved by the class authority DNV-GL for marine passenger vessel use.
6 H2 storage system
The hydrogen storage system is built in a 10-foot container with fire insulation, ventilation
and safety arrangements as described in Section 4.
The H2 fuel storage enables a maximum storage capacity of 83kg of hydrogen at the
nominal storage pressure of 350 bar (abs). The storage consists of 10 composite material
cylinders, which are all connected to each other with piping, being thus continuously in the
same operating pressure. Austenitic stainless steel is used in all metal components in
contact with hydrogen gas. Details of the H2 storage system, including the system process
diagram, are given in Appendix 2.
Hydrogen fuel is dispensed from the storage to the fuel cell system through a pressure
reducing device (PRD, “pressure regulator”), which limits the fuel supply pressure to 10 bar
at the fuel cell system fuel inlet. Refueling of the hydrogen storage occurs through a
standard 350 bar automotive refueling connector. In addition, refueling at industrial hydrogen
depots is possible by using an adapter to the refueling connector.
Relief of stored hydrogen gas in the case of a fire takes place via temperature-activated
pressure relief devices (TPRDs). Several (N:of T.B.D.) TPRDs are installed in the H2
storage module so that exceeding the safe storage temperature at any location in the
module may set off the pressure relief, if necessary. It is estimated that the total exhaustion
of all hydrogen gas from the H2 storage system through the TPRDs, in case of the set-off of
one TPRD, would occur within a matter of seconds. This indicates that once the temperature
inside the container has risen sufficiently to set off the TPRD, fire would not have time to
propagate to the cylinders before they are empty. A manual, operator-activated relief system
is not included in the H2 storage.
The DC/DC converters and DC/AC inverter are heavy-duty rated devices with liquid cooling
to ensure high reliability. Power conditioning, including filtering of ripple and other noise is
included in the power electronics to preserve and protect both the fuel cell power system as
well as the Aranda vessel power system. Also an isolation transformer is included to
galvanically separate the fuel cell power plant from the Aranda power network.
An exemplary, rough, operating mode diagram of the control system is provided in Figure 5.
The operating protocol of each operating state, as well as the transition protocols between
states is defined in detail in further phases of the development.
Control voltage on
OFF
STATE
READY ON STATE
SYSTEM RUNNING
Stopping sequence
From the Aranda vessel operating crew perspective, the fuel cell plant is a power source
which is activated and deactivated as considered useful. A manual emergency stop actuator
(“emergency button”) is installed in the cockpit and possibly at other chosen loci.
ATEX detectors
SD H2D
air exhaust,
H2 connector
insulated and
and flexible hose heatable modified 10 f container
H2 purge
exhaust SD H2D
N2 storage
Fire/H2 alarm
S
FCPM1
S S
L filt. DC/DC
DC/AC AC/AC LCL Power out, 600 V, 3-phase, 160 kW
Isolation
L filt. DC/DC
FCPM2 Radiator Power conditioning cabinet
Comm. / CAN bus
Fire damper
Air in filter
Mechanical
and salt
protection for Fire extinction system
removal
piping outside
the container water exhaust,
insulated and
heatable Owner VTT Oy
Drawn OT
Checked
Approved
Project Maranda
Drawing name Fuel cell plant general description
Date 01.06.2017
Revision 04
ANNEX 02 - H2 Storage system description by system provider
MARANDA PROJECT
DELVERABLE 2.1
OMB Saleri, for its H2 storage module, has selected a TPED approved type IV cylinder.
The H2 tank selected have the following size and dimensions:
length 2424mm
weight 229kg
water capacity 347L
The module is composed of a rack of 10 composite cylinders for storing 8,33 kg of hydrogen gas in each of them at a
maximum nominal pressure of 350 bar(g).
The total storage capacity of the H2 storage module is 83,3 kg of hydrogen.
The rack, as a whole, occupies a total space of 2,56 mt wide, 1,92 m high and 2,52 m in length.
The total empty weight is 2400 kg, while at full load of hydrogen the total weight is 2483 kg.
The individual hydrogen cylinders are connected with each other, and so operating in the same pressure at all times.
The hydrogen storage system is completed by a solenoid tank valve and an additional remote TPRD on each cylinder of
the rack.
The solenoid tank valve includes all the following functions:
Inlet check-valve
Solenoid valve
Manual operated valve
Manual operated bleed valve
Outlet filter 50 micron
Temperature sensor
Pressure sensor
Excess flow limiter
Integrated TPRD
The outlet ports of the valves are connected to a manifold with a pressure regulator integrated to reduce the pressure
from 350 bar to a value of 10 bar.
In order to protect the entire length of the storage system, an additional TPRD will be installed on each cylinders.
The additional TPRD will be connected to a live-port on the valve.
01 02 03
01 02 03
01 02 03
+
Tmax = 90°C 2 1
Pmax = 2.2 bar abs P P P P
Nominal Flow = 77 g/s dry air + 13 g/s water (vapor and liquid) Upper End Plate
8
Product water with < 0.5 Nl/min H2
6 Pmax = 2.4 bar abs
C C
-
V̇= 150 L/min
T in max = 45°C
6
Waste Heat : 78.8 kW
Lower Fluid Plate Electric Terminals
D 2 1 D
T
1
Swiss Hydrogen 4 3
1
T
1
1
Proprietary
2
a R 1 R 1
Information
E E
T
N2 in P A 2 1
0 P P 1
P A A P
0 0 0 0
a 3 4
4
a a a a 8 9
A P P A
1 2
H2 in - from storage P A 1 2
3 Cooling in Cooling out
0 3
F 3 F
1 2
2 1
Anode Drain 6 7 1
T
2
Inverter Anode H2 Purge
T
T 4 1 2
3
Ambiant Air in 1
A T 1 2 1 21 2
4
1
Drain Coolant
3 1
G 4 G
F 3
T
4
1
Cathode Exhaust
3 2
5
H H
Date 25.04.17 FCH JU Swiss Hydrogen SA PID007_Maranda_FCS_R2_specs Project number 1206 Unit =
Work L. Rabiet Passage du Cardinal 1 Project name Maranda Field +
Technology: Fluid Engineering
Check Fribourg sheet 1.a
This diagram is protected by copyright law. The duplication and/or
Status Revision Date Name Norm DIN ISO 1219-2 Created for Created by Switzerland of 1 distribution of this diagram is only allowed with permission from WSCAD
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