FirstElement Fuel Scaling Up The True . - Hydrogen Tools

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6. HYDROGEN SAFETY PLANFirstElement FuelScaling Up the True Zero NetworkRevised Hydrogen Safety Plan Incorporating Liquid HydrogenStorage and DeliveryAll Proposed Station LocationsGFO-15-605:Alternative and Renewable Fuel and Vehicle Technology ProgramLight Duty Vehicle Hydrogen Refueling InfrastructureDate:August 29, 2017Applicant’s Name:FirstElement Fuel, Inc.5151 California Ave., Suite 220, Irvine, CA 92617

Table of ContentsA. SAFETY PLAN REQUIREMENTS . 31. Scope of Work for the Safety Plan . 32. Organizational Safety Information Plan . 33. Project Safety . 44. Communications . 10B. SAFETY PLAN REQUIREMENTS .101. Release and Incident Reporting . 122. Annual Safety Evaluations . 12C. SAFETY PLAN REQUIREMENTS .121. Process and Flow Diagram . 122. Preliminary Design or Functional Description of each Component in the System . 123. Codes and Standards . 134. Layout . 13APPENDIX A .15APPENDIX B.28APPENDIX C .37APPENDIX D .38APPENDIX E .40APPENDIX F .46APPENDIX G .49APPENDIX H.54APPENDIX I .60APPENDIX J.77APPENDIX K.79APPENDIX L .79APPENDIX M .81APPENDIX N .82APPENDIX O.84APPENDIX P .85APPENDIX Q.87APPENDIX R.88APPENDIX S .92APPENDIX T .952

A. Safety Plan Requirements1. Scope of Work for the Safety PlanThe FEFuel Inc (FEFuel) safety plan is incorporated into all aspects of work. The safety planis focused on the hydrogen refueling stations and ancillary equipment projects and coversplanning, engineering, construction and ongoing operation. The integrated approachfacilitates a detailed look at every phase of the project with the same set of standardsapplied throughout. The intent of the plan is to protect personnel, equipment, and theenvironment.a. Planning: In the planning phase, potential sites are identified and then qualified,amongst other things, for safety. This involves verifying that the site meetsapplicable setback distances per applicable codes such as NFPA-2 and CaliforniaBuilding Codes. A qualitative hazard analysis is also performed to ensure riskmitigation. The integrated approach: who we are, what we do, aspects of ourbusiness, safety through design, construction, and operation.b. Engineering: In the engineering phase, many aspects are analyzed and scrutinized forsafety. This includes structural calculations, material suitability analysis, testingprocedures, codes and standards safety checks, design for safe operation, anddesign integrity.c. Construction: This is statistically where most industrial accidents occur. FEFuel hasdeveloped a 200 page long construction safety plan that has been successfullyimplemented during the 2014 CEC grant project in constructing 18 stations withZERO accidents. For brevity, it was not included here, but the table of contents canbe found in Appendix S.d. Operation: FEFuel intends to operate the proposed stations for a minimum of 15years. It is imperative that all personnel arrive and leave from work safely to theirfamilies. FEFuel is continually improving the safety of our service team throughtraining.2. Organizational Safety Informationa. Organizational Policies and Proceduresi.Training: FEFuel policies are intended to ensure that personnel have the righttools and experience for the job. No employee is put in a situation wheretheir safety is compromised. For that reason, we have implemented acompetence tracking system where employees are graded based on theircompetence in a specific field. The four major competence categoriesinclude: Observer: where the personnel can only assist in a task Supervised: where the personnel can perform the task only ifsupervised Independent: where the personnel can perform the work unsupervised Trainer: where the personnel can train others on the taskii.For an employee to work independently in the field they must meet thecompetent criteria after working with a trainer for a sufficient amount of time.This is typically 1-2 months or more. The FEFuel Training Matrix can be seenin Appendix N.Communication3

iii.iv.In addition, the service team meets 3 times a week to discuss operationalstatus and safety procedures. A new safety topic is introduced every weekand discussed at least 3 times. The training includes some or all thecommunication methods; video instructions, group discussion, homework,quick phone quizzes and, when possible, practical hands-on practice. Theattendance is tracked to ensure that, at a minimum, each employee attendstwo of these safety sessions. At these meetings, all new policies andprocedures are introduced and the employee is told where this informationresides within the company. Prior to every operational meeting a moment istaken to discuss a “Safety Moment”.Special WorkWhen a new task is being conducted or the task does not have establishedprocedures, pertinent employees are all trained on performing a Job HazardAnalysis (JHA) prior to conducting the work.ContractorsIn some cases, where FEFuel requires the help of a contractor (for example inconstruction, refrigeration, or crane operation) FEFuel only employscontractors who are qualified to do the work, have similar vision for safety,and have a proven track record. These records are viewed through theirOSHA form 300A for the past three years. If there are any major injuries,these are investigated to ensure that the contractor has the right culture andpolicies in place.b. Hydrogen and Fuel Cell ExperienceFEFuel prides itself on the experience of our team members. The team has many years ofexperience in the hydrogen station refueling field and collectively has experience with50 different fueling stations and technologies from manufactures such as Air Liquide,Linde, Air Products, Powertech, Proton Energy, and Hydrogenics for customers such asChevron, Shell, BP, and the US military across the globe. The team has the skill andsupport system set to conquer any hydrogen related problem from construction, to PLCprograming, to compressor repair. The experience of the team helps us make the bestdecisions from an efficiency and safety perspective. Tim Brown provides the academicperspective; Ghassan Sleiman provides the engineering perspective; and Andrew Youlioprovides the practical perspective. This helps us answer the question of why, what, andhow related to any activity. This extensive experience helps us perform well in identifyingsafety vulnerabilities.Below is a list of the team and relative experience with hydrogen refueling stations.i.Tim Brown Served as Project Manager for FEFuel’s build out of 19 hydrogen stationsawarded under the Energy Commission’s PON-13-607 Successfully completed and opened to the public 15 hydrogen stations atan unprecedented speed Experience with site acquisition, equipment procurement, design &engineering, entitlements and permitting, construction, commission andstartup, operations and budget Managed the operation of the UC Irvine liquid hydrogen station and theOrange County Sanitation District hydrogen station. Helped lead the effort to develop the 68 hydrogen station plan forCalifornia4

ii.iii.iv.v.vi.vii.viii.Ghassan Sleiman, Bachelor of Engineering University of Toronto 17 years designing, testing, building, commissioning, and maintaininghydrogen fueling stations for on-road vehicles Led commissioning, service or engineering on 30 hydrogen stations Registered Service Agent in California for Weights and measureverification Maintained Air Liquide’s Culver City station for ShellAndrew Youlio 10 years designing, testing, building, commissioning, and maintaininghydrogen fueling stations for on-road vehicles 20 years of experience as a top tier technical expert in an industrial gascompany including repair, maintenance, and operation of liquid hydrogenpump material handling equipment Led commissioning on 28 stations Registered Service Agent in California for Weights and measureverificationMichael Strada World’s foremost DMS testing agent with 18 stations tested and certifiedfor FEFuel, APCI, Linde and Shell hydrogen stations MS in Industrial Arts (expected Dec 2016) Masters Theses: Evaluation of Hydrogen Generation Led commissioning on 2 stations Registered Service Agent in California for Weights and MeasureverificationDenver Owens United States Marine Core 11 years: Electrical System Technician;Gunnery Sergeant Commissioned 2 Hydrogen Stations Built Hydrogen panels for hydrogen stations Assembled Point of Sale Panels for FEFuel stationsShane Drummond United States Marine Core 11 years: Engineer; Chief Marine Commissioned 2 Hydrogen StationsTyler Furuya BS in Mechanical Engineer from the Northern Arizona University Instrumental in determining the root cause and repair of Point of Saleissues between Comdata and Air Products Dispensers Coordinate IT and Point of Sale commissioning at FEFuel StationsThree additional Field Representatives have joined the team in May and July2016. Logan Hart, Edgard Cruiel, and Tim McClary have just completed theirtraining and are servicing hydrogen stations.3. Project Safetya. Identification of Safety Vulnerabilities (ISV)For every project, the team conducts an ISV. Two preferred methods: the “What ifAnalysis” and the HAZOP. The What If Analysis looks at failures based on a process bywhich experts on the issue ask the question What If “something” behaves in an abnormalway. The HAZOP (Hazard and Operability) study is a structured and systematic5

examination of the project. Appendix A shows an example of an ISV done for a fuelingstation using the What If analysis. In Appendix B, a HAZOP study is illustrated for a pieceof equipment used for the fueling station. The ISV does discuss the handling ofhydrogen, ignition sources, and leak scenarios, as well as scenarios dealing withhydrogen delivery to the sites. An ISV is conducted for every hydrogen station equipmentmodule (compressor, storage, dispenser, etc.) and/or as a site with equipment modules.The aim of the ISV is to address the situations due to failures that can cause a dangeroushazard to personnel, whether public or private, as well as what vulnerabilities are mostlikely to occur. These can be found by looking at parameters such as;