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Design layout of hydrogen research and development garage

Mathew Thomas a,*, Kevin Braun Martin a, Scott E. Grasman a, John W. Sheffield b,Edward Alexei Anculle Arauco b

aMissouri University of Science and Technology, Engineering Management and Systems Engineering, 600 W 14th Street, Rolla,

MO 65409-0370, USAbMissouri University of Science and Technology, Mechanical & Aerospace Engineering, 400 W 13th Street, Rolla, MO 65409-0050, USA

a r t i c l e i n f o

Article history:

Received 25 April 2010

Received in revised form

21 September 2010

Accepted 31 January 2011

Available online 5 March 2011

Keywords:

Hydrogen garage

Fuel cell plug-in hybrid

electric vehicle

Backup power unit

* Corresponding author. Tel.: þ1 573 3414572E-mail address: mtvw5@mail.mst.edu (M

0360-3199/$ e see front matter Copyright ªdoi:10.1016/j.ijhydene.2011.01.181

a b s t r a c t

Research and development programs toward fuel cells and other hydrogen technologies

have increased significantly during the past two decades. These programs require appro-

priate facilities to undertake the research and development programs. This paper discusses

the design layout of one such facility, the “Missouri S&T EcoCAR Hydrogen Vehicle Garage”,

which can be used as a model while designing a hydrogen R&D garage. The Missouri S&T

EcoCAR garage is a 12.2 m � 7.6 m garage situated at the Missouri University of Science and

Technology (Missouri S&T) and serves as the headquarters for the Missouri S&T EcoCAR

team. Within the garage, students will gain real-world, hands-on experience by trans-

forming a standard production vehicle into a hydrogen Fuel Cell Plug-in Hybrid Electric

Vehicle (FC-PHEV). The garage is classified as a Class 1 Division 2, Group B hazardous

location and is equipped to safely test and integrate the vehicle prototype. Specifically, the

design includes (i) a hydrogen gas detection system, (ii) hazardous location electrical service,

heating, ventilation and air-conditioning, lighting, and compressed air systems, and (iii) emergency

backup electric power system with alarms/monitors/security cameras for the hydrogen R&D

facility. The garage will be connected to an external backup power supply unit which will

be powered by a PEM fuel cell.

Copyright ª 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights

reserved.

1. Introduction and vehicle safety is available [2e7], but there are only a few

Hydrogen refueling stations and maintenance facilities for

hydrogen vehicles are being designed and implemented

globally. Since the infrastructure to support hydrogen vehicles

is relatively new, the codes and standards for safe operation

are still in the developing stage and the industry standards for

research and development facilities for hydrogen vehicles are

being formulated. Cost and availability of hydrogen infra-

structure, fuel quality, codes and standards are some issues

that must be resolved prior to commercial viability of fuel cell

vehicles (FCV) [1]. A comprehensive study on hydrogen safety

.. Thomas).2011, Hydrogen Energy P

studies on facilities for hydrogen vehicle development [8].

This paper discusses the design layout of a research and

development garage which provides both the functionality

and safety for building a hydrogen fuel cell vehicle.

The hydrogen research and development garage face

similar explosion risks as the battery charging rooms in

warehouses where an explosive mixture of hydrogen and air/

oxygen may be present. Lead acid batteries emit hydrogen

during discharge and a mixture of hydrogen with 33% of

oxygen while charging [9]. Some consider hydrogen to be the

most dangerous fuel [10,11] due to its fundamental properties

ublications, LLC. Published by Elsevier Ltd. All rights reserved.

i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 6 ( 2 0 1 1 ) 8 0 1 7e8 0 2 28018

of low ignition energy, and wide flammability limits while

others consider it to be the safest fuel [12] due to its lower

buoyancy, high autoignition temperature, high specific heat,

and diffusivity. Taking these properties of hydrogen into

account, the hydrogen research and development facility

must be designed such that it can operate safely even in

a hydrogen-rich environment. Hydrogen facilities require

intrinsic safety barriers for electrical equipment to prevent

spark and consequent ignition of hydrogen. Hence, all

equipment in the hydrogen research and development facility

must be rated for Class 1, Division 2, Group B hazardous

location. The facility must also have sensors to detect the

presence of hydrogen in order to determine if the concentra-

tion is approaching flammable concentration.

1.1. Background

Missouri University of Science and Technology (Missouri S&T)

is participating in EcoCAR: the NeXt Challenge, a three-year

collegiateadvancedvehicle technologycompetitionsponsored

by the U.S. Department of Energy (DOE) and General Motors

(GM), as well as by Natural Resources Canada and other

industry leaders. The competition challenges engineering

students from universities across North America to re-engi-

neer a light-duty vehicle, minimizing energy consumption,

emissions, and greenhouse gases while maintaining the vehi-

cle’s utility, safety, and performance. The Missouri S&T Eco-

CAR Team is transforming a standard production vehicle into

aHydrogen Fuel Cell Plug-inHybrid Electric Vehicle as a part of

the competition. This paper discusses the design layout of

“Missouri S&TEcoCARGarage”,which serves as a researchand

development garage to support students as they build the

hydrogenpoweredvehicle. TheMissouri S&TEcoCARgarage is

a 12.2m� 7.6m garage and can be used as an archetypewhile

designing a hydrogen R&D garage. The garage is classified as

a Class 1 Division 2, Group B hazardous location and is equip-

ped to safely test and integrate thehydrogenvehicleprototype.

Specifically, the design includes (i) a hydrogen gas detection

system, (ii) hazardous location electrical service, heating,

ventilation and air-conditioning, lighting, and compressed air

systems, and (iii) emergency backup electric power system

with alarms/monitors/security cameras for the hydrogen R&D

facility. The design also includes an external backup power

supply unit powered by a Polymer ElectrolyteMembrane (PEM)

fuel cell.

Since the hydrogen vehicle will be parked inside the

garage, there is a chance of hydrogen leakage from the

compressed hydrogen fuel tanks. Net effect of the leakage is

the formation of an explosive mixture at an elevated

temperature (due to the negative value of the JouleeThomp-

son coefficient of hydrogen) [13], which can cause severe

damage if detonated. Hence, within the EcoCAR R&D garage,

there is a risk of ignition if the concentration of hydrogen is

between the lower flammability limit (4%) and upper flam-

mability limit (74%). The areas of critical importance to

prevent the risk of combustion are near the ceiling and floor.

Gaseous hydrogen being lighter than air will rise to the ceiling

and can form an explosive mixture if the hydrogen concen-

tration in air is between 18.3% and 59%. Cryogenic pool

spreading and vaporization of hydrogen in the event of

a liquid hydrogen spillage [14] makes the area near the floor

equally important. The design must be robust enough keep

hydrogen concentration within the garage less than its lower

flammable limit and avoid critical events while providing

functionality.

2. Functional requirements

For integrating and testing the fuel cell plug-in hybrid electric

vehicle, the EcoCAR garage needs to be equippedwith lighting,

heating, ventilation and air-conditioning, hydrogen detection,

and electrical system. The garage is currently supplied with 3

phase 480 VAC, 240 VAC and 120 VAC power. In order to

accurately design the electrical system components, it is

necessary to predict the equipment that would be required

within the workspace. The main equipment that will be used

during the vehicle development is vehicle lift, air compressor,

vehicle battery charging stations, ethernet communication,

laptop computer, battery backup power supply, and other

electronic equipments. According to NFPA 52 [15], all electrical

equipment must comply with Article 501 of NFPA 70, National

Electrical Code, and Class 1 Division 2, Group B.

3. Component selection

The design of the garage is centered on hazardous location

classification to eliminate potentially unsafe scenarios. Killark

[16], a leading manufacturer of electrical construction prod-

ucts for standard, harsh and hazardous environments is one

of the potential sponsors for the Missouri S&T EcoCAR team.

Hence, the design selected state of the art Killark components

to design the lighting and electrical layout for the Missouri

S&T EcoCAR Garage.

3.1. Lighting

The selected lighting equipment must meet the safety

requirements and be efficient while providing an adequate

bright workspace. Luminous efficacy was used to determine

which lamps were more efficient. Tasks in the garage is

considered to be “visual tasks of high contrast and small size,

or visual tasks of low contrast and large size” and illuminance

level of 538 lux (50 fc) was specified based on the standards set

by the Illuminating Engineering Society of North America

(IESNA) [17]. The maximum illuminance is required at the

desk level or 2.5 feet from the ground where majority of work

will be performed. The design uses wall mounted fixtures

instead of hanging fixtures to prevent interference with the

garage doors and car lift. This would also allow adequate

lighting whether the vehicle is lifted or is on the ground.

3.1.1. Lighting concept comparisonLED lights were the preferred choice based on its luminous

efficacy, extended life, and zero mercury content. But, since

Killark does not make LED lamps they are not a feasible

choice. After reviewing all the hazardous location lighting

fixture options from Killark, it was decided to use either high

pressure sodium lamps or metal halide lamps. Metal halide

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lamps are less efficient than high pressure sodium lamps and

also cause more pollution when destroyed. However, the light

produced by high pressure sodium yields a yellow color that

would be non-conducive to a natural learning environment.

Metal halide lamps were chosen as the best option for the

garage since they have a higher color rendering index (CRI)

than high pressure sodium and provide more light per fixture

than LED or compact fluorescent. The 3-D view of the final

lighting design is shown below in Fig. 1.

The final design use seven of Killark’s metal halide pulse

lamps which will be mounted to the steel beams along the top

of the inside wall. The illuminance of the reference plane in

the garage was simulated using ReluxPro� [18] program and is

shown in Fig. 2 below.

The average illuminance of the room is just above the

design requirements of 538 lux (50 fc). The illuminance drops

below the minimum value underneath the car which can

easily be offset by portable hanging task lighting.

3.2. Hydrogen detection and ventilation

The ventilation for the hydrogen garage has been designed in

accordance with NFPA 52 and employs a mechanical system

that can either run continuously or be activated by a hydrogen

gas detection system. According to NFPA 52, the ventilation

rate shall be at least 0.000472 m3/s m2 (1 ft3/min ft2) of room

area or not less than 0.000472 m3/s � 0.34 m3 (1 ft3/min∙12 ft3)

of room volume and the hydrogen gas concentration within

the facility should not be more than one-quarter of the lower

flammable limit. The Dayton 7A918 spark resistant blower

rated for hazardous location with the motor totally enclosed

and nonventilated was selected for the ventilation in the

garage. The flow rate is 0.59 m3/s (1246 cfm) and 0.44 m3/s

(922 cfm) at 6.35 mm.SP (0.250-In) and 25.4 mm.SP (1.000-In.)

respectively [19] and falls within the garage’s requirement of

Fig. 1 e Overview of ga

0.47 m3/s (1000 cfm). For the hydrogen detection system,

H2 scan’s HY-ALERTA� 2600 explosion proof area hydrogen

monitor was selected. HY-ALERTA� 2600 provides hydrogen-

specific leak detection and measurement for hydrogen con-

centrations as low as 4000 ppm and can be scaled to any

concentration up to 5% hydrogen by volume, a range repre-

senting 10e125% of hydrogen’s lower flammability limit [20].

The monitor is designed for either ceiling or wall mount and

has a capability that extends the interface from the sensor

module to the control module to several hundred feet [14]. If

the concentration reaches a maximum of 25% of the lower

flammability limit, audible alarms with strobes will be acti-

vated, ventilation will remain on, power will be shut off, and

remote security personnel will be notified.

3.3. Heating

A radiant heating system is the most likely choice in order to

obtain a high efficiency heating systemwithout an open flame

or flammable fuels. However, radiant heating system does not

meet the Class 1 Division 2, Group B requirement of the

garage. Hence, hazardous location wall mounted cabinet

electric convection heater was chosen for heating the EcoCAR

garage. The QMark ICG18041B electric convection heater has

an output 6140 Btu/h (1800 ing of 7.5 A, voltage rating of

240 VAC and is rated for Class I, Division 2, Groups B, C, & D

[21]. Depending upon the temperature requirement of the

garage two units were selected.

3.4. Fuel cell backup power

Backup power to the garage is provided by a 5 kW Plug Power

GenCore� 5U120 PEM fuel cell unit. The fuel cell will provide

backup power to the hydrogen detection system, ventilation

system, alarms, emergency lighting, security cameras, and

rage with lighting.

Fig. 2 e Illuminance using MHP lamp; part number VMPB-2-76 GG.

i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 6 ( 2 0 1 1 ) 8 0 1 7e8 0 2 28020

other safety systems critical for the safe shutdown of the

facility. The fuel cell is located outside the garage and use an

APC UPS system to convert DC to AC current.

3.5. Electrical wiring and outlets

The garage requires 120 VAC, 240 VAC, and 480 VAC outlets to

power equipment such as lights, heater, parts washer, car lift,

computer, air compressor, ventilation system, security

system, vehicle battery charger, etc. The power requirements

for the electrical system have been overestimated in the

design to allow for additional equipments and variation in

final product selection. Once the power requirements and

placement of these objects were determined, the outlets and

breaker boxes to supply the power were selected. The Killark

product catalog was investigated to select electrical outlets,

receptacles, fittings, and breaker boxes that would satisfy the

power and hazardous location requirements.

3.6. Conduit

Rigid metal 25.4 mm (1 inch) conduit is used to minimize the

necessary supplemental mounting brackets. The exact type of

mounting devices is not specified in this paper. Due to the

explosive environment, seals were placed to prevent gas

circulation in conduit lines. According to NEC Section 501e5

[21], conduit seals shall be installed within 457.2 mm (18 inch)

of each terminating enclose; such as unions, couplings,

reducers, elbows, capped elbows and conduit bodies.

However, the part specifications on the individual parts

specify the need for a seal to be installed 152.4 mm (6 inch)

from the receptacle.

4. Design results and discussion

All the components selected during the design comply with

Class 1 Division 2, Group B hazardous location specifications.

After careful consideration, it was decided to place eight

120 VAC, two 240 VAC, two 480 VAC, and one overhanging

outlet inside the garage. Except for the overhanging outlet, all

the outlets will be placed just above workbench level. The

lighting design was chosen from the designs simulated by the

program Relux� [18]. The final design uses seven 250 W metal

halide pulse lamps mounted on the upper beam of the inside

wall. The electrical outlets in the design alsomeet the required

standard and were used in conjunction with explosion proof

conduit. A CAD drawing was prepared illustrating the location

of electrical outlets and metal halide pulse lighting within the

EcoCAR garage and is shown in Fig. 3. A summary of selected

components is provided in Table 1.

It has to be noted that the list of electrical fittings are not

comprehensive and may need additional fittings in the final

design. In addition to the components selected in the paper,

the hydrogen research and development garage includes:

parts washer, computer, ethernet communication, car lift,

Fig. 3 e Layout of the Missouri S&T EcoCAR Garage.

i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 6 ( 2 0 1 1 ) 8 0 1 7e8 0 2 2 8021

surveillance cameras, emergency lighting, power tools, and

other electronic equipment for integrating and testing the

vehicle. This equipment is used in strict compliance with the

codes and standards and measures will be taken to make it

intrinsically safe. For example, intrinsically safe purged work

stations that use Type Z purge system is used at the garage.

The Type Z purge system purge and maintain constant pres-

sure within the enclosure so that the equipment inside the

enclosure can be energized. The air compressor will be located

outside the garage to conserve space.

Table 1 e Summary of selected components.

Item Manufacturer Model/PartNumber

Hydrogen gas detection H2 SCAN HY-ALERTA� 2600

Heating Qmark ICG18041B

Ventilation Dayton 7A918

Lighting Killark VMPB-2-76 GG

Air compressor Snap-on ACBL530VP

Fuel cell backup Plug Power GenCore� 5U120

120 VAC plug and receptacle Killark UGRB3-20231

240 VAC plug and receptacle Killark UGRB3-20232

120 VAC GFCI receptacle Killark UGFI20C3

120 VAC GFCI

receptacle adapter

Killark UGFI20AD

120/240 VAC circuit

board panel board

Killark B7L29-112-MBE100

480 VAC circuit board

panel board

Killark B7P26-306-MBE100

Fill sealing fittings Killark ENY40/EYD 40

Aluminum conduit bodies Killark TWOC-1

Flexible coupling Killark ECFUF224

5. Conclusions

The components that were chosen to outfit the EcoCAR garage

will equip students to build and integrate a hydrogen fuel cell

plug-in hybrid electric vehicle. The design in this article could

be applied to design a research and development hydrogen

facility. Even though this article provides amodel for designing

ahydrogenR&Dgarage specified forClass 1,Division2,GroupB

hazardous location, additional appropriate codes and stan-

dards should be followed during the design of a garage. For

example, the garage should have a fire resistance rating of

2hours, a sprinkler system inaccordance toNFPA52, hydrogen

piping in accordance to NFPA 55, etc. Furthermore, local codes

and standards should also be followed during the design of

a hydrogen research and development garage.

Acknowledgments

The authors wish to thank the two Killark senior design teams

from the Department of Mechanical and Aerospace Engi-

neering at Missouri S&T during the spring semester.

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